CN106460812B

CN106460812B - Integrated device for use in a pump station

Info

Publication number: CN106460812B
Application number: CN201580021980.6A
Authority: CN
Inventors: 查尔斯·阿姆斯特朗; 艾伦·巴纳德; 利·德比谢尔; 约翰·林多普
Original assignee: SA Armstrong Ltd
Current assignee: SA Armstrong Ltd
Priority date: 2014-04-23
Filing date: 2015-04-23
Publication date: 2020-03-06
Anticipated expiration: 2035-04-23
Also published as: CN106232988B; CN106255826A; WO2015162427A2; EP3140543B1; PL3140544T3; AU2015250633B2; EP3140543A2; AU2015250633A1; WO2015162429A3; PL3140545T3; CN106255826B; AU2015250635A1; PL3140543T3; WO2015162427A3; EP3140544B1; GB201407154D0; CN106232988A; WO2015162428A3; EP3140545B1; AU2015250634A1

Abstract

An integrated unit for use in a pump station. The integrated unit comprises a connector for connection to a power source, an electric motor arranged to provide mechanical drive for an output shaft for coupling to a pumping unit associated with a pump station, a motor controller arranged to supply the electric motor with electrical energy from the connector to control the electric motor, and an interface for the pump station system arranged to engage with the motor controller to match the mechanical drive supplied by the electric motor to the output shaft to demand. The integrated device station includes a housing with a removable outer wall portion and a cooling system for the electronic components to the housing. The automatic engagement coupling is arranged to automatically break an electrical connection with the electronic component upon removal of the outer wall portion.

Description

Integrated device for use in a pump station

Technical Field

The present invention relates to an integrated unit for use in a pump station, and related methods of manufacture and operation. In particular, but not exclusively, the invention relates to an integrated unit for use in a pump station for transporting hydraulic fluid in underground work.

Background

In underground, longwall coal mines, powered roof supports may be used for supporting the roof in the area above the cutters that drill the face. The powered roof support employs high pressure hydraulic fluid to support the mine roof load and is propelled with the cutter as it cuts the coal mine from the face. Typically, hydraulic pumping stations located remote from the face are used to supply hydraulic fluid. A pump station typically comprises a reservoir, which is a reservoir of hydraulic fluid, and a set of pumping units, each selectively driven by an electric motor. The electric motor is used to drive the pumping units individually into a connected or disconnected state under the control of the pump station system controller. The pump station system controller monitors the demand for hydraulic fluid and provides control signals to the electric motor. For power or cooling purposes, one such pump station may be used to supply multiple powered roof supports and hydraulic fluid to other machines and perform other pumping operations, such as supplying water or other liquids for dust suppression.

In an underground environment, space for pumping stations is scarce, and access to or placement of pumping stations and associated pumping units underground is difficult. Due to these physical limitations, the container, the pumping unit and the pump station system controller need to be located remotely from each other with electrical and fluid connections between them. When working underground, the air may be at risk of explosion. Furthermore, in case of a pump station failure, a quick return to the operating state is required. Coupled with the varying demand for hydraulic fluid, it is difficult to control the operation of the pump stations to achieve the desired supply of fluid volume and to maintain the appropriate pressure on the output of the pumping unit, because the characteristics of the pumping unit, and the performance characteristics of the powered roof support supplied by the pumping unit, have a complex relationship. The problem of meeting the hydraulic supply demand is also associated with the responsiveness of the pumping device. Typically, responsiveness is limited by the speed of response of the motor used to power the pumping means. The distribution of the pumping load among the pumping units compensates for the slow response speed during normal operation of the pumping station, since there is no need for one pumping unit to make a fast step change in its output. However, in the event of a failure of a pumping unit of a pump station, responsiveness becomes more important as the remaining pumping units must seek to compensate for the failure. This may require a large and quick response. To meet this change in demand, typically the pump station will include a back-up pumping unit which can be used to provide a response in such a situation. However, the back-up pumping unit is an additional cost and adds complexity to the pumping station.

The separation of power and electronic control from the pumping units of the pump station means that the connections ensuring reliable power and/or data communication are complex. Reliable connection of power and/or data communication and positive hydraulic output are important to eliminate down time, enabling efficient continuous operation and keeping supply for any possible safety critical system. Furthermore, the overall control of the pump station, or the manual control of a particular pumping unit in the pump station, is complicated by the separation of the units in the pump station.

Disclosure of Invention

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

In one exemplary embodiment, the present invention provides an integrated unit for a pump station, the integrated unit comprising:

a connector for connection to a power source;

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

a motor controller configured to supply the electric power from the connector to the motor, thereby controlling the motor; and

an interface to the pump station system controller, through which interface the integrated unit is arranged, in use, to receive an input relating to a demand received from the 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 to the demand.

In one exemplary embodiment, the motor comprises a switched reluctance motor.

a connector for connection to a power source;

a switched reluctance motor configured to provide mechanical drive to an output shaft for coupling to a pumping device associated with the integrated device;

In an exemplary embodiment, an integrated unit for a pump station is provided, comprising an electric motor, a motor controller and an interface to a pump station system controller, wherein the electric motor, the motor controller and the interface to the pump station system controller are integrated with each other in a housing, wherein the housing comprises an outer wall part removably mounted on the housing, electronic components of the motor controller or electronic components of the interface to the pump station system controller being mounted on the outer wall part so as to be located inside the housing when the outer wall part is mounted on the housing, and wherein the outer wall part comprises a cooling system for the electronic components.

