COOLANT PUMP FOR AUTOMOTIVE USE

Abstract: An impeller pump with thermostatically adjustable guide vanes (4) is suitable for use as an automotive coolant pump. The pump is driven by a constant speed electric motor (1) and flow variation is controlled by varying the orientation of the vanes (4). Orientation of the vanes (4) is effected by a wax-type thermostat, which senses coolant temperature: flow is increased when the coolant is hot, and decreased as the coolant cools. The variable guide vanes (4) are mounted for pivoting about radial axes, and are located just upstream from the pump impeller (2).

Description: i Title: COOLANT PUMP FOR AUTOMOTIVE USE 2 3 This invention relates to coolant pumps for automotive internal-combustion engines. The invention is aimed at providing a coolant pump which delivers flow characteristics 5 in accordance with engine demand. 6 7 8 BACKGROUND TO THE INVENTION 9 1 o Pumps for internal-combustion engine cooling systems have traditionally been belt- i 1 driven, at a fixed ratio, directly from the engine. 1 2 1 3 The coolant flow rate and pressure head required to effectively control the engine 14 temperature are not, however, optimal when driven proportionally to the engine's 1 5 rotational speed. The coolant system has to cope with the fully-laden vehicle 16 struggling up-hill on a hot day, and the same system has to make sure the heater 17 warms up rapidly in very cold conditions. Also, for efficiency, the energy consumed 1 β by the coolant pump ideally should at all times be only the minimum needed to just 19 achieve the optimum temperature in the coolant. Whatever coolant circulation 20 system is used, it must of course cater for the extremes; in the case of the traditional 2i belt-driven coolant pumps, the need to cater for the extremes so compromises the 22 efficiency of normal running that traditional coolant pumps are inherently non-optimal 23 for most of their operating conditions. 24 25 The optimum coolant temperature is dictated by considerations of engine 26 performance, fuel efficiency, exhaust emissions, etc. The coolant circulation system 27 must provide a volumetric flow rate, and a pressure head, such that the coolant is 28 cooled down (or warmed up) to the correct temperature under the extreme conditions. 29 The invention is aimed at making it possible still to accommodate the extremes, and 0 yet to improve the efficiency of the coolant circulation system during normal running, 1 so that the system consumes only a minimum of energy during normal running. 2 3 When the coolant pump provides excessive flow and head, the engine wastes power 4 and the overall engine efficiency is reduced. This extreme condition can occur when 1 the engine is cold and is being revved high. The high revving engine causes the 2 coolant pump to provide a high flow rate which is not required by the cooling system. 3 The high airflow rate impinging across the radiator, while the engine is revving fast in 4 cold ambient temperatures is an example of this extreme condition. 5 6 When the coolant pump provides insufficient coolant flow and head, the engine runs 7 too hot, thereby reducing engine performance, and perhaps damaging the engine. β Overheating can occur when the engine temperature is high while running at a low 9 speed. 10 i i It is recognised that traditional belt-driven-from-the-engine pumps are compromised as 1 2 to power consumption, size, weight and mounting location; these characteristics are 1 3 imposed by system requirements. The traditional type of system consumes much 14 power, occupies much space, is heavy, and provides little design configuration 1 5 flexibility. 16 17 The disadvantages of these traditional fixed-ratio belt driven coolant pump systems ι β when compared to the proposed system configuration may be summarised as: 19 - high space requirements; 20 - restricted mounting locations (direct belt drive from engine is necessary); 2 i - excessive power consumption, reduced engine efficiency; 22 - limited coolant flow capabilities (engine may run too hot or too cold which reduces 23 engine efficiency and life span and adversely affects emissions); 2 - typically heavy; 25 - have numerous moving parts; 26 - difficult to repair and/or replace. 27 28 Although these problems have been recognised, engine designers have not, in 29 general, switched to driving coolant pumps by means of electric motors. This fact 30 should be viewed in light of the fact that it is very common for a designer to specify 31 that the engine's cooling fan to be driven by an electric motor. There, the motor runs 32 at constant speed, and is controlled simply by being switched on/off: the need for 33 switching is signalled by a simple electrical thermostat. That is a simple enough duty 34 requirement for an electric motor to be subjected to. ι It is recognised, however, that a simple on/off control would be far too crude for 2 controlling the flow of coolant. Even under the minimum coolant flow conditions, the 3 coolant must still be pumped and circulated quite vigorously. 