A new energy mobile air compressor

Abstract

This utility model discloses a new energy mobile air compressor, comprising a separate air compressor unit and a mobile battery unit. The air compressor unit mainly includes a mobile chassis, a screw air compressor, a drive motor, a motor controller, and various cooling systems. The air compressor unit is connected to the mobile battery unit via a pluggable integrated composite power supply cable. This cable integrates both high-voltage power supply cables and low-voltage control cables, enabling the transmission of high-voltage DC power and information communication and control between the devices. The mobile battery unit can be a dedicated mobile energy storage box or a new energy vehicle with external discharge capabilities. This design separates the power source from the main unit, improving the flexibility and convenience of equipment use.

Description

Technical Field

[0001] This utility model relates to the field of air compressor technology, and more specifically, to a new energy mobile air compressor powered by a detachable mobile battery. Background Technology

[0002] Mobile air compressors are widely used in outdoor operations such as mining, construction, and pipeline purging due to their flexibility. Traditional mobile air compressors mostly use diesel engines as their power source, but these are noisy, pollute the environment with exhaust emissions, have high fuel costs, and are complex to maintain. Although electric air compressors powered by industrial power grids exist, most of them use three-phase AC asynchronous motors as their power source, resulting in poor control accuracy and high energy consumption; furthermore, their mobility is limited by cable length, leading to poor flexibility. With the development of battery technology, battery power has become possible, but how to efficiently, safely, and rationally integrate large-capacity battery systems with air compressors, and solve the resulting problems of vibration, heat dissipation, range of operation, and mobility, are currently urgent technical challenges that need to be addressed.

[0003] Some existing electric mobile air compressors integrate the battery pack, motor, and air compressor body onto a single mobile chassis. While this integrated design achieves zero emissions, it presents the following problems: 1) The machine is heavy and bulky, making it inconvenient to move; 2) The battery capacity is fixed, making it impossible to flexibly adjust the range according to working conditions; 3) The entire device needs to be stopped and moved to a charging station during charging, affecting the continuity of operations; 4) The battery is tied to the air compressor, which vibrates continuously and dissipates a large amount of heat during operation, challenging the battery's durability. Once the battery fails, maintenance or replacement costs are high, and it may even lead to the scrapping of the entire machine.

[0004] Therefore, how to provide a new energy mobile air compressor that is flexible in structure, easy to use, capable of continuous operation, and has low maintenance costs is a technical problem that urgently needs to be solved in this field. Utility Model Content

[0005] The purpose of this utility model is to provide a new energy mobile air compressor, which aims to solve the technical problems of existing split-type solutions being complex to connect, inconvenient to operate, and posing safety hazards.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A new energy mobile air compressor includes: an air compressor unit; a power supply cable; and a mobile battery unit separately disposed from the air compressor unit; wherein the air compressor unit is provided with a power input interface, and the mobile battery unit is provided with a charging interface and a power supply interface; the air compressor unit is pluggably electrically connected to the power supply interface of the mobile battery unit via the power supply cable; the power supply cable is an integrated composite cable, which integrates a high-voltage power supply line for transmitting high-voltage DC power from the mobile battery unit to the air compressor unit; and a low-voltage control line for information communication and control between the air compressor unit and the mobile battery unit; the air compressor unit includes: a mobile chassis and a housing disposed on the mobile chassis; a screw air compressor mounted on the mobile chassis, a motor for driving the screw air compressor, and a motor controller for controlling the motor.

[0007] Optionally, one end of the power supply cable is provided with an integrated power supply nozzle; the power supply interface of the mobile battery unit includes an integrated socket adapted to the integrated power supply nozzle, and the integrated power supply nozzle and the integrated socket integrate a high-voltage connection socket / pin and a low-voltage control signal socket / pin.

[0008] Optionally, the air compressor unit further includes: a power supply cable compartment installed on the mobile chassis, wherein the power supply cable is installed inside the power supply cable compartment, and the outer casing is provided with a door that can be opened.

[0009] Optionally, the output shaft of the motor is mechanically connected to the input shaft of the screw air compressor via a coupling or a reduction gearbox.

[0010] Optionally, the air compressor unit further includes an electric drive system liquid-cooled radiator for cooling the motor and the motor controller.

