Integrated Pump Station Layout With Sequential Cooling
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Solution Overview
Problem
Existing pump station designs in coal mining face environments require separate mounting and commissioning of components, leading to increased length, weight, and maintenance costs, as well as space inefficiencies and difficulties in movement.
Innovation Solution
An integrated pump station design that includes a mounting frame with a pump body and an electric drive device housed within a single unit, where the motor, frequency converter, and controller are integrated and connected via electric wires, and a water cooling system is optimized for sequential communication between the motor, frequency converter, and pump body oil cooler.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate mounting and commissioning of pump station components is used, then each component can be independently maintained and replaced, but the overall equipment length and weight increase, and space efficiency decreases
Solution Approach 1:
The patent integrates the pump body, motor, frequency converter, and controller into a single compact unit mounted on one frame. This merging of previously separate components reduces the overall equipment length and weight while maintaining the ability to service individual components through standardized interfaces and modular design within the integrated structure.
2Ease of manufacture
If separate mounting and commissioning of pump station components is used, then each component can be independently maintained and replaced, but the overall equipment weight increases
Solution Approach 1:
The patent combines multiple heavy components (pump body, motor, frequency converter, controller) into a single integrated assembly, eliminating the need for separate mounting structures, foundations, and alignment equipment. This integration reduces total equipment weight while preserving maintenance accessibility through designed service ports and modular sub-assemblies.
3Ease of manufacture
If separate mounting and commissioning of pump station components is used, then component independence is maintained, but maintenance costs and complexity increase
Solution Approach 1:
The patent integrates components into a pre-assembled unit with standardized connections for power, control, and fluid flow. This reduces on-site mounting and commissioning complexity to simple connection tasks while maintaining component independence through modular design, thereby reducing maintenance costs and operational complexity.
4Temperature
If traditional separate component arrangement is used, then adequate cooling space is provided for each component, but the overall equipment footprint and space requirements increase
Solution Approach 1:
The patent arranges components in a nested configuration where the frequency converter and controller are housed within or adjacent to the motor assembly, which is itself integrated with the pump body. This nesting strategy provides adequate cooling space for each component through strategically placed ventilation channels and heat sinks while minimizing the overall equipment footprint.
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 integrated design reduces the overall length and weight of the equipment, decreases the number of external water pipes needed, enhances space efficiency, and facilitates easier movement and maintenance, while maintaining effective cooling and operation of the pump station components.
Implementation Method 1
a water cooling pipeline of the motor, a water cooling pipeline of the frequency converter and an oil cooler of the pump body sequentially communicating with one another
Data Source
AI summary
An integrated pump station includes: a mounting frame, a pump body, and an electric drive device. The pump body is arranged on the mounting frame; the electric drive device comprises a housing body, a motor, a frequency converter and a controller; the housing body is arranged on the mounting frame; the motor, the frequency converter and the controller are arranged in the housing body, the motor being connected to the pump body; the motor is connected to the frequency converter by means of an electric wire, the frequency converter is connected to the controller by means of an electric wire, and a water cooling pipeline of the motor, a water cooling pipeline of the frequency converter and an oil cooler of the pump body sequentially communicate with one another.