Air compressors and blowers

Abstract

A compressor or blower includes: an impeller disposed on a high-speed shaft; a motor shaft extending from an end cover of a motor; a gearbox; and a lubrication system. The gearbox is disposed between the motor and the impeller and includes: a pinion gear disposed on the high-speed shaft; and a ring gear disposed directly on the motor shaft and meshing with the pinion gear. The lubrication system includes a single pump module configured to wet bearings on the high-speed shaft prior to starting the motor and to mechanically pump oil to the bearings during motor operation.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 62 / 898021, filed on September 10, 2019, entitled "Air Compressor and Blower", the entire content of which is incorporated herein by reference. Technical Field

[0003] The present invention relates to a compressor and / or blower, and more particularly to a split - gearbox compressor or blower. Background Art

[0004] Split - gearbox compressors and blowers are generally quite large and expensive. For example, split - gearbox compressors or blowers typically have a large footprint and thus require a large substrate to support the device, which can make production and fixation expensive. The footprint is typically large because the high - speed components in compressors and blowers generally require a large lubrication system and expanded couplings. There is a desire for smaller and less expensive compressors and blowers. Summary of the Invention

[0005] The present invention relates to a split - gearbox compressor or blower (which can be configured as a horizontal or vertical split - gearbox compressor / blower). The compressor or blower includes a streamlined lubrication system having a single pump module and a streamlined coupling between the impeller and the motor. In particular, according to one embodiment, the compressor or blower includes: an impeller disposed on a high - speed shaft; a motor shaft that extends beyond the end - cover of the motor (e.g., overhangs); a gearbox; and a lubrication system. The gearbox is disposed between the motor and the impeller and includes: a pinion gear disposed on the high - speed shaft; and a large gear directly disposed on the motor shaft and meshing with the pinion gear. The lubrication system includes a single pump module that is configured to wet the bearings on the high - speed shaft before starting the motor and mechanically pump oil to the bearings during motor operation.

[0006] In at least some embodiments, the pinion gear is defined by a thrust collar and the high - speed shaft is supported by hydrodynamic bearings. Also, in at least some embodiments, the bearings are hydrodynamic bearings. Also, in at least some embodiments, the pump module includes a syringe for wetting the bearings and a mechanically - driven pump disposed on the motor shaft. Brief Description of the Drawings

[0007] Figure 1 and 2 is a perspective view of a compressor formed in accordance with an embodiment of the present invention.

[0008] Figure 3 is Figure 1 and2 Top view of a compressor with multiple components removed to show the internal components of the compressor gearbox.

[0009] Figure 4 and Figure 5 is Figure 1 and Figure 2 Perspective and top views of a cross-sectional view of a compressor.

[0010] Figure 6 is included in Figure 1 and 2 Perspective view of components in the gearbox of a compressor when removed from the compressor.

[0011] Figure 7 is included in Figure 6 Front view of the large gear included in the gearbox components shown.

[0012] Figure 8 is Figure 7 Side sectional view of the large gear along line A-A in Figure 7 .

[0013] Figure 9 is a block diagram showing the lubrication system included in Figure 1 and 2 of a compressor.

[0014] Figure 10 and 11 is a schematic diagram of the pump module included in the lubrication system of Figure 9 .

[0015] Figures 12 - 15 is Figure 1 and 2 Perspective view of a compressor with multiple components removed to show the lubrication system included in Figure 1 and 2 of a compressor.

[0016] Figure 16A is a perspective view of another exemplary embodiment of the lubrication system that can be included in Figure 1 and 2 of a compressor.

[0017] Figure 16B and 16C is the bottom view and perspective top view of the lubrication system of Figure 1 and 2 mounted on a compressor. Figure 16A .

[0018] Figure 17A and 17B is a perspective view of another exemplary embodiment of the lubrication system that can be included in Figure 1 and 2Perspective view of another exemplary embodiment of a lubrication system in a compressor, wherein, Figure 17B shows a compressor installed on Figure 1 and 2 and the Figure 17A lubrication system.

[0019] Figures 18A - 18C is an exemplary exploded view of a compressor showing at least some embodiments of the present invention, Figure 1 and 2 of the compressor.

[0020] Figure 19 is a view showing the gas pressure, gas flow rate, and power that can be output by multiple embodiments of the compressor proposed herein.

[0021] Figure 20 is a flowchart showing a method for lubricating the compressor or blower proposed herein according to an exemplary embodiment.

[0022] Figure 21 is a simplified block diagram of a computing device that can be used to implement multiple embodiments of the disclosed technology according to an exemplary embodiment.

[0023] In all the figures, the same reference numerals represent the same components. Detailed Description

[0024] Generally speaking, the proposed compressor / blower has a smaller form factor and improved efficiency. To achieve a smaller form factor, the compressor / blower includes a large gear directly disposed (e.g., mounted) on the motor shaft, which eliminates any coupling between the large gear and the motor shaft. Moreover, the compressor proposed herein includes: a high-speed shaft supported by a hydrodynamic bearing that can start when wet (as opposed to the case where full pressurization is required); and a lubrication system that includes a single pump module. The pump module is mechanically driven by the motor shaft on which the large gear is disposed (e.g., mounted), but the pump module is also configured to wet the hydrodynamic bearing (i.e., coat the bearing with a lubricant, e.g., oil) before the compressor starts. However, since the hydrodynamic bearing can start when wet, the pump module does not need to supply fully pressurized lubricant (e.g., oil) to the hydrodynamic bearing before starting. Therefore, the compressor / blower does not need to include an auxiliary pump system, which increases the size and cost of many other known split gearbox compressors / blowers.

