Pump drive system

Abstract

A drive system for a fluid displacement pump includes an electric motor, a drive device coupled to a rotor at a first end of the electric motor, a fluid displacement member mechanically coupled to the drive device, and a pump frame mechanically coupled to the electric motor. The electric motor includes a stator and a rotor disposed on an axis. The drive device coupled to the rotor converts the rotary output into a linear reciprocating input to the fluid displacement member.

Description

[0001] This application is a divisional application, which is based on the PCT national phase application with an international application date of March 31, 2021, entered into China on September 26, 2022, with national application number 202180025720.1, and invention name “Pump drive system”. The corresponding PCT international application application number is PCT / US2021 / 025086.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Application No. 63 / 002,676, filed on March 31, 2020, and entitled “OUTERROTATOR DRIVEN PUMP,” and claims the benefit of U.S. Provisional Application No. 63 / 002,681, filed on March 31, 2020, and entitled “EXOSKELETON FRAME FOR PUMP DRIVE SYSTEM,” and claims the benefit of U.S. Provisional Application No. 63 / 002,687, filed on March 31, 2020, and entitled “ECCENTRIC ROTATOR DRIVEN PUMP,” and claims the benefit of U.S. Provisional Application No. 63 / 002,689, filed on March 31, 2020, and entitled “INTEGRATED PUMP-MOTOR BEARINGS.” 691, filed on October 7, 2020, and claims the benefit of U.S. Provisional Application No. 63 / 088,810, filed on October 7, 2020, and entitled “FLUID SPRAYER HAVING RESPONSIVE MOTOR CONTROL,” the disclosure of which is hereby incorporated by reference in its entirety. Technical Field

[0004] The present disclosure relates generally to fluid displacement systems and, more particularly, to drive systems for reciprocating fluid displacement pumps. Background Art

[0005] Fluid displacement systems (e.g., fluid dispensing systems for coatings) typically utilize positive displacement pumps (e.g., axial displacement pumps) to draw fluid from a container and drive it downstream. Axial displacement pumps are typically mounted to a drive housing and driven by a 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 and then driving the fluid downstream from the pump. In some cases, an electric motor can power the pump. The electric motor is attached to the pump via a gear reduction system that increases the motor's torque. Summary of the Invention

[0006] In one example, a fluid displacement pump assembly includes an electric motor, a drive device, a pump having a fluid displacement member, and a pump frame. The electric motor includes a stator and a rotor. The stator and rotor are disposed on an axis. The drive device is coupled to the rotor at a first end of the electric motor. The fluid displacement member is mechanically coupled to the drive device. The drive device converts the rotational output into a linear reciprocating input to the fluid displacement member. The pump frame is mechanically coupled to the electric motor.

[0007] In another example, a method of driving a reciprocating pump includes: providing power to an electric motor to cause rotation of a rotor of the motor; receiving a rotational output from the rotor at a drive device connected to the rotor; converting the rotational output into a linear reciprocating motion by the drive device; providing a linear reciprocating input to a fluid displacement member connected to the drive device by the drive device to cause a pump rod to pump fluid by reciprocating motion; and mechanically supporting the reciprocating pump and the electric motor by a pump frame.

[0008] In yet another example, a pumping system includes an electric motor, a drive device, a pump, and a pump frame. The electric motor includes a stator and a rotor. The stator and the rotor are disposed on an axis. The drive device is coupled to the rotor to receive a rotational output from the rotor and convert the rotational output into linear reciprocating motion. The pump includes a piston and a cylinder. The piston receives the linear reciprocating motion from the drive device, causing the piston to reciprocate within the cylinder. The cylinder and the stator are coupled to the pump frame to stabilize the stator relative to the rotor and the cylinder relative to the piston.

[0009] In yet another example, a drive system for a reciprocating fluid displacement pump includes an electric motor, a drive device, and a fluid displacement member. The motor includes a stator defining an axis and a rotor coaxially disposed about the stator. The drive device is directly connected to the rotor to receive a rotational output from the rotor. The fluid displacement member is mechanically coupled to the drive device. The drive member converts the rotational output into a linear reciprocating input to the fluid displacement member.

[0010] In yet another example, a method of driving a reciprocating pump includes: providing power to an electric motor to cause rotation of a rotor of the motor, the rotor being disposed outside and around a stator of the motor; receiving a rotational output from the rotor at a drive device directly connected to the rotor; converting the rotational output directly into a linear reciprocating motion by the drive device; and providing a linear reciprocating input to a fluid displacement member connected to the drive device by the drive device to cause the pump rod to pump fluid by reciprocating motion.

[0011] In yet another example, a fluid displacement device includes an electric motor, a drive device, a pump, and a pump frame. The motor includes a stator defining an axis and a rotor disposed about the stator. The drive device is coupled to the rotor to receive a rotational output from the rotor and convert the rotational output into a linear reciprocating motion. The pump includes a piston and a cylinder, the piston receiving the linear reciprocating motion from the drive device to cause the piston to reciprocate within the cylinder. The cylinder and the stator are coupled to the pump frame to stabilize the stator relative to the rotor and the cylinder relative to the piston.

[0012] In yet another example, a drive system for a reciprocating fluid displacement pump includes an electric motor, a drive device, a fluid displacement member, and a support frame. The electric motor includes a stator disposed on an axis and supported by a shaft, and a rotor coaxially disposed about the stator. The drive device is directly connected to the rotor to receive a rotational output from the rotor. The fluid displacement member is mechanically coupled to the drive device, wherein the drive device is configured to convert the rotational output into a linear reciprocating input to the fluid displacement member. The support frame is configured to mechanically support the electric motor and the fluid displacement pump, wherein the support frame is mechanically coupled to the stator.

[0013] In another example, a support frame for a reciprocating fluid displacement pump drive system includes a first frame member, a second frame member, and at least one connecting member. The reciprocating fluid displacement pump drive system has an electric motor with an inner stator and an outer rotor. The second frame member is disposed at an end of the electric motor opposite to the first frame member and is separate from the first frame member. The at least one connecting member extends between the first frame member and the second frame member and connects the first frame member and the second frame member. The second frame member and the at least one connecting member are configured to at least partially house and mechanically support the electric motor with the outer rotor.

[0014] In yet another example, a fluid displacement device includes an electric motor extending along an axis having a first end and a second end, a drive device, a pump, a pump frame, and a motor frame. The electric motor includes a stator extending along the axis and a rotor disposed about the stator and extending along the axis. The drive device is connected to the rotor to receive a rotational output from the rotor and convert the rotational output into linear reciprocating motion. The pump includes a piston and a cylinder, the piston receiving the linear reciprocating motion from the drive device to cause the piston to reciprocate within the cylinder. The cylinder and the stator are connected to the pump frame to stabilize the cylinder relative to the piston. The motor frame stabilizes the stator. The motor frame includes a plurality of connecting members extending from the first end of the motor to the second end of the motor. The plurality of connecting members are arranged around the rotor.

[0015] In yet another example, a drive system for a reciprocating pump for pumping fluid includes an electric motor and a drive device. The electric motor includes a rotor. The rotor includes an eccentric drive member extending therefrom. The drive device is directly coupled to the eccentric drive member and is configured to drive reciprocating motion of a fluid displacement member.

[0016] In yet another example, a method of driving a reciprocating pump includes: providing power to an electric motor to cause a rotor to rotate about a rotational axis; providing a rotational output of the electric motor directly to a drive device; providing a linear reciprocating input to a pump rod of the pump via the drive device; and spraying fluid from the fluid displacement pump onto a surface. The fluid displacement pump performs one pumping cycle for one revolution of the rotor.

[0017] In yet another example, a pumping system includes an electric motor, a drive device, and a reciprocating pump. The electric motor includes a rotor. The rotor includes an eccentric drive member extending from the rotor. The drive device is directly coupled to the eccentric drive member. The reciprocating pump includes a fluid displacement member coupled to the drive device and a pump cylinder that at least partially houses the fluid displacement member. The drive device is configured to drive reciprocating motion of the fluid displacement member.

[0018] In yet another example, a drive system for powering a reciprocating pump for pumping fluid to generate a fluid spray includes an electric motor, an eccentric drive member, and a drive device. The electric motor includes a stator and a rotor. The rotor is configured to rotate about a rotational axis. The eccentric drive member extends from the rotor. The drive device is coupled to the eccentric drive and configured to drive reciprocating motion of the fluid displacement member.

[0019] In yet another example, a method of driving a reciprocating pump for generating a pressurized fluid spray for application to a surface includes: providing power to an electric motor to cause a rotor to rotate about a rotational axis; providing a rotational output from the rotor to a drive device; and providing a linear reciprocating input to a fluid displacement member of the pump via the drive device to cause the fluid displacement member to reciprocate along the pump axis to pump fluid. The rotor is connected to the fluid displacement member via the drive device such that the fluid displacement pump performs one pumping cycle for one revolution of the rotor.

[0020] In yet another example, a pumping system for pumping fluid to produce a pressurized fluid spray includes an electric motor, an eccentric drive member, a drive device, and a reciprocating pump. The electric motor includes a stator and a rotor. The rotor is configured to rotate about a rotational axis. The eccentric drive member extends from the rotor. The drive device is coupled to the eccentric drive member to receive a rotational output from the rotor. The reciprocating pump includes a fluid displacement member coupled to the drive device and a pump cylinder that at least partially houses the fluid displacement member. The drive device is configured to receive the rotational output from the motor and convert the rotational output into linear reciprocating motion to drive the reciprocating motion of the fluid displacement member.

[0021] In yet another example, a drive system for a fluid displacement pump includes an electric motor, a drive device, a fluid displacement member, and a pump frame. The electric motor includes a stator and a rotor. The stator and the rotor are disposed on an axis. The drive device is coupled to the rotor at a first end of the electric motor. The fluid displacement member is mechanically coupled to the drive device such that the electric motor is subjected to a pump load generated by the reciprocating motion of the fluid displacement member during pumping. The pump frame is mechanically coupled to the electric motor and is configured to support the fluid displacement pump and the electric motor.

[0022] In yet another example, a drive system for a reciprocating fluid displacement system includes an electric motor, a drive device, a fluid displacement member, and a pump frame. The electric motor includes a stator and a rotor. The stator and rotor are disposed on an axis. The drive device is coupled to the rotor at a first end of the electric motor. The fluid displacement member is mechanically coupled to the drive device, wherein the drive device converts a rotational output from the rotor into a linear reciprocating input to the fluid displacement member. The pump frame is mechanically coupled to the electric motor. A pump reaction force generated by the fluid displacement member during pumping is transmitted to the pump frame via the drive device and the rotor.

[0023] In yet another example, a pumping apparatus includes a frame, at least two bearings, an electric motor, a drive device, and a pump. The electric motor includes a stator and a rotor, the rotor being configured to output rotational motion. The rotor is supported by the at least two bearings, which support the rotation of the rotor. The drive device is configured to receive the rotational motion and convert the rotational motion into linear reciprocating motion. The pump includes a piston and a cylinder. The piston is configured to receive the linear reciprocating motion to reciprocate within the cylinder through an upstroke and a downstroke. When moving through the upstroke, the piston receives a downward reaction force, and when moving through the downstroke, the piston receives an upward reaction force. Both the upward reaction force and the downward reaction force travel through the drive device, the rotor, and then to the at least two bearings.

[0024] In another example, a sprayer including the drive system of any of the preceding paragraphs includes a pump and a controller. The pump includes a piston configured to linearly reciprocate via the drive device. The controller is configured to output electrical energy to the electric motor to control operation of the electric motor.

[0025] In yet another example, a fluid displacement pump includes an electric motor having a first end and a second end, a drive device, and a pump having a fluid displacement member coupled to the drive device so as to be reciprocated by the drive device. The electric motor includes: a stator; and a rotor that rotates about an axis, the stator being radially located within the rotor so that the rotor rotates about the stator, the rotor including a housing having an opening located on the second end of the electric motor, the housing containing a plurality of magnets that rotate with the housing; and a stator support extending through the opening to hold the stator stationary as the housing rotates about the stator. The drive device is coupled to the rotor at the first end of the electric motor, the drive device being configured to convert a rotational output from the rotor into reciprocating motion. The fluid displacement member is positioned closer to the first end of the electric motor than to the second end of the electric motor.

[0026] In yet another example, a fluid sprayer includes an electric motor including a stator and a rotor; a drive device connected to the rotor, the drive device configured to convert a rotational output from the rotor into a reciprocating motion; a pump including a fluid displacement member coupled to the drive device so as to be reciprocated by the drive device; a fluid outlet that sprays a fluid output by the pump; a fluid sensor that outputs a signal indicative of a pressure of the fluid output by the pump; and a controller that receives the signal from the fluid sensor and outputs operating power to the stator, the operating power causing the rotor to rotate relative to the stator.

[0027] The controller is configured to: when the signal indicates that the pressure of the fluid output by the pump is below a pressure set point, deliver a first level of operating power to the stator, the first level of operating power causing the rotor to reciprocate the fluid displacement member via the drive device; and when the signal indicates that the pressure of the fluid output by the pump is at one of the pressure set point or above the pressure set point, deliver a second level of operating power to the stator while the rotor and the fluid displacement member remain stalled when the fluid outlet is closed, the second level of operating power causing the rotor to push against the drive device to cause the fluid displacement member to apply pressure to the fluid while the fluid outlet is closed and the rotor and the fluid displacement member remain stalled.

[0028] In yet another example, a fluid sprayer includes an electric motor including a stator and a rotor; a drive device connected to the rotor, the drive device configured to convert a rotational output from the rotor into a reciprocating motion; a pump including a fluid displacement member coupled to the drive device to be reciprocated by the drive device; a fluid outlet that sprays a fluid output by the pump; and a controller that outputs operating power to the stator, the operating power causing the rotor to rotate relative to the stator. The controller is configured to cause the rotor to reverse its rotational direction between two modes, wherein, in a first mode, the rotor rotates clockwise for a plurality of consecutive complete revolutions to drive the piston through a first plurality of consecutive pumping strokes, each pumping stroke comprising a fluid intake phase in which the fluid displacement member moves in a first direction and a fluid output phase in which the fluid displacement member moves in a second direction opposite to the first direction, and in a second mode, the rotor rotates counterclockwise for a plurality of consecutive complete revolutions to drive the piston through a second plurality of consecutive pumping strokes, each pumping stroke comprising the fluid intake phase and the fluid output phase.

[0029] This summary of the present invention is provided by way of example only and not limitation. Other aspects of the present disclosure will be appreciated upon consideration of the entirety of this disclosure (including the entire text, claims, and drawings). BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1A It is a schematic block diagram of the front elevation of the spraying system.

[0031] Figure 1B yes Figure 1A Side elevation schematic block diagram of the spraying system.

[0032] Figure 2 It is an isometric front-side view of the drive system and positive displacement pump.

[0033] Figure 3 yes Figure 2 Exploded view of the drive system and positive displacement pump.

[0034] Figure 4 It is along Figure 2 A cross-sectional view of the drive system and positive displacement pump taken along line 4-4.

[0035] Figure 4A yes Figure 4 4A is an enlarged view of portion 4A.

[0036] Figure 5 is used for Figure 2 Isometric front-side view of the drive system and support frame of the positive displacement pump.

[0037] Figure 6 is used for Figure 2 Isometric rear-side view of the drive system and support frame of the positive displacement pump.

[0038] Figure 7 yes Figure 2 Exploded view of the eccentric drive of the drive system.

[0039] Figure 8 is an isometric front-side view of another embodiment of a drive system and positive displacement pump.

[0040] Figure 9 yes Figure 8 Isometric cross-sectional view of the drive system and positive displacement pump.

[0041] Figure 10A is used for Figure 8 Isometric rear-side view of the drive system and support frame of the positive displacement pump.

[0042] Figure 10B is an isometric rear view of another embodiment of a support frame.

[0043] Figure 10C is an isometric rear view of yet another embodiment of a support frame.

[0044] Figure 11 is an isometric front cross-sectional view of yet another embodiment of a drive system and positive displacement pump.

[0045] Figure 12 yes Figure 11 Isometric front-side view of the drive system.

[0046] Figure 13 is a cross-sectional side view of yet another embodiment of a drive system and positive displacement pump.

[0047] Figure 14 is a cross-sectional side view of yet another embodiment of a drive system and positive displacement pump.

[0048] Figure 15 is an isometric front-side view of yet another embodiment of a drive system and positive displacement pump.

[0049] Figure 16 It is along Figure 15 An isometric cross-sectional view of the drive system and positive displacement pump taken along line 16-16.

[0050] Figure 17 It is the block diagram of the control system.

[0051] Although the drawings identified above set forth embodiments of the present invention, other embodiments are also contemplated as discussed. In all cases, this disclosure presents the present invention by way of representation and not limitation. It should be understood that those skilled in the art can devise many other modifications and embodiments that fall within the scope and spirit of the principles of the present invention. The drawings may not be drawn to scale, and applications and embodiments of the present invention may include features, steps, and / or components not specifically shown in the drawings. DETAILED DESCRIPTION

[0052] The present disclosure relates to a drive system for a reciprocating fluid displacement pump. The drive system includes an electric motor with an eccentric drive. The drive member converts the rotational output of a rotor into a linear reciprocating input for a fluid displacement member. The rotor can be positioned externally of a stator to rotate about the stator, making the motor an outrotator motor.

[0053] Figure 1A 1 is a schematic block diagram of the front elevation of the spraying system 1 . Figure 1B This is a schematic block diagram of the side elevation of the spraying system 1. Figure 1A and Figure 1BThe support 2, the reservoir 3, the supply line 4, the spray gun 5, and the drive system 10 are shown. The drive system 10 includes an electric motor 12, a drive mechanism 14, a pump frame 18, and a positive displacement pump 19. The support 2 includes a support frame 6 and wheels 7. The fluid displacement member 16 and the pump body 19a of the positive displacement pump 19 are shown. The spray gun 5 includes a handle 8 and a trigger 9.

[0054] The spray system 1 is a system for applying a spray of various fluids (examples of which include paint, water, oil, stain, polish, aggregate, coating, and solvent, among other options) to a substrate. The drive system 10 (which may also be referred to as a pump assembly) can generate high fluid pumping pressures, for example, about 3.4 to 69 megapascals (MPa) (about 500-10,000 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 3,000-5,000 psi). The high fluid pumping pressure is useful for atomizing the fluid into a spray for applying the fluid to a surface.

[0055] Drive system 10 is configured to draw spray fluid from reservoir 3 and pump the fluid downstream to spray gun 5 for application to a substrate. Support 2 is connected to drive system 10 and supports drive system 10 relative to reservoir 3. Support 2 can receive and react loads from drive system 10. For example, support frame 6 can be connected to pump frame 18 to react loads generated during pumping. Support frame 6 is connected to pump frame 18. Wheels 7 are connected to support frame 6 to facilitate movement between and within work sites.

[0056] The pump frame 18 supports the other components of the drive system 10. The motor 12 and the displacement pump 19 are connected to the pump frame 18. The motor 12 is an electric motor having a stator and a rotor. The motor 12 can be configured to be powered by any desired type of electricity, such as direct current (DC), alternating current (AC), and / or a combination of DC and AC. The rotor is configured to rotate about the motor axis MA in response to an electric current (e.g., a DC or AC signal) passing through the stator. In some examples, the rotor can rotate about the stator so that the motor 12 is an external rotor motor. The drive mechanism 14 is connected to the motor 12 to be driven by the motor 12. The drive mechanism 14 receives the rotational output from the motor 12 and converts the rotational output into a linear input along the pump axis PA. The drive mechanism 14 is connected to the fluid displacement member 16 to drive the reciprocating motion of the fluid displacement member 16 along the pump axis PA. As Figure 1BAs shown in FIG. , motor axis MA is disposed transversely to pump axis PA. More specifically, motor axis MA can be orthogonal to pump axis PA. In other embodiments, motor 12, drive mechanism 14, and fluid displacement member 16 can be coaxially disposed such that motor axis MA and pump axis PA are coaxial. Fluid displacement member 16 reciprocates within pump body 19a (e.g., cylinder 94 discussed below) to pump coating fluid from reservoir 3 to spray gun 5 via supply line 4.

[0057] During operation, a user can manipulate drive system 10 to a desired position relative to a target substrate by moving support member 2. For example, a user can manipulate drive system 10 by tilting support frame 6 on wheels 7 and rolling drive system 10 to a desired position. Positive displacement pump 19 can extend into reservoir 3. Motor 12 provides a rotational input to drive mechanism 14, and drive mechanism 14 provides a linear input to fluid displacement member 16 to cause reciprocating motion of fluid displacement member 16. Fluid displacement member 16 draws spray fluid from reservoir 3 and drives the spray fluid downstream through supply line 4 to spray gun 5. A user can manipulate spray gun 5 by, for example, grasping handle 8 of spray gun 5 with a single hand. The user initiates spraying by actuating trigger 9. In some examples, the pressure generated by drive system 10 atomizes the spray fluid exiting spray gun 5 to produce a fluid spray. In some examples, spray gun 5 is an airless sprayer. In some examples, a handle may extend from drive system 10 , and a user may maneuver drive system 10 by grasping the handle and carrying drive system 10 within or between work sites.

[0058] 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 Magnified view of portion 3A. Figure 5 is used for Figure 2 Isometric front-side view of the drive system and support frame of the positive displacement pump. Figure 6 is used for Figure 2 Isometric rear-side view of the drive system and support frame of the positive displacement pump. Figure 7 yes Figure 2 Exploded view of the eccentric drive. Figures 2 to 7 An electric motor 12 , a control panel 13 , a drive mechanism 14 , a fluid displacement member 16 , a support frame 18 and a positive displacement pump 19 are shown. Figures 2 to 4 and Figure 7 One embodiment of a drive mechanism 14 coupled to an outrotor electric motor 12 and configured to power reciprocating motion of a fluid-displacing member of a pump 19 is illustrated. Figure 5 and Figure 6 One embodiment of a support frame 18 configured to mechanically support the electric motor 12 and the pump 19 is illustrated.

[0059] The electric motor 12 includes a stator 20, a rotor 22, and a shaft 23. In the example shown, the electric motor 12 can be a reversible motor because the stator 20 can cause the rotor 22 to rotate in either of two rotational directions (e.g., clockwise or counterclockwise) about a motor axis A, which can be rotated in either direction. Figure 1A and Figure 1B . The electric motor 12 is disposed on an axis A and extends from a first end 24 to a second end 26. The first end 24 may be an output end configured to provide a rotational output from the motor 12. The second end 26 may be an electrical input end configured to receive electrical power to provide to the stator 20 to power the operation of the motor 12. For example, one or more wires w may extend into the electrical input end 26 and to the stator 20 to provide electrical power to operate the stator 20. 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 extends axially relative to the motor axis A between the first wall 30 and the second wall 32. The first wall 30 and the second wall 32 extend substantially radially inward from the cylindrical body 28 and toward the motor axis A. The cylindrical body 28 and / or the first wall 30 and / or the second wall 32 may have fins 31 projecting radially and / or axially from the body 28 and / or the walls 30, 32. The rotor 22 includes an array of permanent magnets 34 disposed on an inner circumferential surface 35. The inner circumferential surface 35 may be the radially inner portion of the cylindrical body 28. The second wall 32 may have an axially extending flange 36 configured to be received within the inner diameter of the cylindrical body 28. The second wall 32 may be secured to the cylindrical body 28 by fasteners, adhesive, welding, a press fit, an 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 shaft 23, for example, via a bearing 48. The annular flange 38 may at least partially define a receiving shoulder for receiving an outer race 49 of the bearing 48 and the preload 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 rotatably couple the rotor 22 to the stator 20 and the support frame 18.

[0060] A bearing 42 having an inner race 43, an outer race 44, and rolling elements 45 rotatably couples rotor 22 to stator 20 at a shaft end 46 opposite second end 26. A bearing 48 having an outer race 49, an inner race 50, and rolling elements 51 rotatably couples rotor 22 to stator 20 at second end 26.

[0061] 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 such 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 such 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.

[0062] The support frame 18 includes a pump frame 58 (at Figure 5 and support member 60 (best seen in Figure 6 ). It should be understood that the term member can refer to a single piece or multiple pieces that are fixed together. The pump frame 58 mechanically supports the pump 19 and the electric motor 12. The pump frame 58 is mechanically coupled to the rotor 22 at the output end 24 via the bearing 52. The pump frame 58 may include a pump housing portion 62, an outer frame body 63, a protrusion 64a, support ribs 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 couples the pump frame 58 and the motor 12 and supports the reaction forces of the pump and the electric motor. The support member 60 extends from the pump frame 58 at the output end 24 to the 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 post 73, a hub 74, ribs 75, and a support ring 76. The base plate 70 may include a support post 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 normal to the motor axis A at the output end 24 can extend through the pump frame 58. A second plane normal to the motor axis A at the input end 26 can extend through the frame member 72. The two planes are axially spaced apart along the motor axis A and do not intersect.

[0063] 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, such 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 extend from the motor 12 in a cantilevered manner via the frame member 72. The control panel 13 can extend from the support frame 18 in a cantilevered manner. In the example shown, the control panel 13 is mounted to the frame member at a control support post 73. The control support post 73 extends axially from the frame member 72 and away from the motor 12. The control support post 73 can provide direct contact (e.g., metal-to-metal contact) between thermally conductive elements of the frame member 72 and the control panel 13 to facilitate heat transfer, as discussed in more detail below.

