MOTOR AND PUMP SYSTEM WITH FLUID LEVEL CONTROL PLATE

Abstract

A pump system, method of manufacturing same, and vehicle includes: a housing with a pump and an electric motor; a pump inlet; a pump outlet; and a drive shaft driven by the motor, for driving the pump to pressurize fluid. An intermediate housing wall is positioned between the pump and motor, covers a motor cavity, and has a return port. An auxiliary circuit directs a portion of fluid flow to the motor cavity. A fill level control plate is positioned between the wall and the motor cavity, forming an overflow region therebetween, and includes an overflow opening for flow from the motor cavity to the overflow region. The plate causes a liquid level within the motor cavity to rise and a return path directs fluid through the overflow opening in the plate and relatively down the overflow region, to return back to the pump via the return port.

Claims

1. A pump system for installation in a generally horizontal orientation comprising: a housing with a pump for pumping a liquid and an electric motor therein; a pump inlet comprising a pump inlet port; a pump outlet comprising a pump outlet port; a drive shaft rotatably driven by the electric motor, for driving the pump to pressurize fluid received through a fluid path of the pump from the pump inlet for output to the pump outlet; an intermediate housing wall positioned between the pump and the electric motor and covering a motor cavity within the housing for the electric motor; an auxiliary circuit configured to direct a portion of fluid flow generated by the pump to the motor cavity; the intermediate housing wall comprising a pump inlet return port for directing the fluid flow from the motor cavity to the pump; a fill level control plate positioned between the intermediate housing wall and the motor cavity, forming an overflow region between the intermediate housing wall and the fill level control plate; the fill level control plate comprising an overflow opening therethrough for directing fluid flow from the motor cavity to the overflow region, the fill level control plate being installed with said overflow opening at a location spaced radially from the drive shaft for positioning substantially vertically above the drive shaft and the pump inlet return port when installed; and wherein the fill level control plate causes a liquid level within the motor cavity to rise during operation of the pump system and the auxiliary circuit comprises a return path through the electric motor for directing the portion of fluid flow for cooling the electric motor through the overflow opening in the fill level control plate and relatively down the overflow region, to return back to the pump via the pump inlet return port.

2. The pump system according to claim 1, wherein the housing further comprises a controller therein, the controller being provided within the motor cavity and configured to drive the drive shaft via the electric motor.

3. The pump system according to claim 2, wherein the pump and the controller are on opposing sides of the electric motor.

4. The pump system according to claim 2, wherein the controller is provided in the form of a printed circuit board.

5. The pump system according to claim 1, wherein the fill level control plate is positioned against at least a portion of the intermediate housing wall.

6. The pump system according to claim 1, wherein the fill level control plate comprises a first axial side and a second axial side, the first axial side of the fill level control plate facing the intermediate housing wall and the second axial side of the fill level control plate facing a motor stator of the electric motor.

7. The pump system according to claim 6, wherein the fill level control plate comprises a plurality of spring tabs positioned circumferentially therearound, the plurality of spring tabs configured for engagement with the motor stator.

8. The pump system according to claim 1, wherein the intermediate housing wall comprises a recessed region therein, the recessed region facing the fill level control plate to form the overflow region therebetween.

9. The pump system according to claim 1, wherein the fill level control plate is configured to be installed in a plurality of discrete rotational positions to enable movement of the overflow opening relative to the drive shaft.

10. The pump system according to claim 9, wherein the intermediate housing wall comprises a polygonal alignment portion, and wherein the fill level control plate comprises a corresponding polygonal opening for mating with the polygonal alignment portion on the intermediate housing wall at one of the plurality of discrete rotational positions and allowing orientation of the overflow opening of the fill level control plate at the location spaced radially from the drive shaft and substantially vertically above the drive shaft and the pump inlet return port when installed.

11. The pump system according to claim 1, wherein the auxiliary circuit includes a path through an internal bore in the drive shaft, for directing the portion of fluid flow to the motor cavity.

12. The pump system according to claim 1, wherein the pump is a gerotor type pump comprising an inner rotor fixedly secured to the drive shaft for rotation therewith and an outer rotor rotatably received within the housing.

13. A method of manufacturing a pump system configured for installation in a generally horizontal orientation, the method comprising: providing a housing, the housing comprising an intermediate housing wall; providing a pump and an electric motor, the pump having a pump inlet comprising a pump inlet port and a pump outlet comprising a pump outlet port; providing a drive shaft to be rotatably driven by the electric motor, for driving the pump to pressurize fluid received through a fluid path of the pump from the pump inlet for output to the pump outlet; positioning the pump and the electric motor within the housing; positioning the intermediate housing wall therebetween and covering a motor cavity within the housing for the electric motor; installing a fill level control plate between the intermediate housing wall and the motor cavity, forming an overflow region between the intermediate housing wall and the fill level control plate; wherein the pump system further comprises an auxiliary circuit configured to direct a portion of fluid flow to the motor cavity; wherein the intermediate housing wall comprises a pump inlet return port for directing the fluid flow from the motor cavity to the pump; wherein the fill level control plate comprises an overflow opening therethrough for directing fluid flow from the motor cavity to the overflow region, wherein the installation of the fill level control plate comprises positioning said overflow opening at a location spaced radially from the drive shaft for positioning substantially vertically above the drive shaft and the pump inlet return port when installed, such that the fill level control plate causes a liquid level within the motor cavity to rise during operation of the pump system and the auxiliary circuit comprises a return path through the electric motor for directing the portion of fluid flow for cooling the electric motor through the overflow opening in the fill level control plate and relatively down the overflow region, to return back to the pump via the pump inlet return port.

14. The method according to claim 13, wherein the method further comprises installing a controller within the motor cavity, the controller being configured to drive the drive shaft via the electric motor.

15. The method according to claim 14, wherein the pump and the controller are positioned on opposing sides of the electric motor.

16. The method according to claim 14, wherein the controller is provided in the form of a printed circuit board.

17. The method according to claim 13, wherein the installation of the fill level control plate comprises positioning the fill level control plate against at least a portion of the intermediate housing wall.

