COOLING FOR AN ELECTRICALLY OPERATED DISPLACEMENT PUMP

An electrically operated displacement pump includes an electric motor having a stator and a rotor. The rotor is connected to the fluid displacer to power pumping by the fluid displacer. A cooling circuit extends at least partially about an exterior of a motor housing that houses the electric motor. A fan assembly blows cooling air through the cooling circuit.

BACKGROUND

This disclosure relates to positive displacement pumps and more particularly to a cooling system for positive displacement pumps.

Positive displacement pumps discharge a process fluid at a selected flow rate. In a typical positive displacement pump, a fluid displacer, usually a piston or diaphragm, pumps the process fluid. Some positive displacement pumps are double displacement pumps that employ two fluid displacers that pump the process fluid.

Fluid-operated double displacement pumps typically employ diaphragms as the fluid displacers and air or hydraulic fluid as a working fluid to drive the fluid displacers. The two diaphragms are joined by a shaft. In an air operated double displacement pump compressed air is the working fluid and is alternatingly provided to drive chambers of each diaphragm to drive displacement of the diaphragms. In a hydraulically-operated double displacement pump, hydraulic fluid, such as non-compressible hydraulic oil, is the working fluid that is alternatingly provided to first and second chambers to displace the fluid displacers.

Double displacement pumps can also be mechanically operated such that the pump does not require the use of working fluid. In such a case, a motor is operatively connected to the fluid displacers to drive reciprocation. In some examples, a gear train is disposed between the motor and the shaft connecting the fluid displacers to ensure that the pump can provide sufficient torque during pumping. The motor and gear train are disposed external to the main body of the pump. In some examples, the motor is disposed axially between the two diaphragms. Such pumps require cooling of the motor and motor controller.

SUMMARY

According to one aspect of the disclosure, a displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid by linear reciprocation of the fluid displacer; a cooling circuit including a flowpath about an exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air through the cooling circuit.

According to an additional or alternative aspect of the disclosure, a displacement pump for pumping a fluid includes an electric motor at least partially disposed in a motor housing and including a stator and a rotor; a first fluid displacer connected to the rotor such that a rotational output from the rotor provides a driving input to the first fluid displacer; and a cooling circuit extending about an exterior of the motor housing that houses the electric motor.

According to another additional or alternative aspect of the disclosure, a displacement pump for pumping a fluid includes an electric motor at least partially disposed in a motor housing and including a stator and a rotor; a controller operatively connected to the electric motor, the controller disposed in a control housing extending from the motor housing; a first fluid displacer connected to the rotor such that a rotational output from the rotor provides a driving input to the first fluid displacer to cause pumping by the first fluid displacer; and a cooling circuit having a flowpath extending between the motor housing and the control housing.

According to yet another additional or alternative aspect of the disclosure, a displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about an exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air into a portion of the flowpath disposed between a first thermally conductive wall of the motor housing and a second thermally conductive wall of a control housing in which electrical control components of the displacement pump are disposed, such that an output from the fan assembly contacts both the first thermally conductive wall and the second thermally conductive wall.

According to yet another additional or alternative aspect of the disclosure, a displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about a curved exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air through the cooling circuit.

According to yet another additional or alternative aspect of the disclosure, a displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about an exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air through the cooling circuit, an inlet of the fan assembly is oriented to receive the air axially along a fan axis that an impeller of the fan assembly rotates on, and an outlet of the fan assembly is oriented to output the air transverse to the fan axis.

According to yet another additional or alternative aspect of the disclosure, a displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a motor housing that houses the electric motor, the motor housing including a housing body and a plurality of heat sinks projecting from the housing body; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about an exterior of the motor housing; and a fan assembly configured to blow air through the cooling circuit.

According to yet another additional or alternative aspect of the disclosure, a displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about an exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air through the cooling circuit. The flowpath extends at least 90-degrees about the motor housing.

DETAILED DESCRIPTION

This disclosure relates to cooling of electrically operated pumps. The electrically operated pumps include an electric motor that provides driving force to a fluid displacement member of the pump. The electric motor and electrical control components, such as those mounted on circuit boards, etc., generate heat during operation. Those components requiring cooling to dissipate the heat. According to the present disclosure, the electric motor and, in some examples, the control components are actively cooled by a cooling assembly that blows cooling air over the housings of such components to wick heat from those heat generating components. The housings of the motor and control components can be formed from thermally conductive material that is exposed directly to the cooling flow generated by the cooling assembly. Such a configuration facilitates cooling of both the electric motor and the control components by a single cooling flow.

FIG.1Ais a first block schematic diagram of electrically operated pump1.FIG.1Bis a second block schematic diagram of electrically operated pump1.FIGS.1A and1Bwill be discussed together. Motor2, fluid displacer3, driver4, cooling assembly5, and controller26. Motor2includes motor components6a,6b. Motor2is at least partially disposed in motor housing7. Controller26is at least partially disposed in control housing8.

Motor2is disposed within a motor housing7and is configured to drive displacement of fluid displacer3. Motor2includes motor components6a,6b, one of which is formed as a stator is configured to electromagnetically drive rotation of the other one of motor components6a,6bthat is formed as a rotor. The rotor rotates on the motor axis MA. For example, motor component6acan be a stator and motor component6bcan be a rotor in an inner rotator example, with the rotor radially within the stator. In other examples, motor component6bcan be a stator and motor component6acan be a rotor in an outer rotator example, with the stator radially within the rotor.

The rotor is configured to rotate on a rotational axis in response to current (such as a direct current (DC) signals and/or alternating current (AC) signals) through the stator. The motor2can be a reversible motor in that the stator can cause the rotor to rotate in either of two rotational directions (e.g., alternating between clockwise and counterclockwise). The rotor is connected to the fluid displacer3via driver4. Driver4can receive a rotational output from the rotor to drive displacement of fluid displacer3.

It is understood that fluid displacer3can be configured to reciprocate along an axis, rotate on an axis, or be otherwise displaced to pump the fluid. In some examples, driver4can be configured to receive a rotary output from the rotor and provide a linear, reciprocating input to fluid displacer3. In other examples, the fluid displacer3can be a rotor configured to rotate within or about a stationary member. Fluid displacers3can be of any type suitable for pumping fluid. For example, fluid displacers20can be configured as diaphragms or pistons in reciprocating examples, or configured as rotating elements in rotational pump configurations. Pump1can be configured as a progressive cavity pump, impeller pump, peristaltic pump, among other options. In examples where the pump1includes a rotating fluid displacer3, it is understood that the fluid displacer3can be directly connected to the rotor. For example, driver4can be formed as a component of the rotor, such as integrally with the rotor. In the example shown, pump1includes a single fluid displacer3, but it is understood that pump1can include one, two, or more fluid displacers3operatively connected to the motor2to be driven by the motor2. It is understood that fluid displacer3can be configured to reciprocate or rotate on an axis coaxial with the motor axis MA or misaligned with the motor axis MA. For example, the motor2can be connected to the fluid displacer3by an eccentric driver such that the motor axis MA and the axis of reciprocation of the fluid displacer3are not coaxial.

Controller26is operatively connected to motor2to control operation of motor2. Controller26can further be operatively connected to cooling assembly5to control operation of the active components of cooling assembly5(e.g., the impeller of the cooling assembly5). The controller26is configured to store software, implement functionality, and/or process instructions. The controller26can include memory and control circuitry configured to implement functionality and/or process instructions. For example, the control circuitry can be capable of processing instructions stored in the memory. Examples of the control circuitry can include one or more of a processor, a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry. The controller26can be of any suitable configuration for gathering data, processing data, etc. The controller26can receive inputs, provide outputs, generate commands for controlling operation of motor2, etc. The controller26can be configured to receive inputs and/or provide outputs via a user interface. The controller26can include hardware, firmware, and/or stored software. The controller26can be entirely or partially mounted on one or more circuit boards.

Cooling assembly5is configured to actively cool the heat generating components of pump1, such as motor2and controller26. Cooling assembly5can include a fan that draws a cooling airflow AF in and blows a cooling airflow AF out. The intake cooling airflow can flow over motor housing7of motor2and, in some examples, over control housing8of controller26. The output cooling airflow from cooling assembly5can flow over both the motor housing7and the control housing8. As shown inFIG.1B, the cooling assembly5can be configured to output the cooling airflow into a passage disposed directly between and defined at least partially by the motor housing7and the control housing8. The motor housing7and control housing8can thus define the passage that the cooling airflow flows through, such that the cooling airflow can wick heat from both the control components and motor components. At least the portions of the motor housing7and the control housing8exposed to the cooling airflow AF can be formed by thermally conductive material to facilitate efficient heat transfer. In some examples, heat sinks extend from one or both of motor housing7and control housing8and be exposed to the cooling airflow AF to increase the surface area of the respective housing and facilitate more efficient heat transfer.

Pump1provides significant advantages. Cooling assembly5actively blows cooling air over the main heat sources of the pump1, providing efficient heat transfer relative to a passive cooling arrangement. The housings7,8of those heat generating components can be formed from thermally conductive material to facilitate efficient heat transfer. Cooling assembly5actively blowing the cooling flow over the housings of the heat generating components, actively exchanging the heated air for cool air providing for more efficient cooling. The cooling configuration of pump1facilitates longer operation and continuous operation of pump1at higher speeds and greater flowrates without overheating. The cooling configuration allows for more efficient pumping and fluid transfer.

FIG.2Ais a front isometric view of electrically operated pump10.FIG.2Bis a rear isometric view of pump10.FIG.2Cis a block schematic diagram of pump10.FIGS.2A-2Cwill be discussed together. Pump10is substantially similar to pump1shown inFIGS.1A and1B. Pump10includes inlet manifold12, outlet manifold14, pump body16, fluid covers18a,18b(collectively herein “fluid cover18” or “fluid covers18”), fluid displacers20a,20b(collectively herein “fluid displacer20” or “fluid displacers20”), motor22, driver24, and controller26. Motor22includes stator28and rotor30. Pump body16is disposed between fluid covers18a,18b. Motor22is disposed within pump body16and is configured to drive displacement of fluid displacers20. While motor22shown as disposed on the pump axis PA such that a rotational axis of rotor28is coaxial with the pump axis PA, it is understood that not all examples are so limited. For example, the motor22can be connected to the fluid displacer20by an eccentric driver and such that the rotational axis and pump axis PA are not coaxial in such a case. The rotational axis can be transverse to the pump axis PA. In some examples, the rotational axis can be orthogonal to the pump axis PA.

