Fuel pump for high torque in compact structure

• US 7,157,828 B2
• Filed: 04/17/2003
• Issued: 01/02/2007
• Est. Priority Date: 04/30/2002
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Ito, Motoya, Iwanari, Eiji, Moroto, Kiyonori
• Primary Examiner(s): LE, DANG D
• Application Number:
  US10/417,270
• Publication Number:
  US 20030202893A1
• Time in Patent Office: 1,356 Days
• Field of Search: 310216-218, 310261-270, 31015401-15449, 310/152, 310/71, 310/234, 310/233, 310 61- 63, 310/60.R, 417/423.7
• US Class Current: 310/261.1
• CPC Class Codes: F02M 37/048 Arrangements for driving regenerative pumps, i.e. side-channel pumps
• CPC Class Codes: F04D 13/0673 the motor being of the inside-out type
• CPC Class Codes: F04D 5/002 Regenerative pumps for elastic fluids F04D23/008
• CPC Class Codes: H02K 1/30 using intermediate parts, e.g. spiders
• CPC Class Codes: H02K 13/04 Connections between commutator segments and windings
• CPC Class Codes: H02K 23/30 having lap or loop windings
• CPC Class Codes: H02K 3/527 applicable to rotors only

Abstract

In a fuel pump, four permanent magnets are installed in a housing. An armature is installed inside the permanent magnets rotatably. Six magnetic pole coil portions of the armature are installed in a central core. Each magnetic pole coil portion has a coil core, a bobbin and a coil formed by winding a winding on the bobbin in a concentrated winding form. Each coil core has an outer region in opposition to the permanent magnet in a direction of revolution, and a board-shaped coil-winding portion extending from the outer region toward the central core. Each bobbin covers the coil core except for the outer surface of the outer region and a convex portion.

Claims

1. A fuel pump for supplying fuel sucked from a fuel tank to an internal combustion engine comprising:

permanent magnets that are installed along a circumference of a circle on an inside surface of a housing and provide different magnetic poles alternately;

an armature installed inside the permanent magnets rotatably, and including a central core installed in a center of revolution of the armature, plural coil cores, which are magnetically coupled with the central core and installed outside the central core in a direction of revolution as a separate body from the central core, bobbins covering the coil cores respectively, and coils made by winding windings on the bobbins in a concentrated winding form, respectively;

a commutator, which has plural segments connected with the coils electrically and revolves with the armature;

a suction force generation means that revolves with the armature and generates a suction force for sucking the fuel from the fuel tank; and

a cover adjacent to and covering at least one axial end surface of the armature to define a passage for fuel to flow around the armature, the cover being imperforate and covering at least an entire axial end surface of the armature on an opposite end thereof with respect to the commutator,

wherein a gap is provided between the cover and the coils of the armature, and

wherein a clearance space is formed between the permanent magnets and the armature, and the fuel sucked by the suction force generation means is discharged from a fuel discharge outlet through the clearance space.

2. A fuel pump according to claim 1, wherein:

the plural coils are connected in a star connection.

3. A fuel pump according to claim 2, wherein:

the commutator is installed on one side of the armature in a longitudinal direction of a revolution shaft, and at least one part of the each coil forms a neutral point of the star connection in the other side of the armature in the longitudinal direction of the revolution shaft.

4. A fuel pump according to claim 1, wherein:

the plural coils are parallel-connected in the star connection.

5. A fuel pump according to claim 1, wherein:

terminals of the commutator and the terminals of the coils are electrically connected directly.

6. A fuel pump according to claim 1, wherein:

the number of the magnetic pole coil portions including the coil cores, the bobbins, and the coils respectively is larger by two than the number of the magnetic poles formed by the permanent magnets.

7. A fuel pump according to claim 1, wherein:

the number of the magnetic poles formed by the permanent magnets is four or six.

8. A fuel pump according to claim 7, wherein:

the number of the magnetic poles formed by the permanent magnets is four, and the number of the magnetic pole coil portions is six.

9. A fuel pump according to claim 1, wherein:

one of each coil core and the central core has a convex portion, and the other one has a concave portion for engaging with the convex portion.

10. A fuel pump according to claim 9, wherein:

the coil cores have the convex portions in their sides opposite the central core respectively, and the central core has the concave portions for engaging with the coil cores respectively in the direction of revolution.

11. A fuel pump according to claim 9, wherein:

the convex portions and the concave portions are formed to extend in the longitudinal direction of the revolution shaft of the armature, and the convex portions are engaged with the concave portions respectively by being inserted in the concave portions along the longitudinal direction of the revolution shaft of the armature, and the widths of the convex portions get larger toward the concave portions respectively, and the widths of the concave portions get smaller toward the convex portions.

12. A fuel pump according to claim 1, wherein:

each coil core includes an outer region being opposite to each permanent magnet along the direction of revolution and a coil-winding portion extending from its outer region to the central core, and each coil core has a T-shape in a cross section of the armature taken vertically with its shaft, and each bobbin magnetically insulates the outer regions of the coil cores, which are contiguous one another in the direction of revolution.

