The present disclosure relates generally to water pumps for motor vehicles. More specifically, the present disclosure relates to a variable flow electric water pump equipped with an axially-moveable rotor/impeller assembly.
This section provides background information related to the present disclosure which is not necessarily prior art.
As is well known, water pumps are typically used in motor vehicles as part of a thermal management system for pumping a liquid coolant to facilitate heat transfer between the coolant and the internal combustion engine during vehicle warm-up and operation. Most commonly, a centrifugal water pump having a rotary pump member, such as an impeller, is configured to draw the coolant into an axial inlet and discharge the coolant through a radial discharge outlet. In many vehicular arrangements, the impeller is fixed to an impeller shaft that is rotatably driven (via an accessory drive system) by the crankshaft of the engine. Thus, the impeller speed is directly proportional to the engine speed. To provide a variable flow feature to such shaft-driven water pumps, it is known to permit limited axial displacement of the impeller within the pump chamber. For example, U.S. Pat. No. 7,789,049 discloses a water pump having an axially-moveable impeller that is spline mounted to the engine-driven shaft, and an electromagnetic actuator operable to control axial movement of the impeller between extended and retracted positions along the shaft so as to variably regulate the fluid flow characteristic between the fluid inlet and the discharge outlet. Similarly, U.S. Pat. No. 5,800,120 discloses a water pump having a shaft-driven impeller equipped with axially-moveable blades, the position of which is controlled via a hydraulic actuator.
It is also well known to install an auxiliary water pump, such as an electric water pump, in the engine coolant system to provide augmented control over the fluid flow. Generally, electric water pumps include an electric motor having a stationary stator and a rotor that is drivingly coupled to the impeller. Examples of electric water pumps are disclosed in commonly-owned U.S. Publication No. US2013/0259720 titled “Electric Water Pump With Stator Cooling” and U.S. Publication No. US2014/0017073 titled “Submerged Rotor Electric Water Pump with Structural Wetsleeve”, the entire disclosures of which are incorporated herein by reference. One drawback associated with many conventional electric water pumps is the need to provide a rotor encoder or another type of speed sensor within the electric motor to assist in accurate low speed (i.e. less than 600 RPM) pump control via a closed loop motor control system. Additionally, a need exists to provide variable flow at such low speeds that is not directly proportional to motor speed in an effort to meet customer expectations.
In view of the above, a need exists in the art to design and develop simplified and low-cost electric water pumps capable of providing variable flow characteristics and which can be easily substituted for otherwise conventional electric water pumps in motor vehicle applications.
This section provides a general summary of the disclosure and is not intended to act as a comprehensive and exhaustive disclosure of its full scope or all of its features, advantages, objectives and aspects.
It is an objective of the present disclosure to provide an electric water pump that meets the above-identified needs and provides a technological advancement over conventional electric water pumps.
It is another objective of the present disclosure to provide an electric water pump equipped with an electric motor having a stationary stator assembly and an axially-moveable rotor unit adapted to cause concurrent axial movement of a rotary pump member within a pump chamber for variably regulating fluid flow between an inlet and an outlet communicating with the pump chamber.
It is similar objective of the present disclosure to provide an electric water pump having a rotor/impeller assembly that is axially moveable relative to a stationary stator assembly for varying the size of a clearance gap between a volute in the pump chamber and the impeller.
It is a related objective of the present disclosure to control movement of the rotor/impeller assembly so as to provide a low flow output at low rotor speeds and a high flow output at high rotor speeds. In this regard, the rotor/impeller assembly is located in a low flow position relative to the stator assembly when rotated at low rotor speeds and in a high flow position relative to the stator assembly when rotated at high rotor speeds.
In accordance with a first embodiment of an electric water pump constructed and functional in accordance with the objectives of the present disclosure, the rotor/impeller assembly is normally biased toward its low flow position by a mechanical biasing arrangement disposed between the rotor unit and a stationary member within a pump housing. Movement of the rotor/impeller assembly from its low flow position toward its high flow position is a result of a pressure differential (AP) generated between upper (i.e. outer) and lower (i.e. inner) portions of the impeller and which is a function of the rotary speed of the rotor/impeller assembly.
In accordance with a second embodiment of an electric water pump constructed and functional in accordance with the objectives of the present disclosure, the rotor/impeller assembly is normally located in its low flow position by a magnetic biasing arrangement provided by an axially-offset magnetic field between the stator assembly and the rotor unit that is established by rotor magnets having an increased length in the direction of the impeller so as to provide a centering relationship with the stator assembly during low speed operation.