In the example shown, motor22is disposed coaxial with fluid displacers20, through it is understood that not all examples are so limited. Motor22is an electric motor having stator28and rotor30. Stator28includes armature windings and rotor30includes permanent magnets. Rotor30is configured to rotate on a rotational axis in response to current (such as a direct current (DC) signals and/or alternating current (AC) signals) through stator28. Motor22is a reversible motor in that stator28can cause rotor30to rotate in either of two rotational directions (e.g., alternating between clockwise and counterclockwise). Rotor30is connected to the fluid displacers20via driver24. In the example shown, driver24is configured to receive a rotary output from rotor30and provide a linear, reciprocating input to fluid displacers20. It is understood that, while fluid displacers20are described as linearly reciprocating, some examples of pump10includes a fluid displacer20that is configured to rotate to pump the fluid. For example, the fluid displacer can be a rotor configured to rotate within or about a stationary member. For example, pump10can be configured as a progressive cavity pump, impeller pump, peristaltic pump, among other options. In examples where the pump10includes a rotating fluid displacer20, it is understood that the fluid displacer20can be directly connected to the rotor28without an intermediate driver24.

Fluid displacers20can be of any type suitable for pumping fluid from inlet manifold12to outlet manifold14. For example, fluid displacers20can be configured as diaphragms or pistons in reciprocating examples, or configured as rotating elements in rotational pump configurations. While pump10is shown as including two fluid displacers20, it is understood that some examples of pump10include a single fluid displacer20. It is understood that the teachings discussed herein can apply equally to displacement pumps having any desired number of fluid displacers20and the fluid displacers20can be formed in any desired manner, such as diaphragms or pistons. Pump10can be referred to as a diaphragm pump when fluid displacers20are formed by one or more diaphragms. Pump10can be referred to as a piston pump when fluid displacers20are formed by one or more pistons.

Controller26is operatively connected to motor22to control operation of motor22. The controller26is configured to store software, implement functionality, and/or process instructions. The controller26can include memory and control circuitry configured to implement functionality and/or process instructions. For example, the control circuitry can be capable of processing instructions stored in the memory. Examples of the control circuitry can include one or more of a processor, a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry. The controller26can be of any suitable configuration for gathering data, processing data, etc. The controller26can receive inputs, provide outputs, generate commands for controlling operation of motor22, etc. The controller26can be configured to receive inputs and/or provide outputs via user interface27. The controller26can include hardware, firmware, and/or stored software. The controller26can be entirely or partially mounted on one or more circuit boards.

User interface27of controller26is shown. The user can provide inputs to controller26via user interface27to control operation of pump10. During operation, control signals are provided to stator28to cause stator28to drive rotation of rotor30. Driver24receives the rotational output from rotor30as an input and converts that rotational input into a linear output to drive reciprocation of fluid displacers20. In some examples, rotor30rotates in the first rotational direction to drive fluid displacers20in a first axial direction and rotates in the second rotational direction opposite the first rotational direction to drive fluid displacers20in a second axial direction opposite the first axial direction.

In the example shown, driver24causes fluid displacers20to reciprocate along pump axis PA through alternating suction and pumping strokes. During the suction stroke, the fluid displacer20draws process fluid from inlet manifold12into a process fluid chamber defined, at least in part, by fluid covers18and fluid displacers20. During the pumping stroke, the fluid displacer20drives process fluid from the process fluid chamber to outlet manifold14. Typically, depending on the arrangement of check valves, the two fluid displacers20are operated 180-degrees out of phase, such that a first fluid displacer20is driven through a pumping stroke (e.g., driving process fluid downstream from the pump) while a second fluid displacer20is driven through a suction stroke (e.g., drawing process fluid from upstream and into the pump). In the example shown, pump10includes two fluid displacers20that can simultaneously changeover (e.g., transition between the pumping stroke and the suction stroke), but 180-degrees out of phase with respect to each other.

Driver24is directly connected to rotor30and fluid displacers20are directly driven by driver24. As such, motor22directly drives fluid displacers20without the presence of intermediate gearing, such as speed reduction gearing. Power cord32extends from pump10and is configured to provide electric power to the electronic components of pump10. Power cord32can connect to a wall socket.

It is understood that, in some examples, the pump10is configured with a single fluid displacer20. Such a pump10can be either a single displacement pump, which outputs the process fluid during the pumping stroke but not the suction stroke, or a double displacement pump, which outputs the process fluid during both the pumping stroke and the suction stroke. For example, the single fluid displacement member20can be a piston for a double displacement pump that reciprocates within a cylinder. The piston includes an internal flowpath through the piston between an upstream pump chamber and a downstream pump chamber that are separated by the piston interfacing with the cylinder. The outlet check valve is disposed within the piston itself to reciprocate with the piston. During a first stroke, the piston reduces the size of the upstream chamber, opens the outlet valve in the piston, closes an inlet valve on an opposite side of the upstream chamber from the piston, and causes the process fluid to flow through the piston and downstream from the cylinder. During a second stroke, the piston reduces the size of the downstream chamber and increases the size of the upstream chamber, closes the outlet valve, opens the inlet valve, outputs process fluid from the downstream chamber, and draws process fluid into the upstream chamber through the inlet valve.

End caps68a,68bare disposed on opposite lateral sides of central portion66and are attached to central portion66to form pump body16. Housing fasteners64extend through end caps68into pump body16to secure end caps68to pump body16. Specifically, housing fasteners64extend through end caps68and into fastener openings formed in body flanges76formed on motor housing70of pump body16. Heat sinks74are formed on central portion66. In the example shown, heat sinks74are formed by fins, but it is understood that heat sinks can be of any configuration suitable for increasing the surface area of pump body16to facilitate heat exchange to cool the heat generating components of pump10, such as motor22and controller26.

Fluid covers18a,18bare connected to end caps68a,68b, respectively. Housing fasteners64secure fluid covers18to end caps68. Inlet manifold12is connected to each fluid cover18. Inlet ones of pump checks58are disposed between inlet manifold12and fluid covers18a,18b. The inlet ones of pump checks58are one-way valves configured to allow the process fluid to flow into process fluid chambers formed by a fluid displacement member20and fluid cover18and prevent retrograde flow from the process fluid chambers to inlet manifold12. Outlet manifold14is connected to each fluid cover18. Outlet ones of pump checks58are disposed between outlet manifold14and fluid covers18a,18b. The outlet ones of pump checks58are one-way valves configured to allow the process fluid to flow out of the process fluid chambers to outlet manifold14and to prevent retrograde flow from outlet manifold14to the process fluid chambers.

Motor22is disposed within motor housing70between end caps68. Control housing72is connected to and extends from motor housing70. Motor housing70can be substantially similar to motor housing7(FIG.1B). Control housing72can be substantially similar to control housing72(FIG.1B). Control housing72is configured to house control elements of pump10, such as controller26(FIGS.1B and2C). Stator28surrounds rotor30and drives rotation of rotor30. As such, motor22can be considered to be an inner rotator motor. Rotor30rotates on a rotational axis, coaxial with pump axis PA in the example shown, and is disposed coaxially with driver24and fluid displacers20. Permanent magnet array86is disposed on rotor body88.

Drive nut90is disposed within and connected to rotor body88. Drive nut90can be attached to rotor body88via fasteners (e.g., bolts), adhesive, or press-fitting, among other options. Drive nut90rotates with rotor body88. Drive nut90is mounted to bearings54a,54bat opposite axial ends of drive nut90. Bearings54are configured to support both axial and radial forces. In some examples, bearings54comprise tapered roller bearings. Screw92extends through drive nut90and is connected to each fluid displacer20. Screw92reciprocates along pump axis PA to drive fluid displacers20through respective pumping and suction strokes. Rolling elements (not shown), such as balls or elongate rollers among other options, can be disposed between drive nut90and screw92to support screw92relative to drive nut90. As such, screw92may not directly contact drive nut90. Instead, the rolling elements engage the thread of screw92, receive the rotational input from drive nut90, and drive axial displacement of screw92.

Motor nut56connects to a portion of pump body16housing stator28. Motor nut56can be considered to connect to a stator housing of pump10, which stator housing can be formed by the motor housing70and end caps68a,68b. In the example shown, motor nut56connects to end cap68aand secures bearings54within pump body16. Motor nut56preloads bearings54. Screw92can reciprocate through motor nut56during operation. Grease cap60ais supported by motor nut56and motor nut56aligns grease cap60arelative to bearing54a. Grease cap60bis disposed adjacent bearing54b. Grease caps60prevent contaminants from entering bearings54and retain any grease that may liquify during operation.

Fluid displacer20ais connected to first end of screw92. Membrane82ais captured between inner plate78aand outer plate80a. Fastener84aextends through each of inner plate78a, outer plate80a, and membrane82aand into screw92to connect fluid displacer20ato driver24. An outer circumferential edge of membrane82ais captured between fluid cover18aand end cap68a. Fluid displacer20bis connected to an opposite axial end of screw92from fluid displacer20a. In the example shown, membrane82bis overmolded onto outer plate80b. Fastener84bextends from outer plate80bthrough the inner plate78band into screw92to connect fluid displacer20bto driver24. An outer circumferential edge of membrane82bis captured between fluid cover18band end cap68b. While fluid displacers20a,20bare described as having different configurations, it is understood that pump10can include fluid displacers20a,20bhaving the same or differing configurations. It is further understood that fluid displacers20can be configured as pistons connected to the opposite axial ends of screw92, among other options.

During operation, current signals are provided to stator28to electromagnetically drive rotation of rotor30. Position sensor62is disposed proximate rotor30, as discussed in more detail below, and generates position data regarding the rotational position of rotor30relative to stator28. For example, position sensor62can include an array of Hall-effect sensors responsive to the polarity of the permanent magnets in permanent magnet array86. Controller26can utilize the position data to commutate motor22.

Driver24converts rotational motion from rotor30into linear motion of fluid displacers20. Rotor body88rotates about pump axis PA, in the example shown, and drives rotation of drive nut90. Drive nut90drives screw92axially along pump axis PA, such as by engagement of rolling elements disposed between drive nut90and screw92and that support drive nut90relative to screw92. The rolling elements support drive nut90relative screw92such that drive nut90does not contact screw92during operation. The rolling elements translate the rotation of drive nut90into linear movement of screw92. Screw92drives fluid displacers20through respective pumping and suction strokes. In some examples, rotor30is rotated in a first rotational direction to cause screw92to displace in a first axial direction and rotor30is rotated in a second rotational direction opposite the first rotational direction to cause screw92to displace in a second axial direction opposite the first axial direction.

Motor22is axially aligned with fluid displacers20and drives reciprocation of fluid displacers20. Rotor30rotates on a rotational axis and fluid displacers20reciprocate on pump axis PA, in the example shown. In the example shown the rotational axis is coaxial with pump axis PA, but it is understood that not all examples are so limited. Pump10provides significant advantages. Motor22being axially aligned with fluid displacers20facilitates a compact pump arrangement providing a smaller package relative to other mechanically-driven and electrically-driven pumps. In addition, motor22does not include gearing, such as reduction gears, between motor22and fluid displacers20. Eliminating that gearing provides a more reliable, simpler pump by reducing the count of moving parts. Eliminating the gearing also provides a quieter pump operation.

