Electric Water Pump Stator Cover Integration for Minimal Air Gap
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Solution Overview
Problem
The presence of a waterproof cover between the stator and rotor in electric water pumps increases the air gap, leading to performance deterioration and difficulty in securing a package space in limited vehicle spaces.
Innovation Solution
The stator core, stator coil, and insulation members are integrally formed in a stator cover, minimizing the air gap between the stator and rotor assemblies by removing the waterproof cover, and enhancing the efficiency of the driving motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a waterproof cover is provided between the stator and rotor, then the coils of the driving motor are insulated and protected from corrosion, but the air gap between the stator and rotor increases, causing performance deterioration
Solution Approach 1:
The patent merges the waterproof cover function with the stator cover by integrating insulation members directly into the stator core structure. The stator cover includes insulating layers that provide waterproof protection while maintaining minimal distance from the rotor, thus combining protection and performance requirements in a single integrated component.
Solution Approach 2:
The patent extracts the waterproof protection function from a separate waterproof cover component and integrates it directly into the stator assembly through insulation members. This eliminates the need for an additional waterproof cover layer, reducing the air gap while maintaining corrosion protection.
2Reliability
If a waterproof cover is provided between the stator and rotor, then the coils are protected from cooling water, but the axial size and radial size of the electric water pump increase, making it difficult to secure package space
Solution Approach 1:
The patent combines the waterproof cover function with the stator cover structure, eliminating the need for a separate waterproof cover component. The insulating members are integrated into the stator core, providing protection while minimizing the overall axial and radial dimensions of the pump.
Solution Approach 2:
The stator cover is designed to serve multiple functions simultaneously: structural support, electrical insulation, and waterproof protection. This multi-functional design eliminates the need for separate dedicated waterproof components, reducing the overall pump size.
3Productivity
If the stator core, stator coil, and insulation members are integrally formed in the stator cover, then the air gap is minimized and motor efficiency is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary assembly of the stator core, stator coil, and insulation members before final integration into the stator cover. The insulation members are pre-positioned on the stator core, and the stator coil is wound and secured in place before the stator cover is molded over them, facilitating a more manageable manufacturing process.
Solution Approach 2:
The patent integrates multiple components (stator core, stator coil, insulation members) into a single stator assembly through integral forming in the stator cover. This consolidation improves motor efficiency by minimizing air gap while the integrated structure simplifies assembly operations despite increasing molding 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
This configuration reduces the axial and radial size of the electric water pump, allowing it to fit in limited vehicle spaces while improving motor efficiency by minimizing the air gap and eliminating the need for a separate waterproof cover.
Implementation Method 1
The electric water pump pumps cooling water while an impeller is rotated by power generated by a driving motor operated by electric energy
Implementation Method 2
insulation members insulating the stator core and the stator coil
Data Source
AI summary
An electric water pump may include: a housing with a cooling water inlet and a cooling water outlet; and a stator assembly provided inside the housing. The stator assembly includes a stator core, a stator coil arranged on the stator core, insulation members insulating the stator core and the stator coil, and a stator cover provided to cover the stator core, the stator coil, and the insulation members. The electric water pump further includes: a rotor assembly rotatably provided inside the stator assembly and having a magnetic body; and an impeller pumping cooling water introduced through the cooling water inlet by rotation of the rotor assembly. In particular, the stator core, the stator coil, and the insulation members of the stator assembly may be integrally formed in the stator cover.