4 5 It might be considered that, if an electrically-driven coolant pump were to be provided, 6 it would be possible to control the coolant flow by controlling the rotational speed of 7 the electric motor. Theoretically, this could be done by varying the electric current 8 supplied to the motor that drives the coolant pump. However, such control of the 9 motor speed by control of the motor current has not found favour with engine I o designers. It is a characteristic of electric motors that, to give good efficiency under I I many load conditions, the system should be so arranged that the electric motor runs 12 at a constant speed. Generally, that is a characteristic of pumps, too; that, to give 13 good efficiency under many load conditions, the system should be so arranged that 1 the pump runs at a constant speed. 1 5 16 Thus, in considering the use of an electric motor to drive the coolant pump, it is 17 apparent, first, that simple thermostatic on/off switching of a pump motor is out of the 18 question, and second, trying to control motor-speed by controlling the current supplied 19 to the electric motor has not found favour. And, even as a last resort, the notion of 20 controlling coolant-flow by means of coupling the pump to a fixed speed motor by 21 means of a mechanical variable speed drive, must be contra-indicated out as being 22 far too elaborate; also, as mentioned, it is important that the pump, as well as the 23 motor, should run at constant speed. 24 25 The invention is aimed at making it possible to vary the coolant flow to suit many 26 different conditions, in a way which allows the pump (and hence the motor) to run at 27 constant speed. 28 29 30 GENERAL PRINCIPLES OF THE INVENTION 31 32 The design configurations as will be described herein employ variable pitch guide 33 vanes to affect the velocity, flow rate, pressure head, etc, of the coolant. The guide 34 vanes are located adjacent to the impeller of the coolant pump, in the flow of coolant ι as it passes through the pump. The vanes are operated in response to a temperature 2 signal corresponding to the actual cooling demand of the engine. The guide vanes 3 serve to boost or to reduce the flow of coolant through the impeller, the change 4 between boost and reduce being effected as a consequence of a change in the positional orientation of the vane in relation to the impeller of the pump. 6 7 The heat rejection demand is made dependent upon the temperature of the system, 8 not engine speed. The system temperature might, for example, be taken as the 9 temperature of the cooling fluid, or the temperature of a particular location on a I o machine, such as near the exhaust valves on the cylinder heads of an internal I I combustion engine. The system temperature may be transduced into a mechanical 1 2 displacement which adjusts the pitch of a set of the guide vanes, which are preferably 1 3 located just upstream of the impeller. When the system temperature is high, the 1 thermostatic transducer adjusts the vanes such that the impeller pump provides a high 1 5 coolant flow rate; when the system temperature is low the vanes are adjusted to 16 provide a lower coolant flow rate. 17 18 It should be noted that, in an internal combustion engine, it is required that the coolant 19 flow be maintained at all times during operation of the engine. The minimum flow 20 demand is still a substantial flow. The engine would overheat in a few seconds if flow 21 were actually to stop. Thus, it will be understood that the flow rate being controlled is 22 just the upper fraction of the maximum flow rate - an area of flow in which it is 23 notoriously difficult for a designer to achieve a desired degree of linearity of control. It 2 is recognised that controlling just the upper fraction of the flow rate is not only easy 2 with the variable pitch vanes, but, when the vanes are moved, the change in flow rate 26 is not too far from being more or less linearly proportional to the movement of the 27 vane. This means that simple automotive wax-type thermostats can be used directly, 28 since they too have a more or less linear temperature /movement characteristic. 