AU2015250633B2

AU2015250633B2 - Integrated unit for use in pump station

Info

Publication number: AU2015250633B2
Application number: AU2015250633A
Authority: AU
Inventors: Charles Armstrong; Alan BARNARD; Lee DERBYSHIRE; John LINDOP
Original assignee: SA Armstrong Ltd
Current assignee: SA Armstrong Ltd
Priority date: 2014-04-23
Filing date: 2015-04-23
Publication date: 2018-11-08
Anticipated expiration: 2035-04-23
Also published as: CN106255826B; EP3140543B1; AU2015250635B2; EP3140544A2; PL3140544T3; AU2015250634B2; AU2015250635A1; WO2015162427A2; EP3140545A2; EP3140543A2; CN106255826A; WO2015162427A3; AU2015250634A1; WO2015162428A3; WO2015162429A3; CN106460812A; EP3140545B1; EP3140544B1; AU2015250633A1; CN106232988A

Abstract

An integrated unit for use in a pump station. The integrated unit comprises a connector for connection to a power supply, a motor arranged to provide mechanical drive to an output shaft for coupling to a pumping unit associated with the pump station, a motor controller arranged to supply the motor with power from the connector to thereby control the motor, and an interface for a pump station system controller arranged to interface with the motor controller to match the mechanical drive supplied to the output shaft by the motor to demand. The integrated unit station comprises a housing with an exterior wall portion that is removable, and to which comprises a cooling system for an electronic component. An automatically engaging coupling is arranged to automatically disconnect the electrical connection to the electronic component on removal of the exterior wall portion.

Description

The present invention concerns integrated units for use in pump stations, and related manufacturing and operating methods. In particular, but not exclusively, the present invention relates to integrated units for use in pump stations that work underground in the delivery of hydraulic fluid.

Background to the Invention

Underground, in a long wall coal mine, powered roof supports may be used for supporting the mine roof in the region above a cutting machine working at the face. The powered roof supports employ high pressure hydraulic fluid to support the roof load and to advance with a cutting machine as the cutting machine cuts coal from the face. Typically, a hydraulic pump station, located away from the face is used to supply the hydraulic fluid. The pump station typically comprises tanks serving as reservoirs of hydraulic fluid, and a group of pumping units which are each selectively driven by electric motors. The electric motors are used to drive the pumping units individually into an on or an off state, under control of a pump station system controller. The pump station system controller monitors demand for hydraulic fluid and provides control signals to the electric motors. One such pump station may be used to supply a plurality of powered roof supports, and to supply hydraulic fluid to other machines, for power or cooling purposes, and to perform other pumping jobs such as supplying water or other liquid for dust suppression.

In the underground environment space for pump stations can be scarce, and access or positioning of pump stations and associated pumping units underground may be difficult. Due to these physical constraints, the reservoirs, pumping units and pump station system controller may need to be positioned remote from one another, with electrical and fluid couplings there30 between. When working underground the atmosphere may be prone to risk of explosion. Furthermore, in the event of failure of a pump station a rapid return to an operational state is required. Coupled with the variable demand for hydraulic fluid, controlling the operation ofthe pump station to give a desired supply of fluid volume and maintain proper pressure at the output of the pumping units is difficult, because characteristics of the pumping units, and the performance characteristics ofthe powered roof supports supplied by the pumping units have complicated relationships. The problem of meeting the demand for hydraulic supply is also linked to the responsiveness ofthe pumping units. Typically, responsiveness is limited by the response speed of the motors used to power the pumping units. In normal operation of the pump station the distribution ofthe pumping load across pumping units compensates for slow

2015250633 01 Oct 2018 responsiveness, as no one pumping unit is required to make rapid step changes in its output. However, in the event of failure of a pumping unit in the pump station, responsiveness becomes much more important because the remaining pumping units must try to compensate for the failure. This can require a large and rapid response. To meet this sort of change in demand, typically a pump station will include a reserve pumping unit which can be employed to provide responsiveness in this sort of situation. However, the reserve pumping unit is an additional cost and adds complexity to the pump station.

Separation of power and control electronics from pumping units of a pump station means that there is complication in ensuring reliable connections for power and/or data communication. Reliable connections for power and/or data communication and indeed hydraulic output are very important to eliminate downtime, so that efficient continuous operation is possible, and so that supply is maintained to any potentially safety-critical systems. Furthermore, overall control of the pump station, or manual control of specific pump units in the pump station is complicated by the separation of the elements in the pump station.

It is an aim of example embodiments of the present invention to address at least one disadvantage of the prior art, whether identified herein or otherwise.

Summary of the Invention

In one example embodiment the present invention provides an integrated unit for use in a pump station, the integrated unit comprising: a connector for connection to a powersupply; a motor arranged to provide mechanical drive to an output shaft for coupling to a pumping unit associated with the integrated unit;

a motor controller arranged to supply the motor with power from the connector to thereby control the motor; and an interface to a pump station system controller, by which the integrated unit is arranged in use to receive an input relating to a demand received from a pump station system controller for output from the pumping unit associated with the integrated unit, and to cause the motor controller to drive the motor in response thereto.

In one example embodiment the motor comprises a switched reluctance motor.