13. A fuel pump according to claim 12, wherein:

an inside surface of each permanent magnet forms a shape of a concave arc, and an outer surface of each outer region forms a shape of a convex arc.

14. A fuel pump according to claim 13, wherein:

the fuel flows in a clearance space formed between the inside surfaces of the permanent magnets and the outer surfaces of the outer regions.

15. A fuel pump according to claim 1, wherein:

in the cross section of the armature taken vertically with its shaft, spaces for windings formed by the bobbins are formed with forming shapes of trapezoids respectively, herein the coil-winding portions are put between the trapezoids, and widths of the trapezoids get smaller from the outer regions toward the central core, respectively.

16. A fuel pump according to claim 1, wherein:

a fuel discharge pressure is in a range of 200–

600 [kPa], and a discharge amount is in a range of 50–

300 [L/h].

17. A fuel pump according to claim 1, wherein:

a ratio of an axial length of the pump is to an outer diameter of the pump is equal to 2.5 or lower than 2.5.

18. A fuel pump according to claim 17, wherein:

the ratio of the axial length of the fuel pump to the outer diameter of the pump is equal to 2.0 or lower than 2.0.

19. A fuel pump according to claim 1, wherein the cover comprises at least a part of the commutator.

20. A fuel pump according to claim 1, wherein the cover is located on the axial end surface of the armature opposite from the commutator.

21. A fuel pump according to claim 1, wherein the commutator has a commutator terminal that is connected with a said segment and fit with a terminal of a said coil.

22. A fuel pump for supplying fuel sucked from a fuel tank to an internal combustion engine comprising:

permanent magnets that are installed along a circumference of a circle and provide different magnetic poles alternately;

an armature installed inside the permanent magnets rotatably, and including a central core installed in the center of the revolution of the armature, plural coil cores, which are magnetically coupled with the central core, and installed outside the central core in the direction of revolution as a separate body from the central core, bobbins that cover the coil cores, and coils that are made by winding windings on the bobbins respectively;

a commutator, which has plural segments connected with the coils electrically and revolves with the armature;

a suction force generation means that revolves with the armature and generates suction force of the fuel from the fuel tank; and

a cover adjacent to and covering at least one axial end surface of the armature to define a passage for fuel to flow around the armature, the cover being imperforate and covering at least an entire axial end surface of the armature on an opposite end thereof with respect to the commutator,

wherein a gap is provided between the cover and the coils of the armature, and

wherein the number of the magnetic poles is equal to four or more than four and an even number, and magnetic pole coil portions, which include the coil cores, the bobbins and the coils respectively, are more than the magnetic poles formed by the permanent magnets.

23. A fuel pump according to claim 22, wherein the cover comprises at least a part of the commutator.

24. A fuel pump according to claim 22, wherein the cover is located on the axial end surface of the armature opposite from the commutator.

25. A fuel pump for supplying fuel sucked from a fuel tank to an internal combustion engine comprising:

permanent magnets that are installed along a circumference of a circle on an inside surface of a housing and provide different magnetic poles alternately;

an armature installed inside the permanent magnets rotatably, and including a central core installed in a center of revolution of the armature, plural coil cores, which are magnetically coupled with the central core and installed outside the central core in a direction of revolution as a separate body from the central core, bobbins covering the coil cores respectively, and coils made by winding windings on the bobbins in a concentrated winding form, respectively;

a commutator, which has plural segments connected with the coils electrically and revolves with the armature;

a suction force generation means that revolves with the armature and generates a suction force for sucking the fuel from the fuel tank; and

a cover adjacent to and covering at least one axial end surface of the armature to define a passage for fuel to flow around the armature,

wherein a clearance space is formed between the permanent magnets and the armature, and the fuel sucked by the suction force generation means is discharged from a fuel discharge outlet through the clearance space, and

wherein the cover comprises a neutral point terminal located on the axial end surface of the armature opposite from the commutator, the neutral point terminal providing a neutral point of a star connection of the coils and being fit with a terminal of the coil.

26. A fuel pump for supplying fuel sucked from a fuel tank to an internal combustion engine comprising:

permanent magnets that are installed along a circumference of a circle and provide different magnetic poles alternately;

an armature installed inside the permanent magnets rotatably, and including a central core installed in the center of the revolution of the armature, plural coil cores, which are magnetically coupled with the central core, and installed outside the central core in the direction of revolution as a separate body from the central core, bobbins that cover the coil cores, and coils that are made by winding windings on the bobbins respectively;

a commutator, which has plural segments connected with the coils electrically and revolves with the armature;

a suction force generation means that revolves with the armature and generates suction force of the fuel from the fuel tank; and

a cover adjacent to and covering at least one axial end surface of the armature to define a passage for fuel to flow around the armature,

wherein the number of the magnetic poles is equal to four or more than four and an even number, and magnetic pole coil portions, which include the coil cores, the bobbins and the coils respectively, are more than the magnetic poles formed by the permanent magnets, and

wherein the cover is provided by a neutral point terminal located on the axial end surface of the armature opposite from the commutator, the neutral point terminal providing a neutral point of a star connection of the coils and being fit with a terminal of the coil.