# Patent

## Title
High-efficiency pump systems

## Abstract

According to one embodiment of the present invention, a system for pumping fluid is provided. According to this embodiment, a fluid pumping system comprises a fluid inlet pipe and a fluid outlet pipe. A plurality of pump units are disposed between the inlet and outlet pipes such that the pump units each pump fluid out of the inlet pipe and into the outlet pipe. The pump units each include at least one DC motor. A solar panel may be used to power the pump units.

## Background
BACKGROUND
The present invention relates to systems for pumping fluids, and more specifically, to high efficiency fluid pumping systems.
Many different kinds of systems have been developed for pumping fluids. Generally such systems include a source of power, a fluid pump and pipes to carry the fluid to and from the pumping system. Examples include pumping systems for municipal water and sewer systems, industrial pumping systems, and residential pumping systems, such as swimming pool pumps. Fluid pumping systems consume a significant portion of the power consumed by modern civilization. It has been estimated that pool pumps alone account for about 25% of the electrical usage of homes having swimming pools.
SUMMARY
According to one embodiment of the present invention a fluid pumping system comprises: a fluid inlet pipe; a fluid outlet pipe; at least one low voltage single speed DC motor having less than 1⁄2 horsepower; at least one AC motor, wherein the DC and AC motors are disposed between said inlet and outlet pipes so as to pump fluid out of said inlet pipe and into said outlet pipe; and a electrical controller for controlling the operation of the DC and AC motors.
According to another embodiment of the present invention, a method of filtering water in a pool comprises: pumping water using a pump from the pool through a filter using a DC motor having less than 1⁄2 horsepower at a relatively low flow rate; providing electrical power to the DC motor using solar power; pumping water using a pump from the pool through the filter using an AC motor at a relatively high flow rate; operating the DC motor for relatively long periods of time during the day; and operating the AC motor for relatively short periods of time during the day.
According to a further embodiment of the present invention, a method of filtering water in a pool comprises: pumping water using a pump from the pool through a filter using a DC motor having less than 1⁄2 horsepower at a relatively low flow rate; providing electrical power to the DC motor; pumping water using a pump from the pool through the filter using an AC motor at a relatively high flow rate; operating the AC motor during a start period to prime the pump; and after a fixed period of time that is sufficient to prime the pump, turning off the AC; and turning on the DC motor for a relatively long period of time.



BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 shows a diagram of a solar powered pool pump system in accordance with an embodiment of the invention;
FIG. 2 shows a diagram of a pump unit used with the pump system shown in FIG. 1 in accordance with an embodiment of the invention
FIG. 3 shows a diagram of a solar powered pool pump system with battery backup in accordance with an embodiment of the invention;
FIG. 4 shows a diagram of a solar powered pool pump system with rechargeable battery backup in accordance with an embodiment of the invention;
FIG. 5 shows a diagram of a non-solar powered pool pump system in accordance with an embodiment of the invention;
FIG. 6 shows a diagram of a retrofit application of a solar powered pool pump system in accordance with an embodiment of the invention;
FIG. 7 shows a top view diagram of a pool pump having both DC and AC motors in accordance with an embodiment of the invention; and
FIG. 8 shows a side view diagram of the pool pump shown in FIG. 7 having both DC and AC motors in accordance with an embodiment of the invention.