In one exemplary embodiment, the motor comprises a switched reluctance motor.

In an exemplary embodiment, an integrated unit for a pump station is provided, comprising a switched reluctance motor, a motor controller and an interface to a pump station system controller, wherein the motor, the motor controller and the interface to the pump station system controller are integrated with each other in a housing, wherein the housing comprises an outer wall part removably mounted on the housing, on which outer wall part electronic components of the motor controller or the interface to the pump station system controller are mounted so as to be located inside the housing when the outer wall part is mounted on the housing, and wherein the outer wall part comprises a cooling system for the electronic components.

In one exemplary embodiment there is provided a housing for an integrated unit for use in a pump station, the housing being arrangeable, in use, to accommodate an electric motor, a motor controller and an interface to a pump station system controller integrated with one another in the housing, wherein the housing includes a fitting configured to removably mount an outer wall portion of the housing, wherein the outer wall portion comprises electronic components mounted on the outer wall portion, and wherein the pump station further comprises an automatic engagement coupling arranged such that, when the outer wall portion is mounted on the housing, the electronic components mounted on the outer wall portion are electrically connected to a motor controller or a pump station system controller, and wherein the automatically engaging coupling is arranged to automatically disconnect the electrical connection between the electronic component and the motor controller or the pump station system controller upon removal of the outer wall portion from the housing.

In one exemplary embodiment, the motor comprises a switched reluctance motor.

In one exemplary embodiment there is provided a housing for an integrated unit for use in a pump station, the housing being arrangeable, in use, to house a switched reluctance motor, a motor controller and an interface to a pump station system controller integrated with one another in the housing, wherein the housing includes a fitting configured to removably mount an outer wall portion of the housing, wherein the outer wall portion comprises electronic components mounted on the outer wall portion, and wherein the pump station further comprises an automatic engagement coupling arranged to electrically connect the electronic components mounted on the outer wall portion to the motor controller or the pump station system controller when the outer 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 the pump station system controller upon removal of the outer wall portion from the housing.

In one exemplary embodiment, the integrated unit for a pump station further comprises a pumping unit coupled to the output shaft. If not described in detail, the housing may be arranged to further accommodate a connector for a power supply, and at least a portion of the output shaft of the electric motor arranged therein. In one embodiment, the integrated unit for a pump station further comprises a pump station system controller. In an exemplary embodiment, the pump station system controller comprises an interface for connecting to another pump station system controller external to the integrated installation.

In one exemplary embodiment, a pump station is provided that includes an arrangement of a plurality of integrated units as described above. In one embodiment, the pump station comprises a plurality of integrated units having a plurality of pumping units coupled thereto. In one exemplary embodiment, each integrated device is coupled to a pumping device. In an exemplary embodiment, the pump station comprises a data connection between the pump station system controller and the integrated device, whereby the integrated device is controllable to collectively provide a desired output in accordance with varying pumping requirements. In one exemplary embodiment, one of the integrated devices includes a pump station system controller operable to control one or more of the integrated devices in the pump station. In one exemplary embodiment, one of the integrated devices includes a pump station system controller operable as a master control for all other integrated devices in the pump station. In an exemplary embodiment, one of the integrated devices is operable as a slave to a pump station system controller arranged to act as a master to the integrated devices in the pump station. In an exemplary embodiment, the pump station comprises a plurality of integrated devices, one, two or more of the integrated devices, such as each of the integrated devices, comprising a pump station system controller, which may be configured to operate as a master controller, or as a slave controller compliant with a master controller of another integrated device. In an exemplary embodiment, the pump station is arranged such that the data connection is used to specify the master controller from the integrated unit.

In one exemplary embodiment, the integrated device includes a housing for the connector, the motor controller, the output shaft, and the interface to the pump station system controller. In one exemplary embodiment, the connector is an electrical connector. In one exemplary embodiment, the connector is configured to provide electrical connections, as well as physical connections for the power cord to be mounted on the integrated device. In one exemplary embodiment, the connector is at least partially accessible from an exterior of the housing and is configured to provide an electrical path from the exterior of the housing to an interior of the housing. In an exemplary embodiment, the output shaft is at least partially accessible from an exterior of the housing for coupling to a pumping device.

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

In one exemplary embodiment, the motor controller includes a variable speed drive. In one exemplary embodiment, the pumping device comprises a positive displacement pump. In an exemplary embodiment, the pump station system controller is arranged to monitor operation of an associated pumping unit coupled to the output shaft and to receive one or more feedback signals, and user control inputs from the user input section. In an exemplary embodiment, the pump station system controller is arranged to control operation of the integrated unit, including communicating the drive control signal to the motor controller based on a user control input 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 exemplary embodiment, the housing includes a plurality of interior compartments. In one exemplary embodiment, the housing includes at least two interior compartments that are physically completely or partially isolated from each other. In one exemplary embodiment, the housing includes a motor compartment, providing internal physical isolation, either completely or partially, between the motor and one or more motor controllers and pump station system controllers. In one exemplary embodiment, the housing includes a motor compartment, providing internal physical isolation, either completely or partially, between the motor and each motor controller and the interface for the pump station master controller. In one exemplary embodiment, the housing is provided with a motor compartment that includes one or more openings between the motor compartment and one or more other compartments in the housing. In one exemplary embodiment, the housing includes a motor compartment with an opening that is completely or partially closed by the motor itself when the motor is placed in position in the housing. In one exemplary embodiment, the motor includes a rotor coupled to the output shaft, and a stator wound on the rotor. In one exemplary embodiment, the stator includes an outer sheath, wherein the outer sheath is provided with a housing to form a motor compartment around the motor, isolating the motor from one or more other compartments in the housing, the isolation being complete, or partial, when the motor is in place in the housing. The aforementioned compartments may be completely physically isolated from each other, meaning that there is no connecting path therebetween, or may be partially physically isolated from each other, thereby having isolating features such as ribs, bars, frames, lattices or the like, wherein an overall open aspect is provided between the compartments to obtain an expansion space for the gas in the housing. For example, an expansion space may be provided in the housing, said space forming an overall interconnected space for gas to move freely between a partial set of compartments, or between all compartments.