[0011] Optionally, the air compressor unit further includes an intake system, an exhaust system, and a screw oil cooler; the intake system is connected to the intake port of the screw air compressor, and the exhaust port of the screw air compressor is connected to the exhaust system.

[0012] Optionally, the screw oil cooler includes a cooling fan for generating cooling airflow; the air compressor unit also includes a fan motor for driving the cooling fan; the motor controller integrates a DC / AC conversion module, and the AC output terminal of the DC / AC conversion module is electrically connected to the fan motor to provide power to the fan motor.

[0013] Optionally, the screw oil cooler and the electric drive system liquid cooler are located on different sides of the housing; the screw oil cooler is equipped with a cooling fan that exhausts air from the inside to the outside, and the electric drive system liquid cooler is equipped with a cooling fan that draws air from the outside to the inside.

[0014] Optionally, the air compressor unit further includes a low-pressure control system, which includes a low-pressure controller, a low-pressure battery, and a human-machine interface; the low-pressure controller is electrically connected to the motor controller and the human-machine interface.

[0015] Optionally, the motor controller integrates a DC / DC conversion module, the output of which is electrically connected to the low-voltage battery for charging the low-voltage battery.

[0016] Optionally, the mobile battery unit is one of the following: a) a dedicated mobile energy storage box, including a battery box, a battery module housed in the battery box, a battery thermal management system and a battery low-voltage control system; or b) a new energy vehicle with external discharge function, wherein its external discharge interface serves as the power supply interface.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] 1) Simple operation and high safety: The innovative use of an integrated high- and low-voltage composite cable and interface combines high-voltage power transmission and low-voltage communication control into one, achieving "one-line connection, one-plug-in," greatly simplifying on-site operation and eliminating the risk of misconnection. The built-in safety interlock function of the low-voltage control circuit ensures that the high-voltage circuit is only energized after a completely reliable connection, significantly improving operational safety. Furthermore, the plug-in interface is preferably located on the battery side, isolating the power supply interface from vibration and high temperatures on the compressor side during operation, ensuring reliability.

[0019] 2) Highly integrated, intelligent and efficient: The main motor controller not only drives the main motor, but also integrates DC / AC and DC / DC modules to supply power to the screw oil cooling fan and the low-voltage system, respectively. It realizes centralized energy management and efficient distribution, has a compact structure, high reliability, and can realize intelligent speed control of the fan.

[0020] 3) Modular structure and flexible use: The air compressor unit and the mobile battery unit are separated, facilitating transportation and deployment. Users can configure multiple mobile battery units and achieve continuous, uninterrupted operation through quick replacement.

[0021] 4) Optimized heat dissipation and stable operation: By arranging the two heat sources (oil circuit heat dissipation and electric drive heat dissipation) on different sides of the cabinet and using opposite airflow directions, a through air duct is formed, which avoids heat cross-interference and improves the overall stability of the machine under harsh working conditions.

[0022] 5) Flexible energy supply and strong scalability: The mobile battery unit can not only be a dedicated battery box, but can also be expanded to use the power battery of a new energy vehicle with external discharge function to directly power the air compressor through its discharge port, which greatly expands the flexibility of energy acquisition and application scenarios. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present utility model.

[0024] Figure 2a This is a top view of the internal structural layout of the air compressor unit in an embodiment of this utility model.

[0025] Figure 2b This is a three-dimensional view of the internal structure of the air compressor unit in this embodiment of the utility model.

[0026] Figure 3 This is a schematic diagram of the heat dissipation structure of the air compressor unit in an embodiment of this utility model.

[0027] Figure 4 This is a schematic diagram of the integrated power supply head and integrated socket in this utility model embodiment.

[0028] Figure label:

[0029] 100 - Air compressor unit; 101 - Screw air compressor; 102 - Intake system; 103 - Exhaust system; 104 - Screw oil cooler; 105 - Intake valve; 106 - Oil-gas separator; 107 - Power cable compartment; 108 - Oil-gas pipeline; 109 - Air filter; 110 - Mobile chassis; 120 - Housing; 201-Motor; 202-Motor controller; 203-Liquid cooling radiator for electric drive system; 204-Screw oil cooling fan motor; 205-Low-voltage battery; 206-Low-voltage controller; 207-Water pump; 208-Expansion tank; 300 - Power supply cable; 310 - Integrated power supply nozzle; 400 - Portable battery unit; 401 - Housing; 402 - Power supply interface; 403 - Power supply interface; 404 - Control panel; 410 - Integrated socket. Detailed Implementation

[0030] To make the objectives, technical solutions and advantages of this utility model clearer, the utility model will be described in further detail below with reference to the accompanying drawings.

