Note: Descriptions are shown in the official language in which they were submitted.
I
ELECTRIC MOTOR -DRIVEN PUMP
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent
Application No. 61/603,907 filed February 27, 2012, which is available for
public inspection in the databases of the United States Patent & Trademark
Office ("USPTO").
FIELD
[0002] The present disclosure relates generally to pumps for use in
generating a flow of a fluid. More particularly, the present disclosure
relates to
an oil pump controlled by a controller for generating a fluid flow such as an
oil
pump for use in an engine in a vehicle.
BACKGROUND
[0003] It is generally known that an oil pump is used to create a flow of
fluid oil through an engine to cool and lubricate components of the drive
train
or engine during operation of the vehicle. It is also generally known to
operate
the oil pump using a power take off from the engine. In some applications, it
is
also generally known to provide an electric motor for operating the oil pump.
Typically, it is also known to provide a controller including a circuit board
and
other electronic components for use in controlling the oil pump during
operation of the vehicle. Most of the current applications have the controller
integrated at the back of the motor housing where it is cooled only by the air
flow. These applications are limited by maximum ambient temperature and the
amount of power (i.e., current) that the system can draw before the electrical
components of the controller overheat and shut down.
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[0004] So,
if the electronic control apparatus is provided in the vehicle's power
generation compartment, the temperature in the compartment generally creates a
potential problem. While the air temperature in the compartment can be
maintained
at a sufficiently low temperature when a vehicle is moving and/or operating
since
fresh air flows can be used to transfer heat from the compartment, when the
vehicle
is stopped, such as after its high-speed running, the air stagnates in the
compartment and is heated by the heat of the engine, with the result that the
air
temperature in the compartment rises to a relatively very high level which may
lead
to component fatigue, failure or other troubles.
[0005] To
obtain an electric motor which is both compact and capable of
delivering high output torque, a large current must be passed through the coil
of the
motor proper and thus the controller must be capable of providing such high
current
to the motor. Passing a large current through the coil of the motor and the
controller
used to manage the supply of electrical energy to the motor can cause the
motor
and/or the controller to heat up and if heated too high, to eventually fail.
Generally, it
is required that the motor be cooled and that the controller be located at a
distance
from the motor and the heat source to protect the controller from extensive
heat.
Further, it is generally known to use very expensive components in the
controller
capable of functioning properly at such elevated temperatures. Accordingly,
space
must be provided to locate the controller and the motor to be able to
function.
However, it is very difficult to provide additional space for accommodating
the
installation of the electric motor and the controller because space is already
very
limited, particularly in the aforementioned motorized vehicle applications.
Thus, it is
very difficult to provide both the electric motor and the pump in a limited
space. This
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has made it almost impossible and very expensive to implement such an electric-
motor-driven pump.
[0006] The present disclosure is based on the object of providing an
electric
motor-driven pump and control device by means of which the above-described
problems of the prior art are avoided.
SUMMARY
[0007] In one exemplary embodiment, there is disclosed an electronic
motor-
driven pump and integrated controller including a housing in which the
controller,
including power control components (e.g., MOSFETS) for supplying power to the
motor, is arranged for controlling the rotational speed of a fluid pump and
the output
of the fluid pump to be supplied to a vehicle component. The electronic motor-
driven
pump includes a motor portion located at one end, the fluid pump in the middle
and
an inlet/outlet housing portion including an integrated portion for containing
the
controller and its components such that the integrated portion is located
proximal the
flowing fluid in the inlet and outlet and has sufficient thermal conductivity
to
sufficiently dissipate heat from the controller located in a cavity formed in
the
inlet/outlet housing portion. The inlet/outlet housing portion may also
include one or
more passages which extend parallel to the central axis of the pump and the
motor
for receipt of the wires required for electrically coupling the controller and
the stator
of the motor such that the wires also pass through a sealed passage extending
axially through the fluid pump. Additionally, the fluid passes through the
pump and
the electric drive-motor to dissipate heat from all of the components of the
assembly.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawings illustrate, by way of example only, embodiments of
the
present disclosure wherein:
[0009] Fig. 1 is a perspective graphic view of an exemplary combined
motor-
driven pump and controller and housing system in accordance with the present
disclosure;
[0010] Fig. 2 is an exploded, perspective graphic view of the combined
motor-
driven pump and controller and housing system of the exemplary embodiment of
Fig.