The present disclosure is directed to a variable flow electric water pump for use in an engine coolant system of a motor vehicle comprising: a pump housing defining a fluid chamber and a motor chamber, the fluid chamber including a fluid inlet and a discharge outlet for providing a flow of a coolant through the fluid chamber; an electric motor disposed in the motor chamber and including a stationary stator assembly and a rotor unit having a rotor shaft supported for rotation about a longitudinal axis and at least partially extending into the fluid chamber; an impeller fixed for rotation with the rotor shaft and disposed within the fluid chamber and being operable to pump the coolant from the fluid inlet to the discharge outlet; and a biasing arrangement operable for normally locating the rotor unit in a first position axially offset relative to the stator assembly for locating the impeller in a retracted position within the fluid chamber so as to provide a low flow characteristic between the fluid inlet and the discharge outlet when the impeller is rotatable driven by the rotor shaft at a low impeller speed.
The variable flow electric water pump of the present disclosure is further operable when the impeller is rotatably driven at a higher impeller speed to forcibly move the impeller to an extended position within the fluid chamber, in opposition to the preload exerted by biasing arrangement, for causing the rotor unit to be located in a second position axially aligned with the stator assembly.
The variable flow electric water pump of the present disclosure can be equipped with a mechanical biasing arrangement configured to normally exert a biasing force on the rotor unit selected to bias the rotor unit toward its first position. The mechanical biasing arrangement can include a mechanical biasing member, such as one or more spring members, disposed between an upper portion of the rotor unit and a stationary member or portion of the pump housing.
The variable flow electric water pump of the present disclosure can optionally be equipped with a magnetic biasing arrangement configured to normally locate the rotor unit in its first position.
The variable flow electric water pump of the present disclosure can further include an interface formed in the pump housing between the fluid inlet and the discharge outlet defining a flange surface. The impeller can be configured to include an outer rim surfaced aligned with the flange surface such that a first larger clearance gap is established therebetween when the impeller is located in its retracted position. The first larger clearance gap functions to establish a low flow characteristic when the impeller is driven at the low impeller speeds by the electric motor. In contrast, a second smaller clearance gap is established when the impeller is located in its extended position so as to create a high flow characteristic when the impeller is driven by the electric motor at the high impeller speeds.
Further areas of applicability will become apparent from the detailed description provided herein. As noted, the description of the objectives, aspects, features and specific embodiments disclosed in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and, as such, are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding components throughout the several views of the drawings.
Example embodiments will now be more fully describe with reference to the accompanying drawings. However, the following description is merely exemplary in nature and is not intended to limit the present disclosure, its subject matter, applications or uses. To this end, example embodiments of an electric water pump are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in this art. Numerous specific details are set forth, such as examples of specific components, devices and methods to provide a thorough understanding of the embodiments in many different forms, and such should not be construed to limit the intended scope of protection afforded by this disclosure. As is understood, some well-known processes, structures and technologies are not described in detail herein in view of the understanding afforded thereto by those skilled in this art.
In general, the present disclosure relates to an electric pump and, more particularly, to an electric water pump of the type applicable and well-suited for use and installation in motor vehicles for pumping a liquid coolant through an engine cooling system. However, the teachings provided herein are considered to be adaptable to any other electric pump required to move a medium (i.e. air, water, coolant, oil, etc.) within a pumping system requiring a variable flow capability.
With particular reference to
Bottom cap 20 is configured, in this non-limiting example, to include an annular rim 44 extending from a planar mounting surface 46, and an elongated cylindrical hub 48, both of which are concentric with the longitudinal axis. End section 24 of outer housing 18 includes an inner diameter wall surface 50 configured to be pressed against an outer diameter surface 52 of annular rim 44. End section 24 also includes a planar end surface 54 configured to engage mounting surface 46 on bottom cap 20. While not specifically shown, a suitable fastening arrangement is provided to secure bottom cap 20 to outer housing 18 so as to define an internal motor chamber 56. A blind bore 58 is formed in hub 48 and further defines a bearing pocket 60.
