EP2725227B1 - Pump assembly - Google Patents
Pump assembly Download PDFInfo
- Publication number
- EP2725227B1 EP2725227B1 EP12189726.8A EP12189726A EP2725227B1 EP 2725227 B1 EP2725227 B1 EP 2725227B1 EP 12189726 A EP12189726 A EP 12189726A EP 2725227 B1 EP2725227 B1 EP 2725227B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- assembly
- housing sub
- pump
- main body
- reagent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
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- 239000003153 chemical reaction reagent Substances 0.000 claims description 62
- 238000005086 pumping Methods 0.000 claims description 50
- 238000000465 moulding Methods 0.000 claims description 27
- 239000002826 coolant Substances 0.000 claims description 24
- 238000005553 drilling Methods 0.000 claims description 22
- 238000000034 method Methods 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 9
- 238000010531 catalytic reduction reaction Methods 0.000 claims description 6
- 230000035699 permeability Effects 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 238000001746 injection moulding Methods 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 13
- 239000007789 gas Substances 0.000 description 11
- 230000008569 process Effects 0.000 description 10
- 239000012530 fluid Substances 0.000 description 7
- 230000007246 mechanism Effects 0.000 description 7
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 5
- 239000003054 catalyst Substances 0.000 description 5
- 238000001816 cooling Methods 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 4
- 239000004202 carbamide Substances 0.000 description 4
- 238000000429 assembly Methods 0.000 description 3
- 239000003638 chemical reducing agent Substances 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
- 238000004891 communication Methods 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 238000007789 sealing Methods 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- 229910021529 ammonia Inorganic materials 0.000 description 2
- 230000000712 assembly Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 238000004806 packaging method and process Methods 0.000 description 2
- 239000000088 plastic resin Substances 0.000 description 2
- 239000002244 precipitate Substances 0.000 description 2
- 238000006722 reduction reaction Methods 0.000 description 2
- 230000000717 retained effect Effects 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- XHCLAFWTIXFWPH-UHFFFAOYSA-N [O-2].[O-2].[O-2].[O-2].[O-2].[V+5].[V+5] Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[V+5].[V+5] XHCLAFWTIXFWPH-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000003491 array Methods 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- QGLKJKCYBOYXKC-UHFFFAOYSA-N nonaoxidotritungsten Chemical compound O=[W]1(=O)O[W](=O)(=O)O[W](=O)(=O)O1 QGLKJKCYBOYXKC-UHFFFAOYSA-N 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 230000005180 public health Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 230000002459 sustained effect Effects 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 229910001930 tungsten oxide Inorganic materials 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 229910001935 vanadium oxide Inorganic materials 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B13/00—Pumps specially modified to deliver fixed or variable measured quantities
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B17/00—Pumps characterised by combination with, or adaptation to, specific driving engines or motors
- F04B17/03—Pumps characterised by combination with, or adaptation to, specific driving engines or motors driven by electric motors
- F04B17/04—Pumps characterised by combination with, or adaptation to, specific driving engines or motors driven by electric motors using solenoids
- F04B17/042—Pumps characterised by combination with, or adaptation to, specific driving engines or motors driven by electric motors using solenoids the solenoid motor being separated from the fluid flow
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B53/00—Component parts, details or accessories not provided for in, or of interest apart from, groups F04B1/00 - F04B23/00 or F04B39/00 - F04B47/00
- F04B53/08—Cooling; Heating; Preventing freezing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B53/00—Component parts, details or accessories not provided for in, or of interest apart from, groups F04B1/00 - F04B23/00 or F04B39/00 - F04B47/00
- F04B53/16—Casings; Cylinders; Cylinder liners or heads; Fluid connections
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/14—Arrangements for the supply of substances, e.g. conduits
- F01N2610/1433—Pumps
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2066—Selective catalytic reduction [SCR]
Definitions
- the present invention relates to a pump assembly. More particularly, but not exclusively, the invention relates to a dosing pump for a selective catalytic reduction system.
- exhaust gases from internal combustion engines contain substances which are harmful to the environment and which can pose a threat to public health.
- a sustained effort has been made within the automotive industry to reduce the release to the atmosphere of harmful substances carried in exhaust gases, both by modifying the combustion process itself to give a reduced yield of harmful combustion products, and by treating the exhaust gases before their emission into the atmosphere, for example by providing a catalyst to induce chemical breakdown of the harmful constituents, particularly the oxides of nitrogen (NO x ), into benign compounds.
- NO x oxides of nitrogen
- One strategy for reducing NO x emissions involves the introduction of a reagent comprising a reducing agent, typically a liquid ammonia source such as an aqueous urea solution, into the exhaust gas stream.
- a reagent comprising a reducing agent, typically a liquid ammonia source such as an aqueous urea solution
- the reducing agent is injected into the exhaust gas upstream of an exhaust gas catalyst, known as an SCR catalyst, typically comprising a mixture of catalyst powders such as titanium oxide, vanadium oxide and tungsten oxide immobilised on a ceramic honeycomb structure.
- Nitrogen oxides in the exhaust gas undergo a catalysed reduction reaction with the ammonia source on the SCR catalyst, forming gaseous nitrogen and water.
- An example of an SCR system is described in the Applicant's European Patent Application Publication No. EP-A-2131020 .
- SCR systems typically include a reagent dosing pump for delivering reagent to the exhaust gas stream.
- a solenoid-actuated pumping arrangement is provided to increase the pressure of the reagent, and the pump includes an atomising nozzle that receives the reagent from the pumping arrangement and delivers it from an outlet end into the exhaust gas stream.
- the nozzle is close-coupled to the pumping arrangement, so that the nozzle and the pumping arrangement form a single unit.
- the outlet end of the nozzle may be positioned directly in the exhaust gas stream, so that the pumping arrangement is located close to the outside of the exhaust pipe that conveys the exhaust gases.
- the pumping work conducted by the dosing arrangement of such solenoid actuated pumps is created by a solenoid coil acting on the magnetic armature of a plunger armature assembly.
- urea-based reducing agents can be used is somewhat limited. Urea crystals tend to precipitate when the temperature of the solution is greater than approximately 70°C. Precipitation is undesirable because the precipitates can cause blockages in the delivery system, for example in the small-diameter outlets typically provided in the outlet end of the atomising nozzle. In addition, the formation of precipitates alters the concentration of the remaining solution, so that the effective quantity of ammonia delivered to the exhaust flow becomes uncertain. This could lead to inefficient catalysis and an insufficient reduction in NO x emissions.
- a housing sub-assembly for a pump assembly for use in a selective catalytic reduction system comprising: a main body having a pump axis A, the main body comprising a pumping zone cavity having a main axis coincident with axis A, and comprising a flow guide cavity disposed about axis A; an outer pole member and a solenoid coil disposed within the main body wherein the main body further comprises a reagent inlet port for receiving a reagent for supply to the pumping zone cavity via a reagent flow path and first and second coolant ports for supplying coolant to and removing coolant from the flow guide cavity wherein the main body, first and second coolant ports and reagent inlet port are integrally formed as a single component.
- the present invention provides a housing sub-assembly for a pump assembly which incorporates an outer pole member and a solenoid coil.
- the outer pole member (which may be formed from a material with a relatively high magnetic permeability) and solenoid coil comprise elements of a magnetic circuit that may be used to drive a pumping plunger of the pump array.
- the magnetic circuit components would be formed together within a particular sub-assembly component.
- the solenoid coil and outer pole member may be arranged to form a magnetic circuit with a pump core located within a pump sub-assembly.
- the pumping zone cavity may be conveniently dimensioned to receive the pump sub-assembly (and pump core) in order to complete the magnetic circuit of the pump assembly.