[0025] Figure 1 and 2Shows an exemplary embodiment of a compressor formed in accordance with the present application. The compressor includes a volute 110 at one end, a motor 150 at its other end, and a gearbox 125 disposed therebetween. The volute 110 includes a housing 112 surrounding an impeller 114. The eye 116 of the impeller 114 is fixedly mounted on a high-speed shaft 130 that extends to the gearbox 125. Thus, when the high-speed shaft 130 rotates, the high-speed shaft 130 drives the rotation of the blades 118 of the impeller to suck in air through an inlet 120 and cause the air to move toward an outlet 122. It should be noted that the housing 112 is disposed at the end of the compressor 100, and thus, the impeller 114 can be easily accessed by removing a portion of the housing 112. In contrast, vertical split multi-stage compressors typically need to be removed from their base plates and disassembled piece by piece before their impellers can be inspected.

[0026] In multiple embodiments, the volute 110 may include inlet guide vanes or diffuser vanes; however, importantly, the volute 110 includes only one impeller 114. The motor 150 drives the impeller 114 to rotate, as described in more detail later. That is, Figure 1 and Figure 2 the motor 150 and the volute 110 shown in are merely examples, and in other embodiments, the motor 150 and the volute 110 may be formed in any manner now known or later developed, as long as the motor 150 can generate a rotational force and the volute 110 can suck in and discharge air.

[0027] The volute 110, the gearbox 125, and the motor 150 are each supported by an assembly frame 190. In this particular embodiment, the assembly frame 190 is formed by a collection of structural members 192 that are connected together in a rectangular shape and are supported on top of feet 194 (such as vibration isolation feet). The structural members 192 generally support the peripheral edges of the motor 150, the gearbox 125, and the volute 110, and include cross beams extending under at least the gearbox 125 and the motor 150. The structural members 192 can be tubular, C-shaped members, solid, hollow, or any other type of structural member. As described above, the characteristics of the compressor 100 enable the total footprint of the compressor 100 to be reduced (for reasons explained later) compared to similar compressors. Thus, in some embodiments, the assembly frame 190 can span a footprint of approximately four feet wide and approximately four to six feet long. In contrast, many compressors that produce a comparable output (combined with Figure 19 to represent and introduce an example of the output) can have a footprint of six feet wide by twelve to fifteen feet long.

[0028] In addition to the substrate, the compressor 100 may include a cover or housing to encapsulate certain components (e.g., to protect the components from contaminants and / or for safety considerations). In the described embodiment, the gearbox 125 is covered by the housing 195. The size of the gearbox housing 195 may be set to cover a variety of components required for different devices, such as gears included in a compressor operating at a frequency in the range of 20 - 60 Hz. Additionally, in the described embodiment, the housing 195 includes an upper half and a lower half and houses many (if not all) of the compressor components that require regular maintenance. Thus, the components (e.g., gears and drive shafts) of the compressor 100 can be easily accessed and inspected by removing only the upper half of the housing 195, without the need to disassemble the drive train. For example, the bearings included in the gearbox 125 can be inspected without removing them from the gearbox 125. In contrast, the bearings of a vertically split multi-stage compressor typically need to be removed from their gearboxes for inspection and are generally not inspected while arranged within the compressor. The housing 195 may also cover at least a portion of the lubrication system 200 included on the compressor 100. The housing 195 may cover the components of the gearbox 125 and the lubrication system 200 either alone or in conjunction with other elements.

[0029] Figures 3 - 6 A plurality of components of the gearbox 125 are shown, where the housing 195 is shown completely removed, partially removed, or in a cross-sectional view. Thus, these figures show the interaction between the high-speed shaft 130 and the motor 150. It should be noted that the large gear 154 is directly arranged (e.g., mounted) on the motor shaft 152, which overhangs (e.g., extends beyond) the end cover 170 of the motor 150. The large gear 154 directly meshes with the pinion 132 included on the high-speed shaft 130 and thus directly transfers the rotational energy generated by the motor 150 to the high-speed shaft 130. In some embodiments, the pinion 132 is formed integrally with the high-speed shaft 130, but in other embodiments, the pinion 132 is separately formed and mounted on the high-speed shaft 130. The pinion 132 is bounded by a pair of thrust collars 134 and is supported by a pair of hydrodynamic bearings 136 arranged outside the thrust collars 134 (see Figure 3 ). It should be noted that since the pinion 132 directly meshes with the large gear 154 arranged (e.g., mounted) on the motor shaft 152, the compressor does not need to include a separate large gear shaft and its own bearings, guards, supports, etc., and there is no need to couple the gear to the motor shaft. Thus, the compressor 100 eliminates many components compared to a compressor that mounts the large gear 154 on its own shaft.

