DESC:FIELD OF THE INVENTION

The present disclosure relates generally to water pumps. More particularly, the present disclosure relates to an improved submersible pump-set for underwater use for supply of water with constant water flow at defined voltage range.

BACKGROUND OF THE INVENTION

A submersible pump is a versatile tool for underwater use for supply of water and differs from an ordinary pump in that a submersible pump is designed for use underwater.

Existing submersible pump set runs on induction motor technology having additional rotor copper loss which reduces the efficiency of such pumps. Further, the induction motor performance in such pumps varies with voltage variation i.e. for lower voltage, pump usually deliver less water flow (2,3) as follows:

…….. (2)
……….. (3)

The present disclosure proposes an improved submersible pump-set wherein even if the rotor is rotating at synchronous speed, rotor copper losses are ensured to be zero which results into increase in efficiency as follows:

…… (Speed remains same at defined voltage)
…….. (Output power remains the same as speed remains same).

Thus, it is intended to provide an improved submersible pump-set for underwater use and a process(s) relating to same addressing the foregoing shortcomings.

OBJECTS OF THE INVENTION

It is a primary object of the present disclosure to provide an improved submersible pump-set for underwater use for the supply of water with constant water flow at defined voltage range overcoming the shortcomings of the existing pump sets. The rotor copper losses are ensured to be zero which results in the increase in efficiency.

Another object of the present disclosure is to provide an improved submersible pump-set having an improved rotor assembly design including rotor lamination, slot profile and magnetic shaft. With the improved rotor assembly design, the submersible pump set of the present disclosure ensures delivery of constant water flow at defined voltage range with higher efficiency.

An additional object of the subject invention is to provide an improved submersible pump-set which ensures constant water flow at defined voltage band.

Still a further object of the subject invention is to provide an improved submersible pump-set which increases overall pump set efficiency as well as saves electrical energy/consumption.

It is another object of the subject invention to provide an improved submersible pump-set which increases the overall efficiency of the pump set enabling cost reduction including reduction in the product cost as well as operating cost.

SUMMARY OF THE INVENTION

According to an aspect of the present disclosure, an improved submersible pump-set for underwater use for supply of water with constant water flow at defined voltage range is provided comprising: a motor including a stator; a rotor assembly; a common casing housing the motor including the stator and the rotor assembly; a power supply connected to the motor to commutate and control the speed and torque of the motor during operation of the submersible pump-set. The rotor assembly comprises a rotor packet, an axial shaft having opposite ends being integral therewith and a pair of balancing rings. Each of the balancing rings includes central opening being in alignment with the opposite ends of the axial shaft. The rotor packet includes openings at opposite ends forming an inner housing wherein the opposite ends of the rotor packet provided with end rings.

The rotor packet including a plurality of rotor laminations, wherein the rotor laminations comprising a plurality of rotor slots. The rotor slots filled with aluminum cage which provide starting torque to rotate rotor assembly from zero speed to synchronous speed.

The submersible pump-set is a combination of motor and pump where motor acts as prime mover and pump delivers the water flow. Overall efficiency of pump-set depends upon motor efficiency and pump efficiency. To increase overall efficiency either it is necessary to enhance motor efficiency or pump efficiency.

In existing induction motor technology, rotor loss is the main component of power loss which decreases motor efficiency. The present disclosure primarily focusses on improving motor efficiency with zero rotor losses ensuring constant power flow at defined voltage range.

The improved submersible pump-set of the present disclosure is a rotating equipment vertical in construction which works on the principle of synchronous reluctance torque. The submersible pump-set of the present disclosure is configured to operate on grid supply such that the stator winding creates rotating magnetic field, and which ensures to follow low reluctance path due to the innovative rotor assembly design which in turn produces reluctance torque ensuring the rotor to catch a synchronous speed. Other alternative methods are induction principle, permanent magnet synchronous motor with drive, brushless DC motor with drive.

