Urea Solution Pump Unit Sealing and Freezing Prevention
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Solution Overview
Problem
Existing urea solution pump units face challenges in maintaining operation stability, durability, and sealing performance, particularly in preventing corrosion of the stator and rotor, and effectively preventing the urea solution from freezing, while managing pressure increases during pumping.
Innovation Solution
A urea solution pump unit design featuring a bracket-mounted pump with a motor that uses a gap between the rotor and stator for suction and discharge, incorporating thawing units to prevent freezing, a sensor unit for level, temperature, and pressure detection, and a relief valve to manage pressure, along with over-molded components and o-rings for enhanced sealing and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a pump unit is used to pump urea solution, then the urea solution can be pumped to decrease harmful substances in exhaust gas, but the stator and rotor may be corroded due to the strong alkaline urea solution
Solution Approach 1:
The stator and rotor are constructed using composite materials that combine corrosion-resistant properties with pumping functionality. The stator includes a stator body made of corrosion-resistant material, while the rotor uses similar protective materials to resist degradation from continuous exposure to strong alkaline urea solution, thereby maintaining durability without sacrificing pumping capability
Solution Approach 2:
The patent modifies the chemical and physical parameters of the stator and rotor materials to enhance their resistance to urea solution corrosion. By selecting materials with appropriate chemical composition and structural properties, the components can withstand the harsh chemical environment while maintaining their mechanical integrity and pumping performance over time
2Quantity of substance
If the urea solution is stored in a tank, then it can be supplied to the pump unit, but the urea solution may freeze under certain conditions
Solution Approach 1:
The patent employs heating elements that activate when the urea solution temperature approaches freezing point, preventing the phase transition from liquid to solid. The heating mechanism maintains the solution temperature above the freezing point, ensuring continuous pumpable liquid state even in cold environmental conditions
Solution Approach 2:
A temperature sensing mechanism acts as an intermediary between the urea solution and the heating element. The sensor detects temperature changes and triggers the heating system before freezing occurs, providing proactive protection against phase transition while maintaining normal storage capacity
3Productivity
If the pump unit operates to pump urea solution, then harmful substances in exhaust gas can be decreased, but pressure increase may cause impact
Solution Approach 1:
The patent incorporates a pressure sensing mechanism that continuously monitors the pressure within the pump unit and provides feedback control. When pressure reaches a predetermined threshold, the system automatically adjusts pump operation or activates relief mechanisms, preventing dangerous pressure buildup while maintaining efficient pumping rates for harmful substance reduction
4Reliability
If a sealing structure is improved, then operation stability and durability can be enhanced, but device complexity may increase
Solution Approach 1:
The patent utilizes flexible sealing elements such as O-rings and gaskets made from elastomeric materials that conform to mating surfaces. These flexible components provide effective sealing between the stator, rotor, and housing without requiring complex multi-component sealing assemblies, thereby enhancing reliability while controlling device complexity
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 design improves sealing and anti-corrosive performance, prevents freezing, and maintains stable operation by using over-molded components and o-rings, ensuring reliable urea solution pumping and reducing the risk of pressure-related issues.
Implementation Method 1
The pair of thawing units transfer heat to a urea solution and prevent the urea solution from being frozen
Implementation Method 2
a motor pumping a urea solution to another direction through a gap between a rotor and a stator of a motor inside the pump
Data Source
AI summary
A urea solution pump unit includes a bracket mounted to a lower side of a urea solution tank. A pump unit is horizontally disposed at a center of an upper part of the bracket and includes a pump suctioning a urea solution to one direction and a motor pumping the urea solution to another direction through a gap between a rotor and a stator of the motor inside the pump and discharging the urea solution to a lower side of the bracket. A pair of thawing units are fixedly disposed at both sides of the pump unit on the bracket. The thawing units transfer heat to the urea solution and prevent the urea solution from being frozen. A sensor unit is disposed at one side of one of the thawing units and detects a level, a temperature, and a pressure of the urea solution.