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.

What is claimed is: 
     
         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.