This patent application is the U.S. national phase of International Application No. PCT/JP2020/022884, filed Jun. 10, 2020, which claims the benefit of Japanese Patent Application No. 2019-155673, filed on Aug. 28, 2019, each of which are incorporated by reference in their entireties herein.
The present invention relates to a pump apparatus for delivering a liquid, and more particularly to a pump apparatus including an impeller having a non-limit load characteristic.
Pump apparatuses for delivering liquids are used in various applications. A head, a flow rate, etc. required for each pump apparatus may vary depending on the application of the pump apparatus. An operating point, which is defined by the head and the flow rate, is one of factors for selecting a pump apparatus.
However, considering running costs of the pump apparatus, it is insufficient to select the pump apparatus based only on the operating point. Specifically, a pump efficiency should also be included as a factor for selecting a pump apparatus, and it is important to select a pump apparatus having a high pump efficiency. In particular, from a viewpoint of energy saving, there has recently been an increasing demand for a pump apparatus that can be driven with less power while achieving a required operating point.
Patent document 1: Japanese Patent No. 5246458
Patent document 2: Japanese laid-open patent publication No. 2009-273197
Therefore, the present invention provides an improved pump apparatus capable of achieving a high pump efficiency and energy saving.
In an embodiment, there is provided a pump apparatus comprising: a pump having an impeller; an electric motor configured to rotate the impeller; and an inverter configured to drive the electric motor at variable speed, wherein the impeller has a non-limit load characteristic in a predetermined discharge flow-rate range, and the inverter is configured to drive the electric motor at a preset target operating point with a rotation speed higher than a rotation speed corresponding to a power frequency of a commercial power source.
In an embodiment, the inverter is configured to drive the electric motor at a first rotation speed when a discharge flow rate of a liquid from the pump is lower than a preset flow rate, and to drive the electric motor at a second rotation speed when the discharge flow rate is higher than the preset flow rate, the second rotation speed is lower than the first rotation speed, and the preset flow rate is in the discharge flow-rate range.
In an embodiment, the second rotation speed is such that a shaft power required for the electric motor is equal to or lower than a rated power of the electric motor.
In an embodiment, the second rotation speed is higher than the rotation speed corresponding to the power frequency of the commercial power source.
In an embodiment, a peak point of a pump efficiency is adjacent to an upper limit of the discharge flow-rate range or on the upper limit of the discharge flow-rate range.
In an embodiment, the inverter is configured to increase the rotation speed of the electric motor as long as a shaft power required for the electric motor does not exceed a rated power of the electric motor.
According to the present invention, a high pump efficiency and energy saving can be achieved by the combination of the impeller having the non-limit load characteristic and the high-speed driving of the electric motor by the inverter.
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
As shown in
The impellers 5 are arranged in the inner casing 15A, and the inner casing 15A is arranged in the outer casing 15B. The outer casing 15B surrounds the entire inner casing 15A, and a flow passage 20 for a liquid is formed between the inner casing 15A and the outer casing 15B. A plurality of through-holes 16 are formed in an end of the inner casing 15A, so that the interior of the inner casing 15A and the flow passage 20 communicate with each other through these through-holes 16. The casing 15 has a suction port 22 communicating with the interior of the inner casing 15A and further has a discharge port 23 communicating with the flow passage 20.
The impellers 5 are arranged in series facing toward the suction port 22. The pump 1 further includes a plurality of diffusers 25 arranged at back sides (downstream sides) of the plurality of impellers 5, respectively. When the electric motor 7 rotates the rotating shaft 17 and the impellers 5, the liquid flows into the inner casing 15A through the suction port 22, and the rotating impellers 5 imparts kinetic energy to the liquid. The kinetic energy is converted to pressure as the liquid passes through the diffusers 25. The liquid is pressurized by the impellers 5 and the diffusers 25, moves into the flow passage 20 through the through-holes 16, flows through the flow passage 20, and is discharged through the discharge port 23.