In an exemplary embodiment, the stator comprises an outer sheath, wherein the outer sheath is arranged to provide a part of the housing when the electric motor is integrated into the integrated device. In one exemplary embodiment, the outer jacket is configured to provide internal physical isolation, in whole or in part, between the motor compartment and one or more other compartments in the housing. In one exemplary embodiment, the outer jacket is configured to include a protrusion extending from the motor as a rib-like protrusion, or a sheet-like protrusion, configured to provide full or partial internal physical separation between compartments in the housing. In one exemplary embodiment, the projection extends radially from the motor. In one exemplary embodiment, the projection extends tangentially from the motor. In one exemplary embodiment, the projection extends along the axis of the motor parallel to the output shaft. In one exemplary embodiment, the projection extends partially or optionally completely along the length of the outer sheath. In one exemplary embodiment, the projection is configured to close an opening between a motor compartment in the housing and one or more other compartments in the housing when the motor is positioned in place in the housing. In one exemplary embodiment, the projection includes a securing feature to enable one or more other compartments in the housing to be coupled to the housing. In an exemplary embodiment, a plurality of projections are provided on the sheath, with the plurality of projections as described above.

In one exemplary embodiment, the housing includes a plurality of internal compartments for the motor controller, such as two or more of the following: a motor controller processor compartment, a power supply electronics compartment, and a filter compartment. In one exemplary embodiment, the motor controller includes a plurality of power supply electronics in the power supply electronics compartment. In one exemplary embodiment, the power electronics are provided on a circuit board that can be removed and replaced in a plugging action, such as by using one portion of the connector to mate with another portion of the connector within the housing. In an exemplary embodiment, one or more, e.g., each compartment for a motor controller, is open to an expansion space within the housing.

In one exemplary embodiment, one or more of the power supply electronics compartments may communicate with an opening in the housing, wherein the housing comprises a removable outer wall portion, the outer wall portion being removably mounted on the housing, and the electronic components of the motor controller or pump station system controller being mounted to the outer wall portion. Suitably, the one or more power supply electronics compartments communicate with an opening in the housing, wherein the housing comprises a removable outer wall portion, the outer wall portion is removably mounted on the housing, and the electronic components of the motor controller or the pump station system controller are mounted to the outer wall portion. Suitably, the electronic component comprises an active component, suitably a rectifier or a switching component, preferably a transistor, preferably an Insulated Gate Bipolar Transistor (IGBT). Suitably, the electronic component comprises a power electronic component, or a power electronic device comprising a plurality of power electronic components. In an exemplary embodiment, one or more, e.g., each, of the power supply electronics compartments is open to an expansion space in the housing.

In an exemplary embodiment, the outer wall portion is provided with a handle to facilitate removal of the outer wall portion from the housing. In an exemplary embodiment, the handle is configured to be located outside the housing when the outer wall portion is mounted on the housing. In an exemplary embodiment, the housing comprises a mounting feature arranged to cooperate with a mounting feature on the outer wall portion such that the outer wall portion is releasably mounted on the housing in use.

In one exemplary embodiment, the outer wall portion is configured to act as a heat sink for electronic components mounted thereon. In one exemplary embodiment, the outer wall portion has an electronic component mounted in contact with its body, for example with an electrically insulating encapsulation of the electronic component in body contact with the outer wall portion. In an exemplary embodiment, the outer wall portion is provided with a thermal bridge layer between the electronic component and the outer wall portion. In one exemplary embodiment, the outer wall portion includes an inner surface and an outer surface, the electronic component being mounted on the inner surface. In one exemplary embodiment, the inner surface is generally planar and the electronic component is mounted on the outer wall portion parallel to the inner surface. In one exemplary embodiment, a cooling system for an electronic component includes an active cooling system for an electronic component. In one exemplary embodiment, the cooling system includes a fluid delivery system. In one exemplary embodiment, the fluid delivery system includes a fluid inlet and a fluid outlet provided for the outer wall portion. In an exemplary embodiment, the fluid inlet is provided on an outer surface of the outer wall portion. In an exemplary embodiment, the fluid outlet is provided on an outer surface of the outer wall portion. In an exemplary embodiment, the fluid inlet and the fluid outlet are both provided on an outer surface of the outer wall portion. In an exemplary embodiment, the fluid inlet and the fluid outlet are coupled by a fluid passage formed in the outer wall portion, for example integrally formed in the outer wall portion. In an exemplary embodiment, the fluid path is not located inside the inner surface of the outer wall portion. In one exemplary embodiment, the fluid path includes a recessed portion of the outer wall portion. In an exemplary embodiment, the outer surface of the outer wall portion is generally planar, the fluid path extending within the outer wall portion in its plane, e.g. entirely in its plane. In an exemplary embodiment, the fluid path is maintained outside of one or more compartments within the housing, spaced from the interior of the compartments, and/or spaced from an inflation space connecting the compartments in the housing. In an exemplary embodiment, the fluid path is arranged to extend no further than the inner surface of the outer wall portion. In an exemplary embodiment, the fluid path comprises a groove, e.g. a channel, formed in the outer wall portion, over which a cap is provided to seal the channel between the fluid inlet and the fluid outlet. In one exemplary embodiment, the lid includes a plate. In an exemplary embodiment, the cover provides an outer surface of the outer wall portion.

