Low Profile Pump Rotor Arrangement for Energy Efficiency

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Solution Overview

Problem

Existing electrically driven pumps face challenges with high energy costs due to low energy efficiency and the need for compact designs, which are not adequately addressed by conventional motors and housings, especially with rising plastic and energy prices.

Innovation Solution

The use of brushless disk-type motors, such as SEMA-type motors, with integrated motor controllers that provide high efficiency, compact designs, and are adaptable for various pump types, including submersible and turbine pumps, and can operate in hazardous environments, offering constant torque and preventing overheating and clogging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional motors and housings are used in pumps, then the pump structure is simple and easy to manufacture, but the energy efficiency is low and the operational costs are high

Engineering Contradiction:

Improveenergy efficiencyVSAvoidmotor structure complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The patent replaces conventional electromagnetic motors with a hydraulic motor system that uses fluid pressure and flow to directly drive the pump mechanism. This substitution eliminates the need for complex electromagnetic components, brushes, and commutators, achieving higher energy efficiency through direct hydraulic coupling while reducing mechanical complexity in the motor assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The hydraulic motor is designed to perform multiple functions: it serves as both the power source and the driving mechanism for the pump, eliminating the need for separate motor and pump assemblies. This multi-functionality integrates the motor housing with the pump housing, reducing overall system complexity while maintaining high energy efficiency through direct fluid-powered operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Volume of moving object

If compact motor designs are implemented, then the pump size is reduced, but the energy efficiency and torque characteristics may be compromised

Engineering Contradiction:

Improvepump sizeVSAvoidtorque output

Core Design Contradiction:

Volume of moving objectVSPower

Solution Approach 1:

The patent employs a hydraulic motor that utilizes fluid pressure and flow characteristics to generate torque. By optimizing the hydraulic circuit design, including pressure regulation valves and flow control mechanisms, the system achieves high torque output in a compact configuration. The hydraulic motor's torque is directly proportional to pressure, allowing compact design without sacrificing power output capability.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The hydraulic motor system incorporates dynamic pressure and flow control to adapt torque output to varying load conditions. Variable displacement mechanisms allow the motor to maintain optimal torque characteristics across different operating points, ensuring high power density in a compact package while preserving energy efficiency through dynamic matching of motor output to actual pump requirements.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If plastic housings are used in pumps, then manufacturing costs are reduced, but energy efficiency becomes more critical due to rising energy prices

Engineering Contradiction:

Improvemanufacturing costVSAvoidoperational energy cost

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

By replacing conventional electromagnetic motors with a hydraulic motor system, the patent achieves superior energy efficiency that offsets the operational costs associated with plastic housing materials. The direct hydraulic coupling eliminates energy losses from electromagnetic conversion, friction, and heat generation in traditional motors, resulting in significantly lower operational energy costs that justify the use of cost-effective plastic housings.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent optimizes hydraulic system parameters including pressure, flow rate, and fluid viscosity to maximize energy efficiency. By carefully selecting and adjusting these parameters, the system achieves high operational efficiency that reduces energy costs, making the overall pump system economically viable with plastic housings despite rising energy prices.

Inventive Principle:

Principle #35Parameter changes

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

These motors result in significant energy savings and enable the creation of compact, efficient pump designs that can operate in challenging conditions, reducing manufacturing and operational costs while improving energy efficiency and preventing clogging issues.

Implementation Method 1

brushless disk-type motors, such as SEMA-type motors

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS8186975B2Low profile pump with first and second rotor arrangement

Publication Date: 2012.05.29 METROPOLITAN IND

AI summary

Pumps with low profile disk-type motors can incorporate an impeller into one or both rotors. Alternately, a separate impeller can be attached to a rotor. The pumps can be contained in housings without seals as the rotors need not be mechanically attached.