The inverter 10 includes an AC-DC converter section 11 to which electric power is supplied from a commercial power source, a DC-AC inverter section 12 having semiconductor elements (switching elements) such as IGBT, and a controller 13 configured to control operation of the entire inverter 10. In
Each vane 35 has a shape twisted along a flow direction of the liquid, i.e., a three-dimensional shape. More specifically, an inlet end of each vane 35 is inclined with respect to a central axis CL of the impeller 5 as viewed from the axial direction of the impeller 5. The impeller 5 having such three-dimensionally shaped vanes 35 can improve a pump efficiency. Furthermore, an angle θ between the outlet end of each vane 35 and a tangential direction of the main plate 33 is larger than that of a conventional impeller described later. As the angle θ increases, a peak point of a shaft power of the impeller 5 moves to a high flow-rate side. Specifically, the impeller 5 having a large angle θ has a non-limit load characteristic over a wide operating range.
The impeller 5 having the non-limit load characteristic can improve the pump efficiency. On the other hand, during the operation of the pump apparatus, the shaft power may exceed a rated power of the electric motor 7. Therefore, the inverter 10 is configured to limit the electric power supplied to the electric motor 7 to the rated power or less of the electric motor 7. The inverter 10 having such configuration can prevent excessive power consumption and can prevent failure of the electric motor 7 due to overload.
As shown in
As described above, the combination of the inverter 10 and the electric motor 7 enables the impeller 5 to rotate at a rotation speed higher than that of a pump apparatus having no inverter. Therefore, the impeller 5 is allowed to have a higher specific speed than that of a general impeller capable of achieving the target operating point TO. More specifically, the impeller 5 can have a diameter D2 (see
In general, the higher the specific speed, the higher the pump efficiency. In the predetermined discharge flow-rate range R, the inverter 10 of the present embodiment drives the electric motor 7 at a rotation speed higher than the rotation speed corresponding to the frequency (50 Hz or 60 Hz) of the commercial power supply, and the electric motor 7 rotates the impeller 5 at a rotation speed higher than the rotation speed corresponding to the frequency (50 Hz or 60 Hz) of the commercial power source in the discharge flow-rate range R. The discharge flow-rate range R is the rated operating range of the pump 1. Since the inverter 10 drives the electric motor 7 at a high rotation speed in this rated operating region (i.e., in the discharge flow-rate range R), the impeller 5 is allowed to have a high specific speed with good pump efficiency. In addition, the diameter of the impeller 5 can be made smaller than that of other impeller that can achieve the same flow rate and the same head.
The impeller 200 of the pump apparatus having no inverter is rotated at a rotation speed corresponding to the frequency (50 Hz or 60 Hz) of the commercial power source. The impeller 200 of
The impeller 5 of the present embodiment shown in
As can be seen from the comparison between
In addition, the reduction of the diameter of the impeller 5 can lower a loss due to a disk friction, and as a result, the pump efficiency can be improved. The pump efficiency is generally expressed as:
Pump efficiency=hydro-theoretical efficiency−various losses (1)
where the hydro-theoretical efficiency is obtained by a formula for calculating the pump efficiency. The various losses include losses due to various factors, and a loss due to the disk friction greatly affects the pump efficiency. The disk friction is a friction between an impeller and a liquid. The disk friction is calculated by the following equation.
Disk friction=Cd×ρ×U23×D22×(1+5e/D2) (2)
where Cd is a drag coefficient with respect to Reynolds number, ρ is a density of the liquid, U2 is a circumferential velocity of the impeller [m/s], D2 is a diameter of the impeller [m], and e is a sum [m] of a thickness of the side plate and a thickness of the main plate of the impeller.
As can be seen from the above equation (2), the smaller the diameter D2 of the impeller, the smaller the disk friction. Therefore, the pump efficiency obtained from the equation (1) is improved as the diameter of the impeller becomes smaller. Since the impeller 5 of the present embodiment has a small diameter, the disk friction is small, and as a result, the pump efficiency can be improved.
As described above, the impeller 5 of the present embodiment includes the vanes 35 each having the three-dimensional shape and has the non-limit load characteristic. The impeller 5 designed to have such configurations can significantly improve the pump efficiency. Further, by operating the pump at a higher rotation speed, the number of stages of the impellers 5 can be reduced by about 40% as compared with the conventional pump apparatus that can achieve the same flow rate and the same head. Specifically, according to the present embodiment, the pump efficiency of the pump apparatus can be improved and the downsizing of the pump apparatus can also be achieved.