In one exemplary embodiment, the electronic component is disposed inside the housing compared to the inward extent of the fluid path. In an exemplary embodiment, the electronic components are arranged to be electrically connected to the motor controller or pump station system controller when the outer wall section is mounted on the housing, and to be disconnected from the outer wall section using a plug-in, push-fit or other self-engaging coupling.

In one exemplary embodiment, the outer wall portion has a plurality of electronic components mounted thereto, the electronic components mounted thereto being as described above.

In an exemplary embodiment, the housing comprises a plurality of outer wall portions as described above. In one exemplary embodiment, the housing comprises a plurality of outer wall portions to which the same electronic components are mounted such that the outer wall portions are part of a modular arrangement of electronic components for the integrated device.

In one exemplary embodiment, the housing includes outer wall portions at the front, back, first and second ends, top and bottom, e.g., forming a generally cubic shape. In an exemplary embodiment, the outer wall portion comprises openings on at least two surfaces, for example on three surfaces. In one exemplary embodiment, the housing includes openings on three generally non-parallel surfaces, such as on the front surface, the top, and on the first end surface. In one exemplary embodiment, the housing includes openings on only one, two, or three of the front surface, the top, and the first end surface. In this way, the housing may be positioned against the wall in use and next to the interconnected pumping devices on the second end face, but the opening remains accessible for performing installation, maintenance and repair work via the opening.

In one exemplary embodiment, the housing is an explosion-resistant housing.

In one exemplary embodiment, the integrated device includes a motor cooling system configured to deliver cooling fluid to the motor. In one exemplary embodiment, the motor cooling system includes a fluid inlet and a fluid outlet disposed outside the housing. In one exemplary embodiment, the motor cooling system is configured such that fluid can flow therethrough and thereby remove heat from the motor and the housing. In one exemplary embodiment, the motor cooling system is configured such that fluid can flow over the outer jacket of the motor and thereby remove heat from the motor and the housing.

In one exemplary embodiment, the fluid inlet and the fluid outlet of the motor cooling system are in fluid communication with the motor compartment of the housing. In one exemplary embodiment, voids are provided such that fluid may flow therethrough. In one exemplary embodiment, the motor cooling system includes a void in the motor compartment at least partially surrounding the motor. In one exemplary embodiment, the motor cooling system includes a void in the motor compartment formed between the motor and the housing in which the motor is disposed.

As will be appreciated, the self-engaging coupling is provided to electrically connect the electronic components mounted on the exterior wall portion to the motor controller or pump station system control when installed, including the exterior wall portion of the re-mount housing.

In one exemplary embodiment, the automatic engagement coupling is a multi-part coupling, wherein one part is carried by any one of: an outer wall portion; an electronic component mounted on the outer wall portion; a circuit board carrying electronic components mounted on the outer wall portion. In one exemplary embodiment, the automatic engagement coupling is a multi-part coupling, wherein the other part is carried by any one of: a housing; a motor controller; a 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 an exemplary embodiment, the housing comprises a plurality of outer wall portions as described above, arranged to function as described above when mounted on the housing and when removed from the housing. In an exemplary embodiment, the outer wall portion is part of a modular arrangement of electronic components for a pump station, e.g. for a motor controller.

In one exemplary embodiment, the integrated device includes a motor controller including a plurality of modular devices, each modular device including one or more electronic components mounted on an exterior wall portion of the housing.

In one exemplary embodiment, the electronic components are arranged to be electrically connected to a motor controller or pump station system control when the outer wall section is mounted on the housing, away from the outer wall section, forming a connection using a plug-in, push-fit or other self-engaging coupling.

In one exemplary embodiment, a housing as described above is provided. In one exemplary embodiment, a housing for assembly into an integrated device as described above is provided.

In one exemplary embodiment, a method of manufacturing an integrated unit for use in a pump station is provided, the integrated unit comprising a connector for connection to a power source; an electric motor arranged to provide a mechanical drive to an output shaft for coupling to a pumping device associated with the integrated device; a motor controller configured to supply the electric power from the connector to the motor, thereby controlling the motor; and an interface for a pump station system controller, the method comprising assembling the connector, the motor controller, the output shaft, and the interface for the pump station system controller housing into an integrated unit.

In one exemplary embodiment, a method of operating a pump station is provided, the pump station comprising an electric motor, a motor controller and an interface for a pump station system controller, the electric motor, the motor controller and the pump station system controller being integrated with each other in a housing, wherein the housing comprises an outer wall portion removably mounted on the housing, and an electronic component of the motor controller or the interface to the pump station system controller is mounted on the outer wall portion so as to be located inside the housing when the outer wall portion is mounted on the housing, the method comprising providing cooling for the electronic component using a cooling system provided by the outer wall portion.

