JP3123183B2 - Vehicle fuel supply system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fuel supply system for a vehicle, and a driving motor for a fuel pump is a brushless motor.
In addition, the control circuit of the brushless motor is integrated with the fuel pump and the motor, and can be installed in the fuel tank of the vehicle.

[0002]

2. Description of the Related Art Conventionally, a vehicle fuel supply system using a brushless motor has been proposed. For example, a vehicle fuel supply system as disclosed in Japanese Utility Model Application Laid-Open No. 62-59794 is known. In this publication, a control circuit for controlling the excitation of a stator coil is housed in a container, and a pressurized gas is sealed in the container, so that the control circuit is integrated in a housing of the fuel pump.

[0003]

In the conventional structure, since the control circuit is isolated from the fuel, it is possible to prevent the control circuit from suffering from continuity failure due to electrolytic corrosion and short circuit connection. However, in the conventional structure disclosed in the above publication, since the connection from the control circuit to the stator coil is exposed in the fuel, electrolytic corrosion occurs in the terminal, the connection copper wire, and the stator coil from the control circuit. However, there is a possibility that a conduction failure may occur or a short circuit may occur.

SUMMARY OF THE INVENTION In view of the above problems, the present invention has a control circuit of a brushless motor for driving a fuel pump integrated with a fuel pump and a motor. The purpose of the present invention is to reduce the amount.

[0005]

SUMMARY OF THE INVENTION In order to solve the above problems, the present invention provides a rotor having a permanent magnet fixed thereto, a plurality of stator coils installed around the rotor, and In a vehicular fuel supply device having a control circuit for controlling energization of a stator coil and a pump unit driven by the rotor in a housing, the stator coil, the control circuit, and a conductive circuit for connecting these components. Utotomo covering a part of a resin material
The resin material introduces fuel near the control circuit.
Vehicle fuel supply characterized by forming a fuel passage
Adopt the technical means of apparatus.

[0006] In addition, the control circuit accommodated in the container, contents
Unit, stator coil and conductive part are integrated with resin material
May be completely covered. This allows
The interface between the heater, stator coil,
And prevents fuel from entering the interface
You. Further, the container accommodating the control circuit may be formed in a dome shape .

[0007]

According to the structure of the present invention, since the stator coil, the control circuit, and the conductive portion connecting them are covered with the resin material, these portions are not exposed in the fuel. Electrolytic corrosion is prevented in the part, poor conduction,
In addition, defects such as short circuits are prevented. Moreover, near the control circuit
Since a fuel passage for introducing fuel is formed nearby, the control circuit
Heat is dissipated to the fuel, reducing the heat dissipation of the control circuit.
The control circuit can be covered with resin material without
You.

If the control circuit is housed in a container and the container is formed in a dome shape, deformation of the container in the molding step using a resin material is prevented .

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of a vehicle fuel pump according to the present invention will be described below with reference to FIGS.

FIG. 1 is a sectional view showing the structure of the vehicle fuel pump of the first embodiment, and shows a cross section taken along the line AA of FIG. 2 when the vehicle fuel pump of the first embodiment is viewed from the discharge port side. In FIG. 1, a cylindrical housing 10 of a fuel pump 1 for a vehicle includes:
It has a thinner upper end portion 11, a thicker central portion 12, and a thinner lower end portion 13. A pump unit 30 is provided at the lower end 13, a motor unit 50 is provided at the center 12, and a discharge unit 90 is provided at the upper end 11.

The pump unit 30 includes a pump casing 31
, A pump cover 32 and an impeller 33. The pump casing 31 is fitted into the thick central portion 12 of the housing 10 from the lower end side of the housing 10 without any gap. The pump cover 32 is press-fitted from the lower end side of the housing 10. Pump casing 31 and pump cover 32
Is stopped by the projection 14 of the housing 10.