FIG.4Ais a rear isometric view of electrically operated pump10.FIG.4Bis a rear isometric view of pump10with housing cover94removed.FIG.4Cis an isometric view of pump body16of pump10.FIG.4Dis a cross-sectional view taken along line D-D inFIG.4A.FIG.4Eis a cross-sectional view taken along line E-E inFIG.4A.FIGS.4A-4Ewill be discussed together. Pump10is substantially similar to pump1shown inFIGS.1A and1B. Pump10includes inlet manifold12, outlet manifold14, pump body16, fluid covers18a,18b(collectively herein “fluid cover18” or “fluid covers18”), fluid displacers20a,20b(collectively herein “fluid displacer20” or “fluid displacers20”), motor22, driver24, controller26, fan assembly104, and housing cover94. Motor22includes stator28and rotor30. Fan assembly104includes impeller106and fan motor110. The cooling configuration shown inFIGS.4A-4Eis substantially similar to the cooling configuration shown inFIGS.1A and1B.

End caps68a,68bare disposed on opposite lateral sides of central portion66and are attached to central portion66to form pump body16. Fluid covers18a,18bare respectively connected to end caps68a,68b. Inlet manifold12is connected to each fluid cover18to provide the pumped fluid to the process fluid chambers. Outlet manifold14is connected to each fluid cover18to receive fluid from the process fluid chambers.

Motor22and control elements122(such as controller26(FIGS.1B and2C), one or more circuit boards, etc.) are supported by pump body16. More specifically, motor22and control elements122are supported by central portion66of pump body16. Motor22is disposed within motor housing70between end caps68. A body of motor housing70extends circumferentially around motor22, relative to the rotational axis RA of the rotor28, and circumferentially encloses the motor22. The body of motor housing70curves away from control housing wall118of the control housing72. The body of motor housing70can be considered to be convex towards the control housing72. Stator28surrounds rotor30and drives rotation of rotor30, such that motor22can be considered to be an inner rotator motor. Rotor30rotates on a rotational axis RA. Rotor30rotates about pump axis PA and is disposed coaxially with driver24and fluid displacers20, in the example shown. Permanent magnet array86is disposed on rotor body88.

Control housing72is connected to and extends from motor housing70. In the example shown, portions of control housing72and motor housing70are integrally formed as a single housing component (e.g, by casting among other options). Control housing72is configured to house control elements122of pump10, such as controller26. In the example shown, control housing block114is integrally formed with motor housing70. Control cover116is mounted to control housing block114, such as by fasteners. In some examples, control cover116can be removably connected to control housing block114to provide access to the internal components within control housing72.

Heat sinks74are formed on central portion66. In the example shown, heat sinks74are formed in multiple configurations and include projections124and fins126. Fins126are elongate about the rotational axis RA of rotor30and wrap at least partially around motor housing70. While heat sinks74are shown as multiple configurations, it is understood that heat sinks74can be of any configuration suitable for increasing the surface area of pump body16to facilitate heat exchange to cool the heat generating components of pump10. In the example shown, at least some of heat sinks74define flow passages forming a cooling fluid circuit CF for pump10. The cooling circuit CF is an outer cooling fluid circuit in that cooling circuit CF extends about the exterior of motor housing70. In the example shown, the cooling fluid circuit CF is disposed axially between the fluid displacers20. In the example shown, the cooling fluid circuit CF does not radially overlap with a fluid displacer20relative to pump axis PA. The cooling fluid circuit CF is fully between the fluid displacers20axially along the pump axis PA.

In the example shown, support sinks128extend between and connect control housing72and motor housing70, as best seen inFIG.4E. The support sinks128are formed by one or more heat sinks74that extend between and connect the control housing block114and motor housing70. The support sinks128can be integrally formed with both the control housing block114and motor housing70. The support sinks128at least partially define the cooling fluid circuit CF. More specifically, the support sinks128at least partially define the channels133of the intermediate passage132of the cooling fluid circuit CF. The support sinks128structurally connect control housing block114and motor housing70and facilitate heat transfer from the heat generating components of pump10. Support sinks128can be exposed to the cooling flow through the cooling fluid circuit CF on both axial sides of the support sinks128relative to the rotational axis RA, which is also relative to the pump axis PA in the example shown.

Housing cover94is mounted to pump body16and at least partially defines flow passages of the cooling fluid circuit CF. Cooling fluid circuit CF is at least partially enclosed by the housing cover94. Inlet openings100and outlet openings102are formed through housing cover94. In some examples, housing cover94is formed as an exhaust cover96connected to pump body16on an upper side of central portion66(e.g., between outlet manifold14and central portion66in the example shown), and as intake cover98connected to pump body16on a lower side of central portion66(e.g., between inlet manifold12and central portion66in the example shown). As such, housing cover94can be formed from multiple discrete components assembled to pump10to at least partially define cooling fluid circuit CF. It is understood, however, that housing cover94can be formed by as many or as few components as desired. In some examples, housing cover94is disposed on only one side of central portion, such as by housing cover94including exhaust cover96and not intake cover98.

The main heat sources of pump10include controller26, stator28, and driver24. Cooling fluid circuit CF directs cooling air through passages proximate the heat generating components to effect heat exchange between the flow of cooling air through cooling fluid circuit CF and the heat sources to thereby cool pump10. Cooling fluid circuit CF is configured to direct cooling air around motor housing70. Cooling fluid circuit CF directs cooling air circumferentially around the rotational axis RA of rotor30. Cooling fluid circuit CF is configured to direct cooling air to provide cooling to elements in both motor housing70and control housing72. A cooling assembly, similar to cooling assembly5(FIG.1B), actively blows cooling airflow through the cooling fluid circuit CF to facilitate cooling of the heat generating components of pump10. In the example shown, the cooling assembly can be considered to include at least fan assembly104. The cooling assembly can be considered to further include flow directing components, such as housing cover94.

The flowpath of cooling fluid circuit CF extends directly between the thermally conductive body of the motor housing70and the thermally conductive control housing wall118. The flowpath of the cooling air in cooling fluid circuit CF wraps at least partially around the motor housing70. In some examples, the flowpath can be curved greater than or equal to 90-degrees around the motor housing70between an inlet and an outlet. In some examples, the flowpath can be curved greater than or equal to 120-degrees around the motor housing70between an inlet and an outlet. In some examples, the flowpath can be curved greater than or equal to 180-degrees around the motor housing70between an inlet and an outlet. The flowpath of the cooling fluid circuit CF extending about the motor housing70exposes a large portion of the motor housing70to the cooling air moved by the fan assembly104, facilitating heat exchange and cooling of motor22. The flowpath of the cooling fluid circuit CF extends circumferentially about the rotational axis RA of the rotor28disposed within motor housing70. As best seen inFIG.4D, the flowpath of the cooling fluid circuit CF is in a plane orthogonal to the axis RA of rotation of the rotor28, which can also be referred to as the motor axis. The flowpath does not extend through the axis of rotation RA of the rotor28, but is instead offset from and flows around the axis of rotation RA of the rotor28.

The flowpath of the cooling fluid circuit CF can be at least partially disposed between the fluid displacers20a,20b, such as along the axes of reciprocation of the fluid displacers20a,20b. In some examples, at least a portion of the flowpath of the cooling fluid circuit CF is disposed directly between the fluid displacers20a,20b. In such an example, a line parallel to the axis of rotation RA of the rotor28can extend through fluid displacer20a, fluid displacer20b, and the flowpath of the cooling fluid circuit CF. Such an axial line can extend through one or more heat sinks74, such that the heat sinks74are disposed directly between the fluid displacers20a,20b. In some examples, as shown inFIG.4E, a portion of the flowpath is disposed radially outside of an area directly between the fluid displacer20aand the fluid displacer20band a second portion of the flowpath is disposed within the area. Disposing a portion of the flowpath directly between the fluid displacers20a,20bprovides a compact pump arrangement and facilitates forming the flowpath close to the motor22to further facilitate heat transfer.

In the example shown, cooling fluid circuit CF includes intake passage130, intermediate passage132, and exhaust passage134. In the example shown, there is no valving in cooling fluid circuit CF to direct flow. Instead, fan assembly104is configured to actively drive cooling air through cooling fluid circuit CF. Fan assembly104is supported by pump body16. More specifically, fan assembly104is supported by control housing wall118of control housing72. Impeller106is disposed within cooling fluid circuit CF. In the example shown, impeller106is disposed at an intersection between intake passage130and intermediate passage132. It is understood, however, that fan assembly104can be disposed at any desired location relative to the cooling fluid circuit CF. For example, the fan assembly104can be disposed at an intersection between intermediate passage132and exhaust passage134, within intermediate passage132, among other location options. Blades108extend from the body of impeller106and drive the cooling fluid through cooling fluid circuit CF. In the example shown, blades108extend straight between a root connected to the body of impeller106and a tip opposite the root.

In the example shown, fan assembly104is at least partially disposed within the cooling fluid circuit CF, but it is understood that not all examples are so limited. More specifically, impeller106is disposed in the flowpath between an inlet of cooling fluid circuit CF and an outlet of cooling fluid circuit CF. In the example shown, impeller106is unshrouded, except by intake cover98, but it is understood that impeller106can be shrouded in other examples. Fan motor110is disposed in control housing72. Fan motor110, which can be an electric motor, is isolated from the environment surrounding stator28by control housing wall118of control housing block114, such that the cooling arrangement shown is suitable for use in hazardous locations. Fan shaft112extends through control housing wall118to connect impeller106and fan motor110.

Impeller106rotates on fan axis FA to blow the cooling air through the cooling fluid circuit CF. The main flow vector of the cooling air exiting the fan assembly104is perpendicular to the fan axis FA and is directed directly between the motor22and control elements122. More specifically, the air existing the fan assembly104flows directly between the thermally conductive body of motor housing70and the thermally conductive control housing wall118. The main flow vector of the cooling air exiting the fan assembly104is directed directly between the motor housing70and the control housing72. Impeller106is configured to output airflow radially relative to fan axis FA. In the example shown, impeller106is disposed axially between the motor housing70and the control housing72along the fan axis FA. In the example shown, the impeller106does not radially overlap with either the motor housing70or the control housing72relative to the fan axis FA. As such, a radial line extending from the fan axis FA that passes through the impeller106does not also pass through either of the motor housing70or the control housing72. The fan assembly104is disposed such that the fan axis FA is disposed in an orientation perpendicular to, but offset from, the axis of rotation RA of the rotor28.

Intake passage130is defined between motor housing70and housing cover94. Specifically, intake passage130is defined between motor housing70and intake cover98. In the example shown, intake passage130includes multiple individual channels131that are at least partially defined by heat sinks74. The individual channels131of intake passage130extend arcuately around motor housing70. The axial sides of the individual flow channels131, along rotational axis RA of rotor30, can be formed by heat sinks74. As such, at least some of the individual channels131can be axially bracketed by heat sinks74relative to the rotational axis RA of rotor30. In the example shown, at least some of heat sinks74can extend circumferentially, but not axially, on motor housing70and about the rotor axis RA of rotor30, which is also circumferentially about the pump axis PA in the example shown. It is understood, however, that heat sinks74of intake passage130can, in some examples, be canted to extend both circumferentially about the rotational axis RA of rotor30and axially relative to the rotational axis RA of rotor30. In the example shown, the individual channels131of intake passage130include at least three sides at least partially formed by thermally conductive material (e.g., the motor housing70and heat sinks74). The body of motor housing70at least partially defines intake passage130. Motor housing70is thereby directly exposed to the cooling flow through cooling fluid circuit CF. Motor housing70is disposed directly between stator28and intake passage130to provide efficient heat transfer from stator28and driver24to the cooling flow through cooling fluid circuit CF.

