Claims:We claim
1. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit, mainly consists of a motor assembly, a pump assembly and an inverter drive assembly
wherein the motor assembly consist of a cylindrical stator assembly containing a stack of stator laminations (1) concentrically positioned within inner diameter of the stator assembly, an electrically insulated stator winding (2) housed in a plurality of stator slot (3), a cylindrical rotor assembly separated by an air gap (5) and concentrically positioned within inner diameter of the stack of stator laminations (1) consist of a rotor core (6) and a plurality of permanent magnet (7) mount in a magnet retaining hollows, a cylindrical motor enclosure (16) rest on a foot base (28) and safeguarded with an enclosure end covers (16a, 16b);
wherein the pump assembly consists of an impeller (9) concentrically positioned in a rotor hub enclosed between a suction stage casing (13) with built-in an inlet port (17) and a discharge stage casing (14) with built-in an outlet port (20), including plurality of an impeller spoke (11) aligned between an impeller hub (12) and a finished annular rim (10), with built-in a single shaft (8) collectively rotating along axis (AA’) and a suction inlet (15) and a discharge outlet (18) built-in the a motor enclosure (16a, 16) respectively;
wherein the inverter drive assembly consists of an inverter drive (26) mounted inside the motor enclosure (16) using fasteners (27).

2. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the stator assembly containing the stack of stator laminations (1) and the stator winding (2) is completely insulation encapsulated and fully watertight with components of epoxy.

3. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the rotor core (6) consists of the plurality of interior mounted permanent magnet (7).

4. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the impeller (9) is concentrically positioned in rotor hub and supported through the built-in common single shaft (8).

5. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said plurality of the impeller spoke (11) are aligned between the impeller hub (12) and the finished annular rim (10) and axially spaced over the impeller hub (12) circumference.

6. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the impeller (9) is positioned in the rotor hub such that inner circumference of the rotor core (6) and outer circumference of the finished annular rim (10) are braced for the seamless rotation of the impeller (9) with rotor assembly.

7. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the priming chamber (22) formed between the suction side motor enclosure end cover (16a) and the suction stage casing (13), filled with surround water, self-primes the pump when the impeller (9) rotates with the rotor assembly.

8. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said an inlet port (17) built-in the suction stage casing (13) pulls the surrounding water with the rotation of impeller (9) positioned in the rotor hub and pushes to circular the side channel (19) stretched around the inner side of discharge stage casing (14), ended to the outlet port (20) with reducing cross-section.

9. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the shaft (8), built-in with the impeller (9) is supported between the suction stage casing (13) and the discharge stage casing (14) through the annular metal counter (24a, 24b) for rotational movement.

10. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the suction inlet (15) fitted with a strainer (23) to prevent large particles and debris from entering into the pump and the discharge outlet (18) with connecting thread for an external pipeline are built-in the motor enclosure (16a, 16) respectively.

11. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the inverter drive (26) is sensorless vector control variable frequency drive that controls the optimum water flow near the duty point and regulates the speed based on supply voltage.

12. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the inverter drive (26) is completely insulation encapsulated and fully watertight with components of epoxy.

13. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the inverter drive assembly is mounted inside the motor enclosure (16) using the fasteners (27) and covered with motor enclosure (16b).

14. An inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit as claimed in claim 1, wherein said the motor assembly and the inverter drive assembly are completely immersed in same surrounding water propelled by the pump assembly.
, Description:FORM 2
THE PATENT ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)

1. TITLE OF THE INVENTION
Novel Electrical Motor Integrated Water Submerged Side Channel Self-priming Pump.

2. APPLICANT (S)
APPLICANT (S)
NAME NATIONALITY COUNTRY OF
RESIDENCE ADDRESS
Konmos Technologies Private Limited INDIA INDIA 401, Ambit, 1, Krishnapark Society,
Pushkar Dham Road,
Rajkot - 360005
Gujarat (INDIA)

PREMABLE TO THE DESCRIPTION
The following specification particularly describes the nature of the invention and the manner in which it is to be performed.