1 in accordance with the present disclosure;
[0011] Fig. 3 is a cross-section, graphic view of the combined motor-driven
pump
and controller and housing system of the exemplary embodiment of Fig. 1 in
accordance with the present disclosure;
[0012] Fig. 4 is an exploded, perspective, graphic view of an alternative
embodiment of a combined motor-driven pump and controller and housing system
of
the exemplary embodiment of Fig. 1 in accordance with the present disclosure;
[0013] Fig. 5 is a perspective, graphic view of a thermal image analysis
for the
combined motor-driven pump and controller and housing system of the exemplary
embodiment of Fig. 1 in accordance with the present disclosure;
[0014] Fig. 6 is a perspective, graphic view of an alternate exemplary
embodiment of a combined electric motor-driven pump, controller and housing
system in accordance with the present disclosure showing the details of the
innovation;
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[0015] Fig. 7 is a further alternate partial, perspective graphic view of
the
exemplary embodiment of Fig. 6 with the controller cover and the controller
removed
showing the passages for routing the wires for the controller and the motor;
[0016] Fig. 8 is a perspective, graphic view and a further alternate
embodiment of
5 .. a pump for inclusion in a combined motor-driven pump controller and
housing
system displaying an alternate side for coupling the pump housing to the motor
for
including the controller within the housing and affecting cooling thereof;
[0017] Fig. 9 is a perspective, graphic view of a further alternate
embodiment of a
pump for inclusion in a combined motor-driven pump and controller and housing
system similar to Fig. 8 and showing an alternate oil inlet/outlet member;
[0018] Fig. 10 is a cross-sectional, graphic view and the further
alternate
embodiment of a pump for inclusion in the motor-driven pump of the exemplary
embodiment of Fig. 9 in accordance with the present disclosure;
[0019] Fig. 11 is a perspective, graphic view of a further alternate
embodiment of
.. a pump for inclusion in a combined motor-driven pump, controller and
housing
system similar to Fig. 8 and showing an alternate oil inlet/outlet member;
[0020] Fig. 12 is an exploded perspective, graphic view of the further
alternate
embodiment of a combined pump for inclusion in the motor-driven pump of the
alternate exemplary embodiment of Fig. 11 in accordance with the present
disclosure and showing an intersecting vane embodiment according to the
present
disclosure;
[0021] Fig. 13 is a perspective, graphic view of a further alternate
embodiment of
a pump for inclusion in the combined motor-driven pump and controller and
housing
system including an intersecting vane similar to Fig. 12;
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[0022] Fig. 14 is a partial, perspective, graphic view of the further
alternate
embodiment of the pump for inclusion the combined motor-driven pump of the
alternate exemplary embodiment of Fig. 13 in accordance with the present
disclosure;
[0023] Fig. 15 is a perspective, graphic view of the further alternate
embodiment
of Fig. 12 showing the detail of the variable displacement pump and the
intersecting
vane design;
[0024] Fig. 16 is a partial, plan graphic view of the further alternate
embodiment
of Figs. 12 and 15 further showing the detail of the variable displacement
pump and
the intersecting vane design according to the present disclosure; and
[0025] Fig. 17 is a diagrammatic view and exemplary boundary diagram of
the
combined motor-driven pump and controller and housing system according to the
present disclosure.
DETAILED DESCRIPTION
[0026] Referring in general to all of the figures, the present disclosure
and
teachings described herein provide for a combined motor-driven pump and
controller
system, hereinafter referred to as an electric motor-driven oil pump assembly
10, for
use in automotive applications such as in association with a vehicle engine or
drive
train, such as a transmission. The electric motor-driven oil pump assembly 10
provides lubrication, cooling and pressure in various system configurations.