DETAILED DESCRIPTION
Embodiments of the invention provide high efficiency fluid pumping systems. In some embodiments the low power requirements of the pumping systems permit the use of alternative power sources, such as DC electrical power, solar and battery power. Many prior pumping systems use relatively large fluid pumps with a relatively high gallons per hour pumping capacity. Such pumps generally require a powerful electrical motor which uses a large amount of electrical power. In many applications the power requirements of these motors necessitates the use of AC electrical power. The present inventor has invented an alternative pumping systems which uses less power, thereby opening up the possibilities of pumping fluids without AC power, for example, using such sources as solar, battery, low voltage DC, wind power, etc. The present invention does this by replacing (or augmenting) an existing pump system with a plurality of smaller pumps, each pump being powered by a smaller electric motor. In some embodiments, the total pumping capacity in gallons per hour may be less than the jump that is replaced. However, the reduced flow rate may be compensated for by operating the pumps for a longer period of time each day.
The exemplary embodiments described herein comprise swimming pool pumping systems. However, those skilled in the art will recognize that the principles may be adapted to other applications, such as pumping systems for ponds, fountains, water features, sump pumps, as well as other systems for pumping other fluids besides water.
FIG. 1 shows a diagram of a solar powered pool pump system 10 in accordance with an embodiment of the invention. The pump system 10 includes three pump units 12, 14, and 16. As shown in FIG. 2, each pump unit 12, 14, and 16, includes a fluid pump 18 and a DC motor 20 to drive the fluid pump 18. Also shown is an inlet opening 21 for directing water into the pump unit and an outlet opening 23 for directing water out of the pump unit.
Referring again to FIG. 1, an intake manifold 22 receives water from a swimming pool (not shown) through an intake pipe 24. Three pump intake pipes 26, 28, and 30 are connected from the intake manifold 22 to each of the pump units 12, 14, and 16 respectively. Because of the negative pressure created by the pump units at its inlet 21, water will flow from the pool intake pipe 24 through the intake manifold 22 and through the pump intake pipes 26, 28, and 30 into each of the respective pump units 12, 14, and 16.
Three output pipes 34, 36, and 38 direct water from the pump outlet openings 23 to an output manifold 32. Water passing through the output manifold 32 is directed to an output pipe 40, which directs water to a pool filter (not shown) and then back to the pool.
The pump units 12, 14, and 16 receive electrical power through electrical wires 42 and 44, which are connected to a photovoltaic solar panel 46 through a disconnect switch unit 48. In this embodiment, the pump units 12, 14, and 16 may each include a 1/25 horsepower 24V DC motor rated at 48 Watts each at 1.8 Amps. One suitable pump unit for this embodiment may be the Model No. 809BRHSC 24V DC motor pump unit available from March Manufacturing Incorporated, of Glenview Ill., USA. Other size pumps may be used depending on the application. However, in the swimming pool application of the present embodiment, each pump unit will typically be in the range of 1/10 to 1/50 horsepower. This is in contrast to conventional pool pumps, which usually are rated at over 1 horsepower.
One suitable photovoltaic solar panel may be the Model No. NO244U1F available from Sharp Electronics Corporation, which is capable of producing 224 watts. The solar-powered pool pump system 10 is capable of a flow rate of 18-22 gallons per minute. The daily running time for this system 10 will depend on the size of the swimming pool and other factors. In general, however, this system 10 may provide adequate volume of recirculation for an average size pool when running between 5 hours and 10 hours per day. It may be noted that a typical pool pump with a single more powerful pump unit may provide a higher flow rate and hence, may only need to run for fewer hours per day. However the inventor has discovered that this configuration with three smaller pump units running for a longer period of time uses substantially less electricity per day, for an equivalent number of gallons of water re-circulated per day, as described in more detail below.
The embodiment in FIG. 1 may be more suitable for environments where the sun shines very consistently. However, in other environments, where there are more cloudy days, the system 10 shown in FIG. 1 may not run when the sun is not shining. In such cases, where the system 10 has been retrofitted to an existing conventional pool pump system powered by AC current, the conventional pump system may need to be operated on cloudy days. In order to extend the operating time of the system 10 to account for cloudy days, an alternative system with battery backup may be used.
For example, FIG. 3 shows a diagram of a solar powered pool pump system 50 with battery backup in accordance with an embodiment of the invention. The like numbered components in this system 50 which are also shown in FIG. 1 may be the same components as described above. The system 50 shown in FIG. 3, however, includes a battery back up system 52, which includes a pair of sealed 12 V batteries 54 and 56, a voltage regulator 58, a relay 60 and a timer 62. In this configuration, when the sun is shining the solar panel 46 will produce about 80 Watts in surplus electrical power, which may be used to charge the batteries 54 and 56. The voltage regulator 58 is used to control of the electricity generated by solar panel 46 to direct the appropriate amount to the pump units 12, 14, and 16 and to the batteries 54 and 56. The timer 62 and relay 60 are used to control the number of hours that the batteries 54 and 56 are operated. It will be appreciated that it is preferable not to drain the batteries down completely. Thus the timer 62 can be used to set the maximum number of hours that the batteries may be operated in a day. When that number of hours is reached the timer 62 will send a signal to the relay 60 to shut down the pumps 12, 14, and 16.
Because of the battery backup system 52, when the sun is not shining and the solar panel 46 does not generate enough electricity to run the pump units 12, 14 and 16, thee pumps may be operated from electricity stored in the batteries 54 and 56. In this embodiment, the sealed batteries 54 and 56 may comprise 12V 26 AH sealed Absorbed Glass Matt (AGM) batteries Model Number 12260-D5747 available from UPG Incorporated. The voltage regulator may comprise a Model PR1010 charge controller available from Steca Company of Germany. The timer 62 may comprise a Model 2EO21 time clock available from the Granger Company. The relay 60 may comprise a model 2CF88 available from the granger Company.
FIG. 4 shows a diagram of a solar powered pool pump system 64 with rechargeable battery backup in accordance with an embodiment of the invention. In this embodiment, the components are identical to those in the system 50 with the addition of a battery charging unit 66 attached to the voltage regulator 58. The battery charging unit 66 may be operated off of 120V house current. In this system 64, when there is not enough sunlight to for the solar panel to generate enough electrical power to recharge the batteries, the batteries may be charged using the battery charging unit 66. The battery charging unit may comprise a model SEC2415A available from Samlex American Company. In some embodiments, the output of the solar panel may be improved by using a tracking device (not shown), which tilts the solar panel toward the sun as it moves across the sky each day. One such tracking device may be the Model UTR-020 tracker available from Zomeworks Corporation.