[0064] The control panel 13 may include and / or support a controller 15 and various other control and / or electrical components of the drive system 10. The controller 15 is operably electrically and / or communicatively connected to the motor 12 to control the operation of the motor 12, thereby controlling the pumping performed by the positive displacement pump 19. The controller 15 can be any desired configuration for controlling the pumping performed by the positive displacement pump 19 and can include control circuitry and memory. The controller 15 is configured to store software, store executable code, implement functional and / or processing instructions. The controller 15 is configured to perform any of the functions discussed herein, including receiving output from any sensor referenced herein, detecting any condition or event referenced herein, and controlling the operation of any component referenced herein. The controller 15 can be 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 can include hardware, firmware, and / or stored software, and the controller 15 can be mounted in whole or in part on one or more boards. The controller 15 can be of any type suitable for operating according to the technology described herein. While controller 15 is illustrated as a single unit, it should be understood that controller 15 may be disposed across one or more boards. In some examples, controller 15 may be implemented as multiple 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 within and / or supported by control panel 13.

[0065] 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. Computer-readable memory may be configured to store information during operation. In some examples, computer-readable memory may be described as a computer-readable storage medium. In some examples, the computer-readable storage medium may include non-transitory media. The term "non-transitory" may indicate that the storage medium is not embedded in a carrier wave or propagating signal. In some examples, non-transitory storage media may store data that may change over time (e.g., in RAM or cache). The computer-readable memory of the controller 15 and / or motor controller 22 may include volatile 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 magnetic hard disks, optical disks, flash memory, or electrically programmable programmable memory (EPROM) or electrically erasable and programmable programmable memory (EEPROM). In some examples, the memory is used to store program instructions for execution by the control circuitry. In one example, the memory is used by software or applications running on the controller 15 or motor controller 22 to temporarily store information during program execution.

[0066] The control panel 13 is further shown to include a user interface 17. The user interface 17 can be configured as an input and / or output device. For example, the user interface 17 can be configured to receive input from a data source and / or provide output regarding bounded areas and paths therein. Examples of the user interface 17 can include one or more of a sound card, a video graphics card, a speaker, a display device (e.g., 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, or other types of devices for facilitating the input and / or output of information in a form understandable to 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 located remotely from the control panel 13 and communicatively connected to other components (e.g., the controller 15).

[0067] Drive mechanism 14 is connected to motor 12 and pump 19. Drive mechanism 14 is configured to receive the rotational output from rotor 22 and convert the rotational output into a linear reciprocating input to fluid displacement member 16. In the example shown, drive mechanism 14 includes an eccentric drive 78, a drive member 80, and a drive link 82. Eccentric drive 78 may include a sleeve 83 and a fastener 84. Drive member 80 may include a follower 86 and a bearing member 89. Drive link 82 may include a connecting slot 90 and a pin 92.

[0068] Pump 19 includes a fluid displacement member 16 configured to reciprocate within a cylinder 94 to pump fluid. In the illustrated example, fluid displacement member 16 is a piston configured to reciprocate along pump axis PA to pump fluid. However, it should be understood that fluid displacement member 16 can be of other desired configurations, such as a diaphragm, a plunger, etc., among other options. In the illustrated example, fluid displacement member 16 includes a shaft 91 and a connector 93. Pump 19 includes a cylinder 94 connected to support frame 18. Check valves 95 and 96 are disposed within cylinder 94 and regulate flow through pump 19. In the illustrated example, check valve 95 is mounted to the piston forming fluid displacement member 16 so as to travel therewith.

[0069] Support frame 18 supports motor 22 and pump 19. As discussed in more detail below, support frame 18 is dynamically connected to rotor 22 and statically connected to stator 20 through a bearing interface. Support frame 18 is statically connected to pump 19. Electric motor 12 is dynamically connected to support frame 18 via rotor 22 and statically connected to support frame 18 via stator 20. Electric motor 12 is dynamically connected to pump 19 via fluid displacement member 16. Pump 19 is statically connected to support frame 18 and dynamically connected to electric motor 12.

[0070] In the illustrated example, motor 12 is an electric motor having an inner stator 20 and an outer rotor 22. Motor 12 can be configured to be powered by any desired type of electricity, such as direct current (DC), alternating current (AC), and / or a combination of DC and AC. Stator 20 includes armature windings 21, and rotor 22 includes permanent magnets 34. Rotor 22 is configured to rotate about motor axis A in response to a current signal passing through stator 20. Rotor 22 is connected to fluid displacement member 16 at an output end 24 of rotor 22 via drive mechanism 14. Drive mechanism 14 receives the rotational output from rotor 22 and provides a linear reciprocating input to fluid displacement member 16. Support frame 18 mechanically supports electric motor 12 at output end 24 and mechanically supports reciprocating fluid displacement pump 19 via a connection between cylinder 94 and pump 19. Support frame 18 at least partially houses fluid displacement member 16 of reciprocating pump 19. In the example shown, cylinder 94 is mounted to pump frame 58 by clamp 25 receiving a portion of the support frame between a first member of clamp 25 and a second member of clamp 25. For example, flange 59 may be received between the two members of clamp 25.

[0071] The stator 20 defines the axis A of the electric motor 12. The stator 20 is disposed about and supported by a shaft 23. The shaft 23 is mounted so as to remain stationary relative to the motor axis A during operation. The stator 20 is fixed to the shaft 23 to maintain its position relative to the motor axis A. Power can be supplied to the armature windings 21 via electrical connections made at or through the electrical input 26 of the electric motor 12. Each winding 21 may be part of a phase of the motor 15. In some examples, the motor 15 may include three phases. Power can be supplied to each phase according to an electrically offset sinusoidal waveform. For example, a three-phase motor can have each phase receive a power signal electrically offset by 120 degrees from the other phases. The shaft 23 may be a hollow shaft that opens to the electrical input 26 to receive electrical wiring from outside the motor 12. In alternative embodiments, the shaft 23 may be solid, keyed, D-shaped, or have other similar designs. In some embodiments, the shaft 23 can 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, the first end of the shaft 23 can be radially disposed between the stator 20 and the rotor 22 and have a larger diameter than the axially opposite end 46 for receiving the electrical input.

[0072] The rotor 22 is disposed coaxially with and around the stator 20 and is configured to rotate about an axis A. The rotor 22 may be formed from 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. At the output end 24 of the electric motor 12, the rotor 22 may overlap the stator 20 and the shaft 23 over their entire radial extent. In some examples, the rotor 22 may completely surround the stator 20 and the shaft 23 at the output end 24 of the electric motor 12. At the electrical input end 26 of the electric motor 12, the rotor 22 may partially or completely overlap the stator 20 over its radial extent. 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 at the electrical input end 26 of the electric motor 12 by a bearing 48 to allow the rotor 22 to rotate relative to the shaft 23.

[0073] Generally, 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 about 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 includes a plurality of permanent magnets 34 circumferentially arranged within the rotor 22, or a plurality of windings that temporarily magnetize a metallic material, both of which are circumferentially arranged 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, causing the rotor 22 to rotate about the stator 20.

[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 (e.g., by fasteners, interference fit, welding, adhesive, etc.). The rotor 22 is formed such that the closed end of the rotor 22 is oriented toward the axis PA of reciprocating motion of the pump 19, and 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 is oriented toward the control panel 13. In the example shown, the opening through the wall 32 leads directly into the space between the control panel 13 and the motor 22.

[0075] The first wall 30 may have a tapered thickness and / or may be angled between the shaft 23 and the cylindrical body 28. The first wall 30 may have a tapered thickness, wherein the thickness increases in a radial direction from the cylindrical body 28 toward the axis A. In the example shown, the profile of the axially oriented face of the first wall 30 is such that the first wall 30 is arched outwardly in the first axial direction. In the example shown, the first wall 30 is integrally formed with the cylindrical body 28.

[0076] In the example shown, the second wall 32 is formed separately from and connected to the cylindrical body 28. In the example shown, the second wall 32 is fastened to the outer diameter portion of the cylindrical body 28 using a plurality of fasteners, more specifically, bolts 37. The second wall 32 may include an axially extending flange 36 at its radially outer end. The flange 36 may form a slip fit with the inner diameter of the cylindrical body 28. The axially extending flange 36 aligns the second wall 32 with the cylindrical body 28, ensuring proper alignment during assembly and preventing imbalance of the rotor 22 due to misalignment. The axially extending flange 36 promotes concentricity between the cylindrical body 28 and the second wall 30. The axially extending flange 36 may be annular. 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 outward (axially and / or radially) to propel air as the rotor 22 rotates. For example, 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 for conducting heat away from the motor 12.

[0077] Bearings 42, 48, and 52 are coaxially disposed on the axis of rotation A, such that the rotating members of bearings 42, 48, and 52 rotate on the axis of rotation A. Bearings 42, 48, and 52 may be substantially similar in size or may vary in size to support different loads and accommodate space constraints. Bearings 42 and 48 may be substantially similar in size, while bearing 52 at output end 24 may be larger to accommodate the reciprocating load received by rotor 22 at output end 24. In some examples, all three bearings 42, 48, and 52 may be of different sizes. In the example shown, end bearing 52 is larger than end bearing 48, and end bearing 48 is larger than intermediate bearing 42. The rolling elements of bearings 42, 48, and 52 may vary in radial position from axis A. Rolling elements 55 of bearing 52 may be disposed at a first radius R1 from the axis of rotation A of electric motor 12, rolling elements 51 of bearing 48 may be disposed at a second radius R2 from the axis of rotation A, and rolling elements 45 of bearing 42 may be disposed at a third radius R3 from the axis of rotation A. like Figure 4A As shown in FIG, first radius R1 may be greater than second radius R2, and third radius R3 may be greater than second radius R2 and less than first radius R1. In some examples, second radius R2 is one of greater than and equal to third radius R3. First wall 30 may be rotatably coupled to a radially inner portion of shaft 23 at shaft end 46 via bearing 42. Bearing 42 includes an inner race 43, an outer race 44, and rolling elements 45. In some examples, bearing 42 may be a roller or ball bearing in which rolling elements 45 are formed from cylindrical members or balls. First wall 30 may be coupled to inner race 43. Stator 20 may be coupled to outer race 44, for example, via shaft 23 interfacing with outer race 44. Rolling elements 45 allow rotor 22 to rotate relative to stator 20. Bearing 42 rotatably supports rotor 22 relative to stator 20 and maintains an air gap between permanent magnet array 34 and stator 20, thereby balancing motor 12. Bearing 42 can be provided to ensure that the stator 20 and rotor 22 deflect the same amount during each pump cycle, so that an air gap between the stator 20 and rotor 22 is maintained and the rotor 22 does not contact the stator 20 under each up and down pump load condition. Bearing 42 minimizes the unsupported length of the rotor 22 and provides intermediate support between bearing 52 and bearing 48. In some examples, bearing 42 can support the torque load generated by the electric motor 12. Bearing 42 can primarily align the stator 20 and rotor 22 while experiencing minimal pump reaction loads. When bearing 42 is positioned inside the shaft 23, the radius R3 of bearing 42 can be determined by the size of the shaft 23 at the shaft end 46.

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

[0079] The first wall 30 of the rotor 22 may extend into the shaft 23 at the output end 24 such that a portion of the shaft 23 and a portion of the first wall 30 radially overlap. Thus, an axial line parallel to the axis A may extend through each of the first wall 30 and the shaft 23. A cylindrical protrusion 40 of the rotor 22 may extend from the output end 24 of the motor 12 in the axial direction AD2 and 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 about the rotation axis A and rotates about the rotation axis A. The cylindrical protrusion 40 may extend into the shaft 23 such that the cylindrical protrusion 40 axially overlaps 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 via a bearing 42. The outer diameter surface of the cylindrical protrusion 40 can be coupled to the inner race 43 such that the rotor 22 rides inside the bearing 42. The shaft 23 can be coupled to the outer race 44. In some embodiments, at least a portion of each of the cylindrical protrusion 40 and the bearing 42 can axially overlap with a portion of the permanent magnet array 34 and, in some examples, a portion of the stator 20. In an alternative embodiment, the first wall 30 can be rotationally coupled to the outer diameter of the shaft 23 such that the rotor 22 is coupled to the outer race 44 and the shaft 23 is coupled to the inner race 43.

[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, while 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, such that the rotor 22 rides on the outside of the bearing 48. In some examples, the bearing 48 can be a roller or ball bearing in which 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 axially outer end surface of the outer ring 49. The second wall 32 can include an annular flange 38 that protrudes radially inward from the rotor 22 toward the axis A. The annular flange 38 can extend radially inward relative to the outer diameter surface of the outer ring 49. The flange 38 can radially overlap and abut the axially outer end surface of the outer ring 49. The flange 38 may extend to radially overlap and abut the fully circumferential axially outer end surface of the outer ring 49. The shaft 23 may extend through the rotor 22 at the electrical input end 26 and may project axially outward from the bearing 48 in the axial direction AD2 to allow the shaft 23 to be coupled to the support frame 18, for example, via the support member 60. The radius R2 of the bearing 48 may be determined by the size of the shaft 23 at the input end 26 and react to pump loads generated during operation.

[0081] Bearing 52 can support both dynamic motor loads and pump reaction loads generated by reciprocating motion of fluid displacement member 16 during pumping. Bearing 48 can support both dynamic motor loads and pump reaction loads generated by reciprocating motion of fluid displacement member 16 during pumping.

[0082] 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. For example, bearing 52 experiences the upward pump reaction forces caused by fluid displacement member 16 being driven through a downstroke, while bearing 48 experiences the downward pump reaction forces during the downstroke. Similarly, bearing 52 experiences the downward pump reaction forces caused by fluid displacement member 16 being driven through an upstroke, while bearing 54 experiences the upward pump reaction forces during the upstroke. The pump reaction loads are transmitted to support frame 18 via bearing 52.

[0083] In some embodiments, one or both of bearings 42 and 48 can be omitted from drive system 10. In such embodiments, rotor 22 can be completely separated from stator 20 and shaft 23 on all three sides and have no mechanical coupling. First wall 30 on output end 24 can extend across axis A to completely cover the radial extent of stator 20 and shaft 23 at output end 24 while maintaining axial and radial separation from stator 20 and shaft 23. Shaft 23 can extend through second wall 32 and can be radially separated therefrom by a gap to allow rotation of rotor 22 relative to shaft 23 in the absence of bearing 48. In such a configuration, rotation of rotor 22 can be supported by a bearing coupling between rotor 22 and pump frame 58 (discussed further herein) alone or in combination with one of bearings 42 and 48.

[0084] 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 race 54, an outer race 53, and rolling elements 55. The bearing 52 can be a roller or ball bearing, wherein the rolling elements 55 are cylindrical members or balls. The rotor 22 can be received in the 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 can 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 can be coupled to the inner race 54, and the pump frame 58 can be coupled to the outer race 53 such that the rotor 22 rides inside the bearing 52. The rolling elements 55 allow rotational movement of the rotor 22 relative to the pump frame 58.

[0085] Bearing 52 is positioned proximate to drive mechanism 14 and is most directly subject to the pump loads generated by the reciprocating motion of fluid displacement member 16 and transmitted via rotor 22 and, more specifically, cylindrical protrusion 41 to which drive mechanism 14 is coupled. Bearing 52 may have a relatively large radius R1, as compared to other motor support bearings (e.g., bearings 42, 48), to accommodate both the pump loads generated by the reciprocating motion of fluid displacement member 16 and the torque loads generated by electric motor 12. Bearing 52 may support both dynamic motor loads (including the torque loads generated by electric motor 12) and the up and down pump loads generated by the reciprocating motion of fluid displacement member 16 substantially along pump axis PA during pumping. Such pump reaction loads may be borne by electric motor 12 and are particularly pronounced in direct drive configurations that do not include an intermediate gear between rotor 22 and drive mechanism 14. For example, Figures 2 to 4 The drive system 10 shown in FIG. 1 has a direct drive configuration.

[0086] 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 electric 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. A bearing 52 may be provided on an outer diameter portion of the cylindrical protrusion 41 to couple the rotor 22 to the pump frame 58 via the cylindrical protrusion 41. The cylindrical protrusion 41 may be coupled to an inner race 54, and the pump frame 58 may be coupled to the outer race 53. The inner race 54 may be provided on the outer diameter surface of the cylindrical protrusion 41. The rolling elements 55 allow rotational movement of the rotor 22 relative to the pump frame 58. 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, such 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 does extend completely through the pump frame 58, such that a portion of the cylindrical protrusion 41 protrudes beyond the structure of the pump frame 58 in the axial direction AD1.

[0087] As used herein, the term "axially outer" refers to a surface facing the exterior of the electric motor 12 (i.e., away from the stator 20 along the axis A), and the term "axially inner" refers to a surface facing the interior portion of the electric 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 radially overlap and abut the axially oriented end surface of the inner race 54 (oriented in the axial direction AD2 in the illustrated example). The wall 30 may thus form a support for the bearing 52. The 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 radially overlap and abut the completely circumferential axially inner end surface of the inner race 54. For example, the wall 30 may include an annular axially extending protrusion that circumscribes the cylindrical protrusion 41 and extends approximately equal to or less than the height of the inner race 54 to interface with the inner race 54. The protrusion is configured to fix the axially inner position of the bearing 52 and axially separate the rotating wall 30 from the stationary outer ring 53 .

[0088] Bearings 42, 48, and 52 can be preloaded by pump frame 58 and support member 60. Pump frame 58 can radially overlap the axial end face of bearing 52. Frame member 72 of support member 60 can radially overlap the axial end face of bearing 48. When support member 60 is secured to connect frame members 58 and 72, an axially inward force is applied to the axial end faces of bearings 52 and 48 as bearings 52, 42, and 48 are compressed between pump frame 58 and frame member 72. Axially inward force in direction AD2 is applied to the radially extending axial end face of bearing 52, and specifically, to the outer axial end face of outer race 53. Axially inward force in direction AD1 is applied to the radially extending axial end face of bearing 48, and specifically, to the outer axial end face of inner race 50. This axial force preloads bearings 42, 48, and 52, removing play from bearings 42, 48, and 52 during operation of drive system 10. Wave spring washers can be used to reduce bearing noise. In some embodiments, a first wave spring washer 56 can be disposed between the pump frame 58 and the axial end surface of the outer race 53 of the bearing 52 at the output end 24. A second wave spring washer 57 can be disposed between a portion of the shaft 23 and the axial end surface of the outer race 44 of the bearing 42. Alternatively or in addition, a wave spring washer can be disposed between a portion of the shaft 23 and the axial end surface of the inner race 50 of the bearing 48.

[0089] The bearing arrangement of drive system 10 provides significant advantages. Bearings 52 and 48 react to pump reaction loads generated during pumping. Bearings 52 and 48 facilitate the direct drive configuration of drive system 10. Bearings 52 and 48 stabilize rotor 22 to facilitate direct drive connection to fluid displacement member 16. Pump reaction forces experienced by bearings 52 and 48 at output end 24 and input end 26 are transferred to portions of support frame 18 that connect to a stand or otherwise support drive system 10 on a support surface. In the illustrated example, pump reaction forces are transferred to baseplate 70 via pump frame 58, frame member 72, and connecting member 68, thereby balancing forces across support frame 18. Baseplate 70 reacts the forces, for example, to a stand connected to mount 71, and the forces are thereby transferred away from motor 12. All pump and motor forces are reacted through base plate 70, which may be integrally formed with or directly connected to pump frame 58 and mechanically coupled to motor shaft 23 via frame member 72. This connection balances motor 12, thereby providing longer life, less wear, less downtime, more efficient operation, and cost savings. Bearings 42 further align rotor 22 on pump axis A. Bearings 42 minimize the unsupported span of rotor 22, thereby aligning rotor 22 and preventing undesirable contact between rotor 22 and stator 20. Bearings 42 thereby increase the operating life of motor 12.

[0090] The support frame 18 mechanically supports the electric motor 12 at an output end 24 and at least partially houses the fluid displacement member 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 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 secure the stator 20 relative to the support frame 18. The shaft 23 is secured relative to the support frame 18 such that the stator 20, secured to the shaft 23, does not rotate relative to the support frame 18 or the motor rotation axis A.

[0091] A support member 60 can extend from the pump frame 58 to the shaft 23 around the exterior of the rotor 22 to connect the pump frame 58 to the shaft 23 such that the stator 20 is fixed relative to the support frame 18 via the support member 60. The support member 60 can be removably fastened to the shaft 23. The support member 60 secures the shaft 23 to the pump frame 58 to prevent relative movement between the stator 20 and the support frame 18. Neither the 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 shaft 23 and the stator 20 and separates the shaft 23 and the stator 20 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.

[0092] The support member 60 can 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 can extend circumferentially around the rotor 22 with sufficient radial spacing therefrom to allow the rotor 22 to rotate unimpeded within the support member 60. In the illustrated example, the support frame 18 does not completely surround the rotor 22. It should be understood that not all examples are so defined. In the illustrated example, 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 it and over the rotor 22.

[0093] The support member 60 includes one or more connecting members 68, a base plate 70, and a frame member 72. It should be understood that each connecting member 68 can be formed from a single component or multiple components fixed together. Each connecting member 68 can also be referred to as a connector. The base plate 70 can also be referred to as a connector. The connecting members 68 and base plate 70 extend across and are spaced apart from the cylindrical body 28. The frame member 72 is disposed at the electrical input end 26 and is coupled to the shaft 23. The frame member 72 can also be referred to as a frame end. The frame member 72 extends radially relative to the motor axis A and is mechanically coupled to the connecting members 68 and base plate 70. The connecting members 68 and base plate 70 can extend axially outward from the pump frame 58 in the axial direction AD2. The connecting members 68 and 70 are radially spaced apart from the cylindrical body 28. The connecting members 68 of the support member 60 can extend parallel to the motor axis A or can be angled such that the end of the connecting member 68 at the output end 24 is circumferentially offset about the axis A from the end of the connecting member at the electrical input end 26.

[0094] The frame member 72 of the support member 60 can extend substantially parallel to the second wall 32 of the rotor 22 and can be axially spaced therefrom. The frame member 72 can be disposed substantially parallel to the pump frame 58. The frame member 72 extends from the shaft 23 to a position radially outward of the cylindrical body 28, where it joins the connecting member 68 and the base plate 70. The frame member 72 is fixed to the shaft 23.

[0095] A support member 60 is connected to the pump frame 58 at the output end 24. The support member 60 may be connected to the pump frame 58 at one or more locations radially outward of the cylindrical body 28 or at one or more locations radially inward of the cylindrical body 28 and then extend radially to a radially outward position of the cylindrical body 28. The support member 60 fixes the axial position of the stator 20 relative to the rotor 22 and the pump axis PA and axially secures the components of the electric motor 12 together along the motor axis A. The support member 60 may be a unitary body or may comprise multiple components fastened together and is capable of connecting the stator 20 to the pump frame 58 to maintain the stator 20 in a fixed axial position relative to the rotor 22 and the pump frame 58 on the axis A.

[0096] In a non-limiting embodiment, the connecting 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 beneath the bottom portion of the motor 12. The base plate 70 may have a width that is 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.

[0097] The frame member 72 can include a hub 74. The frame member 72 can be removably coupled to the shaft 23. For example, the frame member 72 can be slidingly engaged with the shaft 23. In some examples, the frame member 72 can be fixed to the shaft 23. For example, the hub 74 of the frame member 72 can be bolted to the shaft 23 or fixed to the shaft 23 with a retaining nut (not shown). The connecting member 68 and the base plate 70 can be fixed to the frame member 72, and the hub 74 can be fixed to the shaft 23.

[0098] In addition to providing mechanical support to the motor 12, the support member 60 can also 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 electric motor 12. More specifically, the frame member 72 is fixed to the shaft and is in direct heat exchange relationship therewith. As discussed in more detail below, the frame member 72 is configured to conduct heat from both the motor 12 and the control panel 13, which are the primary heat-generating components of the drive system 10.

[0099] Both the shaft 23 and the support member 60 can be formed of a thermally conductive material (e.g., metal). The shaft 23 can be placed in direct contact with the support member 60 (e.g., with the frame member 72) to provide a direct thermal path to direct heat away from the motor 12. Figure 4As shown in FIG, the shaft 23 axially overlaps the stator 20 along its entire axial length. The shaft 23 is capable of extracting heat from the stator 20 and conducting it axially outward from the stator 20 toward the electrical input end 26. The shaft 23 transfers heat to the frame member 72 via conduction at locations where the frame member 72 contacts the shaft 23. Thus, a conductive path for transferring heat 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 an axially extending surface and a radially extending end face of the shaft 23. For example, a portion of the frame member 72 (e.g., a lip extending from the hub 74) can extend radially beyond the end of the shaft 23 to increase the surface area in direct contact and transfer heat away from the shaft 23 and away from the electric motor 12. The shape and surface area of the frame member 72 can be selected to promote heat transfer away from the electric motor 12.

[0100] Figure 5 A 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, for example, casting as a unitary component, or can be formed from multiple components that are mechanically fastened 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 can include a drive 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 from the electric 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.

