Integrated water pump

Abstract

The invention discloses an integrated water pump integrating electric drive, water level detection and illumination functions, and belongs to the technical field of fluid machinery. The water pump comprises a pump shell, a water inlet filter screen cover, a partition plate, a water inlet gland with a water flow channel, a lamp panel, a battery, a control panel and the like, through modular integrated design, physical isolation of a sealed containing cavity and a water inlet cavity is formed in the pump shell, water and electricity separation is achieved, and the containing cavity is filled with protective glue to wrap electronic components so as to improve the waterproof performance. Independent or linkage control of the water pump and illumination can be achieved through the control switch, and the water level detection probe can monitor the water level in real time and trigger a protection mechanism. The split type water pump solves the problems that a traditional split type water pump is complex in pipeline, high in water leakage risk and single in function, has the advantages of being high in integration degree, low in cost and high in safety, and is suitable for various fluid conveying scenes.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of fluid machinery, in particular to an integrated water pump integrating power driving, water level detection and lighting functions. BACKGROUND

[0002] Current water pumps on the market mostly adopt split type design, i.e. water pump main body, controller and power module are installed separately, which has the following defects:

[0003] Pipeline connection is complex, water leakage is prone to occur at the interface, and maintenance cost is increased;

[0004] Electronic components are exposed to the external environment, and have poor waterproof and dustproof performance and short service life;

[0005] The functions are single, and water level monitoring (easily damaged due to lack of water) and emergency lighting (inconvenient to operate at night) functions cannot be integrated;

[0006] Step-by-step production and assembly result in high material and labor costs and low production efficiency.

[0007] Therefore, there is an urgent need for a highly integrated, water and electricity separated, low-cost and comprehensive water pump solution. SUMMARY

[0008] The present application aims to solve the problems of complex pipeline, high risk of water leakage, single function and high cost of the existing split type water pump, and provides an integrated water pump, which realizes water and electricity separation, intelligent control and low-cost production through modular integration and glue sealing process.

[0009] The present application provides an integrated water pump, the top of the pump shell is provided with a water outlet and a lampshade, the water inlet filter cover is detachably installed at the bottom of the pump shell, the partition plate is installed between the pump shell and the water inlet filter cover, and a sealed accommodating cavity (integrating a wire-wound stator core, a control board, a lamp board, a battery and a Hall sensor) and a water inlet cavity are respectively enclosed, the water level detection probe extends to the bottom of the partition plate and is electrically connected with the control board, the accommodating cavity is filled with protective glue to cover the electronic components, the partition plate is provided with a rotor cavity (with a rotor and a bottom connected with an impeller) and a water channel, the wire-wound stator core surrounds the rotor cavity and is magnetically coupled with the rotor, so as to realize water and electricity separation (water flows into the water inlet filter cover, is discharged from the top water outlet through centrifugal action of the impeller, and is physically isolated from the accommodating cavity). The accommodating cavity (electronic component area) and the water inlet cavity (water flow area) are physically isolated by the partition plate, the electronic components are covered by the protective glue, water and electricity separation is realized, the core components are integrated to reduce external connection, the rotor and the wire-wound stator core are magnetically coupled to drive the impeller to pump water, and the water level probe monitors the water level in real time. The water and electricity contact risk is eliminated from the structure, the waterproof safety is improved, the pipeline connection is reduced, the water leakage probability is reduced, the integrated design reduces the volume, the installation is facilitated, and the water level monitoring lays a foundation for subsequent protection mechanism.

[0010] Further, the water inlet pressure cover is installed between the water inlet filter screen cover and the partition plate, guiding the water flow from the water inlet filter screen cover to the water channel and the water outlet of the partition plate, so that the water flow enters from the bottom of the pump shell and is discharged from the top outlet through the centrifugal action of the impeller. The water flow path is optimized through the water flow channel of the water inlet pressure cover to ensure stable flow in the preset direction, avoid turbulence loss, improve water pumping efficiency, and make the water flow more uniform to reduce the noise of the impeller operation and improve the stability of the water pump.