29 30 The use of variable pitch guide vanes combined with a modern high-speed impeller 31 produces increased hydrodynamic flow efficiency over a wide range of flow rates, and 32 provides capability to reduce the flow rate when the demand decreases. In contrast 33 to a conventional direct drive impeller pump which frequently provides excessive 34 coolant flow and uses excessive power, the temperature-responsive variable vane system as described herein, can provide precisely the correct amount of coolant flow to maintain optimum system operating temperatures, while consuming less power. This pump's variable hydrodynamic flow /pressure capability, even though driven at a reasonably constant speed, provides thermal controllability while eliminating the need for a variable or multiple speed electrical motor. Increased hydrodynamic flow efficiency combined with the use of small high-speed motors can result in the overall pump package being small, lightweight, efficient, and easy to integrate within a given cooling system ' s spacial constraints. The thermostatic signal can be transduced directly into a mechanical displacement of the guide vanes, for simple systems. For more sophisticated systems, a thermal signal can be processed by the engine management system which then controls an electrically-activated displacement mechanism to adjust the guide vanes. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS By way of further explanation of the invention, exemplary embodiments of the invention will now be described with reference to the accompanying drawings, in which: Fig 1 is a pictorial cross-section of a water pump which embodies the invention; Fig 2 is a pictorial exploded view of-the components of a water pump for an automotive engine, which embodies the invention; Fig 2a is a close-up of an impeller of the pump; Fig 3 is a pictorial view in close up of the assembled components of the pump of Fig 2; Fig 4 is a diagrammatic cross-sectioned side view of some of the components of the pump of Fig 2; Fig 5 is an end elevation of some of the components of the pump of Fig 2; Fig 6 is cross-section of another water pump which embodies the invention; Fig 7 is a cross-section on line A-A of Fig 6; Fig 8 is a pictorial view of some of the components of the pump of Fig 6; Fig 9 is a cross-section of another water pump which embodies the invention; Fig 10 is a plan view of some of the components of the pump of Fig 9; Fig 1 1 is a graph showing a comparison of power consumption characteristics; Fig 12 is a graph showing a flow rate comparison. The apparatuses shown in the accompanying drawings and described below are examples which embody the invention. It should be noted that the scope of the invention is defined by the accompanying claims, and not necessarily by specific features of exemplary embodiments. As shown in Fig 1 , the motor 1 runs at a high speed, driving the impeller 2. A lip-seal 3 around the motor shaft seals the motor-pump interface between the motor 1 and the pump housing 10. The circular array of adjustable guide vanes 4 direct fluid flow from the fluid inlet passageway 8 onto the impeller 2. The impeller 2 then forces the fluid against the pump housing 10 towards the fluid outlet passageway 9. The adjustable guide vanes 4 impart a variable degree of spin on the fluid flow depending on their angular displacement. The variable fluid flow spin ' ranges from negative to positive relative to the blades of the impeller 2. The degree of spin depends on the amount of angular displacement of the adjustable guide vanes 4. The angular displacement of the guide vanes corresponds to the amount of displacement of the guide vane linkage ring assembly 5. The guide vane linkage ring assembly 5 is displaced by the connected thermostatic element 6. Changes of temperature cause the thermostatic element 6 to expand or contract thus giving a corresponding displacement. A spring forces the thermostatic element 6 to return to its position of minimal displacement relative to its expansion-displacement force. Figs 2-5 show an electrically driven water-pump that embodies the invention. The electric motor 20 is of the high speed (10,000 rpm or more) type, and typically draws a current, during normal operation, of between about 10 and 20 amps (at 12 volts). The body of the motor is bolted to a mounting plate 23. The shaft 25 of the motor is secured to a rotary impeller 27. The impeller 27 is shown in Fig 2a, and is constructed preferably as a plastic or metal moulding. ι The impeller 27 is placed in the path of coolant water flowing from the engine block 2 via entry-passage 29. Water passing through the impeller is channelled away via exit- 3 passage 30 (and thence passes to the radiator, etc). 4 5 Before reaching the impeller 27, water entering the impeller 27 first encounters a set 6 of movable vanes 32. The designer provides that the vanes might be inclined in a 7 sense whereby the vanes induce a rotary swirling motion into the water flow as the 8 water flow enters the impeller. The vanes might be inclined in a first sense such that 9 the swirling induced by the inclined vanes is in the same sense as, and reinforces, the ι o rotary swirling produced by the impeller itself; or, the vanes might be inclined in the 1 1 opposite sense, in which case the swirling induced by the vanes serves to oppose the 1 2 swirling produced by the impeller. 