[0101] The pump frame 58 provides mechanical support for the motor 22. The pump frame 58 may extend radially outward from the bearing 52. The bearing 52 may be received in the hub 67. The rotor 22 may be received through an opening in the inner frame body 63a. The outer frame body 63b is positioned radially outward from 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. Ribs 65 may 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 ribs 65 may be used to reduce the weight of the pump frame 58 while providing structural support. In some embodiments, a plurality of ribs 65 may extend between the hub 67 and the outer frame body 63b (in Figure 6). The ribs 65 can support the load from the bearing 52 and can reduce the weight of the pump frame 58. The ribs 65 can be spaced substantially circumferentially around a portion of the hub 67. The ribs 65 can vary in length depending on the shape of the outer frame body 63b or its positioning relative to the bearing 52, the inner frame body 63a, or the intermediate frame body 63c. Figure 5 , the outer frame body 63b can have a different shape than the bearing 52b, which is cylindrical. Thus, the perimeter of the outer frame body 63 is unevenly spaced from the perimeter of the bearing 52 or hub 67, and the ribs 65 connecting the hub 67 to the outer frame body 63b vary in length accordingly. The size and shape of the outer frame body 63b and the number, thickness, and positioning of the ribs 65 can be selected to support the bearing 52 and the electric motor 12 while reducing the weight of the pump frame 58. The protrusion 64a can be a substantially solid triangular protrusion extending from the hub 67. The protrusion 64a can form an attachment point for the member 68 to secure the frame member 72 to the pump frame 58.

[0102] The drive link housing 61 may be positioned in an opening in the inner frame body 63a. Figure 5 As shown in the example, the drive link housing 62 is positioned below the opening (in the axial direction PAD1 ( Figure 4 6 and is a cylindrical body above the pump housing portion 62. The opening of the drive link housing 61 is orthogonal to the opening through the inner frame body 62a. The drive link housing 61 restricts the movement of the drive link 82 to up and down movement along the pump axis PA.

[0103] The pump housing portion 62 of the pump frame 58 at least partially houses the fluid displacement member 16 and supports the positive displacement pump 19. The pump 19 is disposed at the output end 24 on a pump axis PA that is orthogonal to the motor axis A and 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 house the fluid displacement member 16. Figure 5 , the pump housing portion 62 is formed by a U-shaped wall that is open to the front end of the pump frame 58 in an axial direction AD1 away from the motor 12 and in an axial direction PAD2 toward the pump 19. During operation, a portion of the pump 19 is disposed in a chamber of the pump housing portion 62.

[0104] Figure 6 A rear isometric view of one embodiment of the support frame 18 is shown including the assembled pump frame 58 and support member 60. For clarity, the electric motor 12 has been removed from the illustrated view. Figure 6A support frame 18 is shown that includes a pump frame 58 and a support member 60. The support member 60 includes a connecting member 68, a base plate 70, and a frame member 72. The frame member 72 includes a hub 74 that is configured to receive a portion of the shaft 23 such that the shaft 23 is supported by the frame member 72 and the frame member 72 is in contact with the shaft 23. The frame member 72 is positioned to contact the outer surface of the shaft 23. By maintaining contact with the shaft 23, the frame member 72 can draw heat away from the stator 20 via thermal conduction. Both the shaft 23 and the frame member 72 can be formed of a thermally conductive material (e.g., aluminum) that can conduct heat from the interior of the stator 20 to the input end 26 and the frame member 72. As described with respect to Figure 4 As discussed, the shaft 23 axially overlaps the stator 20 along its full axial length and is capable of drawing heat from the stator 20 and conducting the heat axially outward from the stator 20 toward the electrical input end 26. The shaft 23 transfers the heat to the frame member 72 via conduction at locations where the frame member 72 contacts the shaft 23. Thus, a conductive path for transferring heat from the stator 20 extends through the shaft 23 to the frame member 72.

[0105] The hub 74 of the frame member 72 is configured to be in fixed contact with an axially extending surface of the shaft 23. The frame member 72 extends radially from the shaft 23 to transfer heat radially away from the shaft 23 and away from the electric motor 12. The shape and surface area of the frame member 72 can be selected to promote heat transfer away from the electric motor 12. The protrusions 64b on the frame member 72 can extend radially outward from the hub 74 to direct heat radially outward from the shaft 23. The protrusions 64b provide increased surface area relative to the plate 72 to further promote heat transfer and cooling of the electric motor 12. The number, shape, and positional arrangement of the protrusions 64b on the frame member 72 can be selected to provide effective heat transfer away from the stator 20 and away from the control panel 13 via the shaft 23. As Figure 6 As illustrated in the example of , the protrusion 64b can be a substantially open body formed by a plurality of ribs 75 that extend in a converging shape from the hub 74 to the distal end or protrusion 64b. In the example shown, the plurality of ribs 75 form a triangular protrusion that narrows as the protrusion extends radially away from the axis A. The protrusion 64b provides structural rigidity to the support frame 18 and provides surface area for conductive heat transfer from the stator 20 while allowing airflow between the motor 12 and the control panel 13. The protrusions 64b can be arranged in a star-like shape about the hub 74 with a base at the hub 74 extending to a pointed distal end. As shown Figure 6As shown in FIG, the two lower protrusions 64b are connected to the base plate 70 and are each formed of two ribs 75, and the two upper protrusions 64b are connected to the connecting member 68 and are each formed of three ribs.

[0106] The frame member 72 may further include a plurality of concentric support rings 76 formed around the hub 74 and connected to the protrusions 64b. The support rings 76 can provide increased rigidity to the frame member 72 while allowing airflow between the motor 12 and the control panel 13. The support rings 76 also increase the surface area of the frame member 72, thereby improving heat transfer. Openings are formed through the frame member 72, further increasing the surface area and allowing airflow through the frame member 72 to further promote heat transfer. Alternative designs for increasing the surface area of the frame member 72 are contemplated and may be used without departing from the scope of the present invention.

[0107] The frame member 72 can be connected to the shaft 23 in any desired manner that prevents axial displacement and rotation of the frame member 72 relative to the shaft 23 and fixes the axial position of the stator 20 relative to the rotor 22. In some embodiments, the frame member 72 can be a sliding fit onto the outer surface of the shaft 23. The compressive connection between the pump frame 58 and the frame member 72 can secure the shaft 23 and the stator 20 to prevent movement relative to the pump axis A. The connection between the frame member 72 and the pump frame 58 via the members 68 and 70 prevents relative movement of the frame member 72 about the axis A and can clamp the stator 20 and the shaft 23.

[0108] In some examples, the frame member 72 can be fastened to the outer surface of the shaft 23 with one or more fasteners such that the shaft 23 is fixed relative to the frame member 72, which is fixed to the pump frame 58 via the base plate 70 and the member 68. The shaft 23 is thereby fixed relative to the pump axis A. The frame member 72 contacts the shaft 23 along the outer surface of the shaft 23. The frame member 72 can be fixed to the shaft 23 such that contact between the frame member 72 and the shaft 23 is maintained during operation to provide a conductive path for heat transfer from the stator 20 to the frame member 72.

[0109] The axial length of the frame member 72 in the axial direction at the hub 74 can be selected to increase the contact surface area between the frame member 72 and the shaft 23 and thereby increase the heat transfer capability. The frame member 72 can be connected to interface with the shaft 23 in any desired manner. For example, Figure 4 As shown in FIG, the hub 74 can be slidably fitted onto the outer diameter surface of the shaft 23. The opening through the hub 74 can be sized to allow the inner diameter surface of the hub 74 to maintain contact with the shaft 23 to provide a heat conduction path from the shaft 23 to the frame member 72.

[0110] The frame member 72 can support the control panel 13. Figure 2 and Figure 4 As shown in FIG, the control panel 13 can be mounted to the rear side of the frame member 72 opposite the motor 12. The control panel 13 can be fastened to the mounting posts 73 of the frame member 72 via bolts or other retaining mechanisms known in the art. Conductive material on the control panel 13 can interface with the frame member 72 via the mounting posts 73 to provide a heat conduction path from the control panel 13 to the frame member 72. In this way, the frame member 72 can absorb heat from both the motor 12 and the control panel 13 and transfer the heat to the environment. In the example shown, the control panel 13 is mounted to the frame member 72 at the mounting posts 73. The mounting posts 73 separate the control panel 13 from the frame member 72 along the axis A. A cooling air plenum is thereby formed between the frame member 72 and the control panel 13 to promote airflow therebetween. The mounting posts 73 and a portion of the control panel 13 and / or the fasteners connecting the control panel 13 to the frame member 72 can be formed of a thermally conductive material. As a result, a direct heat path is formed between the control panel 13 and the frame member 72. The control panel 13 is mounted such that it cantilevered from the heat sink formed by the frame member 72. In other embodiments, the control panel 13 may be mounted on a side of the motor 12 disposed axially along the axis A between the pump frame 58 and the frame member 72.

[0111] The frame member 72 is axially disposed between the motor 12 and the control panel 13, which are the primary heat-generating components of the drive system 10. The frame member 72 conducts heat away from components disposed on both axial sides of the frame member 72. The frame member 72 is configured to provide a large surface area and extends radially away from the axis A to facilitate heat transfer. Both the motor 12 and the control panel 13 can have a direct thermal path to the frame member 72 (e.g., through direct metal-to-metal contact). Thus, the frame member 72 structurally supports both the motor 12 and the control panel 13 and provides heat dissipation for the motor 12 and the control panel 13.

[0112] The pump frame 58 and the frame member 72 can each include at least two protrusions 64a, 64b, respectively. The protrusions 64a, 64b can extend radially outward from the axis A, such that the distal end of each protrusion member 64a, 64b is disposed radially outward from the rotor 22. A connecting member 68 can be fastened to the distal ends of the protrusions 64a, 64b. The base plate 70 can be fastened to the distal ends of the protrusions 64b disposed on the bottom side of the frame member 72. The connecting member 68 can be fastened to the distal ends of the protrusions 64a, 64b disposed on the top side of the motor 12 to connect the pump frame 58 to the frame member 72 across the top outer surface of the rotor 22. The base plate 70 can be fastened to the distal end of the lower protrusion 64b to connect the pump frame 58 to the frame member 72 across the bottom outer surface of the rotor 22. The protrusions 64a and 64b can be shaped to provide structural integrity to the support frame 18 during operation while limiting the amount of weight added to the drive system 10. Figure 6 As illustrated in the example in FIG, the protrusion 64a is a substantially solid triangular body having ribs 65 that are provided to increase rigidity while reducing weight.

[0113] The projections 64a, 64b on each of the pump frame 58 and the frame member 72 may be arranged symmetrically or asymmetrically with respect to one another and at equal or unequal intervals. Figure 2 、 Figure 3 and Figure 5 As shown in FIG. 5 , the pump frame 58 may have two protrusions 64 a that align with the protrusions 64 b ( FIG. 5 ) on the frame member 72 . Figure 6 The frame member 72 may have four protrusions 64b arranged in an X configuration that is unequally spaced about the axis A.

[0114] Connecting member 68 and base plate 70 connect pump frame 58 to frame member 72. Connecting member 68 and base plate 70 are rigid and capable of maintaining a fixed relationship between pump frame 58 and frame member 72 during operation of drive system 10. Furthermore, connecting member 68 and base plate 70 are configured to support torque loads generated by electric motor 12 and transmitted through pump frame 58 and frame member 72, and further support pump reaction loads generated by the reciprocating motion of fluid displacement member 16 and also transmitted through pump frame 58 and frame member 72. Connecting member 68 may be a tie rod that may be fastened to protrusions 64a and 64b by bolts or other retaining mechanisms, among other options. Base plate 70 may be a plate or bracket designed to provide additional structural rigidity to support frame 18.

[0115] The base plate 70 can be configured to be mounted to a cart or stationary assembly for ease of handling and transport. The base plate 70 can include a plurality of mounting posts 71 or bosses configured to receive fasteners to secure the drive system 10 to the cart or stationary assembly. In other embodiments, the pump frame 58 and / or the base plate 70 can be configured to be mounted to a cart or stationary assembly for ease of handling and transport. In some embodiments, the pump frame 58 can include attachment features 66 for securing a handle to facilitate carrying the drive system 10.

[0116] As further described herein, the support member 60 is not limited to the illustrated embodiment and may include any single component or combination of components capable of securing the stator 20 relative to the pump frame 58 and relative to the pump axis A. The support member 60 may fully or partially surround the rotor 22, such as Figure 2 , or may be arranged to span a single side of the rotor 22 extending from the output end 24 to the electrical input end 26, as shown in FIG. Figure 12 . In some embodiments, the support member 60 may include a second frame member. The second radially extending member may be disposed between the pump frame 58 and the first wall 30 of the rotor 22. The second frame member may be fixed to the pump frame 58 and axially spaced from the first wall 30 to allow the rotor 22 to rotate unimpeded. The support member 60 may include a single connecting member 68 and / or base plate 70 or a plurality of connecting members 68 and / or base plates 70 or any desired combination thereof, as described in further detail below. The size, shape, number and position of the connecting members 68 and base plates 70 may be selected to reduce weight while providing structural integrity to the drive system 10. Similarly, the size, shape and number of the frame members 72 may be selected to reduce weight while providing structural integrity to the drive system 10.

[0117] The rotor 22 can extend through the pump frame 58 and extend axially outward from the bearing 52 in the axial direction AD1. In the illustrated example, the drive mechanism 14 is directly connected to the rotor 22 at the output end 24 at a position axially outboard of the bearing 52 in the axial direction AD1. The drive mechanism 14 is configured to receive the rotational output from the rotor 22 and convert the rotational output into a linear reciprocating input to the fluid displacement member 16. In the illustrated example, the drive system 10 does not include an intermediate gear between the motor 12 and the drive mechanism 14. However, it should be understood that some examples of the drive system 10 include an intermediate gear between the motor 12 and the drive mechanism 14. In such examples, the rotational axis of the eccentric 78 can be radially offset from the rotational axis of the rotor 22.

[0118] Drive mechanism 14 includes an eccentric drive 78, a drive member 80, and a drive connecting rod 82. Eccentric drive 78 is disposed on rotor 22 of electric motor 12 and rotates with rotor 22. Eccentric drive 78 is radially offset from rotational axis A. Thus, rotation of rotor 22 causes eccentric drive 78 to move in a circular path about rotational axis A. Eccentric drive 78 provides power for drive mechanism 14 and may be referred to as an eccentric crankshaft. Drive member 80 is mechanically coupled to eccentric drive 78 and is configured to drive the reciprocating motion of fluid displacement member 16. Eccentric drive 78 is directly coupled to drive member 80 without an intermediate gear. This direct connection between rotor 22 and fluid displacement member 16 provides a 1:1 ratio of rotor rotation to pump cycle. Thus, for each rotation of rotor 22 about axis A, fluid displacement member 16 undergoes a complete pump cycle, including both an upstroke and a downstroke.

[0119] The eccentric driver 78 protrudes axially outward from the output end 24 of the rotor 22 and is radially offset from the rotation axis A. More specifically, the eccentric driver 78 protrudes in the axial direction AD1 from the cylindrical protrusion 41 of the rotor 22. In some embodiments, the eccentric driver 78 can be formed integrally with the cylindrical protrusion 41. In alternative embodiments, the eccentric driver 78 can be formed from one or more components and assembled with the rotor 22. Figures 2 to 4 and Figure 7 As shown in FIG, the eccentric drive crankshaft 78 can be a cylindrical body that extends into a bore 79 in the rotor 22. In some examples, the bore 79 can extend through the cylindrical protrusion 41 and into the cylindrical protrusion 40. In such an example, the bore 79 can axially overlap both the bearing 52 and the bearing 42. The bore 79 is offset from the axis of rotation of the rotational input of the eccentric drive 78 (e.g., axis A in the direct drive arrangement shown) and therefore has a center that is offset from the center of the cylindrical protrusion 41. As shown in FIG. Figure 7 , the hole 79 can be located adjacent to the outer diameter of the cylindrical protrusion 41. The hole 79 can be located substantially between the center of the cylindrical protrusion 41 and the outer diameter of the cylindrical protrusion 41. The hole 79 can be configured to receive at least a portion of the eccentric driver 78 with a sliding fit. The cylindrical protrusions 40 and 41 can be configured to support the eccentric driver 78 when the pump reaction force is applied to the eccentric driver 78 via the drive member 80.

[0120] The cylindrical protrusion 41 may include a boss 88. The boss 88 may define an opening of the hole 79, may be used to position the eccentric driver 78, and may support the eccentric driver 78 when a reciprocating load is applied to the eccentric driver 78 via the drive member 80. The boss 88 protrudes axially outward from the cylindrical protrusion 41 toward the drive member 80 in a first axial direction AD1. The boss 88 may be a cylindrical protrusion extending from the cylindrical protrusion 41. The boss 88 supports the eccentric driver 78 by reducing the length of the eccentric driver 78 extending in a cantilevered manner from the rotor 22. The boss 88 may have a smaller outer diameter than the cylindrical protrusion 41. A centerline passing through the boss 88 is radially offset from the axis A.

[0121] In some embodiments, the cylindrical protrusion 41 can have a substantially hollow body with a cavity defined by a plurality of ribs 87. The ribs 87 can extend radially outward from the eccentric driver 78 to the outer cylindrical wall of the cylindrical protrusion 41. More specifically, the ribs 87 can extend radially outward from the aperture 79 and the boss 88. The ribs 87 can be configured to support the loads of the bearing 52 and the eccentric driver 78. Additionally, the use of the ribs 87 can reduce the weight of the rotor 22, particularly at the output end 24, where the rotor 22 is coupled to the support frame 18. The ribs 87 can be spaced circumferentially around the eccentric driver 78. The ribs 87 can extend around a portion of the eccentric driver 78 that is less than the entire circumference of the eccentric driver 78. Depending on the location of the ribs 87, the radial length of the ribs 87 between the eccentric driver 78 and the wall of the cylindrical protrusion 41 can vary. The ribs 87 extending from a location surrounding the eccentric driver 78 near the center of the cylindrical protrusion 41 can be longer than the ribs 87 extending from a location surrounding the eccentric driver 78 closer to the outer wall of the cylindrical protrusion 41. The eccentric driver 78 protrudes further in the axial direction AD1 than the cylindrical protrusion 41. As such, the eccentric driver 78 can represent the axially forward-most portion of the rotor 22. In some examples, the crankshaft 78 at least partially axially overlaps the support frame 18.

[0122] The eccentric drive 78 may include a sleeve 83 and a bolt 84 ( Figure 4 、 Figure 4A and Figure 7 ). Sleeve 83 can be received in bore 79 by means of a press fit or a transitional sliding fit. Bolt 84 can be slidably received in sleeve 83. Bolt 84 can be threadedly fastened to bore 79 at the axial inner end of bore 79. The axial inner end of bore 79 can be positioned in cylindrical protrusion 40. Bore 79 can have multiple inner diameters. In the example shown, bore 79 includes two inner diameters D1, D2 (in Figure 4A83 and a bolt 84 having a smaller diameter. The inner diameter D1 may be larger than the inner diameter D2 to accommodate the sleeve 83. The inner diameter D2 may be smaller than the inner diameter D1 to accommodate the bolt 84. A portion of the hole 79 having the inner diameter D1 may extend from the boss 88 in the axial direction AD2 by a first axial length L1. A portion of the hole 79 having the inner diameter D2 may extend from the end of L1 to a second axial length L2 in the axial direction AD2. The portion of the hole 79 having the inner diameter D1 may have a substantially smooth surface to provide a sliding fit with the sleeve 83. The portion of the hole 79 having the inner diameter D2 may be threaded to secure the bolt 84. The bolt 84 may retain the sleeve 83 in the rotor 22. The bolt 84 may extend into the cylindrical protrusion 40 and may be radially positioned within the stator 20. The bolt 84 is disposed in the rotor 22, which holds the permanent magnet array 34. The bolt 84 may be formed from a non-ferrous material to prevent interference with the electric motor 12.

[0123] The eccentric driver 78 extends from the rotor 22 in the axial direction AD1 and is offset from the rotation axis A. A drive member 80 may be rotatably coupled to the crankshaft 78. The drive member 80 may be a connecting rod. The drive member includes a follower 86 at a first end configured to receive a sleeve 83 of the eccentric driver 78. The follower 86 may include a bearing member 89 disposed between the follower 86 and the sleeve 83 to allow the drive member 80 to move in a rocking motion about the eccentric driver 78 as the eccentric driver 78 moves with the rotor 22. The drive member 80 may be coupled to the fluid displacement member 16 via a drive connecting rod 82. The drive connecting rod 82 may be a cylindrical shaft and may include a connecting slot 90 at a first end configured to receive a second end of the drive member 80 opposite the follower 86. Pin 92 can extend through the connecting slot 90 and the hole in the second end of the drive member 80 in a manner that allows the drive member 80 to pivot about the pin 92 within the drive connecting rod 82 and allows the drive member 80 to follow the eccentric driver 78. The drive member 80 converts the rotational motion of the crankshaft 78 into reciprocating motion of the drive connecting rod 82, which drives the fluid displacement member 16 in a reciprocating manner. The drive member 80 can be axially spaced from the boss 88 so that the boss 88 does not interface with or interfere with the movement of the drive member 80 relative to the eccentric driver 78.

[0124] Fluid displacement member 16 is mechanically coupled to drive mechanism 14 at output end 24. Connector 93 of fluid displacement member 16 can be secured to drive link 82 at a second end opposite the first end through which pin 92 extends. Fluid displacement member 16 can be connected to drive link 63 in any desired manner (e.g., via a slotted connection similar to that shown or a pinned connection, among other options). Fluid displacement member 16 can be a piston that moves fluid into and out of pump cylinder 94 as rotor 22 drives fluid displacement member 16 downward through a downstroke and pulls fluid displacement member 16 upward through an upstroke via drive mechanism 14. In some examples, fluid displacement member 16 can be a piston for a dual-displacement pump, such that pump 19 outputs fluid when rotor 22 drives fluid displacement member 16 downward through a downstroke and pulls fluid displacement member 16 upward through an upstroke via drive mechanism 14. Fluid displacement member 16 can be cylindrical, elongated along pump axis PA, and coaxial with pump axis PA. The fluid displacement member 16 may be a piston that may be elongated along and coaxial with the pump axis PA.

[0125] Pump 19 may include a cylinder 94 and check valves 95 and 96. Pump 19 is statically connected to support frame 18 via cylinder 94 and dynamically connected to electric motor 12 via a connection between fluid displacement member 16 and drive mechanism 14. More specifically, pump 19 is statically connected to support frame 18 via clamp 25. Check valve 95 is a one-way valve disposed in cylinder 94. Check valve 96 is a one-way valve disposed in fluid displacement member 16 to reciprocate therewith. Pump 19 is disposed on pump axis PA, which is orthogonal to motor axis A. Pump 19 is a dual-displacement pump, such that pump 19 outputs fluid during both an upward stroke of fluid displacement member 16 in axial direction PAD2 and a downward stroke of fluid displacement member 16 in axial direction PAD1. Pump 19 may include dual dynamic seals between cylinder 94 and fluid displacement member 16. In the example shown, the first dynamic seal is mounted to and travels with the fluid displacement member 16, while the second dynamic seal remains stationary relative to the cylinder 94 and the pump axis PA. Thus, the first dynamic seal reciprocates relative to the cylinder 94 and the pump axis PA, while the fluid displacement member 16 reciprocates relative to the second dynamic seal. In some examples, the first dynamic seal can be mounted to the cylinder 94 so as to remain stationary while the fluid displacement member 16 reciprocates. The piston forming the fluid displacement member 16 can extend out of the cylinder 94 through the second dynamic seal.

[0126] During operation of the drive system 10, power is supplied to the electric motor 12, causing the rotor 22 to rotate about the rotation axis A and causing the eccentric drive 78 to move along with the rotor 22. The eccentric drive 78 moves along a circular path radially offset from the rotation axis A. With each revolution of the rotor 22, the eccentric drive 78 completes a single circular path. The follower 86, which receives the eccentric drive 78, moves along with the eccentric drive 78. Thus, with each revolution of the rotor 22, the follower 86 also completes a complete circular path. As the follower 86 moves along the circular path, the follower 86 changes position relative to the rotation axis A. With each revolution of the rotor 22, the eccentric drive 78 pulls the drive member 80 along the circular path via the follower 86. The end of the drive member 80 opposite the follower 86 is secured to the drive link 82 via a pin 92. The drive link 82 is fixed to the support frame 18. As the eccentric driver 78 moves upward from the bottom dead center position through an upward arc to the top dead center position, the eccentric driver 78 pulls the drive member 80 away from the drive link 82, causing the drive link 82 to be pulled in a linear upward direction toward the rotational axis A of the electric motor 12. As the eccentric driver 78 moves from the top dead center position through a downward arc to the bottom dead center position, the eccentric driver 78 pushes the drive member 80 toward the drive link 82, causing the drive link 82 to be forced in a linear downward direction away from the rotational axis A. With each revolution of the rotor 22, the drive link 82 is forced both upward and downward. In this way, the drive mechanism 14 converts each revolution of the rotor 22 into linear up-and-down motion of the fluid displacement member 16. The drive link 82 is coupled to the fluid displacement member 16 and, therefore, pulls the fluid displacement member 16 through the upward stroke and pushes the fluid displacement member 16 through the downward stroke. Thus, for each revolution of the rotor 22, the pump 19 performs a complete pumping cycle, including both the upstroke and the downstroke.

[0127] During operation, the pump reaction force generated by fluid displacement member 16 during pumping is transmitted to support frame 18 and away from motor 12 via drive mechanism 14, rotor 22, bearings 52, bearings 48, shaft 23, pump frame 58, and support member 60. When moving through an upstroke, fluid displacement member 16 receives a downward reaction force, and when moving through a downstroke, receives an upward reaction force. Both the upward and downward reaction forces travel through drive mechanism 14, rotor 22, and then to bearings 52, 48, 42. Bearings 52, 48, 42 transmit the rotational force associated with the rotation of rotor 22, as well as both the upward and downward reaction forces, to support frame 18. With each stroke, a pump reaction force is generated, and a load is applied to rotor 22 via drive mechanism 14. The pump reaction force is typically an axial load along pump axis PA.