Pump casing 31 and pump cover 32
A pump chamber 34 as a regenerating pump is formed between them. The periphery of the pump chamber 34 is sealed by the pump cover 32 being pressed toward the central part 12 by the caulking part 15 of the housing 10. A shaft 51 is press-fitted and held in the pump cover 32, and a suction port 35 communicating with a suction side position of the pump chamber 34 is formed. Between the pump casing 31 and the pump cover 32, the impeller 33 of the regenerative pump is rotatably housed, and a shaft 51
Penetrates through the impeller 33. Pump casing 31
A discharge port (not shown) communicating the discharge side position of the pump chamber 34 with the inside of the housing 10 is formed in the housing 10.

The motor section 50 includes a rotor 60 rotatably supported by a shaft 51 and a stator section 70 integrally formed of a resin material. Two grooves 52, 53 are formed in the shaft 51, and the respective grooves 52, 53 are formed.
A C-ring is fitted into 53. The shaft 51 includes three washers and a joint 5 from the groove 52 side.
4, one washer, rotor 60, and three washers are inserted and rotatably supported.

The joint 54 has a claw 55 inserted into a joint hole 36 formed in the impeller 33, and rotates together with the impeller 33. Note that the joint 54 has another claw portion (not shown) located on both sides of the shaft 51, and this claw portion is also inserted into another joint hole (not shown) formed in the impeller 33.

The rotor 60 has a cylindrical yoke 61 made of electromagnetic stainless steel. The yoke 61 has a claw 62 inserted into a joint groove 56 formed in the joint 54, and rotates together with the joint 54. The yoke 6
Numeral 1 has another claw portion (not shown) positioned across the shaft 51, and this claw portion is also inserted into another joint groove (not shown) formed in the joint 54. Around the yoke 61, four ferrite magnets 63 are adhered with an epoxy-based adhesive, and stainless steel plate rings 64 and 65 are press-fitted at both ends. Carbon metals 66 and 67 are press-fitted into the inner peripheral surfaces of both ends of the yoke 61. The ferrite magnet 63 and the plate rings 64 and 65 are molded with PPS resin 68, and the four ferrite magnets 63
Is filled in. The plate rings 64 and 65 have a diameter of 0.5 to 0.5 in order to balance the rotation of the rotor 60.
A 2.0 mm hole is drilled as appropriate.

The stator section 70 is formed of an epoxy resin material 71 containing 20% of glass into a substantially cylindrical shape with a bottom. The housing 10 is fitted into the central portion 12 of the housing 10 from the upper end 11 side of the housing 10 without any gap, with the bottom surface facing the upper end of the housing 10, and is prevented from rotating by a projection 16 formed on the housing 10. The stator unit 70 has a built-in three-phase stator in a peripheral side wall and a control circuit unit in a bottom wall thereof.

The stator has a stator core 72 and three-phase stator coils 73 wound around the stator core 72. Copper wires at both ends of each phase of the stator coil extend to the control circuit.

The control circuit is a circular plate 74 made of stainless steel.
And a container 76 comprising a dome-shaped cover 75 made of stainless steel. A control circuit 77 is provided in the container 76. Note that the circular plate 74 and the dome-shaped cover 75 may be made of a nickel-plated iron plate. A terminal holder 79 made of resin is provided on the circular plate 74 side of the container 76. The terminal holder 79 holds a power supply terminal 80 and a power supply terminal 81 shown in FIG. And
The resin material 71 covers the terminal holder 79 and the roots of the terminals 80 and 81.

Further, on the inside of the bottom surface of the stator 70,
A hole 82 for receiving the shaft 51 is formed. A fuel passage 83 is formed from the inside of the bottom surface of the stator 70 to the center of the outside of the bottom of the stator 70 through the inside of the upper end 11 of the housing 10 and avoids the container 76. Thus, the fuel discharged into the housing 10 by the pump unit 30 passes around the rotor 60 and
Radially from the inside of the stator part 70, the stator part 7
The fluid flows between the groove formed in the housing 10 and the housing 10 and flows out toward the upper end 11 of the housing 10.