[0030] For different embodiments, the dimensions of the pinion gear 132 and the thrust collar 134 can vary, but each expected dimension will fit within the gearbox housing 195. On the other hand, the hydrodynamic bearing 136 can be the same for many (if not all) embodiments. The bearing 136 is "hydrodynamic" because the bearing does not include roller elements or anti-friction elements. Thus, when properly lubricated, the bearing 136 can have an infinite life. As described in more detail later, the thrust collar 134 engages the edge of the ring gear 154 and transfers the axial force generated by the thrust of the impeller 114 to the ring gear 154 so as to ensure that the pinion gear 132 remains engaged with the ring gear 154 and to prevent the thrust load from being on the pinion bearing 136. The hydrodynamic bearing 136 allows the high-speed shaft 130 to rotate within the gearbox 125 and can be started when wet (as opposed to starting under full pressure lubrication). Moreover, in at least some embodiments, the hydrodynamic bearing 136 can be a horizontally split hydrodynamic bearing. The horizontally split hydrodynamic bearing 136 allows the lower half of the bearing 136 to be placed within the gearbox 195 prior to installing the high-speed shaft 130 (see Figure 5 ). Then, after installing the high-speed shaft 130, the upper half of the horizontally split hydrodynamic bearing 136 can be installed on the high-speed shaft 130. As an example, in Figure 6 , the horizontal line indicates the split between the two halves of the bearing 136.

[0031] By comparison, only one bearing 180 (here called the motor bearing 180) supports the motor shaft 152 for rotation within the gearbox 125. The bearing 180 is a roller bearing and thus can absorb the thrust load transferred to the motor shaft 152 through the thrust collar 134. The bearing 180 is disposed between the ring gear 154 and the motor 150 and is sealed near the motor 150 using an end cap 170. To provide a strong seal 174 between the end cap 170 and the remainder of the motor 150, the end cap includes gussets 172 and a fastening flange 176, the gussets 172 increasing the structural integrity of the end cap 170 and the fastening flange 176 providing a secure connection to the remainder of the motor 150. On the other side (referred to as the distal side) of the ring gear 154, the motor shaft 152 includes a pump drive member 153. The pump drive member 153 is used to engage and drive a mechanical pump included in the pump module 210 of the lubrication system 200 so that the lubrication system delivers a lubricant (such as oil) to various elements of the gearbox 125 when the motor 150 is operating, as described in more detail later.

[0032] Reference is made below to Figure 7 and 8, the large gear 154 includes a mounting portion 156, a radial flange 160, and an outer edge 164. The mounting portion 156 includes: a central opening 151 sized to receive the motor shaft 152; and a hole 155 sized to receive a fastener such that the large gear 154 can be fixed to the motor shaft 152. As visible in the cross-sectional view of Figure 8 , in the illustrated embodiment, the central opening 151 includes a tapered inner edge 158. The tapered inner edge 158 tapers from the proximal side of the large gear 154 (the side arranged closer to the motor 150) to the distal side of the large gear 154 (the side arranged closer to the pump module 210). The taper can match or mate with a taper included on the motor shaft and can facilitate a secure engagement of the large gear 154 with the motor shaft 152 (e.g., such that the large gear 154 is forged in place on the motor shaft 152).

[0033] The radial flange 160 extends between the mounting portion 156 and the outer edge 164. As visible from Figure 8 , the radial flange 160 is a substantially straight extension (e.g., its sides are parallel to each other), but extends at a pitch angle 162 greater than 90 degrees but less than 180 degrees away from the mounting portion 156. For example, the pitch angle 162 can be between 100 degrees and 120 degrees. Thus, the outer edge 164 extends beyond the distal side of the mounting portion 156. In fact, in some embodiments, the center of the outer edge 164 can be aligned or substantially aligned (e.g., within 10 mm) with the distal side of the mounting portion 156. In other words, the pitch angle 162 moves the outer edge 164 away from the motor 150 and also serves to balance the outer edge 164 to prevent overhang misalignment of the large gear 154, which ensures gear tooth contact between the large gear 154 and the pinion gear 132.

[0034] The outer edge 164 includes the teeth 166 of the large gear 154 and extends from a first side 165 to a second side 167. The sides 165 and 167 (which can also be referred to as thrust surfaces) can engage a thrust collar 134 that holds the pinion gear 132, so as to transfer the axial load (generated during rotation of the impeller 114) from the thrust collar 134 to the large gear 154 and ultimately to the rolling bearing 180 (see Figure 15 ). More specifically, the distal thrust surface 165 can absorb thrust, while the pitch angle 162 of the large gear and the proximal thrust surface 167 together compensate for the axial force (e.g., thrust) generated by the rotation of the impeller 114. This can prevent an unwanted axial deflection that would cause the pinion gear 132 to disengage from the large gear 154 (or vice versa). In fact, in at least some embodiments, the radial flange 160 and the pitch angle 162 can allow the outer edge 164 to deflect into tight engagement with the pinion gear 132. As included in Figure 8As shown in the illustration, the top edges of sides 165 and 167 may each include a chamfer 169. The chamfer 169 may include a concave (i.e., inward) rounding of the corner, which provides a clearance between the teeth 166 of the outer edge 164 and the thrust surfaces 165 and 167.

[0035] Reference is made below to Figures 9 - 15 , the lubrication system 200 of the compressor 100 generally includes a pump module 210, a cooler 220, a filter 228 (see Figures 12 - 15 ) and a lubricant track 240 (see Figure 15 ). Generally, the pump module 210 pushes or pumps a lubricant (e.g., oil) through the cooler 220 and the filter 228 towards the track 240, which distributes the lubricant (e.g., oil) to the components of the gearbox 125. Figure 9 Schematically shows an initial portion of the lubrication system. In particular, Figure 9 shows the pump module 210 that pumps a lubricant (e.g., oil) into the supply line 218. The supply line 218 is a Y-shaped or bifurcated supply line that divides into two passages. One passage connects the pump module 210 to a control valve 230, which may be a temperature control valve (e.g., a temperature control valve of AMOT Controls Corp. in Richmond, California) and / or a pressure control valve, and the other passage connects the pump module 210 to the inlet line 222 of the cooler 220 (e.g., through a valve and / or fitting). The cooler 220 outputs the cooled lubricant towards the control valve 230 through the outlet 224.