[0128] This axial pump reaction load is transverse to the axis of rotation A of the electric motor 12 and is experienced at both the output end 24 and the input end 26 of the electric motor 12. The load is transferred to the pump frame 58 via the bearing 52 and to the support member 60 via the bearing 48 so that the pump reaction force on the bearing 42 is minimized, thereby maintaining the correct air gap. At the output end 24, the load is transferred from the rotor 22 to the pump frame 58 through the bearing 52. At the electrical input end 26, the load is transferred from the rotor 22 to the frame member 72 through the bearing 48 and the shaft 23. Force is transferred from the pump frame 58 and the frame member 72 to the base plate 70. Force can be transferred from the base plate 70 to a bracket or other structure coupled to the base plate 70. The bearings 52 and 48 experience opposing reaction forces with each pump stroke to provide a force balance across the rotor 22, thereby maintaining the air gap and preventing undesirable contact between the rotor 22 and the stator 20. In examples where pump frame 58 is directly connected to a bracket or other support, forces are transferred to frame member 58 via support member 60 and then to the bracket or other support. Forces may be transferred from frame member 72 to frame member 58 via member 68 and base plate 70.

[0129] like Figure 4 As shown in FIG, a drive system 10 can be used to deliver fluids such as paint and other spray fluids to a spray device. The fluid can be drawn from a supply container 97 via a hose 98 and a pump 19 and delivered via a hose 4 to a spray device 5 (e.g., a handheld spray gun) for application. An operator can grasp the handle of the device 5 and initiate spraying by actuating the trigger 9 of the device 5.

[0130] The direct-drive configuration of drive system 10 eliminates intermediate gearing (e.g., reduction gearing) between electric motor 12 and fluid displacement member 16. Eliminating the intermediate gearing provides a more compact, lightweight, reliable, and simpler pump by reducing the number of parts and moving parts. Due to the 1:1 ratio of rotor rotation to pump cycle, the direct-drive configuration provides more efficient pumping. Additionally, eliminating the gearing provides quieter pump operation.

[0131] The outer rotor drive system 10 can offer significant advantages over inner rotor motors. The rotor 22, an outer rotor at least partially radially disposed outside the stator 20, provides increased inertia and torque relative to the inner rotor motor. The increased torque encourages the rotor 22 to generate sufficiently high pumping pressure with the positive displacement pump 19 to produce an atomized spray at an applicator (e.g., a spraying device 5). For example, the drive system 10 can be used to pump paint or other fluids to an airless spray gun, where the fluid pressure generates an atomized spray. In some examples, the rotor 22 can cause the pump 19 to generate a pumping pressure of approximately 3.4 to 69 megapascals (MPa) (approximately 500 to 10,000 pounds per square inch (psi)) or even higher. In some examples, the pumping pressure ranges from approximately 20.7 to 34.5 MPa (approximately 3,000-5,000 psi). High fluid pumping pressures are useful for atomizing a fluid into a spray for application to a surface.

[0132] Figure 8 is an isometric front-side view of the drive system 110 and the positive displacement pump 19 . Figure 9 It is along Figure 8 An isometric cross-sectional view of the drive system 110 and the positive displacement pump 19 taken along line 9-9. FIG. 10A to FIG. 10C is used for Figure 8 Isometric rear side view of the drive system 110 and alternative support frames 118a to 118c for the displacement pump 19. Figure 8 、 Figure 9 and FIG. 10A to FIG. 10C The drive system 110 is, for example, the drive system 10 (in Figures 2 to 4 10.

[0133] The drive system 110 is configured to Figures 2 to 4 The pump 19 and the fluid displacement member 16 operate together. Figure 8 and Figure 9 Drive system 110 , electric motor 112 , drive mechanism 114 , fluid displacement member 16 , support frame 118a , and positive displacement pump 19 are shown. Figure 10A The drive system 110 is shown having a support frame 118a. Figure 10B The drive system 110 is shown having a support frame 118b. Figure 10C The drive system 110 is shown having a support frame 118c.

[0134] Drive mechanism 114 and electric motor 112 are substantially similar to drive mechanism 14 and electric motor 12 of drive system 10. Electric motor 112 can be a reversible motor in that stator 120 can cause rotor 122 to rotate in either of two rotational directions (e.g., clockwise or counterclockwise) about motor axis A. Support frames 118 a to 118 c are similar to support frame 18 but do not include axially extending base plate 70 of drive system 10.

[0135] As described with respect to electric motor 12, electric motor 112 includes a stator 120, a rotor 122, and a shaft 123. Electric motor 112 is disposed on axis A and extends from a first end (output end) 124 to an opposite second end (electrical input end) 126. Rotor 122 may be a housing having a cylindrical body 128, a first wall 130, and a second wall 132. Rotor 122 includes a permanent magnet array 134 disposed on an inner circumference 135. A bearing 148 having an outer race 149, an inner race 150, and rolling elements 151 rotatably couples rotor 122 to stator 120 at electrical input end 126 of electric motor 112. A bearing 142 including an inner race 143, an outer race 144, and rolling elements 145 rotatably couples rotor 122 to stator 120 at shaft end 146. A bearing 152, including an outer race 153, an inner race 154, and rolling elements 155, rotatably couples the rotor 122 to the support frame 118A at the output end 124. The bearings 142, 148, and 152 can be preloaded by the support frame 118A between the output end 124 and the input end 126. A wave spring washer 156 can be disposed between the support frame 118A and the bearing 152 at the output end 124. A wave spring washer 157 can be disposed between the support frame 118A and the bearing 148 at the input end 126. The bearing configurations of the drive system 110 can be substantially the same as those disclosed with respect to the drive system 10, including the bearing configurations shown and disclosed as alternatives.

[0136] The rotor 122 may be substantially similar to the rotor 22, but may have some structural differences as described below. These structural differences are non-limiting. The rotor 122 may be formed from a housing having a cylindrical body 128, a first wall 130, and a second wall 132. The cylindrical body 128 and the second wall 132 may be substantially the same as the cylindrical body 28 and the wall 32 of the rotor 22. Figure 9As shown in FIG, the first wall 130 can be disposed substantially perpendicular to the motor axis A and can have a substantially uniform axial thickness as the wall 130 extends in the radial direction. The first wall 130 thus lacks the thickened area present in the corresponding first wall 30 of the rotor 22. The rotor 122 includes cylindrical protrusions 140 and 141 for supporting the bearings 52 and 42, respectively. The cylindrical protrusions 140 and 141 are substantially similar to the corresponding cylindrical protrusions 40 and 41 on the rotor 22.

[0137] The electric motor 112 can be cantilevered from the support frames 118a-118c, such that the electrical input end 126, located opposite the output end 124, is the free end of the cantilevered electric motor 112. The support frames 118a-118c extend from the bearing 152 at the output end 124 to the shaft 123 at the electrical input end 126. The support frames 118a-118c extend around the outer surface of the rotor 122 and are spaced apart therefrom to allow the rotor 122 to rotate unimpeded within the support frames 118a-118c. The support frames 118a-118c do not completely enclose the rotor 122, and no parts exist between the support frames 118a-118c and the exterior of the rotor 122. Therefore, the support frames 118a-118c allow airflow through them and over the rotor 122. The support frames 118a-118c are connected to the shaft 123 to secure the stator 120 in an axial position relative to the rotor 122. The support frames 118a to 118c can be removably secured to the shaft 123. The support frames 118a to 118c secure the shaft 123 to prevent relative movement between the stator 120 and the support frames 118a to 118c. Neither the shaft 123 nor the stator 120 is secured to the support frames 118a to 118c at the output end 124. Instead, a portion of the rotor 122 is axially disposed between the shaft 123 and the stator 120 at the output end 124, separating the shaft 123 and the stator 120 from the support frames 118a to 118c.

[0138] As described with respect to support frame 18 of drive system 10, support frames 118a through 118c are dynamically connected to rotor 122 and statically connected to stator 120 through bearing interfaces. Support frames 118a through 118c are statically connected to pump 19. Electric motor 112 is dynamically connected to support frames 118a through 118c via rotor 122 and statically connected to support frames 118a through 118c via stator 120. Electric motor 112 is dynamically connected to pump 19 via fluid displacement member 16. Pump 19 is statically connected to support frames 118a through 118c and dynamically connected to electric motor 112.

[0139] Each of support frames 118a through 118c includes a pump frame 158. Support frame 118a includes a support member 160a. Support frame 118b includes a support member 160b. Support frame 118c includes a support member 160c. Each of support members 160a through 160c includes a plurality of connecting members 168. Support member 160a includes a frame member 172a. Support member 160b includes a frame member 172b. Support member 160c includes a frame member 172c.

[0140] As disclosed with respect to drive system 10, pump frame 158 can be disposed at output end 124 in a first plane normal to motor axis A. Frame members 172a through 172c can be disposed at input end 126 in a second plane normal to motor axis A. The first and second planes are spaced apart along axis A and do not intersect. Pump frame 158 is separated from frame members 172a through 172c by stator 120, such that pump frame 158 is disposed on one end of stator 120 and frame members 172a through 172c are disposed on an axially opposite end of stator 120. A portion of rotor 122 is disposed between pump frame 158 and frame members 172a through 172c. A portion of rotor 122 extends through pump frame 158 in axial direction AD1. A plurality of connecting members 168 can extend across the outer surface of rotor 122 and be radially spaced therefrom to connect pump frame 158 to frame members 172a through 172c. The connecting members 168 are radially spaced from the outer surface of the rotor 122 to allow the rotor 122 to rotate within the support frames 118a to 118c. It should be understood that the support frames 118a to 118c may include any desired number of connecting members 168 (e.g., two, three, four, or more connecting members 168 as desired) between the first pump frame 158 and the frame members 172a to 172c to support the motor 112 and the pump 19, and are not limited to FIG. 10A to FIG. 10C The embodiment shown in FIG.

[0141] Pump frame 158 is substantially similar to pump frame 58 of drive system 10, having a pump housing portion 162, an outer frame body 163, projections 164a, support ribs 165, and a hub 167. Bearing 152 is received in hub 167 of pump frame 158, and pump frame 158 extends radially outward from bearing 152. A plurality of ribs 165 may extend between bearing 152 and outer frame body 163 to support loads from bearing 152 while reducing the weight of pump frame 158. Ribs 165 may be spaced circumferentially around hub 167 and may vary in length depending on the shape of outer frame body 163. Pump frame 158 is axially spaced from wall 130 of rotor 122 and radially separated from the portion of rotor 122 extending through pump frame 158 by bearing 152.

[0142] Frame members 172a to 172c are substantially similar to frame member 72 of drive system 10. Each frame member 172a to 172c includes a hub 174, a protrusion 164b, and a rib 175. An opening through hub 174 can receive a portion of shaft 123, so that frame members 172a to 172c are in direct contact with shaft 123. Frame members 172a to 172c are disposed at the free electrical input end 126 of motor 112, which extends in a cantilevered manner. Frame members 172a to 172c are disposed in contact with the outer surface of shaft 123. By maintaining contact with shaft 123, frame members 172a to 172c can draw heat away from stator 120 via thermal conduction. Both the shaft 123 and the support frames 118 a to 118 c can be formed from a thermally conductive material (e.g., aluminum) capable of conducting heat from within the stator 120 to the electrical input end 126 and the frame members 172 a to 172 c. The shaft 123 axially overlaps the stator 120 along its entire axial length. The shaft 123 can draw heat from the stator 120 and conduct it axially outward toward the electrical input end 126 and away from the stator 120. The shaft 123 transfers heat to the frame members 172 a to 172 c via conduction at locations where the frame members 172 a to 172 c contact the shaft 123. Thus, a conductive path for transferring heat from the stator 120 extends through the shaft 123 to the frame members 172 a to 172 c. The frame members 172 a to 172 c can be in fixed contact with the axially extending surface and radially extending end faces of the shaft 123. Frame members 172a-172c can extend radially from shaft 123 to transfer heat radially away from shaft 123 and away from electric motor 112. Because frame members 172a-172c extend radially outward relative to axis A, a thermally conductive path can extend radially outward from stator 20 and, in some examples, from motor 12. The shape and surface area of frame members 172a-172c can be selected to facilitate heat transfer away from electric motor 112.

[0143] The frame members 172a-172c can be secured to the shaft 123 in any desired manner that prevents axial displacement and rotation of the frame members 172a-172c relative to the shaft 123 and fixes the axial position of the stator 120 relative to the rotor 122. In some embodiments, the frame members 172a-172c can be slip-fit onto the outer surface of the shaft 123 and secured to the outer surface of the shaft 123 with one or more fasteners 177 such that the frame members 172a-172c are fixed relative to the shaft 123 and in contact with the shaft 123 along the outer surface of the shaft 123. The frame members 172a-172c can be secured to the shaft 123 such that contact between the frame members 172a-172c and the shaft 123 is maintained during operation to provide a conductive path for heat transfer from the stator 120 to the frame members 172a-172c. The thickness of the frame members 172a to 172c at the hub portion 174 in the axial direction along the axis A can be increased to increase the contact surface area between the frame members 172a to 172c and the shaft 123, thereby increasing heat transfer capacity. The fasteners 177 can be bolts, rivets, screws, or other fastening mechanisms known in the art. The fasteners 177 can secure the frame members 172a to 172c to the axial end of the shaft 123 opposite the end 146. The fasteners 177 can extend axially and can be disposed so as to pass through the end faces of the frame members 172a to 172c in the axial direction AD1 and into the shaft 123. The fasteners 177 can secure the frame members 172a to 172c to a retaining member disposed on the radially inner surface of the shaft 123. In some examples, the fasteners 177 can be formed of a thermally conductive material to facilitate heat transfer from the shaft 123 to the frame members 172a to 172c.

[0144] In some embodiments, the frame members 172a to 172c can have a lip member 176 extending radially inward from the hub 174. The lip member 176 can abut and maintain contact with the end surface of the shaft 123. The lip member 176 can set and maintain the axial position of the frame members 172a to 172c relative to the bearing 148. A fastener 177 can extend through the lip member 176. The lip member 176 further increases the contact area between the shaft 123 and the frame members 172a to 172c to further promote heat transfer.

[0145] The pump frame 158 and frame members 172a to 172c have protrusions 164a and 164b, respectively. The protrusions 164a, 164b can extend radially outward from the motor axis A so that the distal end of each protruding member 164a, 164b is disposed radially outward from the rotor 122. The protrusions 164a, 164b can be shaped to provide structural integrity to the support frames 118a to 118c while limiting the amount of weight added to the drive system 110. The protruding members 164b, which can be referred to as arms, on the frame members 172a to 172c can direct heat radially outward from the shaft 123. The protrusions 164b provide increased surface area relative to the plate to further promote heat transfer and cooling of the motor 112. The protrusions 164a, 164b are rigid. The protrusions 164a, 164b can be solid or can have openings that allow airflow therethrough and serve to further increase the surface area for heat transfer. As FIG. 10A to FIG. 10C As shown in , the protrusions 164a, 164b can be ribbed or have ridges and grooves, which can increase the surface area for heat transfer and reduce weight while providing structural integrity. The hub 174 can be similarly formed with circumferentially spaced ridges and grooves to increase the surface area for heat transfer. The number, shape, and positional arrangement of the protrusions 164b on the frame members 172a to 172c can be selected to provide effective heat transfer away from the stator 120 and away from the electric motor 112 via the shaft 123. FIG. 10A to FIG. 10C Some of the contemplated arrangements for the protrusions 164a are illustrated in FIG.

[0146] The projections 164a, 164b on the pump frame 158 and each of the frame members 172a to 172c may be arranged symmetrically or asymmetrically relative to each other and about the axis A and at equal or unequal intervals. Figure 10A As shown in FIG, the pump frame 158 and frame member 172a can have three axially aligned protrusions 164a, 164b arranged in a Y configuration. Other configurations of the protrusions 164a, 164b can also provide sufficient structural support and heat transfer capabilities. Figure 10B As shown in FIG, the pump frame 158 and frame member 172b can have three axially aligned protrusions 164b, 164a that are asymmetrically arranged in a T-shaped configuration about the motor axis A and, in the example shown, are primarily located on the lower portion of the electric motor 112. Figure 10C, the pump frame 158 and frame member 172c may have four axially aligned protrusions 164b, 164a arranged in an X-shaped configuration, which provides increased surface area for efficient heat transfer away from the motor 112. In an alternative embodiment, the protrusions 164b on the pump frame 158 may be offset from the protrusions 164a on the frame members 172a-172c such that the connecting member 168 is angled relative to the axis A between the pump frame 158 and the frame members 172a-172c.

[0147] In some embodiments, as FIG. 10A to FIG. 10C As shown in , additional protrusions 164a may be provided on the pump frame 158 to accommodate alternative frame members 172a to 172c and connecting members, and to facilitate connecting other components (eg, a handle or control panel) thereto.

[0148] Connecting member 168 secures pump frame 158 to frame members 172a through 172c. Connecting member 168 is rigid and capable of maintaining a fixed relationship between pump frame 158 and frame members 172a through 172c during operation of drive system 110. Additionally, connecting member 168 is configured to support torque loads generated by electric motor 112 and transmitted through pump frame 158 to frame members 172a through 172c, and further support pump reaction loads generated by the reciprocating motion of fluid displacement member 16 and transmitted through motor 12 and further transmitted through pump frame 158.

[0149] Connecting member 168 can be a tie rod that can be received at the distal ends of protrusions 164a, 164b. Connecting member 168 can be fastened to the distal ends using threaded fasteners (e.g., screws or bolts). Alternative fastening mechanisms known in the art can be used to secure connecting member 168 to pump frame 158 and to each of frame members 172a through 172c. In some embodiments, at least one connecting member 168 can be configured as a handle to facilitate carrying drive system 110.

[0150] In some embodiments, a single connecting member can connect multiple protrusions 164a on pump frame 158 with multiple protrusions 164b of frame members 172a through 172c, as provided by base plate 70 in drive system 10. In some embodiments, protrusions 164a, 164b can support control panel 13 (not shown). As provided in drive system 10, control panel 13 can be mounted to frame members 172a through 172c. In other embodiments, control panel 13 can be mounted between protrusions 164a, 164b, for example, at a location where control panel 13 axially overlaps motor 12.

[0151] During operation of pump 19, the pump reaction force generated by fluid displacement member 16 during pumping is transmitted to pump frame 158 via drive mechanism 114, rotor 122, bearing 152, bearing 148, shaft 123, and support member 160. Fluid displacement member 16 experiences a downward reaction force when moving through an upstroke, and an upward reaction force when moving through a downstroke. Both the upward and downward reaction forces travel through drive mechanism 114, rotor 122, and then to bearings 152, 148, 142. Bearings 152, 148, 142 transmit both the rotational force associated with the rotation of rotor 122, as well as the upward and downward reaction forces, to pump frame 158. With each stroke, a pump reaction force is generated and a load is applied to rotor 122 as rotor 122 directly drives fluid displacement member 16 via drive mechanism 114. The pump reaction force is typically an axial load along pump axis PA. The pump reaction force transmitted to the rotor 122 by the drive mechanism 114 is generally downward during the upstroke and generally upward during the downstroke.

[0152] 148 and support member 160. The load is transferred to the pump frame 158 via bearings 152 and 148 and support member 160 so that the pump reaction force on bearing 142 is minimized, thereby maintaining the correct air gap. At the output end 124, the load is transferred from the rotor 122 to the pump frame 158 through bearing 152. At the input end 126, the load is transferred from the rotor 122 to the pump frame 158 through bearing 148 and support member 160. The bearings 152 and 148 experience opposing reaction forces with each pump stroke to provide force balance at the pump frame 158.

[0153] The pump reaction force is thereby transferred from the fluid displacement member 16 to the rotor 122. Bearings 152 and 148 balance the load across the rotor 122 and transfer the load to the pump frame 158. Bearing 152 is directly connected to the pump frame 158. Bearing 148 is connected to the pump frame 158 via support members 160, which transfer the load from bearings 148 to the pump frame 158. Support members 160 thereby transfer the pump load from the rotor 122 to the pump frame 158. The pump frame 158 can be mounted to a bracket or other support surface and can transfer the reaction force to the bracket or other support surface.

[0154] Figure 11 Is a Figure 2 An isometric cross-sectional view of the drive system 210 of the fluid displacement pump 19 . Figure 122 are isometric front and side views of drive system 210. Drive system 210 is an alternative embodiment of an outer rotor drive system. The operation of drive system 210 is substantially similar to drive systems 10 and 110. Drive system 210 utilizes a different eccentric drive, bearing structure, and pump frame configuration, as described herein. The eccentric drive of drive system 210 is integrally formed with the outer rotor and is configured to provide a 1:1 ratio of rotor rotation to pump cycle. Drive system 210 is configured to Figures 2 to 4 The pump 19 and the fluid displacement member 16 operate together. The drive system 110 can include the fluid displacement member 16 and the fluid displacement pump 19 of the drive system 10.

[0155] The electric motor 212 , drive mechanism 214 , fluid displacement member 16 , support frame 218 , and positive displacement pump 19 are shown.

[0156] The electric motor 212 includes a stator 220, a rotor 222, and a shaft 223. The electric motor 212 is disposed on an axis A and extends from a first end (output end) 224 to an opposite second end (electrical input end) 226. The electric motor 212 can be a reversible motor because the stator 220 can cause the rotor 222 to rotate about the motor axis A in either of two rotational directions (e.g., clockwise or counterclockwise). The rotor 222 can be formed by a housing having a cylindrical body 229 disposed between a first wall 230 and a second wall 232. The rotor 222 includes a permanent magnet array 234 disposed on an inner circumference 235. A bearing 242 having an inner race 243, an outer race 244, and rolling elements 245 couples the rotor 222 to the stator 220 at a shaft end 246. A bearing 248 having an outer race 249 , an inner race 250 , and rolling elements 251 couples the rotor 222 to the stator 220 at the electrical input end 226 .

[0157] The support frame 218 includes a pump frame 258 and a support member 260. The support member 260 extends from the pump frame 258 at the output end 224 to the shaft 223 at the electrical input end 226. The support member 260 may include a connecting member 268 and a frame member 272. The pump frame 258 is coupled to the rotor 222 at the output end 224 via a bearing 252 having an outer race 253, an inner race 254, and rolling elements 255. The pump frame 258 and the frame member 272 are disposed in a plane tangential to the motor axis A and at opposite ends of the motor 212. The connecting member 268 connects the pump frame 258 and the frame member 272 across the motor 212.

[0158] The bearings 242, 248, and 252 are disposed about the rotation axis A such that the rotating members of the bearings 242, 248, and 252 rotate on the rotation axis A. The bearings 242, 248, and 252 may be substantially similar in size or may vary in size to support different loads and accommodate space constraints. Figure 11 As shown in , bearings 242 and 248 can be substantially similar in size, while bearing 252 at output end 224 can be smaller. Bearings 242, 248, and 252 can vary in size, and the radial positions of the rolling elements of bearings 242, 248, and 252 can vary from axis A. Rolling element 255 of bearing 252 can be positioned at a first radius R4 from the axis of rotation A of electric motor 112, rolling element 245 of bearing 242 can be positioned at a second radius R5 from the axis of rotation A, and rolling element 251 of bearing 248 can be positioned at a third radius R6 from the axis of rotation A. Figure 11 As illustrated in , the first radius R4 may be smaller than both the second radius R5 and the third radius R6.

[0159] Drive mechanism 214 includes cylindrical protrusion 278, drive member 280, drive link 282, follower 286, bearing surface 289, slot 290, and pin 292. Fluid displacement member 16 includes connector 93. Pump 19 includes cylinder 94 and check valves 95,96.

[0160] As discussed in further detail below, support frame 218 is dynamically connected to rotor 222 and statically connected to stator 220 through a bearing interface. Support frame 218 is statically connected to pump 19. Electric motor 212 is dynamically connected to support frame 218 via rotor 222 and statically connected to support frame 218 via stator 220. Electric motor 212 is dynamically connected to pump 19 via fluid displacement member 16. Pump 19 is statically connected to support frame 218 and dynamically connected to electric motor 212.

[0161] The electric motor 212 includes an inner stator 220 and an outer rotor 222. The motor 212 can be configured to be powered by any desired type of power (e.g., direct current (DC), alternating current (AC), and / or a combination of DC and AC). The stator 220 includes an armature winding (not shown), and the rotor 222 includes permanent magnets. The rotor 222 is configured to rotate about a motor rotation axis A in response to a DC signal or an AC signal passing through the stator 220. The rotor 222 is connected to the fluid displacement member 116 at an output end 224 via a drive mechanism 214. The drive mechanism 214 receives the rotational output directly from the rotor 222 and provides a linear reciprocating input (at Figure 112. The pump frame 258 mechanically supports the electric motor 212 at the output end 224 and mechanically supports the fluid displacement pump 19. The pump frame 258 at least partially houses the fluid displacement member 16 of the fluid displacement pump 19.

[0162] The stator 220 defines an axis A of the electric motor 212. The stator 220 is disposed about and supported by a shaft 223. The stator 220 is fixed to the shaft 223. Electric current can be provided to the armature windings through an electrical input end 226 of the electric motor 212. The shaft 223 can be a hollow shaft that is open to the input end 226 for receiving electrical wires. In alternative embodiments, the shaft 223 can be solid, can have a key, can be D-shaped, or other similar designs. In some embodiments, the shaft 223 can 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 to the support frame 218 at the electrical input end 226 and coupling to the rotor 222 at the axially opposite end of the shaft 223.