In one example embodiment the present invention provides an integrated unit for use in a pump station, the integrated unit comprising: a connector for connection to a powersupply;

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PCT/GB2015/051196 a switched reluctance motor arranged to provide mechanical drive to an output shaft for coupling to a pumping unit associated with the integrated unit;

a motor controller arranged to supply the motor with power from the connector to thereby control the motor; and an interface to a pump station system controller, by which the integrated unit is arranged in use to receive an input relating to a demand received from a pump station system controller for output from a pumping unit associated with the integrated unit, and to cause the motor controller to drive the motor in response thereto.

In one example embodiment there is provided an integrated unit for a pump station, comprising a motor, a motor controller and an interface to a pump station system controller, wherein the motor, motor controller and interface to the pump station system controller are integrated with one another in a housing, wherein the housing comprises an exterior wall portion that is removably mounted on the housing, and to which an electronic component of the motor controller or interface to a pump station system controller is mounted so as to be located internally to the housing when the exterior wall portion is mounted on the housing, and wherein the exterior wall portion comprises a cooling system for the electronic component.

In one example embodiment the motor comprises a switched reluctance motor.

In one example embodiment there is provided an integrated unit for a pump station, comprising a switched reluctance motor, a motor controller and an interface to a pump station system controller, wherein the motor, motor controller and interface to the pump station system controller are integrated with one another in a housing, wherein the housing comprises an exterior wall portion that is removably mounted on the housing, and to which an electronic component of the motor controller or interface to a pump station system controller is mounted so as to be located internally to the housing when the exterior wall portion is mounted on the housing, and wherein the exterior wall portion comprises a cooling system for the electronic component.

In one example embodiment there is provided a housing for an integrated unit for use in a pump station, the housing arrangeable in use to accommodate a motor, a motor controller and an interface to a pump station system controller integrated with one another in a housing, wherein the housing comprises mountings arranged to enable an exterior wall portion thereof to be removably mounted, wherein the exterior wall portion comprises an electronic component mounted thereon and wherein the pump station further comprises an automatically engaging coupling arranged to electrically connect an electronic component mounted on the exterior wall portion to the motor controller or pump station system controller while the exterior wall portion is mounted on the housing, and wherein the automatically engaging coupling is

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PCT/GB2015/051196 arranged to automatically disconnect the electrical connection between the electronic component and the motor controller or pump station system controller on removal of the exterior wall portion from the housing.

In one example embodiment the motor comprises a switched reluctance motor.

In one example embodiment there is provided a housing for an integrated unit for use in a pump station, the housing arrangeable in use to accommodate a switched reluctance motor, a motor controller and an interface to a pump station system controller integrated with one another in a housing, wherein the housing comprises mountings arranged to enable an exterior wall portion thereof to be removably mounted, wherein the exterior wall portion comprises an electronic component mounted thereon and wherein the pump station further comprises an automatically engaging coupling arranged to electrically connect an electronic component mounted on the exterior wall portion to the motor controller or pump station system controller while the exterior wall portion is mounted on the housing, and wherein the automatically engaging coupling is arranged to automatically disconnect the electrical connection between the electronic component and the motor controller or pump station system controller on removal of the exterior wall portion from the housing.

In one example the integrated unit for a pump station further comprises a pumping unit coupled to the output shaft. If not already described, the housing may be arranged to further accommodate a connector for a power supply, and at least part of an output shaft of a motor arranged therein. In one example the integrated unit for a pump station further comprises a pump station system controller. In one example embodiment the pump station system controller comprises an interface for connection to another pump station system controller external to the integrated unit.

In one example embodiment there is provided a pump station comprising an arrangement of plurality of integrated units as set out above. In one example the pump station comprises a plurality of integrated units, with a plurality of pumping units coupled thereto. In one example embodiment each integrated unit is coupled to a pumping unit. In one example embodiment the pump station comprises a data connection between a pump station system controller and the integrated units so that the integrated units are controllable together to provide a required output according to a variable pumping demand. In one example embodiment one of the integrated units comprises a pump station system controller operable to control one or more of the integrated units in the pump station. In one example embodiment one of the integrated units comprises a pump station system controller operable as a master for all of the other integrated units in the pump station. In one example embodiment one of the integrated units is operable as a slave, subservient to pump station system controller arranged

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PCT/GB2015/051196 to act as a master for the integrated units in the pump station. In one example embodiment the pump station comprises a plurality of integrated units, with one, two or more of the integrated units, for example each of the integrated units, comprising a pump station system controller that is configurable to operate as a master controller, or as a slave controller subservient to a master controller of another integrated unit. In one example embodiment the pump station is arranged such the data connection is used to designate a master controller from the integrated units.

In one example embodiment the integrated unit comprises a housing for the connector, 10 motor, motor controller, output shaft and interface to a pump station system controller. In one example embodiment the connector is an electrical connector. In one example embodiment the connector is arranged to provide an electrical connection, and a physical connection for a power supply line to be mounted on the integrated unit. In one example embodiment the connector is at least partially accessible from outside the housing, and is arranged to provide a path for electricity from outside the housing to inside the housing. In one example embodiment the output shaft is at least partially accessible from outside the housing for coupling to a pumping unit.

In one example embodiment the integrated unit comprises a user interface section, arranged to receive user control inputs and to provide operational status information for components of the integrated unit, a pumping unit coupled to the integrated unit, and to pumping units that are operatively connected as part of a pump station. In one example embodiment the user interface section comprises a display screen. The user interface section may comprise a touch screen, keyboard, mouse or the like for receiving user control inputs.