The fuel passage 83 is formed in a groove shape in the stator portion 70 having a bottomed cylindrical shape. Particularly, outside the bottom surface of the stator portion 70, the thickness of the resin material 71 covering the container 76 is reduced. ing. Thereby, the circular plate 7 of the container 76 is
The heat of the power control element attached to the fuel cell 4 can be efficiently radiated to the fuel. For this reason, temperature rise of the power control element is suppressed, and motor stoppage due to abnormal temperature rise of the power control element can be prevented.

The discharge section 90 is provided at the upper end 1 of the housing 10.
1 has an end cover 91 press-fitted therein. The end cover 91 is pressed toward the central portion 12 of the housing 10 by the caulking portion 17 of the housing 10.
The end cover 91 is formed with a discharge port 93 provided with a check valve 92 and communicating with a fuel passage 83 formed in the stator section 70. The end cover 91 has a relief valve 94 communicating with a fuel passage 83 formed in the stator portion 70 and a hole 9 through which the terminals 80 and 81 are inserted.
5, 96 are formed. O-rings are provided in the holes 95 and 96 through which the terminals 80 and 81 are inserted, and the space between the resin material 71 that covers the base of the terminals 80 and 81 and the end cover 91 is sealed.

The structure of the stator 70 will be described in more detail with reference to FIGS. FIG. 3 shows the configuration of the stator unit 70. FIG. 3 is a cross-sectional view of the stator unit 70 taken along the line BB in FIG. 2 before molding, and the outer shape after molding is indicated by broken lines. FIG. 4 shows FIG.
Of the stator portion 70 after molding, indicated by a broken line in FIG.
FIG. 4 is a cross-sectional view taken along arrow C, showing a gate position during molding.

FIG. 5 is a plan view of the stator 70 before molding, as viewed from the direction of arrow D in FIG. As shown in FIG. 5, the terminal holder 79 is provided with brass terminals 84a, 84b, 84c, 84d and 84e (hereinafter collectively referred to as 84). Also,
The terminal 85 of the control circuit extends through the circular plate 74 of the container 76.
a, 85b, 85c, 85d, and 85e (these are collectively referred to as 85) are extracted. Furthermore, copper wires 86a, 86b, 86c, 8 at both ends of each stator coil
6d, 86e and 86f (hereinafter collectively referred to as 86) are drawn out around the terminal holder 79. The terminal 84a connects the terminal 81 to the terminal 85a, the terminal 84b connects the terminal 85b to the copper wire 86a, and the terminal 84c connects to the terminal 85c.
And the copper wire 86b, and the terminal 84d is connected to the terminal 85
d and the copper wire 86c, and the terminal 84e connects the terminal 80 and the terminal 85e to the copper wires 86d, 86e and 86f.

Before molding, the terminal holder 79 holds the terminals 80 and 81 and the container 76. Further, a stopper portion 87 extending from the terminal holder 79 so as to avoid the container 76 and having a cylindrical shape is provided.
By contacting the outer periphery of the stator coil 73 and abutting on the stator core 72, positioning before molding is performed.
The fuel passage 83 formed at the time of molding with the resin material 71 is formed to penetrate a hole provided in the cylindrical stopper portion 87.

The stator portion positioned by the terminal holder 79 and electrically connected by the terminal 84 is put into a resin mold. In this resin mold, the stator core 72 and the stator coil 7
3, a receiving portion 100 protruding into the resin mold as shown in FIG. 3 is in contact with the stepped portion.
Terminals 80 and 81 that are not resin-molded are held by receiving portion 100. As shown by broken lines in FIG.
Are provided at the right end of the container, and are provided at positions far from the container 76. In this resin mold, the resin material 71 is
The stator coil 73, the copper wire 86 of the stator coil, the terminal 84, the terminal 85, and the container 76 are completely covered.

After the stator section 70 is resin-molded in a resin mold, the inner diameter and the outer diameter are cut to be centered. FIG. 6 is a circuit diagram of the control circuit 77.

The control circuit 77 includes a U phase of the stator coil,
A power MOS- that intermittently energizes the V-phase and W-phase
FETs 77a, 77b, 77c and their MOS-F
Drive circuit 7 for driving and controlling ETs 77a, 77b, 77c
7d. The drive circuit 77d sequentially turns on the FETs with a predetermined overlap time to excite the stator coils of each phase.