- the main body, first and second coolant ports and reagent inlet port may comprise an over-moulding member, the over-moulding member having been formed over the coil and outer pole member.
- the over-moulding member may be formed from plastic.
- the housing sub-assembly may further comprise an outer sleeve, the outer sleeve being disposed within the main body about axis A and the solenoid coil being disposed within the outer sleeve.
- the flow guide cavity may be defined in part by the main body and by the outer sleeve.
- the outer sleeve and outer pole member may be formed as a single component.
- the outer sleeve and outer pole member may together form a substantially cylindrical component comprising a first open end and a substantially closed second end, the second end comprising a drilling that aligns with one end of the reagent flow path and a machined slot for allowing electrical connection between the solenoid coil and an electrical connector to be made.
- first and second coolant ports and reagent inlet port comprise an over-moulding member
- the electrical connections may be embedded within the over-moulded component.
- the machined slot may conveniently be located off axis A.
- the pumping zone cavity may be dimensioned to receive a pump core.
- the pumping zone cavity may be further dimensioned to receive a pumping armature for pumping reagent supplied via the reagent flow path to the pumping zone cavity.
- the housing sub-assembly may further comprise a metallic back plate having a drilling, the reagent flow path being arranged to align with the drilling.
- a pump assembly for use in a selective catalytic reduction system comprising: a housing sub-assembly according to the first aspect of the present invention and a pump core, the pump core being located within the pumping zone cavity of the housing sub-assembly.
- the pump core may be part of a pump sub-assembly.
- Other components within the pump sub-assembly may comprise a plunger armature, nozzle tubes and nozzle delivery valves.
- a method of manufacturing a pump assembly comprising manufacturing a housing sub-assembly by: providing a blank disk member of a material having a relatively high magnetic permeability; deep drawing the blank disk member to form an outer pole piece, the outer pole piece defining an internal volume with an opening; inserting a solenoid coil into the internal volume of the outer pole piece; pressing a back stop plate into the outer pole piece, the back stop plate having at least one drilling through the plate; injection moulding an over-mould member to encapsulate the outer pole piece and solenoid coil and to form a main body of the housing sub-assembly, the main body having a pump axis A and defining a pumping zone cavity having a main axis substantially coincident with axis A, and defining a flow guide cavity disposed about axis A; forming a reagent inlet port as part of the over-mould member; forming coolant ports as part of the over-moul
- the method may further comprise inserting an actuator pump core into the pumping zone cavity defined by the main body of the housing sub-assembly.
- the method may also further comprise inserting a coolant flow guide.
- a known pump assembly 10 is shown in Figure 1 .
- the pump assembly 10 includes a reagent dosing unit with an integrated pump and nozzle arrangement, referred to hereafter as a reagent dosing pump sub-assembly 12.
- the pump sub-assembly 12 is a reagent dosing pump of any suitable type, for example as described in EP-A-1878920 , to which reference can be made for further details of the pump sub-assembly 12.
- the pump sub-assembly 12 comprises a pump housing 14 having a generally cylindrical pump body portion 16 that defines a pump axis (axis A in Figure 1 ), and a generally cylindrical nozzle portion 18 that extends from a first face 20 of the body portion 16 along the pump axis A.
- the nozzle portion 18 has a relatively small diameter compared to the body portion 16.
- the body portion 16 of the pump housing 14 houses a pumping mechanism (not shown), such as a solenoid-actuated pumping mechanism.
- the pumping mechanism receives reagent through a reagent inlet 22 provided on a second face 24 of the body portion 16, opposite the first face 20.
- An electrical connection point 26 is also located on the second face 24 of the body portion 16, to provide an operating current to the solenoid actuator of the pumping mechanism.
- the pumping mechanism includes a reciprocating pumping element, such as a plunger or piston, and is arranged to increase the pressure of a pre-defined quantity of reagent on each cycle of the pumping element.
- the nozzle portion 18 of the pump housing 14 houses a delivery passage (not shown) that, in use, receives the pressurised reagent from the pumping mechanism, and conveys it to a reduced-diameter outlet end 28 of the nozzle portion 18.
- the outlet end 28 houses an atomising nozzle that atomises the reagent as it exits the pump sub-assembly 12.
- the pump assembly 10 also includes a housing sub-assembly 30 having an internal cavity 32 in which the pump 12 is received.
- the cavity 32 is defined by an internal wall 34 of the housing sub-assembly 30.
- the shape of the cavity 32 is an enlarged version of the shape defined by the pump housing 14. In this way, the internal wall 34 of the cavity 32 is spaced from the pump housing 14 to define a volume/compartment 36 for cooling fluid therebetween.
- the housing sub-assembly 30 is generally made from cast stainless steel.
- a projection or land 40 extends axially from the internal wall 34 of the cavity 32 towards the outlet end 18 of the pump, to meet the inlet port 22 on the second face 24 of the housing pump body portion 16.
- a collar 42 is provided on the second face 24 of the pump body portion 16 that receives the land 40.
- An O-ring 44 is provided to create a fluid-tight seal between the collar 42 and the land 40. The O-ring 44 is received in an annular ring 46 machined into the body of the housing sub-assembly 30.
- the seal provided by the O-ring 44 prevents leakage of reagent into the compartment 36 between the land 40 of the housing sub-assembly 30 and the collar 42 of the pump housing 14.
- connection block 50 of generally cuboidal shape.
- a top face of the connection block 50 is provided with a reagent inlet port 52 that receives a tubular reagent inlet connector 54.
- the inlet connector 54 extends radially with respect to the pump axis A and is connected to a reagent supply line (not shown) in use.
- a filter 55 is located in the flow path between the inlet connector 54 and the reagent inlet 22 of the pump 12. In this embodiment, the filter 55 is received in the inlet port 54.
- the filter 55 is conveniently a disc filter, arranged to prevent particulate contaminants in the reagent, such as urea crystals, from entering the pump 12.
- connection block 50 is also provided with a drilling 56 to admit an electrical connector 58.
- the electrical connector 58 connects with the electrical connection point 26 of the pump 12.
- a further O-ring 60 is provided to seal the electrical connector 58 in the drilling 56.
- the O-ring 60 is again provided in an annular groove 62 provided in the body of the housing sub-assembly.
- FIG. 2 shows a pump assembly 100 in accordance with an example useful for understanding the present invention. Like features between Figures 1 and 2 are referred to with reference to the same reference numerals
- the pump assembly 100 of Figure 2 comprises a pump sub-assembly 12 contained within a water cooled housing sub-assembly 30.
- the pump sub-assembly 12 comprises an over-moulding member 102 and a solenoid actuator 103, the solenoid actuator 103 comprising: an actuator core (also referred to as pump core or inner pole piece) 104, an outer pole piece 106, a magnetic sleeve 107, a bobbin 108 and a solenoid coil 110, the solenoid coil being carried on the bobbin.
- the components of the actuator are, in turn, supported by the over-moulding member.
- a pumping region 112 within the pump sub-assembly 12 is provided by a volume defined by the outer pole piece 106, a back plate member 114 and a top face 115 of the actuator core 104.
- a bore 116 is provided within the actuator core 104. At the end of the bore remote from the pumping region 112 is a pumping chamber region 118.
- the housing sub-assembly 30 comprises a cavity 120 for receiving the pump sub-assembly 12, the cavity being dimensioned such that a compartment 122 is defined between the housing 30 and pump 12 sub-assemblies in the general region of the solenoid actuator 103.
- a coolant e.g. water
- a hydraulic connector not shown in Figure 2
- the housing sub-assembly 12 comprises a reagent inlet port 52 wherein a reagent connector (not shown) can be interfaced with the housing sub-assembly 30 in order to supply a reagent, e.g. Adblue reagent.
