Compact Modular Pump with Integral Motor and Coaxial Flow
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Solution Overview
Problem
Existing pump and turbine designs face challenges such as leakage and alignment issues due to dynamic seals, complexity and cost from magnetic coupling, limited scalability, and inefficiencies in cooling and motor/generator integration, which restrict their compactness, modularity, and adaptability for varying applications.
Innovation Solution
A modular, sealless pump or turbine design with a concentric flow configuration that allows multiple modules to be combined in series without bulky interconnections, featuring a stator housing surrounded by an outer module housing, direct thermal contact for cooling, and independently controllable rotors and generators, enabling efficient heat management and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If dynamic seals are used to maintain pressure boundaries at the rotating shaft penetration location, then pressure containment is improved, but leakage and failure modes increase
Solution Approach 1:
The patent removes the rotating shaft and dynamic seal from the system by using magnetic coupling. The motor shaft remains stationary while the pump shaft rotates, eliminating the need for dynamic seals at the pressure boundary and thereby preventing leakage and seal failures.
2Manufacturing precision
If rigid baseplates are used to mount and align the pump and motor, then alignment is improved, but vibration issues and alignment problems under nozzle loads persist
Solution Approach 1:
The patent merges the motor and pump into a single integrated assembly where the motor housing is directly coupled to the pump housing. This eliminates the separate rigid baseplate connection, reducing vibration transmission and alignment problems while maintaining precise alignment through direct mechanical coupling.
3Reliability
If magnetic coupling is used to eliminate dynamic seals, then leakage is reduced, but complexity and cost increase
Solution Approach 1:
The magnetic coupling system is designed to be self-aligning and self-adjusting, eliminating the need for complex external alignment mechanisms. The magnetic fields automatically maintain optimal coupling between the motor and pump shafts, reducing operational complexity despite the added magnetic components.
4Reliability
If integral motor design is used to eliminate shaft seals, then sealless operation is achieved, but cooling of motor coils becomes difficult
Solution Approach 1:
The patent introduces a cooling fluid as an intermediary medium that flows through channels in the motor housing and stator core. This cooling fluid acts as a heat transfer mediator, carrying thermal energy from the motor coils to external heat sinks or cooling systems, enabling effective cooling in the sealless integral design.
5Reliability
If radial field motor design is used in integral pump, then sealless operation is achieved, but diameter and length of rotor housing increase significantly
Solution Approach 1:
The patent transitions from a radial field motor configuration to an axial field motor configuration. This dimensional change in the magnetic field orientation allows for a more compact rotor housing design, reducing both diameter and length while maintaining the sealless operational advantage.
6Power
If axial field motor design is used to achieve compactness, then power density is improved, but cooling requirements increase and design complexity arises
Solution Approach 1:
The motor housing and stator core are designed to serve multiple functions: structural support, magnetic flux path, and cooling fluid passage. This multi-functionality integrates the cooling system into the existing motor structure, achieving effective cooling for the high-power-density axial field design without adding significant complexity.
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
This design achieves a compact, modular, and scalable solution that maintains high efficiency, reduces maintenance complexity, and allows for flexible integration of the same motor or generator design across different applications, while ensuring reliable operation and reduced risk of bearing overload and failure.
Implementation Method 1
direct thermal contact for cooling
Implementation Method 2
The shunted working fluid is heated by convection from the stator wall and carries the heat away from the stator
Implementation Method 3
an electromagnetic stator located outside of the sealed can surrounds the rotor
Data Source
AI summary
A coaxial pump or turbine module includes an integral, modular motor or generator comprising a magnet structure containing radial or axial permanent magnets and/or induction coils detachably fixed to a rotor, and a stator housing detachably fixed to the module housing. Working fluid is directed axially through a flow path symmetrically distributed within an annulus formed between the module housing and the stator housing. The stator housing can be cooled by the working fluid, or by a cooling fluid flowing between passages of the flow path. The flow path can extend over substantially a full length and rear surface of the stator housing. A plurality of the modules can be combined into a multi-stage apparatus, with rotor speeds independently controlled by corresponding variable frequency drives. Embodiments include guide vanes and/or diffusers. The rotor can be fixed to a rotating shaft, or rotate about a fixed shaft.