1 3 14 By controlling the inclination of the blades, the output characteristics of the pump 15 impeller can be controlled, in a smoothly progressive manner, and while the electric 16 motor keeps the impeller rotating at more or less constant speed. 17 18 The inclination of the vanes is controlled by means of a thermostat 34, as will now be 19 described. 20 21 Each vane 32 is secured to a respective vane-shaft 36, which is guided for rotation in 22 a respective radially-disposed bore 38 in a fixed base plate 40. The outer end of 23 each vane-shaft 36 carries a respective lever 43, by means of which the shaft 36, and 24 the vane 32, may be rotated. 25 26 The shaft-levers 43 are caused to rotate by the action of a rotor-ring 45. The rotor- 27 ring 45 is mounted for rotation on the fixed base-plate 40. In fact, the rotor-ring is 28 sandwiched between the fixed base-plate 40 and a fixed cover-plate 47. The two 29 fixed plates 40,47 are bolted (at 46) to the mounting plate 23. The plates 40,47 are 30 held apart by spacers 44, and the rotor-ring 45, which lies between the fixed plates, is 31 movable relative thereto. The rotor-ring 45 is biassed in the anti-clockwise sense by 32 means of springs 48. 33 34 The rotor-ring 45 is provided with notches 49, one for each of the shaft-levers 43 (five in this case). When the rotor-ring rotates, the five shaft-levers are dragged around and made to rotate their respective shafts 36 in unison with each other. The rotor-ring 45 is caused to rotate by movement of the stem 50 of a thermostat 52. The distance the stem 50 protrudes from the body of the thermostat is proportional to the temperature of the water flowing over the body. The rotor-ring 45 thus rotates through an angle which is proportional to the temperature of the water, and similarly, the movable vanes 32 thereby lie at an angle of inclination which is proportional to the temperature of the water. The thermostat 52 is of the type which contains an expandable body of wax. Such thermostats are readily available in a body size around 13 mm diameter, where the stem moves through approximately an 8 mm working stroke, between hot and cold. The movement of the stem is more or less proportional to the temperature, over the working stroke. The thermostat is arranged to move the movable vanes 32, in this case, from an angle of about 50 degrees of with-the-impeller bias to an angle of about 25 degrees against-the-impeller bias. With-the-impeller bias is used to reduce the operation of the pump, whereby the pump delivers a smaller volumetric flow, and uses a smaller input energy; this is of use when the coolant is at cooler temperatures. Against-the- impeller bias is used to boost the flow of water through the pump impeller, which is of use when the water is starting to overheat. The electric motor runs continuously while the engine is running, even when the engine coolant flow is at a minimum. Of course, the minimum coolant circulation flow is, and must be, a substantial flow: if the flow were allowed to approach zero flow conditions, the engine would quickly overheat. In fact, one of the reasons a movable-vane system, as described, is so advantageous, is that the movable-vanes, even at the position where the flow is reduced to the maximum extent, still do permit a substantial flow. In the movable-vane system, the required flow adjustment is between two extremes of flow where even the lowest required flow is a long way from the zero flow condition. The movable-vanes system ι may be regarded as making it possible to make fine-tuning adjustments to what is a 2 relatively large flow, in a refined and controllable manner, as distinct from switching a 3 flow between on and off. Generally, it is regarded as quite demanding to obtain good 4 linear control of a flow from, say, 60% of maximum, upwards. The movable-vane 5 system does give excellent control and linearity over that range. It is recognised that 6 this is just the characteristic that is required in an automotive water pump. 7 8 The mounting plate 23 includes cooling air passages, whereby the flow of cooling air 9 over the motor is maximised, which is advisable in the case of a continuously-running I o motor. The flow of water emerging from the impeller passes radially outwards into the I I chamber 54. The mounting plate 23 includes fixed spacers 56, which provide space 1 2 for the coolant to flow around and out of the passage 30. 