- a reagent e.g. Adblue reagent.
- the pump sub-assembly 12 further comprises a neck portion 124 remote from the solenoid actuator, the neck portion being dimensioned to be received within a drilling 126 in the body of housing sub-assembly 30.
- the neck portion 124 in turn comprises a bore 128 that is coincident with the pump assembly axis A. In use, the bore 128 receives an electrical connector cable 58 for connection to terminals of the solenoid coil wire 110.
- the reagent flows from the inlet port 52 through a second drilling 130 in the housing sub-assembly 30 to a radial gallery 132 defined between the housing sub-assembly 30 and the neck portion 124 of the pump sub-assembly 12.
- the gallery 132 permits assembly of the pump sub-assembly into the housing sub-assembly and also allows orientation of the pump sub-assembly relative to the housing sub-assembly during this process.
- the reagent gallery 132 is sealed from the outside environment in the region of the neck portion 124 by two O ring seals (134, 136) and sealed from the main housing water chamber 122 via a third O ring seal 138, all of which are retained by suitable O Ring grooves 140 moulded as part of the coil over-moulding member 102.
- two O rings are shown (134, 136) in the neck portion 124 of the pump sub-assembly, it is noted that a single O ring seal would be sufficient for this primary function.
- reagent is then routed through the coil over-moulding member 102 via a number of flow ports 142, one of which is visible in Figure 2 . It is however noted that three or four ports could be provided equispaced around the axis A to provide efficient fluid communication between the gallery 132 and the internal pumping region 112 of the pump sub-assembly 12.
- the flow port 142 As reagent exits the flow port 142 it then passes through a drilling 144 in the non magnetic plunger back stop plate 114 before entering the pumping region 112. With the reagent delivered to the pumping zone 112, the flow path resumes the route as described in EP1878920 .
- the drilling 144 may be a port that is drilled or manufactured by other means (e.g. produced by stamping/fine blanking etc.).
- the drilling 144 in the back plate 114 is arranged during assembly to line up with the port 142 in the over-moulding member 102.
- the back stop plate would comprise an equal number of drillings 144 in the same orientation as the ports 142.
- the over-moulding member 102 is formed via an injection moulding method.
- One potential method for manufacturing the ports and aligning them with the drillings 144 of the back stop plate 114 would be to align the drillings 144 of the back plate 114 with the removable cores of a mould tool when injection moulding the over-moulding member 102. Alignment is important as it permits the routing of the solenoid coil cable 58 to the coil wire terminals (not shown) which would need to pass within (in between) the gaps of the reagent ports 142.
- the magnetic outer pole piece 106 and magnetic outer sleeve 107 are formed from one deep drawn component, which also incorporates a locating face 146 and crimp feature 148 for the pump core 104. Forming the outer pole piece 106 and magnetic outer sleeve 107 via a deep draw process reduces material waste compared to a process where the components are formed by machining.
- the pump sub-assembly 12 may therefore be assembled by winding the coil wire 110 around the coil former or bobbin 108.
- the wound coil former (110, 108) can then be slid into the magnetic drawn component 107, which will have a slot (not shown in this view) to receive the bobbin terminals.
- Holes 150 in the magnetic outer sleeve 107 permit filling of the volume 152 between the coil windings 110 and the outer sleeve inside face 107.
- the axial positioning of the coil wire 58 allows the water cooled cavity 122 within the housing to be optimized and sized primarily for the purposes of cooling.
- the overall outside diameter of the housing sub-assembly 30 may therefore be reduced.
- a supply passage 154 is defined by an annular cavity between the coil former 108 and the actuator core 104.
- a plurality of filling ports 156 (of which one is shown in Figure 2 ) comprising a radial through bore, extend from the axial bore 116 to the supply passage 154.
- a reciprocating pumping element such as a plunger or piston (not shown in Figure 2 ) is slidably accommodated within the bore 116.
- a disc-shaped armature (also not shown in Figure 2 ) is attached to the plunger.
- a current is passed through the solenoid coil 110 to energise the coil and induce a magnetic field around the coil.
- the resulting magnetic field exerts a force on the armature which, in turn, drives a pumping stroke of the plunger.
- reagent is pumped from the internal pumping region 112 via the passage 154 and ports 156 to the pumping chamber 118 and then out to an adjoining nozzle tube (not shown in Figure 2 ).
- a further seal member 158 is provided between the coil former 108 and actuator core 104.
- Figures 3 and 4 relate to an embodiment of the present invention that simplifies the pump assemblies discussed above.
- the embodiment of Figures 3 and 4 offers a pump assembly that is more compact, has fewer internal components and has improved internal sealing. It is noted that the embodiment of Figures 3 and 4 also has improved external sealing as the over-moulded member as described below removes the need for O ring seals between the reagent/coolant ports and the housing sub-assembly since the connector ports and body of the housing sub-assembly are formed as a unitary piece.
- O ring seal 46 is provided to create a fluid-tight seal between the collar 42 and the land 40 and O ring seal 60 is provided to seal the electrical connector 58 in the drilling 56 (the O-ring 60 being provided in an annular groove 62 provided in the body of the housing sub-assembly).
- the reagent gallery 132 is sealed from the outside environment in the region of the neck portion 124 by two O ring seals (134, 136) and sealed from the main housing water chamber 122 via a third O ring seal 138, all of which are retained by suitable O ring grooves 140 moulded as part of the coil over-moulding member 102.
- a further seal member 158 is provided between the coil former 108 and actuator core 104.
- the pump assembly of Figure 3 comprises a housing sub-assembly 230 in which a number of components of the pump assembly have been incorporated into a single over-moulded housing sub-assembly component 230.
- the pump sub-assembly has been "split in half" and components from the pump assembly have been moved into the housing sub-assembly.
- the overall size of the housing sub-assembly is thereby reduced in the embodiment of Figures 3 and 4 and the number of interfaces requiring a fluid tight seal is also reduced thereby improving the reliability of the pump assembly and improving the ease of assembly.
- a housing sub-assembly 230 comprising an over-moulding member 230 which comprises a main body portion 232 and a number of connector ports 234, 236, 238 for a reagent port inlet, coolant inlet and coolant outlet respectively.
- the connector ports 234, 236, 238 and main body 232 form a unitary piece such that the need for O ring seals at the connector locations 240, 242, 244 is removed.
- the reagent inlet port 234 comprises a flow path 246 which is in fluid communication with a pumping zone 248 (also referred to herein as a pumping zone cavity) which is dimensioned to receive a pump sub-assembly.
- the pumping zone comprises the following components: an actuator core (also referred to as pump core or inner pole piece), a plunger armature, a nozzle tube and nozzle delivery valves (not shown in Figure 3 ) for delivery of reagent from the inlet port 234 to an exhaust flow (direction 250 in Figure 3 ) [these components may individually or in combination be referred to as the pump sub-assembly].
- the flow path 246 passes through a non-magnetic back plate member 247 as described below.
- Coolant inlet and outlet ports 236, 238 are in fluid communication with a cavity 252 (also referred to herein as a flow guide cavity) within the main body 232 of the housing sub-assembly 230 which cavity is dimensioned to receive a flow guide member 254.
- the flow guide member 254 defines first 256 and second 258 volumes and, in use, coolant fluid may flow in via port 236 and flow first through the first volume 256 and then via the second volume 258 in order to allow excess heat within the pump assembly to be extracted. Coolant fluid may then exit the assembly via port 238.
- the main body 232 of the housing sub-assembly 230 is also provided with a female connection port 260 such that electrical cables can be connected via an electrical connector 262.