[0011] Further, the battery is a rechargeable lithium battery, which is placed in the accommodating cavity together with the wire-wound stator core and the Hall sensor, the control board integrates the charging circuit and the protection circuit, and is connected to an external power supply through a power supply line. The built-in rechargeable lithium battery realizes independent operation in a scenario without external power supply, the control board uniformly manages the charging process (adapts to external power supply) and circuit protection (such as overcharge and overdischarge protection), improves the flexibility of the water pump, and adapts to outdoor, emergency and other scenarios without external power supply; the protection circuit prolongs the service life of the battery, reduces the risk of circuit failure, and at the same time simplifies the external wiring and reduces the safety hazard.

[0012] Further, the lamp plate is embedded below the transparent lampshade on the top of the pump shell, and the light source irradiates outward. The transparent lampshade protects the lamp plate from the external environment and does not hinder the light emission.

[0013] Further, the water level detection probe penetrates the partition plate vertically, and the detection end is exposed to the water inlet area at the bottom of the pump shell; when the water level is lower than the detection end of the probe, the control board cuts off the power supply of the water pump and triggers the lamp plate to flash and alarm, preventing the water pump from idling in a water shortage state and avoiding dry grinding damage to the impeller, thereby significantly prolonging the service life of the water pump; the flashing alarm of the lamp plate directly reminds the user to add water, improving the convenience and safety of the equipment.

[0014] Further, the protective glue is epoxy resin, which is injected into the accommodating cavity through the glue injection port of the partition plate, and forms an insulating waterproof layer after curing. Epoxy resin has excellent insulation and sealing properties, and can completely fill the gaps in the accommodating cavity through the glue injection port, forming a whole waterproof layer after curing, which isolates the contact between water vapor and electronic components. The waterproof level of the electronic components in the accommodating cavity reaches IP67, which is suitable for humid and water-rich environments; the insulation characteristics further reduce the risk of electric shock and improve the reliability of the equipment in harsh environments.

[0015] The Hall sensor is embedded in the gap between the wire-wound stator core to monitor the rotor speed in real time and feedback to the control board to realize variable frequency speed regulation. The Hall sensor obtains the speed data by detecting the change of the rotor magnetic field, and the control board adjusts the power supply frequency of the wire-wound stator core according to the speed feedback to change the rotor speed, realizing dynamic adjustment of the water pump speed, which can adjust the pumping efficiency according to the actual demand to achieve energy-saving purpose; avoiding component wear caused by excessive speed to prolong the service life of the equipment.

[0016] The side wall of the pump shell is provided with three-stage control switches, which correspond to independent starting of the water pump, independent starting of the lighting, and linkage of the water pump and the lighting respectively, the circuit connection state is switched through different gears of the switches, independent or collaborative control of the water pump and the lighting is realized, diversified use requirements are met, the operation is simple and intuitive, and the user experience is improved.

[0017] The water channel is in a spiral ascending structure, water flow is accelerated along the impeller and then rises along a spiral path to the top water outlet, and the water outlet is provided with a spray head. The spiral water channel utilizes the combined action of centrifugal force and gravity to keep the kinetic energy of the water flow during the rising process, the spray head can change the water outlet form according to requirements, the spiral structure reduces the energy loss during the rising process of the water flow, and the water outlet pressure is improved; the spray head increases the application scenarios of the water pump and improves the practicality of the product.