Intermediate passage132is disposed between control housing72and motor housing70. More specifically, intermediate passage132is disposed between control housing block114and motor housing70. Control housing wall118at least partially defines intermediate passage132. One or more of the heat generating elements in control housing72can be mounted to control housing wall118. The heat generating elements are thereby mounted to the control housing wall118that is also directly in contact with the cooling air flowing through cooling fluid circuit CF. As such, the heat generating elements are mounted to thermally conductive material (e.g., control housing wall118can be metallic) that is also exposed to a cooling air flow. Mounting the heat generating elements to control housing wall118facilitates efficient heat transfer from those components to the cooling flow through cooling fluid circuit CF.

Intermediate passage132is at least partially defined by the body of motor housing70. Motor housing70is thereby directly exposed to the cooling flow through cooling fluid circuit CF. Motor housing70is disposed directly between stator28and intermediate passage132to provide efficient heat transfer from stator28to the cooling flow through cooling fluid circuit CF. In the example shown, at least one heat sink74extends between and connects control housing72and motor housing70. Specifically, support sinks128extend between and connect control housing block114and motor housing70. The support sinks128at least partially define intermediate passage132and directly contact both control housing72and motor housing70. Such heat sinks74facilitate heat transfer from heat generating components disposed within control housing72and within motor housing70. Intermediate passage132includes multiple individual channels133through which the cooling air flows.

Exhaust passage134is defined between motor housing70and housing cover94. Specifically, exhaust passage134is formed between motor housing70and exhaust cover96. In the example shown, exhaust passage134includes multiple individual channels135at least partially defined by heat sinks74. The individual channels135of exhaust passage134extend arcuately around motor housing70. An axial side, relative to the rotational axis RA of rotor30, of each of the individual channels135of exhaust passage134is formed by a heat sink74. In the example shown, at least some of heat sinks74can extend circumferentially, but not axially, on motor housing70and about the rotational axis RA of rotor30. It is understood, however, that heat sinks74of exhaust passage134can, in some examples, be canted to extend both circumferentially about rotational axis RA of rotor30and axially relative to the rotational axis RA of rotor30. In the example shown, the channels135of exhaust passage134include at least three sides that are at least partially formed by thermally conductive material (e.g., the motor housing70and heat sinks74). The body of motor housing70at least partially defines exhaust passage134. Motor housing70is thereby directly exposed to the cooling flow through cooling fluid circuit CF. Motor housing70is disposed directly between stator28and exhaust passage134to provide efficient heat transfer from stator28to the cooling flow through cooling fluid circuit CF.

During operation, fan motor110is powered to drive rotation of impeller106. Fan assembly104draws air into cooling fluid circuit CF through inlet openings100. Inlet openings100provide locations for air to enter into cooling fluid circuit CF and are in fluid communication with the surrounding environment. As such, the ambient air in the environment of pump10can form the cooling fluid of cooling fluid circuit CF. While multiple inlet openings100are shown, it is understood that cooling fluid circuit CF can include any desired number of inlet openings100, such as one or more. Inlet openings100can also be spaced circumferentially along intake passage130relative to the rotational axis RA of rotor30. For example, one or more additional or alternative inlet openings100can be formed at circumferential locations along housing cover94between the location currently shown and the position of fan104. For example, one or more of the inlet openings100can be disposed between the inlet manifold12and motor housing70.

Impeller106draws intake air (shown by arrow IA) through intake passage130and over motor housing70and heat sinks74. The flow of cooling air (shown by arrows AF inFIG.4D) passes over heat sinks74and motor housing70and draws heat from those elements to effect cooling of those elements. Impeller106blows the air downstream through intermediate passage132and exhaust passage134. The cooling air blown by the impeller106initially flows through the channels133of intermediate passage132. The air flowing through intermediate passage132contacts both control housing72and motor housing70to transfer heat from both the heat generating components in control housing72(e.g., controller26among others) and from the heat generating components of in motor housing70(e.g., stator28and driver24). At least a portion of the flow through cooling fluid circuit CF flows directly between the motor22and an electric component29mounted to housing wall118. A radial line extending from the rotational axis RA of rotor30can extend through driver24, stator28, a passage through cooling fluid circuit CF and an electric component29mounted to housing wall118. Such a configuration facilitates efficient cooling of the heat generating components by wicking heat from heat generating components disposed on opposite sides of and bracketing the cooling fluid circuit CF.

At least a portion of cooling fluid circuit CF is radially bracketed, relative to the rotational axis RA of rotor30, by two unique heat sources. Specifically, intermediate passage132is exposed to thermally conductive element on both radial sides of intermediate passage132relative to the rotational axis RA of rotor30. The electric elements within control housing72form a first heat source cooled by the flow through cooling fluid circuit CF and the stator28and driver24within motor housing70form a second heat source cooled by the flow through cooling fluid circuit CF. Intermediate passage132is adjacent to the fan assembly104. Intermediate passage132is disposed directly downstream from impeller106, in the example shown. The air entering and then flowing through intermediate passage132has the greatest velocity of the flow through cooling fluid circuit CF. The high velocity facilitates quick air exchange and decreases residence time, providing enhanced cooling efficiency in the portion of cooling fluid circuit CF exposed to two independent heat sources disposed on opposite sides of the cooling fluid circuit CF.

Impeller106blows the cooling air downstream through intermediate passage132. The cooling air flows through intermediate passage132and flows through exhaust passage134. The cooling air further cools pump10as the air flows through exhaust passage134to outlet openings102. The cooling air exits cooling fluid circuit CF through outlet openings102as exhaust air (shown by arrow EA). In some examples, pump10includes deflectors and/or contouring to direct heated exhaust air exiting outlet openings102away from inlet openings100. In some examples, pump10includes deflectors and/or contouring such that an air intake is oriented away from outlet openings102to avoid intake of hot exhaust air. In the example shown, the flowpath of the cooling fluid circuit CF extends about the motor housing70such that one or more inlet locations, through which intake air IA is drawn, and one or more outlet locations, through which exhaust air EA is emitted, are on the same side of the motor22. For example, inlet air IA can be drawn into intake passage130at a location proximate blocker wall120and exhaust air EA can be emitted from exhaust passage134at a location proximate blocker wall120but on an opposite circumferential side of blocker wall120from the inlet location. For example, the inlet locations and the outlet locations can be on the same side of a radial line extending through the rotational axis RA of rotor30. In the example shown, the inlet locations and outlet locations are disposed on the same lateral side of a vertical radial line through the rotational axis RA of the rotor30. The inlet and outlet locations are on an opposite side of motor22from control housing72.

Blocker wall120extends radially from motor housing70relative to the rotational axis RA of the rotor30. Blocker wall120is disposed circumferentially between intake passage130and exhaust passage134relative to the rotational axis RA of the rotor30. Blocker wall120prevents cool intake air entering intake passage130from crossing into exhaust passage134and prevents heated exhaust air from exhaust passage134from crossing into intake passage130. Blocker wall120can further act as a heat sink to conduct heat away from stator28and driver24.

One or more of heat sinks74can be formed as a continuous projection extending through multiple portions of the cooling fluid flowpath CF. For example, a single heat sink74can extend from blocker wall120, through intake passage130, through intermediate passage132, and through exhaust passage134and back to blocker wall120. As such, one or more of heat sinks74can extend fully circumferentially about motor22relative to the rotational axis RA of the rotor30and between a common connection point (e.g., blocker wall120).

The cooling air flow AF is drawn into cooling fluid circuit CF by fan assembly104and blown through cooling fluid circuit CF. The cooling air flow AF flows between two independent heat sources contained in control housing72and motor housing70and downstream out of cooling fluid circuit CF. The cooling air flow AF is routed circumferentially about motor housing70and the rotational axis RA of the rotor30. The cooling fluid circuit CF can be considered to extend arcuately about the rotational axis RA of the rotor30. The cooling air flow AF flows around both the axis of rotation RA of rotor30and the axis of reciprocation of fluid displacers20. In the example shown, the cooling air flow AF contacts motor housing70about a full circumferential length of the cooling fluid circuit CF. The cooling air flow AF contacts control housing72along a portion of the length of the cooling fluid circuit CF.

The cooling configuration of pump10provides significant advantages. Cooling fluid circuit CF draws cooling air from the environment surrounding pump10, providing an unlimited source of cooling air. Fan assembly104actively pulls the cooling fluid into cooling fluid circuit CF and blows the cooling fluid downstream through cooling fluid circuit CF to the outlet. Fan assembly104actively blows the air through cooling fluid circuit CF, facilitating greater flow and more efficient cooling. Cooling fluid circuit CF provides cooling to both the heat generating elements in control housing72and the heat generating elements in motor housing70. By cooling multiple distinct heat sources, cooling fluid circuit CF simplifies the arrangement of pump10and provides for a more compact, efficient pumping assembly. Cooling fluid circuit CF routes the cooling air circumferentially around motor housing70, maximizing the heat transfer area between motor housing70and the cooling air flow AF.

FIG.5Ais a first isometric view of a pump10.FIG.5Bis a second isometric view of the pump10.FIG.5Cis an isometric view of central portion66′.FIG.5Dis a cross-sectional view taken along line5-5inFIG.5A.FIGS.5A-5Dwill be discussed together. Central portion66′ and end caps68of pump body16′, motor22, driver24, control elements122, fan assembly104′, and housing cover94′ of pump10are shown. Pump10is substantially similar to pump1shown inFIGS.1A and1B. Central portion66′ includes motor housing70′, control housing72′, and heat sinks74′. Control housing72′ includes control housing block114′ and control cover116′. Motor22includes stator28and rotor30. Driver24includes drive nut90and screw92. Fan assembly104′ includes impeller106′, fan motor110′, and shroud146. Housing cover94′ includes exhaust cover96′ and baffle136.

The cooling configuration shown inFIGS.5A-7Bis substantially similar to the cooling configuration shown inFIGS.4A-4E. The cooling configuration shown inFIGS.5A-7Bis substantially similar to the cooling configuration shown inFIGS.1A and1B. Cooling air is drawn into the cooling fluid circuit by a fan assembly and routed circumferentially about the motor housing70′, relative to the rotational axis RA of the rotor30, to provide active cooling to the heat generating components of the pump10. Components inFIGS.5A-7Bthat are similar to components inFIGS.4A-4Eare indicated with a prime (e.g., motor housing70inFIGS.4A-4Eand motor housing70′ inFIGS.5A-7B).

