Abstract:
Disclosed is an end cap for a motor housing containing an electric motor, including a tubular structure defining an interior space, including an open first end connectable to the motor casing; a second end, including a first planar surface; a second planar surface offset from the first planar surface and substantially parallel to the first planar surface; and at least one air grate surface substantially perpendicular to the first planar surface and the second planar surface, positioned between and attached to the first planar surface and the second planar surface, and wherein the at least one air grate surface includes at least one air grate configured to permit air flow into and/or out of the interior space.

Description:
PRIORITY 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 61/903,583, filed Nov. 13, 2013, the entire content of which is incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure generally relates to motors, motor controllers, systems and methods for controlling motors in various applications, and more particularly, to a motor connected to a pump having a dual speed pump controller for controlling the operation of recirculating pumps used in swimming pool environments. 
       BACKGROUND 
       [0003]    Standard recirculating pumps having a motor section and a pump section are often used in swimming pool environments in connection with the filtering systems. The pumps are often high capacity pumps that move thousands of gallons per hour. The electric power required to move these large volumes of water is often very high and create high temperatures in the motor section. 
         [0004]    Controllers for the pumps are often required to control the operation of the motor, for example, many federal and local governments have enacted laws and regulations to curtail the high electric use. Due to high temperatures in the end caps of the motor, controllers are usually remote from the motor and require extensive wiring connections between the controller and motor to control the motor operation. In addition, the controller will require a separate housing to protect the controller circuitry. 
         [0005]    Attempts that have been made to design pumps to operate within temperature tolerances to prevent damage to the controllers contained in the motor section, none of which adequately address the problem at hand. 
         [0006]    This disclosure describes improvements over these prior art technologies. 
       SUMMARY 
       [0007]    Accordingly, an end cap for a motor housing containing an electric motor is disclosed. The end cap assembly can include a tubular structure defining an interior space, which can include an open first end connectable to the motor casing; a second end, which can include a first planar surface; a second planar surface offset from the first planar surface and substantially parallel to the first planar surface and at least one air grate surface substantially perpendicular to the first planar surface and the second planar surface, positioned between and attached to the first planar surface and the second planar surface, and wherein the at least one air grate surface includes at least one air grate configured to permit air flow into and/or out of the interior space. 
         [0008]    In the end cap the at least one air grate surface can include two air grates each positioned substantially along a different radial line of the end cap. 
         [0009]    In the end cap the air grate surface can be one of a planar surface or an arcuate surface. 
         [0010]    The end cap can further include circuit board mountings positioned within the interior space configured to attach a circuit board thereto; and end cap mountings positioned to attach the end cap to the electric motor. 
         [0011]    In the end cap the air grate surface can include at least two air grates positioned such that as the motor rotates a directional air flow is created within the interior space generating air flow through the air grates with one air grate as an intake air grate and the other grate as an exhaust air grate. 
         [0012]    In the end cap the air grates can be each positioned substantially parallel to radial lines of the end cap. 
         [0013]    In the end cap the air grate surface can define at least one switch receptacle configured to mount a control switch therein. 
         [0014]    Accordingly, a motor assembly having a shaft end and a motor end is disclosed. The motor assembly can include an end cap removably connectable to the motor assembly at the motor end and defining a tubular space therein, which can include a first an open first end connectable to the motor end; a second end, which can include a first planar surface; a second planar surface offset from the first planar surface and substantially parallel to the first planar surface; and at least one air grate surface positioned between the first planar surface and the second planar surface and substantially perpendicular to the first planar surface and the second planar surface, the air grate surface including at least one air grate configured to permit air flow into and/or out of the interior space; and a motor control module having a substantially semi-circular design and configured to be mounted within the tubular space of the end cap and electrically connectable to the motor to provide control to the motor. 
         [0015]    In the motor assembly the at least one air grate surface can include two air grates each positioned substantially along a different radial line of the end cap. 
         [0016]    In the motor assembly the air grate surface can be one of a planar surface or an arcuate surface. 
