Centrifugal pump assemblies having an axial flux electric motor and methods of assembly thereof

• US 10,731,653 B2
• Filed: 01/27/2017
• Issued: 08/04/2020
• Est. Priority Date: 01/27/2017
• Status: Active Grant

• Current Assignee: Regal Beloit America, Inc.
• Original Assignee: Regal Beloit Australia Pty Ltd (Regal Rexnord Corp.)
• Inventors: Turner, Matthew J., Heins, Greg, Thiele, Mark, Kreidler, Jason Jon
• Primary Examiner(s): Hamo, Patrick
• Assistant Examiner(s): Herrmann, Joseph S.
• Application Number:
  US15/418,155
• Publication Number:
  US 20180216622A1
• Time in Patent Office: 1,285 Days
• CPC Class Codes: F04D 13/0666 the motor being of the plane gap type
• CPC Class Codes: F04D 29/0473 for radial pumps
• CPC Class Codes: F04D 29/061 especially adapted for liquid pumps
• CPC Class Codes: F04D 29/588 cooling or heating the machine F04D29/5886, F04D29/5893 take precedence

Abstract

An electric motor assembly includes a bearing assembly including a rotating component and at least one stationary component. The electric motor assembly also includes an impeller coupled to the rotating component. The impeller includes an inlet and an outlet and is configured to direct a fluid between the inlet and the outlet. The electric motor assembly also includes a rotor assembly directly coupled to the impeller. A fluid flow channel is defined between the rotating component and the at least one stationary component. The flow channel includes a first end proximate the impeller outlet and a second end proximate the impeller inlet.

Claims

1. An electric motor assembly comprising:

a bearing assembly comprising a rotating component and at least one stationary component;

an impeller coupled to said rotating component, wherein said impeller comprises an inlet and an outlet and is configured to direct a fluid therebetween;

a rotor assembly directly coupled to said impeller such that said rotating component is coupled radially between said at least one stationary component and said impeller, wherein a fluid flow channel is defined between said rotating component and said at least one stationary component, said fluid flow channel comprising a first end proximate said impeller outlet and a second end proximate said impeller inlet; and

a stator assembly positioned adjacent said rotor assembly to define an axial gap therebetween, wherein said impeller comprises an extension portion positioned radially between said stator assembly and said rotating component such that said extension portion is overlapped in the radial direction by said stator assembly and said rotating component is overlapped in the radial direction by said extension portion.

2. The electric motor assembly in accordance with claim 1, wherein said impeller is configured to pressurize the fluid such that the fluid is at a lower pressure at the impeller inlet than at said impeller outlet, and at a positive pressure at said impeller outlet.

3. The electric motor assembly in accordance with claim 2, wherein said first end comprises an inlet of said fluid flow channel, and wherein said second end comprises an outlet of said fluid flow channel.

4. The electric motor assembly in accordance with claim 1, wherein a portion of said fluid flow channel extends along said axial gap.

5. The electric motor assembly in accordance with claim 1, wherein said at least one stationary component comprises a first stationary component, a second stationary component, and a stationary shaft coupled therebetween.

6. The electric motor assembly in accordance with claim 5, wherein said fluid flow channel comprises:

a first radial portion between said rotating component and said first stationary component;

a second radial portion between said rotating component and said second stationary component; and

an axial portion between said rotating component and said stationary shaft.

7. The electric motor assembly in accordance with claim 6, wherein said first radial portion, said axial portion, and said second radial portion are in serial flow communication.

8. The electric motor assembly in accordance with claim 1, wherein said first end is located on a first axial side of said rotor assembly and said second end is located on a second, opposing axial side of said rotor assembly.

9. A pump assembly comprising:

a pump housing;

a motor housing coupled to said pump housing; and

an electric motor assembly including a plurality of conducting coils and comprising;

a bearing assembly comprising a rotating component and at least one stationary component, wherein said at least one stationary component comprises;

a shaft comprising a first axial end face and a second axial end face;

a first stationary component coupled to said first axial end face; and

a second stationary component coupled to said second axial end face;

an impeller coupled to said rotating component, wherein said impeller comprises an extension portion, an inlet and an outlet and is configured to direct a fluid therebetween;

a rotor assembly directly coupled to said impeller such that said rotating component is coupled radially between said shaft and said impeller, wherein a fluid flow channel is defined between said rotating component and said at least one stationary component, said fluid flow channel comprising a first end proximate said impeller outlet and a second end proximate said impeller inlet;

wherein the extension portion is configured to be overlapped in the radial direction by the plurality of conductor coils, and overlap the rotating component in the radial direction.

10. The pump assembly in accordance with claim 9, wherein said impeller is configured to pressurize the fluid such that the fluid is at a lower pressure at the impeller inlet than at said impeller outlet, and wherein the fluid is at a positive pressure at said impeller outlet, wherein said first end comprises an inlet of said fluid flow channel, and wherein said second end comprises an outlet of said fluid flow channel.

11. The pump assembly in accordance with claim 9, further comprising a stator assembly positioned adjacent said rotor assembly, wherein a portion of said fluid flow channel extends between said motor housing and said stator assembly.

12. The pump assembly in accordance with claim 9, wherein said fluid flow channel comprises:

a first radial portion between said rotating component and said first stationary component;

a second radial portion between said rotating component and said second stationary component; and

an axial portion between said rotating component and said stationary shaft wherein said first radial portion, said axial portion, and said second radial portion are in serial flow communication.

13. The pump assembly in accordance with claim 9, wherein said first end is located on a first axial side of said rotor assembly and said second end is located on a second, opposing axial side of said rotor assembly.

14. A method of assembling a pump assembly, said method comprising:

providing a bearing assembly including a rotating component and at least one stationary component;

coupling an impeller to the rotating component, wherein the impeller includes an inlet and an outlet and is configured to direct a fluid therebetween;

coupling a rotor assembly directly to the impeller such that the rotating component is coupled radially between the at least one stationary component and the impeller;

coupling a stator assembly adjacent the rotor assembly such that an extension portion of the impeller is positioned radially between the stator assembly and the rotating component wherein the extension portion is overlapped in the radial direction by the stator assembly and the rotating component is overlapped in the radial direction by the extension portion; and

defining a fluid flow channel between the rotating component and the at least one stationary component, the fluid flow channel including a first end proximate the impeller outlet and a second end proximate the impeller inlet.

15. The method in accordance with claim 14, wherein coupling the impeller to the rotating component includes coupling the impeller to the rotating component such that the impeller is configured to pressurize the fluid, wherein the fluid is at a lower pressure at the impeller inlet than at said impeller outlet, and wherein the fluid is at a positive pressure at the impeller outlet.

16. The method in accordance with claim 14, wherein defining the fluid flow channel includes defining the fluid flow channel to include an inlet at the first end and an outlet at the second end.

17. The method in accordance with claim 14, wherein a portion of the fluid flow channel extends along an axial gap defined between the stator assembly and the rotor assembly.

18. The method in accordance with claim 14, wherein defining the fluid flow channel includes defining the first end on a first axial side of the rotor assembly and defining the second end on a second, opposing axial side of the rotor assembly.

19. The method in accordance with claim 14,

wherein providing the bearing assembly including at least one stationary component includes providing the bearing assembly with a first stationary component, a second stationary component, and a stationary shaft coupled therebetween;

and

wherein defining the fluid flow channel between the rotating component and the at least one stationary component includes;

defining a first radial portion of the fluid flow channel between the rotating component and the first stationary component;

defining a second radial portion of the fluid flow channel between the rotating component and the second stationary component; and

defining an axial portion of the fluid flow channel between the rotating component and the stationary shaft.