FIELD OF INVENTION
The present invention of novel inverter drive controlled permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit used for lifting the water including but not limited to industrial, agricultural and domestic application.
BACKGROUND OF INVENTION
Side channel self-priming water pump finds its application to lift water from underground storage tank or drain waste water from pool or transfer water from one storage to another storage. Induction motor coupled side channel self-priming water pump unit with distinct flow rate and head available for use experiences the performance combat such as low efficiency, high temperature rise, optimum flow rate control near to duty point, failure due to dry run and manufacturing challenges such as large size, shaft seal mechanism and large number of motor-pump coupling components. Present invention relates to novel electrical motor operated side channel self-priming pump unit. Specifically, permanent magnet synchronous motor operated, inverter drive controlled water submerged side channel self-priming pump unit.
The present invention substitutes the conventional induction motor by permanent magnet synchronous motor coupled to water submerged side channel self-priming pump and completely modifies the pump assembly arrangement. The impeller of present invention is positioned at permanent magnet synchronous motor rotor hub and pump suction inlet and discharge outlet are accommodated in motor enclosure. An innovative permanent magnet synchronous motor run water submerged side channel self-priming pump makes it possible to increase the efficiency, reduce the size of complete motor and pump unit, remove the shaft seal and shrink the number of coupling arrangement components without intervening the performance.
Permanent magnet synchronous motor stator winding accommodated in stator slots are arranged same as induction motor stator winding. However stator winding conductors of permanent magnet synchronous motor are enameled copper wire coated with thin layer of insulation and no added insulation covering for water resistance. Stator winding and core are encapsulated with epoxy insulation that brings excellent waterproofing and superior mechanical strength to entire stator assembly where as conventional induction motor coupled to water submerged pumps are provided with additional conductor and slot insulation for water proofing.
Further objective of the invention is to reduce the input power consumption of electrical motor run water submerged side channel self-priming pump for specific flow rate and head. Accustomed low speed induction motor run pump impeller is of large size and consumes more electrical power for required flow rate and head. When this low speed impeller is used for high speed permanent magnet synchronous motor run pump, an unaltered diameter and amplified speed of impeller increases the flow rate, head and shaft power. On the other hand at amplified pump speed for fixed flow rate and head, impeller diameter and shaft power reduces at great extent.
An added objective of the invention is to modify water submerged side channel self-priming pump assembly and coupling arrangement with no negotiation in performance. Impeller positioned at permanent magnet synchronous motor rotor hub with integral spokes axially spaced over the impeller hub periphery is supported through built-in common rotating shaft. Straight radial spokes attached with impeller hub and ended to finished annular rim are surrounded through suction stage casing and discharge stage casing at circumference and edges. When rotor of permanent magnet synchronous motor rotates, whole impeller assembly rotates along with shaft and pulls water inside the pump through inlet port accommodated in suction stage casing. Water is further flowed to the side channel accommodated in discharge stage casing because of centrifugal force. A curved contour from outer edge to inner edge formed in side channel, transfers the water until it again expedited by impeller spokes. The rotating impeller creates several regenerative moves of water until it reaches the outlet port housed in discharge stage casing. Shaft attached to suction stage casing and discharge stage casing through counter completely eliminates coupling between electrical motor and pump by consequently removing shaft cover, shaft seals, bracket, bearing and flange.
Another objective of the invention is to operate permanent magnet synchronous motor through high frequency inverter drive that makes it possible to increase the speed of motor with more number of pole by reducing the size of motor. Voltage and frequency control through inverter drive runs the water submerged side channel self-priming pump near to duty point to acquire optimum flow and head. Supply voltage based speed regulation prevents pump failure because of voltage fluctuation specifically in rural areas. Furthermore inbuilt protections against overload, short circuit, under voltage, over voltage, temperature rise and motor stall safeguards the pump from failure. Completely epoxy encapsulated inverter drive mounted inside the motor enclosure after discharge outlet is shielded by drive housing.