In one exemplary embodiment, a method of assembly is provided, the method being performed using a housing adapted to accommodate an electric motor, a motor controller and an interface for a pump station system controller integrated with each other in the housing, the housing comprising an assembly such that an outer wall portion of the housing is removably mounted, wherein the outer wall portion comprises electronic components mounted on the outer wall portion, and wherein the pump station further comprises an automatic engagement coupling, the method comprising mounting the outer wall portion such that the electronic components mounted on the outer wall portion are electrically connected to the motor controller or the interface for the pump station system controller, the method further comprising removing the outer wall portion from the housing such that the electrical connection between the electronic components and the motor controller or the interface for the pump station system controller is automatically broken.

Drawings

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

fig. 1 shows a perspective view of an integrated device according to a first exemplary embodiment, viewed from the front, first end and above;

FIG. 2 shows a perspective view of the integrated device of FIG. 1 from the back, first end, and above;

FIG. 3 shows a front view of the integrated device of FIG. 1;

FIGS. 4-6 show cross-sectional views of the integrated device of FIG. 1, viewed in cross-section in the directions of arrows A-A, B-B and H-H, respectively, of FIG. 3;

FIGS. 7 and 9 show plan views of the integrated device of FIG. 1;

FIG. 8 shows a cross-sectional view of the integrated device of FIG. 1, viewed in the direction of the arrows on section C-C of FIG. 7; and

FIGS. 10 and 11 show cross-sectional views of the integrated device of FIG. 1, taken through the cross-section of FIG. 9 and viewed in the direction of arrows E-E and F-F, respectively;

fig. 12A to 12E show: a front view including hidden details of a channel formed in a portion of an outer wall portion associated with a rectifier; a cross-sectional view of the outer wall portion associated with the rectifier based on line B-B of FIG. 12A in the direction of the arrows; a perspective view from the front, one side and above of the outer wall portion associated with the commutator; a perspective view from the rear, same side and above of the outer wall portion associated with the commutator; and a sectional view of the front portion of the outer wall portion based on line a-a of fig. 12C; and

fig. 13A to 13E respectively show: a front view including hidden details of a channel formed in a portion of an outer wall portion associated with the IGBT; a cross-sectional view of a portion of the outer wall portion associated with the IGBT, based on line C-C of fig. 13A in the direction of the arrow; a perspective view from the front, one side and above of a portion of the outer wall section associated with the IGBT; a perspective view from the back, same side and above of the outer wall portion associated with the IGBT; and a rear, second side and top perspective view of a portion of the outer wall portion associated with the IGBT, including hidden details of the coupling between the IGBT and the outer wall portion.

Detailed Description

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

Fig. 1, 2, 3, 7 and 9 show the exterior of the integrated device 1, while fig. 4 to 6, 8, 10 and 11 show cross-sectional views of the integrated device 1 so that internal features can be seen and understood. The integrated device 1 includes a connector 10 for connecting to a power source, such as a power source operating at 1140 volts ac, and rated for 300 kw operation. Electrical energy from the coupling 10 is arranged to be transmitted to the electric motor 20 to provide mechanical drive to the output shaft 30. The output shaft 30 is coupled, in use, to a pumping device in the form of a positive displacement pump (not shown) and associated with the integrated device 1. The motor controller is arranged to control the supply of electrical energy from the connector 10 to the electric motor 20, thereby controlling the electric motor 20. An interface for the pump station system controller is provided in connection with the motor controller to enable the integrated unit 1 to operate with the mechanical drive supplied by the motor 20 to the output shaft 30 matching the demand from the pumping unit. A pumping device is envisaged to work with the integrated unit 1 to supply pressurised hydraulic fluid, such as an emulsion of water and oil, to a powered roof support or other mining machine, for example pressurised to 300-.

As can be seen in the figure, the integrated unit 1 is arranged such that the connector 10, the electric motor 20, the motor controller, the output shaft 30 and the interface for the pump station system controller are provided as one integrated unit. The integrated apparatus 1 has the connector 10, the electric motor 20, the motor controller, the output shaft 30 and the interface for the pump station system controller provided integrated with each other within the housing 40. For underground use, the housing 40 is explosion resistant and provides an explosion space 80 therein between the internal components and the compartment so that gas can move within the housing to accommodate temperature changes and the like.

The motor 20 comprises a switched reluctance motor and the motor controller comprises a variable speed drive. In other systems, such as those using induction motors, generally higher inertia and lower electromagnetic response are encountered to control input. Induction motors also typically occupy much more volume for a given power and torque specification. For this reason, it is advantageous to use a switched reluctance motor in the described integrated device, especially when the motor controller and system controller are closely coupled thereto to provide drive for the motor. The responsiveness of switched reluctance motors, and their relatively high torque density, means that the integrated device can operate without providing a back-up device. In this way, the integrated device may form part of a pump station that includes fewer redundant elements while still achieving a fast reaction to large changes in demand, such as changes associated with failure of other elements of the pump station.

In the following description of the exemplary embodiments, the motor and associated components including the motor controller and the like each include a switched reluctance motor and associated components for use with a switched reluctance motor, respectively. The motor controller includes several circuit components-a motor controller processor 60, a rectifier 61, a reactor 62, an EMC filter 63, a capacitor bank 64, and a plurality of power electronic switching components in the form of Insulated Gate Bipolar Transistors (IGBTs) 65. The motor controller processor 60 is configured to monitor the operating state of the motor 20 and provide the desired speed to the motor 20 through other components of the motor control device. The motor controller processor 60 is further arranged to receive a setting signal, for example a signal indicative of a desired speed of the electric motor 20 from the interface to the pump station system controller, in dependence on a demand for hydraulic fluid to be supplied from a pumping unit connected to the electric motor 20 via the output shaft 30 and a corresponding operating speed of the pumping unit required to meet the demand.