In one example embodiment the motor controller comprises a variable speed drive. In one example embodiment the pumping unit comprises a positive displacement pump. In one example embodiment a pump station system controller is arranged to monitor the operation of an associated pumping unit coupled to the output shaft, and to receive one or more feedback signals, as well as user control inputs from the user input section. In one example embodiment the pump station system controller is arranged to control operation of the integrated unit, including passing drive control signals to the motor controller, based on user control inputs and one or more demand signals related to pumping unit speed, pumping unit flow rate, pumping unit or downstream pressure, and optionally one or more related feedback signals.

In one example embodiment the housing comprises a plurality of internal compartments. In one example embodiments the housing comprises at least two internal compartments that are physically isolated from one another, completely or in part. In one example the housing

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PCT/GB2015/051196 comprises a motor compartment, providing internal physical isolation, completely or in part, between the motor and one or more of the motor controller and the pump station system controller. In one example the housing comprises a motor compartment, providing internal physical isolation between the motor and each of the motor controller and the interface for the pump station master controller, completely or in part. In one example embodiment the housing is arranged with a motor compartment including one or more openings between the motor compartment and one or more other compartments in the housing. In one example embodiments, the housing comprises a motor compartment with openings which are closed by the motor itself, completely or in part, when the motor is arranged in place in the housing. In one example embodiment the motor comprises rotor coupled to the output shaft, and a stator arranged around the rotor. In one example embodiment the stator comprises an outer jacket, wherein the outer jacket is arranged with the housing to form a motor compartment around the motor, isolating the motor from one or more other compartments in the housing while the motor is in place in the housing, said separation being complete, or partial. The aforesaid compartments may be physically isolated from one another completely, in the sense of there being no connecting path there-between, or may be physically isolated from one another in part so that is a separation feature, such as rib, bar, frame, lattice or the like, wherein a generally open aspect between compartments is provided to give an expansion space for gas in the housing. For example, an expansion space may be provided in the housing, said space forming a generally interconnected space for gas to move freely between a sub set of the compartments, or all of the compartments.

In one example embodiment the stator comprises an outer jacket, wherein the outer jacket is arranged, while the motor is integrated into the integrated unit, to provide part of the housing. In one example embodiment the outer jacket is arranged to provide internal physical separation between a motor compartment and one or more other compartments in the housing, completely or in part. In one example embodiment the outer jacket is arranged to include a projection that extends from the motor as a rib-like projection, or sheet-like projection, arranged to provide complete or partial internal physical separation between compartments in the housing. In one example embodiment the projection extends radially from the motor. In one example embodiment the projection extends tangentially from the motor. In one example embodiment the projection runs along the motor parallel to the axis of the output shaft. In one example embodiment the projection runs along the length of the jacket, partially, or alternatively fully along the length of the jacket. In one example embodiment the projection is arranged to close an opening between a motor compartment in the housing, and one or more other compartments in the housing, when the motor is arranged in place in the housing. In one example embodiment the projection comprises fixing features to enable one or more other components in the housing to be connected thereto. In one

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PCT/GB2015/051196 example embodiment a plurality of projections are provided on the jacket, with a plurality of the projections as described.

In one example embodiment the housing comprises a plurality of internal compartments 5 for the motor controller, e.g. two or more of: a motor controller processor compartment, a power electronics compartment, and a filter compartment. In one example embodiment the motor controller comprises a plurality of power electronics units in a power electronics compartment. In one example embodiment the power electronics units are provided on circuit boards that can be removed and replaced by plug-out and plug-in action, for example by including part of a connector to cooperate with another part of a connector within the housing. In one example embodiment one or more, for example each of the compartments for the motor controller is open to an expansion space within the housing.

In one example embodiment one or more of the power electronic compartments is communicative with an opening in the housing, wherein the housing comprises a removable exterior wall portion that is removably mounted on the housing, and to which an electronic component of the motor controller or pump station system controller is mounted. Suitably, one or more of the power electronic compartments is communicative with an opening in the housing, wherein the housing comprises a removable exterior wall portion that is removably mounted on the housing, and to which a circuit board carrying an electronic component of the motor controller or pump station system controller is mounted. Suitably, the electronic component comprises an active component, suitably a rectifier or switching component, preferably a transistor, preferably an insulated-gate bipolar transistor (IGBT). Suitably, the electronic component comprises a power electronics component, or a power electronics unit comprising a plurality of power electronics components. In one example embodiment one or more, for example each of the power electronic compartments is open to an expansion space within the housing.

In one example embodiment the exterior wall portion is provided with a handle to facilitate removal of the exterior wall portion from the housing. In one example embodiment the handle is provided so as to be located externally to the housing when the exterior wall portion is mounted on the housing. In one example embodiment the housing comprises mounting features arranged to cooperate with mounting features on the exterior wall portion to in use enable the exterior wall portion to be releasably mounted on the housing.

In one example embodiment the exterior wall portion is arranged to act as a heat sink for the electronic component mounted thereon. In one example embodiment the exterior wall portion has the electronic component mounted in bodily contact thereto, for example with an electrically insulating package of the electronic component in bodily contact with the exterior

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PCT/GB2015/051196 wall portion. In one example embodiment the exterior wall portion is provided with a thermal bridge layer arranged between the electronic component and exterior wall portion. In one embodiment the exterior wall portion comprises an inner face and an outer face, with the electronic component is mounted on the inner face. In one example the inner face is generally planar, and the electronic component is mounted on the exterior wall portion parallel to the inner face. In one example embodiment the cooling system for the electronic component comprises an active cooling system for the electronic component. In one example embodiment the cooling system comprises a fluid delivery system. In one example the fluid delivery system comprises a fluid inlet and a fluid outlet provided for the exterior wall portion.

