Dual inlet volute, impeller and pump housing for same, and related methods

Disclosed herein are a dual inlet volute with an impeller and pump for same, and related methods. In one form a pump is provided comprising a motor configured to rotate a shaft, an impeller operatively coupled to the shaft, and a volute housing the impeller, the volute having a first inlet, a second inlet, and a discharge in fluid communication with the first and second inlets.

FIELD

This invention relates generally to pumps and, more particularly, to pumps with a double suction impeller, and methods related to same.

BACKGROUND

Pumps with double suction impellers are currently used to increase suction performance and to reduce axial thrust. These pumps are made with the two sides of the impeller being nearly identical to each other.

Two common types of impellers are centrifugal and vortex. Centrifugal impellers require fluid to pass through the vanes and are highly efficient. However, many designs are easily clogged by debris. Vortex pumps are less efficient and do not require fluid to pass through vanes and are therefore more tolerant of debris.

Additionally, bottom suction pumps can experience air lock if not properly vented. Whereas top suction pumps are ineffective at completely emptying areas of liquid.

Accordingly, it has been determined that a need exists for a dual inlet volute with a double impeller for creating flow through each inlet.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Many variations of pumps are discussed herein and even further are contemplated in view of this disclosure. The pumps discussed herein are configured, and designed, to be submerged in a liquid to pump the liquid in which it is submerged through an attached discharge hose or discharge pipe. The pumps herein can be utility pumps, sump pumps, well pumps, sewage/effluent pumps, aquarium pumps, pool pumps, lawn pumps, or any other type of pump. The pumps herein can be vertically configured pumps or horizontally configured pumps. In some embodiments and some applications, despite being called a double suction impeller, one of the two impeller halves will be used solely for venting, and thus only one of the impeller halves provides suction.

FIGS. 1A-3Billustrate a pump assembly having a duel inlet volute120and double suction impeller110.FIG. 1Cshows a cross sectional view of a pump100with a double suction impeller110along the line1C ofFIG. 1B. The pump100includes a motor102contained within a motor housing101. The motor102is controlled by the electrical components103. The pump100has a float switch107(seeFIG. 1A) to control operation of the motor102by detecting the presence of fluid, such as water. The motor102turns the shaft104. The double impeller110has a hub105that connects to the shaft104such that the motor102rotates the double impeller110. As mentioned above, this double suction impeller concept can be utilized with any type of pump (e.g., utility, sump, effluent, aquarium, etc.) and with any type of pump configuration (e.g., vertically configured pumps (as shown), horizontally configured pumps, etc.). Examples of vertically configured pumps are shown in U.S. Pat. No. 2,701,529, to H. Finzel; U.S. Pat. No. Re. 24,909, to R. W. Dochterman; U.S. Pat. No. 4,345,879, to C. W. Steiner; U.S. Pat. No. 3,234,881, to W. J. Ekey; and U.S. Pat. No. 4,396,353, to R. D. MacDonald. Examples of a horizontally configured pumps are shown in U.S. Pat. No. 2,608,157, to W. J. Conery.

The electrical components103can includes control circuitry. The control circuitry controls the power supply to selectively provide power to the motor102. The control circuitry generally includes some method of detecting liquid, such as a float switch or a capacitive water sensor. Alternatively, the control circuitry could be a switch operable by a user.

The double suction impeller110has a top impeller portion or top impeller112, which provides a first style of pumping, and a bottom impeller portion or bottom impeller114, which provides a second style of pumping. In the example shown, the top impeller112is a centrifugal impeller which produces centrifugal style flow and the bottom impeller114is a vortex impeller which produces vortex style flow.

The double impeller110is positioned in a dual inlet volute120which includes a top inlet108, a bottom inlet109, and a discharge122not shown onFIG. 1. The top inlet108is surrounded by a screen106which blocks large debris from entering the volute120and the top impeller112. The bottom inlet109can be either unscreened, or can have a larger screen than the top inlet108as vortex impellers are less affected by debris. The top inlet108is in fluid communication with the top impeller112, meaning fluid is drawn through the top inlet108by the top impeller112. The bottom inlet109is in fluid communication with the bottom impeller114, meaning fluid is drawn through the bottom inlet109by the bottom impeller114. The top inlet108aids in venting the volute120to reduce the likelihood of the bottom impeller114failing due to an air lock.

Referring toFIGS. 3A-3B, the volute120has an open top which forms a top inlet108and a center aperture in the bottom to form bottom inlet109. The volute120defines an open cavity between the two inlets108,109in which the impeller110is positioned. The impeller draws fluid through one or both inlets108,109and forces the liquid out through the discharge122.

