Fluid injector with active cooling

Abstract

A fluid injector active cooling system is configured to actively cool heat generating components of an injection system. The cooling system includes a fan assembly that actively controls between an active state and an inactive state to control flow of cooling fluid through the cooling circuit. The fan assembly operates independently of a motor that powers the pumping through a pump of the injection system.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 396,371, filed on August 9, 2022, entitled “FLUID SPRAYER HAVING ACTIVECOOLING,” the disclosure of which is incorporated herein by reference in its entirety. Background Art

[0003] The present disclosure relates generally to fluid displacement systems and, more particularly, to cooling systems for reciprocating fluid displacement pumps.

[0004] Fluid displacement systems, such as fluid dispensing systems for coatings, typically utilize positive displacement pumps, such as axial displacement pumps, to draw fluid from a container and drive the fluid downstream. Axial displacement pumps are typically mounted to a drive housing and driven by an electric motor. A pump rod is attached to a reciprocating drive that drives the reciprocating motion of the pump rod, thereby drawing fluid from the container into the pump, which is then driven downstream from the pump. In some cases, an electric motor may power the pump. The motor and control components of the fluid displacement system generate heat during operation. Summary of the invention

[0005] According to one aspect of the present disclosure, a fluid ejector includes: a pump that outputs a fluid under pressure; a spray gun that ejects the fluid output from the pump; a motor that has a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame that supports the pump and the motor; and a fan assembly that generates a cooling fluid flow for cooling the motor, the fan assembly having a blade structure that rotates about a second axis, the second axis being non-coaxial with the first axis.

[0006] According to additional or alternative aspects of the present disclosure, a fluid ejector includes: a pump that outputs a fluid under pressure; a spray gun that ejects the fluid output from the pump; a motor that has a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame that supports the pump and the motor; a fan assembly that generates a cooling fluid flow for cooling the motor, the fan assembly having a blade structure that rotates about a second axis; and a cooling circuit that has a chamber, a cooling inlet, and a cooling outlet, the motor being at least partially disposed in the chamber, the cooling inlet being configured to provide cooling fluid from the fan assembly to the chamber, and the cooling outlet being configured to output heated cooling fluid from the chamber.

[0007] According to another additional or alternative aspect of the present disclosure, a fluid ejector includes: a pump that outputs a fluid under pressure; a spray gun that ejects the fluid output from the pump; a motor that has a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame that supports the pump and the motor; a chamber in which the motor is at least partially disposed; a fan assembly that generates a cooling fluid flow that cools the motor and is configured to blow the cooling fluid flow into the chamber, the fan assembly having a blade structure that rotates about a second axis; and a radiator that forms at least one wall of the chamber and is exposed to the cooling fluid flow generated by the fan assembly.

[0008] According to yet another additional or alternative aspect of the present disclosure, a fluid injector includes: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; a motor that has a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame that supports the pump and the motor; a fan assembly that generates a cooling fluid flow for cooling the motor, the fan assembly having a blade structure that rotates about a second axis; a first temperature sensor that is configured to generate temperature information about a first sensed temperature; and a controller that is configured to control the operation of the fan assembly, the controller being configured to control the activation of the fan assembly based on a comparison of the first sensed temperature and a first thermal threshold.

[0009] According to yet another additional or alternative aspect of the present disclosure, a fluid injector includes: a pump that outputs fluid under pressure; a spray gun that sprays the fluid output from the pump; a motor that has a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame that supports the pump and the motor; a fan assembly that generates a cooling fluid flow for cooling the motor, the fan assembly having a blade structure that rotates about a second axis; and a controller that is configured to control the operation of the fan assembly, the controller being configured to control the operation of the fan assembly based on a first sensed temperature and a rotational speed of the motor.

[0010] According to yet another additional or alternative aspect of the present disclosure, a fluid injector includes: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; a motor that has a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame that supports the pump and the motor; a fan assembly that generates a cooling fluid flow to cool the motor, the fan assembly having a blade structure that rotates about a second axis; and a controller that is configured to control the operation of the fan assembly, the controller being configured to change the speed of the fan assembly based on a first sensed temperature.

[0011] According to yet another additional or alternative aspect of the present disclosure, a fluid injector includes: a pump that outputs fluid under pressure; a spray gun that sprays the fluid output from the pump; a motor that has a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame that supports the pump and the motor; a fan assembly that generates a cooling fluid flow for cooling the motor, the fan assembly having a blade structure that rotates about a second axis; and a controller that is configured to control the operation of the fan assembly so that the fan assembly generates the cooling fluid flow only when the rotor rotates.

[0012] According to yet another additional or alternative aspect of the present disclosure, a fluid injector includes: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; a motor that has a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame that supports the pump and the motor; a fan assembly that generates a cooling fluid flow for cooling the motor, the fan assembly having a blade structure that rotates about a second axis; and a controller that is configured to control the operation of the fan assembly based on satisfaction of a primary condition. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1A It is a front elevation schematic block diagram of the injection system.

[0014] Figure 1B is a schematic block diagram of a side elevation of the injection system.

[0015] Figure 2 is an isometric view of the front side of the drive system.

[0016] Figure 3 is an exploded view of the drive system.

[0017] Figure 4 is a cross-sectional view of the drive system.

[0018] Figure 4A yes Figure 4 4A is an enlarged view of portion 4A.

[0019] Figure 5 is used for Figure 2 Isometric front and side view of the drive system and support frame of the displacement pump.

[0020] Fig. 6A A cross-sectional view of the injection system is shown.

[0021] Figure 6B yes Figure 6B Magnified view of detail B.

[0022] Figure 7 yes Fig. 6AAn exploded view of the various components of the injection system is shown in FIG.

[0023] Figure 8 is an isometric view of the drive system.

[0024] Fig. 9 yes Figure 8 A cross-sectional view of the drive system is shown.

[0025] Fig. 10A is an isometric view of the drive system showing a partial cutaway view of the housing.

[0026] Fig. 10B is similar to Fig. 10A An isometric view of the drive system with additional parts of the housing removed.

[0027] Fig. 10C is an isometric view of the drive system as viewed from the underside of the drive system.

[0028] Fig. 10D It is along Fig. 10A A cross-sectional view taken along line DD in FIG.

[0029] Fig.10E It is along Fig. 10A A cross-sectional view taken along line EE in FIG.

[0030] Fig.11A is an exploded isometric view of the drive system.

[0031] Fig. 11B is an enlarged isometric view of the drive system showing the heat sink exploded from the other components of the drive system.

[0032] Fig.12 It is a block diagram of the drive system.

[0033] Fig.13 is a flow chart illustrating a control routine for active cooling of a drive system.

[0034] Fig.14 is a control table for controlling the fan assembly used for active cooling of the drive system. DETAILED DESCRIPTION

[0035] The present disclosure relates to cooling for reciprocating fluid displacement pumps. A cooling system actively cools the electrically driven components of the pump system. The electrically driven system generates excessive heat and requires active cooling via a fan. The present disclosure provides a cooling feature. Fig. 9 The general structure and operation of the fluid ejector are discussed, and cooling features are discussed in conjunction with FIGS. 11-16 .

[0036] The controller can control the operation of the motor to cause the pump to pump. The fan assembly is configured to generate a flow of cooling fluid (such as air) for cooling the motor. The fan assembly can be arranged on the underside of the drive housing. The fan assembly is arranged so that the fan assembly blows the cooling fluid flow vertically upward toward the motor.

[0037] The motor is at least partially disposed in the chamber, and the fan assembly blows a cooling fluid flow through the chamber. The motor is exposed to the cooling fluid flow for thermal cooling of the motor. The cooling circuit through which the cooling fluid flow flows can be configured so that the cooling fluid enters the chamber vertically below the motor and leaves the chamber at a position vertically above the motor.

[0038] The fan assembly draws cooling fluid from the bottom side of the drive system. The fan assembly that draws cooling fluid from the bottom side protects the components of the drive system from the impact of spray particles in the environment of the spray system. The fan assembly is configured so that the spray particles must overcome gravity to move upward to reach the fan assembly and be pulled into the chamber. The fan assembly can be recessed from the longitudinal side and the lateral side of the drive system to further prevent the suction of the spray particles. Isolating the fan assembly from the falling particles prevents such particles from being sucked into the chamber, where the particles may coat or otherwise adhere to the components of the drive system, thereby reducing the operating efficiency of such components.

[0039] The chamber may extend completely around the motor around the axis of the motor. Such a configuration facilitates cooling fluid to flow completely circumferentially around the motor. Cooling fluid flowing completely circumferentially around the motor provides improved cooling efficiency by providing a large surface area of ​​the motor for exposure to the cooling fluid.

[0040] According to some aspects of the present disclosure, the radiator is exposed to the cooling fluid flow output by the fan assembly. The radiator can define the wall of the chamber, the motor is at least partially arranged in the chamber, and the fan assembly blows the cooling fluid flow into the chamber. The radiator can be directly arranged between the chamber and the control chamber, and the controller of the injection system is arranged in the control chamber. The radiator wicks the heat generated by the controller to the cooling fluid flow to cool the controller. In some cases, one or more components are directly mounted to the radiator to better cool those components. In some cases, an insulated gate bipolar transistor (IGBT) is mounted to the radiator. The components of the controller can be directly thermally connected to the radiator to provide a direct thermal path between the components of the controller and the cooling fluid flow via the radiator.

[0041] According to some aspects of the present disclosure, the controller is configured to control the operation of the fan assembly. The fan assembly can operate independently of the motor. When the motor is not running, the fan assembly can operate to generate a cooling fluid flow, and when the motor is running, the fan assembly can be deactivated to not generate a cooling fluid flow. The fan assembly is mechanically separated from the motor and separated from the motor.

[0042] The controller may be configured to change the speed of the fan assembly. The controller may change the speed of the fan assembly based on one or more operating parameters of the injection system. According to some aspects of the present disclosure, the operating parameter may be a sensed temperature. The controller may change the speed of the fan assembly based on the sensed temperature. According to some aspects of the present disclosure, the operating parameter may be a rotational speed of the motor. The controller may change the speed of the fan assembly based on the rotational speed.

[0043] The controller can be configured to operate the fan assembly based on multiple operating parameters. According to some aspects of the present disclosure, the controller can cause the fan assembly to operate to produce a cooling fluid flow based on satisfying multiple operating parameters. For example, if the sensed temperature satisfies a temperature threshold and the motor is actually operating, the controller can cause the fan assembly to operate to produce a rotational output.

[0044] The controller may be configured to operate the fan assembly based on a plurality of tiered thresholds relative to the operating parameter. The controller may be configured to control operation of the fan assembly in different operating modes based on which of the plurality of thresholds is met. For example, if the operating parameter meets a lower threshold, the controller may cause the fan assembly to operate according to a first operating mode, and if the operating parameter meets a higher threshold, the controller may cause the fan assembly to operate according to a second operating mode.

[0045] Figure 1A is a schematic block diagram of the injection system 1 in a front elevation view. Figure 1B is a schematic block diagram of the injection system 1 in side elevation. Figure 1A and Figure 1B Discussed together. A support 2, a reservoir 3, a supply line 4, a spray gun 5 and a drive system 10 are shown. The drive system 10 includes a motor 12, a drive mechanism 14, a pump frame 18 and a displacement pump 19. The support 2 includes a support body 6 and wheels 7. A fluid displacer 16 and a pump body 19a of the displacement pump 19 are shown. The spray gun 5 includes a handle 8 and a trigger 9.

[0046] The spray system 1 is a system for applying the spray of various fluids to a substrate, and examples of various fluids include paint, water, oil, colorant, finish, aggregate, coating and solvent and other options. The drive system 10 (also referred to as a pump assembly) can generate a high fluid pumping pressure, such as about 3.4 to 69 MPa (MPa) (about 500 to 10000 pounds per square inch (psi)) or even higher. In some examples, the pumping pressure is in the range of about 20.7 to 34.5 MPa (about 3000 to 5000 psi). High fluid pumping pressure is useful for atomizing the fluid into a spray for applying the fluid to a surface.

[0047] The drive system 10 is configured to draw a spray fluid from the reservoir 3 and pump the fluid downstream to the spray gun 5 for application to the substrate. The support 2 is connected to the drive system 10 and supports the drive system 10 relative to the reservoir 3. The support 2 can receive and react to loads from the drive system 10. For example, the support body 6 can be connected to the support frame 18 to react to loads generated during pumping. In the example shown, wheels 7 are connected to the support body 6 to facilitate movement between and within a job site.

[0048] Support frame 18 supports other components of drive system 10. Motor 12 and displacement pump 19 are connected to support frame 18. Motor 12 is an electric motor having a stator and a rotor. Motor 12 can be configured to be powered by any desired power source type, such as direct current (DC), alternating current (AC), and / or a combination of DC and AC. The rotor is configured to rotate around the motor axis MA in response to a current (such as a DC or AC signal) passing through the stator. In some examples, the rotor can rotate around the stator so that motor 12 is an outer rotor motor.

[0049] The drive mechanism 14 is connected to the motor 12 to be driven by the motor 12. The drive mechanism 14 may also be referred to as a driver. The drive mechanism 14 receives the rotational output from the motor 12 and drives the movement of the pump 19 to cause the pump 19 to pump. For example, the driver 14 may convert the rotational output into a linear input along the pump axis PA. In the example shown, the driver 14 is connected to the fluid displacer 16 to drive the reciprocating motion of the fluid displacer 16 along the pump axis PA. Figure 1B As shown, the motor axis MA is disposed transversely to the pump axis PA. In some examples, the motor axis MA may be orthogonal to the pump axis PA. In the example shown, the fluid displacer 16 reciprocates within a pump body 19a (such as a cylinder 94 discussed below) to pump the spray fluid from the reservoir 3 to the spray gun 5 through the supply line 4.

[0050] In some examples, the motor 12, drive mechanism 14, and fluid displacer 16 may be coaxially arranged such that the motor axis MA and the pump axis PA are coaxial. For example, the pump 19 may be configured as a rotor-stator pump in which a rotating component moves relative to a stationary component to pump fluid, such as a screw rotating within a leaf-shaped sleeve.

[0051] The pump 19 may be configured to draw fluid into the pump through a pump inlet and output the fluid through a pump outlet. The pump body 19a defines a pump chamber through which the fluid is pumped. The fluid displacer 16 divides the pump chamber into an upstream chamber and a downstream chamber. The piston head of the piston forming the fluid displacer may divide the pump chamber into an upstream chamber and a downstream chamber. The pump 19 may be configured as a dual displacement pump that outputs pumped fluid during both a stroke in a first direction along the pump axis PA and a stroke in a second direction along the pump axis PA.

[0052] During operation, a user can manipulate the drive system 10 to a desired position relative to a target substrate by moving the support 2. For example, a user can manipulate the drive system 10 by tilting the support frame 6 using the wheels 7 and rolling the drive system 10 to a desired position. In some examples, a handle can extend from the drive system 10, and the user can manipulate the drive system 10 within or between work sites by grasping the handle and carrying the drive system 10. A displacement pump 19 is configured to draw a jetting fluid from a reservoir 3. In some examples, the displacement pump 19 can extend into the reservoir 3. The motor 12 provides a rotational input to the drive mechanism 14, and the drive mechanism 14 provides an input to the fluid displacer 16 to drive the operation of the fluid displacer 16. The fluid displacer 16 draws the jetting fluid from the reservoir 3 and drives the jetting fluid downstream through the supply line 4 to the spray gun 5.

[0053] The user can manipulate the spray gun 5 by grasping the handle 8 of the spray gun 5, such as with a single hand of the user. The user causes the spray by actuating the trigger 9. Actuating the trigger 9 can open a valve in the spray gun 5 to allow the pressurized fluid to be released from the spray gun 5. The fluid can be emitted through a nozzle that atomizes the spray fluid. The nozzle can shape the spray fluid into a desired pattern, such as a fan, a cone, etc. In some examples, the pressure generated by the drive system 10 atomizes the spray fluid leaving the spray gun 5 to produce a fluid spray. In some examples, the spray gun 5 is an airless sprayer.

[0054] Figure 2 is an isometric view of the front side of the drive system 10 . Figure 3 is an exploded view of the drive system 10 . Figure 4 is a cross-sectional view of the drive system 10 . Figure 4A yes Figure 4 4A is an enlarged view of portion 4A. Figure 5 is used for Figure 2An isometric front side view of the drive system and the support frame 18 of the displacement pump. The motor 12, control panel 13, drive mechanism 14, fluid displacer 16, support frame 18 and displacement pump 19 are shown. Figures 2 to 4 One embodiment of a drive mechanism 14 is shown that is coupled to the outer rotor motor 12 and configured to power the reciprocating motion of the fluid displacement member of the pump 19 . Figure 5 One embodiment of a support frame 18 configured to mechanically support the motor 12 and the pump 19 is shown.

[0055] The motor 12 includes a stator 20, a rotor 22, and a shaft 23. In the example shown, the motor 12 is configured as a reversible motor because the stator 20 can cause the rotor 22 to rotate about a motor axis A in either of two rotational directions (e.g., clockwise or counterclockwise), and the motor axis A can be rotated with the motor axis A. Figure 1A and Figure 1B 2 is the same as the motor axis MA shown in . However, it should be understood that not all examples are so limited. The motor 12 is arranged along the axis A and extends from the first end 24 to the second end 26. The first end 24 can be an output end that is configured to provide a rotational output from the motor 12. The second end 26 can be an electrical input end that is configured to receive electrical power to provide to the stator 20, thereby providing power for the operation of the motor 12. For example, one or more wires w can extend into the electrical input end 26 and extend to the stator 20 to provide power to operate the stator 20.

[0056] The rotor 22 may be formed by a housing having a cylindrical body 28 disposed between a first wall 30 and a second wall 32. The cylindrical body 28 extends axially between the first wall 30 and the second wall 32 relative to the motor axis A. The first wall 30 and the second wall 32 extend substantially radially inwardly from the cylindrical body 28 and toward the motor axis A. The cylindrical body 28 and / or the first and / or second walls 30, 32 may have fins 31 protruding radially and / or axially and / or cylindrically from and / or along the body 28 and / or the walls 30, 32. The cylindrical body 28, the first wall 30 and the second wall 32 may be considered to form a rotor housing of the rotor 22.

[0057] The rotor 22 includes a permanent magnet array 34 disposed on an inner circumferential surface 35. The inner circumferential surface 35 may be radially inward of the cylindrical body 28. The second wall 32 may have an axially extending flange 36 configured to be received in the inner diameter of the cylindrical body 28. The second wall 32 may be fastened to the cylindrical body 28 by fasteners, adhesives, welding, press fit, interference fit, or other desired connection means. For example, bolts 37 or another fastener may connect the wall 32 and the cylindrical body 28. The second wall 32 may have a radially extending annular flange 38 at the inner diameter opening. The annular flange 38 may be rotatably coupled to the rotating shaft 23, such as through a bearing 48. The annular flange 38 may at least partially define a receiving shoulder for receiving an outer ring 49 of the bearing 48 and preloading the bearing 48. The rotor 22 may include a plurality of cylindrical protrusions 40, 41 extending axially from the first wall 30. The cylindrical protrusions 40 , 41 may rotationally couple the rotor 22 to the stator 20 and the support frame 18 .

[0058] A bearing 42 having an inner race 43, an outer race 44 and rolling elements 45 rotationally couples the rotor 22 to the stator 20 at a shaft end 46 opposite the second end 26. A bearing 48 having an outer race 49, an inner race 50 and rolling elements 51 rotationally couples the rotor 22 to the stator 20 at the second end 26.

