Control system for a smart pump located within a lubrication/cooling assembly

Patent metadata

Field	Value
Publication number	US-12497963-B2
Application number	US-202218264642-A
Country	US
Kind code	B2
Filing date	Mar 3, 2022
Priority date	Mar 3, 2021
Publication date	Dec 16, 2025
Grant date	Dec 16, 2025

Abstract

A fluid pump includes a motor disposed within an outer housing. The motor includes a stator and a rotor in electromagnetic communication with the stator. Windings are disposed on the stator that receive an electric current for defining the electromagnetic communication. A pump element is attached to the rotor via a drive shaft. The pump element operates with the rotor to deliver a fluid through a hydraulic fluid path. A plurality of sensors measure information related to at least one of the stator, the windings, the rotor, the pump element, the fluid and the hydraulic fluid path. A controller is in communication with the windings for delivering the electric current to the windings. The controller is also in communication with the plurality of sensors for measuring and recording the information and communicating this information to one of an external memory and an external controller.

First claim

What is claimed is:

1 . A fluid pump comprising:
an outer housing; a motor disposed within the outer housing, the motor including a stator and a rotor in electromagnetic communication with the stator, wherein windings are disposed on the stator that receive an electric current for defining the electromagnetic communication; a pump element attached to the rotor via a drive shaft, wherein the pump element operates with the rotor to deliver a fluid through a hydraulic fluid path, wherein the pump element is a polymer-based pump element, wherein debris within the fluid is at least partially embedded and captured within polymer material of the polymer-based pump element; a plurality of sensors that measure information related to at least one of the stator, the windings, the rotor, the pump element, the fluid and the hydraulic fluid path; and a controller in communication with the windings for delivering the electric current to the windings, wherein the controller is also in communication with the plurality of sensors for measuring and recording the information and communicating this information to one of an external memory and an external controller.

2 . The fluid pump of claim 1 , wherein the plurality of sensors include an accelerometer that is in communication with at least one of the rotor, the drive shaft and the pump element, wherein the controller and the accelerometer cooperate to monitor the pump element for operating shock events, wherein the controller and the accelerometer are configured to:
compare the operating shock event with an internal acceptance threshold; and time stamp the operating shock event when the operating shock event exceeds the internal acceptance threshold and communicate the operating shock event to an internal memory as a mechanical shock risk event.

3 . The fluid pump of claim 2 , wherein the controller compares the operating shock event in isolation against the internal acceptance threshold to derive the mechanical shock risk event, and wherein the operating shock event is indicative of the debris being within the fluid that at least partially interrupts operation of the pump element.

4 . The fluid pump of claim 2 , wherein the controller compares the operating shock event and previously recorded shock events, collectively, against the internal acceptance threshold to drive the mechanical shock risk event, and wherein the operating shock event is indicative of the debris being within the fluid that at least partially interrupts operation of the pump element.

5 . The fluid pump of claim 2 , wherein the accelerometer is coupled with the pump element.

6 . The fluid pump of claim 1 , wherein the plurality of sensors includes at least one of:
an optic sensor that is positioned relative to the hydraulic fluid path and that monitors the fluid to detect a clarity of the fluid flowing through the hydraulic fluid path; a temperature sensor that measures a temperature of the fluid moving through the hydraulic fluid path; a current sensor that is in communication with the windings; and a positive temperature coefficient (PTC) resistor.

7 . The fluid pump of claim 6 , wherein the plurality of sensors includes the PTC resistor, and wherein the PTC resistor is located proximate a Field-Effect Transistor (FET) of the motor for determining a bridge temperature of the PTC resistor by monitoring a resistance change across the PTC resistor.

8 . The fluid pump of claim 6 , wherein the plurality of sensors includes the current sensor and the temperature sensor, and wherein the temperature of the fluid at a restriction is compared with an electrical current drawn by the windings as measured by the current sensor, wherein the temperature and the electrical current are compared against one another to derive a percentage of oil life remaining.

9 . The fluid pump of claim 1 , wherein the windings include three separate windings and wherein the plurality of sensors include current sensors that are in communication with at least one of the three separate windings, respectively, wherein the three separate windings include a U-phase winding, a V-phase winding and a W-phase winding, and wherein the current sensors cooperate with the controller to operate a Single-Shunt Field-Oriented Control Algorithm in communication with one of the three separate phase windings that includes an estimate of an RMS Phase Current for each respective winding of the three separate phase windings.

10 . The fluid pump of claim 1 , wherein the controller operates a Field-Oriented Control Algorithm that monitors itself and an operation of the motor to determine when the motor is in one of a closed-loop control state, an open-loop control state and a phase advanced state.

11 . The fluid pump of claim 1 , wherein the plurality of sensors includes a rotational speed sensor and a torque sensor that are in communication with the motor, wherein the controller monitors at least one of a command speed of the rotor and a torque output of the rotor to perform an onboard control algorithm, wherein the command speed and the torque output are compared against values of an information table that are indicative of normal operation of the motor, wherein when at least one of the command speed and the torque output have deviated outside of the values of the information table, the controller communicates a signal that is indicative of a need for calibrating the motor.

12 . The fluid pump of claim 1 , wherein the hydraulic fluid path includes a switching valve, and wherein the plurality of sensors include a temperature sensor for monitoring a temperature of the fluid, a current sensor for measuring an electrical current drawn by the windings, and a speed sensor for measuring a rotational speed of the rotor, wherein the controller compares the temperature of the fluid, the electrical current and the rotational speed of the rotor against values of an information table that are indicative of a normal operation of the motor.

13 . The fluid pump of claim 1 , wherein the plurality of sensors includes a run-time sensor that measures a length of time that the motor has been operating and a temperature sensor that measures a temperature of the fluid moving through the hydraulic fluid path, wherein when the controller operates an onboard control algorithm that monitors the length of time that the motor has been operating at a certain temperature to derive a monitored run-time/temperature value and compares the monitored run-time/temperature value against acceptable run-time/temperature values of an information table to determine a percentage of life remaining of the fluid.

14 . The fluid pump of claim 1 , wherein the controller operates an onboard control algorithm which monitors operating conditions of the motor and the hydraulic fluid path and also monitors internal fault conditions of the controller, wherein when the internal fault conditions cannot be corrected, the controller communicates a signal that is indicative of said fluid pump needing replacement.

15 . The fluid pump of claim 1 , wherein the controller cooperates with the plurality of sensors to operate an onboard control algorithm that selectively samples operating parameters at a rate that is 10× faster than a baud rate at which the controller operates, wherein the onboard control algorithm cooperates with the controller to deliver the operating parameters to an onboard memory.

16 . The fluid pump of claim 1 , wherein the outer housing includes a recessed cavity that gravimetrically captures large particles of the debris and prevents entry of the large particl

Assignees

• Ghsp Inc

Inventors

• Mitteer David Michael
• Mcmackin Nathaniel Joseph
• Christensen Paul Anders

Classifications

• H02K7/14

  Structural association with mechanical loads, e.g. with hand-held machine tools or fans (with fan or impeller for cooling the machine H02K9/06) · CPC title

• F04C2270/19

  Temperature · CPC title

• F04C2270/06

  Acceleration · CPC title

• F04C2270/03

  Torque · CPC title

• F04C2240/81

  Sensor, e.g. electronic sensor for control or monitoring · CPC title