CROSS-REFERENCE TO RELATED APPLICATION(S) This application is being filed on October 10, 2014, as a PCT International Patent application and claims priority to U.S. Patent Application Serial N o. 61/889,668 filed on October 1 1 , 2013, the disclosure of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to electric motor driven pumps and, more specifically, axial driven axial piston pumps.

BACKGROUND

Hydraulic control systems typically convert rotating mechanical power into hydraulic fluid power. Hydraulic control systems typically include hydraulic pumps that convert mechanical energy (e.g., torque from a power source such as an electric motor or an engine). One common type of hydraulic pump is an axial piston pump. Axial-piston pumps are often used to power the hydraulic systems of jet aircrafts. An axial-piston pump is a positive displacement pump having a rotating group that includes a number of piston-shoe assemblies arranged in a circular array, powered around a drive shaft, within a piston block. The rotating group can be enclosed within a pump casing containing hydraulic fluid. The pump can be cooled by providing a controlled flow of hydraulic fluid through the pump case. Typically, hydraulic flow into the pump case can be provided by normal leakage from the rotating group of the pump and other leakage sources. Pump cases typically also have case drain ports for allowed hy draulic fluid to exit the pump cases and flow to a system reservoir.

SUMMARY

Teachings of the present disclosure relate to an electric motor driven pump assembly. The pump assembly can be configured to scavenge power from the electric motor to enhance the flow hydraulic fluid (e.g., hydraulic oil) to provide cooling of the pump assembly and the electric motor. In certain examples, the electric motor is controlled and powered via a digital electronic controller, and the pump assembly provides hydraulic fluid cooling flow for cooling the digital electronic controller and other electrical components associated with the electric motor. In certain examples, cooling fluid is enhanced by a pump having multiple inlets with one inlet in fluid communication with an interior of a pump case of the pump assembly and another inlet in fluid communication with a cooling loop for cooling the electric motor and the electronic controller. In certain examples, the pump has a single outlet. In certain examples, the single outlet is in fluid communication with a case drain port of the pump casing. In certain examples, the pump is a vane pump having a rotor that rotates with an output shaft of the electric motor. In certain examples, a main pump is also driven by the output shaft and is housed within the pump casing along with the vane pump. Aspects of the present disclosure allow the electric motor pump to be effectively cooled while minimizing, size, weight and cost.

In certain examples, the electric motor may be a digitally controlled electric motor. Hydraulic fluid flow for cooling can be provided to the hydraulic pump case, electric motor, and digital controller to provide enhanced reliability. Separating dual inlet lobes into two distinct vane pump inlets enables a single scavenge pump to provide both functions. This eliminates the need to have two separate scavenge pumps, subsequently reduces the overall weight and cost and improves reliability due to reduction of parts and complexity. The mass flow rate needed for each cooling path may not be identical; but can be. In certain examples, the displacement for each vane pump inlet can be set independently to provide a customized flow rate for each cooling path from a single scavenge pump.

In one example, the hydraulic pump can be a ten vane, dual lobe vane unit, having a side discharge (single outlet) and a case drain flow out provided by combination of two discharge lobes. The hydraulic pump can also include separated dual inlets, having a pump case scavenge function provided by one lobe and a cooling-loop scavenge function pro vided by the other lobe. Of course, outer styles of pumps ha ving multiple inlets are also contemplated,

A spects of the present disclosure relate to improving overall cooling efficiency of an electric motor pump system. For example, since the electric motor circuitry and a main hydraulic pump preferably are cooled, a hydraulic vane pump disposed in tandem along an axis of rotation and interconnected by a common shaft may be configured to move the cooling fluid through both the electric motor circuitry and a hydraulic pump. Aspects of the present disclosure relate to efficient design of a vane pump assembly within the electric motor driven pump assembly. Since the vane pump assembly is configured to enhance cooling flow to both the electric motor circuitry and a main hydraulic pump, the vane pump can be configured to have multiple inlets. In some examples, one of the inlets is configured to draw hydraulic fluid from within the pump casing and one draws fluid through a cooling loop for cooling the electric motor and corresponding components. As a result, (he dual inlet vane pump is designed to scavenge cooling flow for cooling an electric motor with drive electronics and also for cooling the main hydraulic pump case utilizing the case flow.

