Electric pump system and method
11821420 · 2023-11-21
Assignee
Inventors
- Scott Michael Graves (Felton, CA, US)
- Eric Bellemare (Mountain View, CA, US)
- Yufei Zhu (Sunnyvale, CA, US)
- Benjamin Dellal (San Francisco, CA, US)
- Diego Alberto Silva Rodriguez (Cupertino, CA, US)
Cpc classification
F04C11/008
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C14/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C15/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C2240/808
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C2240/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C15/0096
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C14/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C2240/603
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K9/19
ELECTRICITY
International classification
F04C11/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C14/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C14/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C15/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C15/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04C2/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An electric pump system and method of operating the same involves pumping a fluid through a fluid passageway defined in a mechanical pump from a pump inlet to a hollow shaft of a motor, through the hollow shaft to an internal motor cavity defined by a housing of the motor, and through another fluid passageway defined in the motor housing and mechanical pump that leads to a pump outlet. The system and method further involve pumping the fluid through another fluid passageway defined in the mechanical pump from yet another pump inlet to the pump outlet. The temperature of fluid exiting the hollow shaft can be assessed and used by an electronic control unit (ECU) of the electric pump system to control the same. The electric pump system can be part of a cooling and lubrication system for an electric vehicle transmission, gearbox, differential or transfer case, for example.
Claims
1. An apparatus comprising: a motor having a first side and a second side, the motor including: a stator; a rotor comprising a hollow shaft; a housing around the stator and the rotor and defining an internal motor cavity; a positive displacement pump connected to the second side of the motor, the positive displacement pump comprising a first pump inlet, a second pump inlet adjacent to the first pump inlet, a bypass inlet, and a pump outlet, wherein the first pump inlet is fluidically connected to the pump outlet via a first fluid passageway, wherein the second pump inlet is fluidically connected to the pump outlet via a second fluid passageway, the second fluid passageway conducting fluid through the hollow shaft and then through the internal motor cavity to the pump outlet from the second pump inlet; and an electronic control unit connected to the first side of the motor, the electronic control unit comprising a temperature sensor located adjacent to a shaft outlet of the hollow shaft, wherein the temperature sensor is configured to measure a temperature of the fluid exiting the hollow shaft, wherein responsive to the measured temperature of the fluid exiting the hollow shaft, the electronic control unit determines: a required amount of heat that needs to be rejected from the fluid or at least one of required changes to an operation of an associated vehicle.
2. The apparatus of claim 1, wherein the temperature sensor comprises a thermistor.
3. The apparatus of claim 1, wherein the hollow shaft comprises a shaft inlet and the shaft outlet, wherein fluid in the second fluid passageway flows from the shaft inlet to the shaft outlet, and wherein the pump outlet is proximate to the shaft inlet relative to the shaft outlet.
4. The apparatus of claim 1, wherein at least a portion of the first fluid passageway and the second fluid passageway is common.
5. The apparatus of claim 1, wherein the positive displacement pump comprises a gerotor.
6. The apparatus of claim 1, wherein the electronic control unit includes a microcontroller controlling the positive displacement pump.
7. The apparatus of claim 1, wherein the at least one of the required changes to the operation of the associated vehicle comprises a reduction of torque.
8. A method of pumping a fluid in an electric pump system having a positive displacement pump, the method comprising: controlling a pump via a microcontroller; pumping fluid through a first fluid passageway from a first pump inlet to a pump outlet pumping fluid through a second fluid passageway from a second pump inlet adjacent to a first pump inlet to the pump outlet, wherein the fluid within the second passageway is conducted through a hollow shaft of a rotor and then through an internal motor cavity defined by a housing around the rotor, wherein the fluid flows through the hollow shaft from a shaft inlet to a shaft outlet, wherein the pump outlet is proximate the shaft inlet relative to the shaft outlet; detecting, via a temperature sensor located adjacent to the shaft outlet, a temperature of the fluid exiting the hollow shaft; and determining a required amount of heat that needs to be rejected from the fluid via evaluation of a plurality of corrective actions responsive to the detected temperature of the fluid exiting the hollow shaft; wherein the plurality of corrective actions comprises rejecting heat by the electric pump system or a change to a motor parameter of a motor associated vehicle.
9. The method of claim 8, wherein the detected temperature of the fluid corresponds to a temperature of the fluid prior to the fluid entering the internal motor cavity.
10. The method of claim 8, wherein the detected temperature of the fluid corresponds to a temperature of the fluid prior to the fluid being heated by the electric pump system by a threshold amount.
11. The method of claim 8, wherein the required changes to the motor parameter of the motor of the associated vehicle comprises a reduction of torque.
12. The method of claim 8, further comprising conducting fluid through a bypass inlet.
13. A system comprising: an apparatus including: a motor having a first side and a second side, the motor including: a stator, and a rotor comprising a hollow shaft; an electronic control unit connected to the first side of the motor, the electronic control unit comprising a temperature sensor located adjacent to a shaft outlet of the hollow shaft, wherein the temperature sensor is configured to measure a temperature of a fluid exiting the hollow shaft, wherein the electronic control unit determines: a required amount of heat that needs to be rejected from the fluid or at least one of required changes to an operation of an associated vehicle; a positive displacement pump connected to the second side of the motor, the positive displacement pump comprising a first pump inlet, a second pump inlet adjacent to the first pump inlet, a bypass inlet, and a pump outlet, wherein each of the first pump inlet, the second pump inlet, and the pump outlet is located on the second side of the motor, wherein the first pump inlet is fluidically connected to the pump outlet via a first fluid passageway, and wherein the second pump inlet is fluidically connected to the pump outlet via a second fluid passageway, the second fluid passageway conducting fluid through the hollow shaft and then through an internal motor cavity to the pump outlet from the second pump inlet; a heat exchanger in fluidic communication with the pump outlet; and an oil reservoir in fluidic communication with the first pump inlet.