Next, the operation of the above embodiment will be described. In actual use, a filter (not shown) is provided at the suction port 35, a pipe (not shown) connected to the fuel injection device of the vehicle is connected to the discharge port 93, and the entire fuel pump for the vehicle is provided by an appropriate stay. It is held in the fuel tank.

When power is applied to terminals 80 and 81, drive circuit 77 drives MOS-FETs 77a, 77b and 7
7c are sequentially turned on with a predetermined overlap time to excite the stator coils of each phase. The armature 60 rotates by the three-phase half-wave driving, and the impeller 33 rotates. Then, by the rotation of the impeller 33, the fuel is sucked through the suction port 35, passes through the housing 10, further passes through the fuel passage 83, and is discharged from the discharge port 93.

According to the embodiment described above, the resin material 7
1, the stator coil 73, the copper wire 86 from the stator coil, the container 76 containing the control circuit 77, the terminal 85 from the container 76, and the terminal 84 are all covered and are not exposed to fuel. For this reason, it is possible to reliably prevent problems such as short-circuits and disconnections due to electrolytic corrosion or the like in these conductive portions and to significantly reduce the occurrence of failures.

In the above embodiment, the container 76 containing the control circuit 77 is molded with the resin material 71. In molding the resin material 71, usually 100
A molding pressure of ~ 150 (Kg / cm2) is used. In this embodiment, the pressure is adjusted to 30-50 (Kg / cm2) in consideration of the pressure resistance of the container 76 against the molding pressure. Then, in order to further withstand the pressure during molding, the container 76
Was formed in a dome shape. Thereby, it is possible to provide the container 76 which does not deform even with the molding pressure at the time of molding,
The container 76 containing the control circuit 77 could be molded with the resin material 71.

In this embodiment, the control circuit 77 that generates heat is cooled by the fuel through the resin material 71 and the container 76. By forming the cover 75 of the container 76 in a dome shape, the thickness of the cover 75 can be reduced, and the heat generated from the control circuit 77 can be easily released to the fuel. In particular, since the thickness of the resin material 71 outside the circular plate 74 of the container 76 is reduced,
The heat radiation from the power control element of the control circuit mounted on the device can be improved.

The resin inflow gates 101 and 102 are
Since it is provided at a position far from the container 76, the container 76
In the periphery, the molding pressure decreases due to pressure loss. This also prevents deformation of the container 76 during molding.

Further, according to the above embodiment, the resin material 71 covers the conductive portion and also functions as a holder for supporting the shaft 51, so that the number of parts can be reduced. In the above embodiment, the cylindrical guide 87 is extended from the terminal holder 79.
Thus, reliable positioning before the resin molding can be performed.

Next, a second embodiment of the present invention will be described with reference to FIG. FIG. 7 is a sectional view showing the configuration of the vehicle fuel pump according to the second embodiment. Components corresponding to the configuration of the first embodiment and having substantially no functional difference are denoted by the same reference numerals, and description thereof will be omitted.

In the first embodiment, the shaft 51 is fixed, and the rotor 60 is rotatably supported by the shaft 51. In the second embodiment, the shaft 251 is fixed.
Is rotatably supported, and the shaft 251 is
0 was fixed.

The shaft 251 has one end rotatably supported by a bearing 201 provided on the pump casing 231 and the other end rotatably supported by a centering bearing 202 provided inside the bottom surface of the stator portion 270. Is done.
A groove 20 is formed along the axial direction on the central surface of the shaft 251.
3, the yoke 61 of the rotor 60 is press-fitted therein. Further, the D-cut portion 20 is
4 is formed, and this D-cut portion 204 is
Is inserted into a D-shaped hole 205 formed in the hole. Bearing 2
01 is press-fitted into the pump casing 231. The aligning bearing 202 is supported by a receiving portion 206 formed inside the bottom surface of the stator portion 270, and is held down by a bearing stopper 207.