The
primary elements of this electric motor-driven oil pump assembly 10 system
are: the
pump 20 which may be of any known or appropriate type (such as a fixed or
variable
displacement type pump), a motor 30, in particular a brushless direct current
(DC)
type motor, and a motor controller 40, such as a power inverter and an
appropriate
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electrical connector for electrically coupling the electric motor-driven oil
pump 10 to a
source of electrical current power (such as a battery or similar type device).
In
addition, the electric motor-driven oil pump assembly 10 may also include
known
and/or appropriate diagnostics and sensor signals (not shown). The electric
motor-
driven oil pump assembly 10 is configured such that the whole assembly may be
fully integrated (i.e., the pump 20, motor 30, controller 40 and electrical
connector)
and contained in a single, sealed (integrated) body 60 due to system
restrictions
such as packaging. However, in application, such a system is exposed to high
ambient temperatures due to mounting locations and positions directly on the
transmission or engine body (not shown) and even sometimes locations inside
the
transmission body. In
these applications, the electric motor-driven oil pump
assembly 10 is typically exposed to potentially very severe environments
including
elevated temperatures. The
most sensitive component to high ambient
temperatures is the motor controller 40 which has the effect of limiting the
maximum
operating temperature of the electric motor-driven oil pump assembly 10.
Currently,
maximum operating temperatures for the motor controller subcomponents are as
generally: 175 degrees Celsius for the FET junction, 150 degrees Celsius for
the
motor controller unit MCU and 135 degrees Celsius for the capacitor.
[0027] To
ensure that the noted temperature limits are not exceeded during
maximum ambient temperature operation (Ta = 138 degrees Celsius), the oil pump
20 uses oil flow to cool the controller 40. Primarily, the benefit of the
electric motor-
driven oil pump assembly 10 according to the present disclosure is that it
enables
operation of the electric motor-driven oil pump assembly 10 under relatively
higher
ambient temperature conditions and at the same time provides for the
possibility to
reduce cost by using lower temperature grade electronic components as compared
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to known systems. As best shown in Fig. 5, pursuant to one set of exemplary
operating conditions (i.e., ambient air at 138 degrees Celsius) the
temperature of the
oil flowing through the pump 20 keeps the oil at the inlet and at the outlet
at 125
degrees Celsius which is below the noted temperature limits. Similarly, in
Fig. 6 the
oil flows at 4.5 liters per minute (Ipm) and the controller 40 is located in a
first portion
of an inlet/outlet housing 44 coupled to the oil pump assembly 20. The first
portion
of the inlet/outlet housing 44 includes a first cavity 42 for receiving the
controller 40
therein and having a cover 46 secured to the inlet/outlet housing for sealing
the
controller 40 and its components in the first cavity. The material of the
inlet/outlet
housing 44 is preferably chosen to have a relatively high thermal conductivity
such
as a metal, such as aluminum or an aluminum alloy or other known or
appropriate
materials. The first cavity 42 in the inlet/outlet housing 44 includes at
least a first
passage 45 extending from the first cavity 42 to the pump 20 and to a stator
of the
brushless direct current motor 30. As best shown in the embodiment of Fig. 4,
a
bus-bar may be included in the motor assembly 30, coupled to the stator, and
including an extension for passing through a sealed passage extending through
the
pump 20 and into the passage of the inlet/outlet housing for being coupled and
electrically connected with the controller 40 therein.
[0028] As shown in the cross-section of Fig. 3, the controller 40 is
located in the
first cavity to be reasonably closely located proximate the inlet and outlet
passages
in the inlet/outlet housing 44 so that there is efficient heat transfer
between the
controller 40 and the fluid flowing therethrough. As the oil flows into the
assembly
10, it will have a relatively lower temperature than the heat produced by the
motor 30
and will flow through the pump 20, through the motor 30 and then back through
the
motor 30 and out of the inlet/outlet housing 44 where it will have a hydraulic
pressure
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and flow to the vehicle component, such as a transmission or engine as well
as,
optionally, a heat exchanger where the oil may be cooled using any known or
appropriate system and then returned to the assembly 10. In the embodiments
shown, it is possible for the motor 30 to be completely sealed such that the
fluid
flowing through the motor is completely sealed such that the fluid does not
and
cannot contact any of the electrical components of the motor 30 or of the
controller
40. A completely sealed assembly 10 is particularly significant and important
for a
fluid that may cause the electrical components to short, such as water.