18. The method according to claim 13, wherein the fill level control plate comprises a plurality of spring tabs positioned circumferentially therearound, and wherein the installation of the fill level control plate comprises engaging the plurality of spring tabs with a motor stator of the electric motor.

19. The method according to claim 13, wherein the intermediate housing wall comprises a recessed region therein, and wherein the positioning of the intermediate housing wall comprises positioning the recessed region facing the fill level control plate to form the overflow region therebetween.

20. The method according to claim 13, wherein the intermediate housing wall comprises a polygonal alignment portion, wherein the fill level control plate comprises a corresponding polygonal opening for mating with the polygonal alignment portion on the intermediate housing wall, said fill level control plate being configured to be installed in a plurality of discrete rotational positions to enable movement of the overflow opening relative to the drive shaft, and wherein the method comprises installing the fill level control plate at one of a plurality of discrete rotational positions and orienting the overflow opening of the fill level control plate at the location spaced radially from the drive shaft for positioning substantially vertically above the drive shaft and the pump inlet return port when installed.

21. A vehicle comprising: a device to receive liquid; the pump system of claim 1 coupled to the device to deliver the liquid thereto, wherein the pump system is installed with the overflow opening positioned substantially vertically above the drive shaft and the pump inlet return port.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 shows a schematic view of a pump system in accordance with an embodiment of the disclosure, configured for installation in a generally horizontal orientation.

[0010] FIG. 2A illustrates a first cross-sectional view of one exemplary embodiment of parts of a pump system according to in FIG. 1, according to an embodiment.

[0011] FIG. 2B illustrates a second cross-sectional view of the pump system, according to an embodiment.

[0012] FIG. 3A shows a top view of a first side (pump side) of an intermediate housing wall mounted in the pump system of FIGS. 2A-2B, according to an embodiment.

[0013] FIG. 3B shows a top view of a second side (motor side) of the intermediate housing wall of FIGS. 2A-2B, according to an embodiment.

[0014] FIG. 4 shows an example of a flow path and a fluid level in a pump system when mounted horizontally.

[0015] FIG. 5 illustrates a detailed section of the cross-sectional view of FIG. 2A, showing a fill level control plate of the pump system in accordance with an embodiment of this disclosure.

[0016] FIG. 6 shows a top view of one side of the fill level control plate mounted in the pump system of FIGS. 2A-2B, according to an embodiment.

[0017] FIG. 7 shows a main flow path and an auxiliary path for liquid flow in the disclosed pump system, according to an embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0018] The description set forth below in connection with the appended drawings is intended as a description of various embodiments of the disclosed subject matter and is not necessarily intended to represent the only embodiment(s). In certain instances, the description includes specific details for the purpose of providing an understanding of the disclosed embodiment(s). However, it will be apparent to those skilled in the art that the disclosed embodiment(s) may be practiced without those specific details. In some instances, well-known structures and components may be shown in block diagram form in order to avoid obscuring the concepts of the disclosed subject matter.

[0019] Reference throughout the specification to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases in one embodiment or in an embodiment in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments. Further, it is intended that embodiments of the disclosed subject matter cover modifications and variations thereof.

[0020] It is to be understood that terms such as up, below, top, bottom, side, upper, lower, interior, exterior, inner, outer, and the like that may be used herein merely describe points of reference and do not necessarily limit embodiments of the present disclosure to any particular orientation or configuration. Typically, such references will be to the orientation of the drawings for convenience of the reader. Furthermore, terms such as first, second, etc., merely identify one of a number of portions, components, steps, operations, functions, and/or points of reference as disclosed herein, and likewise do not necessarily limit embodiments of the present disclosure to any particular configuration or orientation, or any requirement that each number must be included or that they must be included in any particular order.

[0021] As understood by one of ordinary skill in the art, pump displacement or displacement as used throughout this disclosure refers to a volume of liquid or fluid (e.g., lubricant, oil) a pump is capable of moving during a specified period of time, i.e., a flow rate. For explanatory and simplicity purposes herein, the term liquid is utilized to reference fluid, lubricant, or oil that is pressurized and pumped by the pump in the disclosed system and provided to the motor cavity for cooling purposes; however, the terms may be used interchangeably throughout this disclosure.

[0022] As evident by the drawings and below description, the disclosed pump system and method of manufacturing the same includes an assembly having an intermediate housing wall positioned between a pump and an electric motor, covering a motor cavity within a housing for the electric motor, an auxiliary circuit configured to direct a portion of fluid flow to the motor cavity, and a fill level control plate is positioned between the intermediate housing wall and the motor cavity, forming an overflow region between the intermediate housing wall and the control plate. As a result, this disclosure provides more control over the distribution of fluid or liquid (e.g., oil) that is not only sent to auxiliary circuit but also enables more liquid to the motor cavity, e.g., for cooling purposes. In particular, no matter the orientation and/or mounting of the assembly, the disclosed system enables more liquid into the motor cavity, thereby avoiding failure of the motor and (optionally) the controller, e.g., due to overheating. This disclosure provides a desired level of fluid via using the fill level control plate which allows for shifting of a location for feeding liquid from the auxiliary circuit back to the pump, and further seals off points within the pump assembly.

[0023] In one non-limiting embodiment, the controller is a wet controller such that it is submerged with the motor in the motor cavity and in the liquid; as such, this liquid is configured to encompass the controller and its associated parts for cooling purposes as well. The controller may also be dry, but mounted on a structure that is in contact with the circulating liquid so that heat from the controller or parts thereof is exchanged through the structure to the circulating liquid. In other embodiments, the controller may be separate and cooled by other means.

[0024] The disclosed designs allow for temperature management of motors, and controllers (and any sensors), no matter the position or orientation of the system.