According to another aspect, the present disclosure relates to an improved rotor pocketing process flow. The method of construction of the rotor packet comprising the step of die casting wherein aluminum alloys for die casting are melted in a furnace and then injected into the dies forming the rotor packet by a die casting machine. The method including the step of inserting one or more magnets in the rotor pocket.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:

The foregoing and other objects, features, and advantages of the invention will be apparent from the following description taken in conjunction with the accompanying drawings, wherein:

Fig. 1 illustrates an exploded view of the submersible pump-set of the present disclosure;

Fig. 2 illustrates an exploded view of the rotor assembly of the submersible pump-set of the present disclosure;

Fig. 3 illustrates a side view of the die casted rotor packet of the submersible pump-set of the present disclosure;

Fig. 4 illustrates a cross-section of the rotor lamination of the rotor pack of the present disclosure;

Figs. 5A & 5B illustrate a cross-sectional side and top view respectively of the balancing ring of the present disclosure;

Fig. 6 illustrates a flow diagram of a contemporary rotor pocketing process flow;

Fig. 7 illustrates a flow diagram of rotor pocketing process flow according to the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the presently disclosed disclosure will now be described in detail with reference to the drawings wherein like reference numerals designate identical or corresponding elements. In the drawings and in the description, the term "proximal", "bottom", "down" or "lower" refers to a location on the device that is closest to a user holding the device and/or any part thereof. Conversely, the term "distal", "top", "up" or "upper" refers to a location on the device that is farthest from the user holding the device and/or any part thereof.

As used herein, the terms first, second, third, etc. are understood to describe different structures/elements so as to distinguish one from another. However, the terms are not structurally limiting unless the context indicates otherwise.

Moreover, the Figures may show simplified or partial views, and the dimensions of elements in the Figures may be exaggerated or otherwise not in proportion for clarity. In addition, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a terminal includes reference to one or more terminals. In addition, where reference is made to a list of elements (e.g., elements a, b, c), such reference is intended to include any one of the listed elements by itself, any combination of less than all of the listed elements, and/or a combination of all of the listed elements.

The present disclosure relates to an improved submersible pump-set for underwater use for supply of water with constant water flow at defined voltage range.

Referring to Fig. 1, which illustrates an exploded view of a submersible motor 10 comprising a stator 12 and a rotor assembly 18 of the present disclosure. The motor 10 including the stator 12 is mounted on the rotor assembly 18. A common casing 14 houses the motor including the stator 12 and the rotor assembly 18. A power supply connector 16 connected to the motor to commutate and control the speed and torque of the motor during operation of the submersible motor 10.

Referring to Fig. 2, an exploded view of the rotor assembly 18 of the present disclosure is illustrated. The rotor assembly 18 comprises a rotor packet 20, an axial shaft 22 having opposite ends being integral therewith, a pair of balancing rings 26. Each of the balancing rings 26 includes central opening 28 being in alignment with the opposite ends of the axial shaft 22. Once assembled, the opposite ends of the axial shaft 22 pass through said central openings 28 of the rings 26.

Referring now to Fig. 3, it illustrates a side view of the rotor packet 20 of the submersible motor 10 of the present disclosure. The rotor packet 20 includes openings at opposite ends forming an inner housing 30. The rotor packet 20 is covered with epoxy resin sealant from top and bottom side of the openings to avoid the water entry into the housing 30 and, thus protecting the rotor laminations 34 from corrosion. The axial shaft 22 as shown in Fig. 2 is received within the inner housing 30 of the rotor packet 32. The opposite ends of the rotor packet 32 provided with end rings 32. The end rings 32 together with the epoxy resin prevents the entry of entry into the housing 30. The end rings 32 of the rotor packet 20 provides power supply path between rotor bars provided therein. It is to be understood that the sealant is not limited to epoxy resin sealant and may include other sealants such as silicone sealants, acrylic sealants, urethane sealants, polyurethane sealants, phenolic sealants and/or a combination thereof.

Referring to Fig. 4, it illustrates a cross-section of a rotor lamination 34 of the rotor packet 20 of the submersible pump-set 10 of the present disclosure. The rotor packet 20 includes a plurality of rotor laminations 34 in a stack arrangement. The rotor lamination 34 comprises a plurality of rotor slots 36. Electrical steel is used for the construction of rotor lamination 34. The unique design of rotor lamination 34 provides reluctance torque to motor. Rotor slots 36 are filled with aluminum cage which provide starting torque to rotate rotor assembly 18 from zero speed to synchronous speed.