Central portion66′ of pump body16′ houses motor22and control elements122that are connected to motor22, electrically and/or communicatively, to control operation of motor22and thus control pumping by pump10. Motor22is disposed within motor housing70′. Motor housing70′ can be substantially similar to motor housing7(FIG.1B). More specifically, motor22is disposed within the body of motor housing70′. The body of motor housing70′ forms a wall that extends fully about the motor22and the rotational axis RA to enclose the motor22within the motor housing70′. The body of motor housing70′ can be considered to form an annular wall that is exposed to the cooling fluid circuit CF. The body of motor housing70′ curves away from control block wall118′ of control housing72′. The body of motor housing70′ can be considered to be convex towards control block wall118′ of control housing72′. In the example shown, motor22is disposed within motor housing70′ and between end caps68. End caps68are mounted to opposite axial sides of motor housing70′ along the rotational axis RA. Stator28surrounds rotor30and drives rotation of rotor30, such that motor22can be considered to be an inner rotator motor. Rotor30rotates about the rotational axis RA and is disposed coaxially with driver24and fluid displacers20(not shown inFIGS.5A-5D). Permanent magnet array86is disposed on rotor body88. It is understood that the rotational axis RA can be coaxial with the pump axis along which the fluid displacers reciprocate.

Control housing72′ is connected to and extends from motor housing70′. Control housing72′ can be substantially similar to control housing72(FIG.1B). In the example shown, portions of control housing72′ and motor housing70′ are integrally formed as a single component (e.g., by casting, among other options). Control housing72′ is configured to house control elements122of pump10, such as controller26. In the example shown, control housing block114′ is integrally formed with motor housing70′. Control housing72′ is mounted to control housing block114′, such as by fasteners. In some examples, control housing72′ can be removably connected to control housing block114′ to provide access to the internal components within control housing72′. In some examples, a width of the control housing72′ is greater than a width of the motor22taken perpendicular to the rotational axis RA. The control housing72′ extends both above and below the motor22such that the motor22can be considered to be fully within a vertical footprint of the control housing72′. In the example shown, a height H1of the control housing72′ is greater than a height H2of the body of the motor housing70′.

Heat sinks74′ are formed on central portion66′. In the example shown, heat sinks74′ are formed in multiple configurations and include projections124′ and fins126′, but it is understood that heat sinks74′ can be of any configuration suitable for increasing the surface area of pump body16to facilitate heat exchange to cool the heat generating components of pump10. Projections124′ are aligned with fastener openings through the axial ends of motor housing70′. Projections124′ define portions of the fastener bores and receive the fasteners, such as the fasteners64that secure end caps68to central portion66′.

In the example shown, at least some of heat sinks74′ define flow passages forming a cooling fluid circuit CF for pump10. The cooling fluid circuit CF is an outer cooling fluid circuit in that cooling fluid circuit CF extends about the exterior of motor housing70′. In the example shown, the cooling fluid circuit CF is disposed axially between the fluid displacers20. In the example shown, the cooling fluid circuit CF does not radially overlap with a fluid displacer20relative to the rotational axis RA. In the example shown, support sink128′ extends between and connects control housing72′ and motor housing70′. The support sink128′ is formed by one or more heat sinks74′ that extend between and connect the control housing block114′ and motor housing70′. The support sink128′ can be integrally formed with both the control housing block114′ and motor housing70′. The support sink128′ at least partially defines a portion of the cooling fluid circuit CF. In the example shown, a single support sink128′ extends between motor housing70′ and control housing72′ within the cooling fluid circuit CF such that that support sink128′ is exposed to the cooling airflow on both axial sides of the support sink128′ relative to the rotational axis RA. Such a configuration provides relatively large cooling channels133′ through the intermediate passage132′ of cooling fluid circuit CF, which intermediate passage132′ is disposed between control housing72′ and motor housing70′. The single support sink128′ within the flowpath of the cooling air provides less restriction than multiple support sinks128′ fully in the flowpath, thereby facilitating laminar flow and decreasing residence time.

Housing cover94′ is mounted to pump body16and at least partially defines flow passages of the cooling fluid circuit CF. Housing cover94′ at least partially encloses the cooling fluid circuit CF. In the example shown, pump10is configured such that the intake passage130′ of the cooling fluid circuit CF is unshrouded and at least a portion of the exhaust passage134′ of the cooling fluid circuit CF is shrouded. In particular, exhaust cover96′ of housing cover94′ is mounted to pump16on an upper side of central portion66′ (e.g., between an outlet manifold14and central portion66′). Specifically, exhaust cover96′ is fixed to control housing72′ by bolts extending through exhaust cover96′ and into control housing72′. Baffle136(shown inFIG.5D) is a portion of housing cover94′ disposed between fan assembly104′ and exhaust cover96′.

Baffle136includes curved surface138configured to redirect the cooling air as the air flows from intermediate passage132′ to exhaust passage134′. Baffle136can be mounted on heat sinks74′ and is enclosed within cooling fluid circuit CF by exhaust cover96′ of housing cover94′. In the example shown, baffle136is separately formed from exhaust cover96′. As such, housing cover94′ can be formed from multiple discrete components assembled to pump10to at least partially define cooling fluid circuit CF. It is understood, however, that housing cover94′ can be formed by as many or as few components as desired. For example, exhaust cover96′ and baffle136can be integrally formed as a single component. In some examples, housing cover94′ further includes an exhaust cover, similar to housing cover94(best seen inFIGS.4A and4D), that at least partially defines intake passage130′ of cooling fluid circuit CF.

Housing cover94′ at least partially defines exhaust passage134′ of cooling fluid circuit CF. In the example shown, housing cover94′ includes cover body140and contoured end142. Cover body140extends between body flanges76disposed at the axial ends of motor housing70′ along the rotational axis RA. Contoured end142extends from cover body140and is disposed at an end of cover body140opposite the end adjacent control housing72′. Contoured end142narrows axially, relative to the rotational axis RA, as the contoured end142extends away from cover body140. Housing cover94′ both directs airflow through exhaust passage134′ of cooling fluid circuit CF and protects components of pump10from moisture. In the example shown, the full width cover body140extends at least to the top dead center TDC radial location of motor housing70′. Cover body140extending to the top dead center TDC location fully encloses those portions of motor housing70′ extending circumferentially towards control housing72′ from the top dead center TDC location. Cover body140prevents liquid from flowing into the intermediate passage132′ of the cooling fluid circuit CF. If any liquid falls on central portion66′, the cover body140prevents that liquid from flowing into intermediate passage132′, and any liquid that does fall on motor housing70′ (e.g., the portion extending circumferentially from the top dead center TDC location and away from control housing72′) flows away from intermediate passage132′ and thus away from the electronic components within control housing72′. Such a configuration facilitates quick cleaning of pump10during washdown as housing cover94′ prevents water ingress into intermediate passage132′.

Housing cover94′ is spaced radially relative to the rotational axis RA from heat sinks74′ by gap144. Gap144is formed such that the individual channels135′ between axially adjacent heat sinks74′, relative to the rotational axis RA, are fluidly connected. The gap144allows the cooling air flow to flow over the outer edges of the heat sinks74′ between the individual channels135′. Such a configuration facilitates efficient cooling by providing larger cooling passages and allowing flow between the adjacent passages.

The main heat sources of pump10include controller26, stator28, and driver24. Cooling fluid circuit CF directs cooling air through passages proximate the heat generating components to effect heat exchange between the flow of cooling air through cooling fluid circuit CF and the heat sources to thereby cool pump10. Cooling fluid circuit CF is configured to direct cooling air around motor housing70′. Cooling fluid circuit CF directs cooling air circumferentially around the rotational axis RA. Cooling fluid circuit CF extends arcuately about motor housing70′. Cooling fluid circuit CF is configured to direct cooling air to provide cooling to the heat generating elements in both motor housing70′ and control housing72′. A cooling assembly, similar to cooling assembly5(FIG.1B), actively blows cooling airflow through the cooling fluid circuit CF to facilitate cooling of the heat generating components of pump10. In the example shown, the cooling assembly can be considered to include at least fan assembly104′. The cooling assembly can be considered to further include flow directing components, such as baffle136and housing cover94′.

In the example shown, cooling fluid circuit CF includes intake passage130′, intermediate passage132′, and exhaust passage134′. In the example shown, there is no valving in cooling fluid circuit CF to direct flow. Instead, fan assembly104′ is configured to actively drive cooling air through cooling fluid circuit CF. The flowpath of cooling fluid circuit CF extends about motor housing70′. The flowpath of cooling fluid circuit CF curves at least 90-degrees about the motor housing70′. The annular wall of the motor housing body collects heat generated by motor22and is exposed to the flowpath of the cooling fluid circuit CF to effect cooling of the motor22and other heat generating elements within the motor housing70′.

Fan assembly104′ is supported by pump body16. More specifically, fan assembly104′ is supported by a control housing wall118′ of control housing72′. Impeller106′ is disposed within cooling fluid circuit CF. In the example shown, impeller106′ is disposed at an intersection between intake passage130′ and intermediate passage132′. It is understood, however, that fan assembly104′ can be disposed at any desired location along the cooling fluid flowpath CF. For example, fan assembly104′ can be disposed proximate an intersection between intermediate passage132′ and exhaust passage134′. In some examples, fan assembly104′ can be mounted within intermediate passage132′ and between intake passage130′ and exhaust passage134′. In such an example, both the inlet and outlet of fan assembly104′ can be oriented vertically such that fan assembly104′ is an axial blower. Fan assembly104′ is at least partially disposed within the cooling fluid circuit CF in the example shown, but it is understood that not all examples are so limited. More specifically, impeller106′ is disposed in the flowpath between an inlet of cooling fluid circuit CF and an outlet of cooling fluid circuit CF. In the example shown, at least a portion of fan assembly104′ is disposed directly between motor22and the control elements122disposed within control housing72′.

Shroud146is mounted to pump body16′. Impeller106′ is at least partially disposed within shroud146. Impeller106′ is disposed in impeller chamber148defined by shroud146and pump body16′. In the example shown, fan assembly104′ includes primary inlet150and secondary inlet152. Primary inlet150is oriented towards intake passage130′. Secondary inlet152is oriented towards control housing72′. A housing passage154is at least partially defined by control housing72′ and provides a flowpath for cooling air to flow to secondary inlet152. In the example shown, primary inlet150and secondary inlet152are disposed coaxially on a fan axis FA on which impeller106′ rotates. Fan motor110′ is disposed in control housing72′. Fan motor110′, which can be an electric motor, is isolated from the environment surrounding stator28by control housing wall118′ of control housing block114′, such that the cooling arrangement shown is suitable for use in hazardous locations. Fan shaft112′ extends through control housing wall118′ to connect fan motor110′ and impeller106′.