[0163] The rotor 222 is coaxially disposed around the stator 220 and is configured to rotate about an axis A. The rotor 222 may be formed from a housing having a cylindrical body 229 extending between a first wall 230 and a second wall 232 and positioned such that the rotor 222 extends around three sides of the stator 220 (e.g., a first axial end, a second axial end, and radial sides). The rotor 222 includes a permanent magnet array 234. The permanent magnet array 234 may be disposed on an inner circumferential surface 235 of the cylindrical body 229. An air gap separates the permanent magnet array 234 from the stator 220, allowing the rotor 222 to rotate relative to the stator 220. At the output end 224 of the electric motor 212, the rotor 222 may overlap the stator 220 and the shaft 223 over their entire radial extent. The rotor 222 may completely surround the stator 220 and the shaft 223 at the output end 224 of the electric motor 212. In some examples, at the electrical input end 226 of the electric motor 212, the rotor 222 can overlap the stator 220 over the entire radial extent of the stator 220. The second wall 232 can extend radially inward from the cylindrical body 229 toward the shaft 223. The shaft 223 can extend through an opening in the second wall 232 that is concentric with the shaft 223 and can extend axially outward from the second wall 232 in the axial direction AD2. The first wall 230 and / or the second wall 232 can be integrally formed with the cylindrical body 229 or can be mechanically fastened to the cylindrical body 229.

[0164] The first wall 230 of the rotor 222 can be rotatably coupled to the outer diameter of the shaft 223 at the shaft end 246 via a bearing 242. The bearing 242 includes an inner race 243, an outer race 244, and rolling elements 245. In some examples, the bearing 242 can be a roller or ball bearing in which the rolling elements 245 are formed by cylindrical members or balls. The rotor 222 can be coupled to the outer race 244. The shaft 223 can be coupled to the inner race 243. The rolling elements 245 allow the rotor 222 to rotate relative to the stator 220. The bearing 242 supports the load and maintains an air gap between the permanent magnet array 234 and the stator 220.

[0165] The second wall 232 of the rotor 222 can be rotatably coupled to the shaft 223 at the input end 226 via a bearing 248. The bearing 248 includes an outer ring 249, an inner ring 250, and rolling elements 251. The rotor 222 can be coupled to the outer ring 249, and the shaft 223 can be coupled to the inner ring 250. The rolling elements 251 allow the rotor 222 to rotate relative to the stator 220. In some examples, the bearing 248 can be a roller or ball bearing in which the rolling elements 251 are cylindrical members or balls. The shaft 223 can extend through the rotor 222 at the electrical input end 226 and can protrude axially outward from the bearing 248 in the axial direction AD2 to allow the shaft 223 to be coupled to the support frame 218. The bearing 248 can be provided to maintain an air gap between the permanent magnet array 234 and the stator 220.

[0166] In contrast to drive systems 10 and 110, rotor 222 rides on the outside of both bearings 242 and 248. Figure 11 As shown in FIG, the rotor 222 does not extend partially into the shaft 223 at the end 246 of the shaft.

[0167] Rotor 222 may include a cylindrical housing 277 extending from wall 230 in axial direction AD1. Cylindrical housing 277 may be coupled to outer race 244 of bearing 242, allowing rotor 222 to ride outside bearing 242. Cylindrical housing 277 may extend around the end surface of outer race 244 to axially retain bearing 242. Second wall 232 may have a radially extending annular flange 238 at the inner diameter opening. Annular flange 238 may be rotatably coupled to shaft 223, for example, via bearing 248. Annular flange 238 may at least partially define a receiving shoulder for receiving outer race 249 of bearing 248 and preload bearing 248.

[0168] The rotor 222 may include a first cylindrical protrusion 278 extending outwardly from the shaft 223 in the axial direction AD1 at the output end 224 . The cylindrical protrusion 278 has a center offset from the axis of rotation A and forms an eccentric drive of the drive mechanism 214 .

[0169] The rotor 222 may further include a second cylindrical protrusion 279 extending outwardly from the cylindrical protrusion 278 in the axial direction AD1. The cylindrical protrusion 279 may be rotatably coupled to the pump frame 258 via a bearing 252. The cylindrical protrusion 279 has a center aligned with the rotation axis A so that the cylindrical protrusion 279 rotates on the rotation axis A. The cylindrical protrusion 279 may be received in the pump frame 258 and separated from the pump frame 258 by the bearing 252. The bearing 252 may have any desired configuration suitable for facilitating relative movement between the pump frame 258 and the cylindrical protrusion 279. For example, the bearing 252 may be a roller or ball bearing that allows rotational movement of the rotor 222 relative to the pump frame 258. As Figure 11 and Figure 12 As shown in , a cylindrical protrusion 278 forming an eccentric drive is arranged between the first wall 230 of the rotor 122 and the inner side of the pump frame 258.

[0170] The pump frame 258 mechanically supports the electric motor 212 at the output end 224 and at least partially houses the fluid displacement member 16. The pump frame 258 can be mechanically coupled to both the rotor 222 and the stator 220. The pump frame 258 can be mechanically coupled to the rotor 222 at the output end 224 and mechanically coupled to the shaft 223 at the electrical input end. The shaft 223 is mechanically coupled to the pump frame 258 to fix the stator 220 relative to the pump frame 258. The shaft 223 is fixed to the pump frame 258 so that the stator 220, which is fixed to the shaft 223, does not rotate relative to the pump frame 258 or the motor rotation axis A.

[0171] The electric motor 212 can extend from the pump frame 258 in a cantilevered manner, such that the input end 226, located opposite the output end 224, is the free end of the cantilevered electric motor 212. A support member 260 can extend from the pump frame 258 to the shaft 223 around the exterior of the rotor 222 to connect the pump frame 258 to the shaft 223, thereby securing the stator 220 relative to the pump frame 258 via the shaft 223. The support member 260 can be removably secured to the shaft 223. The support member 260 secures the shaft 223 to the pump frame 258, preventing relative movement between the stator 220 and the pump frame 258. Neither the shaft 223 nor the stator 220 is secured to the pump frame 258 at the output end 224. Instead, a portion of the rotor 222 is axially disposed between the shaft 223 and the stator 220, separating the shaft 223 and the stator 220 from the pump frame 258.

[0172] The support member 260 can extend from a radially inward position outside the cylindrical body 229 of the rotor 222 to a radially outward position of the cylindrical body 229. The support member 260 can extend around the rotor 222 with sufficient spacing therefrom to allow the rotor 222 to rotate unimpeded within the support member 260. The support member 260 includes one or more connecting members 268 extending across the cylindrical body 229 and at least one frame member 272 disposed on the input end 226 and coupled to the shaft 223. The connecting members 268 can extend outward from the first wall 230 in the axial direction AD1 and can extend axially outward from the second wall 232 in the axial direction AD2. The connecting members 268 of the support member 260 can extend parallel to the axis A.

[0173] The frame member 272 of the support member 260 can extend substantially parallel to the second wall 232 and can be axially spaced apart from the second wall 232. The frame member 272 extends from the shaft 223 to a radially outward position of the cylindrical body 229, where it engages the connecting member 268. The frame member 272 interfaces with the shaft 223 and can be secured thereto. The support member 260 is connected to the pump frame 258 at the output end 224. The support member 260 fixes the axial position of the stator 220 relative to the rotor 222 and holds the electric motor 212 together. The support member 260 can be a unitary body or can include multiple components fastened together and is capable of maintaining the stator 220 in a fixed axial position relative to the rotor 222 and the pump frame 258 via the shaft 223.

[0174] The pump frame 258 is mechanically coupled to the rotor 222 at the output end 224 via bearings 252. The bearings 252 include an outer race 253, an inner race 254, and rolling elements 255. The bearings 252 can be roller or ball bearings, wherein the rolling elements 255 are cylindrical members or balls. The rotor 222 can be received in the pump frame 258 such that a portion of the rotor 222 extends into the pump frame 258 and is radially surrounded by a portion of the pump frame 258. In this way, the rotor 222 is coupled to the inner race 254, and the pump frame is coupled to the outer race 253. The rolling elements 255 allow rotational movement of the rotor 222 relative to the pump frame 258. The pump frame 258 mechanically supports the electric motor 212 via the bearings 258 and the support member 260.

[0175] Additionally, the pump frame 258 is configured to house a portion of the pump 19 and secure the pump 19 in a fixed position relative to the electric motor 212. The pump frame 258 may be configured to be mounted to a cart or stationary assembly for ease of handling and transportation.

[0176] Drive mechanism 214 includes a cylindrical protrusion 278 forming an eccentric drive, a drive member 280, and a drive connecting rod 282. Cylindrical protrusion 278 is disposed on rotor 222 of electric motor 212 and rotates therewith. In the illustrated example, cylindrical protrusion 278 is integrally formed with first wall 230 of rotor 222. Because cylindrical protrusion 278 is offset from axis of rotation A, rotation of rotor 222 causes cylindrical protrusion 278 to rotate about axis of rotation A. Drive member 280 is mechanically coupled to cylindrical protrusion 278 and is configured to drive reciprocating motion of fluid displacement member 16. Cylindrical protrusion 278 is directly coupled to drive member 280 without intermediate gearing to provide a 1:1 ratio of rotor rotation to pump cycle.

[0177] In some embodiments, the cylindrical protrusion 278 can have a substantially hollow body having a cavity defined by a plurality of ribs 284. The ribs 284 can extend radially outward from the cylindrical protrusion 278 to the outer cylindrical wall of the cylindrical protrusion 278. The ribs 284 support the drive member 280 and can reduce the weight of the cylindrical protrusion 278. The ribs 284 can be spaced circumferentially around the cylindrical protrusion 278. The ribs 284 can extend around a portion of the cylindrical protrusion 278 that is less than the entire circumference of the cylindrical protrusion 278. Depending on the location of the ribs 284, the radial length of the ribs 284 between the cylindrical protrusion 278 and the outer wall of the cylindrical protrusion 278 can vary. Figure 11 and Figure 12 As shown in , the cylindrical protrusion 279 can also have a substantially hollow body with a cavity defined by a plurality of ribs.

[0178] Drive member 280 may be a connecting rod having a follower 286 at one end, which is configured to receive cylindrical protrusion 278. Follower 286 may include a bearing member 289 to allow drive member 280 to move in a rocking motion about cylindrical protrusion 278 as cylindrical protrusion 278 rotates with rotor 222. Drive member 280 may be coupled to fluid displacement member 16 via drive link 282 in a manner consistent with that disclosed for drive system 10. Drive member 280 converts the rotational motion of cylindrical protrusion 278 into reciprocating motion and drives fluid displacement member 16 in a reciprocating manner via drive link 282. Operation of drive mechanism 214 and pump 19 is consistent with that disclosed for drive system 10. With each revolution of rotor 222, drive link 282 is forced upward and downward. In this manner, drive mechanism 214 converts each revolution of rotor 222 into linear up-and-down motion. Drive link 282 is coupled to fluid displacement member 16 and, therefore, pulls fluid displacement member 16 through an upward stroke and pushes fluid displacement member 16 through a downward stroke. Thus, for each revolution of rotor 222, the pump performs a full pumping cycle, including both an upward and downward stroke. The increased torque encourages rotor 222 to generate a sufficiently high pumping pressure with positive displacement pump 19 to produce an atomized spray at spray device 5 ( Figure 4 In some examples, rotor 22 can cause pump 19 to generate a pumping pressure of about 3.4 to 69 megapascals (MPa) (about 500 to 10,000 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 3,000-5,000 psi). High fluid pumping pressures are useful for atomizing the fluid into a spray for applying the fluid to a surface.

[0179] During operation of pump 19, the pump reaction force generated by fluid displacement member 16 during pumping is transmitted to pump frame 258 via drive mechanism 214, rotor 222, bearing 252, bearing 248, shaft 223, and support member 260. Both the upward reaction force and the downward reaction force travel through drive mechanism 214, rotor 222, and then to bearings 252, 242, and 248. Bearings 252, 242, and 248 transmit both the rotational force associated with the rotation of rotor 222 and the upward reaction force and the downward reaction force to pump frame 258.

[0180] This axial pump reaction load is transverse to the axis of rotation A of the electric motor 212 and is experienced at both the output end 224 and the electrical input end 226 of the electric motor 212. The load is transferred to the pump frame 258 via bearings 252, 248, and support member 260 so that the pump reaction force on bearing 242 is minimized, thereby maintaining the correct air gap. At the output end 224, the load is transferred from the rotor 222 to the pump frame 258 through bearings 252 and 242. At the electrical input end 246, the load is transferred from the rotor to the pump frame 258 through bearings 248 and support member 260. With each pump stroke, the bearing 252 is subjected to an opposing reaction force from the bearing 248 to provide a force balance at the pump frame 258. It should be understood that in examples where member 268 is mounted to an object or surface to support the drive system 210, the load can react against the support member 260, such as member 268.

[0181] Pump reaction forces are thereby transferred from the fluid displacement member 16 to the rotor 222 during pumping. Bearings 242 and 248 balance the load across the rotor 222 and transfer the load to the static frame member.

[0182] The bearing arrangement of system 210 provides significant advantages. Bearings 242, 248, and 252 react to pump reaction loads generated during pumping. Bearings 242, 248, and 252 stabilize rotor 222 to facilitate direct drive connection to fluid displacement member 16. Pump reaction forces experienced at output end 224 and electrical input end 226 are transferred to pump frame 258 and connection member 260, thereby balancing forces across pump frame 258. The connection balances motor 212, providing longer life, less wear, less downtime, more efficient operation, and cost savings. Bearing 242 further aligns rotor 222 on pump axis A. Bearing 242 minimizes the unsupported span of rotor 222, thereby aligning rotor 222 and preventing undesirable contact between rotor 222 and stator 220. Bearing 242 thereby increases the operating life of motor 212.

[0183] The direct-drive configuration of drive system 210 eliminates intermediate gearing (e.g., reduction gears) between electric motor 212 and fluid displacement member 16. Eliminating the intermediate gearing can provide a more efficient, compact, lightweight, reliable, and simpler pump by reducing the number of parts and moving parts. Additionally, eliminating the gearing provides for quieter pump operation.

[0184] Figure 13 and Figure 14 They are assembled Figure 2 An isometric cross-sectional view of the drive systems 310 and 410 of the pump 19. Figure 13 and Figure 14 Drive systems 310 and 410 are substantially similar to drive system 10, with modifications configured to include a direct drive coupling having a coaxially disposed fluid displacement pump 19 and motor 12. Drive systems 310 and 410 each include the electric motor 12 of drive system 10, the electric motor 12 including an inner stator 20, an outer rotor 22, and a shaft 23. The electric motor 12 and pump 19 are coaxially disposed about a motor / pump axis A. Figure 13 and Figure 14 In the embodiment illustrated in FIG, electric motor 312 can be a reversible motor because stator 20 can cause rotor 22 to rotate in either of two rotational directions about motor / pump axis A (e.g., clockwise or counterclockwise). Drive systems 310 and 410 each include a rotor shaft 380 and a modified drive mechanism 314 and fluid displacement member 316. Drive systems 310 and 410 additionally have modified support frames 318 and 418, respectively, that include different pump frames 358 and 458 and support members 360 and 460. Only the modifications are discussed herein. All other aspects of electric motor 12 are provided in the description of drive system 10.

[0185] Pump frame 358, 458 is dynamically connected to rotor 22 through a bearing interface and statically connected to stator 20. Pump frame 358, 458 is statically connected to pump 19. Electric motor 12 is dynamically connected to pump frame 358, 458 via rotor 22 and statically connected to pump frame 358, 458 via stator 20. Electric motor 12 is dynamically connected to pump 19 via fluid displacement member 216. Pump 19 is statically connected to pump frame 358, 458 and dynamically connected to electric motor 12.

[0186] The pump frame 358, 458 mechanically supports the electric motor 12 at the output end 324 and mechanically supports the fluid displacement pump 19. The pump frame 358, 458 at least partially houses the fluid displacement member 316 of the pump 19. The pump frame 358, 458 is mechanically coupled to the rotor 22 and the stator 20. The pump frame 358, 458 is mechanically coupled to the rotor 22 at the output end 224 via the bearing 42, as described with respect to the drive system 10 and in Figure 2 As shown in FIG. The pump frames 358, 458 are mechanically fixed to the stator 20 at the input end 326 via support members 360, 460 and the shaft 23, respectively. The shaft 23 is mechanically coupled to the pump frames 358, 458 so that the stator 20 fixed to the shaft 23 does not rotate relative to the pump frames 358, 458 or the motor rotation axis A. The pump frames 358, 458 are coaxially arranged with the electric motor 12 and the pump 19, thereby extending outwardly from the electric motor 12 in the axial direction AD1. Figure 13 and Figure 14, the pump frame 358, 458 may be formed from multiple components that are assembled together to house and support the rotor shaft 380 and the drive mechanism 214. The pump frame 358, 458 may be dynamically coupled to the rotor shaft 380 via bearings 381 to support and allow the rotor shaft 380 to rotate within the pump frame 358, 458.

[0187] like Figure 13 As shown in FIG, support member 360 may include a cylindrical body 362 that may form a housing around rotor 22. Cylindrical body 362 may extend axially outward from pump frame 358 at output end 24 to input end 26. Cylindrical body 362 may include a radially extending flange 363 at output end 24 that may be fastened to pump frame 358 with bolts or other fastening mechanisms. Cylindrical body 362 may radially overlap second wall 32 of rotor 22 at the input end to substantially enclose rotor 22 at input end 26. Support member 360 may include a frame member 372 that may secure support member 360 to shaft 23. Frame member 372 may be substantially identical to frame member 72 of drive system 10 and may be secured to shaft 23 in the same manner. Frame member 372 may be fastened to cylindrical body 362 with bolts 365 or a similar fastening mechanism. Bolt 365 may extend through a protrusion of radially extending portion 364 (e.g., as Figure 6 and FIG. 10A to FIG. 10C One or more radially outer ends of the protrusion 64a shown in FIG.

[0188] like Figure 14 , support member 460 can be substantially the same as support member 160 of drive system 110. Support member 460 can include one or more connecting members 468 and a frame member 472. The connecting members can be substantially similar to connecting members 68 and 168, and frame member 472 can be substantially similar to frame members 72, 172a, 172b, and 172c described with respect to drive system 110. Connecting member 68 can be mechanically secured to pump frame 458 by bolts or other fastening mechanisms.

[0189] Drive mechanism 314 includes a drive nut 382, a screw 384, and rolling elements 386. Drive mechanism 314 is connected to rotor shaft 380. Drive mechanism 314 receives rotational output from rotor 22 via rotor shaft 380. More specifically, drive nut 382 of drive mechanism 314 is connected to rotor shaft 380 for rotation therewith about motor / pump axis A. Drive nut 382 may be attached to rotor shaft 380 via fasteners (e.g., screws or bolts), adhesive, or a press fit, among other options. Screw 384 is radially disposed within drive nut 382. Rolling elements 386 are disposed between screw 384 and drive nut 382 and support screw 384 relative to drive nut 382. Rolling elements 386 support screw 384 and drive nut 382 such that a gap is radially provided between screw 384 and drive nut 382. Rolling elements 386 maintain the gap and prevent direct contact between screw 384 and drive nut 382.

[0190] The screw 384 is configured to reciprocate along the motor / pump axis A during operation. Thus, the screw 384 provides a linear output from the drive mechanism 314. The screw 384 can be coupled to the fluid displacement member 316 via a connector 388 to provide linear reciprocating motion of the fluid displacement member 316 as the screw 384 reciprocates. The stator 20 causes the rotor 22 to rotate in a first rotational direction (e.g., clockwise or counterclockwise) about the motor / pump axis A to cause the drive nut 382 to rotate in the first rotational direction, thereby causing the rolling elements 386 to apply an axial driving force to the screw 384 in the axial direction AD1 and drive the screw 384, thereby linearly driving the fluid displacement member 316 in the axial direction AD1 along the motor / pump axis A during a downstroke. Stator 20 causes rotor 22 to rotate in a second rotational direction (e.g., the other of a clockwise or counterclockwise direction) about motor / pump axis A to cause drive nut 382 to rotate in the second rotational direction about motor / pump axis A, thereby causing rolling elements 386 to apply an axial driving force to screw 384 in axial direction AD2 and drive screw 384, and thereby drive fluid displacement member 316 linearly in axial direction AD2 along motor / pump axis A during an upstroke.

[0191] Outer rotor drive systems 310 and 410 offer significant advantages. The outer rotor's rotor 22, which is at least partially radially disposed outside of stator 20, provides increased inertia and torque relative to the inner rotor motor. This increased torque encourages rotor 22 to generate sufficiently high pumping pressure with positive displacement pump 19 to produce an atomized spray at an applicator (e.g., a spray gun). For example, system 10 can be used to pump paint or other fluids to an airless spray gun, where the fluid pressure generates an atomized spray. In some examples, rotor 22 can cause pump 19 to generate a pumping pressure of approximately 3.4 to 69 megapascals (MPa) (approximately 500 to 10,000 pounds per square inch (psi)) or even higher. In some examples, the pumping pressure ranges from approximately 20.7 to 34.5 MPa (approximately 3,000 to 5,000 psi). High fluid pumping pressures are useful for atomizing a fluid into a spray for application to a surface.

[0192] Figure 15 and Figure 16 A drive system 510 is illustrated. Figure 15 is an isometric front view of drive system 510 . Figure 16 It is along Figure 15 An isometric cross-sectional view of the drive system 510 taken along line 16-16. Figure 15 and Figure 16 Drive system 510 is configured for use with drive mechanism 14, fluid displacement member 16, and fluid displacement pump 19 of drive system 10. Electric motor 512, drive mechanism 14, fluid displacement member 16, pump frame 518, and pump 19 are shown.

[0193] Electric motor 512 includes a stator 520 and a rotor 522. Electric motor 512 is disposed on axis A and extends from a first end 524 to a second end 526. Rotor 522 is supported by bearings 542 and 548. Bearing 242 includes an inner race 243, an outer race 244, and rolling elements 245. Bearing 248 includes an outer race 249, an inner race 250, and rolling elements 251. Rotor 522 includes a bore 523 and a permanent magnet array 534.

[0194] The motor 512 is an electric motor having an outer stator 520 and an inner rotor 522. The stator 520 includes an armature winding (not shown) in a stator housing 521. The rotor 522 includes a permanent magnet array 534. The rotor 522 is configured to rotate about the pump axis A in response to a current signal passing through the stator 520. The rotor 522 is connected to the fluid displacement member 16 at a first end 524 via a drive mechanism 14. The drive mechanism 14 receives the rotational output from the rotor 522 and provides a linear reciprocating input to the fluid displacement member 16. The pump frame 518 is configured to mechanically support the electric motor 512 and the fluid displacement pump 19 ( Figure 4 ). The electric motor 512 may extend in a cantilevered manner from the pump frame 518 such that a second end 526 , disposed opposite the first end 524 , is a free end of the cantilevered electric motor 512 .

[0195] The rotor 522 defines an axis of rotation A. The stator 520 is coaxially disposed about the rotor 522 and includes a stator housing 521. The rotor 522 includes a permanent magnet array 534 on an outer diameter surface. An air gap separates the permanent magnet array 534 from the stator 520 to allow the rotor 522 to rotate relative to the stator 520. The rotor 522 can be rotatably coupled to the stator 520 at a first end 524 and a second end 526 via bearings 542 and 548, respectively. The bearings 542 and 548 allow the rotor 522 to rotate relative to the stator 520.

[0196] Bearings 542 and 548 may be roller or ball bearings. Bearing 542 may be disposed at first end 524 and may include an inner race 543, an outer race 544, and rolling elements 545. Rotor 522 may be coupled to inner race 543 such that rotor 522 rides inside bearing 542. Stator 520 may be coupled to outer race 544. Bearing 548 may be disposed at second end 546 and may include an outer race 549, an inner race 550, and rolling elements 551. Rotor 522 may be coupled to inner race 550 such that rotor 522 rides inside bearing 548. Stator 520 may be coupled to outer race 549.

[0197] Bearings 542 and 548 are disposed about the rotation axis A. Bearings 542 and 548 may vary in size, and rolling elements 545 and 551 of bearings 542 and 548, respectively, may vary in radial position from axis A. Rolling element 545 of bearing 542 may be disposed at a radius R7 from the rotation axis A of electric motor 12. Rolling element 551 of bearing 548 may be disposed at a radius R8 from the rotation axis A. Radius R7 of bearing 542 may be greater than radius R8 of bearing 548 to accommodate drive mechanism 14.

[0198] Bearing 542 may be larger in size than bearing 548 to support the pump loads generated by the reciprocating motion of fluid displacement member 16 during pumping and experienced by electric motor 512 due to the direct drive configuration.

[0199] The pump frame 518 mechanically supports the electric motor 512 at a first end 524 and at least partially houses the fluid displacement member 16. The pump frame 518 can be mechanically coupled to the stator 520 at the first end 524 via a plurality of mounting elements 537.

[0200] The eccentric drive 78 is axially offset from the rotation axis A so that rotation of the rotor 522 causes the eccentric drive 78 to move radially along a circular path from the rotation axis A. A bolt 84 can be threadedly fastened to the inner end of the bore 523 to secure the sleeve 83 to the rotor 522. The bolt 84 can extend axially into the rotor 522 so that the bolt 84 is disposed in an axial plane along with the permanent magnet array 534 of the rotor 522 and the armature winding of the stator 520. The bolt 84 can be formed of a non-ferrous material to prevent interference with the operation of the electric motor 512.

