Integrated Rotor-Impeller Axial Pump Design
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Solution Overview
Problem
Existing electric motor vehicle axial liquid pumps are complex and costly to produce due to the need for multiple components, including a separate shaft and additional bearings for the impeller.
Innovation Solution
The design integrates a rotor body with permanent magnets as both the rotor and impeller within a can that forms a plain bearing, eliminating the need for a separate shaft and additional components, and uses a plastic injection-molded stator coil housing to reduce complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate shaft and additional bearings are used for the impeller, then the pump can effectively convey fluid, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the rotor and impeller into a single integrated rotor-impeller unit. The impeller blades are directly formed as extensions of the rotor body, eliminating the need for a separate shaft and additional bearings. This merging of components directly reduces device complexity and manufacturing cost while maintaining the fluid conveyance function.
Solution Approach 2:
The rotor serves multiple functions simultaneously: it acts as both the rotating component of the motor and the impeller for fluid conveyance. The rotor body is designed with integrated impeller blades that perform the pumping function, making the rotor a multi-functional component that eliminates the need for separate dedicated impeller components.
2Productivity
If multiple separate components are used, then each component can be optimized for its specific function, but the assembly time and production efficiency decrease
Solution Approach 1:
The rotor-impeller unit is manufactured as a single integrated component, eliminating the need for assembly of separate shaft, bearing, and impeller parts. This merging reduces assembly time and improves production efficiency while allowing the entire unit to be optimized through single-piece manufacturing processes.
3Productivity
If traditional metal rotors are used, then structural strength is sufficient, but the moment of inertia is higher reducing efficiency
Solution Approach 1:
The patent employs composite material construction for the rotor-impeller unit, using materials with optimized density and strength characteristics. This allows reduction of the moment of inertia compared to traditional solid metal rotors while maintaining sufficient structural strength for the application, thereby improving pump efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration simplifies production, reduces material costs, and enhances efficiency by eliminating unnecessary components and using cost-effective neodymium magnet particles, while maintaining hydraulic performance.
Implementation Method 1
The electric motor has a canned tube arranged radially within the at least one stator coil. The rotor body is permanently magnetized. Thus, the rotor body serves as both rotor and impeller in a single component.
Implementation Method 2
The rotor body features polymer-bonded permanent magnet particles. Neodymium particles are particularly preferred for these permanent magnet particles.
Implementation Method 3
the rotor body and the canned tube together form a sliding bearing. a sliding bearing is defined as the arrangement of the rotor body and the canned tube with a fluid-filled gap between the outer circumferential surface of the rotor body and the inner circumferential surface of the canned tube
Data Source
Figure 1
AI summary
The present invention relates to an electric motor vehicle axial-flow liquid pump (10) which is designed as an internal rotor pump. The electric motor vehicle axial-flow liquid pump (10) comprises a pump housing (12), which forms an axial intake opening (14) and an axial outlet opening (16) for admitting and discharging the liquid, and an electric motor (17) which is provided in the pump housing (12). The electric motor (17) has a motor stator (18) with at least one external stator coil (20), a can (22) which is formed radially inside the stator coils (20), and a rotor body (32) formed as an axial-flow impeller. The rotor body (32) is arranged rotatably within the can (22) and has at least one blade (36) which urges the liquid along the axis of rotation (33) of the rotor body (32) from the inlet opening (14) to the outlet opening (16). The rotor body (32) is of permanently magnetic design.