[0059] The support frame 18 is mechanically coupled to the rotor 22 at the output end 24 via a bearing 52 having an outer ring 53, an inner ring 54, and rolling elements 55. The rotor 22 can be received in the support frame 18 so that a portion of the rotor 22 extends into the support frame 18 and is radially surrounded by a portion of the support frame 18. The bearing 52 can be disposed between the rotor 22 and the support frame 18 so that both the bearing 52 and the support frame 18 are positioned radially outward from the portion of the rotor 22 at the output end 24. A wave spring washer 56 can be disposed between the bearing 52 and the support frame 18. An additional wave spring washer 57 can be disposed between the bearing 42 and the shaft 23.

[0060] The support frame 18 includes a pump frame 58 (at Figure 5) and support member 60. It should be understood that the term member can refer to a single piece or multiple pieces fixed together. The pump frame 58 mechanically supports the pump 19 and the motor 12. The pump frame 58 is mechanically connected to the rotor 22 via the bearing 52 at the output end 24. The pump frame 58 may include a pump housing portion 62, an outer frame body 63, a protrusion 64a, a support rib 65, a handle attachment 66 and a hub 67. The support member 60 provides a frame for the motor 12. The support member 60 mechanically connects the pump frame 58 and the motor 12 and supports both the reaction forces of the pump and the motor. The support member 60 extends from the pump frame 58 at the output end 24 to the rotating shaft 23 at the electrical input end 26. The support member 60 may include a connecting member 68, a base plate 70 and a frame member 72. The frame member 72 may include a protrusion 64b, a support column 73, a hub 74, a rib 75 and a support ring 76. The base plate 70 may include a support column 71. The pump frame 58 and the frame member 72 are disposed on opposite axial ends of the motor 12 relative to the axis A. A first plane perpendicular to the motor axis A at the output end 24 may extend through the pump frame 58. A second plane perpendicular to the motor axis A at the input end 26 may extend through the frame member 72. The two planes are axially spaced apart along the motor axis A and do not intersect.

[0061] The control panel 13 can be mounted to and supported by the support frame 18. Specifically, the control panel 13 can be mounted to the frame member 72 on an axial side of the frame member 72 opposite the motor 12 relative to the axis A, so that the frame member 72 separates the control panel 13 from the motor 12 and is directly disposed between the control panel 13 and the motor 12 along the axis A. The control panel 13 can be cantilevered from the motor 12 via the frame member 72. The control panel 13 can be cantilevered from the support frame 18. In the example shown, the control panel 13 is mounted to the frame member at a control support column 73. The control support column 73 extends axially from the frame member 72 and away from the motor 12. The control support column 73 can provide direct contact, such as metal-to-metal contact, between the thermally conductive elements of the frame member 72 and the control panel 13 to facilitate heat transfer, as discussed in more detail below.

[0062] The control panel 13 may include and / or support various other control and / or electrical components of the controller 15 and the drive system 10. The controller 15 is operatively electrically connected and / or communicatively connected to the motor 12 to control the operation of the motor 12, thereby controlling the pumping of the displacement pump 19. The controller 15 may be any desired configuration for controlling the pumping of the displacement pump 19, and may include control circuits and memory. The controller 15 is configured to store software, store executable code, implement a function set and / or process instructions. The controller 15 is configured to perform any function discussed herein, including receiving outputs from any sensor mentioned herein, detecting any condition or event mentioned herein, and controlling the operation of any component mentioned herein. The controller 15 may have any suitable configuration for controlling the operation of the drive system 10, controlling the operation of the motor 12, collecting data, processing data, etc. The controller 15 may include hardware, firmware and / or stored software, and the controller 15 may be installed in whole or in part on one or more boards. The controller 15 may be of any type suitable for operating according to the technology described herein. Although the controller 15 is shown as a single unit, it should be understood that the controller 15 may be provided on one or more boards. In some examples, controller 15 may be implemented as a plurality of discrete circuit subassemblies. In some examples, controller 15 may be implemented across one or more locations, such that one or more but less than all of the components forming controller 15 are disposed in and / or supported by control panel 13. In some examples, controller 15 is disposed at a location other than control panel 13.

[0063] The controller 15 may include any one or more of a microprocessor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other equivalent discrete or integrated logic circuits. The computer readable memory may be configured to store information during operation. In some examples, the computer readable memory may be described as a computer readable storage medium. In some examples, the computer readable storage medium may include a non-transient medium. The term "non-transient" may indicate that the storage medium is not embodied in a carrier or propagation signal. In some examples, a non-transient storage medium may store data that may change over time (e.g., in a RAM or cache). The computer readable memory of the control module 14 and / or the motor controller 22 may include volatile memory and non-volatile memory. Examples of volatile memory may include random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), and other forms of volatile memory. Examples of non-volatile memory may include a magnetic hard disk, an optical disk, a flash memory, or an electrically programmable memory (EPROM) or an electrically erasable programmable (EEPROM) memory. In some examples, the memory is used to store program instructions executed by the control circuit. In one example, the memory is used by software or applications running on the control module 14 or the motor controller 22 to temporarily store information during program execution.

[0064] The control panel 13 is also shown to include a user interface 17. The user interface 17 can be configured as an input and / or output device. The user interface 17 can be set at a location other than the control panel. The user interface 17 can be configured to receive input and / or provide output. Examples of the user interface 17 can include a sound card, a video graphics card, a speaker, a display device (such as a liquid crystal display (LCD), a light emitting diode (LED) display, an organic light emitting diode (OLED) display, etc.), a touch screen, a keyboard, a mouse, a joystick, a dial, a switch, a graphical user interface (GUI), or one or more of other types of devices for facilitating input and / or output of information in a form that can be understood by a user or machine. Although the user interface 17 is shown as being formed as part of the control panel 13, it should be understood that in some examples, the user interface 17 can be remotely arranged from the control panel 13 and communicatively connected to other components, such as the controller 15.

[0065] The controller 15 may be configured to control the operation of the motor 12 based on a target pressure for the fluid output by the pump 19. The controller 15 may be configured to control the operation of a cooling system that cools the motor 12. In some examples, the controller 15 may be formed as or considered to include a fan control circuit. The fan control circuit is configured to control the operation of a cooling fan that moves air within the cooling system. In some examples, the user interface 17 is formed as and / or includes an input interface through which the target pressure can be provided to the controller 15. The input interface may be actuatable between a minimum pressure state corresponding to a minimum pressure setting of the pump 19 and a maximum pressure state corresponding to a maximum pressure setting of the pump 19. The user may input a parameter output setting at the user interface 17. The input interface is configured to provide parameter setting information to the controller, the parameter setting information indicating a target parameter, such as pressure or flow, for output by the pump 19. In some examples, the user interface 17 is configured to provide pressure setting information to the controller 15, the pressure setting information indicating a target pressure for the output from the pump 19. The input interface may be configured to receive input from a user and provide information about the target pressure to the controller 15. For example, the input interface can be configured as a switch, a dial, a GUI, a knob, a slider, a joystick, etc.

[0066] The driver 14 is connected to the motor 12 and the pump 19. The driver 14 is configured to receive the rotational output from the rotor 22 and convert the rotational output into a movement input to the fluid displacer 16. In the example shown, the driver 14 includes an eccentric driver 78, a drive member 80, and a drive link 82. The eccentric driver 78 may include a sleeve 83 and a fastener 84. The drive member 80 may include a follower 86 and a bearing member 89. The drive link 82 may include a connecting slot 90 and a pin 92.

[0067] In the example shown, the pump 19 includes a fluid displacer 16, which is configured to reciprocate within a cylinder 94 to pump fluid. In the example shown, the fluid displacer 16 is a piston configured to reciprocate along a pump axis PA to pump fluid. However, it should be understood that the fluid displacer 16 can have other desired configurations, such as diaphragms, plungers, etc., as well as other options. In the example shown, the fluid displacer 16 includes a shaft 91 and a connector 93. The pump 19 includes a cylinder 94 connected to a support frame 18. Check valves 95, 96 regulate the flow through the pump 19. In the example shown, the check valve 95 is mounted to the piston forming the fluid displacer 16 to travel with the piston. The pump 16 is configured to draw fluid from the reservoir 3 through a pipeline 98 and output the fluid to the spray gun 5 through a pipeline 4.

[0068] The spray gun 5 is configured to output an atomized spray of a spray fluid. The spray gun 5 is configured as a handheld sprayer in the example shown, including a handle 8 configured to be grasped by a single hand of a user and a trigger 9 configured to be actuated by the user to open a valve in the spray gun 5 to allow spraying of the spray fluid.

[0069] The support frame 18 supports the motor 22 and the pump 19. As discussed in further detail below, the support frame 18 is dynamically connected to the rotor 22 and statically connected to the stator 20 through a bearing interface. The support frame 18 is statically connected to the pump 19. The motor 12 is dynamically connected to the support frame 18 via the rotor 22 and statically connected to the support frame 18 via the stator 20. The motor 12 is dynamically connected to the pump 19 via the fluid displacer 16. The pump 19 is statically connected to the support frame 18 and dynamically connected to the motor 12.

[0070] In the example shown, the motor 12 is an electric motor having an inner stator 20 and an outer rotor 22. The motor 12 can be configured to be powered by any desired power source type, such as direct current (DC), alternating current (AC), and / or a combination of direct current and alternating current. The stator 20 includes an armature winding 21, and the rotor 22 includes a permanent magnet 34. The rotor 22 is configured to rotate around the motor axis A in response to a current signal through the stator 20. The rotor 22 is connected to the fluid displacer 16 at the output end 24 of the rotor 22 via the driver 14. The driver 14 receives the rotational output from the rotor 22 and provides a linear reciprocating motion input to the fluid displacer 16. The support frame 18 mechanically supports the motor 12 at the output end 24 and mechanically supports the reciprocating fluid displacement pump 19 through the connection between the cylinder 94 and the pump 19. The support frame 18 at least partially accommodates the fluid displacer 16 of the reciprocating pump 19. In the example shown, the cylinder 94 is mounted to the pump frame 58 by a clamp 25 that receives a portion of the support frame between a first member of the clamp 25 and a second member of the clamp 25. For example, the flange 59 may be received between the two members of the clamp 25.

[0071] The stator 20 defines the axis A of the motor 12. The stator 20 is arranged around and supported by the shaft 23. The shaft 23 is mounted to be stationary relative to the motor axis A during operation. The stator 20 is fixed to the shaft 23 to maintain the position of the stator 20 relative to the motor axis A. The armature winding 21 can be supplied with power by an electrical connection at or through the electrical input 26 of the motor 12. Each winding 21 can be part of a phase of the motor 12. In some examples, the motor 12 can include three phases. Power can be provided to each phase according to an electrically offset sinusoidal waveform. For example, a motor with three phases can cause each phase to receive a power signal that is electrically offset by 120 degrees from the other phases. The shaft 23 can be a hollow shaft leading to the electrical input 26 for receiving wires from outside the motor 12. In alternative embodiments, the shaft 23 can be solid, can have a key, can be D-shaped, or other similar designs. In some embodiments, the shaft 23 may be defined by a plurality of cylindrical cross-sections taken perpendicular to the axis A, the plurality of cylindrical cross-sections having varying diameters to accommodate mechanical coupling with the support frame 18 at the electrical input end 26 of the shaft 23 and coupling with the rotor 22 at the axially opposite end 46 of the shaft 23. For example, a first end of the shaft 23 may be radially disposed between the stator 20 and the rotor 22 and have a larger diameter than the axially opposite end 46 for receiving electrical input.

[0072] The rotor 22 is coaxial with the stator 20 and disposed around the stator 20 and configured to rotate about the axis A. The rotor 22 may be formed by a housing having a cylindrical body 28 extending between a first wall 30 and a second wall 32, such that the rotor 22 is positioned to extend around three sides of the stator 20. The rotor 22 includes a permanent magnet array 34. The permanent magnet array 34 may be disposed on an inner circumferential surface 35 of the cylindrical body 28. An air gap separates the permanent magnet array 34 from the stator 20 to allow the rotor 22 to rotate relative to the stator 20. The rotor 22 may overlap the stator 20 and the rotating shaft 23 at the output end 24 of the motor 12 over the entire radial extent of the stator 20 and the rotating shaft 23. In some examples, the rotor 22 may completely surround the stator 20 and the rotating shaft 23 at the output end 24 of the motor 12. The rotor 22 may partially or completely overlap the stator 20 over the radial extent of the stator 20 at the electrical input end 26 of the motor 12. The second wall 32 extends radially inward from the cylindrical body 28 toward the shaft 23. The shaft 23 can extend through an opening in the second wall 32 that is concentric with the shaft 23 and can extend axially outward from the second wall 32 in the axial direction AD2. In the example shown, the second wall 32 is radially separated from the shaft 23 by a bearing 48 at the electrical input 26 of the motor 12 to allow the rotor 22 to rotate relative to the shaft 23.

[0073] Typically, the stator 20 generates an electromagnetic field that interacts with the plurality of magnetic elements of the rotor 22 to cause the rotor 22 to rotate around the stator 20. More specifically, the stator 20 includes a plurality of windings 21 that generate an electromagnetic field. The electromagnetic field generated by the windings 21 faces radially outward toward the rotor 22. The rotor 22 either includes a plurality of permanent magnets 34 arranged circumferentially within the rotor 22, or includes a plurality of windings of temporarily magnetized metal material, both of which are arranged circumferentially within the rotor 22. In either configuration of the rotor 22, the electromagnetic field generated by the plurality of solenoids 21 of the stator 20 attracts and / or repels the magnetic elements of the rotor 22 to cause the rotor 22 to rotate around the stator 20. Although the motor 12 is shown as an outer rotary motor, in which the rotor 22 is disposed outside the stator 20 and surrounds the stator 20, it should be understood that not all examples are so limited. For example, the motor 12 can be configured as an inner rotary motor, in which the rotor 22 is disposed within the stator 20, so that the stator 20 at least partially surrounds the rotor 22.

[0074] The first wall 30 and / or the second wall 32 of the rotor 22 may be integrally formed with the cylindrical body 28 or may be mechanically fastened to the cylindrical body 28. The mechanical connection to the cylindrical body 28 may be formed in any desired manner, such as by fasteners, interference fit, welding, adhesives, etc. The rotor 22 is formed so that the closed end of the rotor 22 is oriented toward the reciprocating axis PA of the pump 19, and so that the open end of the rotor 22 is oriented toward the control panel 13. The closed end of the rotor 22 (formed by the wall 30) faces the pump 19, and the open end (formed by the wall 32, which is open to facilitate electrical connection) is oriented away from the pump 19 along the motor axis A. The open end of the rotor 22 faces the control panel 13. In the example shown, the opening through the wall 32 leads directly to the space between the control panel 13 and the motor 22.

[0075] In the example shown, the second wall 32 is fastened to the outer diameter portion of the cylindrical body 28 by a plurality of fasteners, more specifically bolts 37. The second wall 32 may include an axially extending flange 36 at a radially outer end that may form a sliding fit with the inner diameter of the cylindrical body 28.

[0076] The cylindrical body 28 and / or one or both of the first wall 30 and the second wall 32 may include one or more fins 31 extending outwardly (axially and / or radially) to push air as the rotor 22 rotates. For example, the fins 31 may be used to direct cooling air toward the control panel 13. The fins 31 may be formed of a thermally conductive material to act as a heat sink, thereby conducting heat away from the motor 12. The fins 31 may be integrally formed with other portions of the rotor housing, such as the cylindrical body 28, or may be formed separately and mounted to portions of the rotor housing. The fins 31 increase the surface area of ​​the rotor housing, thereby helping to cool the motor 12.

[0077] The bearings 42, 48, and 52 are coaxially disposed along the rotation axis A so that the rotating members of the bearings 42, 48, and 52 rotate along the rotation axis A. The bearings 42, 48, and 52 may be substantially similar in size, or may vary in size to support different loads and accommodate space constraints. The sizes of the bearings 42 and 48 may be substantially similar, while the bearing 52 at the output end 24 may be larger to accommodate the reciprocating load received by the rotor 22 at the output end 24. In some examples, all three bearings 42, 48, 52 may be of different sizes. The rolling elements 55 of the bearing 52 may be disposed at a first radius R1 from the rotation axis A of the motor 12, the rolling elements 51 of the bearing 48 may be disposed at a second radius R2 from the rotation axis A, and the rolling elements 45 of the bearing 42 may be disposed at a third radius R3 from the rotation axis A. As Figure 4A As shown, the first radius R1 may be greater than the second radius R2, and the third radius R3 may be greater than the second radius R2 and less than the first radius R1. In some examples, the second radius R2 is one of greater than and equal to the third radius R3.

[0078] Components may be considered to overlap radially when they are disposed at a common location along an axis (e.g., along motor axis A for shaft 23 and wall 30), such that a radial line projecting the axis extends through each of those radially overlapping components. Similarly, components may be considered to overlap axially when they are disposed at a common location on or radially spaced from the axis (e.g., relative to motor axis A for shaft 23 and wall 30), such that an axis parallel to or coaxial with the axis extends through each of those axially overlapping components.

[0079] The first wall 30 of the rotor 22 may extend into the shaft 23 at the output end 24 so that a portion of the shaft 23 and a portion of the first wall 30 overlap axially. Thus, an axis parallel to the axis A may extend through each of the first wall 30 and the shaft 23. The cylindrical protrusion 40 of the rotor 22 may extend from the output end 24 of the motor 12 in the axial direction AD2 and extend into the shaft 23 at the shaft end 46. Thus, the cylindrical protrusion 40 extends from the front end of the housing of the rotor 22 and axially away from the pump frame 58. The cylindrical protrusion 40 is coaxial with the rotor 22 and the stator 20 along the axis of rotation A and rotates about the axis of rotation A. The cylindrical protrusion 40 may extend into the shaft 23 so that the cylindrical protrusion 40 overlaps radially with the shaft 23. Thus, a radial line extending from the axis A may pass through each of the cylindrical protrusion 40 and the shaft 23. The cylindrical protrusion 40 is rotationally coupled to the shaft 23 by a bearing 42.

[0080] The rotor 22 can be rotationally coupled to the stator 20 at the electrical input end 26 via a bearing 48. The bearing 48 includes an outer ring 49, an inner ring 50, and rolling elements 51. The rotor 22 can be coupled to the outer ring 49, and the shaft 23 can be coupled to the inner ring 50. The rolling elements 51 allow the rotor 22 to rotate relative to the stator 20, so that the rotor 22 runs outside the bearing 48. In some examples, the bearing 48 can be a roller bearing or a ball bearing, wherein the rolling elements 51 are cylindrical members or balls. The second wall 32 can be coupled to the outer diameter surface of the outer ring 49 and can extend around the axial outer end surface of the outer ring 49. The shaft 23 can extend through the rotor 22 at the electrical input end 26, and can protrude axially outward from the bearing 48 in the axial direction AD2 to allow the shaft 23 to be coupled to the support frame 18, such as via the support member 60.

[0081] The pump reaction forces experienced by bearing 48 are in substantially opposite axial directions (PAD1, PAD2) compared to the pump reaction forces simultaneously experienced by bearing 52. The pump reaction loads are transmitted to support frame 18 through bearing 52. In some embodiments, one or both of bearings 42 and 48 may be omitted from drive system 10.

[0082] The rotor 22 is mechanically coupled to the support frame 18 at the output end 24 via a bearing 52. The bearing 52 includes an inner ring 54, an outer ring 53, and rolling elements 55. The bearing 52 may be a roller or ball bearing, wherein the rolling element 55 is a cylindrical member or a ball. The rotor 22 may be received in a pump frame 58 such that a portion of the rotor 22 extends into the pump frame 58 and is radially surrounded by a portion of the pump frame 58. The bearing 52 may be disposed between the rotor 22 and the pump frame 58 such that both the bearing 52 and the pump frame 58 are positioned radially outward from the rotor 22 at the output end 24. The rotor 22 may be coupled to the inner ring 54, and the pump frame 58 may be coupled to the outer ring 53 such that the rotor 22 runs inside the bearing 52. The rolling elements 55 allow rotational movement of the rotor 22 relative to the pump frame 58.