[0036] The control valve 230 then outputs the lubricant to an outlet line 229 towards the filter 228 and the high-speed shaft 130 (through the track 240). However, in other embodiments, such as the embodiment shown in Figures 12 - 15 , the filter 228 is arranged upstream of the control valve 230. Alternatively, a filter and / or a pressure reducing valve may be included in the control valve 230. When the control valve 230 includes a pressure control valve, a temperature control valve, a pressure reducing valve and a filter, the assembly of the compressor can be completed by connecting pipes between the control valve 230, the pump module 210 and other components of the compressor / blower (e.g., lubrication rails and coolers).

[0037] Figure 10 and 11 show two exemplary embodiments of the pump module 210. Each pump module 210 includes a pump 212 and a syringe 216. The pump 212 is driven by a pump drive member 153 (see Figure 5) is mechanically driven, and the pump drive member 153 rotates with the motor shaft 152 and / or is rotated by the motor shaft 152, and when driven, sucks lubricant (such as oil) from the storage tank 214 through the suction pipeline 211. In at least some embodiments, the bottom end of the suction pipeline 211 can be covered by a check valve 213, and the check valve 213 can be opened or closed by the controller 260. Since the pump 212 is driven by the rotation of the motor shaft 152, the pump 212 operates only when the motor is operating. Moreover, since many lubricants have low viscosity, various pumps can be used as the pump 212, including diesel pumps and plunger pumps.

[0038] Meanwhile, the syringe 216 can push the lubricant to the hydrodynamic bearing 136 before the motor shaft 152 rotates. As Figure 10 shown, in some embodiments, the syringe 216 can be arranged in the storage tank 214 and can push out the lubricant through the supply pipeline 217 (the supply pipeline 217 can include a check valve 215). The pump 212 can include sufficient clearance between its components so that the lubricant received from the supply pipeline 217 can enter the same piping system that is used to pump the lubricant from the pump 212 (for example, the lubricant from the syringe can pass through the pump 212 and enter the supply pipeline 218). Alternatively, as Figure 11 shown, the syringe 216 can be arranged above the lubricant arranged in the storage tank 214. Either way, the syringe 216 can be a 12- or 24-volt syringe powered by a local control panel (such as the controller 260) and will inject the lubricant through the lubrication system 200 until it reaches the hydrodynamic bearing 136. Moreover, although the syringe 216 is mainly used to wet the hydrodynamic bearing 136 just before startup (i.e., priming the system), the syringe 216 can also be used to wet the hydrodynamic bearing 136 when the compressor 100 shuts down and / or when the pump 212 fails. However, wetting the hydrodynamic bearing 136 just before startup may be crucial because the high-speed shaft can reach 1000 revolutions per minute in less than three seconds (such as 1 - 3 seconds).

[0039] Importantly, at Figure 10 and 11In the two embodiments shown, syringe 216 is located within the same housing as pump 212. For example, syringe 216 can be strapped, clamped, or otherwise secured to the inner wall of the housing of pump module 210. Thus, in compressor 100, there is no need for additional supports, piping, power lines, etc. that are typically included on a compressor to support an auxiliary pump. For example, some compressors include an auxiliary pump of 5 - 7 horsepower that requires separate electrical wiring, lubricant tubing, and space on the component frame 190. Compressor 100 eliminates all of these components by using a single pump module 210 to provide pre - lubrication and in - operation lubrication. In fact, in some embodiments, power can be extended to syringe 216 through a pre - existing opening in gearbox 125 to further reduce the components required for the lubrication system.

[0040] Regardless of where syringe 216 is located, syringe 216 can be controlled by controller 260. Controller 260 can drive the electronic or mechanical components of syringe 216 by on - off drive, ramp drive, modulated drive, or any way known now or developed later. Below in conjunction with Figure 21 Example computing devices representative of controller 26 are described in detail; however, generally, controller 260 can include a memory, a processor, and various other computing components to facilitate these drives. The memory can store any computer - readable instructions related to operating syringe 216 and / or any other components of compressor 100 that will be executed by the processor.

[0041] For example, the memory can store instructions that cause the processor to start syringe 216 after oiling or oil change and continue to drive the syringe until a pressure threshold is reached at hydrodynamic bearing 136 (as detected by a pressure sensor included at or near hydrodynamic bearing 136). The pressure threshold will indicate that the bearing is wet, but does not necessarily have to be fully pressurized. Then, upon shutdown, the memory can include instructions that cause syringe 216 to maintain the pressure at the pressure threshold for a predetermined time (e.g., to ensure that lubricant pressure is maintained as the motor decelerates to a stop). Below in conjunction with Figure 20 The techniques / operations performed by controller 260 are described in more detail.