Alternatively,
for a fluid that will not cause the electrical components to short, it is
possible for the
motor 30 and the controller 40 to be partially sealed or unsealed such that
the fluid is
allowed to contact the electrical components and thereby increase the heat
transfer
away from the electrical components.
[0029] In an alternate embodiment shown in Figs. 8 through 14, the pump
120 is
shown having a controller 140 located at one side surface of the pump 120. In
particular, different types of pumps may be used such as the external rotor
vane
pump of Figs. 9 and 10 as well as the intersecting vane pump of Figs. 11
through 15
incorporating the teachings and disclosure of the present innovation. As
should be
understood from the present disclosure, it is possible to incorporate the
teachings
and disclosures of the present innovation into motor designs providing a
variety of
performance requirements and specifications including inter and out rotors,
having
between at least 12 Volts and 300 Volts applications. Further, it is possible
to design
the controller for providing a wide variety of design requirements such as FOG
and
Block, and 12V and 300V applications as well as including a variety of control
strategies (i.e., control strategies based upon motor speed, torque, and
current as
well as based upon pump pressure). Accordingly, it should also be understood
that
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the assembly 10 of the present disclosure provides for a variety of
communication
protocols to be utilized including but not limited to PWM, K-line, LINE, CAN
or any
other known or appropriate protocol. Accordingly, it is possible to provide an
assembly 10 that is optimized to a significant variety of design
specifications and
5 preferences.
[0030] In particular, it is contemplated that the assembly 10 according
to the
present disclosure, provides for a novel motor design for increasing the
overall
electric motor-driven pump performance while increasing the efficiency and
reliability
of the assembly 10 while reducing the costs of the components of the
controller 40
10 and thereby the overall costs of the assembly 10.
[0031] Referring now in particular to the intersecting vane pump of
Figs. 13
through 16 there is shown an oil pump 200. The pump 200 includes a top plate,
a
motor, and a pump outer rotor and a pump inner rotor, as best shown in Figs.
15 and
16. In particular, it should be understood that the outer pump rotor and the
inner
pump rotor both rotate with respect to the fixed bushing. Further of note is
that the
pump 200 includes first, second and third vanes (Vane 1, Vane 2, and Vane 3,
respectively). Similar to the assembly 10 above, the pump 200 includes a
controller
(or PCB) coupled to a Base Plate and located under a Top (or Cover) Plate as
best
shown in Figs. 13 and 14. The controller (PCB) is installed on the back side
of the
Base Plate so its heat will be dissipated by the fluid flowing from the Inlet
Port to the
Outlet Port.
[0032] The internal components of the electric motor-driven oil pump 200
generally include the Motor Rotor, the Pump Outer Rotor, Vane 1, Vane 2, Vane
3,
the Pump Inner Rotor and the Bushing all coupled together as shown. The Inlet
Port
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and Outlet Port are located in the Base Plate and are coupled to the pump 200
for
flowing the fluid through the pump using the intersecting vane design as
shown.
[0033] The Pump Outer Rotor is preferably pressed into the Motor Rotor.
The
Pump Outer Rotor includes at a first location a half circle or scallop on the
inner bore
of the Pump Outer Rotor for receiving a first end of Vane 1. Vane 1 extends
from the
scallop in the inner bore of the Pump Outer Rotor and through a first slot
located
transversely across the Pump Inner Rotor. Vane 2 and Vane 3 are installed in
second and third slots of the Pump Inner Rotor and are each guided by the
shaped
contour of the inner circumference of the bore or passage of the Pump Outer
Rotor.
The contour of the inner circumference of the bore or passage of the Pump
Outer
Rotor is shaped to affect the operation of the Vanes 1, 2, and 3 during
rotation of the
rotors for the pump 200 to perform consistent with desired design
requirements.