Top cap 22 is shown, in this non-limiting example, configured to include an axially-extending tubular section 64 defining a fluid inlet 66, a radially-extending tubular section 68 defining a fluid discharge outlet 70, and a volute section 72 defining an impeller cavity 74 in fluid communication with fluid inlet 66 and discharge outlet 70. An interface 76 is formed in top cap 22 between fluid inlet 66 and impeller cavity 74 and includes a first flange surface 78 and a second flange surface 80. Top cap 22 includes a stepped flange section 82 configured to enclose a portion of raised rim 28 on end plate section 26 of outer housing 18. Top cap 22 also includes a planar inner mounting surface 84 configured to engage outer mounting surface 30 on outer housing 18. Suitable fasteners, such as a plurality of bolts 86, are provided for securely connecting top cap 22 to outer housing 18.
With continued reference to
Stator assembly 90 includes, in this non-limiting example, a coil winding 106 and a plurality or stack of plates 108 retained on a stator cage 110. Stator cage 110 in non-moveably mounted to outer housing 18 and/or sleeve 94 within stator cavity 56A.
Rotor unit 92 is shown, in this non-limiting example, to include a rotor shaft 114 and a plurality of circumferentially-aligned permanent magnets 116 retained by or encapsulated in a rotor shell 118. An annular magnetic air gap 120 is established between intermediate sleeve segment 100 of sleeve 94 and rotor unit 92. The components of rotor unit 92 are fixed to rotor shaft 114 for common rotation about the longitudinal axis. A first or lower end portion 114A of rotor shaft 114 is disposed in blind bore 58 formed in bottom cap 20 and is supported for rotary and axial movement therein by a first or lower guide bushing 122 retained in bearing pocket 60. Likewise, a second or upper end portion 114B of rotor shaft 114 extends through throughbore 38 and into impeller cavity 74. End portion 114B of rotor shaft 114 is supported for rotary and axial movement by a second or upper guide bushing 124 retained in bearing pocket 40 formed in annular boss 34.
Pump unit 16 is shown, in this non-limiting example, to include a rotary pump member, such as an impeller 126, that is rigidly fixed to second end portion 114B of rotor shaft 114 for rotation within pump pocket 32. Impeller 126 is configured to include a central hub segment 128, a first or lower rim segment 130 extending radially from hub segment 128, a second or upper rim segment 132, and a plurality of contoured impeller blades 134 extending between lower rim segment 130 and upper rim segment 132. The actual number of impeller blades 134 and their particular contoured configuration (i.e. profile, shape, thickness, etc.) can be selected to provide the desired flow characteristic for a specific pump application. Upper rim segment 132 is configured to define a first rim surface 136 that is generally aligned with first flange surface 78 of volute interface 76, and define a second rim surface 138 that is generally aligned with second flange surface 80.
In accordance with the present disclosure, a rotor/impeller assembly 150 (comprised of rotor unit 92, rotor shaft 114 and impeller 126) is moveable axially with respect to stator assembly 90 and inlet/volute interface 76 to provide a means for varying the flow characteristics of pump 10. In this regard,
As seen in
In contrast to the arrangement shown in
In one non-limiting example, the clearance gap “Y1” is in the range of 3 to 5 mm at low impellor rotary speeds in the range of 400 to 600 RPM. In contrast, the clearance gap “Y2” is in the range of 0.3 to 0.6 mm at higher impellor rotary speeds.
Based on the above, the present disclosure provides a unique and non-obvious variant of an electric water pump 10 that is configured to generate lower flow at low rotor speeds as well as generate high flow at higher rotor speeds. It is contemplated that the preload applied by biasing member 156 to rotor unit 92 can be calibrated based on pump speed so as to maintain rotor/impeller assembly 150 in its low flow position until increased pumping efficiency is required.
Referring now to
In contract to
While pump 10 was illustrated to include a helical coil spring as biasing member 156 those skilled in the art recognize that other types and/or combinations of biasing devices configured to normally bias rotor/impeller assembly 150 to its low flow position during low speed/low flow operation can be employed. In addition, a combination of the spring-biased arrangement 152 of
While not expressly shown, those skilled in the art will recognize that electric pumps 10, 10′ would be equipped with a controller device which functions to control operation of electric motor 12 and the rotational speed of impeller 126. The controller device may include an electronic circuit board (ECB) electrically connected to stator assembly 90 and which can be mounted within pump housing 18.
Referring to
This application is a Continuation of U.S. Application No. 15/079,123 filed Mar. 24, 2016 which claims the benefit of U.S. Provisional Application No. 62/140,854 filed Mar. 31, 2015. The entire disclosure of each of the above applications is incorporated herein by reference.
Number | Date | Country | |
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62140854 | Mar 2015 | US |
Number | Date | Country | |
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Parent | 15079123 | Mar 2016 | US |
Child | 16251444 | US |