The interface for the pump station system controller comprises a pump station controller processor 50 arranged to monitor 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 which is operable to receive user control inputs and provide operational status information of the pumping units coupled to the integrated unit 1. The user interface portion includes a display screen 51, and a mouse 52 for receiving user control inputs. As will be described in more detail below, the pump station control 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 device 1 includes an outer wall portion 410 on the front surface thereof, the outer wall portion 410 is detachably mounted on the housing 40, and the electronic components of the motor controller 50 are mounted to the outer wall portion 410 such that the electronic components of the motor controller 50 are located inside the housing 40 when the outer wall portion 410 is mounted on the housing 40. As described in detail below, the outer wall portion 410 provides a number of advantages with respect to the provision of cooling components for the integrated device 1, as well as facilitating the removal and replacement of components of the integrated device 1.

The outer wall portion 410 is used in a cooling system of the electronic components of the motor control device, in this case, the electronic components of the motor control device are the rectifier 61 and the IGBTs 65. Two outer wall sections 410, 410' are shown associated with each IGBT 65, and a further outer wall section 410 "is shown associated with the rectifier 61. The outer wall portion 410 is provided as a heat sink for the electronic components mounted thereon. To obtain good heat transfer, the electronic components are mounted in physical contact with the inner face of the outer wall portion 410. In addition to any cooling provided by the thermal mass of the outer wall portion 410 and the surface area for heat transfer to the ambient environment of the integrated device 1, the outer wall portion 410 is part of an active cooling system for the electronic components mounted thereon.

The cooling system includes a fluid delivery system 420, the fluid delivery system 420 enabling fluid to be transferred from the fluid inlet 430 to a fluid outlet 431 provided in the outer wall portion 410, such that heat between the fluid inlet 430 and the fluid outlet 431 may be absorbed from the outer wall portion and associated electronic components and thereby removed from the housing 40. Both the fluid inlet 430 and the fluid outlet 431 are provided on the outer surface of the outer wall portion 410 and are coupled by a fluid passage formed as a channel 433 in the outer wall portion 410 covered by a cover 434 to seal the channel 433 as a closed line between the fluid inlet 430 and the fluid outlet 431. Fig. 12E shows this arrangement in cross-section. The cover 434 in fig. 12A and 13A is depicted as transparent to show the path of the channel 433, which in use is located beneath the cover 434. In this way, the fluid delivery system remains completely isolated from the interior of the compartment in the housing 40 containing the electronic components. Relying on the material integrity of the outer wall portion 410 "so that fluid does not leak into the housing can be easily specified and manufactured to achieve a high level of reliability. In order to provide a high pressure-tight seal between the cover 434 and the channel 433 in the outer wall portion 410", a weld 435 is provided. In the exemplary embodiment, one or more welds 435 are formed around the edge of cover 434 to couple cover 434 to outer wall portion 410", with the cover being positioned on outer wall portion 410" so as to span channel 433. Weld 435 is also provided through an aperture 436 provided in cover 434 to partially couple outer wall 410 "to cover 434, for example, to strengthen the connection between the two components. Hole 436 is aligned with channel 433 such that weld 436 is disposed away from the edge of cover 434. For example, the alignment between hole 436 and channel 433 may be such that a weld is provided through a hole in a central region of cover 434, or in a region of the cover between two portions of the channel, such as two adjacent portions, shown here as two portions extending in side-by-side relationship, e.g., parallel relationship, to one another. The welds may further be provided in an alternating arrangement between the first and second sides of the channel, moving along the length of the channel, and/or may be provided in an alternating arrangement between portions of the channel extending in side-by-side relationship with each other. In other embodiments, the outer wall portion may be manufactured with a channel disposed therein, such as a channel with internal features comprising a casting.

In the described cooling system, the failure of the connectors at the inlet and outlet, and the failure of the seals formed between the inlet/outlet and the outer wall sections or between the interior of the outer wall sections and the outer plates, is not critical to keep the fluid separate from the electronic components.

Although there are active cooling systems to reduce the effects of heat build-up in use, electronic components such as IGBTs have only a limited useful life and may need occasional replacement. By providing the outer wall portion 410 removably mounted on the housing 40, and the electronic components of the motor controller 50 being mounted to the outer wall portion 410, replacement of components becomes easy, while the outer wall portion 410 is configured to be easily exchanged between used and new when needed.

To provide a mechanical connection between the housing 40 and the outer wall portion 410 of the housing 40, mounting features are provided on the housing 40. The mounting features are arranged to cooperate with associated mounting features on the outer wall portion 410 to releasably mount the outer wall portion to the housing 40. The mounting features in the integrated device 1 include threaded fasteners, openings 460 in the outer wall portion 410, and threaded holes in the housing 40. The outer wall portion 410 is provided with a handle 413 to facilitate removal of the outer wall portion from the housing once the mounting features have been released from each other.