[0083] The rotor 22 may include a cylindrical protrusion 41 extending from the wall 30 of the rotor 22 in the axial direction AD1. The cylindrical protrusion 41 may extend axially outward from the output end 24 or the front end of the motor 12 in the direction AD1 and may extend into an opening in the pump frame 58. The cylindrical protrusion 41 is centered on the rotation axis A and rotates with the rotor 22 about the rotation axis A. The bearing 52 may be disposed on an outer diameter portion of the cylindrical protrusion 41 to couple the rotor 22 to the pump frame 58 through the cylindrical protrusion 41. The cylindrical protrusion 41 may extend at least partially into the pump frame 58 along the axis A. In some examples, the cylindrical protrusion 41 does not extend completely through the pump frame 58, so that the cylindrical protrusion 41 does not protrude beyond the structure of the pump frame 58 in the first axial direction AD1. In some examples, the cylindrical protrusion 41 extends completely through the pump frame 58, so that a portion of the cylindrical protrusion 41 protrudes beyond the structure of the pump frame 58 in the axial direction AD1.

[0084] As used herein, the term "axially outward" refers to a surface facing the exterior of the motor 12 (i.e., away from the stator 20 along the axis A), and the term "axially inward" refers to a surface facing the interior portion of the motor 12 (i.e., toward the stator 20 along the axis A). A portion of the axially outer end surface of the wall 30 may axially overlap and abut an axially oriented end surface of the inner race 54 (oriented in the axial direction AD2 in the illustrated example). The wall 30 may thereby form a support for the bearing 52. A portion of the axially outer end surface of the wall 30 may extend radially outward from the cylindrical protrusion 41 and completely annularly surround the cylindrical protrusion 41 to axially overlap and abut the entire circumferential axial inner end surface of the inner race 54. For example, the wall 30 may include an annular axially extending protrusion that circumscribing the cylindrical protrusion 41 and extending approximately equal to or less than the height of the inner race 54 to engage with the inner race 54. The projection is configured to fix the axially inner position of the bearing 52 and to axially separate the rotating wall 30 from the stationary outer ring 53 .

[0085] The bearings 52 and 48 react to the pump reaction loads generated during pumping. The bearings 52, 48 facilitate the direct drive configuration of the drive system 10. The bearings 52 and 48 stabilize the rotor 22 to facilitate the direct drive connection with the fluid displacer 16. The pump reaction forces experienced by the bearings 52, 48 at the output end 24 and the input end 26 are transmitted to the portion of the support frame 18 that is connected to the bracket or otherwise supports the drive system 10 on the support surface. In the example shown, the pump reaction forces are transmitted to the base plate 70 via the pump frame 58, the frame member 72 and the connecting member 68, thereby balancing the forces on the support frame 18. The base plate 70 reacts to the forces, such as reacting to the bracket connected to the mounting member 71, and the forces are thereby transmitted away from the motor 12. All pump forces and motor forces act through the base plate 70, which can be integrally formed with the pump frame 58 or directly connected to the pump frame 58 and mechanically coupled to the motor shaft 23 via the frame member 72. The connection balances the motor 12, thereby extending life, reducing wear, minimizing downtime, improving operating efficiency, and realizing cost savings.

[0086] The support frame 18 mechanically supports the motor 12 at the output end 24 and at least partially houses the fluid displacer 16. The support frame 18 can be mechanically coupled to both the rotor 22 and the stator 20. The support frame 18 can be mechanically coupled to the rotor 22 at the output end 24 and mechanically coupled to the shaft 23 at the electrical input end 26. In this way, the support frame 18 can extend completely around the motor 12 and be coupled to axially opposite ends of the motor 12 to support the motor 12. The shaft 23 is mechanically coupled to the support frame 18 to fix the stator 20 relative to the support frame 18.

[0087] The support member 60 may extend from the pump frame 58 to the rotating shaft 23 around the outside of the rotor 22 to connect the pump frame 58 to the rotating shaft 23 so that the stator 20 is fixed relative to the support frame 18 via the support member 60. The support member 60 may be removably fastened to the rotating shaft 23. The support member 60 fixes the rotating shaft 23 to the pump frame 58 to prevent relative movement between the stator 20 and the support frame 18. In the example shown, neither the rotating shaft 23 nor the stator 20 is fixed to the support frame 18 at the output end 24. Instead, a portion of the rotor 22 is axially disposed between the rotating shaft 23 and the stator 20 and separates them from the support frame 18. In this way, the motor 12 is dynamically supported by the support frame 18 at the output end 24 and statically supported by the support frame 18 at the input end 26.

[0088] The support member 60 may extend from a radially inward position of the exterior of the cylindrical body 28 of the rotor 22 to a radially outward position of the cylindrical body 28. The support member 60 may extend circumferentially around the rotor 22 and have sufficient radial spacing from the rotor 22 to allow unimpeded rotation of the rotor 22 inside the support member 60. In the example shown, the support frame 18 does not completely surround the rotor 22. It should be understood that not all examples are so limited. In the example shown, there are no parts between the support frame 18 and the exterior of the rotor 22. Therefore, the support frame 18 allows airflow to pass through itself and over the rotor 22.

[0089] In a non-limiting embodiment, the connection members 68 may be tie rods that may be spaced circumferentially around the top portion of the motor 12. The tie rods may be removably mounted to one or both of the pump frame 58 and the frame member 72. The base plate 70 may be a substantially solid base plate or bracket disposed below the bottom portion of the motor 12. The width of the base plate 70 may be substantially equal to the width of the pump housing portion 62. In some embodiments, the base plate 70 may have a width that is substantially equal to or greater than the diameter of the cylindrical body 28 of the rotor 22.

[0090] The frame member 72 may include a hub 74. The frame member 72 may be removably coupled to the shaft 23. For example, the frame member 72 may be slidingly engaged with the shaft 23. In some examples, the frame member 72 may be fixed to the shaft 23.

[0091] In addition to providing mechanical support to the motor 12, the support member 60 can conduct heat away from the motor 12 during operation. The shaft 23 extends through the rotor 22 and extends axially outward from the rotor at the electrical input end 26, and can protrude outward from the bearing 48 in the axial direction AD2. The portion that extends axially beyond the bearing 48 can be connected to the support member 60 and provide a route for conductive heat transfer from the stator 20 to the support member 60 and away from the motor 12. More specifically, the frame member 72 is fixed to the shaft and is in direct heat exchange relationship therewith. The frame member 72 can be configured to conduct heat from both the motor 12 and the control panel 13, which are the main heat-generating components of the drive system 10.

[0092] The shaft 23 and the support member 60 may both be formed of a thermally conductive material (e.g., metal). The shaft 23 may be placed in direct contact with the support member 60 (e.g., with the frame member 72) to provide a direct conductive heat path to conduct heat away from the motor 12. Figure 4 As shown, the shaft 23 radially overlaps the stator 20 along the entire axial length of the stator 20. The shaft 23 is capable of absorbing heat from the stator 20 and conducting the heat toward the electrical input 26 and the axially outer portion of the stator 20. The shaft 23 transfers heat to the frame member 72 by conduction at the location where the frame member 72 contacts the shaft 23. In this way, the conduction path for heat transfer from the stator 20 extends through the shaft 23 to the frame member 72. In some embodiments, the frame member 72 can be in fixed contact with both the axially extending surface of the shaft 23 and the radially extending end surface of the shaft 23. For example, a portion of the frame member 72 (such as a lip extending from the hub 74) can extend radially over the end of the shaft 23 to increase the surface area of ​​direct contact and transfer heat away from the shaft 23 and away from the motor 12. The shape and surface area of ​​the frame member 72 can be selected to facilitate heat transfer away from the motor 12.

[0093] The controller 15 may receive information from the position sensor 102 ( Figure 4 and Figure 4A 1 ). The position sensor 102 may be included in any disclosed drive system. The position sensor 102 is configured to generate position information about a component of the injection system 10. For example, the position sensor 102 may be configured to sense the rotational position of the rotor 22, the position of the fluid displacer 16, the position of a rotating component of the driver 14, etc.

[0094] Figure 5A front isometric view of one embodiment of a pump frame 58 having a base plate 70 is shown. The pump frame 58 and base plate 70 can be integrally formed, such as by casting as a unitary component, or can be formed from multiple components that are mechanically fixed together. For example, the pump frame 58 and base plate 70 can be removably connected together, such as by bolts or other fasteners. The pump frame 58 may include a drive connecting rod housing 61, a pump housing portion 62, an inner frame body 63a, an outer frame body 63b, an intermediate frame body 63c, a protrusion 64a having a distal end disposed radially outward of the motor 12, support ribs 65, a handle attachment 66, and a hub 67. The pump frame 58 provides mechanical support and housing for the pump 19.

[0095] The pump frame 58 provides mechanical support for the motor 22. The pump frame 58 can extend radially outward from the bearing 52. The bearing 52 can be received in the hub 67. The rotor 22 can be received through the opening in the inner frame body 63a. The outer frame body 63b is positioned radially outward of the inner frame body relative to the motor axis A. The intermediate frame body 63c is positioned between the inner frame body 63a and the outer frame body 63b. The rib 65 can extend between the inner frame body 63a and the intermediate frame body 63c, between the inner frame body 63a and the outer frame body 63b, and between the intermediate frame body 63c and the outer frame body 63b. The rib 65 can be used to reduce the weight of the pump frame 58 while providing structural support. In some embodiments, a plurality of ribs 65 can extend between the hub 67 and the outer frame body 63b. The rib 65 can support the load from the bearing 52 and can reduce the weight of the pump frame 58. The rib 65 can be spaced substantially circumferentially around a portion of the hub 67. The length of rib 65 may vary depending on the shape or positioning of outer frame body 63b relative to bearing 52, inner frame body 63a, or intermediate frame body 63c. Protrusion 64a may be a substantially solid triangular protrusion extending from hub 67. Protrusion 64a may form an attachment point for member 68 to secure frame member 72 to pump frame 58.

[0096] The drive link housing 61 may be positioned in an opening in the inner frame body 63a. Figure 5 As shown in the example in FIG. 1 , the drive rod housing 61 is a cylindrical body positioned below the opening and above the pump housing portion 62. The opening of the drive rod housing 61 is orthogonal to the opening through the inner frame body 61. The drive rod housing 61 restricts the movement of the drive rod 82 to up and down movement along the pump axis PA.

[0097] The pump housing portion 62 of the pump frame 58 at least partially accommodates the fluid displacer 16 and supports the displacement pump 19. The pump 19 is disposed at the output end 24 along a pump axis PA that is orthogonal to the motor axis A and is axially aligned with the drive mechanism 14 along the axis A. The pump housing portion 62 of the pump frame 58 can extend outwardly from the drive mechanism 14 in the axial direction AD1 to accommodate the fluid displacer 16. Figure 5 As shown in the example in FIG. 5 , the pump housing portion 62 is formed by a U-shaped wall which opens toward the front end of the pump frame 58 in the axial direction AD1 away from the motor 12. During operation, a portion of the pump 19 is disposed in a chamber of the pump housing portion 62.

[0098] FIG. 6A to FIG. 7 An embodiment that is different from the previous figures is shown. However, the embodiments are similar to each other, and any detail mentioned in connection with one embodiment is present in another embodiment or may be present in another embodiment. Therefore, unless shown and / or described as obviously different, it can be assumed that all aspects between the embodiments are the same, so that the description and drawings for one embodiment are applicable to the other embodiment. For the sake of brevity, various common aspects are not repeated between the embodiments.

[0099] Components with the same reference numerals may be identical, such that a description and / or drawings directed to one component may be attributed to another component with the same reference numeral of a different embodiment. Likewise, components with the same name may be identical, such that a description and / or drawings directed to one component may be attributed to another component with the same name of a different embodiment.

[0100] Fig. 6A A cross-sectional view of the injection system 1 is shown. The injection system 1 may be similar to the previous embodiments except that the drive mechanism 14 is different.

[0101] Figure 6B yes Figure 6B 2 is an enlarged view of detail B in FIG. In this embodiment, the rotor 22 rotates circumferentially about the stator 20 and is disposed radially outward from the stator 20. The motor 12 is the same as in the previous embodiment except for the manner in which the rotor 22 is connected to the drive mechanism 14 to provide power to the drive mechanism 14. Specifically, in the previous example, the eccentric was directly attached to the housing of the rotor 22 so that the rotor 22 and the eccentric rotated in a 1:1 ratio relationship. FIG. 6A to FIG. 7In the example shown, the pinion cover 39 is attached to the rotor 22 and rotates with the rotor 22. More specifically, the stud 33 is integral with the rotor housing (e.g., a continuous material) or attached to the rotor housing. The pinion cover 39 is mounted on the stud 33. The pinion cover 39 rotates with the rotor 22 about the axis A. The pinion cover 39 is partially fixed to the stud 33 by a fastener 84. The fastener 84 can be a bolt extending from the second end of the pinion cover 39 to the first end of the pinion cover 39 within the pinion cover 39.

[0102] In this embodiment, the stud 33 includes external threads that interface with internal threads of the pinion cover 39. The orientation of the relative thread structure can be in a first direction (e.g., clockwise or counterclockwise). The stud 33 also includes internal threads within a receiver of the stud 33. The internal threads of the stud 33 interface with external threads on the end of the fastener 84. The orientation of the relative thread structure between the stud 33 and the fastener 84 can be a second direction opposite to the first direction, so that the connection between the stud 33 and the pinion cover 39 is maintained even if the motor 12 reverses its rotation direction. The fastener 84 can be a bolt.

[0103] In an alternative embodiment, the pinion cover 39 is keyed (eg, secured by a hexagonal structure) to the stud 33 rather than being threaded to prevent relative rotation.

[0104] The pinion cover 39 is supported by a first bearing 77 and a second bearing 79. Both bearings can be needle roller type bearings. The first bearing 77 is supported by the support frame 18. The second bearing 79 is supported by the retaining plate 47. In this way, the first end of the pinion cover 39 engages the first bearing 77, while the second end of the pinion cover 39 engages the second bearing 79, and the segment of the pinion cover 39 between the first end and the second end contains gear teeth. In this way, the pinion cover 39 includes an outer gear tooth segment. The outer gear tooth segment meshes with the teeth of the gear 69. However, due to the gear reduction between the pinion cover 39 and the gear 69, the gear 69 rotates at a slower rate with the pinion cover 39. Bolts can fasten the retaining plate 47 to the support frame 18. To clamp the pinion cover 39 between them.

[0105] The gear 69 is supported by the eccentric 81. Specifically, the gear 69 is fixed to the eccentric 81 so that the eccentric 81 rotates 1:1 with the gear 69. The eccentric 81 is supported by a third bearing 85 and a fourth bearing 87 (which may also be a needle roller type) that allow the eccentric 81 to rotate. The third bearing 85 is supported by the support frame 18, while the fourth bearing 87 is supported by the retaining plate 47. The eccentric 81 includes an eccentric drive 78 that rotates offset from the center of rotation of the rest of the eccentric 81. The follower 86 and the bearing member 89 are mounted on the eccentric drive 78 to follow a circular pattern that moves the drive member 80 up and down, which causes the fluid displacer 16 of the pump 19 to reciprocate for pumping.

[0106] Figure 7 Shows Fig. 6A and Figure 6B 2 is an exploded view of the various components of an embodiment of the present invention. As shown, the pinion cover 39 includes a first end covered by a first bearing 77, a second end covered by a second bearing 79, and a gear tooth segment between the first end and the second end. This gear tooth segment interfaces with the teeth of the gear 69. In the example shown, the pinion cover 39 is connected to the gear 69 so that for each full rotation of the rotor 22, the gear 69 rotates less than one full rotation. In this way, the rotor 22 is configured to complete multiple full rotations for a single pump cycle of the pump 19.

[0107] Figure 8 is an isometric view of drive system 10 . Fig. 9 yes Figure 8 A cross-sectional view of the drive system is shown. Figure 8 and Fig. 9 Shown with FIG. 6A to FIG. 7 All reference numerals of the previous teachings apply to Figure 8 and Fig. 9 33. The present embodiment also includes a pinion cover 39. However, the pinion cover 39 is mounted on the stud 33 without the use of bolts. The pinion cover 39 may be threaded or welded to the stud 33, among other options. In some examples, the pinion cover 39 and / or the stud 33 may be integrally formed with the housing of the rotor 22.

[0108] In this embodiment, no shaft extends completely axially through the motor, whether or not it is part of a pinion. In this case, a pinion cover 39 is mounted on the outer rotor, the pinion cover 39 including a gear tooth segment having teeth for interfacing with the gear 69. The pinion cover 39 does not extend through the motor. Instead, the pinion cover 39 is connected only to the outer housing of the rotor 22. The pinion cover 39 is supported by dual bearings on opposite ends, wherein a third segment (e.g., a gear tooth segment) is axially located between the opposite ends supported by the bearings. In the example shown, the rotor 22 includes an open end facing away from the pump.

[0109] Fig. 10A is an isometric view of the injection system 1 showing a partial cross-section of the housing of the drive system 10 . Fig. 10B is an isometric view of the injection system 1 with portions of the housing of the drive system 10 removed for ease of illustration. Fig. 10C is an isometric view of the drive system 10 as viewed from the bottom side of the drive system 10 . Fig. 10D It is along Fig. 10A A cross-sectional view taken along line DD in FIG. Fig.10E It is along Fig. 10A A cross-sectional view taken along line EE in FIG. Fig.11A is an exploded view of the injection system 1 . Fig. 11B is an enlarged isometric view of the drive system 10 showing the heat sink 126 exploded. FIG. 10A to FIG. 11B In the example shown, the drive system 10 is configured to be arranged along a longitudinal axis, a lateral axis, and a vertical axis. These directions are relative to Fig. 10A In terms of the XYZ coordinate system shown in . The longitudinal direction is along the direction Y, the lateral direction is along the direction X, and the vertical direction is along the direction Z. The YX plane can be considered to form the vertical plane. The vertical direction Z is perpendicular to the vertical plane. The YZ plane can be considered to form the lateral plane. The lateral direction X is perpendicular to the lateral plane. And the XZ plane can be considered to form the longitudinal plane. The longitudinal direction Y is perpendicular to the longitudinal plane.

[0110] The motor 12, drive 14, pump 19, frame 58, and fan assembly 134 are shown. The rotor 22, stator 20, and shaft 23 of the motor 12 are shown. The drive housing 110 is shown. A motor shroud 112 is disposed around the exterior of the motor 12. The motor shroud 112 extends at least partially around the rotor 22 and is disposed radially outward of the rotor 22. The motor shroud 112 includes openings formed therethrough that allow cooling fluid to flow to and contact the exterior of the rotor 22. The motor 12 is disposed within a chamber 114.

[0111] The frame 58 supports the other components of the injection system 1. The drive housing 110 at least partially surrounds the various components of the injection system 1. In the example shown, the electric motor 12 is at least partially arranged in the drive housing 110. In the example shown, the electromagnetic components of the electric motor 12 are arranged in the drive housing 110. In the example shown, part of the drive housing 110 is formed by the frame 58, and part of the drive housing 110 is formed by the housing 116.

[0112] The pump 19 is configured to pump a pressurized fluid, such as for spraying. The pump 19 can be configured as a reciprocating piston pump, among other options. The drive 14 is connected to the motor 12 to receive the rotational output from the motor 12. The drive 14 is connected to the pump 19 to drive the reciprocating motion of the reciprocating member (e.g., piston) of the pump 19, thereby causing the pump 19 to pump.