[0031] Please see Figure 1 This utility model provides a new energy mobile air compressor, which mainly includes an air compressor unit 100, a power supply cable 300, and a mobile battery unit 400 that is separately installed and can be moved independently. The air compressor unit 100 includes a mobile chassis 110 and a housing 120; the mobile battery unit 400 includes at least one charging interface 402 and at least one power supply interface 403.

[0032] One of the innovations of this utility model lies in the power supply cable 300 connecting the air compressor unit 100 and the mobile battery unit 400. This power supply cable 300 is an integrated composite cable, whose internal sheath simultaneously encases a high-voltage power supply line for transmitting high-voltage DC power and a low-voltage control line for transmitting control and communication signals. The high-voltage line is responsible for supplying electrical energy from the mobile battery unit 400 to the air compressor unit 100, while the low-voltage line is responsible for establishing information exchange between the two, such as transmitting battery SOC, temperature, and other status information, as well as executing high-voltage power-on safety interlock commands.

[0033] In this invention, high-voltage power supply cables refer to physical pathways specifically designed for transmitting high-power DC power. Their core function is to act as the "main artery" of energy transmission, stably and efficiently delivering the high-voltage DC power (e.g., voltage levels typically between 400V DC and 800V DC or higher) stored in the mobile battery unit 400 to the motor controller 202 within the air compressor unit 100 to drive the motor 201. This line typically consists of two or more conductor cores with a large cross-sectional area, for example, 25mm² to 95mm² or larger (depending on power requirements), corresponding to the high-voltage positive (HV+) and high-voltage negative (HV-) terminals, respectively. To ensure safety, these conductor cores are externally wrapped with a thick, high-voltage-resistant, and abrasion-resistant insulation layer, and usually have a metal braided shielding layer to suppress electromagnetic interference (EMC) and provide grounding protection. Visually, high-voltage cables typically adhere to industry safety standards, using a striking orange color as a warning. Low-voltage control cables refer to physical pathways used for transmitting information signals and low-power control currents. Its core function is to facilitate information transmission between the air compressor unit 100 and the mobile battery unit 400, enabling intelligent interaction and safety control. The transmitted voltage is typically a safe low voltage of 12V or 24V. This line usually consists of multiple thin wires with small cross-sectional areas, for example, ranging from 0.5mm² to 4mm², each responsible for transmitting different signals or providing, for example, 12V or 24V low-voltage DC power. To ensure signal quality, critical communication lines typically employ a twisted-pair structure to resist interference.

[0034] Please refer to the following: Figure 1 , Figure 4To complement this integrated composite cable 300, its connection end is designed as an integrated power supply nozzle 310, while the power supply interface 402 of the mobile battery unit 400 is equipped with a matching integrated socket 410. Both the nozzle 310 and the socket 410 integrate a large high-voltage connection port (pin / socket) and a small low-voltage control signal port (pin / socket). During operation, only one alignment and plugging are required to simultaneously complete the connection of high-voltage power and low-voltage control, making operation extremely simple and safe.

[0035] Please see Figure 2a , Figure 2b To facilitate the demonstration of its internal structure, the outer casing 120 and internal wiring harnesses of the air compressor unit 100 are omitted from the figure. The air compressor unit 100 includes a mobile chassis 110 and an outer casing 120 covering it. The core components, such as the screw air compressor 101, drive motor 201, and motor controller 202, are mounted on the mobile chassis 110. In this embodiment, the output shaft of the motor 201 is connected to the input shaft of the screw air compressor 101 via a coupling, achieving efficient power transmission. In some embodiments, the motor 201 is a high-speed permanent magnet synchronous motor with a high rated speed, such as greater than 4000 rpm or higher, while the rated speed of the screw air compressor rotor is lower, typically between 1200-1500 rpm. In this case, the motor 201 can transmit power to the input shaft of the screw air compressor 101 via a reduction gear.