- the housing sub-assembly 230 of Figure 3 comprises a solenoid coil 264, magnetic outer sleeve member 266 (also referred to herein as an outer sleeve), an outer pole piece 268 (also referred to herein as an outer pole member) and a back plate member 247, that is formed from a material with a low magnetic permeability.
- the coil 264 may be carried on a bobbin (not shown in Figure 3 ).
- the outer sleeve member 266 (which is formed from a material with a relatively high magnetic permeability) and the outer pole piece 268 (also formed from a material with a relatively high magnetic permeability) are actually a single component member 270. It is to be appreciated however that the sleeve member 266 and pole piece 268 may be two separate components that are either attached to one another or held in proximity to one another by the over moulded main body 232 of the housing sub-assembly 230.
- the electrical connector 262 is connected through a hole 272 in the outer pole piece 268 to the ends of the solenoid coil 264.
- FIG. 3 Also shown in Figure 3 is a pair of U shaped grooves 274 in the outer surface of the main body of the housing sub-assembly. These are used during installation and assembly to receive a pair of O ring seals between the housing sub-assembly and a front piece portion of the pump assembly (not shown).
- the magnetic outer sleeve 266 also incorporates a locating face 276 and crimp feature 278 for the pump core (not shown in Figure 3 ). It is noted that the outer pole piece 268 and outer sleeve 266 may be formed from a single deep drawn component 270, which incorporates the locating face 276 and crimp feature 278 for the pump core. Forming the outer pole piece 268 and magnetic outer sleeve 266 via a deep draw process reduces material waste compared to a process where the components are formed by machining.
- Figure 4 shows the outer sleeve 266 and outer pole piece 268 in more detail.
- the sleeve and pole piece are formed as a single component 270.
- the component 270 is generally cylindrical in shape and comprises a first, open end 280 through which the solenoid coil 264 and bobbin may be loaded during assembly.
- the second end 282 of the component comprises the outer pole piece 268.
- the outer pole piece incorporates a bore 284 through which reagent may pass in use and also a machined slot 272 through which electrical connections from the coil 264 to the electrical connector 262 may be made during the assembly process.
- the outer surface of the component 270 comprises a number of machined holes 286 (three of which are visible in figure 4 ). These holes are provided to improve the over moulding process as described below and also enable the outer pole piece 268 and sleeve 266 to be held securely in place within the main body 232 of the sub-assembly 230 once over-moulding has occurred.
- a wound coil 264 is introduced into an outer sleeve piece 266 and outer pole piece 268 component (270), the component 270 having a first open end 280 and a second end 282 with a machined orifice 284 and a machined slot 272 (shown in Figure 4 ).
- a backstop plate 247, having at least one drilling 288 therethrough is provided at the second end of the component.
- the ends of the wound coil are passed through the machined slot 272 in the component 270 and then connected (e.g. welded) with an electrical connector 262.
- the coil 264, outer sleeve piece 266, outer pole piece 268, backstop plate 247 and electrical connector 262 are then placed into an over-mould cavity and plastic resin is then introduced into the cavity in order to over mould the main body 232 of the housing sub-assembly 230.
- the coil may first be wound onto a coil former.
- a flow path forming member may also be provided within the over mould cavity in order to provide a flow path 246 from the reagent inlet 234 to a pumping cavity 248 within the outer sleeve 266 and outer pole piece 268.
- Further flow path forming members may also be provided to define flow paths from coolant inlet/outlet 236/238 to a flow cavity 252 within the main body 232 of the housing sub-assembly 230.
- the flow path forming members may comprise solid structures within the over-moulding cavity that are arranged to block over-mould from forming in certain areas of the over-moulding cavity. In this manner various passages and flow paths may be formed within the housing sub-assembly.
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Description
- The present invention relates to a pump assembly. More particularly, but not exclusively, the invention relates to a dosing pump for a selective catalytic reduction system.
- It is known that exhaust gases from internal combustion engines contain substances which are harmful to the environment and which can pose a threat to public health. For many years, a sustained effort has been made within the automotive industry to reduce the release to the atmosphere of harmful substances carried in exhaust gases, both by modifying the combustion process itself to give a reduced yield of harmful combustion products, and by treating the exhaust gases before their emission into the atmosphere, for example by providing a catalyst to induce chemical breakdown of the harmful constituents, particularly the oxides of nitrogen (NO x ), into benign compounds.
- One strategy for reducing NO x emissions, known as selective catalytic reduction or SCR, involves the introduction of a reagent comprising a reducing agent, typically a liquid ammonia source such as an aqueous urea solution, into the exhaust gas stream. The reducing agent is injected into the exhaust gas upstream of an exhaust gas catalyst, known as an SCR catalyst, typically comprising a mixture of catalyst powders such as titanium oxide, vanadium oxide and tungsten oxide immobilised on a ceramic honeycomb structure. Nitrogen oxides in the exhaust gas undergo a catalysed reduction reaction with the ammonia source on the SCR catalyst, forming gaseous nitrogen and water. An example of an SCR system is described in the Applicant's European Patent Application Publication No.
EP-A-2131020 . - SCR systems typically include a reagent dosing pump for delivering reagent to the exhaust gas stream.
- In one known reagent dosing pump, a solenoid-actuated pumping arrangement is provided to increase the pressure of the reagent, and the pump includes an atomising nozzle that receives the reagent from the pumping arrangement and delivers it from an outlet end into the exhaust gas stream. The nozzle is close-coupled to the pumping arrangement, so that the nozzle and the pumping arrangement form a single unit. The outlet end of the nozzle may be positioned directly in the exhaust gas stream, so that the pumping arrangement is located close to the outside of the exhaust pipe that conveys the exhaust gases.
- Examples of such pumps are described in the Applicant's European Patent Application Publication No.
EP-A-1878920 andWO 2012/136 789 . - The pumping work conducted by the dosing arrangement of such solenoid actuated pumps is created by a solenoid coil acting on the magnetic armature of a plunger armature assembly.
- The maximum temperature at which urea-based reducing agents can be used is somewhat limited. Urea crystals tend to precipitate when the temperature of the solution is greater than approximately 70°C. Precipitation is undesirable because the precipitates can cause blockages in the delivery system, for example in the small-diameter outlets typically provided in the outlet end of the atomising nozzle. In addition, the formation of precipitates alters the concentration of the remaining solution, so that the effective quantity of ammonia delivered to the exhaust flow becomes uncertain. This could lead to inefficient catalysis and an insufficient reduction in NO x emissions.
- It is therefore desirable, in many cases, to provide cooling means to cool the reagent in an SCR system and, in particular, in the reagent dosing pump, to prevent overheating of the reagent. Furthermore, when solenoid-actuated pumping arrangements are used, it is also desirable to cool the solenoid coil since the performance of solenoid actuators can decrease at high temperatures. Many known pump assembly arrangements therefore include a water cooling system, e.g. by means of the provision of a water jacket around the solenoid actuator and the provision of water input and output ports to the jacket in order to provide a flow of cooling water.
- In designing and optimising pump assemblies there are a number of requirements that need to be considered. Firstly, packaging of the pump assembly within the engine system is increasingly challenging. The mass of such an assembly is also important in ensuring the product is robust in its attachment to a thin walled exhaust section, and subsequent vibrations seen in use. And finally, one further issue which is important to the integration of a new water cooled product in such an environment is the heat input in to the water cooling system.
- One area which drives opportunities to improve all of the above points is size and arrangement of the solenoid coil. On the design described in
EP1878920 , a terminal block is provided to interface between the coil windings of the solenoid coil of the actuator and an electrical supply cable (the solenoid cable). However, this approach increases the packaging size of the coil, and hence the water jacket required to house it. There is therefore a knock on effect which impacts the size, mass and surface area of the doser exposed to the high ambient temperature environment. - It is therefore an object of the present invention to provide a pump assembly for use in an engine system that substantially overcomes or mitigates the above mentioned problems.