In one example embodiment the fluid inlet is provided on an outer face of the exterior wall portion. In one example embodiment the fluid outlet is provided on an outer face of the exterior wall portion. In one example embodiment both the fluid inlet and the fluid outlet are provided on an outer face ofthe exterior wall portion. In one example embodiment the fluid inlet and fluid outlet are coupled by a fluid pathway formed in the exterior wall portion, for example formed wholly in the exterior wall portion. In one example embodiment the fluid pathway does not lie inwardly of the inner face of the exterior wall portion. In one example embodiment the fluid pathway comprises a recessed portion of the exterior wall portion. In one example embodiment the outer face ofthe exterior wall portion is generally planar, and the fluid pathway runs within the exterior wall portion in its plane, for example wholly in its plane.

In one example embodiment the fluid pathway is maintained outside one or more compartments within the housing, so as to be separated from the interior of the compartments, and/or from an expansion space connecting compartments in the housing. In one example embodiment the fluid pathway is arranged not to extend beyond the inner surface of the exteriorwall portion. In one example embodiment the fluid pathway comprises a recess, e.g. a channel, formed in the exterior wall portion, arranged with a cap over it to seal the channel between the fluid inlet and the fluid outlet. In one example embodiment the cap comprises a plate. In one example embodiment the cap provides an outer face ofthe exteriorwall portion.

In one example embodiment the electronic component is arranged inwardly in the housing compared to the inward extent ofthe fluid pathway. In one example embodiment the electronic component is arranged to be electrically connected to the motor controller or pump station system controller, away from the exteriorwall portion, using a plug-in, push fit or other automatically engaging coupling forming the connection when the exterior wall portion is mounted on the housing.

In one example embodiment the exterior wall portion has a plurality of electronic components mounted thereto, the electronic components mounted thereto as set out above.

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In one example embodiment the housing comprises a plurality of exterior wall portions as set out above. In one example embodiment the housing comprises a plurality of exterior wall portions to which the same electronic component is mounted, such that the exterior wall portions are parts of a modular arrangement of electronic components for the integrated unit.

In one example embodiment the housing comprises exterior wall portions at the front, back, first and second ends, top and bottom, for example forming a generally cuboidal shape. In one example embodiment the exterior wall portions comprise openings on at least two faces, for example on three faces. In one example embodiment the housing comprises openings on three generally non-parallel faces, for example on a front face, a top and on a first end face. In one example embodiment the housing comprises openings on only one, two or three of the front face, a top and a first end face. In this way the housing can be positioned against a wall, and next to an interconnected pumping unit on a second end face in use, but remain generally accessible for installation, maintenance and repair work to be performed via the openings.

In one example embodiment the housing is an explosion-resistant housing.

In one example embodiment the integrated unit comprises a motor cooling system arranged to enable delivery of cooling fluid to the motor. In one example embodiment the motor cooling system comprises a fluid inlet and a fluid outlet provided to the exterior of the housing. In one example embodiment the motor cooling system is arranged so that fluid may flow there-through and in doing so carry heat away from the motor and out of the housing. In one example embodiment the motor cooling system is arranged so that fluid may flow over an outer jacket of the motor and in doing so carry heat away from the motor and out of the housing.

In one example embodiment the fluid inlet and fluid outlet of the motor cooling system are in fluid communication with a motor compartment of the housing. In one example embodiment the void is provided so that fluid may flow there-through. In one example embodiment the motor cooling system comprises a void in a motor compartment, at least partially surrounding the motor. In one example embodiment the motor cooling system comprises a void in a motor compartment, the void formed between the motor and the housing in which the motor is arranged.

As will be understood, the automatically engaging coupling is arranged to electrically connect an electronic component mounted on the exterior wall portion to the motor controller or pump station system controller on mounting, including re-mounting of the exterior wall portion of the housing.

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In one embodiment the automatically engaging coupling is a multi-part coupling with one part carried by any one of: the exterior wall portion; the electronic component mounted on the exterior wall portion; a circuit board carrying the electronic component mounted on the exterior wall portion. In one embodiment the automatically engaging coupling is a multi-part coupling with another part carried by any one of: the housing; the motor controller; the pump station system controller; a circuit board or bus coupled to the motor controller; a circuit board or bus coupled to the pump station system controller.

In one embodiment the housing comprises a plurality of exterior wall portions as set out above, arranged to function as set out above when mounted on the housing and on removal from the housing. In one example embodiment the exterior wall portions are parts of a modular arrangement of electronic components for a pump station, for example for a motor controller.

In one example embodiment the integrated unit comprises a motor controller including a plurality of modular units, each comprising one or more electronic components mounted on an exterior wall portion of the housing.

In one example embodiment the electronic component is arranged to be electrically connected to the motor controller or pump station system controller, away from the exterior wall portion, using a plug-in, push fit or other automatically engaging coupling forming the connection when the exterior wall portion is mounted on the housing.