[0042] Figures 12 - 15The lubrication system 200 included on the compressor 100 is shown from various perspectives. When considered together, the different perspectives clearly show the lubrication system 200. As described above, first, the pump module 210 receives lubricant through the lubricant line 219 and pumps or injects the lubricant into the supply line 218. In this particular embodiment, the supply line 218 is directly supplied to the filter 228 before diverging towards the cooler 220 and the control valve 230. However, in other embodiments, the filter 228 may be downstream of the control valve 230 rather than upstream of the control valve 230. The cooler 220 circulates coolant through the coolant line 223 to cool the lubricant passing through the cooler 220. For example, the cooler 220 may be an air-cooled or water-cooled cooler 220, and thus, the coolant line 223 may circulate air or water through the coolant line 223 (one line is the supply line and one line is the return line). The cooled lubricant leaves the cooler 220 at the outlet 224 and enters the control valve 230 to mix with the lubricant directly delivered to the control valve 230 through the supply line 218.

[0043] The lubricant leaving the control valve 230 flows through the line 229 towards the track 240 (see Figure 15 ). As best seen in Figure 15 , the track 240 extends parallel to the high-speed shaft 130 and can thus deliver lubricant to a plurality of components arranged on the high-speed shaft 130. In this particular embodiment, the first end 242 (also referred to as the distal end, although adjacent to the line 229) of the track 240 delivers lubricant to the first hydrodynamic bearing 136 (distal bearing 136), and the second end 246 (also referred to as the proximal end) of the track 240 delivers lubricant to the second hydrodynamic bearing 136 (proximal bearing 136). Additionally, the central portion 244 includes holes or ports (not shown) sized and oriented to produce a lubricant spray that acts on the engagement point between the pinion 132 and the gear 154. The two ends 242, 246 of the track 240 can deliver oil to the hydrodynamic bearings 136 through any suitable pipes, tubing, etc. For example, the ends 242, 246 may each include holes that are connected to the 1 / 8-inch notches included in the hydrodynamic bearings 136 through flexible hoses.

[0044] Reference is now made to Figure 16A -C, 17A and 17B, although Figures 12 - 15 shows an example arrangement of the lubrication system 200, this arrangement is just an example. Figure 16A -C shows another example lubrication system 200', and Figure 17A and 17Bshows another example lubrication system 200”. In systems 200' and 200”, the pump module 210 still pumps or injects lubricant into the supply line 218. However, at this time, the supply line 218 directly supplies into the control valve 230, which includes a filter 228 and / or is connected to the filter 228. The control valve 230 then circulates the lubricant through the cooler via lines 222 and 224, while directing the cooled lubricant to the track 240 via line 229. This can reduce the amount of tubing / hose and / or fittings required in the lubrication system and thus further reduce the cost of manufacturing and maintaining the compressor / blower proposed herein.

[0045] Moreover, the lubrication system 200 is mainly positioned below or laterally outside the gearbox housing 195 (e.g., outside the gearbox, on the opposite side relative to the motor 150), but the lubrication systems 200' and 200” include components positioned laterally inside the gearbox housing 195 (e.g., outside the gearbox, on the side opposite to the motor 150). Positioning the components of the lubrication system laterally inside the gearbox housing 195 can further reduce the total footprint of the compressor / blower proposed herein and / or reduce the exposure of the lubrication system to potential damaging effects (such as component movement), thereby reducing the manufacturing and / or maintenance costs.

[0046] More specifically, each of the lubrication systems 200' and 200” includes a cooler 220 that is vertically oriented (e.g., offset 90 degrees from the orientation of the cooler 220 of the lubrication system 200) and is laterally inside the gearbox housing 195. First, in the lubrication system 200', the cooler 220 is mounted against a part of the component frame 190 that supports the distal end of the motor 150 (the end of the motor adjacent to the end cap 170 of the motor 150), as Figure 16B and Figure 16C shown. Meanwhile, the control valve 230 is positioned laterally outside the gearbox housing 195, and any tubing / hose / pipeline connecting the control valve 230 and the cooler 220 passes through the gearbox housing 195 or extends below the gearbox housing 195. Second, as Figure 17B visible, in the lubrication system 200', the cooler 220 is mounted on a part of the component frame 190 that extends along the length of the motor 150, and the control valve is also positioned laterally inside the gearbox housing 195 (between the gearbox housing 195 and the motor 150). Then, any tubing / hose / pipeline (such as pipeline 229) connecting the control valve 230 and the track 240 passes through the gearbox housing 195 or extends below the gearbox housing 195.

[0047] Reference is made below to Figures 18A - 18C, in some cases, the compressor 100 can be an independent unit, but in other cases, the compressor 100 proposed herein can be packaged together with additional components to form various assemblies / devices. As an example, the compressor 100 can be enclosed within an air filter 302 to form a first assembly 300A. As another example, the compressor 100 can be enclosed to form a second assembly 300B, and one side of the housing can include an air filter 304 through which air is introduced into the compressor 100. As another example, the component frame 190 of the compressor 100 can extend to support the air filter 304, and the air filter 304 and the compressor 100 can together form a third assembly 300C.

[0048] As described above, in different embodiments, the compressor 100 can be varied to operate at different power parameters. Figure 19 Shows the various output pressures that can be produced by 60Hz iterations of the compressor 100 when operating at different horsepower at different inlet pressures. However, this chart is not limiting, and the compressor proposed herein can be used in any manner. For example, although referred to herein as a "compressor", the compressor can be used as a blower, a vacuum machine, or any other type of device that uses an impeller to move air.