- According to a first aspect of the present invention there is provided a housing sub-assembly for a pump assembly for use in a selective catalytic reduction system, the housing sub-assembly comprising: a main body having a pump axis A, the main body comprising a pumping zone cavity having a main axis coincident with axis A, and comprising a flow guide cavity disposed about axis A; an outer pole member and a solenoid coil disposed within the main body wherein the main body further comprises a reagent inlet port for receiving a reagent for supply to the pumping zone cavity via a reagent flow path and first and second coolant ports for supplying coolant to and removing coolant from the flow guide cavity wherein the main body, first and second coolant ports and reagent inlet port are integrally formed as a single component.
- The present invention provides a housing sub-assembly for a pump assembly which incorporates an outer pole member and a solenoid coil. The outer pole member (which may be formed from a material with a relatively high magnetic permeability) and solenoid coil comprise elements of a magnetic circuit that may be used to drive a pumping plunger of the pump array. In known pump arrays the magnetic circuit components would be formed together within a particular sub-assembly component. By placing the outer pole member and solenoid coil within the housing sub-assembly the magnetic circuit may effectively be "split" between the housing sub-assembly and the pumping sub-assembly and the size of the pump assembly reduced. It is noted that the solenoid coil and outer pole member may be arranged to form a magnetic circuit with a pump core located within a pump sub-assembly. The pumping zone cavity may be conveniently dimensioned to receive the pump sub-assembly (and pump core) in order to complete the magnetic circuit of the pump assembly.
- Conveniently, the main body, first and second coolant ports and reagent inlet port may comprise an over-moulding member, the over-moulding member having been formed over the coil and outer pole member. By forming the main body, first and second coolant ports and reagent inlet port as an over-moulding member the need for various sealing members (O ring seals) may conveniently be reduced.
- Conveniently, the over-moulding member may be formed from plastic.
- The housing sub-assembly may further comprise an outer sleeve, the outer sleeve being disposed within the main body about axis A and the solenoid coil being disposed within the outer sleeve.
- Conveniently the flow guide cavity may be defined in part by the main body and by the outer sleeve.
- The outer sleeve and outer pole member may be formed as a single component.
- The outer sleeve and outer pole member may together form a substantially cylindrical component comprising a first open end and a substantially closed second end, the second end comprising a drilling that aligns with one end of the reagent flow path and a machined slot for allowing electrical connection between the solenoid coil and an electrical connector to be made.
- Conveniently electrical connections between the solenoid coil and the electrical connector member may be routed through the main body of the housing sub-assembly and through the machined slot. Where the main body, first and second coolant ports and reagent inlet port comprise an over-moulding member, the electrical connections may be embedded within the over-moulded component.
- The machined slot may conveniently be located off axis A. The pumping zone cavity may be dimensioned to receive a pump core. The pumping zone cavity may be further dimensioned to receive a pumping armature for pumping reagent supplied via the reagent flow path to the pumping zone cavity.
- The housing sub-assembly may further comprise a metallic back plate having a drilling, the reagent flow path being arranged to align with the drilling.
- According to a second aspect of the present invention there is provided a pump assembly for use in a selective catalytic reduction system comprising: a housing sub-assembly according to the first aspect of the present invention and a pump core, the pump core being located within the pumping zone cavity of the housing sub-assembly.
- The pump core may be part of a pump sub-assembly. Other components within the pump sub-assembly may comprise a plunger armature, nozzle tubes and nozzle delivery valves.
- According to a third aspect of the present invention there is provided a method of manufacturing a pump assembly comprising manufacturing a housing sub-assembly by: providing a blank disk member of a material having a relatively high magnetic permeability; deep drawing the blank disk member to form an outer pole piece, the outer pole piece defining an internal volume with an opening; inserting a solenoid coil into the internal volume of the outer pole piece; pressing a back stop plate into the outer pole piece, the back stop plate having at least one drilling through the plate; injection moulding an over-mould member to encapsulate the outer pole piece and solenoid coil and to form a main body of the housing sub-assembly, the main body having a pump axis A and defining a pumping zone cavity having a main axis substantially coincident with axis A, and defining a flow guide cavity disposed about axis A; forming a reagent inlet port as part of the over-mould member; forming coolant ports as part of the over-mould member; forming at least one flow path through the over-moulding member, the at least one flow path aligning with the at least one drilling in the back stop plate.
- The method may further comprise inserting an actuator pump core into the pumping zone cavity defined by the main body of the housing sub-assembly.
- The method may also further comprise inserting a coolant flow guide.
- Preferred and/or optional features of each aspect of the invention may be used, alone or in appropriate combination, in the other aspects also.
- Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which like reference numerals are used for like parts, and in which:
-
Figure 1 shows a known pump assembly; -
Figure 2 shows a further known pump assembly useful for understanding the present invention; -
Figure 3 shows a pump assembly in accordance with an embodiment of the present invention; -
Figure 4 shows a component of the pump assembly ofFigure 3 in more detail. - A known
pump assembly 10 is shown inFigure 1 . - Referring
Figure 1 , thepump assembly 10 includes a reagent dosing unit with an integrated pump and nozzle arrangement, referred to hereafter as a reagentdosing pump sub-assembly 12. Thepump sub-assembly 12 is a reagent dosing pump of any suitable type, for example as described inEP-A-1878920 , to which reference can be made for further details of thepump sub-assembly 12. - The
pump sub-assembly 12 comprises apump housing 14 having a generally cylindrical pump body portion 16 that defines a pump axis (axis A inFigure 1 ), and a generallycylindrical nozzle portion 18 that extends from afirst face 20 of the body portion 16 along the pump axis A. Thenozzle portion 18 has a relatively small diameter compared to the body portion 16. - The body portion 16 of the
pump housing 14 houses a pumping mechanism (not shown), such as a solenoid-actuated pumping mechanism. In use, the pumping mechanism receives reagent through areagent inlet 22 provided on asecond face 24 of the body portion 16, opposite thefirst face 20. Anelectrical connection point 26 is also located on thesecond face 24 of the body portion 16, to provide an operating current to the solenoid actuator of the pumping mechanism. As is known fromEP-A-1878920 , the pumping mechanism includes a reciprocating pumping element, such as a plunger or piston, and is arranged to increase the pressure of a pre-defined quantity of reagent on each cycle of the pumping element. - The
nozzle portion 18 of thepump housing 14 houses a delivery passage (not shown) that, in use, receives the pressurised reagent from the pumping mechanism, and conveys it to a reduced-diameter outlet end 28 of thenozzle portion 18. The outlet end 28 houses an atomising nozzle that atomises the reagent as it exits thepump sub-assembly 12. - The
pump assembly 10 also includes ahousing sub-assembly 30 having aninternal cavity 32 in which thepump 12 is received. Thecavity 32 is defined by aninternal wall 34 of thehousing sub-assembly 30. In general terms, the shape of thecavity 32 is an enlarged version of the shape defined by thepump housing 14. In this way, theinternal wall 34 of thecavity 32 is spaced from thepump housing 14 to define a volume/compartment 36 for cooling fluid therebetween. - The
housing sub-assembly 30 is generally made from cast stainless steel. - In a region of the
housing sub-assembly 30 remote from the outlet end 18 of the pump, a projection orland 40 extends axially from theinternal wall 34 of thecavity 32 towards the outlet end 18 of the pump, to meet theinlet port 22 on thesecond face 24 of the housing pump body portion 16. Acollar 42 is provided on thesecond face 24 of the pump body portion 16 that receives theland 40. An O-ring 44 is provided to create a fluid-tight seal between thecollar 42 and theland 40. The O-ring 44 is received in an annular ring 46 machined into the body of thehousing sub-assembly 30. - The seal provided by the O-