[0113] The housing 116 is connected to the frame 58. The housing 116 is at least partially disposed around the motor 12. The housing 116 can be formed as a polymer housing, among other options. The housing 116 can also be referred to as a shroud. In the example shown, the housing 116 and the frame 58 together form the drive housing 110.

[0114] In the example shown, at least a portion of the frame 58 is disposed vertically directly below the motor 12. The portion of the frame 58 protrudes to radially overlap the motor 12 relative to the motor axis A. The portion of the frame 58 can be configured such that the portion of the frame 58 protrudes axially beyond the second end 26 of the motor 12. The second end 26 may also be referred to as the unsupported end of the motor 12. When the motor 12 outputs rotational motion through the first end 24, the first end 24 of the motor 12 may also be referred to as the supported end or output end. In some examples, the frame 58 may radially overlap the entire axial length of the motor 12.

[0115] The motor 12 is at least partially disposed within the chamber 114. The chamber 114 is disposed within the drive housing 110. The chamber 114 may be formed in part by the housing 116. In the example shown, the chamber 114 is at least partially defined by the housing 116 and the frame 58. The chamber 114 may include a top plate 118 and lateral walls 120a, 120b (collectively referred to herein as "lateral walls 120" or "lateral walls 120") formed by the housing 116. The chamber 114 may be further formed by longitudinal walls 122a, 122b (collectively referred to herein as "longitudinal walls 122" or "longitudinal walls 122"). The longitudinal walls 122a, 122b are spaced apart from each other along the motor axis A. The longitudinal wall 122a may also be referred to as a first wall or front wall of the chamber 114. The longitudinal wall 122b may also be referred to as a second wall or rear wall of the chamber 114. The longitudinal wall 122a may be formed by the frame 58. The longitudinal wall 122b may be formed by a radiator and / or include a radiator 126. The pump 19 may be arranged on the opposite side of the longitudinal wall 122a relative to the motor 12.

[0116] In the example shown, the chamber 114 is defined in part by the frame 58 and in part by the housing 116. In the example shown, the longitudinal wall 122a and the bottom plate 124 are formed by the frame 58. In the example shown, the lateral walls 120a, 120b and the top plate 118 are formed by the housing. In the example shown, the longitudinal wall 122b is formed by the heat sink 126. The chamber 114 can be considered to be defined by the first wall 122a, the second wall 122b, the pair of lateral walls 120a, 120b, the bottom plate 124, and the top plate 118. In the example shown, at least one wall defining the chamber 114 is formed as a heat sink.

[0117] The heat sink 126 is disposed directly between the chamber 114 and the control chamber 130. In the example shown, the heat sink 126 is a metal structure including a protrusion 128 (formed as a fin or other structure) protruding into the chamber 114. The protrusion 128 increases the surface area of ​​the heat sink 126, thereby improving the heat transfer efficiency of the cooling. The control chamber 130 is disposed in a control housing 132, which may be at least partially formed by the frame 58, the housing 116, the heat sink 126, etc. The controller 15 and other control elements may be disposed in the control chamber 130. The control chamber 130 is spaced apart from the chamber 114 in the second axial direction AD2. The heat sink 126 is disposed directly between the chamber 114 and the control chamber 130 along the motor axis A. In the example shown, the projection of the motor axis A from the motor 12 passes through the heat sink 126 before passing through the control chamber 130. The heat sink 126 may define the walls of both the chamber 114 and the control chamber 130. As shown, the fins of the heat sink 126 project axially into the chamber 114 relative to the motor axis A and axially away from the control chamber 130 .

[0118] The controller 15 is disposed within the control cavity 130. One or more circuit boards of the controller 15 may be mounted directly to a wall of the control cavity 130 formed by the heat sink 126. In one example, the controller 15 includes an insulated gate bipolar transistor (IGBT). One or more components of the controller 15 may be directly thermally connected to the heat sink 126. For example, one or more components may be mounted directly to the heat sink 126, may be connected to the heat sink 126 via a direct thermal path, and so on. The IGBT may be thermally bonded to a circuit board that is mounted to the heat sink 126 or formed as part of the heat sink 126. The IGBT may be considered to form a control component of the controller 15.

[0119] The motor 12 is located on one side of the longitudinal wall 122b, and the control panel 13 is located on the side of the longitudinal wall 122b opposite to the motor 12. Heat generated by the control panel 13 can be conducted through the longitudinal wall 122b to be exposed to the cooling fluid in the chamber 114. In the example shown, the heat is conducted to the cooling fluid in the chamber 114 through the heat sink 126. In the example shown, the heat generated by both the motor 12 and the control panel 13 can be dissipated by the cooling fluid flowing through the chamber 114.

[0120] The fan assembly 134 is configured to blow a cooling fluid through the cooling passage of the drive system 10. The fan assembly 134 includes a blade structure 136, which is configured to rotate around a fan axis FA to generate a cooling air flow. In the example shown, the blade structure 136 is formed with a plurality of blades extending outward from the hub of the blade structure 136. A plurality of blades extend radially outward from the fan axis FA. The blade structure 136 may include one or more blades, and the one or more blades rotate to move a cooling fluid, such as air. Typically, in the example shown, the blade structure 136 rotates to draw air from below the fan assembly 134 and forces the air to enter the chamber 114 through the chamber 114 along a path 146. In the example shown, the fan assembly 134 is exposed to the atmosphere to draw air from the environment surrounding the drive system 10, and such air forms a cooling fluid. The fan assembly 134 is fluidly connected to the chamber 114 to blow cooling air into the chamber 114. The blade structure 136 is connected to a fan motor 138. The fan motor 138 is configured to drive the blade structure 136 to rotate to generate a cooling air flow. The fan motor 138 may be an electric motor that is powered to produce rotational movement of the blade structure 136 .

[0121] In the example shown, the fan assembly 134 is mounted to the frame 58. The fan assembly 134 is mounted on the frame 58 to be supported by the frame 58 independently of the motor 12 and the pump 19. The fan assembly 134 is separated from the motor 12 and the pump 19 so that the operation of the motor 12 or the pump 19 does not directly mechanically operate the fan assembly 134. The cooling fluid flows through the chamber 114 through the fan assembly 134. In this embodiment, the fan assembly 134 is mounted to the frame 58. In particular, the frame 58 includes a duct 148, but not all embodiments necessarily include a duct. The fan assembly 134 is mounted within the duct 148. The fan assembly 134 is disposed within the duct 148. In the example shown, the duct 148 is formed through the frame 58. The duct 148 is at least partially formed by the frame 58. The duct 148 forms a cooling inlet 142 of a cooling circuit 140 of the drive system 10. The cooling fluid enters the cooling circuit 140 through the cooling inlet 142. The cooling fluid flows into the chamber 114 through the cooling inlet 142.

[0122] In the example shown, the duct 148 protrudes vertically. The duct 148 is oriented so that the duct 148 opens to the atmosphere in a vertically downward direction. The duct 148 opens to the atmosphere in a direction away from the motor 12. The duct 148 is oriented so that the duct 148 opens to the chamber 114 in a vertically upward direction. The duct 148 is open so that the cooling fluid exiting from the duct 148 and entering the chamber 114 flows toward the motor 12. In the example shown, the duct 148 opens radially outward relative to the motor axis A so that the cooling fluid flow generated by the fan assembly 134 flows radially toward the motor 12 relative to the motor axis A. In the example shown, the duct 148 is tubular. In the example shown, the duct 148 does not include a turn or bend that changes the direction of the cooling fluid flow. In the example shown, the duct 148 is formed through a portion of the frame 58 that radially overlaps the motor 12. The duct 148 is arranged so that the duct 148 radially overlaps the motor 12. The cooling fluid exits from the cooling circuit 140 through the cooling outlet 144. In the example shown, the cooling outlet 144 is formed by a discharge port 150. The discharge port 150 is formed by the drive housing 110. In the example shown, the discharge port 150 is formed through the housing 116. The discharge port 150 is shown to include a plurality of discharge port openings 142 through which the cooling fluid can exit the cooling circuit 140. The discharge port openings 142 are separated by housing ribs, which can provide structural support for the discharge port 150. In the example shown, the discharge port 150 is vertically disposed above the motor 12. The discharge port 150 is configured so that the cooling fluid rises vertically before being able to exit from the cooling circuit 140. The location of the discharge port 150 facilitates effective cooling flow, and when the heated air rises, the heated air will rise toward the discharge port 150 to be discharged from the cooling circuit 140. The fan assembly 134 is vertically disposed below the motor 12. In the example shown, the fan assembly 134 is vertically disposed directly below the motor 12. The fan assembly 134 can be vertically disposed directly between the motor 12 and the ground. The fan assembly 134 is arranged so that the fan assembly 134 radially overlaps the motor 12 relative to the motor axis A. The fan assembly 134 is arranged so that the fan assembly 134 radially overlaps the rotor 22 relative to the motor axis A. The fan assembly 134 is arranged so that the fan assembly 134 radially overlaps the stator 20 relative to the motor axis A. The fan assembly 134 is arranged so that the fan assembly 134 radially overlaps the magnet array 34 relative to the motor axis A.

[0123] The fan assembly 134 is configured to rotate about a fan axis FA, while the rotor 22 of the motor 12 is configured to rotate about a motor axis A. In the example shown, the fan assembly 134 is arranged so that the fan axis FA is not coaxial with the motor axis A. The fan assembly 134 is arranged so that the fan axis FA passes through one or both of the stator 20 and the rotor 22 of the motor 12. In some examples, the fan assembly 134 can be arranged so that the fan axis FA is transverse to the motor axis A. In some examples, the fan assembly 134 can be arranged so that the fan axis FA is arranged orthogonal to the motor axis A.

[0124] The fan assembly 134 can be positioned such that the fan axis FA is not parallel to the motor axis A. The fan assembly 134 is offset from the motor 12 such that the fan axis FA is not coaxial with the motor axis A. In some examples, the fan assembly 134 is positioned such that the fan axis FA is transverse to the motor axis A. In some examples, the fan assembly 134 is positioned such that the fan axis FA is orthogonal to the motor axis A. In some examples, the fan assembly 134 is positioned such that a first plane along which the fan axis FA extends is transverse to a second plane along which the motor axis A extends. In some examples, the first plane can be positioned orthogonal to the second plane.

[0125] The rotor 22 rotates about a first axis (motor axis A), and the blade structure 136 rotates about a second axis (fan axis FA). The first axis may be arranged transversely to the second axis. The first axis may be orthogonal to the second axis. The first axis may be substantially horizontal, such as within 20 degrees horizontally. The second axis may be substantially vertical, such as within 20 degrees vertically. Other amounts of angular offset ranges are possible, such as within 5 or 10 degrees vertically or horizontally. In some examples, the first axis is oriented transversely to the second axis in the range of 85 to 95 degrees or 80 to 100 degrees. In some examples, the second axis is oriented transversely to the first axis in the range of 85 to 95 degrees or 80 to 100 degrees. In some examples, the first axis is horizontal and the second axis is vertical.

[0126] In the example shown, the fan assembly 134 blows the cooling fluid through the cooling circuit 140. The cooling circuit 140 extends between a cooling inlet 142 and a cooling outlet 144. The cooling fluid is configured to enter the cooling circuit 140 through the cooling inlet 142, flow along a path 146, and exit the cooling circuit 140 through the cooling outlet 144 as heated cooling fluid. In the example shown, a channel 146 is formed through the chamber 114. As the cooling fluid flows through the chamber 114 between the cooling inlet 142 and the cooling outlet 144, the cooling fluid absorbs heat and its temperature increases.

[0127] The air inlet of the fan assembly 134 is located below the motor 12. The fan assembly 134 is disposed vertically below the motor 12. In this particular embodiment, the fan assembly 134 is directly vertically below the motor 12. In the example shown, the fan assembly 134 is located below a portion of the frame 58. The fan assembly 134 is disposed vertically below the motor 12 so that no portion of the fan assembly 134 is exposed from the top side of the drive system 10. The fan assembly 134 is disposed so that the fan assembly 134 is longitudinally recessed from the longitudinal end of the drive system 10 and so that the fan assembly 134 is laterally recessed from the lateral side of the drive system 10. The fan assembly 134 is spaced apart from the rear longitudinal end of the drive system 10 in the first axial direction AD1. The fan assembly 134 is spaced apart from the control panel 13 in the first axial direction AD1. The fan assembly 134 is spaced apart from the longitudinal wall 122b of the chamber 114 in the first axial direction AD1. The fan assembly 134 is spaced apart from the longitudinal wall 122a of the chamber 114 in the second axial direction AD2. The fan assembly 134 is disposed laterally inwardly of both lateral sides of the drive housing 110 .

[0128] Since the inlet for fan assembly 134 is roughly located below the main body of drive system 10, the atomized jet fluid in the environment around the injection system 1 is unlikely to be pulled upwards into the fan assembly 134 and blown into the chamber 114. Usually during the injection process, at least some paint particles or other jet fluids will not adhere to the surface being coated. These particles (also referred to as "dry fall") drift in the environment around the injection system 1 as the particles drift to the ground. Such particles can remain wet, and if they encounter any surface before reaching the ground, this causes the particles to adhere to the surface. For example, if particles are sucked into the chamber 114, such particles can adhere to the blade structure 136, thereby reducing the efficiency of the fan assembly 134, can adhere to the radiator 126, thereby reducing the heat transfer efficiency, etc. Usually, if the atomized jet fluid does not adhere to the target surface, it will fall downwards, so that the housing 116 and the frame 58 protect the inlet of the fan assembly 134 from the impact of the falling jet fluid. Positioning the fan assembly 134 on the vertical underside of the drive system 10 protects the fan assembly 134 from dry drops, thereby inhibiting inhalation into the chamber 114. Also, exhaust through the exhaust port 150 on the top side of the chamber 114 minimizes the risk of falling jet fluid entering the exhaust port 150 while air is blown out of the exhaust port 150.

[0129] The side rails 154 of the frame 58 further partially close the entrance of the fan assembly 134. The side rails 154 are formed as part of the frame 58. In the example shown, the side rails 154 are formed separately from the other parts of the frame 58 and connected to the other parts of the frame 58. However, it should be understood that the side rails 154 can be formed integrally with the other parts of the frame 58. The side rails 154 protrude vertically downward relative to the bottom plate 124 of the chamber 114. The side rails 154 extend vertically downward beyond the fan assembly 134. In the example shown, the fan assembly 134 is axially arranged between the lower side of the side rails 154 (e.g., the part closest to the ground) and the motor 12. The side rails 154 partially enclose and protect the fan assembly 134 from the impact of the falling sprayed fluid particles, thereby further inhibiting inhalation. With the side rails 154, the fluid particles falling on the lateral side of the drive system 10 will need to travel vertically over the side rails and then travel vertically upward against gravity before reaching the fan assembly 134.

[0130] The pump 19 is spaced apart from the fan assembly 134 in a first axial direction AD1. The pump 19 may overlap the fan assembly 134 axially relative to the motor axis A. In the example shown, the pump 19 radially overlaps the fan assembly 134 relative to the fan axis FA. The pump 19 is disposed longitudinally forward of the fan assembly 134. The pump 19 is positioned such that the pump housing 19a may inhibit dry drop from drifting longitudinally rearward toward the fan assembly 134. In this way, the pump 19 may be considered to further protect the cooling circuit 140 from inhaling falling fluid particles.

[0131] The cooling circuit 140 extends from the conduit 148, through the chamber 114, and to the exhaust port 150. The cooling fluid is drawn into the cooling circuit 140 through the conduit 148 (forming the cooling inlet 142) and is discharged from the cooling circuit 140 through the exhaust port 150 (forming the cooling outlet 144). The cooling fluid may extend around the motor 12 along a path 146 along which it flows within the chamber 114. In the example shown, the path 146 is exposed to both axial ends of the motor 12 and circumferentially surrounds the motor 12. In the example shown, the path 146 extends completely around the motor axis A to extend completely circumferentially around the motor 12 around the motor axis A. A portion of the path 146 is directly axially disposed between the motor 12 and the radiator 126. At least a portion of the cooling fluid flows through the fins of the radiator 126 and extracts heat from the radiator 126. The cooling fluid flows through the chamber 114 and is discharged through the exhaust port 150.

[0132] In the example shown, the cooling circuit 140 is configured to suck cooling fluid at a position longitudinally rearward of the pump 19. The cooling inlet 142 is spaced apart from the pump 19 in the second axial direction AD2 along the motor axis A. The cooling circuit 140 absorbs cooling fluid at a position longitudinally forward of the controller 15. The cooling fluid moving through the chamber 114 collects heat from the motor 12 and the radiator 126. The heated cooling fluid is discharged from the chamber 114 through one or more exhaust ports 150. The exhaust port 150 is disposed longitudinally rearward of the duct 148. The exhaust port 150 may be formed in the housing 116. The exhaust port 150 is located vertically above the motor 12. The exhaust port 150 is located on the top side of the chamber 114. In this way, the fan assembly 134 generally draws air from below the chamber 114, and the air is discharged above the chamber 114.

[0133] In the example shown, the drain port 150 is configured to discharge the heated cooling fluid longitudinally away from the pump 19. The drain port 150 is oriented so that the drain port 150 discharges the cooling fluid along the motor axis A and in the axial direction AD2. The drain port 150 is disposed radially outward of the motor axis A so that the drain port 150 discharges the heated cooling fluid at a position radially outward of the motor axis A. In the example shown, the drain port 150 is disposed radially outward of the motor 12 so that the heated cooling fluid exits at a position radially outward of the stator 20 and the rotor 22. Disposing the drain port 150 radially outward of the motor 12 facilitates cooling because the cooling fluid flows through the entire vertical extent of the motor 12 before exiting through the drain port 150.

[0134] The exhaust port 150 is disposed on a radial side of the motor 12 opposite the cooling inlet 142. The exhaust port 150 is disposed on a radial side of the motor 12 opposite the fan assembly 134. The exhaust port 150 is disposed on a radial side of the motor 12 opposite the fan assembly 134, which promotes cooling when the cooling fluid flows vertically through the motor 12 when the cooling fluid flows from the conduit 148 to the exhaust port 150. In some examples, the exhaust port 150 is disposed at least about 120 degrees from the cooling inlet 142 around the motor axis A. In some examples, the exhaust port 150 is disposed between about 120 degrees and 180 degrees from the cooling inlet 142 around the motor axis A. In some examples, the exhaust port 150 is disposed at least about 120 degrees from the fan assembly 134 around the motor axis A. In some examples, the exhaust port 150 is disposed between about 120 degrees and 180 degrees from the fan assembly 134 around the motor axis A.

[0135] In the example shown, the drive system 10 includes a single exhaust port 150 divided into a plurality of exhaust port openings 142. The exhaust port 150 is not disposed on the lateral side of the drive housing 110. The exhaust port 150 is not disposed in the longitudinal front of the motor 12. The exhaust port 150 is not disposed on the front end of the drive housing 110. In the example shown, the exhaust port 150 is disposed at the longitudinal rear end of the chamber 114. The exhaust port 150 is oriented to discharge heated air longitudinally backward. The exhaust port 150 is configured to discharge heated air from the motor 12. The exhaust port 150 is open so that the heated air is discharged through the exhaust port 150 in the second axial direction AD2. In some examples, the exhaust port 150 is further positioned so that the heated air is discharged vertically upward and away from the motor 12. The exhaust port 150 is positioned behind the motor 12 and oriented to discharge the heated cooling fluid further backward, which can further help prevent falling spray particles from entering the chamber 114.

