Encapsulated Stator Assembly for Submersible Pump Fluid Protection
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Solution Overview
Problem
Current centrifugal waste water and sump pump technologies are susceptible to issues when electrical components come into contact with fluid, leading to potential short circuits and operational failures.
Innovation Solution
The development of an encapsulated stator assembly with a watertight seal, utilizing an insert molding technique to encase the stator, electrical leads, and a solid-state switch, which includes water passageways for cooling and sensors for fluid level monitoring, preventing fluid contact with electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical components are exposed to fluid for operational control, then the pump can respond to fluid level changes, but the electrical components become susceptible to short circuits and operational failures
Solution Approach 1:
The pump system is divided into two distinct segments: an electrical control section (stator assembly) and a fluid sensing section. The stator assembly is encapsulated in a watertight housing that physically separates electrical components from direct fluid contact, while fluid level sensors are positioned to detect fluid levels without requiring electrical components to be exposed to fluid. This segmentation allows the pump to maintain fluid level monitoring capability while protecting electrical components from fluid-induced failures.
Solution Approach 2:
A watertight encapsulation housing acts as an intermediary barrier between the electrical stator assembly and the fluid environment. This housing allows the electrical components to remain isolated from fluid while still enabling the system to sense and respond to fluid level changes through dedicated sensors that interface with the fluid externally or through sealed pathways. The intermediary structure preserves both reliability and adaptability.
2Reliability
If a watertight seal is implemented to protect electrical components, then fluid contact is prevented, but manufacturing complexity increases
Solution Approach 1:
The stator assembly is pre-encapsulated in a watertight housing before final pump assembly. This preliminary encapsulation action ensures that electrical components are protected from fluid contact from the outset, eliminating the need for complex post-assembly sealing operations. The pre-formed encapsulated stator assembly can be manufactured using standardized molding processes, reducing overall manufacturing complexity while ensuring reliable protection.
3Reliability
If the stator assembly is encapsulated to prevent fluid contact, then electrical components are protected, but heat dissipation becomes more difficult
Solution Approach 1:
The encapsulation housing incorporates thermal management features such as heat sinks, thermal conduits, or fluid-cooled pathways that conduct heat away from the stator assembly. These thermal management systems use thermal conduction and convection principles to transfer heat from the enclosed electrical components to the surrounding environment or cooling fluid, maintaining effective heat dissipation while preserving the watertight seal that protects electrical components from fluid contact.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The encapsulated stator assembly effectively prevents fluid from adversely affecting electrical components, ensuring reliable operation by maintaining a watertight seal and allowing for controlled pumping without short circuits.
Implementation Method 1
The stator, the switch and electrical leads and connections are at least partly encapsulated in a material so as to form an encapsulated stator assembly with a watertight seal to prevent fluid from contacting the electrical windings
Implementation Method 2
which includes water passageways for cooling
Data Source
AI summary
Apparatus is provided for use in a submersible pump, comprising; a stator having electrical windings and configured with a cavity to receive a rotor of a motor and to provide an electromotive force to drive the rotor arranged inside the cavity; a switch having circuitry configured to response to a level of fluid and control the operation of the stator; and electrical leads and connections configured to electrically couple the stator and the switch, and to provide power to operate the stator and the switch to drive the stator and to turn the electromotive force on and off to control the pumping of the fluid by submersible pump; the stator, the switch and electrical leads and connections being at least partly encapsulated in a material so as to form an encapsulated stator assembly with a watertight seal to prevent fluid from contacting the electrical windings, the circuitry of the switch and the electrical leads and connections.