In one embodiment, each vane 35 may not have the three-dimensional shape as long as the impeller 5 has the non-limit load characteristic. Specifically, the inlet end of each vane 35 is parallel to the central axis CL of the impeller 5 as viewed from the axial direction of the impeller 5, and the angle θ (see
Next, an embodiment of the operation of the inverter 10 in the discharge flow-rate range R (rated operating range) will be described with reference to
Since the impeller 5 of the present embodiment has the non-limit load characteristic, the shaft power increases as the discharge flow rate increases. Therefore, in order to prevent an overload on the electric motor 7, the inverter 10 of the present embodiment is configured to drive the electric motor 7 at a first rotation speed when a discharge flow rate of the liquid from the pump 1 is smaller than a preset flow rate ST and to drive the electric motor 7 at a second rotation speed when the discharge flow rate is higher than the preset flow rate ST. The second rotation speed is lower than the first rotation speed. The preset flow rate ST is equal to or more than the lower limit L1 and less than the upper limit L2 of the discharge flow-rate range R.
The first rotation speed and the second rotation speed are higher than a rotation speed corresponding to the power frequency (50 Hz or 60 Hz) of the commercial power source. The second rotation speed is such that the shaft power required for the electric motor 7 is equal to or less than the rated power of the electric motor 7. The second rotation speed may be a fixed rotation speed or may fluctuate within a range lower than the first rotation speed.
As can be seen from the graph of
Similar to the embodiment of
As can be seen from the graph of
As described above, the pump apparatus of the present embodiment can cover the operating ranges of two conventional pump apparatuses having different performance curves as shown by the thin lines in
As described above, the pump apparatus having the combination of the rotation control of the electric motor 7 (i.e., the impeller 5) by the inverter 10 and the impeller 5 having the non-limit load characteristic can cover a wide operating range. In addition, the pump efficiency can be improved, and the pump apparatus can be downsized.
The operation of the inverter 10 of each of the above-described embodiments is performed according to the program stored in the memory 13a of the controller 13 shown in
The previous description of embodiments is provided to enable a person skilled in the art to make and use the present invention. Moreover, various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles and specific examples defined herein may be applied to other embodiments. Therefore, the present invention is not intended to be limited to the embodiments described herein but is to be accorded the widest scope as defined by limitation of the claims.
The present invention is applicable to a pump apparatus for delivering a liquid.
Number | Date | Country | Kind |
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2019-155673 | Aug 2019 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2020/022884 | 6/10/2020 | WO |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2021/039025 | 3/4/2021 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
4511312 | Hartwig | Apr 1985 | A |
5240380 | Mabe | Aug 1993 | A |
5563490 | Kawaguchi | Oct 1996 | A |
5634772 | Kawaguchi | Jun 1997 | A |
5883489 | Konrad | Mar 1999 | A |
6050780 | Hasegawa | Apr 2000 | A |
20020018721 | Kobayashi et al. | Feb 2002 | A1 |
20110223038 | Ogawa | Sep 2011 | A1 |
Number | Date | Country |
---|---|---|
S6258097 | Mar 1987 | JP |
H11-82316 | Mar 1999 | JP |
H1193881 | Apr 1999 | JP |
2009-273197 | Nov 2009 | JP |
5246458 | Jul 2013 | JP |
2002-242844 | Aug 2022 | JP |
WO 9945276 | Sep 1999 | WO |
WO 2013125034 | Aug 2013 | WO |
Entry |
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Imaichi et al., “Pump Design Basis,” Japan Industrial Publishing Co., Ltd., First Edition, pp. 23-24 (Mar. 25, 1983). |
Japanese Patent Office, Internatinal Search Report in International Patent Application No. PCT/JP2020/022884 (dated Jul. 28, 2020). |
European Patent Office, Extended European Search Report in European Patent Application No. 20856846.9 (dated Aug. 30, 2023). |
Number | Date | Country | |
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20220290675 A1 | Sep 2022 | US |