[0136] The cooling circuit 140 is configured such that the cooling fluid moves longitudinally rearwardly between the cooling inlet 142 and the cooling outlet 144. The cooling fluid moves longitudinally rearwardly between the location where the cooling fluid enters the chamber 114 and the location where the cooling fluid exits the chamber 114. As the cooling fluid flows from the conduit 148 to the discharge port 150, the cooling fluid moves longitudinally away from the pump 19 and toward the control panel 13. The cooling fluid moves axially between the conduit 148 and the discharge port 150 relative to the motor axis A. Axially flowing cooling fluid promotes flow over the entire axial length of the motor 12, thereby enhancing cooling because a larger surface area is located in the direct path between the conduit 148 and the discharge port 150.

[0137] The radiator 126 is spaced apart from the motor 12 along the motor axis A. In the example shown, the radiator 126 does not radially overlap the motor 12 along the motor axis A. In the example shown, an axial gap 160 is formed between the radiator 126 and the motor 12. In the example shown, the radiator 126 is spaced apart from the motor 12 so that the motor 12 and the radiator 126 do not radially overlap each other along the motor axis A. The axial gap 160 can be configured so that no structure of the motor 12 or the radiator 126 bridges the axial gap 160. The axial gap 160 between the motor 12 and the radiator 126 is spaced apart longitudinally rearward of the fan assembly 134. The axial gap 160 between the motor 12 and the radiator 126 is spaced apart from the cooling inlet 142 in the same direction as the longitudinal direction in which the cooling outlet 144 is spaced apart from the cooling inlet 142. The cooling path 146 is configured so that the cooling fluid can flow freely in the axial gap 160 between the motor 12 and the radiator 126. In the example shown, a portion of the rotor extends into the frame 58. The cooling path 146 extends around the portion of the rotor and does not extend axially between the portion of the rotor 22 and the longitudinal wall 122a.

[0138] The radiator 126 is disposed between the cooling inlet 142 and the cooling outlet 144. The radiator 126 is disposed in the cooling path 146 downstream of the cooling inlet 142 and upstream of the cooling outlet 144. The radiator 126 is disposed between the duct 148 and the discharge port 150. When the cooling fluid flows from the duct 148 to the discharge port 150, the cooling fluid flows through the radiator 126. The radiator 126 is disposed longitudinally rearward of the cooling inlet 142. The radiator 126 is spaced apart from the duct 148 along the motor axis A in the second axial direction AD2. The radiator 126 is spaced apart from the motor 12 along the motor axis A in the second axial direction AD2, and the discharge port 150 is also spaced apart from the motor 12 along the motor axis A in the second axial direction AD2. The cooling fluid flows longitudinally rearward from the duct 148 to the discharge port 150, wherein the discharge port 150 is disposed longitudinally rearward of the duct 148. The heat sink 126 is spaced apart from the duct 148 in the same longitudinal direction as the discharge port 150, so that the heat sink 126 is positioned so that the cooling fluid flows through the heat sink 126 when the cooling fluid travels toward the discharge port 150. Placing the heat sink 126 in the flow direction of the cooling fluid provides improved heat transfer efficiency because the cooling fluid is blown through the heat sink 126 to travel to the cooling outlet 144. In some examples, the heat sink 126 is longitudinally disposed between the cooling inlet 142 and the cooling outlet 144. In such an example, the heat sink 126 may be spaced apart from the duct 148 in the second axial direction AD2 and spaced apart from the discharge port 150 in the first axial direction AD1. In some examples, the heat sink 126 is disposed to radially overlap with the discharge port 150.

[0139] The radiator 126 is vertically disposed between the cooling inlet 142 and the cooling outlet 144. The fan assembly 134 is positioned to blow the cooling fluid vertically upward into the chamber 114. The radiator 126 is vertically above the fan assembly 134 so that the fan assembly 134 actively blows air vertically. The exhaust port 150 is disposed on the vertical side of the radiator 126 opposite the duct 148 so that the cooling fluid flows vertically through the radiator 126 before reaching the exhaust port 150. Such a configuration positions the radiator 126 so that the cooling fluid flows through the entire vertical extent of the radiator 126 before exiting through the exhaust port 150. The radiator 126 located in the vertical gap between the duct 148 and the exhaust port 150 provides efficient heat transfer from the radiator 126 to the cooling fluid.

[0140] The heat sink 126 is disposed on the axial side of the motor 12 opposite to the driver 14. The heat sink 126 is disposed near the second end 26 of the motor 12. The heat sink 126 is disposed on the end of the motor 12 opposite to the first end 24 forming the output end of the motor 12. The first end 24 of the motor 12 outputs a rotational motion from the motor 12. The heat sink 126 is disposed on the axial end of the motor 12 opposite to the end that outputs the rotational motion. In some examples, the motor 12 can be considered to be cantilevered from the frame 58 so that the second end 26 is free and spaced apart from the longitudinal wall 122b. The motor 12 is spaced apart from the heat sink 126 so that air can flow freely in the axial gap 160 formed between the motor 12 and the heat sink 126. Such a configuration allows the heat sink 126 to be formed as a plate and allows the surface area of ​​the heat sink 126 to be increased, wherein the motor 12 is axially spaced apart from the heat sink 126 along the motor axis A.

[0141] The heat sink 126 is arranged so that the cooling fluid is directed over the heat sink 126 as the cooling fluid flows from the cooling inlet 142 to the cooling outlet 144. The heat sink 126 is thermally connected to one or more components of the controller 15 so that heat generated by the controller 15 is wicked to the cooling fluid flow through the heat sink 126. The heat sink 126 cools the controller 15.

[0142] In some examples, heat sink 126 is directly thermally coupled to one or more components of controller 15. For example, a direct thermal path can be formed between one or more components and heat sink 126. For example, the components can be directly mounted to heat sink 126, such as by a thermal interface material (TIM), or connected to heat sink 126 by a thermally conductive material extending between the components and heat sink 126. In one example, the IGBT can be thermally bonded to a printed circuit board mounted on a side of the heat exchanger oriented into control cavity 130. Heat sink 126, which forms a wall of control cavity 130, promotes heat transfer from control cavity 130 to chamber 114, thereby facilitating cooling of controller 15.

[0143] The cooling circuit 140 cools the motor 12 and the controller 15. The controller 15 is located on the side of the longitudinal wall 122b opposite the motor 12. The heat sink 126 is directly disposed between the motor 12 and the controller 15. The cooling airflow flows directly through the motor 12. The cooling airflow can directly receive the heat generated by the motor 12 and transfer the heat out of the chamber 114 through the exhaust port 150. The cooling airflow flows directly through the longitudinal wall 122b to absorb heat from the longitudinal wall 122b. The longitudinal wall 122b includes a thermally conductive material that transfers heat to the cooling airflow. In the example shown, the thermally conductive material is formed by the heat sink 126. In some examples, the thermally conductive material can be a metal or the like.

[0144] The cooling airflow can indirectly cool the controller 15 by absorbing heat that is thermally transferred from the controller 15 to the cooling airflow passing through the radiator 126. The single cooling airflow through the cooling loop 140 cools multiple heat generating components. The multiple heat generating components cooled by the single airflow output by the fan assembly 134 are arranged in separate chambers (e.g., chamber 114 and control chamber 130). The fan assembly 134 is configured to actively blow the cooling fluid through a single chamber of those separate chambers. In some examples, the chamber 114 and the control chamber 130 are sealed compartments. In some examples, one or both of the chambers 114 and the control chamber 130 include a small opening or gap that can allow some cooling airflow to escape, but the exhaust port 150 is still configured to eject the heated cooling fluid. In the example shown, the chamber 114 and the control chamber 130 are separated from each other by the longitudinal wall 122b, so that the cooling fluid actively flows through the chamber 114 instead of the control chamber 130. The control chamber 130 can be considered to be isolated from the cooling fluid flow output by the fan assembly 134.

[0145] The fan assembly 134 is mounted independently of the pump 19 and the motor 12. In particular, the fan assembly 134 is mounted to the frame 58 independently of the pump 19, and the motor 12 is also mounted to the frame 58, so that one can be removed without removing the other. The fan assembly 134 is not mounted to the motor 12, or otherwise structurally supported by the motor 12. The fan assembly 134 is not mechanically connected to the motor 12 to be driven by the motor 12. The fan motor 138 is separated from any mechanical drive output from the motor 12. The blade structure 136 is not forced to rotate due to the rotation of the motor 12 to drive air into the chamber 114. On the contrary, the fan assembly 134 is separated from the motor 12, so that the blade structure 136 can rotate separately from the rotation of the rotor 22. The blade structure 136 can be rotated when the rotor 22 is stationary or when the rotor 22 rotates. When the blade structure 136 and the rotor 22 are both rotating, the blade structure 136 can rotate at a different speed from the rotor 22 or at the same speed as the rotor 22.

[0146] The operation of the fan assembly 134 refers to rotating the blade structure 136 via the fan motor 138 of the fan assembly 134 to be sufficient to move air. During the operation of the fan assembly 134, the blade structure 136 is actively rotated by the fan motor 138. The fan assembly 134 includes a fan motor 138 that rotates the blade structure 136 around the fan axis FA. The fan motor 138 can be operated independently of the motor 12. More specifically, the motor 12 can be operated to rotate the rotor 22 without rotating the fan motor 138 or the blade structure 136. The fan motor 138 of the fan assembly 134 can be any type of motor. The fan motor 138 can be controlled by the controller 15 or other control circuits. In some examples, the controller 15 is considered to include a fan control circuit that controls the operation of the fan assembly 134, and the controller 15 can also be considered to include a motor control circuit that controls the operation of the motor 12, thereby controlling the pumping through the pump 19.

[0147] In some examples, the fan motor 138 is controlled to rotate based on the operating conditions of the motor 12. In some examples, the controller 15 operates the fan assembly 134 to output the cooling fluid flow based on whether the rotor 22 is controlled to rotate. In some examples, the controller 15 operates the fan assembly 134 to output the cooling fluid flow, so that when the motor 12 does not operate the pump 19, the fan assembly 134 is not operated to output the cooling fluid flow.

[0148] For example, the fan motor 138 may be controlled to rotate only when the rotor 22 of the motor 12 is driven to rotate, but it should be understood that not all examples are so limited. Such a configuration can minimize the noise generated by the fan assembly 134, which would otherwise be drowned out by the noise of the motor 12. Operating the fan motor 138 only when the motor 12 is running can cause the fan assembly 134 to be unnoticeable when operating, while operating the fan motor 138 and blowing air when the motor 12 is not running. During this condition, the operator can assume that the injection system 1 should not do anything, avoiding operating obvious functions on the injection system 1 when the user expects no obvious operation, thereby increasing the user's confidence in the injection system 1.

[0149] The fan assembly 134 can be controlled to operate based on the operating parameters of the injection system 1. In some examples, the fan assembly 134 is controlled to operate based on the sensed temperature of one or more components of the drive system 10. As discussed in more detail below, the fan assembly 134 can operate when the sensed temperature meets the thermal threshold. When the sensed temperature does not meet the thermal threshold, the fan assembly 134 can be deactivated and not operated. In some examples, the fan assembly 134 is controlled to operate based on the operating conditions of the motor 12. For example, the fan assembly 134 can be rotated only when the rotor 22 rotates.

[0150] In some examples, the controller 15 can change the speed of the fan assembly 134 based on the operating parameters. The controller 15 can change the speed of the fan assembly 134 based on the sensed temperature. For example, the fan assembly 134 can be rotated faster based on a higher sensed temperature. Additionally or alternatively, the controller 15 can change the speed of the fan assembly 134 based on the rotational speed of the rotor 22. For example, the fan assembly 134 can be rotated faster based on a greater rotational speed of the rotor 22.

[0151] In some examples, the controller 15 is configured to control the operation of the fan assembly 134 based on multiple trigger thresholds. For example, the controller 15 can operate the fan assembly 134 in a first operating mode based on the sensed temperature not satisfying a lower threshold. The controller 15 can operate the fan assembly 134 in a second operating mode based on the sensed temperature satisfying a lower threshold. The controller 15 can operate the fan assembly 134 in a third operating mode based on the sensed temperature satisfying an upper threshold. It should be understood that a parameter can satisfy a threshold by exceeding a threshold or by reaching or exceeding a threshold.

[0152] In some examples, the controller 15 may be configured to operate the fan assembly 134 based on each of the plurality of operating parameters being true. For example, the controller 15 may be configured to control the operation of the fan assembly 134 based on the sensed temperature and the operation of the motor 12. In one example, the controller 15 is configured to operate the fan assembly 134 based on the sensed temperature satisfying a threshold and the motor 12 being powered to rotate. In such an example, the controller 15 enables the fan assembly 134 only when both conditions are met. It should be understood that in some examples, the motor 12 may be powered to rotate while the rotor 22 remains stationary. For example, when the valve of the spray gun 5 is closed to prevent the release of the spray fluid, the motor 12 may be powered to rotate. In this case, the motor 12 may cause the pressure in the supply line 4 to be maintained for the next activation of the spray gun 5 for spraying. It should be understood that in other examples, the controller 15 may control the operation of the fan assembly 134 based on whether the rotor 22 actually moves.

[0153] The drive system 10 with active cooling provides significant advantages. The fan assembly 134 is separate from the motor 12 and is independently controllable. The fan assembly 134 can be operated to blow cooling fluid through the chamber 114 regardless of the operating state of the motor 12. The fan assembly 134 that can be operated separately from the motor 12 allows the fan assembly 134 to be controlled to provide customized cooling to the drive system 10. Energy is saved and wear is reduced by operating the fan assembly 134 when cooling is actually needed, rather than simply based on the operation of the motor 12.

[0154] The fan assembly 134 is vertically disposed below the motor 12. The fan assembly 134 is disposed so that the fan assembly 134 and the motor 12 overlap axially along the fan axis FA. The fan axis FA extends vertically through the motor 12. The fan assembly 134 is further disposed so that the fan assembly 134 and the motor 12 overlap radially along the motor axis A. The fan assembly 134 is disposed on the vertical lower side of the drive system 10. The fan assembly 134 is vertically disposed below the chamber 114 into which the fan assembly 134 blows the cooling fluid, protecting the fan assembly 134 from falling spray particles. The fan assembly 134 is vertically shielded by the drive housing 110 and the motor 12, and laterally shielded by the side rails 154. The shielding fan assembly 134 inhibits the spray particles from drifting to the fan assembly 134 and being sucked into the chamber 114, thereby preventing the internal components from being coated by the spray particles.

[0155] The exhaust port 150 is disposed vertically above the motor 12. The exhaust port 150 is disposed on the top side of the chamber 114 so that the heated air is exhausted from the top side of the drive system 10. Placing the exhaust port 150 on the top side of the drive system 10 promotes exhaust from the chamber 114 because the heated air within the chamber 114 will rise vertically toward the exhaust port 150. In addition, the exhaust port 150 is disposed on the side of the chamber 114 opposite to the duct 148, thereby promoting cooling air to flow through the chamber 114 and over the motor 12 and the radiator 126 for effective cooling.

[0156] The radiator 126 extends into the chamber 114 and is disposed within the cooling airflow through the chamber 114. The radiator 126 is positioned to wick heat from the control chamber 130 to cool the controller 15 and other components within the control chamber 130. The radiator 126 is axially spaced from the motor 12 along the motor axis A, thereby providing a flow path for cooling air to flow directly between the motor 12 and the radiator 126. The radiator 126 is disposed between the duct 148 and the exhaust port 150 so that the cooling air flows vertically between the duct 148 and the exhaust port 150 through the radiator 126. The radiator 126 is disposed longitudinally rearward of the duct 148. The radiator 126 is spaced from the duct 148 in the same direction (axial direction AD2) as the exhaust port 150. The positioning of the radiator 126 promotes cooling airflow over the radiator 126 and facilitates effective cooling.

[0157] The cooling circuit 140 provides cooling for a plurality of components disposed in different chambers. The cooling circuit 140 extends around the motor 12 so that the motor 12 is directly exposed to a cooling airflow. The radiator 126 is directly exposed to the cooling airflow. The radiator 126 provides heat transfer from the control chamber 130 which is separate from the chamber 114 which forms part of the cooling circuit 140. The cooling circuit 140 cools components directly exposed to the airflow and components separated from the cooling airflow, thereby providing efficient cooling while inhibiting the stagnation of heated air and allowing the use of a smaller, more efficient fan assembly 134 to provide adequate airflow.

[0158] Fig.12 is a schematic block diagram of the drive system 10. The motor 12, the drive housing 110, the controller 15, the radiator 126, and the fan assembly 134 are shown. The cooling inlet 142, the cooling outlet 144, and the path 146 of the cooling circuit 140 are shown. Sensors 162a, 162b (collectively referred to herein as "sensors" or "sensors") are shown.

[0159] The drive system 10 is configured to generate a mechanical drive output to power pumping through a pump (e.g., pump 19). The motor 12 is an electric motor. The motor 12 includes a rotor similar to the rotor 22, which is configured to rotate about the motor axis A. The motor 12 includes a stator similar to the stator 20, which is configured to generate an electromagnetic signal to drive the rotation of the rotor 22. The motor 12 is disposed in a chamber 114 at least partially defined by the drive housing 110. In the example shown, the radiator 126 at least partially defines the chamber 114. The motor 12 is disposed in a cooling circuit 140. The motor 12 is disposed in the chamber 114 so that the exterior of the motor 12 is directly exposed to the cooling fluid flowing through the chamber 114.

[0160] The controller 15 can be any desired configuration for controlling the pumping performed by the displacement pump 19, and can include control circuits and memory. The controller 15 is configured to store software, store executable code, implement a function set and / or process instructions. The controller 15 is configured to perform any function discussed herein, including receiving outputs from any sensor mentioned herein, detecting any condition or event mentioned herein, and controlling the operation of any component mentioned herein. The controller 15 is configured to control the operation of the motor 12 and the fan assembly 134. The controller 15 controls the operation of the motor 12 to control the pumping of the pump 19. The controller 15 controls the operation of the fan assembly 134 to control the supply of cooling fluid to the drive system 10. In the example shown, the controller 15 is shown to include a motor control circuit 156 configured to control the operation of the motor 12 and includes a fan control circuit 158 ​​configured to control the operation of the fan assembly 134. The motor control circuit 156 may also be referred to as a motor controller. The fan control circuit 158 ​​may also be referred to as a fan controller. It should be understood that the motor control circuit 156 and the fan control circuit 158 ​​may be mounted on the same circuit board or across one or more circuit boards.

[0161] The controller 15 is disposed in a control chamber 130 of the control panel 13. In the example shown, the control chamber 130 is fluidly disconnected from the chamber 114 so that no direct fluid path extends between the control chamber 130 and the chamber 114. However, it should be understood that not all examples are so limited. For example, the cooling circuit 140 can be configured so that the cooling fluid blown by the fan assembly 134 flows in both the chamber 114 and the control chamber 130.

[0162] The heat sink 126 is disposed between the chamber 114 and the control chamber 130. The heat sink 126 forms at least a portion of the longitudinal wall 122b. The longitudinal wall 122b is disposed between the chamber 114 and the control chamber 130. The longitudinal wall 122b may be considered to form a rear wall of the chamber 114 and a front wall of the control chamber 130.

[0163] The heat sink 126 is exposed to the cooling fluid flowing through the chamber 114. In the example shown, one or more components of the controller 15 are directly mounted to the heat sink 126. For example, a printed circuit board supporting one or more components of the controller 15 can be directly mounted to the heat sink 126. In some examples, a thermal interface material (TIM) can adhere one or more components of the controller 15 to the heat sink 126. In the example shown, the components of the controller 15 thermally mounted to the heat sink 126 are not directly exposed to the cooling fluid flow. Instead, such components are thermally connected to the cooling fluid flow via the heat sink 126.

[0164] The fan assembly 134 is configured to blow cooling air through the cooling circuit 140. The fan assembly 134 is mounted to draw cooling air into the cooling circuit 140 through the cooling inlet 142, and drive the cooling air through the cooling circuit 140 and out through the cooling outlet 144. The fan assembly 134 can be a variable speed assembly, in which the blade structure 136 can be rotated at different speeds, but it should be understood that not all examples are so limited. For example, the fan assembly 134 can be configured to operate at a single speed or at multiple speeds.

