Thrust Bearing Driver for Fuel Pump Torque Transfer
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Solution Overview
Problem
Current electronic fuel pumps face increased wear and tear due to variable pressure and flow control requirements, leading to noise, fretting wear failures, and mechanical failures under high cyclic loading, particularly in low-lubricity fuel environments, necessitating a more robust drive shaft to gear coupling.
Innovation Solution
The implementation of a thrust bearing driver with a disc-like plate and symmetrically arranged posts that mate with slots on the shaft and rotating element, providing improved durability, noise reduction, and torque transfer between the motor drive shaft and pump gears, while allowing angular and radial self-alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a steel shaft is engaged to a steel rotor interface to transfer torque, then torque transfer capability is improved, but noise increases and fretting wear failures occur in low-lubricity fuel
Solution Approach 1:
A plastic coupling member is introduced as an intermediary between the steel drive shaft and the steel rotor interface. This plastic member serves as a mediator that reduces noise and prevents fretting wear failures by providing a damping interface, while still effectively transferring torque between the metal components.
Solution Approach 2:
The coupling interface uses a composite material approach by combining plastic with metal components. The plastic coupling member is molded to fit both the steel drive shaft and the steel rotor, creating a hybrid metal-plastic assembly that leverages the strength of metal and the noise-damping properties of plastic.
2Object-generated harmful factors
If a plastic member is used to couple the shaft to the inner gear, then noise and wear are reduced, but strength decreases and susceptibility to fracturing increases under high cyclic loading
Solution Approach 1:
The plastic coupling member acts as an intermediary that is strategically positioned between the steel shaft and steel rotor. Rather than using plastic for the entire coupling, the plastic member serves as a noise-damping intermediary while the metal-to-metal interfaces handle the primary torque transfer, balancing noise reduction with structural strength.
Solution Approach 2:
Different materials are used in different locations within the coupling system. The plastic member is placed specifically where noise and wear are concerns (at the interface between shaft and rotor), while the steel components maintain their metal-to-metal engagement for strength-critical areas, achieving local optimization of both noise reduction and strength.
3Productivity
If variable pressure and flow control is implemented in electronic fuel pumps, then fuel system efficiency is improved, but wear and tear on pump components increases
Solution Approach 1:
The plastic coupling member serves as a protective intermediary that absorbs the increased stress and wear from variable pressure and flow control operations. By placing this damping element between the shaft and rotor, the system can withstand the additional cyclic loading from efficiency-enhancing control mechanisms without suffering proportional increases in component wear.
Solution Approach 2:
The plastic coupling member provides beforehand cushioning by being pre-installed between the steel shaft and rotor to absorb future wear and stress. This cushioning element is in place before high cyclic loading occurs, preventing fretting wear failures and extending the life of the pump components under variable operating conditions.
Data Source
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AI summary
A fluid pump (10) includes an inlet plate (26) and an electric motor (20). The electric motor has a shaft (22) that rotates about an axis (24). A pumping arrangement (28, 30) is rotationally coupled to the shaft (22). The pumping arrangement (28, 30) includes a rotating element (28). The fluid pump (10) further includes a thrust bearing driver (54) including a disclike plate (56) having first and second faces (58, 60), and two posts (62) extending perpendicularly from the first face (58). The shaft (22) has a terminal end (64) including a pair of slots (66) that cooperate with the posts (62) of the thrust bearing driver (54). The rotating element (28) has an inner surface (70) including a pair of slots (72) that cooperate with the posts (62) of the thrust bearing driver (54). The posts (62) of the thrust bearing driver (54) are received in the slots (66, 72) of both the shaft (22) and the rotating element (28), and the thrust bearing driver (54) is sandwiched between the shaft (22), the inlet plate (26), and the rotating element (28).