Electric Water Pump Rotor Assembly With Plastic-Coated Magnetic Sheets
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Solution Overview
Problem
Conventional electric water pumps have high costs due to the consumption of neodymium-iron-boron materials in magnetic rings and high-cost, difficult-to-process graphite bearings, and suffer from connection issues between components, leading to reduced reliability and efficiency.
Innovation Solution
The electric water pump design replaces the magnetic ring with a first plastic coating layer and the graphite bearing with a second plastic coating layer, featuring protruding ribs and recesses for enhanced connection strength, and uses injection molding to simplify assembly, reducing material consumption and processing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetic ring made of neodymium-iron-boron material is used directly by molding injection, then the magnetic performance is improved, but the material consumption and cost increase
Solution Approach 1:
The magnetic ring is segmented into multiple magnetic sheets arranged in alternating polarity patterns (N-S-N-S). This segmentation allows for more efficient magnetic field distribution and reduced material consumption while maintaining or improving magnetic performance. The magnetic sheets are embedded in a plastic coating layer, further optimizing material usage.
Solution Approach 2:
The patent uses a composite structure combining plastic coating material with magnetic sheets. The plastic coating layer (first plastic coating layer) serves as both a structural support and a magnetic carrier, reducing the need for pure neodymium-iron-boron material while maintaining magnetic performance through the integrated composite design.
2Reliability
If a graphite bearing is used to protect the rotor assembly from wearing, then the wear resistance is improved, but the processing difficulty and cost increase
Solution Approach 1:
The patent replaces the expensive and difficult-to-process graphite bearing with a plastic coating layer that provides sufficient wear protection for the application. This substitution uses more readily manufacturable materials and processes while achieving the required protective function, effectively treating the bearing function as a coating rather than a separate component.
Solution Approach 2:
The patent changes the material parameters from graphite to plastic coating material, which has different but sufficient wear properties for this application. The plastic coating layer is applied through molding processes that are easier and cheaper than graphite processing, while still providing the necessary wear resistance to protect the rotor assembly.
3Device complexity
If the magnetic ring and injection molding adapting piece are connected conventionally, then the assembly is simple, but the connection is easily disconnected at high speed
Solution Approach 1:
The patent merges the magnetic ring and injection molding adapting piece into a single integrated first plastic coating layer. The magnetic sheets are embedded directly within the plastic coating material, eliminating the need for separate connection interfaces. This integration ensures that the magnetic components and structural support move as a unified entity, preventing disconnection at high speeds while maintaining manufacturing simplicity through injection molding.
Data Source
AI summary
An electric water pump including a rotor assembly, wherein the rotor assembly includes an iron core body having a central through-hole, a plurality of magnetic plates disposed inside the iron core body, a first plastic coating layer for enclosing the iron core body, and a second plastic coating layer. At least one protruding rib is provided on a top surface and/or a bottom surface of the first plastic coating layer, a recess matching the protruding rib is provided on the second plastic coating layer, and the first plastic coating layer can drive the second plastic coating layer to rotate relative to an axis of the central through-hole of the iron core body.