The motor type brushless DC water pump is composed of a brushless DC motor and an impeller. The shaft of the motor is connected to the impeller, and between the stator and rotor of the water pump
There are gaps, and if used for a long time, water will seep into the motor, increasing the possibility of motor burnout.
Advantages: Brushless DC motors have been standardized and mass-produced by specialized manufacturers, resulting in lower costs and higher efficiency.
Brushless DC Magnetic Isolation Solar Water Pump: The brushless DC water pump adopts electronic component commutation, without the need for carbon brush commutation. It adopts high-performance wear-resistant ceramic shaft and ceramic sleeve, which are connected to the magnet through injection molding to avoid wear and tear. Therefore, the lifespan of the brushless DC magnetic water pump is greatly enhanced. The stator and rotor parts of the magnetic isolation water pump are completely isolated. The stator and circuit board parts are sealed with epoxy resin, 100% waterproof. The rotor part is made of permanent magnet. The water pump body is made of environmentally friendly materials, with low noise, small volume, and stable performance. Various required parameters can be adjusted through the winding of the stator, allowing for wide voltage operation.
Advantages: Long lifespan, low noise can reach below 35dB, and can be used for hot water circulation. The stator and circuit board of the motor are sealed with epoxy resin and completely isolated from the rotor, which can be installed underwater and completely waterproof. The shaft of the water pump is made of high-performance ceramic shaft, with high accuracy and good seismic resistance.
According to the fact that everything has opposites, where there are advantages, there will be disadvantages. What are the disadvantages of solar water pumps? The upfront cost is relatively high, and the initial investment in installing the system may be costly for some systems depending on the size of the required water pump; Intermittent, requiring good sunlight exposure, especially during the prime time of 9am to 3pm, while cloudy days convert to lower output, which may be a potential issue in some applications. A key fact of energy dispersed solar water pumps is that they only provide electricity during the day. In many cases, this is sufficient for the intended use, but if the sun sets and pumping is required, a water pump with battery storage should be considered.
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Pros:
Compared to the AC motor, the DC motor has excellent speed control performance, a wide speed regulation range, large torque, good low-speed performance, stable operation performance, and high efficiency.
Cons:
However, since conventional DC motors are commutated through brushes and commutator contacts, there are several drawbacks:
Sparks, Mechanical Wear, Electromagnetic Interference, Loud noise, Short Working Lifespan…
Due to the complex structure, the pump’s reliability is poor, easy to be failure, and frequent maintenance is required. In a complex system, it is an important source of the system’s unreliability, so its application is limited.
The invention of the brushless DC motor benefited from the development of electronic technology, which used transistor commutation circuits instead of brushes and commutators.
The structure of the brushless DC motor is similar to that of the AC permanent magnet synchronous motor, with coil windings on the stator and permanent magnets on the rotor.
As you can see from the BLDC PUMP structure diagram above, the stator coil and circuit board are entirely isolated from the liquid and rotor by the isolation layer. Unlike the dynamic seal of the o-ring, this is a complete static seal. It guaranteed absolutely no leakage.
In addition to preventing liquid leakage, this structure also brings another benefit: good heat dissipation, which allows the pump to have a longer service lifespan. The pumping liquid medium cools the high-speed operation rotor, and the cooling efficiency is much better than the airflow cooling inside the traditional water pump.
Because of this unique structure of the brushless DC pump, it is often called another name: magnetic drive pump.
The working principle of the brushless DC water pump is similar to that of the AC water pump. That is, the rotor is driven to rotate by the changing magnetic fields generated by the paired winding coils on the stator. But please note that, unlike AC water pumps, brushless DC water pumps use low voltage DC power sources instead of 110V or 220V AC power.
The 2-phase brushless DC pump has two pairs of magnetic fields and a 4-slots stator, while the 3-phase brushless DC pump has three pairs of magnetic fields and a 6-slots stator.
The 2-phase brushless DC pump usually has a lower cost than the 3-phase brushless DC pump. This is because it requires the circuit inside of the pump body to place the Hall sensor to detect the position of the rotor.
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To ensure that electronic components are not burned, we usually require that the temperature of the medium being pumped cannot exceed 60 degrees Celsius. At the same time, the pump’s power should not be too large (because the winding coil itself will generate a lot of heat when the pump is working).
The 3-phase brushless DC pump use MCU control and intelligent commutation position detection in place of the Hall sensor. You can place the circuit with all electronic components in a control box outside of the pump body according to your needs.
Compared to a 2-phase brushless DC pump, a 3-phase brushless DC pump allow us significantly increase the pump’s rated power to improve the pump’s performance.
At the same time, the 3-phase brushless DC pump can work in a higher temperature environment.
In addition, due to the use of MCU, we can add many program functions to the pump, such as Reverse protection, stuck protection, over-current protection, manual speed control, gifted program, and so on.
The 3-phase brushless DC pump is a milestone upgrade, to sum up the above.
Compared with the AC water pump and the traditional DC water pump, the noise of the brushless DC water pump is very low, about 40dB or less. However, in some particular environments, such as the plumbing mattress used in the bedroom, the circulation system of the fish tank, the cooling circulation system of the CPU, etc., our requirements for noise will be more critical.
To further reduce noise, we have adopted the sine wave drive control technology instead of square wave drive in some product models.
The principle of sine wave drive is as follows:
The pump’s control system obtains the precise position of the rotor by the 3-phase sensorless control technology. It uses the complex control circuit to provide the changing phase current matched with each opposite electromotive force. Ideally, using sine-wave drive control technology can achieve a constant pump torque.
As a result, compared with square wave drive, sine wave drive can achieve some advantages, including low torque fluctuation, smooth operation, super low noise, etc.
Because of the high cost, the sine wave drive control technology was mainly used in the military and in a few high-required applications. However, in recent years, due to the price reduction of high-speed MCU and DSP, it has received more and more attention.
With the advancement of various technologies and the continuous innovation of materials and processes, the performance of brushless DC pumps in all aspects has become more and more excellent. It has gradually become widely used in more and more fields in the past few decades.
It is the product of the combination of modern electronic technology (including power electronics, microelectronics technology), control theory, motor technology, fluid mechanics, and other disciplines.
Frankly, it’s not easy to sort out some of its concepts. So we wrote this article hoping it will help. The following infographic will give you a quick idea of how some of its confusing concepts relate to each other. If helpful, please enjoy and share.
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