In this embodiment, the shaft 251 rotates together with the rotor 60, and the impeller 233 rotates with the rotation of the shaft 251. Then, the fuel is discharged in the same manner as in the first embodiment.

In the second embodiment, as in the first embodiment, all the conductive portions are covered, and the same effects as in the first embodiment can be obtained. Next, a third embodiment to which the present invention is applied will be described with reference to FIG.

FIG. 8 is a sectional view showing the structure of a vehicle fuel pump according to the third embodiment. In addition, corresponding to the configuration of the second embodiment, the same reference numerals are given to components having substantially no functional difference, and description thereof will be omitted.

In this third embodiment, a brass cylindrical member 301 is provided on the stator portion 370, and the pump casing 331 is provided.
Is provided with a relief valve 394. The cylindrical member 301 forms a discharge port 393, and a check valve 392 is provided inside the discharge port 393. Then, the resin is held in a resin mold during resin molding of the stator section 370, and is integrally molded with the resin material 71 as a part of the stator section 370.

The stator section 370 includes a stator section 370
Fuel passage 302 extending radially outward from the inside of
And a groove 303 extending along the thick portion 312 of the housing 310, and a fuel passage 304 extending radially inward from the groove 303. Fuel inside the stator portion 370 is supplied to the fuel passage 302 and the groove. 303, and is led to the discharge port 393 through the fuel passage 304. Therefore, also in this embodiment, since the fuel is introduced to the outside of the circular plate 74 of the container 76 and the thickness of the resin material 71 at that portion is formed thin, the heat from the control circuit 77 in the container 76 is Is radiated well. This stator portion 370 is similar to the end cover 91 of the first embodiment described above, and is similar to the housing 310.
It is fixed by the caulking part 17.

A hole 305 from inside the housing 310 and a hole 306 from the radial direction are formed in the pump casing 331, and a relief valve 394 is housed in the hole 306. Further, the pump casing 331 has a hole 30 therein.
6, a groove 307 is formed along the housing 310, and the pump housing 332 is formed with a groove 308 connected to the groove 307. Thereby, the fuel discharged from the relief valve 394 is discharged to the outside of the housing 310.

In this embodiment, the cylindrical member 301 is integrated with the stator portion 370 to form the discharge port 301. Therefore, according to this embodiment, the number of parts can be further reduced.

Also, in the third embodiment, as in the first embodiment, all the conductive portions are covered, and the same effects as in the first embodiment can be obtained. Next, a fourth embodiment to which the present invention is applied will be described with reference to FIGS.

FIG. 9 is a partial sectional view showing the structure of a vehicle fuel pump according to a fourth embodiment. FIG. 9 is a sectional view of the vehicle fuel pump according to the fourth embodiment, taken along line BB of FIG. FIG. 10 is a sectional view taken along line EE of FIG. Components corresponding to the configuration of the first embodiment and having substantially no functional difference are denoted by the same reference numerals, and description thereof will be omitted.

In the fourth embodiment, the circular plate 7
The resin material 71 that covers the outside of the fourth member 4 is formed to be thinner to promote heat radiation. A fuel passage 83 is formed in a groove shape outside the bottom surface of the stator portion 70. A thick portion 71a along the outer periphery of the circular plate 74 and a thin portion 7 corresponding to the central portion of the circular plate 74 are formed on the outside of the bottom surface of the stator portion 70 by a resin material 71.
1b are formed. The heat dissipation from the control circuit 77 mounted on the circular plate 74 is further promoted by the thin portion 71b. Thereby, the temperature rise of the power control element of the control circuit 77 is suppressed, and the stop of the motor due to the abnormal temperature rise is prevented.

Next, a fifth embodiment to which the present invention is applied is shown in FIG.
1, will be described with reference to FIG. FIG. 11 is a partial sectional view showing the configuration of the vehicle fuel pump according to the fifth embodiment.
FIG. 12 is a sectional view taken along line FF of FIG. In addition, corresponding to the configuration of the fourth embodiment, the same reference numerals are given to components having substantially no functional difference, and description thereof will be omitted.

