Water pump manufacturers growing with flow of new technologies

Even if the internal combustion engine eventually goes the way of the horse and buggy, expect water pumps to remain circulating as a fluid and competitive fluid category.

GMB reports that the firm’s engineers are actively going with the flow of the latest in automaker designs by developing specialized electrical water pumps for hybrid, all-electric and fuel cell propulsion technologies in addition to pumping up its line of mechanical OEM and aftermarket units.

Forward-looking electrically powered cooling systems are continually being enhanced to overcome proportional dependence based solely on an engine’s rpm cycles. Just control of coolant volume on demand is not mechanically possible when applied to unconventional powerplants, according to the company's website. It may either overcool or undercool.

“By cooling the engine precisely and only as required, electronic coolant pumps reduce fuel consumption with the additional benefit of curbing friction losses and emissions,” says YH Park, president and CEO of Halla Visteon Climate Control (HVCC).

Along with facilitating start/stop applications, “the pumps support a wide range of next-generation thermal management systems where an engine belt may not be available, including cooling of batteries, DC/DC converters and power electronics,” he says. “The onboard electronics deliver precise, variable flow control and respond rapidly to provide engine cooling and cabin comfort, especially at cold start.”

Among other components, HVCC is supplying coolant heaters and high-voltage cooling modules for Hyundai’s fuel cell-powered Tucson compact crossover SUV.

Surging product releases

“The water pump category faces many of the same opportunities and challenges as other aftermarket product categories,” observes FMI Automotive CEO John Wall, “including parts proliferation, an increased focus on import nameplate applications, and the importance of fit, form and function.”

“The name of the game in this market is to come out with the newest part numbers,” says Alfred Cardoza, North American sales director for US Motor Works. “Any manufacturer that develops new product faster has an edge on the competition and controls that small portion of the market for a relatively short period of time.”

And while BMW is applying electric water pumps to about 95 percent of its vehicles, replacement units have yet to generate hot demand, according to Cardoza. “The majority of the market is still mechanical water pumps, and I don’t think that’s going anywhere for a while,” he says. “As long as there are internal combustion engines mechanical water pumps will remain the norm.”

Of the nearly 1,200 water pump SKUs currently available in the U.S., only about 15 SKUs are electric, says Cardoza.

“For hybrids there may be a main pump – mechanical – for the internal combustion engine and two or three more electrical backup pumps for the electrical portion of the vehicle. There are other vehicles that are non-hybrids but use a main pump and an electric backup pump,” he says. “There are a few companies that make conversion high performance electric pumps for muscle cars that run on 12 volts and take load away from the engine.”

Water pump housings have evolved from cast iron to aluminum and stamped steel, and differing materials are also being applied to manufacture the impellers. The makeup of water pump seals is also changing, and most newer systems have weep-hole reservoirs to capture the coolant, Cardoza points out, adding that some models have accessories such as thermostats, pulleys and tensioners directly mounted onto the water pump housing.

In October US Motor Works was selected to supply water pumps for the new ultra-high mileage vehicle being brought to market by Elio Motors.

Manufactured in Shreveport, La., in a 4.1-million square-foot facility previously owned by General Motors, “the three-wheeled Elio is engineered to attain a highway mileage rating of up to 84 mpg while providing the comfort of amenities such as power windows, power door locks and air conditioning accompanied by the safety of multiple air bags and an aerodynamic, enclosed vehicle body,” says an impressed Cardoza. “I’m thinking of buying one because it’s such a novelty.”

Due to hit the road next year, the Elio is scheduled to carry a $6,800 price tag. As of November, more than 35,000 adventurous motorists have made reservations for the vehicle.

Beating overheating

As for repairing a more traditional water pump assembly, “it is just another replacement job,” Cardoza says. “The difficulty is more on the diagnostic portion of the job. Most mechanics may not be equipped to properly diagnose the vehicle.”

Enter Water Pump U, an online resource posted by Airtex and ASC Industries. “Technicians, counterpeople and do-it-yourselfers now have a one-stop shop to learn about ‘everything’ water pump-related,” says Brandon Kight, director of marketing and program development.

The company’s free American-based technical support telephone line is augmented by the website’s real-time education assistance, technical bulletins and continuous customer service for water pump replacement. “You can also use your smartphone or tablet to visit the Water Pump U mobile site for on-demand access to technical resources such as installation instructions, interactive diagnostics and a comprehensive product catalog,” Kight reports.

“The site was created in response to the void in comprehensive information about today’s complex cooling systems, leading to misdiagnosis and overall difficulty during repair work,” he explains, noting that the goal is to “keep up with the evolving technology and alleviate these pain points. We felt it was important to share that knowledge and provide a place where technicians, counterpeople and DIYers can go to get the answers they need when they need it.”

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