Impeller106′ is configured to draw cooling fluid into shroud through both primary inlet150and secondary inlet152. Impeller106′ blows the cooling air downstream out of fan outlet176. In the example shown, the fan outlet176is disposed directly between the motor housing70′ and the control housing72′ such that a line parallel to the fan axis FA can pass through each of the motor housing70′, the shroud146, and the control housing72′, In the example shown, the fan assembly104′ is configured such that a line parallel to the fan axis FA can pass through each of the motor housing70′, shroud146, impeller106′, and control housing wall118′. As such, those components can be considered to axially overlap relative to fan axis FA.

The main flow vector of the cooling air exiting the fan assembly104′ is perpendicular to the fan axis FA and is directed directly between the motor22and control elements122. More specifically, the air existing the fan assembly104′ flows directly between the thermally conductive body of motor housing70′ and the thermally conductive control housing wall118′. The main flow vector of the cooling air exiting the fan assembly104′ is directed directly between the motor housing70′ and the control housing72′. Impeller106is configured to output airflow radially relative to fan axis FA. In the example shown, impeller106is disposed axially between the motor housing70and the control housing72along the fan axis FA. In the example shown, at least a portion of the impeller106does not radially overlap with either the motor housing70or the control housing72relative to the fan axis FA. As such, a radial line extending from the fan axis FA that passes through the impeller106does not also pass through either of the motor housing70or the control housing72. The fan assembly104is disposed such that the fan axis FA is disposed in an orientation perpendicular to, but offset from, the axis of rotation RA of the rotor28.

Impeller106′ includes blades108′ that include primary blade projection158and secondary blade projection160. Blades108′ are supported by the body of impeller106′ and blow the cooling fluid through cooling fluid circuit CF. Primary blade projections158extend from a first side of impeller body164and away from control housing72′. Secondary blade projections160extend from a second side of impeller body164, opposite the first side, and towards control housing72′. Primary blade projections158have a length L1and secondary blade projections160have a length L2. The length L1is larger than the length L2. For example, a length ratio of the length L1to the length L2can be 2:1, 3:1, 4:1, or any other desired length ratio. The longer primary blade projections158facilitate greater flow of the cooling fluid through primary inlet150than through secondary inlet152to facilitate efficient cooling.

Intake passage130′ of cooling fluid circuit CF is unshrouded in the example shown. Intake passage130′ is formed on an opposite radial side of motor housing70′ from exhaust passage134′ relative to the rotational axis RA. Intake passage130′ includes multiple individual channels131′ that are each at least partially defined by heat sinks74′. Intake passage130′ is disposed upstream of primary inlet150of fan assembly104′. The individual channels131′ of intake passage130′ extend arcuately around motor housing70′. One or both of the axial sides of the individual channels131′, along the rotational axis RA, can be formed by a heat sink74. As such, at least some of the individual channels131′ can be axially bracketed by heat sinks74′ relative to the rotational axis RA. In the example shown, at least some of heat sinks74′ can extend circumferentially, but not axially, on motor housing70′ and about the rotational axis RA. It is understood, however, that heat sinks74′ of intake passage130′ can, in some examples, be canted to extend both circumferentially about the rotational axis RA and axially relative to the rotational axis RA.

In the example shown, the individual channels131′ of intake passage130′ include at least three sides that are each at least partially formed by thermally conductive material (e.g., the motor housing70′ and heat sinks74′). The body of motor housing70′ at least partially defines intake passage130′. Motor housing70′ is thereby directly exposed to the cooling flow through cooling fluid circuit CF. Motor housing70′ is disposed directly between stator28and intake passage130′ to provide efficient heat transfer from stator28to the cooling flow through cooling fluid circuit CF. In the example shown, the upstream intake passage130′ is unshrouded such that cooling air can be drawn into fan assembly from multiple different points about the rotational axis RA. As impeller106′ rotates, the cooling air is drawn into shroud146through both primary inlet150and secondary inlet152and is blown downstream through intermediate passage132′ and then to downstream exhaust passage134′. Specifically, a first portion of the cooling air is drawn into primary inlet150from intake passage130′ and a second portion of the cooling air is drawn into secondary inlet152through housing passage154.

Intermediate passage132′ is disposed between control housing72′ and motor housing70′. More specifically, intermediate passage132′ is disposed between control housing block114′ and motor housing70′. Control housing wall118′ at least partially defines intermediate passage132′. One or more of the heat generating elements in control housing72′ can be mounted to control housing wall118′. The heat generating elements are thereby mounted to a thermally conductive part of control housing72′, formed by control housing wall118′, that is also directly in contact with the cooling air flowing through cooling fluid circuit CF. At least some of the heat generating control elements122are mounted directly to thermally conductive material that is also exposed directly to the cooling air flow, which thermally conductive material is formed by control housing wall118′ in the example shown. The control housing wall118′ is configured to collect heat from the control elements122and is also exposed to the cooling flow through the cooling fluid circuit CF. As best seen inFIG.5D, the control elements122extend both above and below the motor22such that the motor22can be considered to be within a footprint of the control elements122. Mounting the heat generating elements to control housing wall118′ facilitates efficient heat transfer from those components to the cooling flow through cooling fluid circuit CF.

Intermediate passage132′ is at least partially defined by the body of motor housing70′. Motor housing70′ is thereby directly exposed to the cooling flow through cooling fluid circuit CF. Motor housing70′ is disposed directly between stator28and intermediate passage132′ to provide efficient heat transfer from stator28to the cooling flow through cooling fluid circuit CF. In the example shown, at least one heat sink74′ extends between and connects control housing72′ and motor housing70′. Specifically, support sinks128′ extend between and connect control housing block114′ and motor housing70′. The support sinks128′ at least partially define intermediate passage132′ and directly contact both control housing72′ and motor housing70′. The support sinks128′ define the channels133′ of intermediate passage132′. Such heat sinks74′ facilitate efficient heat transfer from both control housing72′ and motor housing70′. In the example shown, central portion66′ includes a single support sink128′ fully within the intermediate passage132′. Such a configuration encourages flow through intermediate passage132′ downstream from fan assembly104′ by limiting the restrictions within the intermediate passage132′ of cooling fluid circuit CF.

Exhaust passage134′ extends downstream from intermediate passage132′. Exhaust passage134′ is at least partially defined between motor housing70′ and housing cover94′. Baffle136is mounted to redirected the flow of cooling air from the intermediate passage132′ to the exhaust passage134′. Curved surface138of baffle136provides a smoothly contoured surface at a downstream end of intermediate passage132′ such that the cooling airflow is redirected without encountering a 90-degree corner. Redirecting the cooling flow by the curved surface138encourages continuous flow and decreases the residence time of the cooling air within cooling flowpath CF. Baffle136redirecting the flow of the cooling airflow facilitates efficient cooling.

In the example shown, a first portion of exhaust passage134′ extends from intermediate passage132′ and is at disposed between motor housing70′ and exhaust cover96′. A second portion of exhaust passage134′ extends from the first portion and can be considered to be unshrouded. The portions of the heat sinks74′ in the unshrouded portion of the exhaust passage134′ are directly exposed to the atmosphere, which is also the source of the cooling air, providing passive heat transfer to those portions of the exhaust passage134′.

In the example shown, exhaust passage134′ includes multiple individual channels135′ at least partially defined by heat sinks74′. The individual channels135′ of exhaust passage134′ extend arcuately around motor housing70′. An axial side, relative to the rotational axis RA, of each channel135′ is formed by a heat sink74. In the example shown, at least some of heat sinks74′ can extend circumferentially, but not axially, on motor housing70′ and about the rotational axis RA. It is understood, however, that heat sinks74′ of exhaust passage134′ can, in some examples, be canted to extend both circumferentially about the rotational axis RA and axially along the rotational axis RA. In the example shown, each of the individual channels135′ can include at least three sides at least partially formed by thermally conductive material (e.g., the motor housing70′ and heat sinks74′). The body of motor housing70′ at least partially defines the exhaust passage134′. Motor housing70′ is thereby directly exposed to the cooling flow through cooling fluid circuit CF. Motor housing70′ is disposed directly between stator28and exhaust passage134′ to provide efficient heat transfer from stator28to the cooling airflow through cooling fluid circuit CF.

During operation, fan motor110′ is powered to drive rotation of impeller106′. Fan assembly104′ draws air into cooling fluid circuit CF through intake passage130′. The cooling air can enter into the cooling fluid circuit CF at any point circumferentially along the intake passage130′ about the rotational axis RA. The intake passage130′ is in fluid communication with the surrounding environment. The portions of the heat sinks74′ in the intake passage130′ are exposed to the ambient air in the environment. The ambient air in the environment of pump10forms the cooling fluid drawn into cooling fluid circuit CF by fan assembly104′.

Fan assembly104′ draws a first portion of intake air (shown by arrows IA1) through primary inlet150in shroud146. Fan assembly104′ draws the intake air IA1from multiple locations separated circumferentially about the motor22. The various flows forming the intake air IA1can flow over the motor housing70′ and heat sinks74′ to conduct heat from those thermally conductive components. Fan assembly104′ also draws a second portion of intake air (shown by arrow IA2) into the shroud146through secondary inlet152. The second portion of intake air IA2contacts control housing block114′ prior to entering shroud146such that the second portion of intake air IA2can provide cooling to control housing72′ at locations upstream of shroud146.

The flow of cooling air (shown by arrows AF inFIG.5D) passes over heat sinks74′, control housing72′, and motor housing70′ and draws heat from those elements to effect cooling of those elements. Fan assembly104′ blows the air downstream through intermediate passage132′ and exhaust passage134′. The cooling airflow generated by fan assembly104′ initially flows through intermediate passage132′ after exiting from shroud146. The air flowing through intermediate passage132′ contacts both control housing72′ and motor housing70′ to transfer heat from both the heat generating components in control housing72′ (e.g., control elements122among others) and from the heat generating components of in motor housing70′ (e.g., stator28and driver24). At least a portion of the flow through cooling fluid circuit CF flows directly between the motor22and a control component122mounted to control housing wall118′. A radial line extending from the rotational axis RA can extend through driver24, stator28, a passage through cooling fluid circuit CF, and a control component122mounted to control housing wall118′. Such a configuration facilitates a compact pump and efficient cooling of heat generating components on opposite sides of the cooling fluid circuit CF.

At least a portion of cooling fluid circuit CF is bracketed by two unique heat sources. Specifically, intermediate passage132′ is exposed to thermally conductive elements on both radial sides of intermediate passage132′ relative to the rotational axis RA. The electric control elements122within control housing72′ form a first heat source cooled by the flow through cooling fluid circuit CF and the stator28and driver24within motor housing70′ form a second heat source cooled by the flow through cooling fluid circuit CF. In the example shown, intermediate passage132′ is disposed directly downstream from impeller106′. As such, the air entering and then flowing through intermediate passage132′ has the greatest velocity of the flow through cooling fluid circuit CF. The high velocity facilitates quick air exchange within the cooling fluid circuit CF and decreases residence time, providing enhanced cooling efficiency in the portion of cooling fluid circuit CF exposed to two independent heat sources disposed on opposite sides of the cooling fluid circuit CF.