In the fifth embodiment, similarly to the fourth embodiment, the thick portion 71a along the outer periphery of the circular plate 74 and the thick
4 and a thin portion 71b corresponding to the central portion. Further, in the fifth embodiment, three ribs 71c extending from the thick portion 71a are provided. These ribs 71c are formed along the fuel flow in consideration of the resistance to the fuel flow in the fuel passage 83. This rib 7
By 1c, sufficient strength can be given to the resin material 71 even when the thin portion 71b is formed outside the circular plate 74. For this reason, even when the temperature of the circular plate 74 becomes high, peeling and cracking of the resin material 71 can be prevented.

In the fourth embodiment, a plurality of ribs are formed along the fuel flow direction. However, a single rib or a rib having an appropriate shape is formed in consideration of the strength of the thin portion. You may.

In the above embodiments, the circular plate 74 is used.
The thickness of the resin material 71 was reduced corresponding to the central part of
The thickness of the resin material 71 may be reduced to correspond to the position where the temperature of the circular plate 74 rises most, for example, the position where the power control element is mounted.

[0052]

As described above, according to the present invention, since the stator coil, the control circuit, and the conductive portion connecting them are covered with the resin material, these portions are not exposed to the fuel. Thus, it is possible to prevent electrolytic corrosion in these portions, and to prevent defects such as conduction failure and short circuit. Only
Also forms a fuel passage near the control circuit to introduce fuel
Therefore, the heat from the control circuit is radiated to the fuel,
Control circuit made of resin material without lowering heat dissipation
Can be covered.

[Brief description of the drawings]

FIG. 1 is a sectional view of a vehicle fuel pump according to a first embodiment to which the present invention is applied.

FIG. 2 is a top plan view of the vehicle fuel pump according to the first embodiment to which the present invention is applied.

FIG. 3 is a cross-sectional view illustrating a configuration of a stator unit.

4 is a sectional view taken along the line CC in FIG. 3;

FIG. 5 is an upper plan view of a stator unit.

FIG. 6 is a circuit diagram of a control circuit.

FIG. 7 is a sectional view of a vehicle fuel pump according to a second embodiment of the present invention.

FIG. 8 is a sectional view of a vehicle fuel pump according to a third embodiment of the present invention.

FIG. 9 is a partial sectional view of a vehicle fuel pump according to a fourth embodiment to which the present invention is applied.

10 is a sectional view taken along the line EE in FIG. 9;

FIG. 11 is a partial sectional view of a vehicle fuel pump according to a fifth embodiment to which the present invention is applied.

FIG. 12 is a sectional view taken along the line FF in FIG. 11;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Vehicle fuel pump 10 Housing 30 Pump part 50 Motor part 60 Rotor 70 Stator part 72 Stator core 73 Stator coil 76 Container 77 Control circuit 83 Fuel passage 79 Terminal holder 80, 81 Terminal 84 Terminal 85 Terminal 86 Copper wire 90 Discharge part

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Seiji Tanizawa 1-1-1, Showa-cho, Kariya-shi, Aichi Japan Inside of Denso Co., Ltd. −59794 (JP, U) Hira 3-32197 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) F02M 37/10

Claims (3)

(57) [Claims] 1. A rotor on which a permanent magnet is fixed, a plurality of stator coils installed around the rotor, a control circuit for controlling energization of the stator coils, and a drive by the rotor. in the fuel supply apparatus for a vehicle having a built-in housing and a pump unit, Utotomoni covering the conductive portion to be connected to the stator coil and the control circuit these with a resin material, the resin material, the
The vehicle fuel supply device comprising a this <br/> to form a fuel passage for introducing the fuel in the vicinity of the control circuit. 2. The control circuit according to claim 1, wherein the control circuit is housed in a container, and the container, the stator coil, and the conductive portion are integrally and completely covered with the resin material. Vehicle fuel supply system. Wherein said container is a fuel supply apparatus for a vehicle according to claim 1, characterized in that it is formed in a dome shape.