1 3 14 The motor-shaft 25 carries a seal 58. The seal 58 must be designed for high shaft 1 5 speeds: however, because the shaft diameter is small (e.g 5 mm) the rubbing speed 16 of the shaft on the seal is small, and in fact the seal 58 can be expected to have an 17 adequate service life (as that expression is used in relation to automotive seals). The ι β designer may prefer to provide a mechanical (rubbing) seal in place of the lip seal, if 19 problems with lip-seals are feared. Another alternative is to provide a magnetic drive 20 coupling from the electric motor to the impeller. Magnetic-drive couplings, which 21 avoid the need for seals, are commonly available, and are not expensive, in the size 22 of drive herein described. 23 2 Fig 6 shows another type of water pump, which embodies the invention. In this case, 25 water from the engine enters the pump at port 60, and leaves through port 63. The 26 incoming water flows around an annular passage 65 (Fig 7). The electric motor 67 27 driving the impeller 69 is located internally of the annular passage 65. 28 29 The vanes induce a degree of rotary swirling motion of the water passing through the so annular passage 65, as the water approaches the rotating impeller 69 (upwards in Fig 31 6). The water flow can be biassed to swirl clockwise or anticlockwise in the annular 32 passage 65, depending on the orientation of movable vanes 70. As shown in Fig 7, 33 the vanes are inclined to the left, whereby the water flow is biassed clockwise. Flow 34 through the impeller 69, with the electric motor 67 set in the normal rotational sense, will be enhanced by a clockwise-biassed water flow. Inclining the vanes 70 to the right (Fig 7) would reduce the water flow through the impeller, for a given speed of the motor. Again, even when the flow is reduced to a maximum extent, the flow is still substantial. The thermostat 72 senses the temperature of the flowing water, and adjusts the angle of the vanes 70 accordingly. Fig 8 shows how the thermostat 72 is configured so as to control the angular movement of the movable vane 70. The other vanes are linked by suitable connecting rods. The Fig 6 structure is suitable for fitment, as an insert, into the hoses which convey water on an automotive engine. As such, the unit may be fitted as a repair to a vehicle with a damaged water pump of the traditional belt-driven type. Alternatively, the Fig 6 configuration may be incorporated as an OEM water pump. Figs 9,10 show another water pump which embodies the invention. The thermostat 89 acts upon a rotatable ring 90, in which are carried several movable vanes 92, mounted on spindles. The vane spindles terminate in respective tags 94, which engage corresponding slots 96 in the pump housing 98. Movement of the thermostat stem is effective to drag the ring around, and cause the vanes to rotate to a new orientation. In some cases, the vanes are positioned in the flow of water leaving, rather than entering, the impeller. This gives a somewhat different characteristic of speed/ motor- current/ pressure/ flow-rate/ efficiency/ etc, but one which may be more appropriate in some circumstances. In the graph of Fig 1 1 , curve 120 shows the estimated power consumption of a typical conventional fixed-ratio, engine-driven coolant pump system, with the engine thermostat open. (With the thermostat closed, the power needed to pump the coolant would be a little lower.) Curve 123 shows the estimated power consumption of a movable-vane, electric-motor driven pump system, of the type as described herein, in which the coolant flow-rate is boosted by the vanes. Curve 125 is of the same thing, in which the flow rate is reduced by the vanes. The new system can provide a ι constant coolant flow rate, independent of engine speed, even down to zero engine 2 speed: in the new system, the flow rate changes in response to a change in 3 temperature of the coolant, and the new system is arranged to increase or reduce the flow-rate of the coolant as the temperature goes up or down. 5 6 Fig 12 is another graph showing an estimation of the improvement of the new pump 7 system over a conventional system. 8 9 Some further benefits of the coolant flow control systems as described herein will now ι o be described. 1 1 1 2 1. Improved control of engine temperature. Most conventional engine driven systems 1 3 rely on fan-airflow modulation of the airflow across the radiator to maintain engine 14 coolant temperature within a specified operating range. By contrast with thermostatic 1 5 on/off control of a cooling fan, which needs a wide difference between on and off to 16 operate reliably, the water temperature can be much more tightly controlled with the 17 present system. Control the temperature within tight limits allows overall engine ι β efficiency to be improved. Minimizing the temperature operating range is a design 19 objective because of the inherent engine performance benefits associated with 20 operation at optimal temperatures, such as better combustion etc. Also, the tighter 21 control of coolant temperature by the new pump system may be expected to lead to a 22 reduced need for modulation from the fan. 23 24 2. Coolant pump efficiency. The amount of energy spent on cooling, aggregated over 25 the entire operating range, is considerably reduced. 