[0201] As described with respect to drive system 10 and as Figure 4 , the drive member 80 can be configured to receive the eccentric driver 78 in a manner that allows the drive member 80 to rotate relative to the eccentric driver 78 as the eccentric driver 78 moves with the rotor 522. The drive member 80 can be coupled to the fluid displacement member 16 via a drive link 82 and a pin 92. The drive member 80 converts the rotational motion of the eccentric driver 78 into reciprocating motion and drives the fluid displacement member 16 in a reciprocating manner via the drive link 82.

[0202] As described with respect to drive system 10, with each revolution of rotor 522, drive link 82 is forced upward and downward. In this way, drive mechanism 14 converts each revolution of rotor 522 into linear up-and-down motion. Drive link 82 is coupled to fluid displacement member 16 and thereby pulls fluid displacement member 16 through an upward stroke and pushes fluid displacement member 16 through a downward stroke. Thus, with each revolution of rotor 522, the pump performs a full pumping cycle, including both an upstroke and a downstroke. The increased torque encourages rotor 522 to generate a sufficiently high pumping pressure with positive displacement pump 19 to produce an atomized spray at spray device 5. In some examples, rotor 522 can cause pump 19 to generate a pumping pressure of approximately 3.4 to 69 megapascals (MPa) (approximately 500 to 10,000 pounds per square inch (psi)), or even higher. In some examples, the pumping pressure is in the range of approximately 20.7 to 34.5 MPa (approximately 3,000-5,000 psi). High fluid pumping pressures are useful for atomizing the fluid into a spray for applying the fluid to a surface.

[0203] During operation of the pump 19, the pump reaction force generated by the fluid displacement member 16 during pumping is transmitted to the pump frame 518 via the drive mechanism 14, the rotor 522, the bearing 542, the bearing 548, and the stator housing 521. Both the upward reaction force and the downward reaction force pass through the drive mechanism 14, the rotor 522, and then reach the bearings 542 and 548. The bearings 542 and 548 transmit the rotational force associated with the rotation of the rotor 522 and both the upward reaction force and the downward reaction force to the pump frame 518. With each stroke, the pump reaction force is generated and a load is applied to the rotor 522 because the rotor 522 directly drives the fluid displacement member 16 via the drive mechanism 14.

[0204] This axial pump reaction load is transverse to the axis of rotation A of the electric motor 512 and is experienced at both the output end 524 and the input end 526 of the electric motor 512. The load is transferred to the pump frame 518 via the bearings 542, 548 and the stator housing 521 so that the electric motor 512 is not subjected to pump reaction forces. At the first end 524, the load is transferred from the rotor 522 through the bearings 542 and the stator housing 521 to the pump frame 518. At the electrical input end 548, the load is transferred from the rotor 522 through the bearings 548 and the stator housing 521 to the pump frame 518. The bearings 542, 548 experience opposing reaction forces with each pump stroke to provide force balance at the pump frame 518.

[0205] Due to the direct drive connection between the rotor 522 and the fluid displacement member 16, pump reaction forces are thereby transferred from the fluid displacement member 16 to the rotor 522. Bearings 542, 548 balance the load across the rotor 522 and transfer the load to the pump frame 518. Bearing 542 is proximal to the pump frame 518 and is coupled to the pump frame 518 via the stator housing 521. Bearing 548 is distal to the pump frame 518 but is also coupled to the pump frame 518 via the stator housing 521, which transfers the load from bearing 548 to the pump frame 518. The stator housing 521 thereby transfers the pump load from the rotor 522 to the pump frame 518.

[0206] The bearing arrangement of system 510 provides significant advantages. Due to the direct-drive arrangement, bearings 542, 548 react to the pump reaction loads generated during pumping. Bearings 542, 548 stabilize rotor 522 to facilitate the direct-drive connection to fluid displacement member 16. Pump reaction forces experienced at first end 524 and electrical input end 528 are transferred to pump frame 518, thereby balancing the forces across pump frame 518. The connection balances motor 512, providing longer life, less wear, less downtime, more efficient operation, and cost savings.

[0207] The direct-drive configuration of drive system 510 eliminates the intermediate gearing (e.g., reduction gears) between electric motor 512 and fluid displacement member 16 that is used in conventional motor-driven pumps. Eliminating the intermediate gearing provides a more efficient, compact, lightweight, reliable, and simpler pump by reducing the number of parts and moving parts. Additionally, eliminating the gearing provides for quieter pump operation.

[0208] Figure 17 yes Figures 1A to 16 A block diagram of a control system for any of the drive systems disclosed herein is provided. The diagram shows a control system 700, a control panel 13, a controller 15, a user interface 17, a fluid sensor 101, a motor sensor 102, a temperature sensor 103, and an additional sensor 104 (e.g., a current sensor). The controller 15 can be included in any of the drive systems disclosed herein and used according to the following disclosure. The controller 15 can be one or more logic circuits, such as a chip or a microprocessor. The controller 15 can include code for the logic circuits to execute to perform the functions referenced herein. The controller 15 can receive data, including data in the form of analog signals, from any of the sensors or transducers or other components referenced herein.

[0209] Each of the fluid sensor 101, the motor sensor 102, the temperature sensor 103, and the additional sensor 104 provides an electronic signal to the controller 15. For example, the controller 15 may receive an electronic signal from the fluid sensor 101 (at Figure 4 and Figure 9 1 . The fluid sensor 101 may be included in any of the disclosed drive systems. The fluid sensor 101 may be a pressure transducer that measures the pressure of the fluid output by the pump 19. The fluid sensor 101 may be, for example, a spring gauge sensor.

[0210] The controller 15 can also obtain the information from the motor sensor 102 (in Figure 4 and Figure 9) receives a signal. Any of the disclosed drive systems may include a motor sensor 102. Motor sensor 102 directly or indirectly measures parameters of the operating state of rotor 22. For example, motor sensor 102 may register and count revolutions of rotor 22. Motor sensor 102 can determine the orientation of rotor 22, so that the rotational position of rotor 22 is always known, which may be useful when reversing rotor 22. For example, electric motor sensor 102 may be a multi-axis magnetic sensor having multiple magnets on rotor 22 in different orientations and a magnetic field sensor on stator 20. The magnetic field sensor measures changes in the magnetic field to determine the instantaneous rotational position of rotor 22. In some cases, the position of rotor 22 may not be directly measured but may be inferred. For example, a circulation sensor may sense the circulation of rotor 22 and / or pump 19, for example by measuring the displacement of fluid displacement member 16, thereby inferring the cyclic position of rotor 22.

[0211] The controller 15 is configured to control the operation of the motor 12. The controller 15 controls the power supplied to the stator 20 to control the rotation of the rotor 22 about the motor axis. The controller 15 can be configured to cause the pump 19 to output the spray fluid according to the target pressure. The controller 15 provides current to the motor 12 to achieve the desired pressure. The current provided to the motor 12 is proportional to the pressure output by the pump 19. In this way, the controller 15 can be configured to control the current to the motor 12 based on the desired pressure.

[0212] The pump 19 can maintain a constant pressure of the spray fluid throughout operation. In some examples, the pump 19 is configured to output the spray fluid at approximately 500 to 7500 pounds per square inch (psi), although typically in the range of 1500-3300 psi. The pump 19 can operate in a pumping state and a stalled state. In the pumping state, the rotor 22 applies torque to the drive mechanism 14, causing the fluid displacement member 16 to apply force to the spray fluid. In the stalled state, the rotor 22 applies torque to the drive mechanism 14 but does not rotate, causing the fluid displacement member 16 to apply force to the spray fluid but not displace axially. For example, when the pump 19 is deadheaded due to the closure of the downstream valve, such as when the trigger 9 (in Figure 4When the pump 19 (shown in FIG. 1 ) is not actuated for spraying, a stall may occur. When the pump 19 stalls due to the constant push of the rotor 22, the pump 19 continues to apply pressure to the spray fluid. While the rotor 22 is stalled, the rotor 22 is pushed forward, allowing pressure to continue to be applied to the fluid displacement member 16 via the rotor 22 and the drive mechanism 14. This way, when the trigger 9 is actuated, spray pressure is already present and immediately applied, minimizing any pressure drop that might occur at the start of spraying and any adverse effects on the spray quality of the spray fluid. With the constant push of the rotor 22, the spray blower can synchronize the trigger pull (activation) to the trigger release (stalled state).

[0213] During both the pumping state and the stalled state, the controller 15 can be configured to supply current to the stator 20, causing the rotor 22 to apply torque to the drive mechanism 14, thereby causing the fluid displacement member 16 to continue applying force to the spray fluid, even when the rotor 22 stalls due to back pressure from the spray fluid downstream of the pump 19. Back pressure, for example caused by the closure of a downstream valve, prevents axial displacement of the fluid displacement member 16 and, thereby, rotation of the rotor 22. In the stalled state, the controller 15 causes current to continue to flow to the motor 12, causing the rotor 22 to apply a constant torque to the drive mechanism 14. The drive mechanism 14 converts the torque into a linear drive force, causing the drive mechanism 14 to apply a constant force to the fluid displacement member 16. During the stalled state, the rotor 22 does not rotate. When the pump 19 is in the stalled state, the rotor 22 applies torque at zero rotational speed. The pump 19 is driven entirely mechanically because, during the stalled state, the rotor 22 mechanically causes the fluid displacement member 16 to apply pressure to the spray fluid.

[0214] The amount of current delivered to the motor 12 can be determined based on the pressure setting. The user can set the pressure at which the pump 19 outputs the spray fluid. The controller 15 can calculate the motor speed based on the desired pressure (e.g., via an index that relates the rotor speed to the set pressure), and can then calculate the amount of torque required to achieve the motor speed or pressure. Torque is proportional to current, and the controller 15 can determine the required current based on the desired torque. Torque is proportional to current, and current is proportional to pressure. In this way, the pressure setting of the drive system 10 can correspond to the amount of current supplied to the motor 12 (or other electrical power measurement results), so that a higher pressure setting corresponds to a larger current, and a lower pressure setting corresponds to a smaller current. The controller 15 can adjust the voltage supplied to the motor 12 to change the speed of the rotor 22.

[0215] The controller 15 commands a current corresponding to the set pressure in push mode. The controller 15 may not command the motor speed in push mode. The current supplied to the motor 12 causes the pump to produce an output pressure, and the actual speed of the motor will be whatever speed is required to maintain a constant pressure. For example, if there is no restriction in the downstream flow, the motor speed is at its maximum, so that the actual pressure cannot be built up to the target pressure. If the motor is overloaded (for example, due to a stall condition), the actual speed of the motor is zero, but the pressure is maintained at the desired pressure. When the downstream pressure drops (for example, when the trigger 9 is actuated), the motor speed will increase to the speed required to maintain the set pressure, which is proportional to the current.

[0216] The disclosed drive system has an offset crank pump load, which results in two current spikes per motor revolution. The controller 15 can be configured to determine the actual pressure based on pressure readings taken over a period of time. Multiple pressure readings on a time scale provide a smoother pressure output signal, thereby facilitating more accurate control and smoother pumping. The user can set the desired pressure via the user interface 17. The controller 15 controls the operation of the motor 12 to cause the pump 19 to output fluid based on the desired pressure. The current and motor speed are determined based on the pressure set point. The controller 15 determines the target speed and torque to produce the target pressure, and commands the current to the motor 12 based on this information. As the motor speed changes, the current, pressure and torque can remain the same during the pumping state and during the stall state.

[0217] During operation, the actual pressure is determined based on the information generated by the pressure transducer 101. If the pressure is lower than the target or set pressure, the current can be increased. If the motor speed cannot meet the target pressure and the current is at the maximum operating current, the voltage can be increased to increase the speed of the motor 12. The amount of current delivered to the motor 12 to maintain a constant pressure at the set pressure depends on the material composition of the spraying fluid. For example, the current required to generate 3000psi will vary between systems depending on the viscosity of the pumped material and other factors. The controller 15 can be configured to determine the required current based on the pressure information provided by the pressure transducer 101.

[0218] Although in some embodiments, more current may be delivered to the motor 12 when the rotor 22 is rotating, and less current may be delivered to the motor 12 when the rotor 22 is stalled but pushing, the amount of current delivered to the motor 12 can be approximately the same regardless of whether the rotor 22 is rotating or stalled. The continuous current regulated by the controller 15 causes the pump 19 to apply a constant pressure to the spray fluid via the fluid displacement member 16. When the motor 12 is rotating, the controller 15 can supply more power to the motor 12 than when the motor 12 is stalled. The current can remain constant both when stalled and when rotating, but the voltage changes due to changes in speed. The voltage increases to increase the speed of the motor 12, resulting in additional power during rotation. Thus, at zero speed and with the desired pressure, the voltage is at a minimum because no additional speed is required to achieve the pressure. When the electric motor 12 is commutating, power is applied according to a sinusoidal waveform. For example, the electric motor 12 may receive AC power. For example, power may be supplied to the phases of the electric motor 12 according to an electrically offset sinusoidal waveform. In the event that motor 12 stalls, the signal is maintained at the stall point, providing a constant signal while motor 12 is in a stalled state. Thus, at least one phase of motor 12 can be considered to receive a DC signal while motor 12 is in a stalled state. Motor 12 can thus receive two types of electrical signals during operation: a first during rotation and a second during stall. The first can be sinusoidal, and the second can be constant. The first can be AC, and the second can be considered DC. The first power signal can be greater than the second power signal.

[0219] In some examples, a set current can be supplied to motor 12 throughout the stall. For example, a maximum current can be supplied to motor 12 throughout the stall. The maximum current can be the maximum operating current of motor 12, a maximum current set by the user, or some other form of maximum current. In some examples, controller 15 can vary the current supplied to motor 12. For example, the current can be pulsed, so that current is constantly supplied to stator 20 but at varying levels. This allows pump 19 to apply a continuous and variable force to the spray fluid while motor 12 is in a stalled state. In some examples, the current can be pulsed between a maximum current and one or more currents less than the maximum current. When the back pressure of the spray fluid drops sufficiently, pump 19 returns to a pumping state, so that the current supplied to motor 12 can cause rotation of rotor 22 and axial displacement of fluid displacement member 16, for example, when the user resumes spraying. Pump 19 thus returns to a pumping state when the force applied to the spray fluid overcomes the back pressure of the spray fluid. Controller 15 can be configured to restore the current according to the pumping state based on the pressure drop, allowing motor 12 to rotate.

[0220] When fluid displacement member 16 is in an upstroke, stall occurs when the driving force on the rotor equals the reaction force of the fluid downstream from one of the fluid displacement members 16 and the suction force of the fluid upstream from pump 19. When downstream pressure decreases, pump 19 exits the stall, causing the forces to no longer be balanced, and rotor 22 overcomes the force acting on fluid displacement member 16. Continuously supplying current to motor 12 during the stall provides a constant push on rotor 22. In some examples, rotor 22 can be forced out of the stall condition by the constant current overcoming the downstream pressure, rather than in response to any pressure signal from pressure transducer 101 indicating a pressure drop. This continuous push on rotor 22 ensures that rotor 22 remains balanced, allowing fluid displacement member 16 to resume movement just as fluid begins to flow again.

[0221] When the pressure sensor indicates that the set pressure has been reached, other spraying systems can stop delivering driving power to the motor. Before the controller resumes supplying current to the motor, the pressure must drop enough to make the pressure sensor register a drop. This process can cause the spraying pressure to drop when the user resumes spraying, and this is called a dead zone. The drop in this spraying pressure is usually undesirable because it may cause a reduction in the spraying blower and a change in the spraying blower when spraying begins. For example, the spraying blower changes from the time when the trigger is actuated to the time when the pressure set point has been reached. By contrast, in the case of the constant push of rotor 22, the pressure set point is realized immediately or almost immediately when the trigger is actuated. Once the downstream flow path is opened, motor 12 begins to rotate, and pump 19 starts pumping, thereby minimizing any potential dead zone and providing desired spraying pressure when starting spraying.

[0222] Stalling the pump 19 in response to the back pressure of the spray fluid provides significant advantages. The user can idle the pump 19 without damaging the internal components of the pump 19. The controller 15 adjusts to maximum current, causing the pump 19 to output a constant pressure. The pump 19 continuously applies pressure to the spray fluid, allowing the pump 19 to quickly resume operation and output a constant pressure when the downstream pressure is released. Pulsing the current during the stall reduces the heat generated by the stator 20 and uses less energy.

[0223] Motor 12 can remain stalled while still propelling fluid displacement member 16 for an indeterminate period of time. However, if the user does not use pump 19 for an extended period of time, such as when the user goes to lunch, controller 15 can save power and reduce heat accumulation if it stops power delivery to motor 12. Controller 15 can sense a stall condition, for example, by using motor sensor 102 to detect the cessation of rotor 22 rotation and / or based on the amount of a current spike experienced and sensed by current sensor 104 when the downstream flow path is initially closed. In some examples, controller 15 can start a timer based on motor 12 entering a stalled state. If rotation of rotor 22 is sensed, the timer can be stopped and, in some examples, reset. However, after a predetermined amount of time (e.g., 30 seconds, 5 minutes, 10 minutes, or any other desired time threshold) of rotor 22 not rotating, controller 15 can stop delivering operating power (electrical energy) to motor 12. When the controller 15 has ceased supplying operating power to the motor 12, the controller 15 may continue to monitor a fluid parameter, such as pressure, via the fluid sensor 101. If the fluid sensor 101 senses a change in a fluid parameter, such as a drop in pressure or a flow of fluid, the controller 15 may resume supplying power to the motor 12 to rotate the rotor 22 and operate as previously described, assuming that the operator has resumed spraying operations.

[0224] While current is supplied to provide constant propulsion to the rotor 22, the motor 12 continues to generate heat during a stall condition. Over time, the heat generation increases in proportion to the current supplied. In some examples, a temperature sensor can be used to measure the motor temperature or the temperature of the atmosphere adjacent to the motor 12. If a threshold temperature is reached before rotation of the rotor 22 has resumed and / or before a predetermined amount of time has passed without rotation, the controller 15 can terminate the supply of operating power to the motor 12. In this case, the predetermined period of continued propulsion is dynamic, as opposed to a predetermined period of time, based on temperature. Temperature-based control of the supply of operating power to the motor 12 during a stall condition can be attributed to changes in the environment in which the drive system 10 operates. Dynamic and static timeouts for a stalled motor, based on temperature and time, respectively, can both prevent overheating and damage to the drive system 10. Once the fluid sensor 101 senses a change in a fluid parameter indicating that spraying operation has resumed, the controller 15 can resume supplying power to the motor 12.

[0225] Controller 15 can reverse the direction of rotation of rotor 22 based on the power supplied to motor 12. For example, controller 15 can cause rotor 22 to rotate clockwise for a number of complete revolutions, and then counterclockwise for a number of complete revolutions. Regardless of whether rotor 22 rotates clockwise or counterclockwise, drive mechanism 14 will still reciprocate fluid displacement member 16 in the same manner. For example, rotor 22 can rotate clockwise for a number of complete revolutions to drive the piston through a first number of pumping strokes, and then rotate counterclockwise for a number of complete revolutions to drive the piston through a second number of pumping strokes. Switching between clockwise and counterclockwise rotation of rotor 22 can increase component wear life by providing more even wear on parts (e.g., bearings) and can minimize side loading on fluid displacement member 16. Reversing the direction of rotation can also be used to troubleshoot problems, such as a locked rotor condition. Reversing the direction of rotation can immediately release pressure on fluid displacement member 16, aiding in loosening fluid displacement member 16. For example, it may be difficult to start the motor 12 against the pressure. Changing the direction of rotation provides a 90-degree transition, allowing the fluid displacement member to encounter the load when moving in the opposite direction and, with some momentum, ramrod into the load on another pump stroke. It should be understood that the controller 15 can be configured to reverse the direction of rotation of the rotor 22 based on various operating conditions.

[0226] Controller 15 can periodically reverse the direction of rotor 22, for example, based on a schedule. For example, after rotating in a first direction for a predetermined amount of time, controller 15 can cause rotor 22 to rotate in a second direction, opposite the first direction, for the same or a different predetermined or given amount of time. Upon expiration of this amount of time, controller 15 can wait until the moment of stall to reverse the direction of rotor 22 so as not to reverse rotor 22 during pumping. Alternatively, controller 15 can time the reversal of rotor 22's rotation based on a reversal of direction of the fluid displacement member 16's stroke (e.g., when fluid displacement member 16 is at the top or bottom of its stroke and reverses direction regardless).

[0227] Controller 15 can reverse the direction of rotor 22 based on the number of pump cycles. For example, rotor 22 can be reversed based on a predetermined number of complete revolutions of rotor 22 in one direction (e.g., 1,000 revolutions) before switching to the other direction for a predetermined or another predetermined number of rotations and before switching back again. For example, motor revolutions can be determined based on information generated by motor sensor 102. In some examples, a sensor can be associated with fluid displacement member 16 to sense displacement and count pump cycles. A predetermined number of pump strokes (where two pump strokes constitute a complete pump cycle) can be used instead of motor revolutions. In some examples, pump cycles or strokes can be counted using pressure spikes experienced by pressure transducer 101. Thus, the periodic reversal of rotor 22 can be based on information from motor sensor 102, pressure transducer 101, or another sensor in the system.

[0228] The controller 15 can reverse the direction of the rotor 22 based on the fact that power to the sprayer has been turned off, for example, by actuating a power switch. For example, when a user turns the sprayer on, the controller 15 can cause the rotor 22 to rotate in a first direction as needed until the sprayer is turned off. When the user turns the sprayer back on, the controller 15 causes the rotor 22 to rotate in a second direction as needed until the sprayer is turned off again. This can continue, switching the rotational direction of the rotor 22 based on the sprayer being turned on and off. In some examples, the controller 15 can reverse the rotational direction based on the backup power being turned off (e.g., when the sprayer is unplugged). Thus, each time the sprayer is plugged back in and activated, the rotor 22 can start in the new rotational direction.

[0229] The controller 15 may monitor fluid parameters using the fluid sensor 101 and / or may monitor the current drawn by the motor 12 and may switch the rotational direction of the rotor 22 based on the monitored parameters. For example, if the current draw of the motor 12 exceeds a threshold (which may indicate increased resistance), the controller 15 may cause the rotor 22 to reverse direction. In some embodiments, if the rotor 22 stalls and the set pressure has not yet been reached, indicating an inability to reach pressure, the controller 15 may cause the rotor 22 to reverse direction. In some embodiments, if the rotor 22 is rotating in a first direction and still cannot reach the set pressure after a predetermined amount of time, indicating an inefficiency error, the controller 15 may cause the rotor 22 to reverse direction to rotate in a second direction.

[0230] If rotor 22 fails to complete a full revolution, as indicated, for example, by motor sensor 102, controller 15 may cause rotor 22 to switch rotational direction. For example, if rotor 22 completes a partial revolution in a first direction but is unable to complete a full revolution, and the actual pressure is less than the target pressure, this may indicate a locked rotor condition or a jam or other obstruction. Based on such a condition, controller 15 may cause rotor 22 to rotate in a second direction. If rotor 22 is unable to complete a full revolution in the second direction, controller 15 may again cause rotor 22 to reverse direction. This may be repeated until rotor 22 is able to complete a full revolution, either for a predetermined period of time or for a predetermined number of switches, among other options. Controller 15 may be configured to generate an error code based on rotor 22's failure to rotate when not under pressure, and may provide this error information to the user, for example, via user interface 17. In some examples, controller 15 may cause rotor 22 to continue switching between rotational directions, which may result in some pumping depending on the displacement provided by pump 19, thereby allowing the system to operate at partial capacity.

[0231] During a locked condition in which the rotor 22 is unable to complete a full 360-degree rotation, the controller 15 may cause the rotor 22 to rotate in a first rotational direction until it stops (due to a blockage / lock), and then in an opposite, second rotational direction until it stops (due to a blockage / lock). The controller 15 may continue to reverse the rotation until a predetermined switching threshold (e.g., the number of direction reversals) is reached, until the locked condition is broken. The controller 15 may be configured to generate an error code based on the rotor 22's failure to rotate when not under pressure, and may provide this error information to the user, for example, via the user interface 17. If the rotor 22 is able to complete a full 360-degree rotation, the controller 15 continues to drive the rotor 22 to establish the actual pressure at the target pressure. If the lock / blockage is overcome, the controller 15 then resumes operating the rotor 22 in pumping mode. In some examples, the controller 15 may cause the rotor 22 to continue switching between rotational directions, which may result in some pumping depending on the displacement provided by the pump 19, thereby allowing the system to operate at partial capacity.

[0232] The controller 15 can cause the rotor 22 to reverse direction periodically based on a time-based or event-based schedule (e.g., based on the calendar, time of use, each time the sprayer is turned off or unplugged, number of revolutions, etc.). The controller 15 can also cause the rotor 22 to reverse direction in response to a blockage or inefficiency in motor operation. For example, the controller 15 can cause the rotor 22 to reverse direction if the rotor 22 is unable to complete a full revolution or if the rotor 22 is rotating but cannot meet a set pressure.

[0233] During operation, control circuitry 13 can determine whether motor 12 is rotating, for example, based on pressure sensor 101 or motor sensor 102. If motor 12 is rotating, rotation can continue in the current direction of rotation. If motor 12 is not rotating, controller 15 can determine whether power to motor 12 has been interrupted (e.g., the sprayer has been turned off or unplugged). If power to motor 12 has been interrupted, controller 15 can cause rotor 22 to change its direction of rotation the next time motor 12 is operated.