[0165] The sensor 162 is configured to generate information about the operating conditions of the drive system 10. In the example shown, the sensor 162 is formed as a temperature sensor. The temperature information generated by one or more sensors 162 can be used to control the operation of the fan assembly 134, as discussed in more detail below. Although the drive system 10 is shown as including a plurality of temperature sensors 162, it should be understood that not all examples are so limited. For example, the fan assembly 134 can be controlled based on temperature information from a single temperature sensor or based on the operation of the motor 12 without input from the sensor 162.

[0166] The sensor 162a is operatively associated with the motor 12. The sensor 162a is configured to generate information about the temperature of the motor 12. In some examples, the sensor 162a can be considered to form a motor sensor. In some examples, the sensor 162a can be mounted to a circuit board within the motor 12. In some examples, the sensor 162a can be disposed near an encoder of the motor 12. In some examples, the sensor 162a is mounted within the chamber 114 near the motor 12 but outside the motor 12. In some examples, the sensor 162a is radially disposed within the stator 20 of the motor 12. The sensor 162a can be disposed radially inward of the rotor 22.

[0167] Sensor 162b is operatively associated with controller 15. Sensor 162b is configured to generate information about a temperature of controller 15. In some examples, sensor 162b is configured to generate information about a temperature of a component of controller 15. For example, sensor 162b may be configured to generate information about a temperature of an IGBT of controller 15.

[0168] One or more temperature sensors 162 may be provided as part of the controller 15, within the motor 12, within the chamber 114, and / or elsewhere as part of the injection system 1. The data generated by the one or more temperature sensors 162 may be part of a control algorithm for operating the fan assembly 134. In some examples, the fan assembly 134 may only operate when the temperature sensor 162 senses a temperature above a threshold. Thus, the fan assembly 134 may only operate for cooling as needed, such that even if the motor 12 is operating, the fan assembly 134 may not operate as long as the sensed temperature remains below the threshold.

[0169] The fan assembly 134 is operated based on the operating conditions of the drive system 10. The rotation speed of the fan assembly 134 can vary based on the operating conditions. For example, the fan assembly 134 can be operated at different speeds according to the cooling needs. The controller 15 can be configured to operate the fan assembly 134 at a first speed based on the sensed temperature satisfying the first temperature threshold. The controller 15 can be configured to operate the fan assembly 134 at a second speed different from the first speed based on the sensed temperature satisfying the second temperature threshold. For example, the controller 15 can operate the fan assembly 134 at a first speed based on the sensed temperature satisfying the first temperature threshold (e.g., a lower thermal threshold), and then the fan assembly 134 can be operated at a higher second speed based on the sensed temperature satisfying the second temperature threshold (e.g., a higher thermal threshold). It should be understood that the fan assembly 134 can be operated based on one, two or more temperature thresholds. For example, based on the sensed temperature satisfying a third temperature threshold higher than the first temperature threshold and the second temperature threshold, the fan assembly 134 can be operated at a third speed greater than the first speed and the second speed.

[0170] The controller 15 may additionally or alternatively be configured to control the speed of the fan assembly 134 based on the rotational speed of the motor 12. The speed of the fan assembly 134 may vary as the speed of the motor 12 varies. For example, when the rotor 22 rotates at a relatively high speed, the controller 15 may cause the fan assembly 134 to operate at a relatively high speed. When the rotor 22 rotates at a relatively low speed, the controller 15 may similarly cause the fan assembly 134 to operate at a relatively low speed.

[0171] In some examples, the controller 15 is configured to control the operation of the fan assembly 134 based on a speed threshold of the motor 12. The speed threshold can be set based on the rotational speed of the rotor 22, such as based on a speed that reaches or exceeds a certain revolutions per minute (RPM) threshold. The controller 15 can operate the fan assembly 134 at a first speed based on the speed of the motor 12 satisfying a first speed threshold, and can operate the fan assembly 134 at a second speed based on the speed of the motor 12 satisfying a second speed threshold. For example, based on the second speed threshold being greater than the first speed threshold, the first speed of the fan assembly 134 can be less than the second speed of the fan assembly 134. It should be understood that the speed of the fan assembly 134 can be zero. For example, based on the motor speed being less than the first threshold, the controller 15 can deactivate the fan assembly 134 so that the speed of the fan assembly 134 is zero.

[0172] In some examples, the controller 15 is configured to actively control the speed of the fan assembly 134 by ramping the speed based on the operating conditions of the drive system 10. For example, the controller 15 can be configured to ramp the speed of the fan assembly 134 based on the sensed temperature. The controller 15 can operate the fan assembly 134 at a first speed based on the sensed temperature satisfying a first temperature threshold. Then, as the temperature rises, the controller 15 can accelerate the fan assembly 134 at various speeds. Such ramping can continue until the fan assembly 134 operates at 100% fan speed. The controller 15 can be configured to cause the fan assembly 134 to reach 100% fan speed at a second temperature threshold greater than the first temperature threshold.

[0173] In some examples, the fan control circuit operates the fan assembly 134 to output a cooling fluid flow based on both conditions being met: (1) when the motor is powered to operate the pump, and (2) a sensed temperature at the fluid ejector is above a temperature threshold.

[0174] In some examples, the controller 15 is configured to control the operation of the fan assembly 134 based on the satisfaction of multiple conditions. In some examples, at least two conditions must be met to cause the operation of the fan assembly 134. In some examples, the two conditions include a sensed temperature above a threshold and the simultaneous operation of the motor 12. If any of those conditions are not met, the fan assembly 134 may not start operating (until it is finally met), or if it is operated when the condition is lost, the fan assembly 134 may be disengaged until both conditions are met again. In such an example, the controller 15 can cause the fan assembly 134 to operate based on both the temperature condition and the motor speed condition. The controller 15 will cause the fan assembly 134 to operate only if each of the baseline conditions is true. For example, if the motor speed condition is not met (e.g., the motor speed is below the speed threshold), the controller 15 will not cause the fan assembly 134 to operate even if the temperature condition is met (e.g., the sensed temperature is greater than the temperature threshold or the sensed temperature is greater than or equal to the temperature threshold). Similarly, if the motor speed condition is met but the temperature condition is not met, the controller 15 will not cause the fan assembly 134 to operate.

[0175] Fig.13 1 is a flow chart illustrating an example control routine 1000 for active cooling of the drive system 10. In the example discussed, at step 1002, the fan assembly 134 is initially disabled and does not operate to generate a cooling fluid flow. At step 1004, the controller 15 checks to determine whether a first level primary condition is met. The primary condition may be an operating condition of the drive system 10. The primary condition may be based on a temperature threshold associated with one or more components of the drive system 10. For example, the primary condition may be a thermal threshold that is lower than a sensed motor temperature and / or a thermal threshold that is lower than a sensed controller temperature. The controller 15 may compare the sensed temperature to the temperature threshold to determine whether the primary condition is met. In some examples, the sensed temperature meets the thermal threshold by reaching or exceeding the thermal threshold. In some examples, the sensed temperature meets the thermal threshold by exceeding the thermal threshold.

[0176] The primary condition may further include other thermal conditions, such as a thermal alarm being enabled and / or the motor 12 operating in a power saving mode. The motor 12 may operate in a power saving mode, wherein the controller 15 limits the current flowing to the motor 12 to limit heat generation. The controller 15 may operate the motor 12 in a power saving configuration based on sensed temperature, power consumption of the motor 12, and other considerations. The primary condition may be based on the operating state of the motor 12, such as whether the motor is spinning.

[0177] Different levels of primary conditions may be associated with different primary conditions. For example, a first level primary condition may include a temperature threshold, while a second level primary condition may include a temperature threshold, an alarm state, a motor operating mode, etc. In one example, a first level primary condition may include a lower thermal threshold, and a second level primary condition may include a higher thermal threshold. It should be understood that any condition that satisfies a second level primary condition may be considered to also satisfy the first level primary condition.

[0178] If the first level primary condition is not met, the control routine 1000 returns to step 1002 and the fan assembly 134 remains deactivated. In the event that the first level primary condition is not met, the controller 15 can be considered to be operating the fan assembly 134 in the first operating mode. If the first level primary condition is met (e.g., the sensed temperature meets the lower temperature threshold), the control routine 1000 proceeds to step 1006. In the event that the first level primary condition is met, the controller 15 can be considered to be operating the fan assembly 134 in the second operating mode.

[0179] At step 1006, the controller 15 determines whether a secondary condition is satisfied. If the secondary condition is not satisfied, the control routine 1000 moves to step 1008 and the fan assembly 134 operates at a first fan speed. If the secondary condition is satisfied, the control routine 1000 moves to step 1010 and the fan assembly 134 operates at a second fan speed. It should be understood that in some examples, the first fan speed is the same as the second fan speed. In other examples, the first fan speed is different from the second fan speed.

[0180] In some examples, a secondary condition may be required to operate the fan assembly 134. In such an example, the first fan speed may be zero, causing the fan assembly 134 to be disabled. Therefore, the controller 15 may be configured to cause the fan assembly 134 to be disabled unless both the primary condition and the secondary condition are met. For example, the secondary condition may be that the motor is powered to rotate. If the motor 12 is not powered, the secondary condition is not met and the fan assembly 134 remains disabled. In another example, the secondary condition may be that the rotor 22 actually rotates. If the rotor 22 does not rotate, the secondary condition is not met and the fan assembly 134 remains disabled.

[0181] In some examples, the primary condition controls whether the fan assembly 134 is powered to generate a cooling fluid flow, and the secondary condition controls the speed of the fan assembly 134. For example, the secondary condition may be a speed threshold (e.g., revolutions per minute (RPM)) of the rotor 22 of the motor 12. If the speed threshold is met (such as the rotor 22 exceeds the speed threshold or the rotor 22 reaches or exceeds the speed threshold and the speed threshold is met), the fan assembly 134 operates at a second fan speed. If the speed threshold is not met, the fan assembly 134 operates at a first fan speed. The first fan speed may be less than the second fan speed, which provides cooling while also reducing the noise level generated by the fan assembly 134 to be consistent with the slower rotor 22 movement. For example, the first fan speed may be about 20%, 30%, 40%, 50%, or more or less than the full speed of the operation of the fan assembly 134. The second fan speed may be about 70%, 80%, 90%, 100%, or less than the full speed of the operation of the fan assembly 134.

[0182] The control routine 1000 moves to step 1012 and determines whether the second level primary condition is satisfied. If the second level primary condition is not satisfied, the control routine 1000 moves to step 1022 and determines whether the first level primary condition has been cleared. In some examples, the primary condition is cleared by the primary condition no longer satisfying the associated threshold. For example, the sensed motor temperature may drop to a lower motor temperature threshold (or in an example where the threshold is satisfied by reaching or exceeding the threshold, below the lower motor temperature threshold) so that the primary condition is no longer satisfied. In some examples, the controller 15 may be configured to implement a trigger point offset (i.e., hysteresis) when clearing the primary condition. The trigger point offset facilitates effective cooling and prevents the fan assembly 134 from oscillating between activation and deactivation based on small changes in temperature, and such rapid oscillations may increase wear on the fan assembly 134. The trigger point offset involves the controller 15 clearing the primary condition by clearing the associated threshold-offset value based on the sensed state of the primary condition. For example, the sensed temperature drops to a thermal threshold and then further falls below an offset value measured in degrees. For example, the thermal threshold may be "X" (e.g., 75 degrees, 90 degrees, 100 degrees, etc.) and the offset value may be "Y" (e.g., 2 degrees, 3 degrees, 5 degrees, etc.), in which case the primary condition is triggered to cause the controller 15 to proceed to step 1006 based on the sensed thermal parameter reaching the thermal value X, and the controller 15 clears the primary condition based on the sensed thermal parameter reaching the thermal value (XY). For example, a thermal threshold of 95 degrees (value X) and an offset value of 2 degrees (value Y) result in a gap threshold of 93 degrees. The controller 15 may deem the primary condition cleared based on the sensed parameter reaching the gap threshold. It should be understood that the controller 15 may implement different values ​​of thermal offsets between different condition levels. For example, a first offset value may be associated with clearing a first level primary condition, and a different offset value may be associated with clearing a second level primary condition.

[0183] If the second level primary condition is met, such as by the sensed temperature meeting the upper thermal threshold, the thermal alarm being activated, the motor operating in a power saving mode, etc., then the control routine 1000 proceeds to step 1014. The satisfied second level primary condition may be considered to cause the controller 15 to operate the fan assembly 134 in the third operating mode.

[0184] At step 1014, the controller 15 determines whether the secondary condition is met. If the secondary condition is not met, the control routine 1000 moves to step 1016, and the fan assembly 134 operates at a third fan speed. If the secondary condition is met, the control routine 1000 moves to step 1018, and the fan assembly 134 operates at a fourth fan speed. It should be understood that in some examples, the third fan speed is the same as the fourth fan speed. In other examples, the third fan speed is different from the fourth fan speed. In some examples, the third fan speed is the same as the first fan speed and / or the second fan speed. In some examples, the fourth fan speed is the same as the first fan speed and / or the second fan speed.

[0185] The secondary condition analyzed in step 1014 may be the same or different from the secondary condition analyzed in step 1006. In some examples, the third fan speed may be zero. In some examples, the secondary condition may be a speed threshold (e.g., revolutions per minute (RPM)) of the rotor 22 of the motor 12. If the speed threshold is met (such as the rotor 22 exceeds the speed threshold or the rotor 22 reaches or exceeds the speed threshold and the speed threshold is met), the fan assembly 134 operates at a fourth fan speed. If the speed threshold is not met, the fan assembly 134 operates at a third fan speed. In some examples, the third fan speed is the same as the fourth fan speed, so that when the controller 15 controls the fan assembly 134 in the third operating mode, the secondary condition does not affect the fan speed.

[0186] The control routine 1000 proceeds to step 1020, where the fan assembly 134 is operated at a third fan speed or a fourth fan speed. At step 1020, the controller 15 determines whether the second level primary condition is cleared. Similar to the first level primary condition, the second level primary condition can be cleared. For example, the second level primary condition can reach an associated threshold or be below an associated threshold-offset value. In some examples, the second level primary condition requires active clearing. For example, if a thermal alarm is triggered, the thermal alarm can remain activated until cleared by the user (e.g., by interacting with the user interface 17, reducing the output of the injection system 1, etc.).

[0187] If the second level primary condition is not cleared, the controller 15 continues to control the operation of the fan assembly 134 in the third operating mode. If the second level primary condition is cleared, the control routine 1000 moves to step 1022 and determines whether the first level primary condition is cleared. If the first level primary condition is not cleared, the controller 15 moves to step 1006 and determines the secondary condition state, and the controller 15 controls the operation of the fan assembly 134 in the second operating mode. If the first level primary condition is cleared, the control routine 1000 moves to step 1002, and the controller 15 returns to controlling the operation of the fan assembly 134 in the first operating mode.

[0188] Control routine 1000 provides significant advantages. Operating fan assembly 134 to generate cooling fluid flow based on the operating conditions of drive system 10 enables fan assembly 134 to operate only when cooling is actively required. Operating fan assembly 134 when cooling is required reduces the wear on fan assembly 134, thereby increasing operating life and reducing time cost and maintenance cost. Operating fan assembly 134 based on multi-stage primary conditions adapts fan assembly 134 operation to the actual conditions experienced by drive system 10. When a smaller amount of cooling is required, fan assembly 134 can be operated at a lower speed, and when a larger amount of cooling is required, it can be operated at a higher speed to generate a larger cooling fluid flow. Adapting fan assembly 134 operation to actual operating conditions reduces the wear on fan assembly 134 while providing desired cooling.

[0189] Control table 200 Fig.14 . The control table 200 is a non-limiting example of a control scheme for the operation of the fan assembly 134. The control table 200 includes three control levels 202a to 202c (collectively referred to herein as "control level 202" or "multiple control levels 202") for operating the main operating conditions of the fan assembly 134. The control level 202a can be referred to as the first control level, the control level 202b can be referred to as the second control level, and the control level 202c can be referred to as the third control level. The controller 15 can be considered to operate the fan assembly 134 in the first operating mode in the control level 202a, in the second operating mode in the control level 202b, and in the third operating mode in the control level 202c.

[0190] exist Fig.14 In the example shown, at least some of the primary conditions are based on sensed temperatures of different components of the drive system 10. At the control level 202a, the primary conditions are the motor temperature, such as based on temperature data from the sensor 162a, and the control temperature, such as based on temperature data from the sensor 162b. For example, the control temperature may be based on the sensed temperature of the IGBTs of the controller 15. In the example shown, the motor temperature threshold is different from the control temperature threshold, and either temperature threshold may trigger the activation of the fan assembly 134.

[0191] In the example shown, the motor temperature is associated with a lower threshold MT1 and an upper threshold MT2. The lower threshold MT1 is a temperature that is lower than the upper threshold MT2. The lower threshold MT1 can be associated with a temperature of approximately 95 degrees Celsius (approximately 200 degrees Fahrenheit). The upper threshold MT2 can be associated with a temperature of approximately 110 degrees Celsius (approximately 230 degrees Fahrenheit). The upper threshold MT2 can be approximately 10% to 20% higher than the lower threshold MT1. In some examples, the upper threshold MT2 is approximately 13% to 17% higher than the lower threshold MT1. In some examples, the upper threshold MT2 is approximately 15% higher than the lower threshold MT1. In the example shown, the lower threshold MT1 is configured as a lower level primary condition (e.g., as regards Fig.13 The first level main condition discussed above) and in the example shown, the higher threshold MT2 is configured as a higher level main condition (e.g., as discussed above) Fig.13 The second level main condition discussed). The lower threshold MT1 can also be referred to as the first lower threshold. The upper threshold MT2 can also be referred to as the first upper threshold.

[0192] In the example shown, the control temperature is associated with a lower threshold CT1 and an upper threshold CT2. The lower threshold CT1 is a temperature that is lower than the upper threshold CT2. The lower threshold CT1 can be associated with a temperature of approximately 75 degrees Celsius (approximately 167 degrees Fahrenheit). The upper threshold CT2 can be associated with a temperature of approximately 90 degrees Celsius (approximately 194 degrees Fahrenheit). The upper threshold CT2 can be approximately 15% to 25% higher than the lower threshold CT1. In some examples, the upper threshold CT2 is approximately 20% higher than the lower threshold CT1. In the example shown, the lower threshold CT1 is configured as a lower level primary condition (e.g., as described with respect to Fig.13 The first level main condition discussed above) and in the example shown, the higher threshold CT2 is configured as a higher level main condition (e.g., as discussed above). Fig.13 The second level main condition discussed). The lower threshold CT1 can also be referred to as the second lower threshold. The higher threshold CT2 can also be referred to as the second higher threshold.

[0193] In the example shown, the controller 15 is configured to control the operation of the fan assembly 134 in the first operating mode based on the first sensed temperature (e.g., motor temperature) not satisfying the first thermal threshold MT1 and the second sensed temperature (e.g., control temperature) not satisfying the third thermal threshold CT1. The controller 15 can control the operation of the fan assembly 134 in the second operating mode based on one of the first sensed temperature satisfying the first thermal threshold MT1 and the second sensed temperature satisfying the third thermal threshold CT1. In some examples, the controller 15 can cause the fan assembly 134 to not generate a cooling fluid flow in the first mode, and the controller 15 causes the fan assembly 134 to generate a cooling fluid flow in the second mode. In the example shown, the thermal threshold CT1 is greater than the thermal threshold MT1.