OBJECT OF INVENTION
A comprehensive purpose of the invention is to make available high efficient inverter drive controlled permanent magnet synchronous motor run water submerged side channel self-priming pump.
Usually stator conductors of induction motor integrated with side channel self-priming pump are finished off with an insulating varnish or paper or cotton or rubber whereas stator conductors of permanent magnet synchronous motor of present invention are enameled copper wire coated with thin layer of insulation. Along with this, no added insulation for water resistance on stator conductors of permanent magnet synchronous motor is provided whereas conventionally additional polypropylene insulation covering on stator conductors for water resistance is required when integrated with water submerged pump. Enameled stator conductors without additional insulation for water resistance in present invention increases the slot fill factor by way of permitting more conductor per slot. As a consequence of increased slot fill factor, optimum amount of conductor material is housed in stator slot that maximizes the torque and reduces the size of motor for definite output.
Output of electrical motor is governed by the product of peripheral speed and volume of active parts of motor, it becomes hand holding limitation when implemented for pump. Inverter drive controlled permanent magnet synchronous motor integrated with water submerged side channel self-priming pump of present invention runs at high speed that consequently reduces volume of active parts compared to conventional induction motor. Curtailed volume of active part calls for less active conductor material and magnetic material and subsequently less copper loss and iron loss of the motor.
Permanent magnet synchronous motor uses permanent magnets inserted in rotor core to produce magnetic field that completely disposes of the requisite of rotor copper conductor and hence rotor copper loss, on the other hand conventional induction motor uses rotor copper conductors housed in slots to produce magnetic field that contributes to rotor copper loss. Moreover, zero relative speed between stator magnetic field and rotor magnetic field of permanent magnet synchronous motor leads to zero slip and rotor frequency resulting in zero hysteresis and eddy current loss in rotor whereas induction motor suffers from added hysteresis and eddy current loss in rotor due to non-zero slip and rotor frequency.
Inverter drive operated permanent magnet synchronous motor integrated with water submerged side channel self-priming pump is developed for large number of pole to get small pole pitch and short mean turn length of stator conductor in overhang section. Curtailed overhang decreases the proportion of inactive copper to active copper of stator winding and stator copper loss. Shorten overhang consequently reduces additional support assembly required to strengthen extended overhang against high dynamic stress during motor operation.
Permanent magnet synchronous motor integrated with water submerged side channel self-priming pump adopts interior permanent magnet type rotor that disposes of the gluing of magnet on rotor surface and allows to further increase motor speed in the context of centrifugal force. Moreover, interior permanent magnet arrangement uses reluctance torque and magnetic torque that develops maximum torque per ampere and reduces size of motor. Usage of rare earth permanent magnet material makes it possible to develop high power density motor with more output on same volume.
Induction motor cannot be developed above certain speed due to the acute constrain of number of pole and hence pump impeller too. Usually low speed impeller with large diameter results in bulky pump unit for desired flow rate and head. Permanent magnet synchronous motor run water submerged side channel self-priming pump of present invention is developed for high speed that enables small impeller diameter for same shaft power, flow rate and head. In another words, impeller of induction motor run pump when used for permanent magnet synchronous motor run pump, unchanged diameter and increased speed of impeller increases shaft power, flow rate and head remarkably.
Manufacturing practice is to couple driving side end of induction motor with impeller through weighty bracket to tighten the shaft and to reduce the misalignment at coupling. This invention completely eliminates the bracket assembly as impeller is housed in permanent magnet synchronous motor rotor hub and supported through built-in common rotating shaft. Conventional induction motor run side channel self-priming pump contains shaft seal that prevents the water leakage at coupling and surrounding water seepage inside motor body whereas existing water submerged side channel self-priming pump pulls the water through suction inlet and moves to discharge outlet via impeller housed in rotor hub that completely immerses the permanent magnet synchronous motor with water and eliminates shaft seal arrangement.