Teachings of the present disclosure pro vide an improved operating system for the electric motor driven pump assembly by which overheating of the main hydraulic pump may be prevented; which includes reducing pump size requirements and decreasing weight size reduction of the pump assembly. A further teaching of the disclosure is to pro vide an improved hydraulic system by which each of the abo ve objects may be accomplished; which will require a minimum of additional apparatus; and which will be compact, dependable, simple and inexpensive.

A variety of additional aspects will be set forth in the description that follows. The aspects can relate to individual features and to combinations of features. It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad concepts upon which (he examples disclosed herein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate various examples of the present disclosure. In the drawings:

Figure 1 is a schematic depiction of an electric motor driven pump arrangement in accordance with the principles of the present disclosure;

Figure 2 is a schematic block-style diagram of the electric motor driven pump arrangement of Figure i ;

Figure 3 is a perspective view illustrating an example configuration for the electric motor driven pump arrangement of Figures 1 and 2;

Figure 4 is a cross-sectional view through a pump assembly of the electric motor driven pump arrangement of Figure 3; Figure 5 is another cross-sectional view through the pump assembly of the electric motor driven pump arrangement of Figure 3;

Figure 6 is an enlarged view of a cooling flow pump that is part of the pump assembly of Figures 4 and 5;

Figure 7 is a schematic representation of the cooling flow pump of Figure

6;

Figure 8 is a cross-sectional view of the cool ing flow pump of Figure 6; Figure 9 is another cross-sectional view of the cooling flow pump of Figure

6:

Figure 10 schematically illustrates an example cooling circuit for cooling an electric motor and various motor control components of the electric motor driven pump arrangement of Figure 3; and

Figure 1 1 schematically illustrates another electric motor driven pump arrangement in accordance with the principles of the present disclosure.

DETAILED DESCRIPTION

An electric motor driven pump assembly in accordance with the principles of the present disclosure can incorporates a digitally controlled electric motor designed to drive a hydraulic pump to convert electrical power to hydraulic power. The assembly can include a cooling system for circulating hydraulic fluid within a flow loop from a reservoir through a motor casing containing the electric motor and related control components. The cooling system can also circulate hydraulic fluid through a pump casing of the assembly. In certain examples, a multiple inlet pump (e.g., a dual inlet pump) is used to enhance cooling flow. The pump can outlet the cooling flo to a reservoir or the system. One or more filters can be provided for filtering the hydraulic fluid before it enters the reservoir or elsewhere in the system.

Figures 1 and 2 illustrate an electric motor pump arrangement 20 in accordance with the principles of the present disclosure. Electric motor pump

arrangement 20 includes an electric motor system 22 having an electric motor 24 and an integrated control arrangement 26. The electric motor 24 of the electric motor system 22 drives rotation of an output shaft 28 about an axis of rotation 29. The electric motor pump arrangement 2.0 also includes a pump assembly 30 including a plurality of pumps powered by rotation of the output shaft 28 by torque provided by the electric motor 24. The plurality of pumps can be positioned along the axis of rotation 29 and can be coupled to the output shaft 28. In one example, the plurality of pumps of the pump assembly 30 can include a main hydraulic pump 32, a suction boost pump 34 and a cooling flow pump 36. The main hydraulic pump 32 can include a rotating group 38 configured to be rotated about the axis of rotation 29 by the output shaft 28. The suction boost pump 34 has an inlet 40 in fluid communication with tank 42 (the system reservoir) and a first outlet 44a in fluid communication with an inlet 46 of the main hydraulic pump 32. The main hydraulic pump 32 also includes an outlet 48 in fluid communication with driven system

components 50 of a corresponding hydraulic system intended to be powered by the electric motor pump arrangement 20. Thus, the main hydraulic pump 32. provides system pressure and flow for meeting the power demands of the system components 50.

