Electric Liquid Pump Rotor Structure for Lower Weight Assembly
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Solution Overview
Problem
Existing electric liquid pumps face challenges in reducing manufacturing costs and weight due to the use of metal shafts and metal magnet portions, which require complex manufacturing processes and heavy metal bearings.
Innovation Solution
The electric liquid pump integrates a shaft with a sleeve of the same material, featuring a large diameter at one end, and uses a bonded magnet for the magnet portion, eliminating the need for press-fitting and simplifying the manufacturing process while reducing weight and torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal shaft and metal magnet portion are used in the motor rotor, then the motor rotor can be manufactured with simple materials, but the mass and rotational torque become large, requiring heavy metal bearings
Solution Approach 1:
The patent changes the material parameters of the motor rotor by using a resin shaft instead of a metal shaft, and integrating the magnet portion directly into the resin shaft. This parameter change reduces the density and mass of the motor rotor, thereby reducing the overall weight while maintaining structural integrity and magnetic functionality
Solution Approach 2:
The patent employs composite materials by integrating the magnet portion (which may be a bonded magnet containing magnetic powder and binder) directly into the resin shaft structure. This composite approach allows the motor rotor to achieve both structural support and magnetic function in a single integrated component, reducing the need for separate metal parts and heavy bearings
2Adaptability or versatility
If the magnet portion is integrated with a sleeve having large diameter on the shaft, then the magnet portion can be downsized and functionality is improved, but the manufacturing process becomes complicated with multiple components
Solution Approach 1:
The patent merges the shaft and magnet portion into a single integrated resin motor rotor structure. The magnet portion is directly formed as part of the resin shaft, eliminating the need for separate sleeves and multiple assembly steps. This merging reduces structural complexity while maintaining the functional benefits of having the magnet portion integrated with the shaft
3Reliability
If multiple components are used to constitute the motor rotor, then the motor can achieve required functionality, but the manufacturing process requires many steps and manufacturing cost increases
Solution Approach 1:
The patent combines multiple motor rotor components (shaft, magnet portion, and back yoke) into a single integrated resin motor rotor. This merging reduces the number of manufacturing steps from multi-component assembly to single-component molding, significantly improving productivity and reducing manufacturing costs while maintaining reliable motor performance
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 design reduces manufacturing costs and weight by eliminating complex assembly steps and metal bearings, allowing for a lightweight and efficiently operating pump.
Implementation Method 1
The bonded magnet is a magnet made by bonding magnetic powder with a binder
Implementation Method 2
an electric motor including a motor rotor that has a shaft and a magnet portion integrated with one axial end of the shaft, and a stator that is disposed radially outside or inside the magnet portion and rotates the motor rotor
Implementation Method 3
an inner rotor that has an external tooth and is integrated with an other axial end of the shaft, and an outer rotor that has an internal tooth meshing with the external tooth and forms, together with the inner rotor, a gap volume portion into which a liquid is suctioned from a suction passage and from which the liquid is discharged toward a discharge passage
Data Source
AI summary
An electric liquid pump has a motor, a liquid pump including an inner rotor having an external tooth and integrated with an axial end of a shaft of the motor and an outer rotor having an internal tooth meshing with the external tooth and forming a gap, a motor case having a box shape and including therein first and second accommodation chambers and a partition wall allowing the first and second accommodation chambers to communicate with each other, and a body including a centering body portion, a general body portion, and a bearing portion formed to penetrate the centering body portion and the general body portion. The shaft is integrally formed with a sleeve of the shaft and a general shaft portion. The sleeve and the general shaft portion are made of the same material. The magnet portion is made of a bonded magnet and is integrated with the sleeve.