Integrated Motor-Pump-Inverter Assembly for Heat-Controlled Packaging
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Solution Overview
Problem
Existing electric motor and hydraulic pump systems are often separate entities with multiple controllers and cables, leading to inefficiencies and potential damage from heat generation, necessitating a more integrated and cooled assembly.
Innovation Solution
An integrated assembly of an electric motor, hydraulic pump, and electronic drive device with shared components, lubricated spline connections, and a cooling configuration using external cooling fluid to cool both the electric motor and electronic drive device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electric motor and hydraulic pump are kept as separate entities with multiple controllers and cables, then system control flexibility is maintained, but device complexity and space requirements increase
Solution Approach 1:
The patent combines the electric motor, hydraulic pump, and electronic drive device into a single integrated assembly. The motor rotor and pump rotor are coupled to the same drive shaft, and the electronic drive device is mounted within the motor housing, eliminating the need for separate controllers and cables while maintaining control functionality through integrated circuitry.
Solution Approach 2:
The integrated assembly serves multiple functions within a single device: the motor provides mechanical power, the pump converts mechanical power to hydraulic flow, and the electronic drive device controls both motor operation and pump actuation. This multi-functionality reduces the number of separate components needed in the system.
2Device complexity
If electric motor and hydraulic pump are integrated into a single assembly, then device complexity is reduced and space is saved, but heat generation from multiple components increases
Solution Approach 1:
The patent converts the harmful effect of heat generation into a beneficial cooling system. The electronic drive device housing incorporates cooling channels that route fluid to absorb heat from both the motor and inverter. The motor cooling fluid and inverter cooling fluid are combined and directed to a heat exchanger, where the heat is dissipated, turning the heat problem into an integrated thermal management solution.
Solution Approach 2:
Cooling fluid acts as an intermediary medium to transfer heat from the motor and inverter to the heat exchanger. The fluid circulates through cooling channels in the motor housing and inverter housing, absorbing heat and carrying it away from the heat-generating components to be dissipated externally.
3Ease of operation
If multiple separate controllers are used for electric motor and hydraulic pump, then individual component control is simplified, but loss of time for communication between controllers increases
Solution Approach 1:
The patent merges the motor controller and pump controller into a single electronic drive device. The controller board within the inverter housing manages both motor drive signals and pump actuation signals, eliminating communication delays between separate controllers and enabling coordinated control of both components through unified processing.
4Ease of manufacture
If mechanical components are shared between hydraulic pump and motor, then manufacturing costs are reduced, but reliability of lubrication and component support becomes critical
Solution Approach 1:
The drive shaft serves itself by providing both mechanical support for the rotors and a sealed pathway for lubricant distribution. The spline connection between the drive shaft and pump rotor is designed to be self-lubricated, with lubricant delivered through sealed passages in the drive shaft, eliminating the need for external lubrication systems while ensuring reliable maintenance of moving components.
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
The integrated assembly reduces costs, saves space, enhances reliability, and effectively manages heat to prolong component life while maintaining efficient operation.
Implementation Method 1
one or more motor cooling fluid channels configured to receive cooling fluid from an external source of cooling fluid and allow cooling fluid to flow about the electric motor to cool the electric motor
Implementation Method 2
one or more inverter cooling fluid channels configured to allow cooling fluid from the external source to cool the inverter board
Data Source
AI summary
An example assembly includes: a main housing (108) having an internal chamber (110) therein; an electric motor (102) disposed in the internal chamber of the main housing and comprising a motor rotor (114); a cooling inner ring (700) disposed in the internal chamber of the main housing about the electric motor, wherein the cooling inner ring comprises one or more motor cooling fluid channels configured to receive cooling fluid from an external source of cooling fluid and allow cooling fluid to flow about the electric motor to cool the electric motor; a hydraulic pump (104) positioned in the main housing, at least partially within the motor rotor of the electric motor; and an enclosure (173) coupled to the main housing and comprising (i) an inverter board (202) disposed therein, and (ii) one or more inverter cooling fluid channels configured to allow cooling fluid from the external source to cool the inverter board.