26 27 3. Improved heater performance. At idle, conventional engine-driven pumps 28 commonly deliver insufficient coolant to the heater-core resulting in poor cabin heater 29 performance. Engine driven pumps typically do not deliver a level of flow through the 30 heater core beyond the "knee region" of the heater core's performance characteristic 31 curve. This results in far less than optimal heat transfer and cabin heater 32 performance at idle. The new system can be designed to have a minimum flow-rate 33 tuned for a given system resistance and higher flow through the heater core to boost 34 cabin heater performance during warm-up. 1 4. After-run cooling capability. An electrically driven pump, as depicted herein, can 2 be switched to provide after-run cooling. After-run cooling occurs when the engine is 3 shut down and therefore cooling cannot be provided by means of an engine-driven 4 pump. A simple thermal switch similar to that used for the switching off a 5 conventional cooling fan could be employed here. After shutdown, when engine- 6 driven pumps no longer function, conventional engines sometimes experience a large 7 temperature rise referred to as after-boil, even though the electric cooling fan may still 8 be running, to cool the radiator: the residual heat is present in the engine block and 9 head, not in the radiator. Excessive after-boil can cause premature deterioration of I o components and fluids. Some engines have even had special electric coolant pumps I I fitted, in addition to the conventional belt-driven coolant pump, just to keep the coolant 12 circulating for a few minutes after the engine stops. Similarly, if an engine is fitted 1 3 with a cold weather pre-heater to warm the engine prior to starting, an electric pump 1 is advantageous in that it can be switched on to circulate the coolant prior to starting. 1 5 16 5. Cost advantages. A conventional water pump requires a belt drive, robust 17 bearings, and generally an elaborate and costly infrastructure, although the pump 18 itself is quite cheap. Also, the conventional system is labour-intensive on the 19 assembly line. The present system, as a pre-manufactured self-contained unit, is 20 simply bolted onto the engine block, and requires virtually no other assembly-line 21 work. The unit also is lighter in weight overall than the belt-driven unit. A high-speed, 22 low-torque drive (which are the characteristics that lead to lightness) is simple with an 23 electric motor drive, but not possible with a belt drive. 24 25 6. Versatility. A conventional water pump is restricted as to its mounting position and 26 manner of driving. The new pumping system may be configured to be installed by 27 bolting it to the engine block, or the unit may be configured to be inserted into the 28 plumbing arrangements of the engine. The motor driving the new system preferably is 29 constant-speed, as described; all the variation in flow being derived from varying the 30 orientation of the vanes. But the system could be configured to utilise a two-speed or 31 multi-speed motor, or even a steplessly-variable-speed motor if the needed 32 sophisticated controls are included. 33 34 7. Range of operation. Typically, an automotive engine requires the coolant flow to ι vary between about 10 and 30 gallons a minute. The system as described can 2 provide that level of flow, and that variation in the level of flow, in an inexpensive, self- 3 contained unit. 4 5 8. Reliability. The system as described herein is intended to replace the belt driven 6 coolant pump, not to supplement it. Modern electric motors, even high-speed 7 designs, are very reliable. By contrast, a conventional belt-driven water pump, in 8 order to reach its present state of acceptable reliability (i.e reliability in the very 9 demanding automotive sense), has had to be over-engineered to a considerable ι o degree. Of course, electrical components can fail, and a failed water pump can 1 1 quickly lead to engine damage. But the outcome of a reliability comparison between 12 an electrical component that runs at more or less constant speed, and a mechanical 13 belt drive, is all too clear. As to the pump itself, of course engine coolant water must 14 be expected to be dirty, and contain deposits of various kinds, corrosion products, 1 5 harmful chemicals, etc. It has been found that such things have little effect on the 16 impeller of the pump, nor on the vanes and their operating mechanisms. Wax-type 17 thermostats are cheap, and very reliable. In the case where the vane orientation is 18 operated by an electronic engine-management system, it is noted that such systems 19 are becoming increasingly reliable, and the systems as described herein are able to 20 take advantage of that (which a mechanical belt-drive is not). 