[0194] In the example shown, the controller 15 can be configured to control the operation of the fan assembly 134 in the third operating mode based on one of the first sensed temperature satisfying the second thermal threshold MT2 and the second sensed temperature satisfying the fourth thermal threshold CT2. In some examples, the third thermal threshold CT1 is between the first thermal threshold MT1 and the second thermal threshold MT2. The fourth thermal threshold CT2 can be greater than each of the first thermal threshold MT1, the second thermal threshold MT2, and the third thermal threshold CT1.

[0195] exist Fig.14 In the example shown, the secondary condition is based on the operating speed of the motor 12. The secondary condition can be considered a speed threshold for the rotational speed of the rotor 22. The speed of the fan assembly 134 is determined based on the secondary condition. In the example shown, the secondary condition is based on a first speed threshold ST1. The fan speeds FS1 to FS6 are the speeds at which the controller 15 causes the fan assembly 134 to operate given the primary and secondary conditions.

[0196] In the case of control levels 202a, 202b, the controller 15 determines whether the first level primary condition is met. If the first level primary condition is not met, the controller 15 operates the fan assembly 134 according to the control level 202a. The controller 15 operates the fan assembly 134 at a fan speed FS1 based on the sensed motor speed being less than the motor speed threshold MS1, so that the secondary condition is not met. The controller operates the fan assembly 134 at a fan speed FS2 based on the sensed motor speed being greater than or equal to the motor speed threshold MS1. In some examples, the fan speed FS1 and the fan speed FS2 are the same. In some examples, the fan speed FS1 and the fan speed FS2 are both equal to zero, so that the fan assembly 134 is not operated at the control level 202a. If the sensed motor temperature does not meet the lower threshold MT1 and the sensed control temperature does not meet the lower threshold CT1, the fan assembly 134 is controlled at the fan speed FS1 or the fan speed FS2. It should be understood that one or both of the fan speed FS1 and the fan speed FS2 can be zero, so that when the lower thresholds MT1, CT1 are not met, the fan assembly 134 is disabled. In some examples, controller 15 further defaults to control level 202 a if power to drive system 10 is shut off.

[0197] If the motor temperature satisfies the lower temperature threshold MT1 or the control temperature satisfies the lower temperature threshold CT1, the controller 15 controls the operation of the fan assembly 134 at the control level 202b. In the case of the control level 202b, the controller 15 changes the speed of the fan assembly 134 based on the sensed speed of the motor 12. The controller 15 determines the commanded operating speed of the fan assembly 134 based on the sensed speed of the motor 12.

[0198] In the example shown, if the speed of the motor 12 meets the speed threshold ST1, the controller 15 operates the fan assembly 134 at a fan speed FS4. For example, the fan speed FS4 may be about 100% of the full speed of the operation of the fan assembly 134. In this way, the controller 15 may operate the fan assembly 134 at full speed while controlling in the control level 202b. If the speed of the motor 12 does not meet the speed threshold ST1, the controller 15 operates the fan assembly 134 at a fan speed FS3. The fan speed FS3 may be less than the full speed of the operation of the fan assembly 134. In some examples, the fan speed FS3 may be about 30% of the full speed of the operation of the fan assembly 134. However, it should be understood that other speed levels of the fan assembly 134 are possible, such as about 20%, about 40%, about 50%, etc.

[0199] The controller 15 continues to control the operation of the fan assembly 134 at the control level 202b until the motor temperature decreases below the lower threshold MT1 and the control temperature decreases below the lower threshold CT1, or until the predominant conditions of the control level 202c are satisfied. In some examples, the controller 15 reverts to the control level 202a based on the sensed temperature dropping below the associated lower threshold by an offset value, as discussed in more detail above.

[0200] When operating in the second operating mode, the controller 15 can change the speed of the fan assembly 134 as the speed of the motor 12 changes. If the speed of the motor 12 drops below the speed threshold ST1, the controller 15 will operate the fan assembly 134 at the fan speed FS3, and if the speed of the motor 12 increases above the speed threshold ST1, the controller 15 will operate the fan assembly 134 at the fan speed FS2.

[0201] The controller 15 is configured to control the speed of the fan assembly 134 based on the control level 202c if at least one of the primary conditions of the control level 202c is met. In the example shown, the controller 15 is configured to control the fan assembly 134 based on the control level 202c if the motor temperature meets the upper threshold MT2, if the control temperature meets the upper threshold CT2, if the alarm is active, or if the motor 12 is operating in a power saving mode.

[0202] The controller 15 operates the fan assembly 134 at a fan speed FS5 based on the sensed motor speed being less than the motor speed threshold MS1, so that the secondary condition is not satisfied. The controller operates the fan assembly 134 at a fan speed FS6 based on the sensed motor speed being greater than or equal to the motor speed threshold MS1. In some examples, the fan speed FS5 and the fan speed FS6 are the same.

[0203] In some examples, at control level 202c, the speed of the fan is set independently of the operating speed of motor 12, such that fan speed FS5 and fan speed FS6 are equal and do not vary with changes in the speed of motor 12. For example, fan speed FS5 and fan speed FS6 can both be set to 100% of the full operating speed of fan assembly 134.

[0204] If the motor temperature satisfies the upper temperature threshold MT2 or the control temperature satisfies the lower temperature threshold CT2, the controller 15 controls the operation of the fan assembly 134 based on the control level 202c.

[0205] The controller 15 can be configured to control the operation of the fan assembly 134 based on the control level 202c when an alarm is activated. The alarm can be a thermal alarm that is triggered based on a sensed temperature exceeding an alarm threshold. For example, the controller 15 can be configured to operate at the control level 202c based on one or more thermal alarms. The first thermal alarm is associated with the sensed temperature of the motor 12 and may also be referred to as a motor temperature alarm. The motor temperature alarm is set to be triggered based on temperature data from the sensor 162a indicating that the temperature has exceeded the motor thermal alarm threshold. The motor thermal alarm threshold may be greater than the upper threshold MT2. In this way, even if the controller 15 controls the fan assembly 134 based on the control level 202c, the motor temperature alarm is set to be triggered if the temperature sensed by the sensor 162a continues to rise. The second thermal alarm is associated with the sensed temperature of the controller 15 and may also be referred to as a control temperature alarm. The control temperature alarm is set to be triggered based on temperature data from the sensor 162b indicating that the temperature has exceeded the control thermal alarm threshold. The control thermal alarm threshold may be greater than the upper threshold CT2. Thus, even when the controller 15 controls the fan assembly 134 based on the control level 202c, if the temperature continues to rise, the control temperature alarm is set to be triggered.

[0206] The alarm may be configured such that the alarm remains activated even if the alarm condition is remedied. For example, the alarm may remain activated even if the sensed temperature drops below the thermal alarm threshold. In some examples, the alarm condition requires active clearing by the user before the alarm will deactivate and reset. For example, a notification may be provided to the user via the user interface 17 to indicate that the alarm condition is active. In some examples, the user must power off the injection system 1 to clear the alarm. In some examples, the temperature must also drop below the alarm threshold to clear the alarm.

[0207] The controller 15 may be configured to control the operation of the fan assembly 134 based on the control level 202c when the motor 12 is operated in a particular operating mode, such as a power saving mode. The power saving mode is an operating mode in which the power level (e.g., current) provided to the motor 12 is reduced based on temperature information of the drive system 10. For example, in the event that the sensed temperature exceeds a certain threshold level, the maximum operating power that can be provided to the motor 12 may be reduced. The controller 15 then limits the maximum drive power provided to the motor 12 to less than the maximum drive power that can be provided when not operating in the power saving mode. The controller 15 operating the motor 12 in the power saving mode may cause the controller 15 to operate the fan assembly 134 by default based on the control level 202c.

[0208] In the example shown, each control level 202 is triggered by a single primary condition being true. Discussing the example operation in more detail. The spray system 1 is enabled and used to pump paint, such as for spraying. The motor 12 generates heat, and the sensor 162a provides motor temperature information to the controller 15. The controller 15 generates heat, and the sensor 162b provides control temperature information to the controller 15. As described above, the control temperature information can be generated based on the temperature at or around the components of the controller 15, such as the IGBTs. Additionally or alternatively, the components of the controller 15 can be thermally connected by the heat sink 126 via a direct thermal path, such as by thermal bonding to the heat sink 126. The controller 15 is initially in the control level 202a and controls the operation of the fan assembly 134 based on the control level 202a.

[0209] The temperature of the motor 12 and the controller 15 increases with the operation of the injection system 1. If the motor temperature meets one of the lower threshold MT1 or the control temperature meets the lower threshold CT1, the controller 15 operates at control level 202b. At control level 202b, the controller 15 enables the fan assembly 134.

[0210] When operating in the second control mode of the control level 202b, the controller 15 causes the fan assembly 134 to blow the cooling fluid through the cooling circuit 140. When operating under the control level 202b, the controller 15 causes the speed of the fan assembly 134 to be based on the sensed speed of the motor 12. In the example shown, if the motor speed reaches or exceeds (in some examples, exceeds) the motor speed threshold ST1, the controller 15 causes the fan assembly 134 to operate at a fan speed FS4. If the motor speed is lower than (in some examples, meets or is lower than) the motor speed threshold ST1, the controller 15 causes the fan assembly 134 to operate at a fan speed FS3. The fan speed FS3 is slower than the fan speed FS4. The fan speed FS3 corresponding to the relatively low speed of the motor 12 reduces the noise generated by the fan assembly 134, while the motor 12 operates slower and also generates relatively less noise. Reducing the fan speed relative to the reduced motor speed reduces wear on the fan assembly 134, thereby extending the operating life. The reduced noise of the fan assembly 134 at the relatively lower speeds of the motor 12 makes the operation of the fan assembly 134 less noticeable to the user.

[0211] If the over temperature parameter drops below the associated lower threshold (e.g., threshold MT1 for motor temperature or threshold CT1 for control temperature), the controller 15 will return to operating at control level 202a. In such an example, the controller 15 deactivates the fan assembly 134, and the fan assembly 134 does not operate until cooling is needed again.

[0212] The temperature of the drive system 10 may continue to increase. If any of the primary conditions associated with the control level 202c are met, the controller 15 controls the fan assembly 134 based on the control level 202c. In the example shown, if any of the motor temperature meets the upper threshold MT2, the control temperature meets the upper threshold CT2, the motor temperature alarm is triggered, the control temperature alarm is triggered, or a specific operating condition of the motor 12 is entered, the controller 15 operates in the third control mode and controls the fan assembly 134 based on the control level 202c. In the case of the control level 202c, the controller 15 causes the fan assembly 134 to operate. The fan assembly 134 operates at a fan speed FS5 or a fan speed FS6 according to the motor speed. In some examples, the fan speed FS5 and the fan speed FS6 are the same, so that the fan speed is independent of the motor speed. In some examples, the fan speed FS5 and the fan speed FS6 can be the same as the fan speed FS4.

[0213] The controller 15 continues to operate at the control level 202c until the primary condition of the control level 202c is not satisfied. As described above, the alarm condition may remain active until sufficient cooling occurs and the alarm is actively cleared. Thus, the controller 15 may continue to operate at the control level 202c regardless of the sensed motor temperature and the sensed control temperature as long as the alarm condition remains active.

[0214] As the temperature decreases, the controller 15 may revert from control level 202c to control level 202b, and then from control level 202b to control level 202a. As an example, assume that the motor temperature exceeds the upper threshold MT2 and the control temperature exceeds the upper threshold CT2, causing the controller 15 to operate at control level 202c. If one of the thermal conditions is cleared (e.g., falls below the associated upper thermal threshold or falls below the associated upper threshold by an offset value), the controller 15 continues to operate at control level 202c based on the other thermal parameter remaining above its associated upper thermal threshold. If both thermal conditions are cleared (e.g., falls below the associated upper thermal threshold or falls below the associated upper threshold by an offset value), the controller 15 reverts to operating at control level 202b.

[0215] The controller 15 controls the operation of the fan assembly 134 at the control level 202b until one or more thermal conditions are cleared relative to the lower thermal threshold (e.g., fall below the associated lower thermal threshold or fall below the associated lower threshold by an offset value). If the thermal condition is cleared relative to the lower threshold, the controller 15 returns to operating the fan assembly 134 at the control level 202a. The fan assembly 134 is disabled until sensing a thermal condition triggers operation again.

[0216] In some examples, such as when a thermal alarm is triggered to cause the controller 15 to operate at the control level 202c, the controller 15 can revert directly from the control level 202c to the control level 202a. For example, the alarm can remain activated even after the monitored temperature drops below one or more lower temperature thresholds (e.g., lower threshold MT1, lower threshold CT1). Once the alarm is actively cleared, the controller 15 will operate at the control level 202a based on the sensed temperature being below the lower threshold.

[0217] In one example, the controller 15 may implement a thermal offset when transitioning between control levels 202. In such an example, the controller 15 transitions from control level 202b to control level 202a based on an over-threshold temperature dropping to a thermal threshold plus an additional offset value, such as three degrees Celsius. For example, if the motor temperature is a below-threshold temperature, the controller 15 will continue to operate at control level 202b until the sensed motor temperature drops three degrees below the lower threshold MT1. For example, if the lower threshold MT1 is 95 degrees Celsius, the controller 15 will not transition to control level 202a until the sensed motor temperature drops to 92 degrees Celsius. If the control temperature is an over-threshold temperature, the controller 15 will continue to operate at control level 202b until the sensed control temperature drops three degrees below the lower threshold CT1. If both the motor temperature and the control temperature exceed the threshold, the controller 15 will continue to operate at control level 202b until the sensed control temperature drops three degrees below the lower threshold CT1 and the sensed motor temperature drops three degrees below the lower threshold MT1.

[0218] In the example shown, the primary operating condition determines whether the fan assembly 134 is operated to generate a cooling fluid flow. If the primary condition is met, the fan assembly 134 is operated, and a cooling fluid flow is generated and flows through the cooling circuit 140. The secondary operating condition determines the speed at which the fan assembly 134 operates. In the example shown, the secondary operating condition does not determine whether the fan assembly 134 is enabled; on the contrary, the secondary operating condition determines the operating characteristics of the fan assembly 134 when it is in operation. In the example discussed, the fan assembly 134 is enabled based on meeting the primary condition. As long as the primary condition is not met, the fan assembly 134 remains disabled. The secondary condition does not cause the activation or deactivation of the fan assembly 134. However, it should be understood that not all examples are so limited. In some examples, the secondary condition can determine whether the fan assembly 134 is enabled. For example, the secondary condition can be whether the motor 12 is powered and the fan speed associated with the secondary condition not being met (e.g., when the motor 12 is not powered) can be set to zero, so that the fan assembly 134 does not operate unless both the primary condition and the secondary condition are met.

[0219] The control routine 1000 and active cooling of the drive system 10 provide significant advantages. When cooling is actually needed, the fan assembly 134 is operated to provide cooling fluid to the drive system 10. When a relatively low level of cooling is required, the speed of the fan assembly 134 can be controlled based on the rotational speed of the rotor 22, and when a relatively high level of cooling is required, the speed of the fan assembly can be controlled independently of the motor speed. Such a configuration is conducive to providing sufficient cooling while also reducing wear on the fan assembly 134 and reducing the noise generated by the fan assembly 134.

[0220] Although the present invention has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from the scope of the present invention. In addition, many modifications may be made to adapt specific situations or materials to the teachings of the present invention without departing from the essential scope of the present invention. Therefore, it is intended that the present invention is not limited to the specific embodiments disclosed, but that the present invention may include all embodiments falling within the scope of the appended claims. Any single feature or any combination of features from an embodiment shown herein may be used in different embodiments independently of other features shown in the embodiments herein. Therefore, the scope of the present invention and any claims thereof are not limited to the combination of specific embodiments and / or features shown herein, but may include any combination of one, two or more features shown herein.

Claims

1. A fluid ejector, comprising: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; an electric motor having a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame supporting the pump and the motor; as well as A fan assembly generates a cooling fluid flow for cooling the electric motor, the fan assembly having a blade structure that rotates about a second axis that is not coaxial with the first axis.

2. The fluid ejector according to claim 1, wherein: The first axis is transverse to the second axis.

3. The fluid ejector according to claim 2, wherein: The first axis is oriented orthogonal to the second axis.

4. The fluid ejector according to any one of claims 1 to 3, wherein: The first axis extends along a first plane and the second axis extends along a second plane, the first plane being transverse to the second plane.

5. The fluid ejector according to claim 4, wherein: The first plane is arranged to be orthogonal to the second plane.

6. A fluid injector according to any preceding claim, wherein: The second axis is oriented within 10 degrees of vertical.

7. A fluid injector according to any preceding claim, wherein: The first axis is oriented within 10 degrees of horizontal.

8. A fluid injector according to any preceding claim, wherein: The fan assembly is located vertically directly below the motor.

9. A fluid injector according to any preceding claim, wherein: The fan assembly is mounted on the frame independently of the pump and the motor.

10. A fluid injector according to any preceding claim, wherein: The fan assembly is mounted within a duct at least partially defined by the frame.

11. The fluid ejector of claim 10, wherein: The duct protrudes vertically downward.

12. The fluid ejector according to any one of claims 10 and 11, wherein: The duct opens radially outward relative to the first axis such that a cooling fluid flow generated by the fan assembly flows radially toward the first axis.

13. A fluid injector according to any preceding claim, wherein: At least a portion of the frame radially overlaps the rotor.

14. The fluid ejector of claim 13, wherein: The portion of the frame radially overlaps the stator and the rotor.

15. The fluid ejector according to any one of claims 13 and 14, wherein: The frame extends axially outward from an unsupported end of the motor.

16. The fluid ejector of claim 15, wherein: The supported end of the motor is disposed axially opposite the unsupported end of the motor along the first axis, and the motor is configured to output rotational motion through the supported end to power pumping through the pump.

17. The fluid ejector according to any one of claims 13 to 16, wherein: The duct is formed through the portion of the frame.

18. A fluid injector according to any preceding claim, wherein: The motor is located in a chamber, the fan assembly blows cooling fluid into the chamber, and the cooling fluid is discharged from the chamber through a discharge port.

19. The fluid ejector of claim 18, wherein: The exhaust port is located above the motor and the fan assembly is located below the motor.

20. The fluid ejector according to any one of claims 18 and 19, wherein: The exhaust port is disposed on a radial side of the motor opposite an inlet port through which the fan assembly blows the cooling fluid into the chamber.

21. The fluid ejector of any one of claims 18 and 19, wherein: The discharge port is disposed at least 120 degrees about the first axis from an inlet through which the fan assembly blows the cooling fluid into the chamber.

22. The fluid ejector of claim 21, wherein: The discharge port is disposed between 120 and 180 degrees, inclusive, from the inlet port about the first axis.

23. The fluid ejector of claim 18, wherein: The stoma includes a plurality of stoma openings.

24. The fluid ejector according to any one of claims 18 and 23, wherein: The discharge port is oriented to discharge heated cooling fluid longitudinally away from the pump.

25. The fluid ejector according to any one of claims 18 and 23, wherein: The exhaust port is oriented to exhaust heated cooling fluid axially along the first axis at a location radially outward of the first axis.

26. A fluid ejector according to any one of claims 18 to 25, wherein: The chamber is defined by a first wall, a second wall, a pair of lateral walls, a bottom plate, and a top plate.

27. The fluid ejector of claim 26, wherein: The first wall is formed by the frame.

28. The fluid ejector according to any one of claims 26 and 27, wherein: The second wall is formed by a heat sink.

29. The fluid ejector of claim 28, wherein: The radiator is arranged between the chamber and the control chamber, and the controller is arranged in the control chamber.

30. The fluid ejector of claim 29, wherein: At least a portion of the controller is mounted directly to the heat sink.

31. The fluid ejector of claim 29, wherein: At least a portion of the controller is thermally coupled to the heat sink.

32. A fluid ejector according to any one of claims 29 to 31, wherein: An insulated gate bipolar transistor is mounted to the heat sink and disposed within the control cavity.