14. The system of claim 13, wherein the temperature sensor is a thermistor.
15. The system of claim 13, wherein at least a portion of the first fluid passageway and the second fluid passageway is common.
16. The system of claim 13, wherein the positive displacement pump comprises a gerotor.
17. The system of claim 13, wherein the electronic control unit includes a microcontroller controlling the positive displacement pump.
18. The system of claim 13, wherein fluid flows through the hollow shaft from a shaft inlet to the shaft outlet, wherein the pump outlet is closer to the shaft inlet than the shaft outlet.
19. The system of claim 13, wherein the at least one of the required changes to the operation of the associated vehicle comprises a reduction of torque.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE DISCLOSURE
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(18) Starting from oil reservoir 102, which may include a sump or dry-sump system (oil reservoir external to the drive unit), oil flows through meshed filter 104 to electric pump system 106. Oil pumped out of electric pump system 106 passes through oil filter 108 and heat exchanger 110 and splits between a first branch that leads to motor 112 and another that leads to gear box 114. Oil from both branches drains back to oil reservoir 102.
(19) Various operational issues with the cooling and lubrication system 100 are described herein in conjunction with various embodiments. One operational issue relates to heat exchange within the electric pump system 106. Another operational issue relates to assessing and controlling the temperature of oil in the cooling and lubrication system 100. The oil temperature may be controlled by heat transfer in heat exchanger 110, i.e., exchange of heat between the vehicle coolant and the oil. Firmware or software typically controls the Engine Control Unit (ECU) which is not shown in
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(34) Fluid passageway 1115 may also be referred to as the first fluid passageway. Main pump inlet 1120 may also be referred to as the first pump inlet. Fluid passageway 1126 may also be referred to as the second fluid passageway. Pump inlet 1124 may also be referred to as the second pump inlet. Fluid passageway 1114 may also be referred to as the third fluid passageway. Secondary pump inlet 1116 may also be referred to as the third pump inlet.
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(40) A benefit of the system and method of the disclosed embodiments, is that very little heat is absorbed by the fluid from operation of electric pump system 106 when the fluid is exiting hollow shaft 706. By measuring at this point, ECU 206 can, therefore, get an accurate reading of the fluid prior to being substantially heated by electric pump system 106, but without having to use sensors positioned at or near the pump inlets which would necessitate communications channels for relaying information to ECU 206 thereby adding expense, complexity and additional points of failure. Information regarding the temperature of the fluid prior to being substantially heated by electric pump system 106 can be used for purposes of determining how much heat needs to be rejected from the fluid and what changes to make to the operation of the associated vehicle (e.g. reduce torque).
(41) As will be appreciated by one of skill in the art, a slow rotating gear requires oil of a specific viscosity to stick to its surface. A gear of the same size with much higher rotational speed, e.g. at a reduction gear stage before the one above, may require a different temperature of oil in order to have it stick to the gear surface because the centrifugal forces are much higher. If the temperature is the same, because two separate oil temperatures are not available in the gearbox, one could use much more oil more orifices for the fast rotating gear.
(42) According to embodiments described herein, the fluid temperature can be used to control and attempt to optimize the cooling and lubrication system of a vehicle so as to improve the efficiency of the associated electric drive unit. Specifically, the fluid temperature may be controlled to achieve certain lubrication properties. For example, hotter oil has lower viscosity which reduces drag and hydraulic power to pump the fluid, which can increase efficiency. If the oil becomes too hot, however, it will not provide sufficient cooling.
(43) The fluid temperature reading feature of the oil pump can monitor the general health and performance of the fluid in the electric drive unit system. For example, if the oil is too hot, the oil pump may alert the car computer that something is wrong, for oil that is too hot can damage or/and reduce the life of some components on the drive unit.
(44) Stated another way the temperature of fluid may be used to monitor the health and performance of the drive unit. The ECU may capture other information besides the temperature, such as pump speed, pump current composition, oil pressure, or other information. The information captured by the ECU may then be fed into a proprietary algorithm that monitors oil pump and overall drive unit health. The algorithm may provide an indication of service, such as when oil must be replaced or when the drive train needs to be serviced.
(45) In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as one skilled in the art will appreciate, various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered as illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the disclosed system, method, and computer program product. It is to be understood that the forms of disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, materials, processes or steps may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the disclosure.
(46) As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any contextual variants thereof, are intended to cover a non-exclusive inclusion. For example, a process, product, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements, but may include other elements not expressly listed or inherent to such process, product, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition “A or B” is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B is true (or present).
(47) Although the steps, operations, or computations may be presented in a specific order, this order may be changed in different embodiments. In some embodiments, to the extent multiple steps are shown as sequential in this specification, some combination of such steps in alternative embodiments may be performed at the same time. The sequence of operations described herein can be interrupted, suspended, reversed, or otherwise controlled by another process.
(48) It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application.