[0234] During operation, control circuitry 15 can determine a reversal of rotor 22 based on a time threshold and / or an event threshold. For example, if a predetermined time threshold (e.g., 15 minutes of operation, 1 hour of operation, 5 hours of operation, or other time) has been reached since the last reversal, control circuitry 15 can initiate a reversal. The predetermined time threshold can be based on the time power has been supplied to motor 12 or the time rotor 22 has actually rotated, among other options. In another example, if a predetermined revolution threshold (e.g., 500 revolutions, 1,000 revolutions, 10,000 revolutions, or other revolution count) has been reached since the last reversal, control circuitry 15 can initiate a reversal. If a time and / or event threshold is reached, such as if the revolutions per minute are below a threshold or based on fluid displacement member 16 being at the end of its stroke, control circuitry 15 can cause rotor 22 to reverse direction the next time rotor 22 stops and subsequently begins rotating, or during rotation of rotor 22.

[0235] In some examples, the control circuit 15 can stop supplying power to the motor based on a predetermined push time threshold (e.g., 5 seconds, 1 minute, 5 minutes, or other period of inactivity). For example, even when the motor 12 stalls, the control circuit 15 will continue to supply current to provide fluid propulsion, maintain pressure, and enable a quick response when spraying resumes. If the predetermined push time has not been reached, the control circuit 15 can determine whether a predetermined maximum temperature (e.g., the temperature of the motor or the temperature of the ambient air) has been reached. If the predetermined maximum temperature has been reached, the control circuit 15 can stop supplying operating power to the motor 12. If the predetermined temperature has not been reached, the control circuit 15 can continue supplying power to the motor 12 to continue propulsion until the predetermined push time or the predetermined temperature is reached.

[0236] The control circuit 15 can determine, for example, whether the target pressure has been reached based on data from the pressure sensor 101. The control circuit 15 can determine when the rotor 22 is rotating based on data from the motor sensor 102. If the rotor 22 is able to rotate but has not yet reached the target pressure, the control circuit 15 can cause the rotor 22 to reverse its rotational direction. If the pressure is below the target pressure but the rotor is stalled or has a low rotation per minute (e.g., below a minimum threshold), the controller 15 can cause the rotor 22 to reverse its rotational direction. Based on the low target pressure and the operating state of the rotor 22 (e.g., speed), the controller 15 can cause the rotor 22 to continue reversing its direction in an attempt to overcome an inefficient, locked rotor, or other obstruction. In some examples, the controller 15 can provide an error code to the user via the user interface 17, for example, if the rotor 22 has reversed a set number of times and has not broken the lock / obstruction.

[0237] The examples discussed with respect to controller 15 controlling the rotation of rotor 22 and the supply of current to motor 12 are non-limiting examples. Additional, fewer, and / or alternative steps may be taken. For example, drive system 10 may operate with or without constant rotor thrust, and the direction of motor rotation may be reversed based on any one or more of scheduled (e.g., time-based or event-based) conditions or operating conditions (e.g., a blockage).

[0238] While the pumping assemblies of the present disclosure and claims are discussed in the context of a spray system, it should be understood that the pumping assemblies and controls can be utilized in a variety of fluid handling contexts and systems and are not limited to those discussed. Any one or more of the pumping assemblies discussed can be utilized alone or in conjunction with one or more additional pumps to deliver fluid for any desired purpose (e.g., position delivery, spraying, metering, application, etc.).

[0239] Discussion of non-exclusive examples

[0240] The following is a non-exclusive description of possible examples of the invention.

[0241] A drive system for a reciprocating fluid displacement pump includes an electric motor, a drive device, and a fluid displacement member. The motor includes a stator defining an axis and a rotor coaxially disposed about the stator. The drive device is directly connected to the rotor to receive a rotational output from the rotor. The fluid displacement member is mechanically coupled to the drive device. The drive member converts the rotational output into a linear reciprocating input to the fluid displacement member.

[0242] Additionally and / or alternatively, the drive system of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional components:

[0243] The fluid displacement member is mechanically coupled to the drive arrangement at an output end of the electric motor.

[0244] The electric motor further includes an electrical input end configured to receive electrical power, the electrical input end being disposed opposite the output end on the axis.

[0245] A pump frame mechanically supports the electric motor.

[0246] The electric motor extends in a cantilevered manner from the pump frame.

[0247] The output end of the electric motor is coupled to the pump frame such that an end of the electric motor disposed opposite the output end is a free end of the electric motor extending in a cantilevered manner.

[0248] The pump frame is mechanically coupled to each of the rotor and the stator.

[0249] A coupling member connects the pump frame to the shaft of the stator such that the stator is fixed relative to the pump frame.

[0250] The coupling member is connected to the shaft at the free end of the electric motor.

[0251] The coupling member extends from the pump frame to the shaft around the exterior of the rotor.

[0252] The coupling member includes an axially extending portion extending from the pump frame across the exterior of the rotor, wherein the axially extending portion is radially separated from the rotor, and a radially extending portion extending from the axially extending portion to the shaft, wherein the radially extending portion is axially separated from the rotor.

[0253] The rotor is formed from a housing and includes an array of permanent magnets on an inner circumferential surface of the housing.

[0254] The housing extends around three sides of the stator and wherein the housing is rotatably coupled to a pump frame at an output end of the electric motor that is coupled to the drive device.

[0255] The housing radially overlaps the stator at the output end and radially overlaps the stator at an input end of the electric motor that is located opposite the output end.

[0256] The stator is fixed to a shaft, and wherein the shaft extends axially outward from the housing at the input end.

[0257] A coupling member connects the pump frame to the shaft such that the stator is fixed relative to the pump frame.

[0258] a pump frame supporting the electric motor, wherein the electric motor is supported by the pump frame at an output end of the electric motor coupled to the drive device; and a first bearing disposed between the pump frame and the rotor at the output end to support the rotor and allow rotational movement of the rotor relative to the pump frame.

[0259] The rotor extends through the pump frame, and wherein the rotor is coupled to an inner race of the bearing and the pump frame is coupled to an outer race of the bearing.

[0260] The pump frame is mechanically coupled to a shaft of the stator at an input end opposite the output end, wherein the input end is configured to receive an electrical input.

[0261] A coupling member extends from the pump frame to the shaft around the exterior of the rotor to secure the stator relative to the pump frame.

[0262] In another example, a method of driving a reciprocating pump includes: providing power to an electric motor to cause rotation of a rotor of the motor, the rotor being disposed outside and around a stator of the motor; receiving a rotational output from the rotor at a drive device directly connected to the rotor; converting the rotational output directly into a linear reciprocating motion by the drive device; and providing a linear reciprocating input to a fluid displacement member connected to the drive device by the drive device to cause the pump rod to pump fluid through the reciprocating motion.

[0263] Additionally and / or alternatively, the method of the preceding paragraph may optionally include any one or more of the following features, configurations, additional components and / or steps:

[0264] The rotational output is received from a first end of the electric motor, and an electrical input is provided to a second end of the electric motor opposite the first end.

[0265] The electric motor is mechanically supported by a pump frame disposed at the first end.

[0266] The rotor is rotatably coupled to the pump frame at the first end, and the stator is mechanically fixed to the pump frame at the second end.

[0267] In yet another example, a fluid displacement device includes an electric motor, a drive device, a pump, and a pump frame. The motor includes a stator defining an axis and a rotor disposed about the stator. The drive device is coupled to the rotor to receive a rotational output from the rotor and convert the rotational output into a linear reciprocating motion. The pump includes a piston and a cylinder, the piston receiving the linear reciprocating motion from the drive device to reciprocate the piston within the cylinder. The cylinder and the stator are coupled to the pump frame to stabilize the stator relative to the rotor and the cylinder relative to the piston.

[0268] Additionally and / or alternatively, the fluid displacement device of the preceding paragraph may optionally include any one or more of the following features, configurations, and / or additional components:

[0269] One or more coupling members. The stator includes a first end and a second end opposite the first end, the first end being attached to the pump frame and the second end extending away from the pump frame, and the one or more coupling members are attached to the second end of the stator and extend along the exterior of the rotor to connect to the pump frame.

[0270] One or more wires extend into the second end of the stator, the one or more wires providing power to operate the stator.

[0271] In yet another example, a drive system for a reciprocating fluid displacement pump includes an electric motor, a drive device, a fluid displacement member, and a support frame. The electric motor includes a stator disposed on an axis and supported by a shaft, and a rotor coaxially disposed about the stator. The drive device is directly connected to the rotor to receive a rotational output from the rotor. The fluid displacement member is mechanically coupled to the drive device, wherein the drive device is configured to convert the rotational output into a linear reciprocating input to the fluid displacement member. The support frame is configured to mechanically support the electric motor and the fluid displacement pump, wherein the support frame is mechanically coupled to the stator.

[0272] Additionally and / or alternatively, the drive system of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional components:

[0273] The support frame is coupled to the rotor at a first end of the electric motor via a first bearing that allows the rotor to rotate within the support frame.

[0274] The support frame is mechanically coupled to the stator at a second end of the electric motor axially opposite a first end of the motor, wherein the drive arrangement is connected to the rotor at the first end.

[0275] The support frame includes a first frame member at the first end, a second frame member coupled to the stator at the second end, and at least one connecting member connecting the first and second frame members. The at least one connecting member extends across an outer surface of the rotor and is spaced apart from the rotor to allow the rotor to rotate within the support frame.

[0276] The second frame member includes at least one protruding member, wherein the at least one protruding member extends radially outward from the axis such that a distal end of the at least one protruding member is disposed radially outward from the rotor, and wherein the at least one axially extending member is connected to the at least one protruding member.

[0277] The electric motor extends in a cantilevered manner from the first frame member such that the first end is connected to the first frame member and the second end extends in a cantilevered manner.

[0278] The second frame member includes a plurality of protruding members, wherein the protruding members of the plurality of protruding members are symmetrically arranged around an axis of the electric motor.

[0279] The second frame member includes a plurality of protruding members, wherein the protruding members of the plurality of protruding members are asymmetrically arranged about the axis.

[0280] The plurality of protruding members includes one of three protruding members and four protruding members.

[0281] The protruding members of the plurality of protruding members are arranged in an X-shaped configuration.

[0282] The protruding members of the plurality of protruding members are arranged in a Y-shaped configuration.

[0283] The first frame member includes at least one protruding member extending radially outward from the rotor, and wherein the at least one connecting member is connected to the at least one protruding member of the first frame member.

[0284] The first frame member includes a first plurality of protruding members, and the second frame member includes a second plurality of protruding members, and wherein a plurality of connecting members connects the first and second pluralities of protruding members.

[0285] Protruding members of the first plurality of protruding members are axially aligned with protruding members of the second plurality of protruding members.

[0286] The at least one connecting member is a tie rod.

[0287] The second frame member is in fixed contact with the shaft.

[0288] The second frame member is supported by the shaft and contacts an outer radial surface of the shaft.

[0289] The second frame member is in contact with an end surface of the shaft.

[0290] A retaining element is in fixed contact with the second frame member and the radially inner surface of the shaft.

[0291] The shaft is formed of a conductive material to transfer heat from the stator to the second frame member.

[0292] The second frame member is mechanically coupled to the shaft adjacent a second bearing, and wherein the first and second frame members compress the first and second bearings therebetween to preload the first and second bearings.

[0293] A wave spring washer is disposed between the second bearing and the second frame member.

[0294] A retaining element, wherein the retaining element secures the second frame member to the shaft.

[0295] The retaining element is connected to the shaft via an interfacing thread.

[0296] A control panel is mechanically coupled to the first and second frame members and partially surrounds the rotor.

[0297] The first frame member forms a pump frame configured to partially house the fluid displacement member.

[0298] The support frame includes a plurality of connection members extending across the exterior of the rotor between a first frame member at a first end of the motor and a second frame member at a second end of the motor, the drive member being connected to the rotor at the first end of the motor, and the support frame being configured to support both torque loads and pump reaction loads.

[0299] The connection members of the first subset are positioned to support torque loads and pump reaction loads.

[0300] In another example, a support frame for a reciprocating fluid displacement pump drive system includes a first frame member, a second frame member, and at least one connecting member. The reciprocating fluid displacement pump drive system has an electric motor with an inner stator and an outer rotor. The second frame member is disposed at an end of the electric motor opposite to the first frame member and is separate from the first frame member. The at least one connecting member extends between the first frame member and the second frame member and connects the first frame member and the second frame member. The second frame member and the at least one connecting member are configured to at least partially accommodate the electric motor and mechanically support the electric motor with the outer rotor.

[0301] Additionally and / or alternatively, the support frame of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional components:

[0302] The first frame member and the second frame member each include at least three protruding members, and wherein the connecting member connects the protruding members of the first frame member with the protruding members of the second frame member.

[0303] The protruding member of the first frame member is axially aligned with the protruding member of the second frame member.

[0304] The protruding members of each of the first and second frame members are arranged in one of a Y-shaped configuration and an X-shaped configuration.

[0305] The connecting member is a tie rod.

[0306] In another example, a fluid displacement device includes an electric motor extending along an axis to have a first end and a second end, a drive device, a pump, a pump frame, and a motor frame. The electric motor includes a stator extending along the axis and a rotor disposed about the stator and extending along the axis. The drive device is connected to the rotor to receive a rotational output from the rotor and convert the rotational output into a linear reciprocating motion. The pump includes a piston and a cylinder, the piston receiving the linear reciprocating motion from the drive device to cause the piston to reciprocate within the cylinder. The cylinder and the stator are connected to the pump frame to stabilize the cylinder relative to the piston. The motor frame stabilizes the stator. The motor frame includes a plurality of connecting members extending from the first end of the motor to the second end of the motor. The plurality of connecting members are arranged around the rotor.

[0307] Additionally and / or alternatively, the fluid displacement device of the preceding paragraph may optionally include any one or more of the following features, configurations, and / or additional components:

[0308] The motor frame is fixed relative to the pump frame.

[0309] A first frame member and a second frame member are provided. The first frame member is located on the first end of the motor, and the second frame member is located on the second end of the motor. Each of the plurality of connecting members extends from the first frame member to the second frame member.

[0310] The first frame member, the second frame member, and the plurality of connecting members form an exoskeleton around the motor that structurally supports the motor while allowing airflow through the exoskeleton and around the rotor.

[0311] Either the first frame member or the second frame member is star-shaped.

[0312] In yet another example, a drive system for a reciprocating pump for pumping fluid includes an electric motor and a drive member. The electric motor includes a rotor. The rotor includes an eccentric drive extending from the rotor. The drive member is directly coupled to the eccentric drive and is configured to drive reciprocating motion of a fluid displacement member.

[0313] Additionally and / or alternatively, the drive system of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional components:

[0314] The eccentric drive is directly coupled to the drive member to provide a 1:1 ratio of rotor rotation to pump cycle.

[0315] The eccentric drive projects axially outward from an end of the rotor and is offset from the axis of rotation of the rotor.

[0316] The drive member is coupled to the eccentric drive via a bearing element, which allows relative movement between the eccentric drive and the drive member.

[0317] The eccentric drive is formed integrally with the rotor.

[0318] The eccentric drive extends into the bore of the rotor and is secured to the rotor.

[0319] The driving device includes a sleeve and a bolt, wherein the sleeve is received in the hole of the rotor, and the bolt is received in the sleeve and threadedly fastened to the rotor.

[0320] The rotor is coaxially disposed around the stator.

[0321] The rotor is formed by a housing extending around the stator, wherein the housing includes an array of permanent magnets on an inner circumference.

[0322] The housing comprises a first cylindrical projection comprising the eccentric drive.

[0323] The first cylindrical protrusion extends from a front end portion of the housing in a first axial direction, and wherein the housing further comprises a second cylindrical protrusion extending from the front end portion of the housing in a second axial direction into a shaft of the stator.

[0324] The eccentric drive includes a pin extending into each of the first cylindrical protrusion and the second protrusion.

[0325] The eccentric drive device is formed of a non-ferrous metal material.

[0326] The housing further includes a spacing member, wherein the spacing member extends axially outward from the first cylindrical protrusion and supports the eccentric drive.

[0327] The drive system further includes a pump frame, and wherein the first cylindrical protrusion is coupled to the pump frame via a first bearing, wherein the first bearing allows rotational movement of the rotor relative to the pump frame.

[0328] The first cylindrical protrusion is coupled to the first bearing.

[0329] The housing extends through the pump frame, and wherein the eccentric drive and drive member are positioned axially outboard of the first bearing.

[0330] The eccentric drive and drive member are positioned axially inwardly of the first bearing.

[0331] The eccentric drive is formed integrally with the rotor.

[0332] No gears are provided between the rotor and the fluid displacement member.

[0333] The pump is a dual displacement pump.

[0334] In yet another example, a method of driving a reciprocating pump includes: providing power to an electric motor to cause a rotor to rotate about a rotational axis; providing a rotational output of the electric motor directly to a drive member; providing a linear reciprocating input to a pump rod of the pump through the drive member; and spraying fluid from the fluid displacement pump onto a surface. The fluid displacement pump performs one pump cycle for one revolution of the rotor.

[0335] Additionally and / or alternatively, the method of the preceding paragraph may optionally include any one or more of the following features, configurations, additional components and / or steps:

[0336] A rotational output is provided by an eccentric drive on the rotor, wherein the eccentric drive is located offset from the axis of rotation.

[0337] The eccentric drive is formed integrally with the rotor or extends into and is fixed to the rotor.

[0338] In yet another example, a pumping system includes an electric motor, a drive member, and a reciprocating pump. The electric motor includes a rotor. The rotor includes an eccentric drive extending from the rotor. The drive member is directly coupled to the eccentric drive. The reciprocating pump includes a fluid displacement member coupled to the drive member and a pump cylinder that at least partially houses the fluid displacement member. The drive member is configured to drive reciprocating motion of the fluid displacement member.

[0339] Additionally and / or alternatively, the pumping system of the preceding paragraph may optionally include any one or more of the following features, configurations, and / or additional components:

[0340] The eccentric drive is directly coupled to the drive member to provide a 1:1 ratio of rotor rotation to pump cycle.

[0341] The eccentric drive projects axially outward from an end of the rotor and is offset from the axis of rotation of the rotor.

[0342] The eccentric drive is formed integrally with the rotor or extends into the rotor.

[0343] The rotor is rotatably coupled to the pump frame via a first bearing, and wherein the eccentric drive and the drive member are positioned axially inwardly of the first bearing.

[0344] The rotor is rotatably coupled to the pump frame via a second bearing, and wherein the eccentric drive and the drive member are positioned axially outboard of the second bearing.

[0345] The reciprocating pump is a dual displacement pump such that the reciprocating pump is configured to output fluid during each of an upstroke and a downstroke of the fluid displacement member.

[0346] In yet another example, a drive system for a fluid displacement pump includes an electric motor, a drive device, a fluid displacement member, and a pump frame. The electric motor includes a stator and a rotor. The stator and the rotor are disposed on an axis. The drive device is coupled to the rotor at a first end of the electric motor. The fluid displacement member is mechanically coupled to the drive device such that the electric motor is subjected to a pump load generated by the reciprocating motion of the fluid displacement member during pumping. The pump frame is mechanically coupled to the electric motor and is configured to support the fluid displacement pump and the electric motor.

[0347] Additionally and / or alternatively, the drive system of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional components:

[0348] One of the pump frame and the stator is coupled to the rotor at the first end by a first bearing, the first bearing allowing rotational movement of the rotor relative to the one of the pump frame and the stator and supporting a pump load, wherein the pump load is an axial load along the axis of reciprocating motion of the pump.

[0349] The pump frame is mechanically coupled to the stator at a rear end of the electric motor opposite the first end.

[0350] The rotor is coaxially disposed around the stator, and wherein the rotor is formed by a housing and a plurality of magnets on an inner circumferential surface of the housing.

[0351] The housing is coupled to an inner race of the first bearing, and the pump frame is coupled to an outer race of the first bearing.

[0352] A second bearing is disposed between the rotor and the stator adjacent the rear end to permit rotational movement of the rotor relative to the stator, the second bearing being positioned to withstand pump loads.

[0353] The rotor is coupled to an outer race of the second bearing, and the stator is coupled to an inner race of the second bearing.

[0354] The rotor is coupled to an inner race of the second bearing, and the stator is coupled to an outer race of the second bearing.

[0355] The rotor extends into the shaft of the stator at the first end.

[0356] A third bearing is disposed between the rotor and the shaft to allow rotational movement of the rotor relative to the stator and to support the rotor relative to the stator such that an air gap is maintained between the stator and a permanent magnet array disposed on the rotor.

[0357] The rotor is coupled to an inner race of the third bearing, and the shaft is coupled to an outer race of the third bearing.

[0358] The first bearing is located at a first radius from an axis of rotation of the electric motor, and the second bearing is located at a second radius from the axis of rotation, wherein the first radius is greater than the second radius.

[0359] The third bearing member is positioned at a third radius from the rotational axis, wherein the third radius is greater than the second radius and less than the first radius.

[0360] The stator is coupled to the rotor at the first end via the first bearing, and wherein the stator is mechanically fixed to the pump frame at the first end, wherein a pump reaction force generated by the fluid displacement member during pumping is transmitted to the pump frame via the drive device, the rotor, the first bearing, and the stator.

[0361] The stator is coupled to the rotor at a rear end opposite the first end of the electric motor by a second bearing, the second bearing permitting rotational movement of the rotor relative to the stator, and wherein a pump reaction force generated by the fluid displacement member during pumping is transmitted to the pump frame via the drive device, the rotor, the first bearing, the second bearing, and the stator.

[0362] In yet another example, a drive system for a reciprocating fluid displacement system includes an electric motor, a drive device, a fluid displacement member, and a pump frame. The electric motor includes a stator and a rotor. The stator and rotor are disposed on an axis. The drive device is coupled to the rotor at a first end of the electric motor. The fluid displacement member is mechanically coupled to the drive device, wherein the drive device converts a rotational output from the rotor into a linear reciprocating input to the fluid displacement member. The pump frame is mechanically coupled to the electric motor. A pump reaction force generated by the fluid displacement member during pumping is transmitted to the pump frame via the drive device and the rotor.

[0363] Additionally and / or alternatively, the drive system of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional components:

[0364] A first bearing is disposed at the first end between the rotor and one of the stator and the pump frame. The first bearing supports a pump load, which is an axial load along the reciprocating axis of the pump.

[0365] A pump reaction force generated by the fluid displacement member during pumping is transmitted to the pump frame via the drive device, the rotor, and the first bearing.

[0366] A pump reaction force generated by the fluid displacement member during pumping is transmitted to the pump frame via a drive device, the rotor, the first bearing, and the stator.

[0367] A second bearing is disposed between the rotor and the stator at a rear end of the electric motor opposite the first end, the second bearing being positioned to experience a pump load.

[0368] The pump frame is mechanically fixed to the stator at a rear end and is completely decoupled from the stator at the first end, and wherein a pump reaction force generated by the fluid displacement member during pumping is transmitted to the pump frame via the drive device, the rotor, the second bearing and the stator.

[0369] a third bearing disposed at the first end between the rotor and the shaft of the stator to provide rotational movement of the rotor relative to the stator and maintain a gap between the stator and a plurality of permanent magnets disposed on the rotor, wherein the rotor is coupled to an inner race of the third bearing, and the shaft is coupled to an outer race of the third bearing.

[0370] The third bearing is axially disposed between the first bearing and the second bearing.

[0371] The pump frame is mechanically fixed to the stator at the first end, and wherein a pump reaction force generated by the fluid displacement member during pumping is transmitted to the pump frame via the drive, the rotor, the second bearing, and the stator.

[0372] The first bearing is located at a first radius from an axis of rotation of the electric motor, and the second bearing is located at a second radius from the axis of rotation, wherein the first radius is greater than the second radius.

[0373] In yet another example, a pumping apparatus includes a frame, at least two bearings, an electric motor, a drive device, and a pump. The electric motor includes a stator and a rotor, the rotor being configured to output rotational motion. The rotor is supported by the at least two bearings, which support the rotation of the rotor. The drive device is configured to receive the rotational motion and convert the rotational motion into linear reciprocating motion. The pump includes a piston and a cylinder. The piston is configured to receive the linear reciprocating motion to reciprocate within the cylinder through an upstroke and a downstroke. When moving through the upstroke, the piston receives a downward reaction force, and when moving through the downstroke, the piston receives an upward reaction force. Both the upward reaction force and the downward reaction force travel through the drive device, the rotor, and then to the at least two bearings.

[0374] Additionally and / or alternatively, the pumping apparatus of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional components:

[0375] The at least two bearings transmit both the rotational force associated with the rotation of the rotor and the upward and downward reaction forces to the frame.

[0376] In yet another example, a drive system for powering a reciprocating pump for pumping fluid to generate a fluid spray includes an electric motor, an eccentric drive member, and a drive device. The electric motor includes a stator and a rotor. The rotor is configured to rotate about a rotational axis. The eccentric drive member extends from the rotor. The drive device is coupled to the eccentric drive and configured to drive reciprocating motion of the fluid displacement member.

[0377] Additionally and / or alternatively, the drive system of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional components:

[0378] The eccentric drive member is directly coupled to the rotor and directly coupled to the drive to provide a 1:1 ratio of rotor rotation to pump cycle of the fluid displacement member.

[0379] The eccentric drive member projects axially outwardly from an end of the rotor and is radially offset from the axis of rotation.

[0380] The drive arrangement is coupled to the eccentric drive member via a bearing that allows relative movement between the eccentric drive member and the drive arrangement.