The cooling flow pump 36 can be referred to as a scavenge pump because it scavenges energy from the output shaft 28. In certain embodiments, the cooling flo pump 36 is configured to boost or enhance cooling flow through the electric motor pump arrangement 20. For example, the cooling flow pump 36 can be configured to boost or enhance the flow of hydraulic fluid used to cool the pump assembly 30 and also can be used to boost or enhance the flow of hydraulic fluid for cooling the electric motor syste 22.

Referring to Figure 2, the pump assembly 30 can be housed within a pump case 52 and the electric motor system 22 can be housed within a motor case 54. The pump case 52 can include an inlet port 56 in fluid communication with the inlet 40 of the suction boost pump 34 for allowing the suction boost pump 34 to be coupled to tank 42. The pump case 52 can also include an outlet port 58 in fluid communication with the outlet 48 of the main hydraulic pump 32 for allowing the outlet 48 to be coupled to the system components 50. The pump case 52 further can include a case drain port 60 in fluid communication with an interior 62 of the pump case 52 for allowing hydraulic fluid to be drained and/or pumped from the pump case 52. In certain examples, the cooling flow pump 36 is configured to scavenge energy from the output shaft 28 for use in enhancing or boosting cooling flow through the interior 62 of the pump case 52 and also through a cooling loop 64 that extends through the motor case 54. The cooling loop 64 or a portion of the cooling loop can also be referred to as a cooling flow path or a cooling flow route.

In certain examples, the cooling flow pump 36 can have a multiple inlet configuration. For example, the cooling flow pump 36 can include a first inlet 66 for drawing hydraulic fluid from the inferior 62 of the pump case 52, and a second inlet 68 for drawing hydraulic fluid from the cooling loop 64 that passes through the motor case 54. As shown at Figure 1 and 2, hydraulic fluid flow is introduced into the cooling loop 64 from the suction boost pump 34 which provides pressure and flow for moving the hydraulic fluid through the cooling loop 64. In certain examples, a portion of the cooling loop 64 extending from the suction boost pump 34 to the motor case 54 can extend outside of the pump case 52 and the motor case 54 (e.g., see section 70 of the cooling loop 64). By providing the section 70 of the cooling loop 64 outside of the pump case 52. and the motor case 54, additional components (e.g., heat exchangers for providing further cooling of the hydraulic fluid or other structures), can be more easily added to the overall system to satisfy future system demands, in certain examples, section 70 includes a tube (e.g., a hose) coupled between an outlet port 72 on the pump case 52 and an inlet port 74 on the motor case 54.

As depicted at Figure 2, the cooling flow pump 36 has a single output 76 in fluid communication with the case drain port 60. In this way, hydraulic fluid drawn from the interior 62 of the pump case 52 and from the cooling loop 64 can be combined and directed out of the pump case 52 to tank 42.

Referring again to Figure 1 , the suction boost pump 34 can include a first outlet 44a positioned 180 degrees out of phase with respect to a second outlet 44b, The first outlet 44a can provide hydraulic fluid at a boost pressure level to the inlet 46 of the main hydraulic pump 32. The first outlet 44a can also provide hydraulic fluid at boost pressure into the interior 62 of the pump case 52. Hydraulic fluid flow to the inlet 46 of the main hydraulic pump 32 can be provided through fine 78 and hydraulic fluid flow to the interior 62 of the pump case 52 can be provided through line 80. The outlet 44b is in fluid communication with the cooling loop 64 and pumps hydraulic fluid through the cooling loop 64, Other arrangements for the outlets 44a, 44b can also be used (e.g., other phase angles could be used or flow could be branched from a single outlet to the inlet 46, the pump case 52 and the cooling loop 64).