[0025] FIG. 1 shows a schematic view of a pump system 100 or pump assembly in accordance with an embodiment herein, configured for installation in a generally horizontal orientation. Pump system 100 may include an electronic pump 102, or e-pump, also referred to herein as simply a pump 102 (shown in cross-sections in FIGS. 2A and 2B). The pump 102 is designed for pumping a liquid. In an embodiment, the pump system 100 is designed to provide power to actuate clutch or transmission.

[0026] In accordance with a non-limiting embodiment, pump system 100 may be a system or assembly such as described in U.S. Pat. No. 10,808,697 (U.S. Ser. No.: 15/653,690) which is hereby incorporated by reference in its entirety herein, i.e., a pump assembly (or system) that has an assembly inlet for inputting fluid, an assembly outlet for outputting fluid, an electric motor contained within a motor casing, a pump having a pump housing, a drive shaft connecting the electric motor to the pump, and a controller configured to drive the electric motor. In such embodiment, the pump of the incorporated '697 application has an inlet for receiving input fluid from the assembly inlet and a transfer outlet for outputting pressurized fluid; the drive shaft is configured to be driven about an axis by the electric motor; and the pump and the electric motor are on opposing axial sides of the controller. The pump assembly of the incorporated '697 application also has a heat conductive plate positioned between the pump and the controller, for conducting heat from the controller; a transfer passage provided in the pump assembly for receiving the pressurized fluid output from the transfer outlet of the pump and directing the pressurized fluid along and in contact with the heat conductive plate to conduct heat therefrom into the pressurized fluid, and an outlet passage that communicates the transfer path with the assembly outlet to discharge the pressurized fluid. However, such assembly or system of the incorporated '697 application is not limiting. Another example for pump system 100 may be a system or assembly such as described in U.S. application Ser. No. 15/653,690, which is also hereby incorporated by reference in its entirety herein. Other pump systems and/or features may be utilized.

[0027] Pump system 100 has multiple structural sections that are connected to house or contain its parts therein, i.e., within a system housing 104, as shown in FIGS. 2A and 2B. In an embodiment, a pump housing 20 is provided as part of the system housing 104, which includes the pump 102 therein. An outer portion of the pump housing 20 may be generally cylindrical according to an embodiment. The pump housing 20 includes a pump chamber 22, which, in embodiments, may be cylindrical, ovular, or circular, for receiving parts of the pump 102 therein (noted later below). The pump housing 20 has a pump inlet 10 for receiving input fluid to direct said fluid to a pump inlet port 10B (generally shown in FIG. 2B, see also FIG. 3A) that is connected to an inlet path 10A and a pump outlet 14 for outputting pressurized fluid from a pump outlet port 14B (generally shown in FIG. 2A, see also FIG. 3A), e.g., via an outlet path 14A. Specifically, in the depiction of FIG. 3A, the inlet port 10B and outlet port 14B are provided on the same side (e.g., under or below the gear set) within the pump 102, in accordance with embodiments herein. A drive shaft 18 (see, e.g., FIGS. 2A-2B and 6) is provided for rotation about an axis A-A and rotatably driving parts of the pump 102 to pressurize the input fluid received through a fluid path-i.e., main path 12 [from the inlet 10 for the input fluid] (see FIG. 6), for outputting pressurized fluid, e.g., from outlet path 14A to the pump outlet 14.

[0028] The type of pump 102 and its parts provided in the pump system/assembly 100 is not limited. In an embodiment, the pump 102 has a gerotor drive, wherein an inner rotor is rotatably driven by the drive shaft 18 to in turn rotatably drive an outer rotor. A pump end of the shaft 18 extends to (or through) a portion of the pump housing 20. The inner rotor is fixedly secured to the shaft 18 for rotation about axis A with the drive shaft 18. The outer rotor may be rotatably received in the pump chamber 22 of the housing 20. In embodiments, the pump chamber 22 and the outer surface of the outer rotor are cylindrical. A motor end of the drive shaft 18 is positioned on an opposite side of an electric motor 32 (described below). Although not shown, it is generally known that the drive shaft 18 may be supported, for example, by journal bearings within housing(s) of the pump system 100. As is understood by one of ordinary skill in the art, rotation of the inner rotor also rotates the outer rotor via their intermeshed teeth to pressurize the input fluid received in areas between the complimentary parts for output from the pump 102, and thus such details are not described here. In accordance with a non-limiting embodiment herein, the inner rotor and outer rotor are part of gerotor pump and configured for operation like that which is disclosed in the aforementioned and incorporated U.S. '697 Patent or the incorporated '690 application. In another non-limiting embodiment, the inner rotor and outer rotor are part of a gerotor pump and configured for operation like that which is disclosed in U.S. Pat. No. 5,722,815 (U.S. Ser. No.: 08/515,054) which is also incorporated by reference in its entirety herein.

[0029] Other types of pump parts for pressurizing input fluid may also be used in pump in accordance with other embodiments, including gear pumps, vane pumps, etc. and other types of positive displacement pumps, and thus pump 102 should not be limited to gerotor-type pumps in pump system 100.

[0030] As generally understood by one skilled in the art, as the pump 102 rotatese.g., in an exemplary embodiment of a gerotor pump, as inner rotor is rotatably driven by drive shaft 18, to rotate/drive an outer rotor via their intermeshed teethfluid is pressurized in areas between the complimentary parts for output from the pump 102. Additionally, in embodiments, fluid may be pressurized within a displacement area or chamber between the rotors. As the rotors rotate, the area/chamber moves across the inlet port 10B and its lobes, as well as across the outlet port 14B and its lobes. Such movements and feature in pump 102 are known and thus are not described here in detail.