[0018] Compared with the prior art, the present application has the following beneficial effects:

[0019] High integration: the water pump, the controller, the power supply, the lighting and the detection module are integrated, the pipeline connection is reduced, and the risk of water leakage is reduced;

[0020] Water and electricity separation: the accommodating cavity and the water inlet cavity are physically isolated, and the electronic components are completely covered by epoxy resin glue, the waterproof level reaches IP67, and the humid environment is adapted;

[0021] Intelligent protection: the water level detection probe can prevent the water pump from idling due to lack of water, the Hall sensor realizes variable frequency speed regulation, and the service life is prolonged;

[0022] Comprehensive function: supporting independent / linkage control of the water pump and the lighting, meeting the night operation and emergency requirements;

[0023] Low cost and high efficiency: integrated design reduces the types of materials and assembly steps, reduces production and maintenance costs, and improves product competitiveness. BRIEF DESCRIPTION OF DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0025] Figure 1 、 2 The overall schematic diagram provided for the embodiments of the present application;

[0026] Figure 3 The explosion schematic diagram provided for the embodiments of the present application;

[0027] Figure 4 The winding stator core, rotor and partition plate structure schematic diagram provided for the embodiments of the present application;

[0028] Figure 4 、 5 Structure diagram provided for the embodiment of the present application;

[0029] Figure 6 Overall cross-sectional view provided for the embodiment of the present application.

[0030] In the drawings, various reference signs represent:

[0031] 1, pump shell; 11, water outlet; 12, lampshade; 2, water inlet filter cover; 21, water inlet; 3, partition plate; 31, rotor cavity; 32, water channel; 33, glue injection port; 4, water inlet gland; 5, lamp panel; 6, control panel; 61, battery; 62, wire-wound stator core; 63, rotor; 64, impeller; 65, switch; 66, power cord; 7, accommodating cavity.

[0032] The specific embodiments of the present application have been shown by the above drawings, and will be described in more detail hereinafter. These drawings and written descriptions are not intended to limit the scope of the concept of the present application in any way, but to illustrate the concept of the present application to those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0033] The technical solutions in the embodiments of the present application will be described clearly and completely below in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative efforts belong to the scope of protection of the present application.

[0034] To make the technical solutions and advantages of the present application clearer, the embodiments of the present application will be described in further detail below in combination with the drawings.

[0035] Please refer to Figures 1-6 The integrated water pump of the present application is realized by the following ways, and those skilled in the art can understand the technical details in combination with the drawings. The pump shell 1 is made of nylon with 30% glass fiber material and is injection molded, the water outlet 11 and the transparent polycarbonate material lampshade 12 are integrally arranged on the top, and the switch 65 mounting hole and the power cord 66 through hole are arranged on the side wall. The water inlet filter cover 2 is detachably connected to the bottom of the pump shell 1 through a buckle structure, and a stainless steel filter screen is arranged in the water inlet 21 to intercept solid impurities. The partition plate 3 is made of polypropylene material and is molded, the upper surface thereof forms a sealed accommodating cavity 7 with the inner wall of the pump shell 1, and the lower surface thereof forms a water inlet cavity with the water inlet filter cover 2.

[0036] As Figure 4As shown, the partition plate 3 is also provided with a cylindrical rotor cavity 31 with an inner diameter of φ15mm±0.05mm, which forms a gap of 0.05mm-0.08mm with the rotor 63(φ14.9mm±0.02mm), ensuring flexible rotation of the rotor 63 and reducing the risk of water seepage into the containing cavity 7 through the narrow gap. The rotor cavity 31 is designed on one side with a spiral rising water flow channel, i.e. water channel 32, which in some embodiments has a cross-sectional area that decreases by 20% from bottom to top to achieve water flow pressurization.

[0037] The electronic module integrated in the containing cavity 7 includes: a bottom layer fixed electromagnetic winding stator core 62, which is arranged around the rotor cavity 31. The winding stator core 62 is made of 0.35mm thick silicon steel sheets stacked together, and the enameled wire is wound for 60 turns to form a three-phase winding with an impedance of 3Ω±5%. The core is fixed to the outside of the rotor cavity 31 of the partition plate 3 through interference fit, and forms a magnetic coupling gap of 0.3mm with the rotor 63(neodymium-iron-boron permanent magnet, residual magnetism 1.2T), ensuring that the magnetic field energy transmission efficiency is ≥90%. The middle layer is installed with the control board 6 through the support, which integrates the following core elements: microcontroller: STM32F103(32-bit ARM architecture, main frequency 72MHz), responsible for processing sensor signals and executing control logic; charging management chip: TP4056(supporting 5V / 2A input, with overcharge, overdischarge, and short circuit protection functions); motor drive chip: DRV8833(supporting PWM speed regulation, maximum output current 2A); Hall sensor: A1104(linear Hall element, sensitivity 1.3mV / G, used for detecting the rotation speed of the rotor 63).