ring 44 prevents leakage of reagent into the compartment 36 between theland 40 of thehousing sub-assembly 30 and thecollar 42 of thepump housing 14. - The end of the
housing sub-assembly 30 remote from theoutlet end 18 comprises a connection block 50 of generally cuboidal shape. A top face of the connection block 50 is provided with areagent inlet port 52 that receives a tubularreagent inlet connector 54. - The
inlet connector 54 extends radially with respect to the pump axis A and is connected to a reagent supply line (not shown) in use. - A
filter 55 is located in the flow path between theinlet connector 54 and thereagent inlet 22 of thepump 12. In this embodiment, thefilter 55 is received in theinlet port 54. Thefilter 55 is conveniently a disc filter, arranged to prevent particulate contaminants in the reagent, such as urea crystals, from entering thepump 12. - The connection block 50 is also provided with a drilling 56 to admit an
electrical connector 58. Theelectrical connector 58 connects with theelectrical connection point 26 of thepump 12. A further O-ring 60 is provided to seal theelectrical connector 58 in the drilling 56. The O-ring 60 is again provided in anannular groove 62 provided in the body of the housing sub-assembly. -
Figure 2 shows apump assembly 100 in accordance with an example useful for understanding the present invention. Like features betweenFigures 1 and2 are referred to with reference to the same reference numerals - The
pump assembly 100 ofFigure 2 comprises apump sub-assembly 12 contained within a water cooledhousing sub-assembly 30. - The
pump sub-assembly 12 comprises anover-moulding member 102 and asolenoid actuator 103, thesolenoid actuator 103 comprising: an actuator core (also referred to as pump core or inner pole piece) 104, anouter pole piece 106, amagnetic sleeve 107, abobbin 108 and asolenoid coil 110, the solenoid coil being carried on the bobbin. The components of the actuator are, in turn, supported by the over-moulding member. Apumping region 112 within thepump sub-assembly 12 is provided by a volume defined by theouter pole piece 106, aback plate member 114 and atop face 115 of theactuator core 104. Abore 116 is provided within theactuator core 104. At the end of the bore remote from thepumping region 112 is apumping chamber region 118. - The
housing sub-assembly 30 comprises acavity 120 for receiving thepump sub-assembly 12, the cavity being dimensioned such that acompartment 122 is defined between thehousing 30 and pump 12 sub-assemblies in the general region of thesolenoid actuator 103. In use, a coolant, e.g. water, is supplied via a hydraulic connector (not shown inFigure 2 ) to the compartment 3 to provide water cooling of the actuator. - The
housing sub-assembly 12 comprises areagent inlet port 52 wherein a reagent connector (not shown) can be interfaced with thehousing sub-assembly 30 in order to supply a reagent, e.g. Adblue reagent. - The
pump sub-assembly 12 further comprises aneck portion 124 remote from the solenoid actuator, the neck portion being dimensioned to be received within adrilling 126 in the body ofhousing sub-assembly 30. Theneck portion 124 in turn comprises abore 128 that is coincident with the pump assembly axis A. In use, thebore 128 receives anelectrical connector cable 58 for connection to terminals of thesolenoid coil wire 110. - The reagent flows from the
inlet port 52 through asecond drilling 130 in thehousing sub-assembly 30 to aradial gallery 132 defined between thehousing sub-assembly 30 and theneck portion 124 of thepump sub-assembly 12. Thegallery 132 permits assembly of the pump sub-assembly into the housing sub-assembly and also allows orientation of the pump sub-assembly relative to the housing sub-assembly during this process. - The
reagent gallery 132 is sealed from the outside environment in the region of theneck portion 124 by two O ring seals (134, 136) and sealed from the mainhousing water chamber 122 via a thirdO ring seal 138, all of which are retained by suitable O Ring grooves 140 moulded as part of thecoil over-moulding member 102. Although, two O rings are shown (134, 136) in theneck portion 124 of the pump sub-assembly, it is noted that a single O ring seal would be sufficient for this primary function. - From the
gallery 132, reagent is then routed through thecoil over-moulding member 102 via a number offlow ports 142, one of which is visible inFigure 2 . It is however noted that three or four ports could be provided equispaced around the axis A to provide efficient fluid communication between thegallery 132 and theinternal pumping region 112 of thepump sub-assembly 12. - As reagent exits the
flow port 142 it then passes through a drilling 144 in the non magnetic plunger backstop plate 114 before entering thepumping region 112. With the reagent delivered to thepumping zone 112, the flow path resumes the route as described inEP1878920 . Note that the drilling 144 may be a port that is drilled or manufactured by other means (e.g. produced by stamping/fine blanking etc.). - It is noted that the drilling 144 in the
back plate 114 is arranged during assembly to line up with theport 142 in theover-moulding member 102. In the event ofmultiple ports 142 the back stop plate would comprise an equal number of drillings 144 in the same orientation as theports 142. - The
over-moulding member 102 is formed via an injection moulding method. One potential method for manufacturing the ports and aligning them with the drillings 144 of theback stop plate 114 would be to align the drillings 144 of theback plate 114 with the removable cores of a mould tool when injection moulding theover-moulding member 102. Alignment is important as it permits the routing of thesolenoid coil cable 58 to the coil wire terminals (not shown) which would need to pass within (in between) the gaps of thereagent ports 142. - To allow the assembly of the plunger back stop accurately and for the solenoid to operate correctly the magnetic
outer pole piece 106 and magneticouter sleeve 107 are formed from one deep drawn component, which also incorporates a locatingface 146 and crimpfeature 148 for thepump core 104. Forming theouter pole piece 106 and magneticouter sleeve 107 via a deep draw process reduces material waste compared to a process where the components are formed by machining. - The
pump sub-assembly 12 may therefore be assembled by winding thecoil wire 110 around the coil former orbobbin 108. The wound coil former (110, 108) can then be slid into the magnetic drawncomponent 107, which will have a slot (not shown in this view) to receive the bobbin terminals. Then with theback plate 114 in place, and flowport 142 cores aligned to the back plate ports 144 over moulding will take place over thewhole pump sub-assembly 12.Holes 150 in the magneticouter sleeve 107 permit filling of thevolume 152 between thecoil windings 110 and the outer sleeve insideface 107. - The axial positioning of the
coil wire 58 allows the water cooledcavity 122 within the housing to be optimized and sized primarily for the purposes of cooling. The overall outside diameter of thehousing sub-assembly 30 may therefore be reduced. - As noted above, the pumping mechanism of the pump sub-assembly is known from, for example
EP-A-1878920 . Briefly however, asupply passage 154 is defined by an annular cavity between the coil former 108 and theactuator core 104. A plurality of filling ports 156 (of which one is shown inFigure 2 ) comprising a radial through bore, extend from theaxial bore 116 to thesupply passage 154. - A reciprocating pumping element, such as a plunger or piston (not shown in
Figure 2 ) is slidably accommodated within thebore 116. A disc-shaped armature (also not shown inFigure 2 ) is attached to the plunger. - In order to dispense reagent, a current is passed through the
solenoid coil 110 to energise the coil and induce a magnetic field around the coil. The resulting magnetic field exerts a force on the armature which, in turn, drives a pumping stroke of the plunger. By means of the reciprocating plunger reagent is pumped from theinternal pumping region 112 via thepassage 154 and ports 156 to thepumping chamber 118 and then out to an adjoining nozzle tube (not shown inFigure 2 ). Afurther seal member 158 is provided between the coil former 108 andactuator core 104. -
Figures 3 and4 relate to an embodiment of the present invention that simplifies the pump assemblies discussed above. The embodiment ofFigures 3 and4 offers a pump assembly that is more compact, has fewer internal components and has improved internal sealing. It is noted that the embodiment ofFigures 3 and4 also has improved external sealing as the over-moulded member as described below removes the need for O ring seals between the reagent/coolant ports and the housing sub-assembly since the connector ports and body of the housing sub-assembly are formed as a unitary piece. - As can be seen in