[0031] Pump system 100 also includes electric motor 32 (shown in FIGS. 2A-B and 6) for mechanical output and a motor drive shaft provided in system housing 104. In embodiments, the motor drive shaft and pump drive shaft 18 are the same drive shaft, i.e., one singular shaft, that extends through and from the motor 32 and through the pump 102. In another embodiment, the motor drive shaft and pump shaft are different parts. In the non-limiting illustrated embodiment, the electric motor 32 is connected to the pump 102 via the drive shaft 18, which is configured to be driven about axis A-A. The electric motor 32 is configured to drive the drive shaft 18 of the pump 102 via the motor drive shaft, to rotatably drive parts of the pump 102, i.e., to pressurize the input fluid, and to cool the motor/traction system or other device 32 using the liquid as a coolant (or for whatever reason the device requires fluid, such as for lubrication, general liquid delivery, etc.). As understood by those skilled in the art, the motor 32 includes a motor rotor 24 and a motor stator 26. The rotor 24 is connected to the motor drive shaft 18 and is contained within a motor casing 28 along with the stator 26. The motor casing 28 (or motor housing) is part of the system housing 104 and designed for connection to the pump housing 20. The motor casing 28 may be generally cylindrical and may include an inner motor cavity 30 or portion thereof for housing the rotor 24 and stator 26. The stator 26 may be optionally fixed to the motor casing 28.

[0032] As will be described below, according to embodiments, the motor cavity 30 is designed for receipt of liquid (e.g., oil) therein. A cover 36 may be included as part of system housing 104 to assist in enclosing the motor cavity 30 and containing the liquid therein. In particular, as shown in the Figures, an opposite side or end of the motor casing 28 may include cover 36 attached thereto for further containing at least the motor parts within and forming the motor cavity 30. The motor casing 28 and cover 36 may include alignment devices for aligning and securement. In embodiments, the cover 36 may be welded (e.g., plastic welded) to the motor casing 28. An optional outer cover may be provided around cover 36; this outer cover may include one or more channels for allowing placement of terminals, wiring, etc. to a controller 34, for example, which is described later below.

[0033] An auxiliary circuit 16 or auxiliary fluid path is included in pump system 100, as schematically shown in FIG. 1. Auxiliary circuit 16 is configured to direct a portion (or percentage) of fluid flow to the motor cavity 30 of motor casing 28, according to embodiments herein. In embodiments, fluid or liquid directed through the auxiliary circuit 16 may be directed to this circuit from the pump inlet 10 and/or deviate from the main path 12 of the pump 102. In an embodiment, the pump 102 uses negative pressure (suction), via a connection to the inlet port on the motor side of the pump 102, to draw the working fluid or liquid (e.g., oil) through a hollow shaft. In an embodiment, the auxiliary circuit 16 includes a path through an internal bore 38 (see FIG. 2A) in the drive shaft 18, for directing the portion of fluid flow into the motor cavity 30 and a return path 21. FIG. 6, which is described later, illustrates one exemplary embodiment showing the auxiliary circuit 16 includes a fluid passageway defined in, at, or near the inlet 10 of the pump that deviates from the main path 12 to direct lubricant to the motor cavity 30 via the drive shaft 18. In particular, the auxiliary circuit 16 directs fluid through a length of the drive shaft 18 for outlet to the return path 21. After flowing to the motor end of the drive shaft 18, lubricant is redirected to return path 21 which includes a pathway of return flow for motor cooling. The return path 21 may include multiple pathways therein such that the fluid/lubricant is directed through a number of places of the motor parts, in the motor cavity 30. For example, the lubricant may be directed through multiple pathways through the rotor and stator components 24 and 26, and across the motor, such as generally shown in FIG. 6. As described below, the return path 21 includes redirecting a portion of flow of the liquid/fluid back to the pump 102 via directing fluid to the motor cavity 30, to overflow region 60, and to return port 42.

[0034] In embodiments, the electric motor 32 may be further contained within the system housing 104 of the pump system 100 by a wall that separates the motor parts and parts of the pump 102. Specifically, according to embodiments herein, an intermediate housing wall 40 is positioned between the pump 102 and the electric motor 32. The intermediate housing wall 40 covers motor cavity 30 on one side or end of the motor casing 28/within the housing for the electric motor 32. The intermediate housing wall 40 may be provided against/adjacent to and connected to each of the pump housing 20 as well as the motor casing 28. In an embodiment, the intermediate housing wall 40 may be a separate part. In another embodiment, the intermediate housing wall 40 may be formed integrally therewith the housing 20 or casing 28. For example, openings 41 (shown in FIGS. 3A and 3B) in the intermediate housing wall 40 may be spaced circumferentially around a lip of the wall 40 and aligned with corresponding openings on pump housing 20. Fasteners 31 and/or bolts (shown in FIGS. 2A and 2B) may be inserted through the aligned openings to connect and secure the pump housing 20 and intermediate housing wall 40. The intermediate housing wall 40 may have a first axial side (also referred to as the pump-facing side) of the intermediate housing wall 40 that faces the pump 102. FIG. 3A shows a top view of the first side (pump side) of the intermediate housing wall 40, according to an embodiment. This first axial side of wall 40 may have one or more receiving recesses 48 (see FIG. 2A) formed therein which form part of inlet and outlet ports 10B, 14B of the pump 102. Each receiving recess 48 provided in the intermediate housing wall 40 may be in the form of an indentation that extends an axial depth from the surface and into the first axial side thereof. When the intermediate housing wall 40 is secured against the pump housing 20, the inlet port 10B and outlet port 14B are formed in-between the recess 48 and the rotor(s) of the pump 102 (i.e., due to the depth of the recess extending into the wall 40 (that is, in towards the motor side). As described previously, fluid is input via pump inlet 10, through the path 10A, and into pump inlet port 10B, for pressurization by the pump parts. Pressurized fluid is directed from pump outlet port 14B towards the outlet path 14A and outlet 14A of the pump 102.