[0049] Figure 20 Shows an example method 500 that can be performed by a controller connected (i.e., in communication) with the compressor / blower proposed herein. First, at 502, the controller detects the pressure at one or more bearings (e.g., the hydrodynamic bearing 136 on the high-speed shaft 130) on the high-speed shaft. In some embodiments, a single pressure sensor can detect the pressure representative of the pressure in all bearings on the high-speed shaft, and detecting the pressure can include aggregating data from the single sensor. Alternatively, each bearing can have a sensor, and detecting the pressure can include aggregating data from one or more of these sensors. For example, the controller can receive pressure data from two sensors and process the data to detect the pressure at two bearings. Although not shown, the sensors can be disposed within the bearings (e.g., the hydrodynamic bearing 136 on the high-speed shaft 130) on the high-speed shaft, or can communicate with the bearings. Alternatively, the sensors can communicate with the tracks, tubes / hoses / lines, or any other component of the lubrication system that delivers lubricant to the bearings, as long as the sensors are positioned close enough to the bearings, e.g., downstream of a control valve, to provide an accurate pressure reading. The sensors can be any pressure sensor known now or developed later that can produce data representative of the lubricant pressure.

[0050] At 504, 506, and 508, the controller determines the operating state of the compressor or blower. That is, the controller determines at 504 whether the compressor / blower is starting up, at 506 whether the compressor / blower is shutting down, and at 508 whether the compressor / blower is operating. These determinations can be made by monitoring the operation of the motor (such as motor 150), monitoring the operation of the volute, and / or based on user input to the controller. It should be noted that although operations 504, 506, 508 are shown as being consecutive after operation 502, operations 502, 504, 506, and 508 can be performed in any order or iteration and repeated at any time interval, as long as the execution of these operations determines the operating state of the compressor / blower while also detecting the pressure at the bearing on the high-speed shaft of the compressor / blower. Also, although steps 510, 520, and 530 are shown as the end points of method 500, this is for simplicity only, and it should be understood that these operations include a constant or near-constant pressure assessment (i.e., the method can have a feedback loop from 510, 520, and / or 530 to 502, 504, 506, and / or 508).

[0051] When at 504 the controller determines that the compressor / blower is starting up, the controller can cause the pump module to maintain the bearing pressure at a pressure threshold during a startup period at 510. The startup period can be a predetermined time period (such as 1 - 3 seconds), or it can be a dynamically determined time period, such as a time period determined based on motor operation. For example, the startup period can continue until the motor reaches a predetermined or set (such as user input) speed. The pressure threshold can ensure that the bearing is lubricated before and during the startup. For example, in some cases, the pressure threshold can be set to any pressure below 5 pounds per square inch (psi), such as 5 psi, 3 psi, 0.5 psi, etc. This pressure can lubricate the bearing but does not provide full pressurization. In at least some embodiments, the pump module maintains the bearing pressure at the pressure threshold by injecting lubricant through the lubrication system to the bearing using its syringe. It should be noted that the mechanical pump does not operate before startup and may not be operating at full speed at startup.

[0052] When, at 506, the controller determines that the compressor / blower is stopping, whether intentionally (e.g., due to a scheduling or user stop command) or due to a fault / error, the controller can cause the pump module to maintain the bearing pressure at a pressure threshold during a shutdown period at 520. The shutdown period can be a predetermined time period (e.g., 1 - 3 seconds) or can be a dynamically determined time period, such as a time period determined based on motor operation. For example, the shutdown period can continue until the motor has completely stopped or reached a minimum speed. The pressure threshold can ensure that the bearings are lubricated at the time of shutdown. For example, in some cases, the pressure threshold can be set to any pressure below 5 psi (e.g., 5 psi, 3 psi, 0.5 psi, etc.). The pump module maintains the bearing pressure at the pressure threshold by utilizing its syringe and / or its mechanical pump. For example, as the motor decelerates, the mechanical pump can continue to supply lubricant to the bearings, but when the controller determines that the pressure has dropped below the threshold, the controller can cause the syringe to supplement the mechanical pump or act in place of the mechanical pump. That is, since the mechanical pump can decelerate as the motor decelerates, the syringe can compensate for the mechanical pump and maintain the bearing pressure at the pressure threshold.

[0053] When, at 508, the controller determines that the compressor / blower is operating, at 530, the controller can cause the lubrication system to provide full pressurization to the bearings. For example, during operation, the motor of the compressor / blower can fully operate the mechanical pump in the pump module, and the controller can monitor the pressure of the bearings during operation and correspondingly control some aspects (e.g., operating parameters) of the mechanical pump, control valve, or any other part of the lubrication system.

[0054] Figure 21 An example hardware view of the computing device 1101 is shown, and the techniques provided herein (e.g., Figure 20 the techniques shown therein) can be implemented on the computing device 1101. For example, the computing device 1101 can be representative of the controller 260. The device 1101 includes a bus 1102 or other communication mechanism for communicating information and a processor 1103 coupled to the bus 1102 for processing information. Although the figure shows a symbolic block 1103 for the processor, it should be understood that the processor 1103 represents multiple processing cores, and each processing core can perform separate processing. The device 1101 can also include dedicated logic devices (e.g., application specific integrated circuits (ASICs)) or programmable logic devices (e.g., simple programmable logic devices (SPLDs), complex programmable logic devices (CPLDs), and field programmable gate arrays (FPGAs)), which, in addition to microprocessors and digital signal processors, can be used as processing circuitry either individually or in combination. The processing circuitry can be located in one device or distributed across multiple devices.

