Integrated solar pump design incorporating a brushless DC motor for use in a solar heating system

Most solar thermal hot water heating systems utilize a pump for circulation of the working fluid. An elegant approach to powering the pump is via solar energy. A “solar pump” employs a photovoltaic module, electric motor, and pump to collect and convert solar energy to circulate the working fluid. This article presents an experimental investigation of a new integrated solar pump design that employs the stator of a brushless DC motor and a magnetically coupled pump that has no dynamic seal. This design significantly reduces total volume and mass, and eliminates redundant components.The integrated design meets a hydraulic load of 1.7 bar and 1.4 litres per minute, equal to 4.0 watts, at a rotational speed of 500 revolutions per minute. The brushless DC motor and positive displacement pump achieve efficiencies of 62% and 52%, respectively, resulting in an electric to hydraulic efficiency of 32%. Thus, a readily available photovoltaic module rated 15 watts output is suitable to power the system.A variety of design variations were tested to determine the impact of the armature winding, pump size, pulse width modulation frequency, seal can material, etcetera. The physical and magnetic design was found to dominate efficiency. The efficiency characteristics of a photovoltaic module are such that over-sizing is wasteful.The integrated design presents a robust, efficient package for use as a solar pump. Although focus has been placed on application to a solar thermal collector system, variations of the design are suitable for a wide variety of applications such as remote location water pumping.