Submersible Pump Power Circuit Cooling via Fluid Flow
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Solution Overview
Problem
Existing submersible pumps face challenges in cooling electrical components, particularly with permanent magnet brushed DC motors, as oil cooling contaminates the oil and air cooling is not practical, limiting high-speed capabilities and efficiency.
Innovation Solution
A submersible pump design that incorporates a sealed electronic controller enclosure with a power circuit to convert AC to DC, using the surrounding fluid for heat dissipation, either through a heat sink or embedding components in a potting compound, allowing heat transfer via fluid flow induced by the impeller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If oil cooling is used to cool the motor and electrical components, then cooling effectiveness is improved, but the oil becomes contaminated with carbon particles from brush wear, spoiling its di-electric properties
Solution Approach 1:
The patent divides the cooling function into two separate systems: oil cooling for the motor and electrical components, and water cooling for the power control module. This segmentation prevents contamination of the oil by carbon particles from affecting the cooling of electrical components, as the power control module is cooled by a separate water circulation system.
Solution Approach 2:
The patent introduces water as an intermediary cooling medium for the power control module, separating it from the oil cooling system. The water circulation system with heat sinks and pumps provides cooling without contaminating the oil, thus preserving the oil's di-electric properties while maintaining effective cooling of electrical components.
2Temperature
If air cooling with fan is used for electrical components, then cooling is provided, but the design is disqualified for submersible pump applications
Solution Approach 1:
The patent transitions from air cooling to hydraulic cooling by using water circulation through heat sinks and cooling channels. This allows the pump to be submerged in water while effectively cooling the power control module and electrical components through the water-based heat transfer system.
Solution Approach 2:
The patent uses water as an intermediary cooling medium that serves dual purposes: it cools the electrical components through heat sinks and circulation, and it enables submersible operation. The water circulation system acts as a mediator between the electrical components and the surrounding water environment.
3Productivity
If permanent magnet DC motors are used for high speed operation, then efficiency and speed capability are improved, but cooling of electrical components becomes a critical challenge in submersible applications
Solution Approach 1:
The patent implements a water circulation cooling system with heat sinks, pumps, and cooling channels to effectively manage the heat generated by high-speed permanent magnet DC motors. This hydraulic cooling approach enables sustained high-speed operation by continuously removing heat from the electrical components.
Solution Approach 2:
The patent creates a multi-functional water circulation system that simultaneously cools the power control module, motor, and electrical components. This universal cooling approach supports high-speed operation of permanent magnet DC motors by providing comprehensive thermal management across all heat-generating components.
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 solution effectively cools electrical components, enabling higher speed operation and efficiency while maintaining reliability and reducing contamination risks, thus overcoming the limitations of traditional cooling methods.
Implementation Method 1
using the surrounding fluid for heat dissipation, either through a heat sink or embedding components in a potting compound, allowing heat transfer via fluid flow induced by the impeller
Implementation Method 2
using the surrounding fluid for heat dissipation, either through a heat sink or embedding components in a potting compound, allowing heat transfer via fluid flow induced by the impeller
Data Source
AI summary
A submersible pump and related methods are disclosed herein. The pump assembly includes a pump housing and a motor with a motor housing/cap and an output shaft connected to an impeller that is disposed in a volute. In some forms, a separate power circuit compartment is formed integral to one of the pump housing and/or volute to store power circuitry that allows a DC pump to be used and powered by AC voltage. In other forms, the power circuit compartment is formed separate from the pump assembly and fastened or connect to the pump assembly. In preferred forms, the power circuit compartment is positioned relative to the pump assembly at a point where it will be maintained at least partially within the fluid surrounding the pump to dissipate heat from the power circuit. Numerous methods are also disclosed and contemplated herein.