         [0017]    The motor assembly can further include circuit board mountings positioned within the interior space configured to attach a circuit board thereto; and end cap mountings positioned to attach the end cap to the electric motor. 
         [0018]    In the motor assembly the air grate surface can include at least two air grates positioned such that as the motor rotates a directional air flow is created within the interior space generating air flow through the air grates with one air grate as an intake air grate and the other grate as an exhaust air grate. 
         [0019]    In the motor assembly the air grates can be each positioned substantially parallel to radial lines of the end cap. 
         [0020]    In the motor assembly the air grate surface can define at least one switch receptacle configured to mount a control switch therein. 
         [0021]    Accordingly, disclosed is a control module for controlling a motor and mountable within an interior tubular cavity of a tubular end cap of a motor assembly. The control module can include a circuit board having a substantially semi-circular configuration with a diameter less than a diameter of the interior tubular cavity and mountable within the interior tubular cavity. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    The present disclosure will become more readily apparent from the specific description accompanied by the attached drawings, in which: 
           [0023]      FIG. 1  is a side perspective view of a pump/motor assembly including a motor end cap according to the present disclosure; 
           [0024]      FIG. 2  is a side perspective view of a pump/motor assembly including a partially-removed motor end cap according to the present disclosure; 
           [0025]      FIG. 3  is a top perspective view of a motor end cap according to the present disclosure; 
           [0026]      FIG. 4  is a top plan view of a motor end cap according to the present disclosure; 
           [0027]      FIG. 5  is a side plan view of a motor end cap according to the present disclosure; 
           [0028]      FIG. 6  is a bottom perspective view of a motor end cap according to the present disclosure; 
           [0029]      FIG. 7  is a bottom plan view of a motor end cap according to the present disclosure; 
           [0030]      FIG. 8  is a top plan view of a circuit board for use in a motor end cap according to the present disclosure; and 
           [0031]      FIG. 9  is a bottom plan view of a motor end cap with a circuit board included therein according to the present disclosure; 
           [0032]      FIG. 10  is a top perspective view of a motor end cap according to the present disclosure; and 
           [0033]      FIG. 11  is a top perspective view of a motor end cap according to the present disclosure. 
       
    
    
       [0034]    Like reference numerals indicate similar parts throughout the figures. 
       DETAILED DESCRIPTION 
       [0035]    The present disclosure may be understood more readily by reference to the following detailed description of the disclosure taken in connection with the accompanying drawing figures, which form a part of this disclosure. It, is to be understood that this disclosure is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed disclosure. 
         [0036]    Also, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or approximately one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. 
         [0037]    Reference will now be made in detail to the exemplary embodiments of the present disclosure, which are illustrated in the accompanying figures. 
         [0038]    Controllers are often used to control the operation of a motor. The motors can operate various devices, for example, pumps, vehicles, cooling units, etc. One example of a pump/motor assembly having a controller is disclosed in U.S. application Ser. No. 14/536,929, filed Nov. 10, 2014, and entitled DUAL SPEED MOTOR CONTROLLER AND METHOD FOR OPERATION THEREOF, the entire contents of which are incorporated herein by reference. 
         [0039]    A pump/motor assembly  10  according to the present disclosure includes a pump section  13  and a motor section  12 . Motor section  12  includes novel end cap  11 . Controller circuit board  80  (see  FIG. 8 ) is designed to fit within motor end cap  11  as shown in  FIG. 9 . End cap  11  is removable from motor section  12  to expose motor  21  contained within motor housing  22 . (See  FIG. 2 ). 
         [0040]    End cap  11  comprises a tubular body  31 , open at one end and closed at the other. The closed end includes a first planar surface  32 , a second planar surface  33 , and at least one air grate surface  34 . First planar surface  32  is substantially parallel to second planar surface  33 . The at least one air grate surface  34  is substantially perpendicular to and positioned between first and second planar surfaces  32 / 33 . The at least one air grate surface  34  includes an air grate  36  to permit airflow there through. 