Referring toFIG. 2, the top impeller112of the double impeller110has a plurality of vanes212. Rotation of the double impeller110causes fluid to be drawn through the centrifugal vanes212, and then the centrifugal vanes212transport the fluid out to the impeller outer diameter. The bottom impeller114of the double impeller110has a plurality of vortex vanes214that are of a different shape and configuration from the centrifugal vanes212. In one embodiment the centrifugal vanes212curve as they extend outward from the center of the double impeller110as shown. The vortex vanes214extend radially from the center of the double impeller110. In alternative embodiments, different shapes and configurations of vanes can be used to achieve a similar effect. When the double impeller110is rotated, the vortex vanes214induce a whirlpool or vortex below the double impeller110. The vortex draws fluid in through the bottom inlet109and forces it radially outward. The majority of the fluid, and the debris contained therein, never directly interact with the vortex vanes114which makes it more resistant to clogging. The top impeller112and bottom impeller114of the double impeller110are separated by the impeller plate116.

In standard operation, the motor102rotates the double suction impeller110which causes fluid to be drawn in through the top inlet108and the bottom inlet109and expelled through the discharge122. Both the top impeller112and the bottom impeller114create thrust along their axis when rotating. The axial thrust of the top impeller112is in the opposite direction as the axial thrust of the bottom impeller114and therefore is at least partially offsetting.

If the pump100is operated in a fluid with debris, the screen106may become clogged. If the screen106becomes clogged, the bottom impeller114of the double impeller110continues to pump fluid in through the bottom inlet109and out through the discharge122. This allows the pump100to continue functioning in conditions where a pump with a single impeller (e.g., a single centrifugal impeller) would clog completely.

The top impeller112of the double impeller110is self-venting. This reduces the risk of the pump100failing due to air lock, making the pump more reliable than traditional bottom feed vortex pumps. Additionally, the top impeller112provides venting for the bottom impeller114. In some embodiments, the top impeller112provides no suction and is used purely as a vent for the bottom impeller114to prevent air lock.

In other embodiments, the double impeller110has a top impeller112and a bottom impeller114that are of a different type than those discussed above. Example types of impellers include closed channel impellers, screw impellers, propellers, shredder impellers, mixed flow impellers, semi-open impellers, and hardened sand/slurry impellers in addition to the centrifugal impeller and vortex impeller described above. Each type of impeller has advantages and weaknesses. By having the top impeller112be a first type of impeller and the bottom impeller114be a second type of impeller, the pump100has the advantages of both impellers and does not fail in instances where a single one of the impellers would. Additionally the volute120would vary based on the combination of impellers used to have a bottom cavity129configured to house the type of impeller used for the bottom impeller114and a top cavity128configured to house the type of impeller used for the top impeller112.

In other embodiments, the double impeller110has a top impeller112and a bottom impeller114that are of the same type as each other (e.g., dual vortex impellers, dual centrifugal impellers, etc.). However, in preferred forms utilizing at least one vortex impeller, the vortex impeller will always be situated on the bottom side or below the second impeller type to take advantage of the pump design illustrated and ensure some fluid moves through the pump even when the upper inlet gets clogged. As mentioned above, the top impeller112may further provide venting benefits for the bottom impeller114to prevent air lock and/or eliminate the need for a pump installer to drill a vent hole somewhere in the discharge pipe or plumbing of the system. Additionally, the redundancy of having the two volutes (e.g., regardless of whether that means they are two portions of a common volute or literally two separate volutes) prevents system failure when a single inlet becomes clogged.

FIG. 4illustrates a double impeller410according to an embodiment of the present invention. The double impeller410includes a seal plate420. In the embodiment shown, the seal plate420is separate from the double impeller410. In alternative embodiments, the seal plate420can be coupled to the impeller410. In operation, the seal plate420creates a seal on the top inlet108that prevents fluid from back feeding and leaking across the vane. The seal plate420also increases the efficiency of the centrifugal vanes412by forcing all of the fluid flowing in the top inlet108to flow through the centrifugal vanes412.

FIG. 5illustrates an impeller510according to an embodiment of the present disclosure. Pumps using the impeller510primarily draw fluid inward through a single inlet, the bottom inlet109, and the top inlet108in the volute120is used as a vent to reduce air lock. The impeller510includes bottom vanes514and top vanes512. The bottom vanes514induce flow to draw fluid in through the bottom inlet109and out the outlet122. The top vanes512serve to reduce the static pressure and reduce the leaking of fluid out of the top inlet108. The top vanes512and the bottom vanes514each can be shaped like those on any known type of impeller including, but not limited to, closed channel impellers, screw impellers, propellers, shredder impellers, mixed flow impellers, semi-open impellers, and hardened sand/slurry impellers in addition to the centrifugal impeller and vortex impeller described above. In some embodiments, the top vanes512include a notch513that creates a dynamic seal. The notch513draws in fluid, such as air, from the top inlet108and induces a flow in it so as to create an air barrier preventing fluid from leaking out of the top opening108.