When the motor 200 is working, the Motor Rotor and Pump Outer Rotor will
rotate in
a clockwise direction as shown in Fig. 15, and will drive Vane 1 and the Pump
Inner
Rotor and then will drive Vane 2 and Vane 3 but, the three Vanes will only
swing
back and forth during some angles related to the Pump Rotor to move fluid
through
the pump 200 causing oil to flow from the Inlet Port through the pump to the
outlet
port.
[0034] The configuration of the pump 200 according to the present
disclosure is
selected so the Pump Outer Rotor is a driving member and the Inner Rotor is
driven
by Vane 1 connected with Pump Outer Rotor. This type of pump driving method
and
configuration is unique so the contour of the inner circumference of the bore
or
passage of the Pump Outer Rotor is a pre-selected curve so that when the Pump
Outer Rotor is rotated, the three Vanes 1, 2, and 3 will only swing back and
forth
during some angles related to the Pump Rotor.
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[0035] The pump 200 of the present disclosure particularly benefits from
the
current design because the electric motor-driven oil pump 200 may work at high
ambient temperature conditions while at the same time providing the
possibility for
significantly reduced cost by using lower temperature grade electronic
components
in the controller (PCB) as well as a reduced number of mechanical components
making up the pump 200 as compared to conventional vane pumps thereby further
reducing cost.
[0036] Any numerical values recited herein or in the figures are intended
to
include all values from the lower value to the upper value in increments of
one unit
provided that there is a separation of at least 2 units between any lower
value and
any higher value. As an example, if it is stated that the amount of a
component or a
value of a process variable such as, for example, temperature, pressure, time
and
the like is, for example, from 1 to 90, preferably from 20 to 80, more
preferably from
30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51, 30
to 32 etc.
are expressly enumerated in this specification. For values which are less than
one,
one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These
are
only examples of what is specifically intended and all possible combinations
of
numerical values between the lowest value and the highest value enumerated are
to
be considered to be expressly stated in this application in a similar manner.
As can
be seen, the teaching of amounts expressed as "parts by weight" herein also
contemplates the same ranges expressed in terms of percent by weight. Thus, an
expression in the Detailed Description of the Invention of a range in terms of
at "'x'
parts by weight of the resulting polymeric blend composition" also
contemplates a
teaching of ranges of same recited amount of "'x' in percent by weight of the
resulting polymeric blend composition."
13
[0037] Unless otherwise stated, all ranges include both endpoints and
all numbers between the endpoints. The use of "about" or "approximately" in
connection with a range applies to both ends of the range. Thus, "about 20 to
30" is intended to cover "about 20 to about 30", inclusive of at least the
specified endpoints.
[0038] The term "consisting essentially of" to describe a combination
shall include the elements, ingredients, components or steps identified, and
such other elements, ingredients, components or steps that do not materially
affect the basic and novel characteristics of the combination. The use of the
terms "comprising" or "including" to describe combinations of elements,
ingredients, components or steps herein also contemplates embodiments that
consist essentially of the elements, ingredients, components or steps. By use
of the term "may" herein, it is intended that any described attributes that
"may"
be included are optional.
[0039] Plural elements, ingredients, components or steps can be
provided by a single integrated element, ingredient, component or step.
Alternatively, a single integrated element, ingredient, component or step
might
be divided into separate plural elements, ingredients, components or steps.
The disclosure of "a" or "one" to describe an element, ingredient, component
or step is not intended to foreclose additional elements, ingredients,
components or steps.
[0040] It is understood that the above description is intended to be
illustrative and not restrictive. Many embodiments as well as many
applications
besides the examples provided will be apparent to those of skill in the art
upon
reading the above description. The scope of the invention should, therefore,
be determined not with reference to the above description, but should instead
be determined with reference to the appended claims, along with the full scope
of equivalents to which such claims are entitled. The omission in the
following
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claims of any aspect of subject matter that is disclosed herein is not a
disclaimer of such subject matter, nor should it be regarded that the
inventors
did not consider such subject matter to be part of the disclosed inventive
subject matter.
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