In one example embodiment there is provided a housing as set out above. In one example embodiment there is provided a housing for assembly into an integrated unit as set out above.

In one example embodiment there is provided a method of manufacturing an integrated unit for use in a pump station, the integrated unit comprising a connector for connection to a power supply, a motor arranged to provide mechanical drive to an output shaft for coupling to a pumping unit associated with the pump station, a motor controller arranged to supply the motor with power from the connector to thereby control the motor, and an interface for a pump station system controller, the method comprising assembling the connector, motor, motor controller, output shaft and interface for the pump station system controller as an integrated unit.

In one example embodiment there is provided a method of operating a pump station, the pump station comprising a motor, a motor controller and an interface for a pump station system controller, the motor, motor controller and pump station system controller integrated

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PCT/GB2015/051196 with one another in a housing, wherein the housing comprises an exterior wall portion that is removably mounted on the housing, and to which an electronic component of the motor controller or interface for a pump station system controller is mounted so as to be located internally to the housing when the exterior wall portion is mounted on the housing, the method comprising method comprising a providing cooling to the electronic component using a cooling system provided by the exterior wall portion.

In one example embodiment there is provided a method of fitting or assembly, the method performed using a housing suitable for accommodating a motor, a motor controller and an interface for a pump station system controller integrated with one another in a housing, the housing comprising mountings to enable an exterior wall portion thereof to be removably mounted, wherein the exterior wall portion comprising an electronic component mounted thereon and wherein the pump station further comprises an automatically engaging coupling, the method comprising mounting the exterior wall portion to thereby electrically connect the electronic component mounted on the exterior wall portion to the motor controller or interface for the pump station system controller. The method further comprises removal of the exterior wall portion from the housing to thereby automatically disconnect the electrical connection between the electronic component mounted on the exterior wall portion and the motor controller or interface for the pump station system controller.

Brief Introduction to the Drawings

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings in which:

Figure 1 shows a perspective view of an integrated unit in accordance with a first example embodiment, from the front, first end and above;

Figure 2 shows a perspective view of the integrated unit of Figure 1 from the back, first end and above;

Figure 3 shows a front elevation of the integrated unit of Figure 1;

Figures 4 through 6 show sectional views of the integrated unit of Figure 1, viewed on the sections and in the direction of the arrows A-A, B-B and H-H of Figure 3, respectively;

Figures 7 and 9 show a plan view of the integrated unit of Figure 1;

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Figure 8 shows a sectional view ofthe integrated unit of Figure 1, viewed in the on the section C-C and in the direction ofthe arrows of Figure 7; and

Figures 10 and 11 show sectional views of the integrated unit of Figure 1, viewed on the 5 sections and in the direction ofthe arrows E-E and F-F of Figure 9, respectively;

Figures 12A-12E respectively show: a front view including hidden detail of a channel formed in a portion of an exterior wall portion associated with a rectifier; a sectional view of an exterior wall portion associated with a rectifier, based on line B-B of Figure 12A in the direction ofthe arrows; a perspective view from the front, one side and above of an exterior wall portion associated with a rectifier; a perspective view from behind, the same side and above of an exterior wall portion associated with a rectifier; and a sectional view of the front part of the exterior wall portion, based on line A-A of Figure 12C; and

Figures 13A-13E respectively show: a front view including hidden detail of a channel formed in a portion of an exterior wall portion associated with IGBTs; a sectional view of a portion of an exterior wall portion associated with IGBTs, based on line C-C of Figure 13A in the direction ofthe arrows; a perspective view from the front, one side and above of a portion of an exterior wall portion associated with IGBTs; a perspective view from behind, the same side and above of an exterior wall portion associated with IGBTs; and a perspective view from behind, a second side and above ofa portion of an exterior wall portion associated with IGBTs, including hidden detail ofthe coupling between the IGBTs and the exterior wall portion.

Description of Example Embodiments

Example embodiments will now be described with reference to the accompanying drawings.

Figures 1,2,3,7 and 9 shows the exterior of an integrated unit 1, with Figures 4 through

6, 8, 10 and 11 showing section views ofthe integrated unit 1 so that interior features can be seen and understood. The integrated unit 1 comprises a connector 10 for connection to a power supply, such as an electrical power supply operating at 1140V AC, and is rated for operation at 300kW. Power from the connector 10 is arranged to pass to a motor 20 so as to provide mechanical drive to an output shaft 30. The output shaft 30 is in use coupled to a pumping unit in the form of a positive displacement pump (not shown) that is associated with the integrated unit 1. A motor controller is arranged to control the supply of power from the connector 10 to the motor 20 to thereby control the motor 20. An interface for a pump station system controller is provided to interface with the motor controller, so that the integrated unit 1 can be operated with the mechanical drive supplied to the output shaft 30 by the motor 20

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PCT/GB2015/051196 matched to demand from the pumping unit. The pumping unit is envisaged working with the integrated unit 1 to supply pressurised hydraulic fluid, for example an emulsion of water and oil to powered roof supports or other mining machinery, for example pressurised to 300-400 bar.

As can be seen in the Figures, the integrated unit 1 is arranged so that the connector

10, motor 20, motor controller, output shaft 30 and interface for the pump station system controller are provided as an integrated unit. The integrated unit 1 has the connector 10, motor 20, motor controller, output shaft 30 and interface for a pump station system controller provided integrated with one another within a housing 40. For underground use the housing

40 is explosion-resistant, and an expansion space 80 is provided therein between internal components and compartments so that gas can move within the confines of the housing to account for temperature changes etc.

