Electric Water Pump Stator Assembly Manufacturing
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Solution Overview
Problem
Conventional electric water pumps face challenges in maintaining performance and durability, particularly in regulating coolant flow independently of engine speed, leading to inefficient heating and cooling operations and increased fuel consumption.
Innovation Solution
The method involves manufacturing a stator assembly for an electric water pump using a magnetic core-insulator assembly with a coil, where the core is formed by stacking magnetic material pieces, molded with an insulator, and connected in an annular shape, along with a rotor that generates a magnetic field to pressurize coolant, and using a stator case made of bulk mold compound with a low coefficient of contraction for improved waterproofing and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanical water pump is connected to a pulley fixed to a crankshaft, then the pump is driven by engine rotation, but the coolant amount cannot be regulated independently and fuel consumption increases when engine speed is increased to maintain heating/cooling performance
Solution Approach 1:
The patent replaces the mechanical water pump driven by engine rotation with an electric water pump driven by an electric motor. This substitution allows the pump to operate independently of engine speed, enabling independent coolant flow regulation through electronic control while reducing fuel consumption since the electric motor can operate at optimal efficiency regardless of engine工况.
Solution Approach 2:
The patent implements variable speed control of the electric water pump motor, allowing the rotation speed to be dynamically adjusted based on actual heating and cooling demands. This dynamic operation enables precise coolant flow regulation without being constrained by engine speed, thereby improving energy efficiency and reducing fuel consumption.
2Ease of operation
If electric components are used in the water pump, then independent coolant flow regulation is achieved, but waterproof performance becomes critical for durability
Solution Approach 1:
The patent employs waterproof sealing structures including gaskets and sealing films to protect electric components from coolant exposure. These flexible sealing elements create effective barriers between the electric motor/stator assembly and the coolant environment, ensuring reliable waterproof performance while maintaining independent coolant flow control capability.
Solution Approach 2:
The patent implements a nested structure where the stator assembly with electric components is enclosed within a waterproof housing or case. This nested design protects the sensitive electric components from direct contact with coolant while allowing the outer housing to be in contact with the coolant environment, thus achieving both independent flow regulation and reliable waterproofing.
3Manufacturing precision
If the stator assembly is manufactured by stacking magnetic material pieces and molding insulators, then assembly precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the stator assembly into discrete stackable magnetic material pieces (laminations) with insulators molded between them. This segmentation allows for precise manufacturing of individual components that can be stacked to achieve high overall assembly precision while enabling modular manufacturing and assembly processes.
Solution Approach 2:
The patent combines multiple manufacturing operations into integrated processes, such as molding insulators directly onto magnetic material pieces during the same manufacturing cycle. This merging of operations simplifies the overall manufacturing process by reducing the number of separate steps while maintaining high assembly precision through integrated component production.
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 solution enhances the performance and durability of electric water pumps by allowing independent coolant flow regulation, improving heating and cooling efficiency, reducing fuel consumption, and preventing coolant leakage, while also enhancing the structural integrity and heat dissipation of the pump components.
Implementation Method 1
a stator assembly including a plurality of core-insulator assemblies generates a magnetic field according to a control signal and a rotor is rotated by the magnetic field generated at the stator assembly to pressurize coolant
Data Source
AI summary
A method for manufacturing a stator for an electric water pump may be used for manufacturing the stator used in the electric water pump. In the electric water pump which includes stator assembly for an electric water pump, wherein the stator assembly including a plurality of core-insulator assemblies generates a magnetic field according to a control signal and a rotor is rotated by the magnetic field generated at the stator assembly to pressurize coolant, the method for manufacturing the stator assembly may include a) stacking a plurality of pieces made of a magnetic material to form a core stack, b) molding an insulator to the core stack, c) coiling a coil to the insulator to form a core-insulator assembly so as to form a magnetic path, and d) connecting the respective core-insulator assembly in an annular shape in sequence to form the stator assembly.