FIG. 5 shows a diagram of a non-solar powered pool pump system 68 in accordance with an embodiment of the invention. This system 68 would be applicable for areas where there may be insufficient sunlight to use the systems shown in FIGS. 1-3. In this embodiment, the solar panel is replaced by a 24 V DC power supply unit 70 that provides the necessary electrical power to drive the pump units 12, 14, and 16. The power supply unit 70 receives its power from a 120V AC outlet 74 and may be controlled by a time clock 72. It is noted that, even without using a solar panel the system 68 provides significant savings in electrical power due to the above-discussed efficiencies resulting from the use of three relatively small pumps and by having the pumps run for a longer period of time per day than conventional pool pumps.
FIG. 6 shows a diagram of a retrofit application of a solar powered pool pump system 76 in accordance with an embodiment of the invention. In many instances the present invention may be retrofitted to an existing swimming pool filter and recirculation system 78. This existing system 78 includes a filter 80, an existing jump 82, a check valve 84, inlet pipes 86 and outlet pipes 88. The new pump system 76 may comprise any embodiment of the present invention, such as those shown in FIGS. 1-5. The new pump system 76 is configured to bypass the existing pump 82 by means of inlet 90 and output 92 bypass pipes. Control over whether the new pump system 76 or the existing pump 82 is used may be achieved by using check valves 84 to either block or permit water to pass through either pump.
The existing pump 82 will typically be a larger pump and will be useful to perform vacuuming of the pool, since vacuuming may require a higher flow rate than the new system 76 may provide. In some embodiments a flow meter (not shown) may be useful to determine the flow rate to insure that there is adequate daily recirculation of the pool water. It will be appreciated that the size of the pipes is an important consideration in designing a pool pumping system. In the examples shown, it is assumed that pipes having 11⁄2 inch inside diameter are used. This is a common pipe size used in existing pool systems. For other diameter pipes, the size of the particular pumps and other system parameters may need to be modified to optimize efficiency. Also it may be noted that a different number of pumps besides three may be employed. However, the present inventor has found the optimum results with three pumps.
Tests have shown embodiments of the invention to achieve substantial energy savings. For example, a typical conventional pool pump system was tested. This system used a 11⁄2 horsepower pump and operated 6 hours a day and used 1,533 watts per hour. This would add up to 3,312,000 watts per year. At a cost of $0.29 per kilowatt, this would cost $960.48 per year to operate. Alternatively, the conventional pool pump may operate for 8 hours per day, which would cost $1,280.35 per year to operate.
In contrast, in tests on an embodiment of the invention, three 144 Watt rated pump units operated a rate of 117 watts per hour, and moved about 1800 gallons per hour. This test system and was operated for about 8.75 hours per day, which is adequate for most swimming pools. The system thus consumed about 1,023 watts per day, which adds up to 368,280 watts per year. At a cost of $0.29 per kilowatt, this would cost only $106.72, as compared to $960.48 or $1,280.35 in the conventional systems described above.
Referring now to FIGS. 7 and 8, another embodiment of the invention is shown. A hybrid pool pump system 100 integrates two low volume DC pumps with a conventional AC pump. The low volume DC pumps enable alternative power sources, including solar, as described above in the systems in FIGS. 1-6. The conventional AC pump is useful for the occasional need for high volume pumping, such as during pool vacuuming, to power water features, and for priming when pumping is initiated. The hybrid pool pump system 100 provides great flexibility in the variety of ways to provide power, which may include AC power, DC power, solar power, wind power, and other alternative power sources.
FIG. 7 shows a top view, and FIG. 8 shows a side sectional view of the hybrid pool pump system 100. The hybrid pool pump system 100 includes a pump body 102, a pair of DC motors 104, 106, and a pair of DC motor bell housings 108, 110. The hybrid pool pump system also includes an AC motor 136 that has an output shaft 138 which is connected to a high output impeller 140.
The pump body 102 has an interior 118 for holding water that has contours defined by line 118. A basket strainer 120 is in the interior of the pump body, and a removable clear cap 122 covers the strainer 120. Pool water from a pool is directed through a pipe (not shown) that is connected to the pump body 102 at an intake port 124. Pool water entering the intake port 124 passes through the strainer 120, and enters the lower portion of the interior of the pump body 118.
The DC motors 104, 106 each include an output shaft 116, which are each connected to a magnetic coupling unit 112, which are magnetically coupled to a low volume impeller 114. The rotation of the output shaft thus causes rotation of the low volume impellers 114 through magnetic coupling. The low volume impellers 114 are each surrounded by a low volume cavity 126, which are each connected to a low volume venturi 128 that leads to a check valve body 130. The check valve body 130 contains a pair of rubber check valves 132, and includes an output port 134 at the top. The check valves 132 prevent water from passing back into the pump body 118 from the output port 134. The output port 134 leads to a pipe (not shown) that directs water back to a pool. When the DC motors rotate, the DC motor shaft 116 turns the magnetic coupling unit 112, which causes the low volume impeller 114 to rotate. Rotation of the low volume impeller 114 causes water in the pump body 118 to enter the low volume venture 128, pass through the check valves 132, and out of the output port 134 and back to the pool.
When the AC motor 136 is rotating, the shaft 138 rotates, which rotates the high output impeller 140. The high output impeller 140 is in a portion of the interior of the pump body 118, which includes a high volume venturi portion 142 that leads to the check valve body 130. Rotation of the high output impeller 140 directs water from the pump body 118 into the check valve body 130, past the check valves 132, out of the output port 134, and back to the pool.
Electrical power is supplied to the DC and AC motors through a controller unit 144, which controls which of the DC or AC motors are operating at any given time. The controller unit 144 receives electrical power from one or more external sources 146.
In some embodiments, the DC motors are single speed motors of less than 1⁄2 horsepower each. In some applications, such as small residential pools, only a single DC motor may be needed, while larger pools may require both DC motors. The DC motors may be powered by a single solar panel, such as the 224 Watt Sharp Electronics Corporation units mentioned above. Alternatively, the DC motors may be powered by 110 Volt power through a 24 Volt DC power supply, such as the one shown in FIG. 5, or other alternative sources of electrical power. In some embodiments, the DC motors may operate at a flow rate of 600-1500 gallons per hour, with a rate of 1,200 gallons per hour being optimum for some applications. Depending on the size of the pool, the DC motors may need to run between 5-10 hours per day.
As can be seen from the above disclosure, embodiments of the invention provide fluid pumping systems that are highly efficient as compared to conventional pumping systems, thereby reducing energy consumption. If the present invention were widely adopted there would be a substantial reduction in the overall energy usage. As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” From the above description, it can be seen that the present invention provides a system and method for implementing the embodiments of the invention. References in the claims to an element in the singular is not intended to mean “one and only” unless explicitly so stated, but rather “one or more.” All structural and functional equivalents to the elements of the above-described exemplary embodiment that are currently known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the present claims. No claim element herein is to be construed under the provisions of 35 U.S.C. section 112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or “step for.”
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