The motor 20 comprises a switched reluctance motor, and the motor controller comprises a variable speed drive. In other systems, for example those using induction motors, a generally higher inertia and lower electromagnetic responsiveness to control inputs is experienced. Induction motors typically also take up much more volume for a given power and torque specification. For this reason, use of a switched reluctance motor in an integrated unit as described is advantageous, in particular when motor controller and system controllers are closely integrated therewith to provide the drive for the motor. Responsiveness of switched reluctance motors, and their relatively high torque density means that the integrated unit may be operated without a reserve unit provided. In this way the integrated unit can form part of a pump station which includes fewer redundant elements while still enabling a rapid response to large changes in demand, such as changes associated with failure of an other element in the pump station.

In the following description of the example embodiments, the motor, and the associated components including the motor controller etc respectively comprise a switched reluctance motor, and associated components for use with a switched reluctance motor. The motor controller comprises a number of circuit elements - a motor controller processor 60, a rectifier 61, a line reactor 62, an EMC filter 63, a capacitor bank 64 and a plurality of power electronics switching elements in the form of insulated-gate bipolar transistors (IGBTs) 65. The motor controller processor 60 is arranged to monitor the operation status of the motor 20 and to provide, through the other components of the motor controller a desired speed for the motor

20. The motor controller processor 60 is further arranged to receive a setting signal, for example a signal representative of a desired speed for the motor 20 from the interface to a pump station system controller, according to the demand for supply of hydraulic fluid from the pumping unit connected to the motor 20 via the output shaft 30 and the corresponding operation speed of the pumping unit required to meet the demand.

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The interface for the pump station system controller comprises a pump station controller processor 50 that is arranged to monitor the operation of an associated pumping unit coupled to the output shaft 30, and to receive one or more feedback signals, as well as user control inputs from a user. To facilitate user interaction the interface for the pump station system controller comprises a user interface section that can be used to receive user control inputs and to provide operational status information for a pumping unit coupled to the integrated unit

1. The user interface section comprises a display screen 51, and a mouse 52 for receiving user control inputs. As will be described in more detail below, the pump station controller processor 50 may also be used to control other integrated units that are connected to the integrated unit 1 as part of a pump station by operating as a pump station system controller.

The integrated unit 1 includes on its front face exterior wall portions 410 that are removably mounted on the housing 40, and to which electronic components of the motor controller 50 are mounted so as to be located internally to the housing 40 when the exterior wall portions 410 are mounted on the housing 40. As described in detail below, the exterior wall portions 410 provide a number of advantages for the integrated unit 1, in terms of the arrangements for cooling components of the integrated unit 1, and facilitating removal and replacement of components of the integrated unit 1.

The exterior wall portions 410 are used in a cooling system for electronic components of the motor controller, in this case the rectifier 61 and the IGBTs 65. Two exterior wall portions 410, 410' are shown associated with the IGBTs 65, and a further exterior wall portion 410 is shown associated with the rectifier 61. The exterior wall portions 410 are arranged to act as a heat sink for the electronic components mounted thereon. To get good thermal transfer the electronic components are mounted in bodily contact with the inner face of the exterior wall portions 410. Beyond any cooling provided by the thermal mass of the exterior wall portions 410 and the surface area for heat transfer to the environment around the integrated unit 1, the exterior wall portions 410 are part of an active cooling system for the electronic components mounted thereto.

The cooling system comprises a fluid delivery system 420 that causes fluid to pass from a fluid inlet 430 to a fluid outlet 431 provided in the exterior wall portion 410, so that between the fluid inlet 430 and the fluid outlet 431 heat can be absorbed from the exterior wall portion and the associated electronic components and thereby removed from the housing 40. The fluid inlet 430 and the fluid outlet 431 are both provided on an outer face of the exterior wall portions 410, and are coupled by a fluid pathway formed as a channel 433 in the exterior wall portions 410 covered with a cap 434 to seal the channel 433 as a closed conduit between the fluid inlet 430 and the fluid outlet 431. Figure 12E shows this arrangement in cross section. In

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Figures 12A and 13A the cap 434 is depicted as transparent, in order to show the path of the channel 433 which in use lies under the cap 434. In this way the fluid delivery system is kept entirely separate from the interior of the compartments in the housing 40 which contain the electronic components. The material integrity of the exterior wall portion 410 is relied upon to keep the fluid from leaking into the housing, which can easily be specified and manufactured to a high level of reliability. To provide a highly pressure resistant seal between the cap 434 and the channel 433 in the exterior wall portions 410, welds 435 are provided. In the example embodiments one or more welds 435 are made around the edge of the cap 434 to couple the cap 434 to the exterior wall portion 410, with the cap located on the exterior wall portion 410 so as to lie over the channel 433. Welds 435 are also provided through apertures 436 provided in the cap 434, to couple the exterior wall 410 portion to the cap 434, for example to reinforce the connection between the two components. The apertures 436 are aligned with the channel 433 so that the welds 436 are provided away from the edges of the cap 434. For example the alignment between apertures 436 and channel 433 may be such that the welds are provided through the apertures in a central region of the cap 434, or in a region of the cap which lies between two portions of the channel, such as two adjacent portions, here shown as two portions which extend in side-by-side relation with one another, such as in parallel with one another. The welds may further be provided in alternating arrangement between first and second sides of the channel, moving along the length of the channel, and/or may be provided in alternating arrangement between portions of the channel that extend in side-by-side relation with one another. In other embodiments the exterior wall portion may be manufactured with the channel provided therein, for example with the channel comprising an interior feature of a casting.