[0055] The apparatus 1101 also includes a main memory 1104, such as a random access memory (RAM) or other dynamic storage device (such as dynamic RAM (DRAM), static RAM (SRAM), and synchronous DRAM (SDRAM)), which is coupled to the bus 1102 for storing information and instructions to be executed by the processor 1103. The memory 1104 pressure control logic 1120, when executed by the processor 1103, enables the computing device 1101 to perform the operations described herein (such as Figure 20 the techniques). Additionally, the main memory 1104 can be used to store temporary variables or other intermediate information while the processor 1103 executes instructions. The apparatus 1101 also includes a read-only memory (ROM) 1105 or other static storage device (such as programmable ROM (PROM), erasable PROM (EPROM), and electrically erasable PROM (EEPROM)) coupled to the bus 1102 for storing static information and instructions for the processor 1103.

[0056] The apparatus 1101 also includes a disk controller 1106 coupled to the bus 1102 for controlling one or more storage devices for storing information and instructions, such as a magnetic hard disk 1107 and a removable media drive 1108 (such as a floppy disk drive, a read-only optical disk drive, a read / write optical disk drive, a CD jukebox, a magnetic tape drive, and a removable magneto-optical drive). The storage devices can be added to the apparatus 1101 using a suitable device interface (such as Small Computer System Interface (SCSI), Integrated Device Electronics (IDE), Enhanced IDE (E-IDE), Direct Memory Access (DMA), or Ultra DMA). Thus, generally, the memory can include one or more tangible (non-transitory) computer-readable storage media (such as memory devices) encoded with software including computer-executable instructions, and when the software is executed (by the processor), it is operative to perform the operations described herein.

[0057] The apparatus 1101 may also include a display controller 109 coupled to the bus 1102 to control a display 1110 for displaying information to a computer user. The computer system 1101 may also include input devices such as control buttons 1111 and sensors 1112 for interacting with the computer user and providing information to the processor 1103. The sensor 1112 may detect or sense the pressure of a bearing (such as a hydrodynamic bearing) included on the high-speed shaft of the compressor / blower proposed herein. The control buttons may include buttons, rotary encoders, keyboards, and / or pointing devices such as a mouse, trackball, or pointing stick for communicating direction information and command selections to the processor 1103 and for controlling cursor movement on the display 1110. Additionally, a printer may provide a printed listing of data stored and / or generated by the apparatus 1101.

[0058] In response to the processor 1103 executing one or more sequences of one or more instructions contained in a memory (such as main memory 1104), the apparatus 1101 performs some or all of the processing steps described herein. Such instructions may be read from another computer-readable medium (such as a hard disk 1107 or a removable media drive 1108) into the main memory 1104. One or more processors in a multi-processing device may also be used to execute instruction sequences contained in the main memory 1104. In alternative embodiments, hardwired circuitry may be used in place of or in combination with software instructions. Accordingly, embodiments are not limited to any particular combination of hardware circuitry and software.

[0059] As described above, the apparatus 1101 includes at least one computer-readable medium or memory for holding instructions programmed in accordance with the embodiments for containing data structures, tables, records, or other data described herein. Examples of computer-readable media are compact discs, hard disks, floppy disks, magnetic tapes, magneto-optical discs, PROMs (EPROM, EEPROM, flash EPROM), DRAM, SRAM, SD RAM, or any other magnetic medium, compact discs (such as CD-ROM), or any other optical medium, punch cards, paper tapes, or other physical media with hole patterns, or any other medium readable by a computer.

[0060] When stored on any one or combination of non-transitory computer-readable storage media, the embodiments presented herein include software for controlling device 1101, for driving a device that implements the techniques described herein (e.g., for performing pressure logic so as to keep bearing pressure at, above, or below a pressure threshold), and for enabling device 1101 to interact with a human user (e.g., a network engineer). Such software can include, but is not limited to, device drivers, operating systems, development tools, and application software. Such computer-readable storage media also include computer program products for performing all or part of the processing described herein (when the processing is distributed).

[0061] The computer code device can be any interpretable or executable code mechanism, including, but not limited to, scripts, interpretable programs, dynamic link libraries, Java classes, and fully executable programs. Moreover, the components of the processing can be distributed to achieve better performance, reliability, and / or cost.

[0062] Device 1101 also includes a communication interface 1113 coupled to bus 1102. Communication interface 1113 provides two-way data communication with a network link 1114, which is connected to, for example, a local area network (LAN) 1115 or another communication network 1116 (e.g., the Internet). For example, communication interface 1113 can be a wired or wireless network interface card for attachment to any packet-switched (wired or wireless) LAN. As another example, communication interface 1113 can be an asymmetric digital subscriber line (ADSL) card, an integrated services digital network (ISDN) card, or a modem for providing a data communication connection to a corresponding type of communication line. A wireless link can also be implemented. In any such implementation, communication interface 1113 transmits and receives electrical, electromagnetic, or optical signals carrying digital data streams representing various types of information.