21 22 It is not suggested that every single previous water-cooled engine has had a belt- 23 driven water-pump, but on the other hand the mechanical belt-drive has certainly been 2 almost universal. Even when an electric coolant pump has been provided, generally it 25 has been as a supplement to the belt-driven pump. Of course, some specialised 26 engines have operated under near-constant running conditions, in which case a 27 constant-speed electric coolant pump would not have been too restrictive. But the 28 demanding requirements of general automotive applications require flow-control, and 29 flow control by temperature-orientation of variable-pitch guide vanes, as described 30 herein, is now available to meet that need. 31 32 In this specification, it has been suggested that the electric motor may run at constant 33 speed. However, this is not to say that a real, practical motor, does indeed operate at 34 constant speed. Rather the emphasis is that the invention provides a means for ι controlling the flow of coolant, wherein the flow is controlled by a means other than by 2 controlling the speed of the pump. That is to say, the motor and the pump are 3 enabled to run at constant speed, and still the flow rate of the coolant can be varied. Whether or not the speed of the motor actually is constant depends on the 5 characteristics of the motor. The conventional type of 12-volt DC motor currently in 6 widespread use for operating accessories on automobiles is suitable. The 7 characteristic of this type of motor is that the extent to which speed drops as the 8 torque increases is slight, at first; but then the speed drops quickly with increasing 9 torque. That is to say, the speed-drop-off is gentle at low to medium torques, but the I o speed-drop-off becomes unusably rapid as the torque increases from medium to high. I I The motor should be selected on the basis that the torque on the motor, including the 12 variations in torque due to pumping at the different flow rates, as described herein, 1 3 remain within the low-to-medium range of torque, for the selected motor. Thus, the 14 in-practice variation in motor speed between low and high pumping coolant rates can 15 be quite small. It may be noted that the practical range of good operational efficiency 16 of such a motor occurs over the same low-to-medium range of torque. 17 18 Also, in this specification, the relationship of flow-rate vs temperature, and the linearity 19 of the components of the relationship, has been described as linear: this is expressed 20 substantively, not absolutely. For example: a wax-type thermostat has only an 21 approximately linear relationship between temperature change and distance moved. 22 Similarly, in the pump, the relationship of the coolant flow rate to the change in 23 angular orientation of the vanes, is more a raised-power relationship, rather than 24 linear. However, the relationships are described as more or less linear in the context 25 of, for example, a conventional flow-controlling butterfly valve, which is so grossly non- 26 linear that automatic control of the flow-rate is barely contemplatable.

Claims: CLAIMS CLAIM 1. A liquid-pumping apparatus, wherein: the apparatus includes a rotatable impeller, mounted in a fixed housing; the housing defines a pump chamber, in which liquid being pumped is conveyed through the impeller; the apparatus includes a motor means, for rotating the impeller; the apparatus includes a flow-deflector; the flow-deflector is so located in relation to the impeller as to be effective to impart a bias condition onto the flow of liquid passing through the impeller; the flow-deflector is movable through a range of conditions, between a flow-reducing bias condition and a flow-boosting bias condition; the apparatus includes a temperature-transducer, having an output member; the output member is movable through a range of positions, in response to changes in temperature of the liquid, between a cold-liquid position and a hot-liquid position of the output member; the apparatus includes a connecting means, which operatively connects the output member of the temperature transducer to the flow-deflector, whereby movement of the output member produces a corresponding movement of the flow-deflector; the apparatus is so arranged that when the output member of the temperature transducer is in the cold-liquid position, the flow-deflector is in the flow- reducing bias condition, and when the movable member is in the hot-liquid position, the flow-deflector is in the flow-boosting bias condition. CLAIM 2. Apparatus of claim 1 , wherein the movable member lies upstream of impeller. CLAIM 