Figures 1 and2 a number of O ring seals are required to ensure a fluid tight seal at interfaces between thepump sub-assembly 12 andhousing sub-assembly 30 and between the various connectors and the housing. - In
Figure 1 , for example O ring seal 46 is provided to create a fluid-tight seal between thecollar 42 and theland 40 and O ring seal 60 is provided to seal theelectrical connector 58 in the drilling 56 (the O-ring 60 being provided in anannular groove 62 provided in the body of the housing sub-assembly). - In
Figure 2 , thereagent gallery 132 is sealed from the outside environment in the region of theneck portion 124 by two O ring seals (134, 136) and sealed from the mainhousing water chamber 122 via a thirdO ring seal 138, all of which are retained by suitable O ring grooves 140 moulded as part of thecoil over-moulding member 102. Afurther seal member 158 is provided between the coil former 108 andactuator core 104. - However, the pump assembly of
Figure 3 comprises ahousing sub-assembly 230 in which a number of components of the pump assembly have been incorporated into a single over-mouldedhousing sub-assembly component 230. In effect, in comparison toFigures 1 and2 , the pump sub-assembly has been "split in half" and components from the pump assembly have been moved into the housing sub-assembly. By subsequently over-moulding the components into place the need for the various O ring seals inFigures 1 and2 above is reduced. The overall size of the housing sub-assembly is thereby reduced in the embodiment ofFigures 3 and4 and the number of interfaces requiring a fluid tight seal is also reduced thereby improving the reliability of the pump assembly and improving the ease of assembly. - Referring to
Figure 3 , ahousing sub-assembly 230 is provided comprising anover-moulding member 230 which comprises amain body portion 232 and a number ofconnector ports Figure 3 theconnector ports main body 232 form a unitary piece such that the need for O ring seals at theconnector locations - The reagent inlet port 234 comprises a flow path 246 which is in fluid communication with a pumping zone 248 (also referred to herein as a pumping zone cavity) which is dimensioned to receive a pump sub-assembly. When the pump assembly has been assembled, the pumping zone comprises the following components: an actuator core (also referred to as pump core or inner pole piece), a plunger armature, a nozzle tube and nozzle delivery valves (not shown in
Figure 3 ) for delivery of reagent from the inlet port 234 to an exhaust flow (direction 250 inFigure 3 ) [these components may individually or in combination be referred to as the pump sub-assembly]. The flow path 246 passes through a non-magnetic back plate member 247 as described below. - Coolant inlet and
outlet ports main body 232 of thehousing sub-assembly 230 which cavity is dimensioned to receive aflow guide member 254. Theflow guide member 254 defines first 256 and second 258 volumes and, in use, coolant fluid may flow in viaport 236 and flow first through the first volume 256 and then via thesecond volume 258 in order to allow excess heat within the pump assembly to be extracted. Coolant fluid may then exit the assembly viaport 238. - The
main body 232 of thehousing sub-assembly 230 is also provided with afemale connection port 260 such that electrical cables can be connected via anelectrical connector 262. - Contained within the
housing sub-assembly 230 of the embodiment ofFigure 3 are a number of components that were located within the pump sub-assembly inFigure 2 . In particular, thehousing sub-assembly 230 ofFigure 3 comprises asolenoid coil 264, magnetic outer sleeve member 266 (also referred to herein as an outer sleeve), an outer pole piece 268 (also referred to herein as an outer pole member) and a back plate member 247, that is formed from a material with a low magnetic permeability. Thecoil 264 may be carried on a bobbin (not shown inFigure 3 ). As shown inFigure 3 the outer sleeve member 266 (which is formed from a material with a relatively high magnetic permeability) and the outer pole piece 268 (also formed from a material with a relatively high magnetic permeability) are actually asingle component member 270. It is to be appreciated however that thesleeve member 266 andpole piece 268 may be two separate components that are either attached to one another or held in proximity to one another by the over mouldedmain body 232 of thehousing sub-assembly 230. - Although the connections are not shown in
Figure 3 theelectrical connector 262 is connected through ahole 272 in theouter pole piece 268 to the ends of thesolenoid coil 264. - Once the housing sub-assembly has been assembled with a pump sub-assembly the
solenoid coil 264, magneticouter sleeve member 266 andouter pole piece 268 form part of the magnetic circuit that is used to drive the pumping plunger of the pump array. - Also shown in
Figure 3 is a pair of U shapedgrooves 274 in the outer surface of the main body of the housing sub-assembly. These are used during installation and assembly to receive a pair of O ring seals between the housing sub-assembly and a front piece portion of the pump assembly (not shown). The magneticouter sleeve 266 also incorporates a locatingface 276 and crimpfeature 278 for the pump core (not shown inFigure 3 ). It is noted that theouter pole piece 268 andouter sleeve 266 may be formed from a single deep drawncomponent 270, which incorporates the locatingface 276 and crimpfeature 278 for the pump core. Forming theouter pole piece 268 and magneticouter sleeve 266 via a deep draw process reduces material waste compared to a process where the components are formed by machining. -
Figure 4 shows theouter sleeve 266 andouter pole piece 268 in more detail. The sleeve and pole piece are formed as asingle component 270. Thecomponent 270 is generally cylindrical in shape and comprises a first,open end 280 through which thesolenoid coil 264 and bobbin may be loaded during assembly. Thesecond end 282 of the component comprises theouter pole piece 268. The outer pole piece incorporates abore 284 through which reagent may pass in use and also a machinedslot 272 through which electrical connections from thecoil 264 to theelectrical connector 262 may be made during the assembly process. - The outer surface of the
component 270 comprises a number of machined holes 286 (three of which are visible infigure 4 ).These holes are provided to improve the over moulding process as described below and also enable theouter pole piece 268 andsleeve 266 to be held securely in place within themain body 232 of the sub-assembly 230 once over-moulding has occurred. - The process of constructing the pump assembly according to
Figures 3 and4 is as follows. Awound coil 264 is introduced into anouter sleeve piece 266 andouter pole piece 268 component (270), thecomponent 270 having a firstopen end 280 and asecond end 282 with amachined orifice 284 and a machined slot 272 (shown inFigure 4 ). A backstop plate 247, having at least onedrilling 288 therethrough is provided at the second end of the component. - The ends of the wound coil are passed through the machined
slot 272 in thecomponent 270 and then connected (e.g. welded) with anelectrical connector 262. Thecoil 264,outer sleeve piece 266,outer pole piece 268, backstop plate 247 andelectrical connector 262 are then placed into an over-mould cavity and plastic resin is then introduced into the cavity in order to over mould themain body 232 of thehousing sub-assembly 230. - As part of the assembly process the coil may first be wound onto a coil former. A flow path forming member may also be provided within the over mould cavity in order to provide a flow path 246 from the reagent inlet 234 to a
pumping cavity 248 within theouter sleeve 266 andouter pole piece 268. Further flow path forming members may also be provided to define flow paths from coolant inlet/outlet 236/238 to aflow cavity 252 within themain body 232 of thehousing sub-assembly 230. The flow path forming members may comprise solid structures within the over-moulding cavity that are arranged to block over-mould from forming in certain areas of the over-moulding cavity. In this manner various passages and flow paths may be formed within the housing sub-assembly. - As described above in relation to
Figure 4 there are a number of machinedholes 286 in theouter sleeve piece 266. During the over moulding process plastic resin may flow through theseholes 286 into the volume defined within the oversleeve piece 266. After the resin sets there will therefore be a continuous formation of plastic over-moulding material that passes through each of these machinedholes 286. This aids retention of theouter sleeve piece 266 within themain body 232 of thehousing sub-assembly 230. - Further variations and modifications not explicitly described above may also be contemplated without departing from the scope of the invention as defined in the appended claims.