In the example shown, fan assembly104′ blows the air downstream through intermediate passage132′. As discussed above, it is understood that some examples include a fan assembly104′ mounted at the downstream end of intermediate passage132′, within intermediate passage132′, or at any other desired location within the cooling fluid circuit CF. In such an example, fan assembly104′ can be considered to draw the air downstream through intermediate passage132′. The air flow exits intermediate passage132′ and flows through exhaust passage134′. The air further cools pump10as the air flows through exhaust passage134′. The air is exhausted from cooling fluid circuit CF as exhaust air (shown by arrow EA). In the example shown, the exhaust air is directed through outlets156. The outlets156can be considered to be formed between the housing cover94′ and the pump body16′. In the example shown, the outlets156are formed radially between the contoured end142of exhaust cover96′ and motor housing70′ relative to the rotational axis RA. Contoured end142of exhaust cover96′ curves around motor housing70′. The curved contoured end142directs the exhaust air to flow within the individual channels135′ between the heat sinks74′ even after passing out from under housing cover94′, further facilitating cooling. In the example shown, the flowpath of the cooling fluid circuit CF extends about the motor housing70′ such that one or more inlet locations, through which intake air IA1is drawn, and one or more outlet locations, through which exhaust air EA is emitted, are on the same side of the motor22. For example, inlet air IA1can be drawn into intake passage130′ at a location proximate blocker wall120′ and exhaust air EA can be emitted from exhaust passage134′ at a location proximate blocker wall120′ but on an opposite circumferential side of blocker wall120′ from the inlet location. For example, the inlet locations and the outlet locations can be on the same side of a radial line extending through the rotational axis RA. In the example shown, the inlet locations and outlet locations are disposed on the same lateral side of a vertical line extending radially through the rotational axis RA of the rotor28.

Blocker wall120′ extends radially from motor housing70′ relative to the rotational axis RA. Blocker wall120′ is disposed circumferentially between intake passage130′ and exhaust passage134′ on an opposite side of motor22from control housing72′. Blocker wall120′ prevents heated exhaust air from crossing into intake passage130′ and being recirculated. Blocker wall120′ can further act as a heat sink to conduct heat away from stator28and driver24.

One or more of heat sinks74′ can be formed as a continuous projection extending through multiple portions of the cooling fluid flowpath CF. For example, a single heat sink74can extend from blocker wall120′, through intake passage130′, through intermediate passage132′, and through exhaust passage134′, and back to blocker wall120′. As such, one or more of heat sinks74′ can extend fully circumferentially about motor22between a common connection point (e.g., blocker wall120′).

The cooling air flow AF is drawn into cooling fluid circuit CF by fan assembly104′ and flows between two independent heat sources contained in control housing72′ and motor housing70′ and downstream out of cooling fluid circuit CF. The cooling air flow AF is routed circumferentially about motor housing70′ and the rotational axis RA. The cooling air flow AF thereby flows around both the axis of rotation of rotor30and the axis of reciprocation of fluid displacers20, in the example shown. In the example shown, the cooling air flow AF can contact motor housing70′ about a full circumferential length of the cooling fluid circuit CF. The cooling air flow AF contacts control housing72′ along a portion of the length of the cooling fluid circuit CF.

The cooling configuration of pump10provides significant advantages. Cooling fluid circuit CF draws cooling air from the environment surrounding pump10, providing an unlimited source of cooling air. Fan assembly104′ actively pulls the cooling fluid into cooling fluid circuit CF and blows the cooling fluid downstream through cooling fluid circuit CF to the outlet. Fan assembly104′ actively blows the air through cooling fluid circuit CF, facilitating greater flow and more efficient cooling. Cooling fluid circuit CF provides cooling to both the heat generating elements in control housing72′ and the heat generating elements in motor housing70′. By cooling multiple distinct heat sources, cooling fluid circuit CF simplifies the arrangement of pump10and provides for a more compact, efficient pumping assembly. Cooling fluid circuit CF routes the cooling air circumferentially around motor housing70′, maximizing the heat transfer area between motor housing70′ and the cooling air flow AF.

Fan assembly104′ is mounted to pump body16′ to blow cooling air through the cooling fluid circuit CF (best seen inFIG.5D). Impeller106′ is supported by fan shaft112′ (FIG.5D) that extends through control housing wall118′ between the fan motor110′ (FIG.5D) disposed within control housing72′ and the impeller106′. The impeller106′ is mounted within the impeller chamber148and rotates within the impeller chamber148. Shroud146at least partially defines impeller chamber148. Impeller chamber148is further defined by pump body16′.

Impeller chamber148includes chamber wall174that extends about impeller106′. Chamber wall174is partially formed by shroud146and partially formed by pump body16′. Chamber wall174is formed as an involute curve in the example shown. The portions of chamber wall174formed by pump body16′ and shroud146form a smooth curve that encourages flow of the cooling air through fan outlet176. The smooth curvature of the chamber wall174includes wall portion178aformed by pump body16′, wall portion178bformed by shroud146, and wall portion178cformed by pump body16′. As such, the smoothly curved chamber wall174can be formed by portions of the pump body16′ bracketing the shroud146about the fan axis FA.

Impeller106′ rotates within impeller chamber148. Impeller106′ draws cooling air into impeller chamber148through primary inlet150and secondary inlet152(FIG.5D). The cooling air is blown radially outward relative to fan axis FA by blades108′ and is ejected from impeller chamber148through fan outlet176. Fan outlet176is oriented vertically into the intermediate passage132′ of cooling fluid circuit CF. The cooling air can be ejected from the impeller chamber148through intermediate passage132′ and towards baffle136. In the example shown, the cooling air is ejected vertically upward, though it is understood that the configuration can vary depending on the orientation of pump10. As shown inFIG.6A, a radially inner portion of each blade108′, relative to fan axis FA, is exposed through the primary inlet150. Impeller body164includes openings166such that cooling air can flow through the impeller body164. As such, the primary inlet150and secondary inlet152are not fluidly isolated.

Blades108′ are formed on impeller106′ and move the cooling air. The pressure side168of each blade108′ is concave and the suction side170of each blade108′ is convex. Both the primary blade projection158and secondary blade projection160of each blade108′ can be curved. In some examples, the primary blade projection158and secondary blade projection160are curved in the same manner such that blades108′ can be considered to have a common profile across the blade body from the tip of the secondary blade projection160to the tip of the primary blade projection158. Impeller106′ is configured to rotate towards the pressure side168(e.g., in the rotational direction RI shown inFIG.6B).

Baffle136is mounted on heat sinks74′. Baffle136is formed with grooves172that are disposed over the heat sinks74′ and receive the heat sinks74′. The heat sinks74′ extending into the grooves172locates the baffle136on pump body16′. Baffle136is formed such that curved surface138of baffle136is in a direct flowpath of the cooling air exiting from fan assembly104′. The curved surface138smoothly redirects the cooling airflow through the cooling fluid circuit CF.

Intermediate passage132′ of cooling fluid circuit CF is shown. Heat sinks74′ are formed on and project from both control housing72′ and motor housing70′ of pump body16′. As shown, a single support sink128′ is disposed within the intermediate passage132′ of the cooling fluid circuit CF. The support sink128′ divides the intermediate passage132′ into multiple cooling channels133′. The support sink128′ is connected to both the control housing72′ and the motor housing70′ such that the support sink128′ can dissipate heat from the heat generating components within the control housing72′ and within the motor housing70′. Others of the heat sinks74′ project into the intermediate passage132′ but do not span the intermediate passage132′. In the example shown, motor sinks180extend from motor housing70′ and control sinks182extend from control housing72′. The motor sinks180increase the surface area of motor housing70′ to effect cooling of the heat generating components within motor housing70′. The control sinks182increase the surface area of control housing72′ to increase the surface area of control housing72′ to effect cooling of the heat generating components within control housing72′. Such partial-width heat sinks74′ increase the surface areas of the control housing72′ and the motor housing70′, facilitating effective heat transfer, but without the restriction that occurs from a full width heat sink. As such, heat sinks74′ can be disposed in an external portion of the flowpath of cooling fluid circuit CF (e.g., in exhaust passage134′ proximate blocker wall120′) and heat sinks74′ can be disposed in an internal portion of the flowpath of cooling fluid circuit CF (e.g., in intermediate passage132′). The individual channels133′ within the intermediate passage132′ provide the cooling air to the individual channels135′ within the exhaust passage134′ (best seen inFIG.5D) of the cooling flowpath CF.

In the example shown, intermediate passage132′ can be considered to include dual channels133′ extending through the intermediate passage132′ and divided by the support sink128′. In some examples, the exhaust passage134′ has a larger number of individual channels135′ than the intermediate passage132′ includes individual channels133′. As such, the cooling flow in an individual channel133′ within the intermediate passage132′ can flow into multiple individual channels135′ within the exhaust passage134′. Multiple individual channels131′ of the intake passage130′ can feed fan assembly104′ and then be blown into the individual channels133′ of the intermediate passage132′.

The cooling configuration of pump10provides significant advantages. Cooling fluid circuit CF draws cooling air from the environment surrounding pump10and drives the cooling air around the exterior of motor housing70′. Fan assembly104′ actively pulls the cooling fluid into cooling fluid circuit CF and blows the cooling fluid downstream through cooling fluid circuit CF to the outlet. Intermediate passage132′ has a small number of individual channels133′ to facilitate efficient air flow through cooling fluid circuit CF. Fan assembly104′ actively blows the air through cooling fluid circuit CF. Cooling fluid circuit CF provides cooling to both the heat generating elements in control housing72′ and the heat generating elements in motor housing70′. By cooling multiple distinct heat sources, cooling fluid circuit CF simplifies the arrangement of pump10and provides for a more compact, efficient pumping assembly.

While the pumping assemblies of this disclosure and claims are discussed in the context of a double displacement pump, it is understood that the pumping assemblies and controls can be utilized in a variety of fluid handing contexts and systems and are not limited to those discussed. Any one or more of the pumping assemblies discussed can be utilized alone or in unison with one or more additional pumps to transfer fluid for any desired purpose, such as location transfer, spraying, metering, application, etc. It is further understood that the cooling configurations can be used on double displacement or single displacement pumps and can be utilized for cooling of displacement pumps utilizing any desired fluid displacer.

Discussion of Non-Exclusive Examples

The following are non-exclusive descriptions of possible examples according to the present disclosure.

A displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about an exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air through the cooling circuit.

A control housing extending from the motor housing, wherein electrical control components of the displacement pump are disposed in the control housing; and wherein at least a portion of the flowpath is disposed between the motor housing and the control housing such that the air blown by the fan assembly flows over and contacts both the control housing and the motor housing.

The portion of the flowpath is defined by a thermally conductive wall of the control housing and a thermally conductive body of the motor housing.

The thermally conductive body curves away from the thermally conductive wall.

The electrical control elements are mounted on a first side of the thermally conductive wall and a second side of the thermally conductive wall is exposed to the flowpath, the first side opposite the second side.