[0038] The upper layer is attached with the lamp panel 5, which is opposite to the transparent lamp shade 12. The lamp panel 5 uses an aluminum substrate and welds 6 SMD LEDs of 0.5W, which are evenly distributed in a ring shape, ensuring that the light range covers an area of 1.5 meters around the water pump. The LEDs are powered by a constant current driving circuit(current 200mA±5%), with stable brightness and a service life of ≥50000 hours. The power supply uses a rechargeable lithium battery, i.e. battery 61 group, with a capacity of 2000mAh. A 10A self-resetting fuse(action temperature 70℃) is connected in series between the battery 61 group and the control board 6 to prevent the risk of overcurrent when short-circuiting. The side fixed lithium ion battery and the magnetic field induction sensor. The electronic module is filled with a flame-retardant epoxy resin mixed at a weight ratio of 3:1 of the main agent and the curing agent. After injecting into the containing cavity 7 through the glue injection port 33, it is degassed in a negative pressure vacuum environment for ten minutes to form a full-coverage waterproof layer.

[0039] During assembly, a water inlet pressure cover 4 is installed between the water inlet filter cover 2 and the partition plate 3. The rotor 63 made of neodymium-iron-boron permanent magnet is connected with the impeller 64 through a stainless steel shaft and is installed in the rotor cavity 31. Two stainless steel water level detection probes vertically penetrate the partition plate 3, with the lower end exposed to the bottom of the water inlet cavity and the upper end connected to the analog-digital conversion sampling circuit of the control board 6.

[0040] The water and electricity separation mechanism is realized through double protection: as shown in the figure, the water flows into the water inlet cavity from the bottom water inlet 21, is delivered to the water channel 32 through the water inlet gland 4, is accelerated by the impeller 64, and is discharged from the top water outlet 11, and the whole process is physically blocked outside the containing cavity 7 by the partition plate 3; even if the partition plate 3 fails to seal, the cured epoxy resin layer can still prevent liquid water from eroding the electronic components. Figure 6

[0041] The water pump realizes the functions of water pumping, lighting, water level protection, frequency conversion speed regulation and the like through the cooperation of hardware design and software algorithm, and the following is the specific logic:

[0042] 1. Three-gear control switch 65 operation

[0043] The switch 65 adopts three gears corresponding to different circuit connection states:

[0044] First gear (water pump independent operation): the control panel 6 connects the driving circuit of the wire-wound stator core 62, the microcontroller outputs the PWM signal (frequency 50Hz-200Hz) to drive the rotor 63 to rotate, and the impeller 64 pumps water;

[0045] Second gear (lighting independent opening): the control panel 6 connects the lamp panel 5 circuit, and the LED is always on at 100% brightness (current 200mA), which is suitable for night inspection or emergency lighting;

[0046] Third gear (linkage mode): the water pump and lighting circuit are connected at the same time, and the built-in light sensor (photosensitive resistor, dark resistance≥1MΩ, bright resistance≤10kΩ) automatically adjusts the lighting state - the lighting is turned off during the day (light intensity≥500lux), and only the water pump is operated; the lighting is turned on at night (light intensity<500lux), which meets the needs of water pumping and lighting.