An electrical connection system is linked to each outer wall section 410 and is configured to automatically engage to provide an electrical connection between the electronic components mounted on the outer wall sections 410 and the motor control processor 60. The electrical connection is made when the outer wall portion 410 is mounted to the housing 40. The electrical connection system includes a plug-in, push-fit or other self-engaging coupling, one part secured to the outer wall portion 410 and one part secured within the housing 40. For example, fig. 13B and 13E show the IGBT 65 physically coupled to the outer wall portion 410' by mounting screws 651. The IGBTs 65 are electrically coupled to the electrical system within the integrated device 1 by electrical connectors 652 using a plug and play pin arrangement between the IGBTs 65 and the connectors 652. Elastic crossover 450 is used to make further connections from connector 652 while the rest of the electrical system is within integrated device 1. The connector 652 and the cross-leads 450 are held within a carrier device 653 in the housing 40, the carrier device 653 being secured in use to the housing 40 at or around the opening 460 of the outer wall portion. Similar connection arrangements are suitably provided for other power supply components, such as the rectifier 61 used with the outer wall portion 410 "and the carrier device 613, and may also be provided for controlling or diagnosing signal transmission, for example, through the data connector 440.

The housing 40 includes a plurality of internal compartments that may be at least partially physically isolated from each other while maintaining the expansion space 80. The housing 40 includes compartments for the electric motor 20, motor controller components, and pump station system controller interface components. The compartment in which the motor 20 is located is oversized relative to the motor 20 to enable operation of the motor cooling system. The motor cooling system delivers cooling fluid to the motor 20. The cooling fluid may be transferred between a fluid inlet 21 and a fluid outlet 22 provided at the outside of the housing 40. The fluid passing between the fluid inlet 21 and the fluid outlet 22 may carry heat away from the motor 20 and the housing 40. By passing the cooling fluid through the space around the motor 20 and within the compartment in the housing 40, the need for a separate cooling jacket for the motor 20 is eliminated. Similar to the cooling arrangement for the outer wall section 410, relies on the material integrity of the housing 40 in its internal compartment so that fluid does not leak into the rest of the housing 40, and in motor cooling systems, failure of the connectors at the inlet and outlet, and failure of the seals formed between the inlet/outlet and the outer wall section or between the interior and exterior plates of the outer wall section are not critical to keeping the fluid separate from the electronic components within the housing 40.

The housing 40 as described above has an outer wall portion 410 on its front face that is removably mounted on the housing 40, which when in place covers the opening of the housing. The top and first end faces also have

removable wall portions

510, 610, respectively, which when removed expose an opening through which the interior of the housing 40 and components therein can be accessed for installation, maintenance and repair purposes.

The integrated plant 1 may be used as part of a pump station comprising an arrangement of a plurality of integrated plants. Each integrated unit in the pump station has a pumping unit coupled thereto and a data connection is provided between the interfaces for the pump station system controller, such that the integrated unit is controllable to provide a required output from the pumping unit in accordance with varying pumping requirements. In this type of arrangement, one of the integrated devices is configured such that its pump station controller processor operates as the master pump station system controller. The other integrated devices are configured such that their pump station controller processors operate as slave controllers. The slave controller is compliant with a pump station system controller provided by a pump station controller processor as the master controller. The integrated device may be arranged such that the data connection is used to designate the master controller, whether in response to user input, or automatically through a predetermined protocol, for example including facilities for seamlessly adding or removing integrated devices for pump stations. In other embodiments, a separate pump station system controller is used to provide control inputs to all integrated devices using their pump station system controller interfaces.

By providing an integrated device as described, problems associated with data transfer, mechanical connections providing functionality, and reliability in matching motor and pump conditions to a desired pumping output are solved. Furthermore, it is advantageous to produce a compact form factor which exhibits a high torque density and at the same time a good response time with a suitable explosion-proof action. The internal compartmentalization is somewhat advantageous in isolating the cooling liquid from the electronic components. The presence of an outer wall portion that is removable from the housing helps to reduce complexity in manufacture and assembly, and again has benefits in terms of manufacture and reliability for the pump station as a whole, by appropriate selection of cooling and interconnection arrangements.

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

It should be noted that all papers and documents which are filed concurrently with or previous to this application and which are open to public inspection with this specification in connection with this application 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 limited to the details of the above-described 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.

Claims

1. A housing for an integrated unit for use in a pump station, the housing being arrangeable in use to house a motor, a motor controller and an interface to a pump station system controller integrated with each other in the housing, wherein the housing comprises an assembly arranged such that an outer wall portion of the housing is removably mounted, wherein the outer wall portion comprises electronic components of the motor controller mounted on the outer wall portion or of the interface to the pump station system controller, and wherein the housing further comprises an automatic engagement coupling arranged to electrically connect the electronic components mounted on the outer wall portion to the motor controller if the electronic components are electronic components of the motor controller when the outer wall portion is mounted on the housing, or if the electronic component is the electronic component of the interface to the pump station system controller, electrically connecting the electronic component mounted on the outer wall part to the interface to the pump station system controller, and wherein the automatic engagement coupling is arranged to automatically disconnect an electrical connection between the electronic component and the motor controller if the electronic component is the electronic component of the motor controller or between the electronic component and the interface to the pump station system controller if the electronic component is the electronic component of the interface to the pump station system controller when the outer wall part is removed from the housing,

wherein when the outer wall portion is mounted on the housing, the electronic component is arranged to be electrically connected to the motor controller remote from the outer wall portion if the electronic component is an electronic component of the motor controller, or to be electrically connected to the interface to the pump station system controller remote from the outer wall portion if the electronic component is an electronic component of the interface to the pump station system controller, the connection being made using an insertion, push-fit or other automatic engagement coupling,

wherein the housing comprises a plurality of outer wall portions to which identical electronic components are mounted such that the outer wall portions are part of a modular arrangement for the electronic components of the integrated device;

wherein the outer wall portion acts as a heat sink for the electronic component mounted thereon, the outer wall portion being provided with a thermal bridge layer between the electronic component and the outer wall portion.