[0035] A second axial side (also referred to as the motor-facing side) of the intermediate housing wall 40, which is opposite to the first axial side, may include an extension wall 46 and one or more recessed regions 44 therein. FIG. 3B shows a top view of this second side (motor side) of the intermediate housing wall 40, according to an embodiment. Extension wall 46 and region(s) 44 face the electric motor 32 when mounted, which is shown in the cross-section of FIG. 2A, for example. In an embodiment, the extension wall 46 is designed for insertion to the motor casing 28 and sealing via an O-ring seal (e.g., press-fit) to enclose the motor cavity 30. Thus, the intermediate housing wall 40 effectively acts as a cover for the pump 102 on the pump side and as a cover for the motor cavity 30 within the system housing 104 for the electric motor 32 on the motor side. The recessed region(s) 44 within the intermediate housing wall 40 are designed for holding a portion of fluid therein and providing a path for said portion of fluid from a level or amount of fluid within the motor cavity 30 during operation of the pump system 100 (described later below with reference to overflow region 60). In addition, the drive shaft 18 may be configured to extend through an inner opening 50 within the intermediate housing wall 40, according to embodiments. This inner opening 50 may be a central opening within the wall 40. In one embodiment, the intermediate housing wall 40 may have an alignment portion 52 that surrounds the inner opening 50 and extends axially. Such an alignment portion may be provided for not only aligning the drive shaft 18 therethrough, but also for aligning additional parts (e.g., a fill level control plate 54) within the system housing 104, as described later.

[0036] In embodiments, the intermediate housing wall 40 has a pump inlet return port 42 for directing the fluid flow of the liquid from the motor cavity 30 to the pump 102 (e.g., to the main path 12 of the pump 102, shown in the exemplary embodiment of FIG. 1). FIGS. 3A and 3B shows a top view of the second axial side (motor-facing side) of the intermediate housing wall 40 with the pump inlet return port 42 therein. FIG. 3A shows a pump-side view of pump inlet return port 42, and how it communicates with the inlet port 10B of pump; FIG. 3B shows a motor-side view of the placement of pump inlet return port 42 within the wall 40. The pump inlet return port 42 may be an opening that extends axially and through a thickness of the wall 40.

[0037] Generally, providing an opening or return port 42 for directing fluid from the motor cavity 30 to the pump 102 may be known by those skilled in the art. However, because the pump system 100 may be positioned in any number of orientations when mounted for use, e.g., as shown in the Figures in a horizontal configuration (or in a vertical configuration, angled configuration, etc.), then, a level of fluid within the motor cavity, and thus the motor casing, may be altered based on that configuration. As an example, FIG. 4 shows an example of a pump system oriented and mounted horizontally, wherein the pump is configured to pressurize fluid (as known) and output the pressurized fluid through the outlet. An alternate flow path 16A through a drive shaft is designed for directing fluid into a motor cavity thereof during operation. When using a return port to direct flow from the motor cavity to the pump in this orientation, however, a level of fluid within the motor cavity is not typically maintained, as depicted by the dashed line 19, in FIG. 4. That is, because the fluid moves through the motor cavity and to the pump through the opening or return, only a certain level at 19 of fluid is typically maintained, and in some cases, the motor cavity 30 would not or does not fill with fluid based on the orientation of the return connection to the pump. If the connection (opening) to the pump is positioned at the bottom of the pump's installed orientation, the resulting oil level (e.g., level 19) in the motor cavity will be lower than if the return is positioned at the top. Understandably to one skilled in the art, then, when such a system is mounted generally horizontally, including at an angle, or the like, since the level of fluid cannot be maintained, then cooling of the motor and parts contained within the motor cavity is affected and may be ineffective. Since it is beneficial for the motor, its parts, and other components and devices contained in the motor cavity to be mostly if not fully submerged in the oil/fluid for cooling, then, if this cavity is only partially filled, the parts and components will be not only exposed to air but also have reduced cooling and a risk of over-heating. This issue can occur during initial start-up, where the liquid has drained down to that level while the vehicle is parked. This issue can also occur during vehicle driving in hybrid vehicles if the pump is used only when the electric motor is operating, as the liquid may drain down while the internal combustion engine is operating for longer periods of time. But it can also occur in some designs even if the pump is always running during vehicle operation, as the fill level may take time to rise, particularly if there is not a sufficiently large difference between the drain rate through the return port and the intake rate through the shaft (or other path for delivering the liquid to the motor cavity) and/or the pump is being run at a lower speed.

[0038] As a result, the disclosed pump system 100 includes an extra component to control the level of liquid/fluid in the motor cavity 30, independently of the installed orientation of the pump 102 and system housing 104.

[0039] According to embodiments, a fill level control plate 54 is positioned between the intermediate housing wall 40 and the motor cavity 30 in the pump system 100. A detailed, cross-sectional view of the fill level control plate 54 is shown in FIG. 5, while FIG. 6 shows a top view of the plate 54, as mounted. In an embodiment, the fill level control plate 54 is positioned against at least a portion of the intermediate housing wall 40. The fill level control plate 54 may be placed inside an area formed by the extension wall 46, for example, in one embodiment. In one embodiment, as seen in FIG. 6, the control plate 54 is substantially circular and is sized for fitting into the area defined inside of the extension wall 46 of the intermediate housing wall 40. The fill level control plate 54 forms an overflow region 60 (see FIG. 5) between the intermediate housing wall 40 (e.g., its recessed region(s) 44) and the control plate 54 within the pump system 100. In an embodiment, the fill level control plate 54 includes an overflow opening 56 (see FIG. 6) therethrough for directing (or selectively directing) fluid flow of liquid from the motor cavity 30 to the overflow region 60. Such an overflow opening 56 may be a portion or region that is cut out of an edge of the plate 54, such as shown in FIG. 6 for example. However, such depiction and shape is not intended to be limiting. For example, the opening could be formed through the plate and spaced from its outer edge, rather than being cut into its outer edge.

[0040] In embodiments, such as shown in FIG. 6, an edge of the fill level control plate 54 may have one or more stress relieving openings therearound, which are sized for such purposes while still restricting fluid flow.