[0063] Network link 1114 generally provides data communication to other data devices via one or more networks. For example, network link 1114 may provide a connection to another computer via a local area network 1115 (e.g., LAN) or via a device operated by a service provider that provides communication services via communication network 1116. Local network 1114 and communication network 1116 use, for example, electrical signals, electromagnetic signals, or optical signals carrying digital data streams, as well as associated physical layers (e.g., CAT5 cables, coaxial cables, optical fibers, etc.). Signals through various networks and signals on network link 1114 and through communication interface 1113 may be implemented in baseband signals or carrier-based signals that carry digital data to and from device 1101. Baseband signals transmit digital data as unmodulated electrical pulses that describe a digital data bit stream, where the term "bit" should be interpreted broadly to represent a symbol, and each symbol transmits at least one or more information bits. Digital data may also be used to modulate a carrier, such as by amplitude, phase, and / or frequency shift keying signals that propagate on a conductive medium or as electromagnetic waves through a propagation medium. Thus, digital data may be sent as unmodulated baseband data via a "wired" communication channel and / or sent by modulating a carrier within a predetermined frequency band different from the baseband. Device 1101 may send and receive data including program code via networks 1115 and 1116, network link 1114, and communication interface 1113. Moreover, network link 1214 may provide a connection via LAN 1115 to a mobile device 1117 (e.g., a personal digital assistant (PDA), a laptop computer, or a cellular phone).

[0064] It should be understood that terms used herein such as "left", "right", "top", "bottom", "front", "rear", "side", "height", "length", "width", "upper", "lower", "inner", "outer", "inside", "outside", etc. only introduce reference points or reference parts and do not limit the present invention to any particular orientation or arrangement. Moreover, the term "exemplary" used herein introduces an example or illustration. Any embodiment described herein as exemplary should not be construed as a preferred or advantageous embodiment, but rather as an example or illustration of a possible embodiment of the present invention.

[0065] Although in this document, the invention is shown and described as implemented in one or more specific instances, it is not limited to the details shown, as various changes and structural alterations may be made without departing from the scope of the invention and within the scope of equivalents of the claims. Additionally, various features from one embodiment may be incorporated into another embodiment. Therefore, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention as set forth in the appended claims.

Claims

1. A compressor or blower, comprising: An impeller disposed on a high-speed shaft; A motor shaft extending from an end housing of a motor; A gearbox disposed between the motor and the impeller and comprising: A pinion disposed on the high-speed shaft; and A large gear disposed directly on the motor shaft and meshing with the pinion; and A lubrication system having a single pump module, and the pump module is configured to wet a bearing on the high-speed shaft before starting the motor and mechanically pump oil to the bearing during motor operation; Wherein: the single pump module comprises: A syringe that performs wetting of the bearing; and A mechanically driven pump disposed on the motor shaft and performing mechanical pumping; wherein the motor is the only motor for driving the single pump module.

2. The compressor or blower according to claim 1, wherein: The gearbox further comprises: a pair of thrust collars disposed on the high-speed shaft on each side of the pinion.

3. The compressor or blower according to claim 1 or 2, wherein: The lubrication system further comprises: A lubricant track extending from a proximal end to a distal end, the proximal end for supplying lubricant to a first bearing among the bearings, the distal end for supplying lubricant to a second bearing among the bearings, and a central portion between the proximal end and the distal end for lubricating a meshing point between the pinion and the large gear.

4. The compressor or blower according to any one of the preceding claims 1 and 2, wherein: The mechanically driven pump is coupled to the gearbox.

5. The compressor or blower according to claim 4, wherein: The mechanically driven pump is bolted to an inner surface of the gearbox.

6. The compressor or blower according to any one of the preceding claims 1, 2, and 5, wherein: The syringe also performs a priming fill of the lubrication system.

7. The compressor or blower according to any one of the preceding claims 1, 2 and 5, wherein: The gearbox comprises a housing having an upper half and a lower half, the upper half removably coupled to the lower half and removable to provide access to components of the compressor or blower that require periodic maintenance.

8. The compressor or blower according to any one of claims 1, 2, and 5, further comprising: An assembly frame supporting the motor, the impeller, and the gearbox, the assembly frame having a width of four feet or less and a length of six feet or less.

9. The compressor or blower according to any one of the preceding claims 1, 2 and 5, wherein: The bearing on the high-speed shaft is a hydrodynamic bearing that supports the high-speed shaft and allows the high-speed shaft to rotate.

10. A method of providing lubrication to a compressor or blower using a single pump module, wherein the motor of the compressor or blower is the only motor for driving the single pump module, the method comprising: Before starting the motor of the compressor or blower, wetting a bearing on the high-speed shaft that supports an impeller of the compressor or blower having the single pump module, the high-speed shaft including a pinion that meshes with a large gear directly mounted on the motor shaft of the motor; During operation of the motor, mechanically pumping oil to the bearing on the high-speed shaft using the single pump module; And Wherein: the single pump module comprises: a syringe that performs wetting of the bearing; and a mechanically driven pump disposed on the motor shaft and performing mechanical pumping.

11. According to the method of claim 10, wherein: The bearing on the high-speed shaft is a hydrodynamic bearing that supports the high-speed shaft and allows the high-speed shaft to rotate.

12. The method according to claim 10 or 11, wherein: The compressor or blower includes a sensor for monitoring lubrication at the bearing, and the method further comprises: Wet the bearing until the pressure detected by the sensor at the bearing reaches a pressure threshold, which indicates that the bearing is wet but not fully pressurized.

13. According to the method according to any one of claims 10-11, wherein: The compressor or blower includes a sensor for monitoring lubrication at the bearing, and the method further includes: When the motor is off, wet the bearing so that the pressure detected by the sensor remains at or above the pressure threshold for a predetermined time, which indicates that the bearing is wet but not fully pressurized.

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