Investigation into the Internal Flow Characteristics of an Axial-Flux Canned Motor Pump

Canned motor pumps are widely utilized due to their distinct advantage of a completely leakage-free structure. Among them, an integrated impeller–rotor configuration is employed in the axial-flux canned motor pump, resulting in a shorter axial length and higher power density. This novel configuration allows for easy integration into space-constrained systems, such as electric vehicles, aerospace applications, and liquid-cooled servers. However, research on the internal flow characteristics of these pumps remains scarce. To address this gap, the present study investigates the internal flow across various flow rates. Numerical simulations are validated against experimental data. The average error remains below 2%. The pump achieves a peak efficiency of 68.6% at the design condition, but experiences efficiency drops of 15.0 and 25.2 percentage points under 0.5Qd and 1.5Qd, respectively. Results demonstrate that flow rates significantly govern internal characteristics. These include pressure, velocity, and entropy distributions, along with vortex structures and pressure fluctuations. Notably, operating at off-design conditions can intensify the internal pressure fluctuations by up to a factor of 29.4. Entropy analysis identifies major losses on blade suction sides and diffusers. These findings provide crucial hydrodynamic guidelines for low-noise thermal management systems in electric vehicles and ensuring high-reliability cooling loops in aerospace and liquid-cooled servers.