[0041] According to embodiments, the fill level control plate 54 is installed with the overflow opening 56 at a location spaced radially from the drive shaft 18 and substantially vertically above the drive shaft 18 and the pump inlet return port 42. In embodiments, the overflow opening 56 may be positioned in an orientation that places it in the highest position depending on the (intended) installation orientation. As such, the fill level control plate 54 is configured to cause a liquid level 27 within the motor cavity 30 to rise during operation of the pump system 100, such as shown and described with reference to FIG. 7. In particular, when the system 100 is mounted substantially horizontally or horizontally or an at acute angle relative to a horizontal, during operation, the auxiliary circuit 16 has a return path 21 through the electric motor 32 (and motor cavity 30) for directing a portion of fluid flow for cooling the motor 32, through the overflow opening 56 in the fill level control plate 54 and relatively down a path 23 in the overflow region 60, to return back to the pump 102 via the pump inlet return port 42.

[0042] In an embodiment, fill level control plate 54 has a first axial side (pump-facing side) and a second axial side (motor-facing side). In the illustrated embodiment of FIG. 5, the first axial side of the fill level control plate 54 faces the intermediate housing wall 40 and the second axial side of the fill level control plate 54 faces the motor stator 26 of the electric motor 32. Since the intermediate housing wall 40 may include recessed region 44 therein, then, the recessed region 44 facing the fill level control plate 54 may assist in forming the overflow region 60 therebetween. The overflow region 60 thus has an axial depth defined between the second axial side of the intermediate housing wall 40 (e.g. its recessed region 44) and the first axial side of the fill level control plate 54. Accordingly, the overflow region 60 allows for flow of liquid relatively above the pump 102, between intermediate housing wall 40 and the plate 54. Since such liquid in the overflow region 60 is directed to the pump inlet return port 42, then, if the port 42 is provided relatively below the drive shaft 18 and adjacent the pump inlet, then each side [of the pump inlet side] of the pump 102 effectively draws in (via suction or negative pressure) liquid. That is, in embodiments, the pump inlet return port 42, which is an opening or hole, acts as an inlet shadow port connected to the pump. More specifically, the pump inlet return port 42 may be positioned so as to direct a portion of the fluid to the back to the inlet section of the pump 102, in embodiments herein. According to embodiments, the connection to the inlet section of the pump via the pump inlet return port 42 may be located at a lowest point once the pump system 100 is installed or mounted. For example, the pump inlet return port 42 may be positioned relatively near the bottom of the system 100, as shown in FIG. 2A. In such a configuration, then, the fill level control plate 54 assists in avoiding failure or negative performance of the system 100 (e.g., due to overheating and a low level of liquid in the motor cavity 30) by using and positioning its overflow opening 56 to allow for shifting of the return of liquid from the motor cavity 30. As such, fluid flow is directed to where it is needed by the fill level control plate 54 limiting and/or sealing off points within the pump system 100. The disclosed pump system and more particularly the use of the fill level control plate 54 provides freedom to control a liquid level relative to the orientation of the pump system 100.

[0043] The inlet port 42 thus can be at any location, as the fill level control plate's overflow opening 56 sets the fill level in the motor cavity. Thus, if the customer decides to install the pump in a different rotational orientation (which may be dictated by packaging space, access to connectors, etc.), the only change required to manage the fill level is to change to rotational orientation of the control plate so that its overflow opening 56 is at a suitably high location to set a corresponding fill level. Likewise, this enables the same pump to be used for different applications, e.g., vehicles, where the installation orientation will vary.

[0044] As shown in FIG. 5 and FIG. 6, according to an embodiment, the fill level control plate 54 may have a number of spring tabs 58 positioned circumferentially therearound. The spring tabs 58 are configured for engagement with the motor stator 26, as shown in FIG. 6, to hold the control plate 54 in place. In an embodiment, the stator 26 of the motor is configured to hold the control plate against the surface of the intermediate housing wall 40. As such, providing the spring tabs 58 assists in maintain engagement therewith, setting a position and placement of the control plate 54 such that there is no axial movement of the control plate 54 relative to the intermediate housing wall 40. In the illustrated embodiment, six spring tabs 58 are shown; however, such number is an example only and not intended to be limiting.

[0045] As previously described, according to an embodiment, the intermediate housing wall 40 has an alignment portion 52, which may be centrally located and receive the drive shaft 18 through its inner opening 50. The alignment portion 52 extends axially and its outer surface may be utilized as a mounting projection for aligning and mounting the fill level control plate 54 thereon. For example, the fill level control plate 54 may include a central opening 62 therein through which the alignment portion 52 of the intermediate housing wall 40 extends.

[0046] In one embodiment, the alignment portion 52 may be a polygonal alignment portion. More specifically, in such an embodiment, an outer surface 64 of the alignment portion 52 may include a number of linear edges or flats along its perimeter (see FIG. 6) which form a polygonal shape therearound. The polygonal shape may be any number of shapes, including, but not limited to, a hexagon, an octagon, and a dodecagon shape. Such a polygonal shape may be provided such that the fill level control plate 54 is configured to be installed in a plurality or number of discrete rotational positions. Accordingly, such a configuration enables movement and orientation of the overflow opening 56 relative to (around) the drive shaft 18. Further, this design allows the same part to be used with different installation orientations for different customers. In an embodiment, then, the central opening 62 of the fill level control plate 54 may be a corresponding polygonal opening for mating with the outer surface 64 of the polygonal alignment portion 52 on the intermediate housing wall 40 at one of the number of discrete rotational positions. Since this polygonal shape on the control plate 54 is complementary to the shape of the alignment portion 52, then, the number of linear edges (or flats) around the central opening 62 corresponds to the number of linear edges around the alignment portion 52. Again, the overflow opening 56 of the fill level control plate 54 may thus be moved to a different location (than that as depicted in FIG. 6) while still being spaced radially from the drive shaft 18 and substantially vertically above the drive shaft 18 and the pump inlet return port 42 (not shown in FIG. 6, as the control plate 54 is covering this port).

[0047] In an embodiment, the alignment portion 52 has twelve flats around its perimeter. Accordingly, the fill level control plate 54 may be positioned in twelve different positions around the axis A-A, i.e., the overflow opening 56 may be moved to twelve different positions within the motor cavity 30. This exemplary number of flats, however, is not intended to be limiting. In embodiments, four, six, eight, or ten flats may be provided.