[0047] 2. Water level detection and protection mechanism

[0048] The water level detection probe is a 316 stainless steel rod (better than 304 in corrosion resistance, suitable for water bodies containing salt), the lower end is exposed to the bottom of the water inlet cavity, and the upper end is connected to the ADC sampling circuit (sampling frequency 10Hz) of the control panel 6. Its protection logic is as follows:

[0049] When the water level is normal, a loop is formed between the two probes due to the conductivity of the water body, the resistance value is ≤50kΩ, and the control panel 6 maintains normal operation of the water pump;

[0050] When the water is lacking (the water level is lower than the detection end of the probe), the loop resistance is ≥100kΩ, the control panel 6 immediately cuts off the power supply of the water pump (response time ≤100ms), and at the same time drives the lamp panel 5 to enter the flashing mode (1Hz frequency, bright 0.5s and dark 0.5s), until the water level is restored or manually powered off;

[0051] ​Fault self-diagnosis: If the probe is short-circuited (resistance ≤ 1 kΩ), the control board 6 determines that the probe is faulty, and the lamp panel 5 flashes at a frequency of 2 Hz to alert the user to repair.

[0052] 3. Hall sensor variable frequency speed regulation

[0053] The Hall sensor is embedded in the gap of the wound stator core 62, which detects the magnetic field change in real time when the rotor 63 rotates, and outputs a pulse signal (the frequency is proportional to the speed: 3000 r / min corresponds to 300 Hz). The control board 6 realizes speed regulation through the following algorithm:

[0054] Speed sampling: collect pulse signal every 10 ms, calculate current speed N (r / min);

[0055] Target speed setting: automatically adjust according to load, for example: set 2000 r / min for low lift (≤ 2 meters), set 3000 r / min for high lift (6 meters);

[0056] PWM regulation: adjust the duty cycle of the driving signal (5% ~ 95%) through the PID algorithm, so that the deviation between the actual speed and the target speed is ≤ 50 r / min, to achieve energy saving (30% power saving compared with constant speed operation) and noise reduction effect.

[0057] 4. Automatic cleaning and anti-blocking function

[0058] The control board 6 has a built-in timing program, which triggers the rotor 63 to reverse alternately every 30 minutes (which can be adjusted to 1 hour through firmware settings). The reverse water flow impacts the inlet filter cover 2 to automatically remove the attached debris (such as water grass, sand). During the reverse process, the control board 6 monitors the current change through the Hall sensor, if the current ≥ 3A (determined as serious blockage), then reverse for 3 times continuously, if still ineffective, trigger the lamp panel 5 to flash at 3 Hz to alarm.

[0059] When the water pump is used in the courtyard landscape fish pond, it can be placed at the bottom of the pond to intercept water grass and impurities through the filter screen. Turn the switch 65 to the third gear, only the water pump runs to maintain water circulation during the day, and automatically turns on the lighting under the lampshade 12 at night; When the water level drops to the probe detection position, it automatically triggers the stop and light alarm. In the emergency drainage operation scene, the built-in battery 61 supports continuous work for three hours without external power supply, the waterway 32 structure provides six meters of vertical lift, cooperates with the replaceable spray head to adapt to different drainage distance requirements, and the magnetic field sensor automatically increases the output speed according to the pipeline resistance.

[0060] The comparative test verifies that the annual water leakage failure rate of the product is less than 0.005%, which is 90% lower than that of the traditional split type water pump; the assembly time of a single product is shortened from 25 minutes to 8 minutes, and the production efficiency is increased by 68%. The accelerated life test shows that the wear of the impeller is less than 0.1 mm after 2000 hours of continuous operation, and the epoxy resin packaging layer has no cracking phenomenon; the speed regulation function remains stable in the temperature range of-10 to 50 degrees Celsius, and the illumination brightness attenuation rate is less than 10%.

[0061] Those skilled in the art can make technical modifications within the scope of the claims: for example, replace the battery 61 with a super capacitor module to achieve a five-minute fast charging feature; or add a temperature detection probe to automatically trigger a speed reduction protection mechanism when the water temperature exceeds 50 degrees Celsius; a wireless communication module can also be added to remotely adjust the water pump speed and light working mode through a mobile terminal application. The above embodiments have completely disclosed the essential technical content of the application, and any equivalent technical transformation based on the core principle of the application belongs to the scope of patent protection.