## Claims

1. A method of filtering water in a pool comprising:
pumping water from the pool through a filter using a first pump having a DC motor having between 1/50 and 1⁄2 horsepower at a first flow rate;
providing electrical power to the DC motor using solar power;
pumping water from the pool through a filter using a second pump having an AC motor at a higher flow rate than the first flow rate;
operating the DC motor for a longer period of time than the AC motor; and
operating the AC motor during a start period to prime at least one of the first pump and the second pump.

2. The method of claim 1 wherein said first flow rate is between 600 and 1500 gallons per hour.

3. The method of claim 1 wherein said longer period of time is between 5-10 hours per day.

4. The method of claim 1 further comprising:
after the pump is primed, turning off the AC motor and turning on the DC motor.

5. A method of filtering water in a pool comprising:
pumping water from the pool through a filter using a first pump having a DC motor having between 1/50 and 1⁄2 horsepower at a first flow rate;
providing electrical power to the DC motor;
pumping water from the pool through a filter using a second pump having an AC motor at a higher flow rate than the first flow rate;
operating the AC motor during a start period to prime at least one of the first pump and the second pump; and
after a period of time that is sufficient to prime the at least one of the first pump and the second pump, turning off the AC motor; and
turning on the DC motor for a longer period of time than the AC motor.

6. The method of claim 5 wherein said first flow rate is between 600 and 1500 gallons per hour.

7. The method of claim 5 wherein said longer period of time is between 5-10 hours per day.