Referring now to Figs. 5A & 5B, a cross-sectional side view and top view respectively of the balancing rings 26 having central openings 28 are illustrated. The balancing rings 26 help hold the axial shaft 22 within the rotor packet 20. The balancing ring 26 comprises a top 40 and a bottom surface 42 being integral therewith. The top surface 40 extends vertically from the bottom surface 42 and has a profile providing a corrosion free and seal proof interaction once the balancing ring 26 is received over the rotor packet 20. The bottom surface 42 comprises a portion extending horizontally in an area of end portion of the balancing ring 26. Rotor assembly 18 is kept in balance by one or more means for example, by drilling to balancing ring 26. In some examples, such drilling is done on the portion extending horizontally in the bottom surface 42 of the balancing ring. 26 The extended top surface 40 of the balancing ring 26 is configured to support the axial shaft 22 in position in a press-fit manner. In some examples, the balancing rings 26 are flame and waterproof protecting the rotor assembly 18 from ingress of water or moisture.

In existing induction motor technology as illustrated in Fig. 6 copper rotor bar is used to increase overall efficiency. The process of copper bar making, insertion in rotor lamination and end ring breezing operation to construct a final rotor packet is a time taking process requiring extra manpower. As opposed to such a process, in the current disclosure as shown in Fig. 7, an aluminium die casting process is used which is less time consuming. Referring to Fig. 7, the method of construction of the rotor packet comprises die casting wherein aluminum alloys for die casting are melted in a furnace and then injected into the dies forming the rotor packet by a die casting machine. Once the liquid aluminum is injected into the dies, it goes into and rapidly cools and solidifies into the final cast part forming the rotor packet. One or more magnets may be inserted if required in the rotor pocket.

From the foregoing description, it will be appreciated that and the improved submersible pump-set for underwater use for supply of water with constant water flow at defined voltage range of the present invention represents a significant improvement over the prior art. While preferred embodiment(s) of the improved submersible pump-set and the process for manufacturing the same has been disclosed, it should be further appreciated that modifications may be made without departing from the scope of the present invention. In addition, while various features and components have been disclosed in an exemplary fashion, various other features and components may be employed. It is intended by the foregoing to cover these and any other departures from these disclosed embodiments which fall within the true spirit of this invention.

Thus, it is intended that the scope of the present invention herein disclosed should not be limited by disclosed embodiments described above but should be determined only by a fair reading of the appended claims.

List of reference numerals:

10 submersible motor
12 motor including a stator
14 casing
16 power supply/power connection
18 rotor assembly
20 rotor packet
22 shaft
26 balancing ring(s)
28 central opening(s)
30 inner housing
32 end rings
34 rotor lamination
36 rotor slots
40 top surface
42 bottom surface
,CLAIMS:WE CLAIM:

1. A submersible pump-set for underwater use for supply of water with constant water flow at defined voltage range comprising:
a motor (10) including a stator (12);
a rotor assembly (18);
a common casing (14) housing the motor (10) including the stator (12) and the rotor assembly (18);
a power supply (16) connected to the motor (10) to commutate and control the speed and torque of the motor (10) during operation of the submersible pump-set.

2. The submersible pump-set as claimed in claim 1, wherein the rotor assembly (18) comprises a rotor packet (20), an axial shaft (22) having opposite ends being integral therewith and a pair of balancing rings (26).

3. The submersible pump-set as claimed in claim 2, wherein each of the balancing rings (26) includes central opening (28) being in alignment with the opposite ends of the axial shaft (22).

4. The submersible pump-set as claimed in claim 2, wherein the rotor packet (20) includes openings at opposite ends forming an inner housing (30).

5. The submersible pump-set as claimed in claim 4, wherein the opposite ends of the rotor packet (32) provided with end rings (32).

6. The submersible pump-set as claimed in claim 2, wherein the rotor packet (20) including a plurality of rotor laminations (34).

7. The submersible pump-set as claimed in claim 6, wherein the rotor laminations (20) comprising a plurality of rotor slots (36).

8. The submersible pump-set as claimed in claim 6, wherein rotor slots (36) filled with aluminum cage which provide starting torque to rotate rotor assembly (18) from zero speed to synchronous speed.
9. The submersible pump-set as claimed in claim 2, wherein the balancing ring (26) comprises a top (40) and a bottom surface (42) being integral therewith wherein the top surface (40) extends vertically from the bottom surface (42) and has a profile providing a corrosion free and seal proof interaction.

10. The submersible pump-set as claimed in claim 9, wherein the bottom surface (42) comprises a portion extending horizontally in an area of end portion of the balancing ring (26).

11. A method of construction of the rotor packet comprising the step of die casting wherein aluminum alloys for die casting are melted in a furnace and then injected into the dies forming the rotor packet by a die casting machine.

12. The method of claim 11, including the step of inserting one or more magnets in the rotor pocket.