It will be appreciated that the cooling flow pump 36 is configured to provide enhanced hydraulic fluid flow through the pump case 62 to provide effective cooling of the various components within the pump case 52. It will be appreciated that hydraulic fluid flow to the interior 62 of the pump case 52 can be pro vided by normal leakage from the various components and rotating groups of the pump assembly 30. Additionally, as described above, hydraulic fluid flow can also be provided to the interior cooling flow pump 36 is designed and or sized so thai the maximum inlet flow through the first inlet 66 is less than the anticipated flow into the pump case 52 due to hydraulic fluid leakage plus make-up flow provided by the suction boost pump 34. in this way, the cooling flow pump 36 is prevented from cavitating.

Figure 3 shows the electric motor pump arrangement 20 with the pump case 52 secured to the motor case 54, In certain examples, pump case 52 can be fastened with fasteners (e.g., bolts) to the pump case 52. As shown, at Figure 3, the inlet port 56 and the outlet port 58 for the main hydraulic pump 32 are accessible on the exterior of the pump case 52. Additionally, the section 70 of the cooling loop 64 that is positioned outside the pump case 52 is shown routed from the outlet port 72 to the inlet port 74.

In certain examples, the electric motor 24 of the electric motor system 22 includes a brushless motor. In certain examples, the control arrangement 26 is a digital controller that powers and controls operation of the electric motor 24. In certain examples, the cooling loop 64 can be configured to draw heat away from the electric motor 24 as well as the control arrangement 26. In certain examples, the cooling loop 64 is routed from the pump case 52, through the motor case 54, back into the pump case 52 to the cooling flow pump 36 and then out the pump case 52 through the case drain port 60.

Figures 4 and 5 are cross-sectional views that depict the pump assembly 30 within the pump case 52. As shown at Figures 4 and 5, the main hydraulic pump 32 is depicted as an axial-piston pump that includes a piston block 82 coupled to the output shaft 28 so as to rotate in unison with the output shaft 28 about the axis of rotation 29. The piston block 82 defines a plurality of cylinders 84 that receive pistons 86 such that the pistons 86 can reciprocate within the cylinders 84. The pistons 86 have heads coupled to hydrostatic shoes 88 that ride on a swash plate 90. The swash plate 90 can be pivoted relative to the axis of rotation 29 to vary the stroke lengths of the pistons 86 and thereby alter the displacement rate of the main hydraulic pump 32. The piston block 82 and cylinders 84 form part of the rotating group 38 of the main hydraulic pump 32.

Referring still to Figures 4 and 5, the suction boost pump 34 is depicted as a boost impeller coupled to the end of the output shaft, 28 so as to rotate with the output shaft 28. As previously described, the suction boost pump 34 can include first and second outlets 44a, 44b positioned 180 degrees apart from one another. The first outlet 44a can be in fluid communication with inlet of the main hydraulic pump 32 and the interior of the pump case 52, while the second outlet 44b can be in fluid communication with the cooling loop 64. Figures 4 and 5 also show an example of the cooling flow pump 36.

Specifically, Figures 4 and 5 show the cooling flow pump 36 as a radial vane pump. As previously described, the cooling flow pump includes a first inlet 66 (see Fig. 4) in fluid communication with the interior 62 of the pump case 52 and a second inlet 68 (see Fig. 4) in fluid communication with the cooling loop 64. Referring to Figures 7-9, the cooling flow pump 36 includes a rotor 92 that carries a plurality of vanes 94. The rotor 92 is coupled to the output shaft 28 such that the rotor 92 rotates with the output shaft 28 about the axis of rotation 29. In certain examples, rotor 92 can be keyed, splined or otherwise coupled to the output shaft 2.8. The rotor 92 rotates with the output shaft 28 relative to a cam ring 96 (e.g., a double throw cam ring). As the rotor 92 rotates, the vanes 94 move radially relative to the rotor 92 so as to follow the cam ring 96.