In the cooling systems described, failure of connectors at the inlet and outlet, and failure of seals made between the inlet/outlet and the exterior wall portion or between inner part and an outer plate of the exterior wall portions are not critical in maintaining fluid separate from the electronic components.

Despite the presence of an active cooling system to reduce the effect of heat build-up in use, electronic components such as IGBTs only have a finite service life and may need occasional replacement. By providing exterior wall portions 410 that are removably mounted on the housing 40, and to which electronic components of the motor controller 50 are mounted the replacement of the components can be facilitated, with the exterior wall portions 410 configured for easy swapping between used and new when required.

To provide a mechanical connection between the housing 40 and the exterior wall portions 410 of the housing 40, mounting features are provided on the housing 40. The mounting features are arranged to cooperate with related mounting features on the exterior

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PCT/GB2015/051196 wall portions 410 to enable the exterior wall portions to be releasably mounted on the housing 40. The mounting features in the integrated unit 1 comprise threaded fasteners, openings 460 in the exterior wall portions 410 and threaded bores in the housing 40. The exterior wall portions 410 are provided with handles 413 to facilitate removal of the exterior wall portions from the housing once the mounting features have been released from one another.

Linked to each of the exterior wall portions 410 is an electrical connection system which is arranged to automatically engage, to provide an electrical connection between an electronic component mounted on the exterior wall portion 410 and the motor control processor 60. The electrical connection is made on mounting of the exterior wall portion 410 to the housing 40. The electrical connection system comprises a plug-in, push fit or other automatically engaging coupling with one part fixed to the exterior wall portion 410 and one part fixed within the housing 40. For example, Figures 13B and 13E show the IGBTs 65 physically coupled to the exterior wall portion 410' by mounting screws 651. The IGBTs 65 are electrically coupled to the electrical systems within the integrated unit 1 by electrical connectors 652, using a plugand-play pin arrangement between the IGBTs 65 and the connectors 652 Flexible flying leads 450 are used to form a further connection from the connectors 652 with the rest of the electrical system within the integrated unit 1. The connectors 652 and flying leads 450 are retained in the housing 40 within a carrier unit 653 that is in use fixed to the housing 40 at, or around the openings 460 for the exterior wall portions. Analogous connection arrangements are suitably provided for other power components, such as the rectifier 61 in conjunction with the exterior wall portion 410 and carrier unit 613, and may also be provided for control or diagnostic signal transmission, for example by a data connector 440.

The housing 40 comprises plurality of internal compartments, which may be at least partially physically isolated from one another, while maintaining the expansion space 80. The housing 40 comprises compartments for the motor 20, the elements of the motor controller and the elements of the interface for the pump station system controller. The compartment in which the motor 20 is located is oversized with respect to the motor 20, to enable operation of a motor cooling system. The motor cooling system enables delivery of cooling fluid to the motor 20. Cooling fluid can be passed between a fluid inlet 21 and a fluid outlet 22 provided to the exterior of the housing 40. Cooling fluid passing between the fluid inlet 21 and the fluid outlet 22 can carry heat away from the motor 20 and out of the housing 40. By passing the cooling fluid through a void around the motor 20 and within a compartment in the housing 40 the need for a separate cooling jacket for the motor 20 is eliminated. Similarly to the cooling arrangements for the exterior wall portions 410, the material integrity of the housing 40 at its internal compartments is relied upon to keep the fluid from leaking into the rest of the housing 40, and in the motor cooling system failure of connectors at the inlet and outlet, and failure of seals made between the inlet/outlet and the exterior wall portion or between inner part and an

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PCT/GB2015/051196 outer plate of the exterior wall portions are not critical in maintaining fluid separate from the electronic components within the housing 40.

The housing 40 as described above has on its front face exterior wall portions 410 that 5 are removably mounted on the housing 40, which when in place cover over openings in the housing. The top face and a first end face also have removable wall portions 510, 610 respectively which when removed reveal openings by which the interior of the housing 40, and components therein can be accessed for installation, maintenance and repair purposes.

The integrated unit 1 can be used as part of a pump station comprising an arrangement of plurality of integrated units. Each integrated unit in the pump station is provided with a pumping unit coupled thereto, and a data connection is provided between the interfaces for the pump station system controllers so that the integrated units are controllable together to provide a required output from the pumping units according to a variable pumping demand. In this type of arrangement one of the integrated units is configured with its pump station controller processor operating as a master pump station system controller. The other integrated units are configured with their pump station controller processors operating as slaves. The slaves are subservient to the pump station system controller provided by the pump station controller processor that acts as the master. The integrated unit can be arranged so that the data connection is used to designate a master, either in response to a user input, or automatically through a predetermined protocol, for example including facility for seamlessly adding or removing integrated units to the pump station. In other embodiments a separate pump station system controller is used to provide control inputs for all of the integrated units using their interfaces for pump station system controllers.