Customary induction motor run side channel self-priming pump consists of bulky built-in priming chamber between suction inlet and suction stage casing filled with surrounding water in order to self-prime the pump by recirculating the water within pump on initial cycle and to pressurize the water before entering to inlet port. Along with that priming chamber is intended to house built-in suction flange that makes it more heavy weight and large in size whereas in present invention permanent magnet synchronous motor enclosure end cover functions as suction inlet with built-in strainer over its front periphery. Priming chamber is formed between suction side enclosure end cover and suction stage casing. Moreover permanent magnet synchronous motor enclosure at other end with built-in discharge outlet over its top periphery eliminates base plate usually affixed with induction motor run pump.
Induction motor driven side channel self-priming pump always suffers from motor insulation failure due to temperature rise. An industrial practice is to develop forced air cooled motor for pump integration whereas present permanent magnet synchronous motor and side channel self-priming pump are completely submerged in water that absolutely wipes out the temperature rise concern of electrical motor and excludes prerequisite of forced air cooling when integrated with pump.
Permanent magnet synchronous motor integrated water submerged side channel self-priming pump of this invention is cost effective and industry applicable due to high efficiency, low temperature rise, optimum flow and head near to duty point, compact size, shaft seal less arrangement and limited coupling components.
STATEMENT OF INVENTION
Sensorless vector controlled inverter drive operated permanent magnet synchronous motor integrated water submerged side channel self-priming pump consist of fully insulation encapsulated motor stator assembly, impeller housed in motor rotor hub, suction inlet and discharge outlet integrated with motor enclosure, short motor stake length, small impeller dimensions, shaft seal less arrangement and limited coupling components . High speed, zero rotor copper loss, minimum stator copper loss and mechanical transmission loss, optimum flow and head near to duty point, more pump shaft power makes it possible to increase the efficiency and reduce the size of complete unit.
SUMMARY OF INVENTION
An aspiration of the invention is to develop high speed, compact, efficient and shaft seal less inverter drive operated permanent magnet synchronous motor integrated water submerged side channel self-priming pump for optimum flow and head near to duty point.
Present invention holds a completely operational permanent magnet synchronous motor integrated water submerged side channel self-priming pump with insulation encapsulated stator assembly arranged at outside periphery, rotor inside the cylindrical stator, pump impeller on rotor hub, impeller spokes surrounded through suction stage casing and discharge stage casing at circumference as well as at sides and supported through built-in shaft on impeller hub, suction inlet and discharge outlet in motor enclosure.
Sensorless vector control inverter drive operation of permanent magnet synchronous motor makes possible to develop it for high speed with large number of pole resulting in short motor stack length and stator winding overhang, small impeller dimensions, optimum flow and head near to duty point, more pump shaft power, elevated efficiency, low temperature rise and compact size.
Impeller housed in rotor hub pulls the water inside directly form inlet port accommodated in suction stage casing and pumped to outlet port accommodated in discharge stage casing that eliminates coupling between electrical motor and pump through shaft, bracket, shaft seal and bearing. Improved motor enclosure with built-in suction inlet and discharge outlet submerges the motor and pump assembly in the water.
BRIEF DESCRIPTION OF DRAWING
The structure and the technical means adopted by the present invention to achieve the above and other objects that can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings,
FIG. 1 is an exploded view of permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit containing motor assembly, pump assembly and inverter drive assembly.
FIG. 2 is a sectional view of permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit containing motor assembly, pump assembly and inverter drive assembly.
FIG. 3 is a perspective view of permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit containing motor assembly, pump assembly and inverter drive assembly.
DETAILED DESCRIPTION OF THE INVENTION
Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompanying drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.
According to present invention permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit consist of a motor assembly, pump assembly and inverter drive assembly.