[0062] Other embodiments of the application will be apparent to those skilled in the art from consideration of the specification and practice of the application. This application is intended to cover any variations, uses or adaptations of the application following the general principles thereof and including such departures from the present disclosure as come within known use or custom in the art to which the application pertains. The specification and examples are to be regarded as illustrative only, and the true scope and spirit of the application are indicated by the appended claims.

[0063] It should be understood that the application is not limited to the precise construction that has been described above and illustrated in the accompanying drawings, and that various modifications and changes can be made by those skilled in the art without departing from the scope of the application. The scope of the application is limited only by the appended claims.

Claims

1. An integrated water pump, characterized by: Comprising Pump shell (1), top set out water outlet (11) and lampshade (12); Water inlet filter cover (2) is detachably installed at the bottom of the pump shell (1); The partition plate (3) is installed between the pump shell (1) and the water inlet filter cover (2), which is surrounded with the top of the pump shell (1) to form a sealed cavity (7), and is surrounded with the water inlet filter cover (2) to form a water inlet cavity; The cavity (7) is integrated with a winding stator core (62), a control board (6), a lamp board (5), a battery (61) and a hall sensor; The water level detection probe extends to the bottom of the partition plate (3) and is electrically connected with the control board (6); The cavity (7) is filled with protective glue, which completely covers all electronic components; The partition plate (3) is provided with a rotor cavity (31) and a water channel (32), the rotor cavity (31) is provided with a rotor (63), and the bottom of the rotor (63) is connected with an impeller (64); The winding stator core (62) is arranged around the rotor cavity (31) and is magnetically coupled with the rotor (63). Water and electricity are separated: water flows from the water inlet filter cover (2) into the water inlet cavity, and is discharged from the top water outlet (11) after centrifugal action of the impeller (64), which is physically isolated from the cavity (7) throughout the process.

2. The integrated water pump of claim 1, wherein: It also includes a water inlet pressure cover (4) with a water channel, which is installed between the water inlet filter cover (2) and the partition plate (3), guides the water flow from the water inlet filter cover (2) to the water channel (32) of the partition plate (3) and the water outlet (11), and the water flow enters from the bottom of the pump shell (1), is discharged from the top water outlet (11) after centrifugal action of the impeller (64).

3. The integrated water pump of claim 1, wherein: The battery (61) is a rechargeable lithium battery, which is co-located with the winding stator core (62) and the hall sensor in the cavity (7), the control board (6) is integrated with a charging circuit and a protection circuit, and the control board (6) is also connected with an external power supply through a power line (66).

4. The integrated water pump of claim 1, wherein: The lamp board (5) is embedded below the transparent lampshade (12) on the top of the pump shell (1), and the light source irradiates outward.

5. The integrated water pump of claim 1, wherein: It also includes a water level detection probe, which vertically penetrates the partition plate (3) and exposes the detection end to the water inlet area at the bottom of the pump shell (1); when the water level is lower than the detection end of the probe, the control board (6) cuts off the power supply of the water pump and triggers the lamp board (5) to flash and alarm.

6. The integrated water pump of claim 1, wherein: The protective glue is epoxy resin, which is injected into the cavity (7) through the glue injection port (33) of the partition plate (3), and forms an insulating and waterproof layer after curing.

7. The integrated water pump of claim 1, wherein: The hall sensor is embedded in the gap of the winding stator core (62), which monitors the rotating speed of the rotor (63) in real time and feeds back to the control board (6) to realize variable frequency speed regulation.

8. The integrated water pump of claim 1, wherein: The sidewall of the pump shell (1) is provided with a three-stage control switch (65): the first stage independently starts the water pump; the second stage independently turns on the lighting; the third stage links the water pump and the lighting.

9. The integrated water pump of claim 2, wherein: The water channel (32) is in a spiral upward structure, the water flow is accelerated along the spiral path after passing through the impeller (64) and rises to the top water outlet (11), and the water outlet (11) is provided with a spray head.

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