33. A fluid ejector according to any one of claims 29 to 32, wherein: The heat sink is axially aligned with the electric motor such that the first axis first passes through the heat sink and then through the control cavity.

34. A fluid ejector according to any one of claims 28 to 33, wherein: A plurality of fins of the heat sink are exposed in the cavity.

35. A fluid ejector according to any one of claims 28 to 34, wherein: The heat sink is vertically disposed between the fan assembly and the exhaust port of the chamber.

36. A fluid ejector according to any one of claims 28 to 35, wherein: The heat sink and the drain port are disposed on the same longitudinal side of the motor.

37. The fluid ejector of any one of claims 26 to 36, further comprising a housing surrounding the motor, wherein: The pair of lateral walls and the top plate are formed by the housing.

38. A fluid ejector according to any one of claims 26 to 37, wherein: The bottom plate is formed by the frame.

39. The fluid ejector of any one of claims 26 to 28 and claims 34 to 38, further comprising a controller, wherein: The controller is located on an opposite side of the second wall relative to the motor.

40. The fluid ejector of claim 39, wherein: Thermally conductive material in the second wall allows heat to pass through the second wall to be removed by cooling fluid flowing through the chamber via the fan assembly.

41. The fluid ejector of claim 40, wherein: The thermally conductive material is metal.

42. The fluid sprayer of any preceding claim, further comprising a fan control circuit for controlling the fan.

43. The fluid ejector of claim 42, wherein: The fan control circuit operates the fan assembly to output the cooling fluid flow based on whether the rotor of the motor is controlled to rotate.

44. The fluid ejector of claim 43, wherein: The fan control circuit operates the fan assembly to output the flow of cooling fluid such that when the motor is not operating the pump, the fan assembly is not operated to output the flow of cooling fluid.

45. The fluid ejector of any one of claims 43 and 44, further comprising a temperature sensor, wherein: The fan control circuit operates the fan assembly to output the cooling fluid flow such that when the sensed temperature generated by the temperature sensor is below a threshold, the fan assembly is not operated to output the cooling fluid flow.

46. ​​A fluid ejector according to any one of claims 42 to 45, wherein: The fan control circuit operates the fan assembly to output the cooling fluid flow based on two conditions being satisfied: (1) when the motor is powered to operate the pump, and (2) a sensed temperature at the fluid ejector is above a temperature threshold.

47. The fluid ejector of claim 1, further comprising: a first temperature sensor configured to generate a first sensed temperature; as well as A controller is configured to control operation of the fan assembly, the controller being configured to cause the fan to operate based on a comparison of the sensed temperature and a first temperature threshold.

48. The fluid ejector of claim 47, wherein: the controller being configured to operate the fan assembly in a first operating mode in which the fan assembly is not powered to blow the cooling fluid based on the first sensed temperature not satisfying the first threshold; and The controller is configured to operate the fan assembly in a second operating mode in which the fan assembly is powered to blow the cooling fluid based on the first sensed temperature satisfying the first temperature threshold.

49. The fluid ejector of claim 48, wherein: The first sensed temperature satisfies the first temperature threshold by reaching or exceeding the first temperature threshold.

50. The fluid ejector of any one of claims 48 and 49, wherein: In the second operating mode, the controller varies the speed of the fan assembly based on the rotational speed of the motor.

51. The fluid ejector of claim 50, wherein: The controller is configured to operate the fan at a first fan speed based on the rotational speed not satisfying a speed threshold, and the controller is configured to operate the fan at a second fan speed based on the rotational speed satisfying the speed threshold.

52. The fluid ejector of claim 51, wherein: The rotational speed satisfies the speed threshold by reaching or exceeding the speed threshold.

53. The fluid ejector of any one of claims 51 and 52, wherein: The second fan speed is greater than the first fan speed.

54. A fluid ejector according to any one of claims 48 to 53, wherein: The controller is configured to operate the fan assembly in a third operating mode based on the first sensed temperature satisfying a second temperature threshold, the second temperature threshold being greater than the first temperature threshold.

55. The fluid ejector of claim 54, wherein: The controller is further configured to operate the fan assembly in the third operating mode based on a thermal alarm being triggered.

56. The fluid ejector of claim 54, wherein: The controller is further configured to operate the fan assembly in the third operating mode based on the motor operating in the power save mode.

57. The fluid ejector of claim 54, wherein: In the third operating mode, the fan assembly operates independent of the speed of the electric motor.

58. A fluid ejector according to any one of claims 47 to 57, wherein: The first temperature is the temperature of the electric motor.

59. A fluid ejector according to any one of claims 47 to 57, wherein: The first temperature is the temperature of the controller.

60. A fluid ejector according to any one of claims 47 to 57, wherein: The first temperature is a temperature of an insulated gate bipolar transistor of the controller.

61. The fluid ejector of any one of claims 47 to 57, further comprising: a second temperature sensor configured to generate a second sensed temperature; and Wherein, the controller is configured to operate the fan assembly to blow the cooling fluid based on a comparison of the second sensed temperature and a third temperature threshold.

62. The fluid ejector of claim 61, wherein: The first temperature sensor is operatively associated with the motor and the second temperature sensor is operatively associated with the controller.

63. The fluid ejector of any one of claims 61 and 62, wherein: The first temperature threshold is different from the third temperature threshold.

64. The fluid ejector of claim 61, wherein: The controller is configured to operate the fan assembly to blow the cooling fluid based on one of the first sensed temperature satisfying the first temperature threshold and the second sensed temperature satisfying the third temperature threshold.

65. A fluid ejector, the fluid ejector comprising: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; an electric motor having a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame supporting the pump and the motor; a fan assembly that generates a cooling fluid flow that cools the motor, the fan assembly having a blade structure that rotates about a second axis; and A cooling circuit has a chamber, a cooling inlet, and a cooling outlet, wherein the motor is at least partially disposed within the chamber, the cooling inlet is configured to provide cooling fluid from the fan assembly to the chamber, and the cooling outlet is configured to output heated cooling fluid from the chamber.

66. The fluid sprayer of claim 65, wherein: The fan assembly is disposed vertically directly below the motor.

67. The fluid ejector of claim 66, wherein: A pair of side rails of the frame extend vertically below the fan assembly.

68. The fluid ejector of claim 67, wherein: Each side rail of the pair of side rails is spaced laterally outward from the fan assembly.

69. A fluid ejector according to any one of claims 65 to 68, wherein: The cooling outlet is disposed on a radial side of the electric motor opposite to the cooling inlet.

70. A fluid ejector according to any one of claims 65 to 69, wherein: A housing extends at least partially around the motor and at least partially defines the chamber, wherein the cooling outlet is formed as a discharge opening through the housing.

71. The fluid ejector of claim 70, wherein: The exhaust port is disposed vertically above the motor.

72. The fluid ejector of any one of claims 70 and 71, wherein: The drain includes a plurality of drain openings separated by housing ribs.

73. A fluid ejector according to any one of claims 65 to 72, wherein: At least one wall defining the chamber is formed as a heat sink.

74. The fluid ejector of claim 73, wherein: A controller is disposed on a side of the radiator opposite to the motor.

75. The fluid ejector of claim 74, wherein: The controller is isolated from the cooling fluid output by the fan assembly.

76. A fluid ejector according to any one of claims 65 to 75, wherein: The fan assembly is oriented to output cooling fluid radially relative to the first axis.

77. A fluid ejector according to any one of claims 65 to 76, wherein: The cooling outlet is axially spaced from the electric motor along the first axis, and wherein the cooling inlet radially overlaps the electric motor along the first axis.

78. A fluid ejector according to any one of claims 65 to 77, wherein: The cooling inlet is formed as a duct in the frame, and wherein the fan assembly is mounted in the duct.

79. A fluid ejector, the fluid ejector comprising: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; an electric motor having a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame supporting the pump and the motor; a chamber, the motor being at least partially disposed within the chamber; a fan assembly that generates a cooling fluid flow that cools the motor and is configured to blow the cooling fluid flow into the chamber, the fan assembly having a blade structure that rotates about a second axis; as well as A heat sink forms at least one wall of the chamber, the heat sink being exposed to the flow of cooling fluid generated by the fan assembly.

80. The fluid ejector of claim 79, wherein: The chamber is defined by a first wall, a second wall, a pair of lateral walls, a bottom plate and a top plate, and the heat sink forms the second wall.

81. The fluid ejector of claim 80, wherein: The pump is disposed along the first axis on an axial side of the front wall opposite to the motor.

82. The fluid ejector of any one of claims 79 to 81, wherein: The radiator is arranged between the chamber and a control chamber, and the controller of the fluid ejector is arranged in the control chamber.

83. The fluid ejector of claim 82, wherein: At least one component of the controller is mounted to the heat sink.

84. The fluid sprayer of claim 83, wherein: The at least one component includes an insulated gate bipolar transistor.

85. The fluid ejector of any one of claims 82 to 84, wherein: The heat sink defines a wall of the control chamber.

86. A fluid injector according to any one of claims 79 to 85, wherein: The radiator is disposed between a duct where the fan assembly is mounted and a discharge port through which the heated cooling fluid exits the chamber.

87. The fluid sprayer of claim 86, wherein: The radiator is vertically disposed between the pipe and the discharge port.

88. The fluid ejector of any one of claims 86 and 87, wherein: The radiator and the exhaust port are spaced apart from the motor in the same direction along the first axis.

89. A fluid injector according to any one of claims 86 to 88, wherein: The discharge port is disposed vertically above the radiator.

90. The fluid ejector of any one of claims 79 to 89, wherein: The heat sink does not radially overlap the electric motor along the first axis.

91. The fluid ejector of any one of claims 79 to 90, wherein: The heat sink is spaced apart from the motor along the first axis such that an axial gap is provided between the heat sink and the motor.

92. A fluid ejector, the fluid ejector comprising: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; an electric motor having a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame supporting the pump and the motor; a fan assembly that generates a flow of cooling fluid to cool the electric motor, the fan assembly having a blade structure that rotates about a second axis; a first temperature sensor configured to generate temperature information regarding a first sensed temperature; as well as A controller is configured to control operation of the fan assembly, the controller being configured to control enabling of the fan assembly based on a comparison of the first sensed temperature and a first thermal threshold.

93. The fluid ejector of claim 92, wherein: The controller is configured to cause the fan assembly to output the cooling fluid flow based on the first sensed temperature satisfying the first thermal threshold, and the controller is configured to cause the fan assembly to not operate to output the cooling fluid flow based on the first sensed temperature not satisfying the first thermal threshold.

94. The fluid ejector of claim 93, wherein: The first sensed temperature satisfies the first thermal threshold by reaching or exceeding the first thermal threshold.

95. A fluid ejector according to any one of claims 92 to 94, wherein: The controller is configured to vary a speed of the fan assembly based on the first sensed temperature.

96. A fluid ejector according to any one of claims 92 to 94, wherein: The controller is configured to vary the speed of the fan assembly based on a rotational speed of the rotor of the electric motor.

97. The fluid sprayer of claim 92, wherein: The controller is configured as follows: controlling operation of the fan assembly in a first operating mode based on the first sensed temperature not satisfying the first thermal threshold; controlling operation of the fan assembly in a second operating mode based on the first sensed temperature satisfying the first thermal threshold; as well as controlling operation of the fan assembly in a third operating mode based on the first sensed temperature satisfying a second thermal threshold, the second thermal threshold being greater than the first thermal threshold; The controller causes the fan assembly to not generate the cooling fluid flow in the first mode, and the controller causes the fan assembly to generate the cooling fluid flow in the second mode and the third mode.

98. The fluid sprayer of claim 97, wherein: The controller is configured to set a speed of the fan assembly based on a speed of the rotor of the motor in the second mode.

99. The fluid ejector of claim 98, wherein: The controller is configured to set the speed of the fan assembly independently of the speed of the rotor in the third mode.

100. The fluid ejector of any one of claims 98 and 99, wherein: In the second mode, the controller is configured to set the speed of the fan assembly to a first speed based on the speed of the rotor satisfying a speed threshold, and the controller is configured to set the speed of the fan assembly to a second speed less than the first speed based on the speed of the rotor not satisfying the speed threshold.

101. The fluid ejector of claim 100, wherein: The rotational speed satisfies the speed threshold by reaching or exceeding the speed threshold.

102. The fluid ejector of any one of claims 97 to 101, wherein: The controller controls operation of the fan assembly in the third operating mode based on a thermal alarm being activated.

103. The fluid ejector of claim 102, wherein: The thermal alarm is actively cleared.

104. The fluid ejector of any one of claims 97 to 103, wherein: The controller controls operation of the fan assembly in the third operating mode based on the motor operating in the power saving mode.

105. The fluid ejector of any one of claims 92 to 104, further comprising: a second temperature sensor configured to generate temperature information regarding a second sensed temperature; Wherein, the controller is configured to control the operation of the fan assembly, and the controller is configured to control the enabling of the fan assembly based on a comparison of the second sensed temperature and a third thermal threshold.

106. The fluid ejector of claim 105, wherein: The third thermal threshold is greater than the first thermal threshold.

107. The fluid ejector of claim 92, further comprising: a second temperature sensor configured to generate temperature information regarding a second sensed temperature; Wherein, the controller is configured to control the operation of the fan assembly, and the controller is configured to control the enabling of the fan assembly based on a comparison of the second sensed temperature and a third thermal threshold.

108. The fluid ejector of claim 107, wherein: The controller is configured as follows: controlling operation of the fan assembly in a first operating mode based on the first sensed temperature not satisfying the first thermal threshold and the second sensed temperature not satisfying the third thermal threshold; controlling operation of the fan assembly in a second operating mode based on one of the first sensed temperature satisfying the first thermal threshold and the second sensed temperature satisfying the third thermal threshold; The controller causes the fan assembly to not generate the cooling fluid flow in the first mode, and the controller causes the fan assembly to generate the cooling fluid flow in the second mode; and The third thermal threshold is greater than the first thermal threshold.

109. The fluid ejector of claim 108, wherein: the controller being configured to control operation of the fan assembly in a third operating mode based on one of the first sensed temperature satisfying a second thermal threshold and the second sensed temperature satisfying a fourth thermal threshold; wherein the third thermal threshold is between the first thermal threshold and the second thermal threshold; and The fourth thermal threshold is greater than the first thermal threshold, the second thermal threshold, and the third thermal threshold.

110. The fluid ejector of any one of claims 107 to 109, wherein: The first temperature sensor is configured to generate temperature information about the electric motor.

111. The fluid ejector of any one of claims 107 to 110, wherein: The second temperature sensor is configured to generate temperature information about the controller.

112. A fluid ejector, the fluid ejector comprising: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; an electric motor having a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame supporting the pump and the motor; a fan assembly that generates a cooling fluid flow that cools the motor, the fan assembly having a blade structure that rotates about a second axis; as well as A controller is configured to control the operation of the fan assembly, the controller being configured to control the operation of the fan assembly based on a first sensed temperature and a rotational speed of the motor.

113. The fluid ejector of claim 112, wherein: The fan assembly is mounted on the frame independently of the pump and the motor.

114. The fluid ejector of any one of claims 112 and 113, wherein: The controller is configured to control activation of the fan assembly based on the first sensed temperature, and the controller is configured to control a speed of the fan assembly based on a rotational speed of the rotor.

115. The fluid ejector of any one of claims 112 to 114, wherein: The fan assembly is controlled separately from the motor such that the fan assembly can be controlled to not generate the cooling fluid flow when the rotor is rotating.

116. The fluid ejector of any one of claims 112 to 115, wherein: The fan assembly is oriented to blow the cooling fluid flow radially relative to the first axis.

117. The fluid ejector of any one of claims 112 to 116, wherein: The fan assembly is vertically disposed below the motor.

118. The fluid ejector of any one of claims 112 to 117, wherein: The first sensed temperature is generated by a first temperature sensor disposed radially within a stator of the electric motor.

119. A fluid ejector, the fluid ejector comprising: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; an electric motor having a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame supporting the pump and the motor; a fan assembly that generates a cooling fluid flow that cools the motor, the fan assembly having a blade structure that rotates about a second axis; as well as A controller is configured to control operation of the fan assembly, the controller being configured to vary a speed of the fan assembly based on a first sensed temperature.

120. The fluid ejector of claim 119, wherein: the controller being configured to control operation of the fan assembly in a first operating mode based on the first sensed temperature not satisfying a first thermal threshold; and The controller is configured to control operation of the fan assembly in a second operating mode based on the first sensed temperature satisfying the first thermal threshold.

121. The fluid ejector of claim 120, wherein: The controller does not change the speed of the fan assembly in the first operating mode, and the controller changes the speed of the fan assembly in the second operating mode.

122. The fluid ejector of any one of claims 119 to 121, wherein: The controller is further configured to vary the speed of the fan assembly based on the rotational speed of the rotor.

123. The fluid ejector of any one of claims 119 to 122, wherein: The fan assembly is vertically disposed below the motor.

124. The fluid ejector of claim 123, wherein: A drain port for discharging heated cooling fluid is disposed vertically above the electric motor.

125. A fluid ejector, the fluid ejector comprising: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; an electric motor having a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame supporting the pump and the motor; a fan assembly that generates a flow of cooling fluid to cool the electric motor, the fan assembly having a blade structure that rotates about a second axis; as well as A controller is configured to control operation of the fan assembly so that the fan assembly generates the cooling fluid flow only when the rotor is rotating.

126. A fluid ejector, the fluid ejector comprising: a pump that outputs a fluid under pressure; a spray gun that sprays the fluid output from the pump; an electric motor having a rotor that rotates about a first axis; a driver that receives the rotational motion output by the motor to operate the pump; a frame supporting the pump and the motor; a fan assembly that generates a cooling fluid flow that cools the motor, the fan assembly having a blade structure that rotates about a second axis; as well as A controller is configured to control operation of the fan assembly based on primary conditions being satisfied.

127. The fluid ejector of claim 126, wherein: The main conditions are thermal conditions.

128. The fluid ejector of claim 127, wherein: The thermal condition includes a lower threshold, and the controller is configured to compare the sensed temperature to the lower threshold to determine whether the primary condition is satisfied.

129. The fluid ejector of claim 128, wherein: The thermal condition includes a plurality of thermal conditions, a first thermal condition of the plurality of thermal conditions is a sensed temperature of the motor, and a second thermal condition of the plurality of thermal conditions is a sensed temperature of the controller.

130. The fluid ejector of any one of claims 126 to 129, wherein: The controller is further configured to control operation of the fan assembly based on a secondary condition.

131. The fluid ejector of claim 130, wherein: The controller deactivates the fan assembly based on the secondary condition not being met.

132. The fluid ejector of claim 130, wherein: The controller varies the speed of the fan assembly based on whether the secondary condition is satisfied.

133. The fluid ejector of any one of claims 130 to 132, wherein: The secondary condition is a motor speed threshold of the motor.

134. The fluid ejector of any one of claims 130 and 131, wherein: The secondary condition is that driving power is provided to the electric motor.

135. The fluid ejector of claim 126, wherein: The main conditions include at least one first-level main condition and at least one second-level main condition; The controller is configured to control the fan assembly in a first operating mode based on satisfaction of the at least one first-level primary condition, and the controller is configured to control the fan assembly in a second operating mode based on the at least one second-level primary condition.

136. The fluid ejector of claim 135, wherein: The controller is further configured to control operation of the fan assembly based on a secondary condition in the first operating mode, and the controller is configured to control operation of the fan assembly independent of the secondary condition in the second operating mode.

137. The fluid ejector of claim 136, wherein: The secondary condition is a motor speed threshold of the motor.

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