By providing an integrated unit as described, problems associated with data transfer, providing functional mechanical connection and reliability in matching of motor and pump conditions to a desired pumping output are addressed. In addition, the production of a compact form factor, which exhibits high torque density and at the same time good responsiveness time, with suitable explosion-proofing is facilitated. Internal compartmentalisation imparts a degree of benefit in isolating cooling fluids from electronic components. The presence of exterior wall portions that are removable from the housing aids reduces complexity in manufacturing and assembly, and by suitable selection of cooling and interconnection arrangements there are benefits again in manufacture and reliability for a pump station as a whole.

Although a few preferred embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.

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Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

2015250633 01 Oct 2018

Claims

CLAIMS:

1. An integrated unit for a pump station, the integrated unit comprising: a connector for connection to a power supply;

a motor arranged to provide mechanical drive to an output shaft for coupling to a pumping 5 unit associated with the integrated unit;

a motor controller arranged to supply the motor with power from the connector to thereby control the motor; and an interface to a pump station system controller, by which the integrated unit is arranged in use to receive an input relating to a demand received from a pump station system controller

10 for output from the pumping unit associated with the integrated unit, and to cause the motor controller to drive the motor in response thereto.
2. An integrated unit according to claim 1, wherein the motor comprises a switched reluctance motor.
3. An integrated unit according to any one of the preceding claims, wherein the integrated unit comprises a housing for the connector, motor, motor controller, output shaft and interface to a pump station system controller.

20 4. An integrated unit according to any one of the preceding claims, wherein the connector is an electrical connector.

5. An integrated unit according to any one of the preceding claims, wherein the output shaft is at least partially accessible from outside the housing for coupling to a pumping unit.

6. An integrated unit according to any one of the preceding claims, wherein the motor, the motor controller and the interface to the pump station system controller are integrated with one another in a housing, wherein the housing comprises an exterior wall portion that is removably mounted on the 30 housing, and wherein an electronic component of the motor controller or interface to the pump station system controller is mounted on the exterior wall portion so as to be located internally to the housing when the exterior wall portion is mounted on the housing, and wherein the exterior wall portion comprises a cooling system for the electronic 35 component.

7. An integrated unit according to claim 6, wherein the cooling system for the electronic component comprises an active cooling system for the electronic component.

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8. An integrated unit according to any one of the preceding claims, wherein the integrated unit comprises a motor cooling system arranged to enable delivery of cooling fluid to the motor.

9. An integrated unit according to any one of claims 3 to 8, wherein the housing is arranged 5 to further accommodate a connector for a power supply, and at least part of an output shaft of a motor arranged therein.

10. An integrated unit according to any one of the preceding claims, wherein the integrated unit for a pump station further comprises a pump station system controller.

11. An integrated unit according to claim 10, wherein the pump station system controller comprises an interface for connection to another pump station system controller external to the integrated unit.

15 12. An integrated unit according to any one of the preceding claims, wherein the integrated unit comprises a user interface section, arranged to receive user control inputs and to provide operational status information for components of the integrated unit, a pumping unit coupled to the integrated unit, and to pumping units that are operatively connected as part of a pump station.

13. An integrated unit according to any one of the preceding claims, compromising a housing arranged in use to accommodate the motor, the motor controller and the interface to a pump station system controller integrated with one another in a housing, wherein the housing comprises mountings arranged to enable an exterior wall portion thereof to be removably

25 mounted, wherein the exterior wall portion comprises an electronic component mounted thereon and wherein the pump station further comprises an automatically engaging coupling arranged to electrically connect an electronic component mounted on the exterior wall portion to the motor controller or pump station system controller while the exterior wall portion is mounted on the housing, and wherein the automatically engaging coupling is arranged to automatically

30 disconnect the electrical connection between the electronic component and the motor controller or pump station system controller on removal of the exterior wall portion from the housing.

14. A pump station comprising an arrangement of a plurality of integrated units according to any one of claims 1-13.

15. A pump station according to claim 14, wherein one integrated unit is coupled to a pumping unit.

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16. A pump station according to claim 14 or 15, wherein the pump station comprises a data connection between a pump station system controller and the integrated units so that the integrated units are controllable together to provide a required output according to a variable pumping demand.

17. A pump station according to any one of claims 14 to 16, wherein one of the integrated units comprises a pump station system controller operable to control one or more of the integrated units in the pump station.

10 18. A pump station according to any one of claims 14 to 17, wherein the pump station comprises a plurality of integrated units, wherein one of the integrated units comprises a pump station system controller that is configurable to operate as a master controller, or as a slave controller subservient to a master controller of another integrated unit.

15 19. A method of manufacturing an integrated unit for use in a pump station, the integrated unit comprising a connector for connection to a power supply, a motor arranged to provide mechanical drive to an output shaft for coupling to a pumping unit associated with the pump station, a motor controller arranged to supply the motor with power from the connector to thereby control the motor, and an interface for a pump station system controller, the method comprising

20 assembling the connector, motor, motor controller, output shaft and interface for the pump station system controller as an integrated unit.

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1/11

FIG. 1

FIG. 2

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ί._

FIG. 3

FIG. 4

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510 40

FIG. 5

510

FIG. 6

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FIG. 7

FIG. 8

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51 65 65

FIG. 10

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64 62 40 63

FIG. 11

B

460

460 i 433 460

FIG. 12A

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FIG. 12B

613

FIG. 12C

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FIG. 12D

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460—4-θ ⁴⁶⁰ FIG. 13D

FIG. 13C

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FIG. 13E

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