         [0041]    In an embodiment illustrated in  FIG. 3 , five air grate surfaces  34   a - 34   e  are shown, two of which, i.e.  34   b  and  34   d , include air grates  36   i  and  36   e , respectively. In another embodiment illustrated in  FIG. 10 , one air grate surface  34  is shown, having a single air grate  36 . Other configurations varying the number of air grate surfaces  34  and air grates  36  are contemplated. For example, although air grate surface is shown as a planar surface, as shown in  FIG. 11  the air grate surface can be configured as an arcuate surface having one or more air grates positioned thereon. Other configurations having a combination of planar and arcuate surfaces are also contemplated. 
         [0042]    The embodiment of  FIG. 3  shows a plurality of air grate surfaces connected in series, at least two of which include air grates positioned substantially opposite each other such that as the motor rotates a directional air flow is created in the interior space with one air grate being an intake air grate and the other grate being an exhaust air grate. 
         [0043]    In operation, as the motor spins, air currents will be produced through air grates  36 . The air currents will flow into and out of the interior of end cap  11 . This continuous air flow will continuously cool the interior of end cap  11  and thus cool controller circuit board  80 , thus protecting controller circuit board  80  from overheating. 
         [0044]    In a preferred embodiment and described with reference to  FIG. 7 , planar surface  34  includes 2 air grate surfaces  34   b  and  34   d  each including an air grate  36 . The positioning of surfaces  34   b  and  34   d  are selected to maximize the air flow produced as an effect of the rotation of the motor. As motor rotates about axis z in direction A the rotation causes air flow within tubular body  31  in direction B. Intake air grate  36   i  permits air flow into tubular body  31  in direction C and exhaust air grate  36   e  permits air flow out of tubular body  31  in direction D. Angles α and β are selected to maximize the air flow and can change based on the position of the planar surfaces  34   b  and  34   d . Air flow can be maximized when an air grate is substantially perpendicular to the air flow at the position of the air grate. In other words, air grates positioned substantially along radial lines of the end cap can maximize the air flow. In addition, although the configuration shown is substantially symmetrical about a line between the 2 air grates, other non-symmetrical designs are contemplated. 
         [0045]    In the embodiment of  FIG. 10 , the air flow can be further maximized if the single planar surface  34  is provided with 2 air grates spaced apart from each other and the planar surface is positioned substantially on a diameter line of the end cap. This will position the air grates substantially perpendicular to the direction of the air flow at the each air grate. 
         [0046]    Also shown in  FIG. 3  is optional switch cut-out  37  positioned within one of the at least one air grate surfaces  34  into which a switch (not shown) can be mounted to provide input to the controller circuit board  80  as described in U.S. application Ser. No. 14/536,929. Also includes are screw receptacles  35  to receive a screw to attach end cap  11  to motor housing  22  and/or motor  21 . End cap  11  can also include a power cord access  38  to permit connection of electric power to the electrical components of the pump/motor assembly  10 . 
         [0047]    The interior of end cap  11  is mostly hollow and designed to accept controller circuit board  80 . For example, a typical inside diameter of an end cap might be 5½ inches in diameter. If so, end cap  11  would have that same inside diameter. Controller circuit board  80  is specially designed as a semi-circle having a diameter of 5¼ inches to fit within the interior of end cap  11  (see  FIG. 6 ) as shown in  FIG. 9 . 
         [0048]    The present disclosure has been described herein in connection with a pump/motor assembly in a swimming pool environment, but is applicable to any electric motor that requires cooling in its end cap. Other applications are contemplated. 
         [0049]    Where this application has listed the steps of a method or procedure in a specific order, it may be possible or even expedient in certain circumstances, to change the order in which some steps, are performed, and it is intended that the particular steps of the method or procedure claim set forth herebelow not be construed as being order-specific unless, such order specificity is expressly stated in the claim. 
         [0050]    While the preferred embodiments of the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. Modification or combinations of the above-described assemblies, other embodiments, configurations, and methods for carrying out the invention, and variations of aspects of the invention that are obvious to those of skill in the art are intended to be within the scope of the claims.