[0048] In other embodiments, the rotational alignment can be provided using other techniques. For example, the inner periphery of wall 46 could have flat surfaces and the outer edge of the plate 54 could have corresponding flat surfaces. The installation and orientation is similar to the illustrated design, except that the flat surface engagement occurs at the outer edge of plate 54 and wall 46. Likewise, teeth or other inter-engaging structure (at the inner edge of the plate 54 and the alignment portion 52, or also at the outer edge of the plate 54 and the inner surface of wall 46) could be inter-engaged to maintain the rotational orientation of the plate 54. The plate likewise have a fastener hole therethrough, and the wall 40 could have a number of circumferentially spaced fastener receiving openings, such that a fastener can be inserted to secure the plate 54 in a desired rotational orientation. Any suitable approach for securing the plate 54 in its desired rotational orientation may be used.

[0049] Turning to FIG. 7, then, the updated auxiliary circuit 16 is illustrated, in addition to the main fluid path 12. The disclosed pump system 100 is shown with the fill level control plate 54 mounted therein, adjacent (or against) the intermediate housing wall 40 and forming the overflow region 60. As shown via the drawn fluid path 16, during operation of the pump system 100, negative pressure (suction) causes a portion of the liquid to be drawn through the bore 38 of the hollow drive shaft 18 and then direct the fluid flow of liquid into the motor cavity 30. The liquid follows return path 21 through the electric motor 32, for cooling the rotor/stator of the motor 32. The use of the fill level control plate 54 allows not only for adjustment of the auxiliary fluid flow path but also filling of the motor cavity 30 with liquid to a liquid level 27 by restricting flow of the liquid out of the motor cavity 30. The auxiliary circuit 16 allows for a portion of liquid flow through overflow opening 56 (which is positioned near the top in FIG. 7) to the overflow region 60, thus allowing the motor cavity 30 to fill substantially, if not almost entirely full. The portion of liquid that flows through overflow opening 56 then follows a return path 23 of the auxiliary circuit such that it is directed relatively down the overflow region 60, to the pump inlet return port 42 (positioned near the bottom in FIG. 7), to return back to the pump 102. Accordingly, the disclosed design enables cooling of the motor parts and components in the motor cavity 30 via the addition of the fill level control plate.

[0050] In an embodiment, the system housing 104 further include an electronic control unit (ECU) or controller 34 therein. The controller 34 is configured, among other features, to drive the electric motor 32 to drive the drive shaft 18 of the pump 102. In the illustrated embodiments, the ECU is shown in the form of a printed circuit board (PCB) 34 with electrical components thereon. As known in the art, a number of components, such as sensors, temperature sensors/heat sink, etc. may mounted on the controller 34 or PCB. In an embodiment, the electric motor 32 is flanked by the controller 34 and the pump 102 in the pump assembly/system 100. That is, the pump 102 and the controller 34 may be on opposing sides of the electric motor 32.

[0051] In embodiments, which is also depicted in the Figures, the controller 34 may be provided within the motor cavity 30. That is, the controller 34 may be a wet controller associated with a wet motor and cooled via liquid in the motor cavity 30. Similar to the previous description, orientation determines how much the motor/controller cavity 30 may be filled with liquid. completely fill with oil. Like the electric motor 32, it is critical for the controller 34 to be mostly if not fully submerged in the liquid for cooling purposes because exposure of the controller to air will have reduced cooling and a risk of over-heating. As such, using the fill level control plate 54 further provides an advantage of cooling a wet controller when provided in the motor cavity 30. In operation of pump system 100 with wet controller 34, the pump 102 is configured to pressurize input fluid (as known) and output the pressurized fluid through the outlet 14. In addition, a portion of liquid is directed through the drive shaft 18 to an opposite end thereof and discharged into the motor cavity 30 which contains the electric motor 32 and the controller 34 (i.e., PCB). The fill level control plate 54 is held up against the intermediate housing wall 40 via contact with the motor stator 26, restricting liquid flow to the pump inlet return connection (port 42) everywhere but through overflow opening 56 in the plate. This overflow opening 56 may be positioned in the orientation that places it in the highest position depending on the installation orientation. Thus, the portion of liquid in the auxiliary circuit 16 flows through the electric motor 32 via path 21 and back to the pump 102 via the overflow opening 56 and overflow region 60 of the fill level control plate 54 and intermediate housing wall 40, through path 23, and then the pump inlet return port 42.

[0052] Of course, it should be understood that, in accordance with embodiments herein, particularly when the controller 34 is provided in the motor cavity 30, the auxiliary circuit 16 may include directing liquid towards sensors and devices associated with or mounted on the controller 34. Such sensors and devices may be directly exposed to the path 16, according to an embodiment. However, such sensors and devices may not necessarily be exposed directly to the liquid being pumped. Similarly, the controller 34 does not need to be a wet controller that is included in the motor cavity 30 and subject to liquid. Rather, the cover 36 may include a closed housing portion therein for housing the controller and electronics, without being exposed to the liquid.

[0053] It should be understood that the auxiliary circuit 16 may also assist in drawing heat, i.e., cooling, additional parts within the pump system 100 or assembly. Such parts may include, but are not limited to, cooling the controller/ECU (by way of the flow of fluid/lubricant through the path 16 and drawing heat therefrom and its components) and/or cooling the housing components used to secure the motor parts therein.

[0054] The portion or percentage of the liquid provided to the auxiliary circuit or path 16 is not intended to be limited with regards to amount or volume. In an exemplary embodiment, the percentage of fluid provided to the auxiliary circuit 16 may be in the range of approximately 1% to approximately 50%. In another exemplary embodiment, the percentage of fluid provided to the auxiliary circuit may be in the range of approximately 1% to approximately 25%. In yet another exemplary embodiment, the percentage of fluid provided to the auxiliary circuit may be in the range of approximately 1% to approximately 10%. In still yet another exemplary embodiment, the percentage of fluid provided to the auxiliary circuit may be in the range of approximately 1% to approximately 5%. In one embodiment, the percentage of fluid provided to the auxiliary circuit is approximately 5%.