3. Apparatus of claim 1 , wherein the motor means comprises an electric motor. CLAIM 4. Apparatus of claim 3, wherein the electric motor is co-axial with the impeller, and drives the impeller directly. CLAIM 5. Apparatus of claim 1 , wherein: the flow-deflector comprises a movable swirl-inducing element, which is so arranged in conjunction with the impeller as to induce, during operation of the pump, a biassing swirl in the flow of liquid passing through the impeller; the movable swirl-inducing element is so arranged that movement thereof produces a corresponding change in the degree of swirl bias induced; and the connecting-means comprises a means for moving the movable swirl-inducing element. CLAIM 6. Apparatus of claim 5, wherein: the movable swirl-inducing element comprises a set of movable vanes; the movable vanes are mounted on respective spindles mounted in a ring member; the spindles have respective levers; the apparatus includes a plate member, which engages the levers; one of the ring and plate members is movable, the other being fixed, and the connecting means connects the output member of the temperature transducer to the movable one of the members. CLAIM 7. Apparatus of claim 1 , wherein the temperature transducer includes a temperature sensor, and includes a means for transmitting temperature signals from the sensor to the output member. CLAIM 8. Apparatus of claim 3, wherein the electric motor is effective to rotate the impeller, during operation, at a speed in excess of 10,000 rpm. CLAIM 9. Apparatus of claim 1 , wherein: the temperature sensor and the output member are combined in a thermostat unit; the thermostat unit includes a bulb, which, in operation of the pump, is located within, and is sensitive to the temperature of, the liquid being pumped; the output member is defined as a plunger of the thermostat unit. CLAIM 10. Apparatus of claim 1 , wherein: the temperature-sensor is effective to provide an electrical signal indicative of temperature; the output-member is an electric-actuator-means, and the transducer includes a means for relating the magnitude of output of the electric-actuator-means to the level of the signal. CLAIM 11. Apparatus of claim 10, wherein the electric-actuator-means is a stepper motor. CLAIM 12. Apparatus of claim 10, wherein the electric-actuator-means is a servo- motor. CLAIM 13. Apparatus of claim 10, wherein the electric-actuator-means is a solenoid. CLAIM 14. Apparatus of claim 1 , wherein the arrangement of the apparatus is such that, during operation, when the flow-deflector is in an extreme flow-reducing bias condition, that the flow through the chamber is substantial. CLAIM 15. Apparatus of claim 14, wherein the arrangement of the apparatus is such that, during operation, when the flow-deflector is in the liquid-flow-boosting bias condition, the flow through the chamber is more than twice the corresponding flow through the chamber when the flow-deflector is in the flow- reducing bias condition. CLAIM 16. Apparatus of claim 1 , wherein: the motor is encased within a cylindrical double-walled tubular fluid flow chamber around its circumference which extends from the outlet area from the impeller to an outlet flange area of the fluid flow chamber; the said outlet flange area integrates the double-walled tubular fluid flow passageway with a single walled tubular outlet embodiment; the said tubular outlet embodiment is configured to allow mounting integration of the pump as well as sealed fluid passageway through which the system fluid leaves the pump and enters the adjoining cooling system component. CLAIM 17. Apparatus of claim 4, wherein: the housing provides a portion of the pump chamber, which portion is of annular cross-section, and which is located downstream of the impeller; the portion comprises inner and outer cylindrical walls, and the inner cylindrical wall defines a motor chamber therewithin; the electric motor is located in the motor chamber; the apparatus includes an air-circulation system, which is effective to circulate cooling air over and around the electric motor. CLAIM 18. Apparatus of claim 1 , in combination with an automobile engine of the type having a liquid-cooled cooling system, and containing a quantity of a liquid coolant, wherein the pump apparatus is so arranged as to circulate the coolant. CLAIM 19. Apparatus of claim 18, wherein the pump apparatus is configured as an integral whole unit, and the apparatus includes a means for affixing the unit directly to the block of the engine.

Inventors: FULTON JOHN ROBERT LEWIS, REPPLE WALTER OTTO, FULTON, JOHN, ROBERT, LEWIS, REPPLE, WALTER, OTTO
Applicants: FULTON JOHN ROBERT LEWIS, REPPLE WALTER OTTO, FULTON, JOHN, ROBERT, LEWIS, REPPLE, WALTER, OTTO
Application year: 1997
Main classification: F04D15
IPC codes: F01P5, F01P7, F04D15, F04D29