In some embodiments, a divided volute620houses the double impeller110. Referring toFIGS. 6A-6B, the volute620has a ring624in which the bottom impeller114of the double impeller110is set. The ring624and the impeller plate116collectively form a recess, surrounding the vortex vanes214on all but one side (the bottom). Having the sides of the vortex vanes214surrounded or encircled by the ring624may create a better vortex, which results in less debris being drawn into the double impeller110. The top impeller112of the double impeller110is above the ring624with the centrifugal vanes212in the flow path of the fluid. As explained above, this permits the centrifugal vanes212to draw in fluid and then force it out to the side. The outer cavity626of the volute620connects the top cavity628and the bottom cavity629. The flow of fluid produced by both the top impeller112and the bottom impeller114of the double impeller110join in this outer cavity126and flows out of the same discharge122. In some forms, the volute620is used in combination with the impeller510such that the top inlet608is used substantially for venting while the bottom inlet609is used to intake fluid. Alternatively or additionally, the seal plate420is used in a pump having the volute620to reduce discharge through the top inlet608.

This detailed description described specific examples of pumps. A person of ordinary skill in the art would recognize that these descriptions are sufficient to understand how to build and/or operate any of the pumps disclosed herein. Therefor this description covers the methods of making or using the pumps and/or individual components of the pumps described (e.g., methods of manufacturing a dual flow impeller, methods of manufacturing a dual inlet pump, etc.). For example, in addition to the numerous impeller, volute and pump embodiments disclosed herein, there are also disclosed methods of manufacturing a dual inlet pump with dual flow characteristics. In a preferred form, the pump will be provided with a dual flow impeller configured to offer two distinct flow types or characteristics. For example, the dual flow impeller may have a centrifugal portion on one side and a vortex portion on a second side to generate centrifugal fluid flow at one inlet and vortex fluid flow (e.g. a vortices) at a second inlet to offer redundancy and ensure that fluid continues to flow through the pump even if one input gets clogged or slowed significantly. The benefit of such redundancy is that it greatly reduces the likelihood that the surrounding area or environment the pump is used in will flood.

In other forms, the dual flow impeller may be configured to offer similar flow types or characteristics. For example, the dual flow impeller may be configured with two vortex portions, each positioned by a respective inlet unique to that portion of the volute to generate a vortex flow (e.g., vortices) proximate each inlet. Alternatively, in other forms, the dual flow impeller may be configured with two centrifugal portions, each positioned by a respective inlet unique to that portion of the volute to generate centrifugal flow proximate each inlet. Either of these configurations offer redundancy as well, they just do not offer dual flow characteristics like the preferred embodiment mentioned above. One reason the preferred embodiment is preferred is that by offering a pump with dual flow characteristics that are distinct from one another allows the pump to be a multi-functioning pump that can use the different flow characteristics to address fluids with different characteristics or are not consistent in their makeup. For example, the centrifugal inlet of the pump may move fluid with less contaminants or debris better, while the vortex input may move the fluid with more contaminants or debris better. In other applications, this level of redundancy may not be needed and it may be sufficient to simply include two inputs with similar flow characteristics (e.g., an impeller with two vortex portions, an impeller with two centrifugal portions, an impeller with two grinder portions, etc.).

While it mentions that the inlets may be unique to each impeller portion, it should be understood that in alternate embodiments the inlets may have some overlap with one another and so that they are only primarily associated with one impeller portion or the other. In still other forms, the inlet may be configured as one large inlet opening that feeds both impeller portions.

Other methods disclosed herein include methods of manufacturing a dual flow impeller, methods of processing fluid through a pump/pump inlet/impeller, methods for providing redundancy in a pump, methods for generating different fluid flow in, through, or via a pump, and/or methods for pumping fluids having different characteristics or make-up (e.g., methods for pumping fluids having a lower debris content portion and a higher debris content portion).

This detailed description refers to specific examples in the drawings and illustrations. These examples are described in sufficient detail to enable those skilled in the art to practice the inventive subject matter. These examples also serve to illustrate how the inventive subject matter can be applied to various purposes or embodiments. Other embodiments are included within the inventive subject matter, as logical, mechanical, electrical, and other changes can be made to the example embodiments described herein. Features of various embodiments described herein, however essential to the example embodiments in which they are incorporated, do not limit the inventive subject matter as a whole, and any reference to the invention, its elements, operation, and application are not limiting as a whole, but serve only to define these example embodiments. This detailed description does not, therefore, limit embodiments of the invention, which are defined only by the appended claims. Each of the embodiments described herein are contemplated as falling within the inventive subject matter, which is set forth in the following claims.