At least a portion of the fan assembly is disposed directly between the motor housing and the control housing.

The flowpath wraps at least 90-degrees about the motor housing.

The flowpath wraps at least 120-degrees about the motor housing.

The flowpath wraps at least 180-degrees about the motor housing.

The fan assembly includes an impeller configured to generate a radial output flow relative to a fan axis on which the impeller rotates.

The impeller is configured to draw air into the fan assembly from multiple inlet locations disposed about around the motor housing.

The flowpath is curved about the motor housing.

The flowpath is curved such that an inlet of the flowpath and an outlet of the flowpath are disposed on a same side of the motor relative to a radial line through an axis of rotation of the rotor.

A control housing that extends from the motor housing and within which electrical control components of the displacement pump are disposed is disposed on an opposite side of the radial line from the inlet and the outlet.

A main flow vector of cooling air exiting the fan assembly is perpendicular to a fan axis on which an impeller of the fan rotates and is directed directly between the motor and electrical control elements of the displacement pump.

A plurality of heat sinks formed on an exterior of the motor housing.

At least one first heat sink of the plurality of heat sinks extends between and connects the motor housing and a control housing within which electrical control components of the displacement pump are disposed, such that a portion of the flowpath is at least partially defined by the motor housing, the control housing, and the at least one first heat sink of the plurality of heat sinks.

At least one second heat sink of the plurality of heat sinks extends partially across the portion of the flowpath.

At least one control housing sink extends from the control housing, towards the motor housing, and partially across the portion of the flowpath; and at least one motor housing sink extends from the motor housing, towards the control housing, and partially across the portion of the flowpath.

The fan assembly includes an impeller disposed within the flowpath and configured to rotate on a fan axis; a fan motor disposed within a control housing that is connected to the motor housing; and a fan shaft extending through a wall of the control housing between the fan motor and the impeller, wherein the wall of the control housing isolates an interior of the control housing from the flowpath and is exposed to the flowpath.

At least one electrical component is mounted to the wall within the control housing.

A heat sink extends between and connects the wall and the motor housing.

The fan assembly includes a shroud and an impeller disposed within the shroud.

The shroud includes a primary inlet on a first axial side of the impeller along the fan axis.

The shroud includes a secondary inlet on a second axial side of the impeller along the fan axis.

A housing passage is at least partially defined by the control housing, wherein the housing passage is disposed on an opposite axial side of the shroud from an intake passage of the cooling circuit along the fan axis and extending from an exterior of the control housing to the secondary inlet.

An outlet of the fan assembly is oriented to output cooling airflow in a direction orthogonal to the fan axis.

The impeller includes a plurality of blades.

Each blade of the plurality of blades is curved to have a concave pressure side and a convex suction side.

At least one blade of the plurality of blades includes a primary blade projection extending in a first axial direction from a body of the impeller along the fan axis and includes a secondary blade projection extending in a second axial direction from the body of the impeller along the fan axis, and wherein the first axial direction is opposite the second axial direction.

The primary blade projection has a greater axial length along the fan axis than the secondary blade projection.

The impeller is disposed in an impeller chamber at least partially defined by the shroud, and wherein a surface of the impeller chamber oriented towards the impeller is formed as an involute curve.

A housing cover is mounted to a pump body of the displacement pump, the pump body including the motor housing, and wherein the housing cover at least partially encloses the flowpath.

The housing cover includes an exhaust cover extending over a portion of the motor housing downstream of the fan assembly.

The exhaust cover extends to a top dead center location of the motor housing.

The housing cover includes a baffle having a curved surface exposed to the flowpath, wherein the curved surface is configured to redirect cooling flow through the flowpath from an intermediate passage of the cooling circuit to an exhaust passage of the cooling circuit, wherein the intermediate passage is disposed between the motor housing and a housing block within which control elements of the displacement pump are disposed; and wherein the exhaust passage is disposed between the motor housing and the exhaust cover.

The rotor is configured to rotate on a pump axis.

The fluid displacer is configured to pump the fluid by linear reciprocation of the fluid displacer.

A driver connected to the rotor and the fluid displacer, the driver configured to convert a rotational output from the rotor into a linear input to the fluid displacer.

The fan assembly is at least partially disposed in the flowpath.

The fluid displacer is a first fluid displacer; the displacement pump further includes a second fluid displacer; and the flowpath is disposed between the first fluid displacer and the second fluid displacer,

At least a portion of the flowpath is directly between the first fluid displacer and the second fluid displacer.

A first portion of the flowpath is disposed radially outside of an area directly between the first fluid displacer and the second fluid displacer and a second portion of the flowpath is disposed within the area.

A displacement pump for pumping a fluid includes an electric motor at least partially disposed in a motor housing and including a stator and a rotor; a first fluid displacer connected to the rotor such that a rotational output from the rotor provides a driving input to the first fluid displacer; and a cooling circuit extending about an exterior of the motor housing that houses the electric motor.

A control housing extending radially from the motor housing relative to the axis, wherein electrical control components of the displacement pump are disposed in the control housing; wherein a portion of the flowpath is disposed between the motor housing and the control housing such that the air blown by the fan assembly flows over and contacts both the control housing and the motor housing; wherein the portion of the flowpath is defined by a thermally conductive wall of the control housing and a thermally conductive body of the motor housing; and wherein the electrical control components are mounted to the thermally conductive wall on an opposite side of the thermally conductive wall from the portion of the flowpath.

The portion of the flowpath is formed as a plurality of channels at least partially defined by the motor housing and the control housing.

The control housing and the motor housing are integrally formed.

The flowpath is curved around the motor housing.

A fan assembly configured to blow air through the cooling circuit.

An impeller of the fan assembly is disposed in the flowpath.

A fan motor of the fan assembly is disposed in the control housing.

The impeller is disposed upstream of the portion of the flowpath.

The impeller is configured to rotate on a fan axis and the fan assembly is configured to output cooling air radially relative to the fan axis.

An outlet of the fan assembly is disposed directly between the motor housing and the control housing.

A plurality of heat sinks are formed on an exterior of the motor housing and at least one heat sink of the plurality of heat sinks extends between and connects the motor housing and the control housing such that the portion of the flowpath is at least partially defined by the motor housing, the control housing, and the at least one heat sink of the plurality of heat sinks.

A housing cover is mounted to the motor housing, wherein the flowpath is at least partially defined by the housing cover.

The flowpath includes an inlet portion, an intermediate portion extending downstream from the inlet portion, and an outlet portion extending downstream from the intermediate portion, wherein the intermediate portion is disposed between the motor housing and a control housing within which control elements of the electric motor are disposed.

The flowpath is disposed between the first fluid displacer and a second fluid displacer, the first fluid displacer and the second fluid displacer connected to the rotor to be linearly reciprocated by the rotor.

A displacement pump for pumping a fluid includes an electric motor at least partially disposed in a motor housing and including a stator and a rotor; a controller operatively connected to the electric motor, the controller disposed in a control housing extending from the motor housing; a first fluid displacer connected to the rotor such that a rotational output from the rotor provides a driving input to the first fluid displacer to cause pumping by the first fluid displacer; and a cooling circuit having a flowpath extending between the motor housing and the control housing.

The flowpath includes an inlet portion at least partially defined by the motor housing, an intermediate portion between the motor housing and the control housing, and an outlet portion between the motor housing and a housing cover, wherein cooling airflow through the intermediate portion contacts both a thermally conductive wall of the control housing and a thermally conductive body of the motor housing.

The intermediate portion is formed by a plurality of flow channels disposed between the motor housing and the control housing.

A fan assembly configured to blow cooling air through the flowpath.

A displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about an exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air into a portion of the flowpath disposed between a first thermally conductive wall of the motor housing and a second thermally conductive wall of a control housing in which electrical control components of the displacement pump are disposed, such that an output from the fan assembly contacts both the first thermally conductive wall and the second thermally conductive wall.

At least a portion of the fan assembly is disposed directly between the electric motor and the control housing.

At least a portion of an impeller of the fan assembly is disposed directly between the electric motor and the control housing.

An outlet of the fan assembly is disposed directly between the motor housing and the control housing.

A main flow vector output from the fan assembly is disposed orthogonal to a rotational axis of the fan assembly.

A displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about a curved exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air through the cooling circuit.

The fan assembly outputs the air to a portion of the flowpath between a thermally conductive wall of a control housing of the displacement pump and the curved exterior of the motor housing, and wherein electrical control components of the displacement pump are mounted on an the thermally conductive wall on an opposite side of the thermally conductive wall from the flowpath.

The curved exterior is convex towards the control housing.

A displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about an exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air through the cooling circuit, an inlet of the fan assembly is oriented to receive the air axially along a fan axis that an impeller of the fan assembly rotates on, and an outlet of the fan assembly is oriented to output the air transverse to the fan axis.

The outlet is oriented to output the air radially relative to the fan axis.

The motor housing is spaced in a first axial direction along the fan axis from a control housing within which electrical control components of the electric motor are disposed, and wherein the inlet is a primary inlet oriented in the first axial direction.

The fan assembly further includes a secondary inlet through which a secondary flow of air is drawn into the housing by the impeller.

The secondary inlet is disposed coaxially with the primary inlet on the fan axis.

The secondary inlet is oriented in the second axial direction.

The primary inlet is configured to draw intake air from multiple locations about the motor housing.

The fan assembly includes a motor disposed within the control housing and a fan shaft extending through a wall of the control housing and connected to the fan motor and the impeller.

A displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a motor housing that houses the electric motor and that has a housing body and a plurality of heat sinks projecting from the housing body; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about an exterior of the motor housing; and a fan assembly configured to blow air through the cooling circuit.

A first heat sink of the plurality of heat sinks is exposed to ambient air.

A second heat sink of the plurality of heat sinks is disposed within an enclosed portion of the flowpath.

The enclosed portion of the flowpath is formed between the housing body and a control housing within which electrical control components of the electric motor are disposed.

A support heat sink extends between and connects the housing body and the control housing.

The second heat sink extends only partially across the enclosed portion of the flowpath.

The control housing includes a housing wall exposed to the flowpath, and wherein at least one control heat sink extending from the housing wall and into the flowpath.

The at least one control heat sink extends only partially across the enclosed portion of the flowpath.

A displacement pump for pumping a fluid includes an electric motor including a stator and a rotor; a fluid displacer configured to pump fluid and connected to the rotor to be driven by the rotor; a cooling circuit including a flowpath about an exterior of a motor housing that houses the electric motor; and a fan assembly configured to blow air through the cooling circuit. The flowpath extends at least 90-degrees about the motor housing.

The flowpath extends at least 90-degrees from a fan outlet of the fan assembly to an exhaust outlet of the cooling circuit.

The flowpath extends at least 120-degrees about the motor housing.

The flowpath extends at least 180-degrees about the motor housing.

The flowpath extends between an intake and an exhaust, and wherein the exhaust is at least partially defined by a cover extending over and spaced from the motor housing.