Pump with external electrical components and related methods

Abstract

A submersible pump and related methods are disclosed herein. The pump assembly includes a pump housing and a motor with a motor housing/cap and an output shaft connected to an impeller that is disposed in a volute. In some forms, a separate power circuit compartment is formed integral to one of the pump housing and/or volute to store power circuitry that allows a DC pump to be used and powered by AC voltage. In other forms, the power circuit compartment is formed separate from the pump assembly and fastened or connect to the pump assembly. In preferred forms, the power circuit compartment is positioned relative to the pump assembly at a point where it will be maintained at least partially within the fluid surrounding the pump to dissipate heat from the power circuit. Numerous methods are also disclosed and contemplated herein.

What is claimed is: 
     
         1 . A pump assembly comprising:
 a housing having an upper portion defining a motor cavity and a lower portion defining a fluid collector;   a motor disposed at least partially within the motor cavity;   a sealed power circuit enclosure separate and apart from the housing;   a power circuit disposed at least partially within the sealed power circuit enclosure; and   a conductive cable extending from the sealed power circuit enclosure to the upper portion of the housing to connect the sealed power circuit enclosure to the housing, the conductive cable further electrically connecting the power circuit to the motor to provide electrical power to the motor.   
     
     
         2 . The pump assembly of  claim 1  wherein the sealed power circuit enclosure is spaced apart from the housing by a support member. 
     
     
         3 . The pump assembly of  claim 2  wherein the support member connects the sealed power circuit enclosure to the lower portion of the housing. 
     
     
         4 . The pump assembly of  claim 2  wherein the support member supports the sealed power circuit enclosure away from the housing in an at least partially horizontal direction such that when the pump assembly is submerged in a fluid, the fluid enters an area between a portion of the pump housing and a portion of the sealed power circuit enclosure. 
     
     
         5 . The pump assembly of  claim 1  wherein the conductive cable extends through an opening in the upper portion of the housing and into the motor cavity of the housing. 
     
     
         6 . The pump assembly of  claim 5  wherein the conductive cable extends from the sealed power circuit enclosure to the upper portion of the housing external to the housing. 
     
     
         7 . The pump assembly of  claim 5  further comprising a cable seal disposed within the opening in the upper portion of the housing, the conductive cable passing through the cable seal. 
     
     
         8 . The pump assembly of  claim 5  wherein the opening in the upper portion of the housing is in a top wall of the upper portion of the housing. 
     
     
         9 . The pump assembly of  claim 1  wherein the a power circuit comprises a rectifier for converting AC supply voltage to DC voltage. 
     
     
         10 . The pump assembly of  claim 1  wherein the motor is a permanent magnet motor. 
     
     
         11 . The pump assembly of  claim 1  wherein the fluid collector includes a fluid inlet and a fluid discharge, the pump assembly further comprising an impeller operatively coupled to the motor and positioned at least partially within the fluid collector. 
     
     
         12 . The pump assembly of  claim 11  wherein the sealed power circuit enclosure is connected to the fluid collector such that a fluid flow induced by the impeller when the pump motor is operated causes fluid to flow past the sealed power circuit enclosure to aid in dissipating heat generated by the power circuit. 
     
     
         13 . The pump assembly of  claim 1  wherein the power circuit includes a capacitive water sensor. 
     
     
         14 . A method of manufacturing a pump comprising:
 providing a pump housing having an upper portion defining a motor cavity and a lower portion defining a fluid collector;   positioning a DC motor at least partially within the motor cavity, the DC motor including an output shaft;   connecting an impeller to the output shaft of the DC motor such that the impeller is positioned within the fluid collector;   providing an external power control housing containing power circuitry to convert AC supply voltage to DC voltage to power the DC motor; and   connecting the external power control housing to the pump housing via a power cable extending from the external power control housing and into the upper portion of the housing through an opening in the upper portion of the pump housing.   
     
     
         15 . The method of  claim 14  further comprising electrically connecting the power circuitry to the DC motor via the power cable. 
     
     
         16 . The method of  claim 14  further comprising rigidly connecting the external power control housing to a lower portion of the pump housing such that the external power control housing rests in fluid at least partially when the pump is positioned in fluid to allow the fluid to be used to dissipate heat generated from the power circuitry. 
     
     
         17 . The method of  claim 16  wherein rigidly connecting the external power control housing to the lower portion of the pump housing includes spacing the external power control housing from the lower portion of the pump housing with a support member.