Submersible Pump Control Module Integration
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Solution Overview
Problem
Submersible pump systems have a high number of components and increased complexity due to separate control devices at the surface and motor assemblies in bore-holes, leading to higher costs and installation difficulties.
Innovation Solution
A submersible pump system with a control module integrated into the motor housing, featuring a controller and variable frequency drive that maintains constant pressure output by using a pressure sensor to adjust motor speed, and includes a method to calibrate the system by measuring maximum pressure and adjusting setpoint pressure to match desired output conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separate control device is placed at the surface and motor assembly in the bore-hole, then the control function is achieved, but the number of components increases and installation difficulty increases
Solution Approach 1:
The patent merges the control device with the motor assembly by integrating the control circuit board into the motor housing. The control circuit board is positioned within the motor assembly structure, electrically connected to the motor windings, and mechanically integrated with the motor components. This consolidation reduces the number of separate components from two (control device + motor assembly) to one integrated unit, simplifying installation while maintaining full control functionality.
2Ease of operation
If a separate control device is placed at the surface and motor assembly in the bore-hole, then the control function is achieved, but installation difficulty increases
Solution Approach 1:
The control device is integrated into the motor assembly as a single unit. The control circuit board is housed within the motor housing and electrically connected to the motor windings through internal connections. This integration eliminates the need for separate installation of control devices at the surface and motor assemblies in the bore-hole, reducing installation steps and difficulty while preserving the control function.
3Ease of operation
If multiple separate components are used, then the control function is achieved, but the cost of the pump system increases
Solution Approach 1:
The patent consolidates the control device and motor assembly into one integrated unit, reducing the total number of components required in the pump system. This merger eliminates redundant parts, reduces material usage, and simplifies manufacturing processes, thereby lowering the overall cost of the pump system while maintaining the control function.
4Ease of operation
If control functions are separated from motor assembly, then independent control is achieved, but operational efficiency decreases
Solution Approach 1:
The control circuit board is integrated within the motor assembly, with direct electrical connections to the motor windings and mechanical coupling to the motor structure. This integration enables the control function to operate independently and directly control the motor without external interference or signal transmission delays, thereby maintaining independent control capability while improving operational efficiency through reduced latency and simplified control pathways.
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 configuration reduces the number of system components, simplifies installation, and maintains consistent pressure output by integrating control functions within the motor assembly, thereby lowering costs and improving operational efficiency.
Implementation Method 1
The control module has a controller and a variable frequency drive driven by the controller based on pressure data from the pressure sensor. The controller operates the variable frequency drive to drive the motor to maintain a constant pressure output condition from the pump assembly.
Implementation Method 2
A pressure sensor measures the pressure of fluid directed through the discharge fitting into the piping and is positioned proximate to the discharge fitting.
Data Source
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AI summary
A submersible pump system includes a submersible pump assembly having one or more stages of impellers and a submersible motor assembly that drives the pump assembly. The submersible pump assembly includes a motor housing, a motor within the motor housing for driving the pump assembly and a control module mounted to the motor housing for operating the motor. The control module is electrically connected to a power line and comprises a controller and a variable frequency drive driven by the controller. The controller operates the variable frequency drive to drive the motor to maintain a constant pressure output condition from the pump assembly.