The depicted cooling flow pump 36 has a balance configuration with first and second inlet locations 98a, 98b and first and second outlet locations 100a, 100b. The inlet locations 98a, 98b are positioned 180 degrees apart and the output locations 100a, 100b are positioned 180 degrees apart. The input location 98a corresponds to the first inlet 66 of the cooling flow pump 36 and draws fluid from the interior 62 of the pump case 52. The inlet location 98b corresponds to the second inlet 68 of the cooling flow pump 36 and draws hydraulic fluid from the cooling loop 64. The output locations 100a, 100b are fluidly coupled to passages 102a, 102b that merge and combine the flow from the dual inlets before reaching the case drain port 60 such that the cooling flow pump 36 has only a single outlet port. In certain examples, the passages 102a, 102b can flow circumferentiaJly around an exterior of the cam ring 96 as shown at Figure 9.

In operation of the cooling flow pump 36, hydraulic fluid from the inlet locations 98a, 98b is drawn into pocket regions between the vanes 94 due to expansion of the volume defined by the pocket regions between the vanes 94. Expansion occurs as the vanes 94 follow the cam ring 92 and move radially out of the rotor 92. After the hydraulic fluid has been drawn into the pocket regions at the inlet locations 98a, 98b, interaction between the vanes 94 and cam ring 96 causes the vanes 90 to move radially into the rotor 92 thereby reducing the volumes of the pocket regions between the vanes 94. This reduction in volume causes the hvdi'aulic fluid contained within the pocket regions to be pressurized and forced out the outlet locations 100a, 100b, The cyclical expansion and contraction of the volumes between the vanes 94 creates a pumping action that draws hydraulic fluid into the inlets 66, 68 and forces hydraulic fluid out the case drain port 60. In certain examples, inlet flow rates between the inlet locations can be varied by altering the displacement profiles on the double -throw cam ring.

Figure 10 is another schematic illustration of the cooling loop 64. As previously described, the cooling loop 64 extends from the suction boost pump 34, through the motor case 54 and then back to the cooling flow pump 36 which then directs the flow through the case drain port 60 to tank 42. As shown at Figure 10, the electric motor system 20 includes the electric motor 24 and the control arrangement 26 which can be positioned within the motor case 54. Within the motor case 54, the cooling loop 60 can include a plurality of heat exchangers 104, 106, 108 for removing heat from the electric motor system 22. The heat exchangers 104, 06, 108 can include cooling plates in which the cooling loop 64 is routed in a serpentine or other convoluted path. The heat exchangers 104, 106, 108 can be positioned adjacent to various components of the control arrangement 26. For example, the heat exchangers 104, 106, 108 can respectively correspond to an electronic controller unit 1 10 including an arrangement of control circuitry, an electromagnetic interference filter unit 1 12 and a transtonner rectification unit 1 4. The heat exchangers 104, 106, 108 can also be positioned adjacent to the electric motor 24 so as to remove heat generated by the motor shaft, the motor coils, the structure within the electric motor itself. More or fewer heat exchanges can be provided within the motor case 54 as needed.

Figure 11 shows another electric motor pump arrangement 20' in accordance with the principles of the present disclosure. The electric motor pump arrangement 20' has the same general configuration as the electric motor pump arrangement 20 except make-up hydraulic flow provided to the interior 62 of the pump ease 52 is pro vided by a flo line 120 in fluid communication with the inlet 46 of the suction boost pump 34. Also, a flow restriction 122 (e.g., a fixed orifice) and a pressure- relief valve 124 are provided along the cooling loop.

It will be appreciated that the various operating environments depicted herein are exemplary and explanatory only and are not restrictive of the broad concepts upon which the examples disclosed herein are based.