Shaftless Synchronous Motor Pump Rotor Design
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Solution Overview
Problem
Existing synchronous motor pumps for applications like aquariums and household appliances face high production and maintenance costs due to complex construction, wear issues, and contamination from aggressive fluids, leading to rotor jamming and premature failure.
Innovation Solution
A simplified design where the rotor has a circular cross-section matching the cylindrical element, eliminating the need for a shaft and bushes, with direct contact and self-lubricating materials to prevent contamination and reduce wear, and a duct for fluid lubrication and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a shaft and bushes are used to transmit motion from the rotor to the impeller, then the motor can operate, but the construction becomes complex and production costs increase
Solution Approach 1:
The invention extracts and eliminates the shaft and bushes from the motor pump construction. Instead of using a separate shaft to transmit rotation from the rotor to the impeller, the rotor itself is designed with a hollow cylindrical body that directly houses and drives the impeller, removing the intermediate transmission components and simplifying the overall structure.
Solution Approach 2:
The invention merges the rotor and impeller into a single integrated component. The rotor's hollow cylindrical body directly contains the impeller, combining the functions of rotation generation and fluid pumping into one unified structure, thereby eliminating the need for separate shafts and connection mechanisms.
2Reliability
If a gasket is used to seal the cylindrical element, then insulation is provided, but the gasket is subject to wear and attack from aggressive fluids requiring frequent replacement
Solution Approach 1:
The invention replaces the vulnerable gasket seal with a more robust sealing arrangement that eliminates the need for replaceable soft seals. The sealing is achieved through the structural design of the cylindrical element and rotor assembly, using durable materials and geometric sealing surfaces that do not degrade from fluid exposure.
Solution Approach 2:
The invention employs composite construction with the rotor body made from materials resistant to aggressive fluids. The hollow cylindrical rotor is constructed to withstand chemical attack and wear, integrating multiple material properties to achieve both sealing and durability without relying on separate gasket components.
3Ease of operation
If air chambers are present between the rotor and cylindrical element, then the rotor can rotate freely, but fluid backflow occurs and impurities accumulate causing rotor jamming
Solution Approach 1:
The invention converts the potential harm of fluid contact into a beneficial sealing mechanism. By eliminating air chambers and allowing direct contact between the rotor surface and the cylindrical element interior, the design uses the fluid itself to create a sealing effect that prevents backflow and impurity accumulation, while the rotor still rotates freely through proper clearance design.
Solution Approach 2:
The invention uses the rotor's hollow cylindrical body as a flexible sealing shell that maintains direct contact with the cylindrical element interior. This thin-walled cylindrical structure provides both structural support and sealing function, preventing fluid leakage and impurity ingress while allowing rotational movement through controlled clearances.
4Productivity
If multiple components (shaft, bushes, gasket, rotor with hole) are assembled, then the motor functions, but assembly time and specialized maintenance intervention are required
Solution Approach 1:
The invention merges multiple separate components into a single integrated rotor-impeller assembly. The hollow cylindrical rotor body directly houses the impeller, eliminating the need for separate shafts, bushes, and gaskets, thereby reducing the number of assembly steps and enabling faster production and maintenance.
Solution Approach 2:
The invention segments the motor pump into two main functional modules: the motor section with stator and field windings, and the integrated rotor-impeller section. This segmentation allows for simplified assembly where the pre-assembled rotor-impeller unit can be directly installed, reducing overall assembly complexity and time.
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
Significantly reduces production costs, extends motor lifespan by minimizing wear and preventing contamination, and enhances operational reliability by eliminating air chambers that cause fluid backflow and impurity accumulation.
Implementation Method 1
the rotor (132, 232), for at least part of its length, has a circular cross section essentially corresponding to the inner section of the cylindrical element (124, 224) so that the rotor (132, 232) is in contact with the cylindrical element (124, 224), and then there is a friction between the rotor (132, 232) and the cylindrical element (124, 224) when the rotor (132, 232) rotates
Implementation Method 2
with self-lubricating materials to prevent contamination and reduce wear
Implementation Method 3
a duct for fluid lubrication and cooling
Data Source
AI summary
A synchronous electric motor for operating a pump includes a motor body, a stator and a rotor coupled to an impeller of the pump. The motor also comprises a cylindrical element that extends towards the inside of the motor body from one of its outer walls so as to define a first cylindrical cavity open to the outside to insert inside the rotor, wherein the rotor has a circular cross section essentially corresponding to the inner section of the cylindrical element so that the rotor is in contact with the cylindrical element and then there is a friction between the rotor and the cylindrical element when the rotor rotates, and the rotor is shaftless and axially and directly coupled to the impeller of the pump.