Claims (15)
- A housing sub-assembly for a pump assembly (230) for use in a selective catalytic reduction system, the housing sub-assembly comprising:a main body (232) having a pump axis (A), the main body comprising a pumping zone cavity (248) having a main axis substantially coincident with axis A, and comprising a flow guide cavity (252) disposed about axis A;an outer pole member (268) and a solenoid coil (264) disposed within the main body (232);wherein the main body further comprises a reagent inlet port (234) for receiving a reagent for supply to the pumping zone cavity (248) via a reagent flow path (246) and first and second coolant ports (236, 238) for supplying coolant to and removing coolant from the flow guide cavity (252);characterised in that the main body, first and second coolant ports and reagent inlet port are integrally formed as a single component (230).
- A housing sub-assembly as claimed in Claim 1, wherein the main body, first and second coolant ports and reagent inlet port comprise an over-moulding member, the over-moulding member having been formed over the coil (264) and outer pole member (268).
- A housing sub-assembly as claimed in Claim 2, wherein the over-moulding member is formed from plastic.
- A housing sub-assembly as claimed in any one of Claims 1 to 3, further comprising an outer sleeve (266), the outer sleeve being disposed within the main body (232) about axis A and the solenoid coil (264) being disposed within the outer sleeve (266).
- A housing sub-assembly as claimed in Claim 4, wherein the flow guide cavity (252) is defined in part by the main body (232) and by the outer sleeve (266).
- A housing sub-assembly as claimed in Claim 4 or Claim 5, wherein the outer sleeve (266) and outer pole member (268) are formed as a single component (270).
- A housing sub-assembly as claimed in any one of Claims 4 to 6, wherein the outer sleeve (266) and outer pole member (268) together form a substantially cylindrical component (270) comprising a first open end (280) and a substantially closed second end (282), the second end comprising a drilling (284) that aligns with one end of the reagent flow path (246) and the second end comprising a machined slot (272) for allowing electrical connection between the solenoid coil (264) and an electrical connector (262) to be made.
- A housing sub-assembly as claimed in Claim 7, wherein electrical connections between the solenoid coil (264) and the electrical connector (262) are routed through the main body (232) of the housing sub-assembly (230) and through the machined slot (272).
- A housing sub-assembly as claimed in Claim 7 or Claim 8, wherein the machined slot (272) is located off axis A.
- A housing sub-assembly as claimed in any preceding claim, wherein the pumping zone cavity (248) is dimensioned to receive a pump core.
- A housing sub-assembly as claimed in any preceding claim, further comprising a metallic back plate (247) having a drilling (288), the reagent flow path (246) being arranged to align with the drilling.
- A pump assembly for use in a selective catalytic reduction system comprising:a housing sub-assembly (230) according to any one of Claims 1 to 11 and a pump core, the pump core being located within the pumping zone cavity (248) of the housing sub-assembly.
- A method of manufacturing a pump assembly comprising manufacturing a housing sub-assembly (230) by:providing a blank disk member of a material having a relatively high magnetic permeability;deep drawing the blank disk member to form an outer pole piece, the outer pole piece defining an internal volume with an opening;inserting a solenoid coil (264) into the internal volume of the outer pole piece (268);pressing a back stop plate (247) into the outer pole piece (268), the back stop plate having at least one drilling (288) through the plate;injection moulding an over-mould member (230) to encapsulate the outer pole piece (268) and solenoid coil (264) and to form a main body (232) of the housing sub-assembly (230), the main body having a pump axis (A) and defining a pumping zone cavity having a main axis substantially coincident with axis A, and defining a flow guide cavity disposed about axis A ;forming a reagent inlet port (234) as part of the over-mould member;forming coolant ports (236, 238)as part of the over-mould member;forming a flow path (346) through the over-moulding member, the flow path aligning with the at least one drilling (288) in the back stop plate.
- A method as claimed in Claim 13, further comprising inserting an actuator pump core into the pumping zone cavity (248) defined by the main body of the housing sub-assembly.
- A method as claimed in Claim 13 or 14 further comprising inserting a coolant flow guide (254).
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP12189726.8A EP2725227B1 (en) | 2012-10-24 | 2012-10-24 | Pump assembly |
PCT/EP2013/068728 WO2014063859A1 (en) | 2012-10-24 | 2013-09-10 | Pump assembly |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP12189726.8A EP2725227B1 (en) | 2012-10-24 | 2012-10-24 | Pump assembly |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2725227A1 EP2725227A1 (en) | 2014-04-30 |
EP2725227B1 true EP2725227B1 (en) | 2015-05-20 |
Family
ID=47143561
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP12189726.8A Active EP2725227B1 (en) | 2012-10-24 | 2012-10-24 | Pump assembly |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP2725227B1 (en) |
WO (1) | WO2014063859A1 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2555115B (en) * | 2016-10-18 | 2020-05-20 | Delphi Tech Ip Ltd | Selective catalytic reduction doser with an electrical adapter |
JP6954102B2 (en) | 2017-12-25 | 2021-10-27 | 株式会社デンソー | Additive injection valve cooling device and cooling system |
JP6954101B2 (en) | 2017-12-25 | 2021-10-27 | 株式会社デンソー | Cooling device for additive injection valve |
JP6954103B2 (en) | 2017-12-25 | 2021-10-27 | 株式会社デンソー | Cooling device for additive injection valve |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE19542914C2 (en) * | 1994-12-23 | 1997-09-18 | Keller Kg Wilhelm | Electromagnetic vibrating piston pump and method for producing a vibrating piston pump |
DE10305812A1 (en) * | 2003-02-12 | 2004-09-02 | DMT GmbH Feinwerktechnische Komplettlösungen | High pressure cleaning unit, to deliver a fluid, has a high pressure liquid-cooled pump embedded in a filling material in a housing fitted with supply lines |
DE102005039772A1 (en) * | 2005-08-22 | 2007-03-08 | Prominent Dosiertechnik Gmbh | solenoid |
US20070224058A1 (en) * | 2006-03-24 | 2007-09-27 | Ingersoll-Rand Company | Linear compressor assembly |
ATE512300T1 (en) | 2006-07-12 | 2011-06-15 | Delphi Tech Holding Sarl | DOSING PUMP FOR A REDUCING AGENT |
DE102006060147B4 (en) * | 2006-12-18 | 2009-05-14 | Andreas Hofer Hochdrucktechnik Gmbh | Fluid-working machine |
GB2460825A (en) | 2008-06-06 | 2009-12-16 | Delphi Tech Inc | Reagent dosing system |
GB201105884D0 (en) * | 2011-04-07 | 2011-05-18 | Delphi Tech Holding Sarl | Reagent dosing connector arrangement |
-
2012
- 2012-10-24 EP EP12189726.8A patent/EP2725227B1/en active Active
-
2013
- 2013-09-10 WO PCT/EP2013/068728 patent/WO2014063859A1/en active Application Filing
Also Published As
Publication number | Publication date |
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EP2725227A1 (en) | 2014-04-30 |
WO2014063859A1 (en) | 2014-05-01 |
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