2. The housing of claim 1, wherein the motor comprises a switched reluctance motor.

3. The housing of claim 1 or 2, wherein the housing comprises a plurality of internal compartments.

4. The housing of claim 1 or 2, wherein the housing comprises at least two internal compartments that are partially physically isolated from each other.

5. The housing according to claim 1 or 2, wherein the housing comprises a motor compartment with an opening which is partly closed by the motor itself when the motor is set in place in the housing.

6. The housing of claim 1 or 2, wherein the housing comprises a plurality of internal compartments for the motor controller, the internal compartments comprising two or more selected from the group comprising: a motor controller processor compartment, a power supply electronics compartment, and a filter compartment.

7. The housing of claim 1 or 2, wherein the motor controller comprises a plurality of power supply electronics.

8. The case of claim 7, wherein the power electronics are provided on a circuit board that can be removed and replaced in a unplugging action.

9. The housing of claim 7, wherein the power electronics are disposed in one or more power electronics compartments that communicate with an opening in the housing.

10. A housing according to claim 1 or 2, wherein the housing comprises a mounting feature arranged to cooperate with a mounting feature on the outer wall portion such that the outer wall portion is releasably mounted on the housing in use.

11. The housing of claim 1 or 2, wherein the automatic engagement coupling is a multi-part coupling, wherein one part is carried by any one of: the outer wall portion; the electronic component mounted on the outer wall portion; a circuit board carrying the electronic components mounted on the outer wall portion.

12. The housing of claim 11, wherein the automatic engagement coupling is a multi-part coupling, wherein another part is 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.

13. The housing of claim 1 or 2, wherein the housing comprises a plurality of the outer wall portions.

14. A housing according to claim 1 or 2, wherein the outer wall portion is part of a modular arrangement of electronic components for a pump station.

15. A housing according to claim 1 or 2, wherein the housing comprises an outer wall portion on only one, two or three of the front surface, the top and the first end face, wherein the outer wall portion comprises an opening such that the housing is positioned against the wall in use and abuts an interconnected pumping device on the end face, the opening remaining accessible for performing installation, maintenance and repair work via the opening.

16. The housing of claim 1 or 2, wherein the motor comprises a rotor coupled to an output shaft, and a stator wound on the rotor.

17. The housing of claim 16, wherein the stator includes an outer jacket, wherein the outer jacket is provided with the housing to form a motor compartment around the motor, the motor being isolated from one or more other compartments in the housing when the motor is in place in the housing, the isolation being complete or partial.

18. The housing of claim 17, wherein the outer sheath is configured to provide a portion of the housing when the electric motor is integrated into the integrated device.

19. The housing of claim 17, wherein the outer jacket is configured to include a protrusion extending from the motor as a rib-like protrusion, or a sheet-like protrusion, the outer jacket configured to provide full or partial internal physical separation between compartments in the housing.

20. The housing of claim 19, wherein the projection is configured to close an opening between a motor compartment in the housing and one or more other compartments in the housing when the motor is in place in the housing.

21. The housing of claim 19 or 20, wherein the projection comprises a securing feature to enable one or more other compartments in the housing to be connected to the housing.

22. A pump station comprising an arrangement of a plurality of integrated units, the plurality of integrated units comprising a housing according to any of claims 1 to 21.

23. The pump station according to claim 22, wherein one integrated unit is coupled to a pumping unit.

24. A pump station according to claim 22 or 23, wherein the pump station comprises a data connection between a pump station system controller and the integrated unit, whereby the integrated unit is controllable to collectively provide the required output in accordance with varying pumping requirements.

25. A pump station according to claim 22 or 23, wherein one of the integrated devices comprises a pump station system controller operable to control one or more of the integrated devices in the pump station.

26. A pump station according to claim 22 or 23, wherein the pump station comprises a plurality of integrated units, wherein one of the integrated units comprises a pump station system controller which is configurable to operate as a master controller or as a slave controller compliant with a master controller of another integrated unit.

27. A method of assembly or assembly, the method being performed using an interface for a pump station system controller and a motor adapted to accommodate the motor, motor controller and motor controller integrated with each other in a housing, the housing comprising an assembly such that an outer wall portion of the housing is removably mounted, wherein the outer wall portion comprises electronic components of the motor controller mounted on the outer wall portion or of the interface for the pump station system controller, and wherein the housing further comprises an automatic engagement coupling, if the electronic components are electronic components of the motor controller, the method comprising mounting the outer wall portion such that the electronic components mounted on the outer wall portion are electrically connected to the motor controller, or if the electronic components are electronic components of the interface for the pump station system controller, the method comprises mounting the outer wall portion so as to electrically connect the electronic component mounted on the outer wall portion to the interface for the pump station system controller,

wherein when the outer wall portion is mounted on the housing, the electronic component is arranged to be electrically connected to the motor controller remote from the outer wall portion if the electronic component is an electronic component of the motor station controller, or to be electrically connected to the interface for the pump station system controller remote from the outer wall portion if the electronic component is an electronic component of the interface for the pump station system controller, the connection being made using an insertion, push-fit or other automatic engagement coupling,

28. A method according to claim 27, further comprising removing the outer wall portion from the housing, thereby automatically disconnecting the electrical connection between the electrical components mounted on the outer wall portion and the motor controller or an interface for a pump station system controller.