[0381] The eccentric drive member is integrally formed with the rotor.

[0382] The eccentric drive member extends into a bore formed in the body of the rotor and is secured to the rotor within the bore.

[0383] The eccentric drive member includes a sleeve and a bolt, wherein the sleeve is received in the bore of the rotor, and the bolt is received in the sleeve and threadably fastened to the rotor.

[0384] The rotor is formed by a housing extending around the stator, wherein the housing includes an array of permanent magnets on an inner circumference of a body of the housing.

[0385] The housing includes a first cylindrical projection extending axially along the rotational axis and including the eccentric drive member.

[0386] The first cylindrical protrusion extends from the first end of the housing in a first axial direction, and wherein the housing further includes a second cylindrical protrusion extending from the first end of the housing into the shaft of the stator in a second axial direction, the second axial direction being opposite to the first axial direction.

[0387] The eccentric drive member includes a pin extending into each of the first cylindrical protrusion and the second protrusion.

[0388] The eccentric drive member is formed of a non-ferrous metal material.

[0389] A pump frame, and wherein the first cylindrical protrusion is coupled to the pump frame.

[0390] The first cylindrical protrusion is coupled to the pump frame via a first bearing, wherein the first bearing allows rotational movement of the rotor relative to the pump frame.

[0391] The housing extends through the first bearing such that the eccentric drive member and the drive arrangement are arranged on a side of the first bearing axially opposite the stator.

[0392] There are no gears coupling the rotor and the fluid displacement member.

[0393] In yet another example, a method of driving a reciprocating pump for generating a pressurized fluid spray for application to a surface includes: providing power to an electric motor to cause a rotor to rotate about a rotational axis; providing a rotational output from the rotor to a drive device; and providing a linear reciprocating input to a fluid displacement member of the pump via the drive device to cause the fluid displacement member to reciprocate along the pump axis to pump fluid. The rotor is connected to the fluid displacement member via the drive device such that the fluid displacement pump performs one pumping cycle for one revolution of the rotor.

[0394] Additionally and / or alternatively, the method of the preceding paragraph may optionally include any one or more of the following features, configurations, additional components and / or steps:

[0395] The rotational output is provided to the drive arrangement by an eccentric drive member coupled to and extending from the rotor, wherein the eccentric drive is configured to be radially offset from and rotate about the axis of rotation.

[0396] In yet another example, a pumping system for pumping fluid to produce a pressurized fluid spray includes an electric motor, an eccentric drive member, a drive device, and a reciprocating pump. The electric motor includes a stator and a rotor. The rotor is configured to rotate about a rotational axis. The eccentric drive member extends from the rotor. The drive device is coupled to the eccentric drive member to receive a rotational output from the rotor. The reciprocating pump includes a fluid displacement member coupled to the drive device and a pump cylinder that at least partially houses the fluid displacement member. The drive device is configured to receive the rotational output from the motor and convert the rotational output into linear reciprocating motion to drive the reciprocating motion of the fluid displacement member.

[0397] Additionally and / or alternatively, the pumping system of the preceding paragraph may optionally include any one or more of the following features, configurations, and / or additional components:

[0398] The eccentric drive member is directly coupled to the rotor and directly coupled to the drive to provide a 1:1 ratio of rotor rotation to pump cycle of the fluid displacement member.

[0399] The eccentric drive projects axially outward from an end of the rotor and away from the stator, and wherein the eccentric drive member is radially offset from the axis of rotation of the rotor.

[0400] The eccentric drive member is integrally formed with the main body of the rotor.

[0401] The rotor is rotatably coupled to the pump frame via a first bearing, and wherein the eccentric drive and drive member are positioned on an axially opposite side of the first bearing from the permanent magnet array of the rotor.

[0402] In yet another example, a drive system for a reciprocating fluid displacement pump configured to pump a fluid for spraying includes an electric motor, a drive device, and a fluid displacement member. The reciprocating fluid displacement pump includes an electric motor, a stator defining an axis, and a rotor coaxially disposed about the stator. The drive device is connected to the rotor to receive a rotational output from the rotor. The fluid displacement member is mechanically coupled to the drive device. The drive device converts the rotational output into a linear reciprocating input to the fluid displacement member to power the pumping performed by the fluid displacement member.

[0403] Additionally and / or alternatively, the drive system of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional components:

[0404] The fluid displacement member is mechanically coupled to the drive arrangement at a first axial end of the electric motor.

[0405] The electric motor further includes a second axial end portion through which the electric motor is configured to receive power, wherein the second axial end portion is disposed opposite the first axial end portion along the axis.

[0406] A pump frame mechanically supports the electric motor and the fluid displacement member.

[0407] The electric motor extends in a cantilevered manner from the pump frame.

[0408] The pump frame is mechanically coupled to each of the rotor and the stator.

[0409] A support member connects the pump frame to the shaft of the stator at the second axial end such that the stator is fixed to the pump frame to prevent relative movement of the stator and pump frame.

[0410] The support member extends from the pump frame to the shaft around the exterior of the rotor.

[0411] The rotor includes a housing and a permanent magnet array disposed on an inner circumferential surface of the housing.

[0412] The housing is rotatably coupled to a pump frame at a first axial end of the electric motor, wherein the pump frame supports the fluid displacement member.

[0413] The stator is fixed to the shaft, and wherein the housing completely radially overlaps the stator and the shaft at the first axial end and at least partially radially overlaps the stator at a second axial end of the electric motor located opposite the first end on the axis.

[0414] The housing includes an opening at the second axial end such that the housing is closed at the first axial end and open at the second axial end.

[0415] The shaft extends axially outwardly through the opening and beyond the housing at the second axial end.

[0416] The pump frame is statically connected to a portion of the shaft disposed outside the housing such that the stator is fixed to the pump frame at the second axial end.

[0417] A pump frame supports the electric motor, and a first bearing. The electric motor is dynamically supported by the pump frame at a first axial end of the electric motor coupled to the drive device. The first bearing is disposed between the pump frame and the rotor at the first axial end to support the rotor on the pump frame and allow rotational movement of the rotor relative to the pump frame.

[0418] The rotor extends through the pump frame, and wherein the rotor is coupled to an inner race of the bearing and the pump frame is coupled to an outer race of the bearing.

[0419] The pump frame is mechanically coupled to the stator at a second axial end of the electric motor opposite the first axial end.

[0420] The rotor is formed of a cylindrical body having a first end wall at the first axial rotor end and a second end wall at a second axial rotor end opposite the first axial rotor end, wherein the first wall is closed to completely radially overlap the stator, and wherein the second wall includes an opening extending through the second wall and aligned on the axis.

[0421] In yet another example, a method of driving a reciprocating pump to pump a fluid to produce a fluid spray for application to a surface includes: powering an electric motor to cause rotation of a rotor of the electric motor, the rotor being disposed outside and around a stator of the electric motor; receiving a rotational output from the rotor at a drive device connected to the rotor; converting the rotational output into a linear reciprocating motion by the drive device; and providing a linear reciprocating input to a fluid displacement member of the pump via the driver device, the fluid displacement member being connected to the drive device to cause the fluid displacement member to pump the fluid via the reciprocating motion.

[0422] Additionally and / or alternatively, the method of the preceding paragraph may optionally include any one or more of the following features, configurations, additional components and / or steps:

[0423] The rotational output is received from a first axial end of the electric motor and an electrical input is provided to the electric motor to power the electric motor through a second axial end of the electric motor disposed opposite the first axial end.

[0424] The electric motor is mechanically supported by a pump frame provided at the first axial end, and the reciprocating pump is mechanically supported by the pump frame.

[0425] The rotor is rotatably coupled to the pump frame at the first axial end, and the stator is mechanically fixed to the pump frame at the second axial end.

[0426] In yet another example, a fluid displacement device includes an electric motor, a drive device, a pump, and a pump frame. The electric motor includes a stator defining an axis and a rotor disposed about the stator for rotation about the stator. The drive device is coupled to the rotor to receive a rotational output from the rotor and convert the rotational output into a linear reciprocating motion. The pump includes a piston and a cylinder. The piston receives the linear reciprocating motion from the drive device to cause the piston to reciprocate within the cylinder. The cylinder and the stator are coupled to the pump frame to stabilize the stator relative to the rotor and the cylinder relative to the piston.

[0427] Additionally and / or alternatively, the fluid displacement device of the preceding paragraph may optionally include any one or more of the following features, configurations, and / or additional components:

[0428] The pump frame is dynamically coupled to the rotor at a first axial end of the electric motor such that the rotor can move relative to the pump frame, and the pump frame is statically coupled to the shaft of the stator at a second axial end of the electric motor opposite the first axial end such that the stator is fixed relative to the pump frame.

[0429] One or more wires extend into the stator at the second axial end, the one or more wires providing power to operate the stator.

[0430] In yet another example, a pumping system includes an electric motor, a drive device, a pump, and a pump frame. The electric motor includes a stator and a rotor. The stator and the rotor are arranged on an axis. The drive device is coupled to the rotor to receive a rotational output from the rotor and convert the rotational output into a linear reciprocating motion. The pump includes a piston and a cylinder, the piston receiving the linear reciprocating motion from the drive device to cause the piston to reciprocate within the cylinder. The cylinder and the stator are connected to the pump frame so that the stator is stable relative to the rotor and the cylinder is stable relative to the piston. The pumping system may include any one of the features of the pumping systems or apparatuses of the preceding paragraphs, any one or more of any features referenced herein and / or shown in any one or more of the accompanying drawings.

[0431] In yet another example, a sprayer includes an electric motor including a stator and a rotor configured to output rotational motion; a drive device that converts the rotational motion output by the electric motor into linear reciprocating motion; a pump including a piston configured to reciprocate linearly by the drive device; and a controller configured to output electrical energy to the electric motor to control operation of the electric motor.

[0432] Additionally and / or alternatively, the sprayer of the preceding paragraph may optionally include any one or more of the following features, configurations, and / or additional components:

[0433] The controller causes the electric motor to reverse the direction of rotation of the rotor between two modes. In a first mode, the rotor rotates clockwise for a plurality of complete revolutions to drive the piston through a first plurality of pumping strokes. In a second mode, the rotor rotates counterclockwise for a plurality of complete revolutions to drive the piston through a second plurality of pumping strokes.

[0434] The controller causes the rotor to periodically switch between the first mode and the second mode.

[0435] The controller causes the rotor to periodically switch between the first mode and the second mode based on a time-based schedule.

[0436] The controller causes the rotor to switch between the first mode and the second mode based on discontinuing the supply of electrical energy to the electric motor.

[0437] The controller causes the motorized rotor to switch between the first mode and the second mode based on turning the sprayer on and off.

[0438] The controller causes the rotor to switch between the first mode and the second mode based on a stall of the rotor.

[0439] The switching between the first mode and the second mode is based on achieving a locked rotor condition.

[0440] The controller causes the rotor to switch between the first mode and the second mode based on a rotational speed of the rotor.

[0441] The controller causes the rotor to switch between the first mode and the second mode based on a parameter of the spraying fluid measured downstream of the pump.

[0442] The controller causes the motorized rotor to switch between the first mode and the second mode based on the measured parameter not satisfying the set pressure within a predetermined period of time even while the piston reciprocates through the rotor.

[0443] The parameter is pressure.

[0444] The controller causes the rotor to switch between the first mode and the second mode based on the measured parameter failing to meet a set pressure.

[0445] The controller causes the electric motor to switch between the first mode and the second mode based on the measured parameter failing to satisfy the set pressure within a predetermined period of time as the piston reciprocates through the rotor.

[0446] The controller is configured to deliver drive power to the electric motor when the rotor stalls due to resistance of the spray fluid applied to the piston at a pressure level, and the controller is configured to continue delivering drive power to the electric motor so that the rotor is urged forward while the rotor stalls and pressure continues to be applied to the piston through the rotor and the drive device, and the rotor resumes rotation when the spray fluid pressure decreases.

[0447] The pressure level is set by the user.

[0448] When the spray fluid pressure drops below the pressure level, the rotor resumes rotation.

[0449] The controller is configured to discontinue delivery of driving power to the electric motor based on the rotor stalling for a predetermined period of time.

[0450] The predetermined time period is at least five minutes.

[0451] The fluid sensor is configured to monitor a parameter of the spray fluid output by the pump. The controller is configured to monitor the parameter when the controller has stopped supplying driving power to the electric motor, and based on a change in the parameter, resume supplying power to the electric motor to rotate the rotor to operate the pump.

[0452] The controller is configured to discontinue delivery of driving power to the electric motor based on a sensed temperature of the electric motor or surrounding ambient air.

[0453] A temperature sensor is configured to monitor the temperature of the electric motor and / or the surrounding ambient air.

[0454] The controller causes the electric rotor to switch between the first mode and the second mode based on a parameter of electrical energy delivered to the motor exceeding a threshold value.

[0455] The parameter is current.

[0456] The controller causes the motorized rotor to switch between the first mode and the second mode based on the measured parameter not satisfying the set pressure within a predetermined period of time even while the piston reciprocates through the rotor.

[0457] The controller is configured to stall the rotor based on resistance from the spraying fluid passing through the rotor.

[0458] The controller is configured to stall the rotor based on resistance from the spraying fluid passing through the rotor at a pressure level.

[0459] The controller is configured to continue to supply electrical power to the electric motor so that the rotor is urged forward when the rotor stalls, and so that pressure continues to be applied to the piston through the rotor and the drive device when the piston stalls.

[0460] The controller is configured to continue to supply electrical power to the electric motor so that the rotor is urged forward when the rotor stalls, so that pressure continues to be applied to the piston through the rotor and the drive device when the piston stalls, and the rotor resumes rotation when the spray fluid pressure decreases.

[0461] The controller is configured to continue to supply electrical power to the electric motor so that the rotor is constantly urged forward when the rotor stalls, so that pressure continues to be applied to the piston through the rotor and the drive device when the piston stalls, and so that when the spray fluid pressure drops below a pressure level due to the constant urging on the rotor, the rotor resumes rotation, thereby causing the piston to overcome the lower pressure of the spray fluid.

[0462] Although the present invention has been described with reference to preferred embodiment(s), those skilled in the art will understand that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

1. A fluid spraying machine comprising: An electric motor, the electric motor comprising a stator and a rotor, the stator and the rotor being arranged on an axis; a drive coupled to the rotor and configured to convert a rotational output of the rotor into linear reciprocating motion; and a pump comprising a fluid displacement member mechanically coupled to the drive device for reciprocation by the drive device; a fluid outlet for spraying the fluid output by the pump; a controller configured to output driving electrical energy to the electric motor to control operation of the electric motor; The controller is configured to receive a pressure setpoint set by a user and control a level of power supplied to the electric motor based on the pressure setpoint, such that the rotor stalls while power is supplied to the electric motor to control the output spray pressure relative to the pressure setpoint.

2. The fluid sprayer assembly of claim 1 , further comprising: A motor sensor is configured to sense rotation of the rotor on the axis, wherein the controller is configured to control a level of power provided to the electric motor based on an output from the motor sensor regarding a rotational state of the rotor.

3. The fluid sprayer assembly of claim 1, wherein the power level is an electrical current level.

4. The fluid sprayer assembly of claim 1 , wherein the controller is configured to deliver the drive power to the electric motor while the rotor remains stalled due to resistance of the spray fluid applied to the piston; and wherein the controller is configured to continue delivering the drive power to the electric motor such that the rotor pushes the fluid displacement member while the rotor remains stalled, thereby continuing to apply pressure to the fluid displacement member through the rotor and the drive device when the rotor is stationary.

5. The fluid sprayer assembly of claim 1, wherein the rotor resumes rotation from stall when the pressure of the spray fluid downstream of the pump decreases due to the spray gun resuming spraying. 6 . The fluid sprayer assembly of claim 1 , wherein the controller is configured to discontinue power to the electric motor based on the rotor being stalled for a period of time.

7. The fluid sprayer assembly of claim 6, wherein the time period is a predetermined time period.

8. The fluid sprayer assembly of claim 7, wherein the time period is greater than ten seconds.

9. The fluid sprayer assembly of claim 7, wherein the time period is greater than five minutes.

10. The fluid sprayer assembly of claim 1 , further comprising a fluid sensor configured to monitor a parameter of the spray fluid output by the pump, wherein the controller is configured to: monitoring the parameter when the controller has ceased delivering the driving power to the electric motor, and Based on the change in the parameter, the driving power is resumed to the electric motor to rotate the rotor to operate the pump.

11. The fluid sprayer assembly of claim 10, wherein the parameter is the pressure of the fluid output by the pump. 12 . The fluid sprayer assembly of claim 1 , wherein the controller is configured to initiate a count based on the rotor stalling, and wherein the controller is configured to stop providing the driving power to the electric motor based on the count reaching a count threshold.

13. The fluid sprayer assembly of claim 12, wherein the count is a time count and the count threshold is a time threshold.

14. The fluid sprayer assembly of claim 1, wherein the controller is configured to vary a level of power provided to the electric motor when the rotor stalls.

15. The fluid sprayer assembly of claim 1 , further comprising: a pressure transducer configured to generate pressure information regarding a pressure of a fluid output by the pump; wherein the controller is configured to determine a power level of the driving power provided to the electric motor based on pressure information output by the pressure transducer.

16. The fluid sprayer of claim 1, wherein: The electric motor includes a first axial end and a second axial end; The rotor includes a housing having an opening at the second axial end; The stator is at least partially located inside the rotor; a support frame supporting the electric motor; a stator support extending through the opening of the housing and holding the stator stationary relative to the support frame; and The pump is positioned closer to the first end of the electric motor than to the second end of the electric motor.

17. A method for spraying a fluid using a fluid sprayer, the method comprising: receiving a pressure setting value set by a user through a controller of the electric motor, the pressure setting value corresponding to a set output pressure of a pump, the pump being connected to the electric motor through a drive device to be driven by the electric motor via the drive device, and the pump pumping fluid to a downstream fluid outlet for spraying, the electric motor including a stator and a rotor, the rotor being configured to rotate on an axis; providing driving power to the electric motor through the controller to power the electric motor; as well as A power level provided to the electric motor is controlled by the controller based on the pressure set point such that the rotor is stalled while power is delivered to the electric motor to control output spray pressure relative to the pressure set point.

18. A fluid displacement pump assembly comprising: An electric motor, comprising: stator; and a rotor, said stator and said rotor being arranged on an axis; and a drive coupled to the rotor at a first end of the electric motor; a pump comprising a fluid displacement member mechanically coupled to the drive device, wherein the drive device converts a rotational output into a reciprocating input to the fluid displacement member; a pump frame mechanically attached to the electric motor; and An eccentric drive extends from the rotor, wherein the eccentric drive is coupled to the rotor and to the drive arrangement to provide a 1:1 ratio of rotor rotation to pump cycle.

19. A method for driving a reciprocating pump, the method comprising: providing electrical power to an electric motor to cause a rotor of said motor to rotate; receiving a rotational output from the rotor at a drive coupled to the rotor; The driving device converts the rotational output into a linear reciprocating motion; providing a linear reciprocating input from the drive device to a fluid displacement member connected to the drive device to cause the pump rod to pump the fluid through reciprocating motion; and The reciprocating pump and the electric motor are mechanically supported by a pump frame.

20. A pumping system comprising: An electric motor, comprising: stator; and a rotor, said stator and said rotor being arranged on an axis; and a drive coupled to the rotor to receive a rotational output from the rotor and convert the rotational output into linear reciprocating motion; and a pump comprising a piston and a cylinder, the piston receiving the linear reciprocating motion from the driving device to reciprocate the piston within the cylinder; and A pump frame is provided to which the cylinder and the stator are connected so as to stabilize the stator relative to the rotor and the cylinder relative to the piston.

21. A fluid displacement pump comprising: An electric motor having a first end and a second end, the electric motor comprising: stator; and a rotor that rotates about an axis, the stator being located radially within the rotor so that the rotor rotates about the stator, the rotor including a housing having an opening located on the second end of the electric motor, the housing containing a plurality of magnets that rotate with the housing; a stator support extending through the opening to hold the stator stationary as the housing rotates about the stator; and a drive device connected to the rotor at the first end of the electric motor, the drive device configured to convert a rotational output from the rotor into reciprocating motion; A pump includes a fluid displacement member coupled to the drive device for reciprocation by the drive device, the fluid displacement member being positioned closer to the first end of the electric motor than to the second end of the electric motor.

22. A fluid spraying machine comprising: an electric motor comprising a stator and a rotor; a drive device connected to the rotor, the drive device being configured to convert a rotational output from the rotor into reciprocating motion; a pump comprising a fluid displacement member coupled to the drive device for reciprocation by the drive device; a fluid outlet for spraying the fluid output by the pump; a fluid sensor that outputs a signal indicative of a pressure of the fluid output by the pump; and a controller that receives the signal from the fluid sensor and outputs operating power to the stator, the operating power causing the rotor to rotate relative to the stator, the controller being configured to: When the signal indicates that the pressure of the fluid output by the pump is lower than a pressure setting value, a first level of operating power is supplied to the stator, the first level of operating power causing the rotor to reciprocate the fluid displacement member via the drive device. When the signal indicates that the pressure of the fluid output by the pump is at or above the pressure setting when the rotor and the fluid displacement member remain stalled with the fluid outlet closed, a second level of operating power is delivered to the stator, the second level of operating power causing the rotor to urge against the actuator device to cause the fluid displacement member to apply pressure to the fluid while the fluid outlet is closed and the rotor and the fluid displacement member remain stalled.

23. A fluid spraying machine comprising: an electric motor comprising a stator and a rotor; a drive device connected to the rotor, the drive device being configured to convert a rotational output from the rotor into reciprocating motion; a pump comprising a fluid displacement member coupled to the drive device for reciprocation by the drive device; a fluid outlet for spraying the fluid output by the pump; and a controller that outputs operating power to the stator, the operating power causing the rotor to rotate relative to the stator, the controller being configured to cause the rotor to reverse its rotational direction between two modes, wherein: In a first mode, the rotor rotates clockwise for a plurality of consecutive complete revolutions to drive the piston through a plurality of consecutive first pumping strokes, each pumping stroke comprising a fluid intake phase during which the fluid displacement member moves in a first direction and a fluid output phase during which the fluid displacement member moves in a second direction opposite to the first direction, and In a second mode, the rotor rotates counterclockwise for a plurality of consecutive complete revolutions to drive the piston through a plurality of consecutive second pumping strokes, each pumping stroke comprising the fluid intake phase and the fluid output phase.

24. A fluid displacement pump, comprising: An electric motor having a first end disposed opposite a second end along an axis, the electric motor comprising: a rotor configured to rotate about the axis, the rotor comprising a housing having an opening at a second end of the electric motor; a stator located inside the rotor, the stator being configured to generate an electromagnetic field that interacts with the rotor to cause the rotor to rotate about the stator; and a shaft, the shaft being located inside the stator and the rotor, and extending through an opening of the housing to the outside of the rotor; a drive device connected to the housing of the rotor at a first end of the electric motor to receive a rotational output from the rotor, the drive device being configured to convert the rotational output into reciprocating motion; A pump comprising: cylinder; and a fluid displacement member mechanically connected to the drive device so as to cause linear reciprocation of the fluid displacement member within the cylinder; and a pump frame on which the cylinder is mounted; and A bearing mounts a housing of the rotor to the pump frame at a first end of the electric motor.

25. A pumping system comprising: An electric motor, comprising: stator; and A rotor, wherein the stator and the rotor are arranged on an axis; wherein the rotor is disposed around the stator, and a drive coupled to the rotor to receive a rotational output from the rotor and convert the rotational output into linear reciprocating motion; and a pump comprising a piston and a cylinder, the piston receiving the linear reciprocating motion from the driving device to reciprocate the piston within the cylinder; and a pump frame to which the cylinder and stator are connected to stabilize the stator relative to the rotor and the cylinder relative to the piston, the pump frame being mechanically coupled to the rotor at a first end of the electric motor and to the shaft at a second end of the electric motor, and wherein one or more wires extend into the electric motor through the second end of the electric motor, the one or more wires providing power to operate the stator.

26. A pumping system comprising: An electric motor, comprising: stator; and a rotor, said stator and said rotor being arranged on an axis; and a drive coupled to the rotor to receive a rotational output from the rotor and convert the rotational output into linear reciprocating motion; and a pump comprising a piston and a cylinder, the piston receiving the linear reciprocating motion from the driving device to reciprocate the piston within the cylinder; and a pump frame to which the cylinder and the stator are connected so as to stabilize the stator relative to the rotor and the cylinder relative to the piston, a first bearing disposed between the pump frame and the rotor at a first end of the electric motor to support the rotor and allow rotational movement of the rotor relative to the pump frame; and A second bearing is disposed between the shaft and the rotor at an end of the electric motor opposite the first end to support the rotor and allow rotational movement of the rotor relative to the shaft.

27. A pumping system comprising: An electric motor, comprising: stator; and A rotor, wherein the stator and the rotor are arranged on an axis; wherein the rotor is disposed about the stator, and wherein the rotor is formed by the cylindrical body having a first end wall at a first end of the electric motor and a second end wall at a second end of the electric motor opposite the first end, wherein the first end wall completely radially overlaps the stator and a shaft of the stator at the first end, and wherein the shaft extends axially outwardly from the second end wall at the second end; and a drive coupled to the rotor to receive a rotational output from the rotor and convert the rotational output into linear reciprocating motion; and A pump includes a piston and a cylinder, wherein the piston receives the linear reciprocating motion from the driving device so as to reciprocate the piston in the cylinder.

Images