Said motor assembly consists of cylindrical stator assembly that includes stack of stator laminations (1) and stator winding (2) accommodated along stator assembly inner diameter. Electrically insulated stator winding (2) housed in plurality of stator slot (3) consists of enameled copper conductors (not shown) coated with thin insulation layer results in increased slot fill factor which subsequently accommodates more copper conductor in stator slot (3) and shorten the stator winding (2) overhang (4). Complete stack of stator laminations (1), stator winding (2) and plurality of stator slot (3) are encapsulate with epoxy insulation that brings excellent waterproofing and mechanical strength to stator assembly.
Said motor assembly consists of cylindrical rotor assembly concentrically positioned such that inner diameter of stack of stator laminations (1) and outer diameter of cylindrical rotor assembly are bordered through air gap (5). In the said embodiment, rotor assembly is a part of permanent magnet synchronous motor and it consists of rotor core (6) and plurality of permanent magnet (7) interior mount in respective magnet retaining hollows. Permanent magnets (7) are arranged end-to-end configuration to form single rotor magnetic pole, plurality of such rotor magnetic pole formed by permanent magnets (7) fixed at rotor core (6) produces the rotor magnetic field.
Said stator winding (2), connected by means of waterproof cable (25) is supplied through inverter drive (26) which is completely insulation encapsulated and fully watertight with components of epoxy, mounted inside the motor enclosure (16) using fasteners (27). An interaction of rotating magnetic field produced by stator winding (2) and rotor magnetic field produced by plurality of permanent magnet (7) causes the rotation of rotor assembly and consequently rotation of shaft (8) along axis (AA’).
Said pump assembly consists of an impeller (9) concentrically positioned in rotor hub such that inner circumference of rotor core (6) and outer circumference of finished annular rim (10) are braced, and plurality of impeller spoke (11) axially spaced over impeller hub (12) circumference are supported through built-in common single shaft (8). Radially expanded plurality of impeller spoke (11) aligned between impeller hub (12) and finished annular rim (10) are enclosed through suction stage casing (13) and discharge stage casing (14) at circumference as well as at sides.
Rotation of impeller (9) along with rotor assembly pulls the surrounding water through suction inlet (15) built-in the motor enclosure end cover (16a) to inlet port (17) housed in suction stage casing (13) and centrifugally propelled it to side channel (19) housed in discharge stage casing (14). A circular side channel (19) stretched around the inner side of discharge stage casing (14), tapered to outlet port (20) with decreasing cross-section transfers the water till it again accelerated by plurality of impeller spoke (11). Continual regenerating moves of impeller (9) forces the water coming out from outlet port (20) to discharge outlet (18) built-in the motor enclosure (16), connected through pipe (21). Priming chamber (22) built between suction side motor enclosure (16a) and suction stage casing (13) is filled with surrounding water that self-primes the pump on initial cycle by circulating water within pump. Said suction inlet (15) built-in the motor enclosure end cover (16a) pulls the surrounding water directly through strainer (23) to prevent large particles and debris from entering into the pump assembly. Discharge outlet (18) with built-in threads, connects the pipe line (not shown) to lift the water at preferred location. Entire permanent magnet synchronous motor integrated water submerged side channel self-priming pump unit rests on a foot base (28) to reduce the vibration during the operation.
According to present invention embodiment, shaft (8) is supported between suction stage casing (13) and discharge stage casing (14) through annular metal counter (24a, 24b) positioned over the shaft (8) such that inner diameter of counter (24a, 24b) coincides with the outer diameter of shaft (8). Counters (24a, 24b) filled with lubricants reduces the frictional loss at shaft (8) surface and concentrically align the shaft (8) along axis (AA’). At the time of water transit from inlet port (17) to outlet port (20), motor assembly is completely filled with surrounding water as pump impeller (9) is housed in rotor hub and enclosed between suction stage casing (13) and discharge stage casing (14). Completely water submerged stator assembly and rotor assembly eliminates the temperature rise concern of respective assembly.
For, the invention described here with respect to the given embodiment, it is appreciated that many variations, modifications and other applications of the invention may be made. However, it is to be expressly understood that such modifications and adaptations are within the scope of the present invention, as set forth in the following claims.