[0055] The pump housing 20, motor casing 28, intermediate housing wall 40, fill level control plate 54, and cover 36 may be formed from any number of heat conductive materials, such as aluminum or other metals, in accordance with embodiments herein. Alternatively, in other embodiments, such components may be formed from other materials, including plastic. The materials used to form the parts of the pump system 100 may be materials that are capable of allowing fluid (e.g., oil) flow with heat emitting surfaces, according to embodiments herein.

[0056] It is noted that a number of features have been depicted in the drawings in a particular location. However, it should be noted that elements may be moved without deviating from the herein disclosed features and advantages. Moreover, the depictions and placement of the pump system 100 as shown in the Figures is not meant to limit the positioning or mounting of the pump system itself. That is, while the pump system 100 is shown in a horizontal position such that the motor 32 and optional controller 34 is positioned relatively to the right in the motor cavity 30 in the Figures, which are both to the right of the pump 102, the pump system 100 and thus its housed components may be positioned at any number of angles that are different than those shown in the Figures, or mirrored, and accomplish the same effects. As one example, the pump system 100 may be turned 15 to 45 degrees in a relatively upward direction and mounted at an angle, such that the pump inlet 10 is on a lower, left side and the motor cavity 30 on an upper right side.

[0057] In addition to providing the disclosed pump system, this disclosure also

[0058] encompasses a method of manufacturing such a pump system 100. Such method includes, but is not limited to: providing a housing, such as system housing 104 (and optionally any of its associated housing pieces (e.g., pump housing 20, motor housing 28, etc.) having an intermediate housing wall 40; providing a pump 102 and an electric motor 32, the pump having a pump inlet 10 having a pump inlet port 10B and a pump outlet 14 having a pump outlet port 14B; and providing a drive shaft 18 to be rotatably driven by the electric motor 32, for driving the pump 102 to pressurize fluid received through a fluid path 12 of the pump 102 from the pump inlet 10 for output from an outlet path 14A to the pump outlet 14. The method also includes positioning the pump 102 and the electric motor 32 within the housing 104; positioning the intermediate housing wall 40 therebetween and covering a motor cavity 30 within the housing 104 for the electric motor; and installing a fill level control plate 54 between the intermediate housing wall 40 and the motor cavity 30, forming an overflow region 60 between the intermediate housing wall 40 and the control plate 54. In the method, the pump system 100 further includes an auxiliary circuit 16 configured to direct a portion of fluid flow to the motor cavity 30; the intermediate housing wall 40 has a pump inlet return port 42 for directing the fluid flow from the motor cavity 30 to the pump 102; and the fill level control plate 54 has an overflow opening 56 therethrough for directing fluid flow from the motor cavity 30 to the overflow region 60. The installation of the fill level control plate 34 includes positioning said overflow opening 56 at a location spaced radially from the drive shaft 18 and substantially vertically above the drive shaft 18 and the pump inlet return port 42, such that the fill level control plate 54 causes a liquid level within the motor cavity 30 to rise during operation of the pump system 100 and the auxiliary circuit 16 has a return path 21, 23 through the electric motor 32 for directing the portion of fluid flow for cooling the motor 32 through the overflow opening 56 in the fill level control plate 54 and relatively down the overflow region 60, to return back to the pump 102 via the pump inlet return port 42.

[0059] As noted previously, in this disclosure, the auxiliary circuit 16 or auxiliary fluid path may deviate from the main path 12 of the pump 102; that is, deviating is a term used to describe that there is liquid/fluid communication between some portion of the liquid/fluid flow in the pump's path 12 and the auxiliary circuit 16. In the illustrated embodiment, the deviation may be regarded as pump inlet side receiving both liquid via the pump inlet path 10A as well as the liquid returned from return port 42 via the auxiliary circuit 16 including the hollow drive shaft 18, as both liquid flows end up in the pump's fluid path 12. The illustrated embodiment may also be regarded as having a deviation in the sense that the liquid/fluid flowing into the pump's inlet mouth at the left end in FIGS. 2A and 2B, via pump inlet 10, is partially drawn into the hollow shaft 18, while also being drawn into the pump inlet 10A. Similarly, if part of the output from the outlet side of the pump 103 is delivered to the motor cavity 30, that may also be regarded as deviation from the pump's fluid path that flows out the pump outlet port 14B and pump outlet 14. Thus, when the term deviation is used in reference to the auxiliary path's relation to the pump's main fluid path, a broad interpretation is intended to refer to any such fluid communication between the two.

[0060] Further, this disclosure includes a vehicle having a device to receive liquid as well as the disclosed pump system 100 coupled to the device to deliver the liquid thereto, wherein the pump system 100 is installed with the overflow opening positioned substantially vertically above the drive shaft and the pump inlet return port. Such a device that receives liquid may be, for example, a clutch or a transmission, in accordance with embodiments.

[0061] The present invention is not limited to the design where the liquid is drawn into the motor cavity via a hollow shaft. For example, a portion of the liquid ejected from the outlet side of the pump 102 may be directed to the motor cavity 30. Such liquid could be directed by one or more conduits or channels formed in the intermediate housing wall's outer wall 46 so as to provide the auxiliary circuit and enable that liquid to enter the cavity 30. Any other flow path may be used and the invention is not limited to the embodiment illustrated.

[0062] While the principles of the disclosure have been made clear in the illustrative embodiments set forth above, it will be apparent to those skilled in the art that various modifications may be made to the structure, arrangement, proportion, elements, materials, and components used in the practice of the disclosure.

[0063] It will thus be seen that the features of this disclosure have been fully and effectively accomplished. It will be realized, however, that the foregoing preferred specific embodiments have been shown and described for the purpose of illustrating the functional and structural principles of this disclosure and are subject to change without departure from such principles. Therefore, this disclosure includes all modifications encompassed within the spirit and scope of the following claims.