[0036] The screw air compressor 101 and its auxiliary systems in this embodiment constitute the core of compressed air generation and processing. Its working process is as follows: Air intake process: Outside air enters the main chamber of the screw air compressor 101 through the intake system 102, first passing through the air filter element 109 for preliminary filtration to remove large dust particles, and then entering through the intake valve 105.

[0037] Compression process: Motor 201 drives the screw rotor inside screw air compressor 101 to rotate through coupling or reduction gearbox. The volume between the rotor teeth decreases with rotation, thereby compressing the air. During this process, a large amount of lubricating oil is sprayed into the compression chamber, playing a key role in lubrication, sealing, and cooling.

[0038] Oil-gas separation and exhaust process: The compressed, high-temperature, high-pressure oil-gas mixture enters the core component of the exhaust system 103—the oil-gas separator tank 106—through the oil-gas pipeline 108. Inside the tank, most of the oil is separated and settles to the bottom through collision, centrifugation, and gravity. The gas containing a small amount of oil mist is then finely filtered through the oil-gas separator filter element, ultimately producing clean compressed air for external supply.

[0039] Lubricating oil circulation: The hot lubricating oil collected from the oil-gas separator 106 flows through the screw oil radiator 104 under pressure difference for forced air cooling, and then returns to the compressor main unit after being filtered by the oil filter, completing a cooling and lubrication cycle.

[0040] To facilitate the storage and transportation of the power supply cable 300, a power supply cable compartment 107 is also provided on the mobile chassis 110 of the air compressor unit 100. When not in use, the power supply cable 300 can be coiled and stored in it. The outer casing 120 is provided with a corresponding door to protect the cable terminals.

[0041] The air compressor unit 100 also includes a complete low-voltage control system, consisting of a low-voltage controller 206, a low-voltage battery 205, and a human-machine interface mounted on the housing 120. The low-voltage battery 205 provides a stable low-voltage power supply to the entire control system. Similarly, its charging is accomplished by the DC / DC conversion module integrated within the main motor controller 202. This module steps down the high-voltage DC power to charge the low-voltage battery 205, achieving unified energy management. Operators can monitor equipment status, set parameters, and start / stop the equipment through the human-machine interface.

[0042] The heat dissipation system in this embodiment is carefully designed and includes two independent heat dissipation components. The first is a liquid-cooled radiator 203 for the electric drive system, used to cool the motor 201 and motor controller 202, which generate a large amount of heat. This system consists of a radiator body, a cooling fan, a water pump 207, coolant pipes, and an expansion tank 208. The water pump 207 drives the coolant to circulate between the water channels inside the motor and controller and between the radiator, dissipating heat to the atmosphere through the cooling fan. The cooling fan and water pump of the electric drive system are directly powered by a low-voltage battery. The expansion tank 208 is used for venting and adding coolant, and also serves as a coolant level observation window. The second is a screw oil radiator 104. In this embodiment, the cooling fan of the screw oil radiator 104 is driven by a fan motor. The main motor controller 202 integrates a DC / AC conversion module, which converts the high-voltage DC power from the mobile battery unit 400 into AC power to directly power the fan motor. This design reduces the need for separate power converters, increases integration, and facilitates intelligent control of fan speed based on real-time temperature via the low-voltage controller 206, achieving energy saving and noise reduction.

[0043] like Figure 3As shown, the two are arranged on different sides of the air compressor unit 100. The screw oil cooler 104 is located at the rear of the air compressor unit 100, while the electric drive system cooler 203 is located on the side of the air compressor unit 100. The fan of the screw oil cooler 104 exhausts air from the inside to the outside, drawing heat out of the unit; while the fan of the electric drive system liquid cooler 203 draws in cool air from the outside for cooling. This "one in, one out" layout forms a highly efficient through-flow cooling air duct inside the unit, avoiding heat accumulation and mutual interference, and ensuring stable operation of the system in high-temperature environments.

[0044] Please see Figure 1 In this embodiment, the mobile battery unit 400 is a standardized, independent energy module. It mainly includes: a robust battery housing 401 for protecting internal components; a battery module housed within the housing, composed of multiple cells connected in series and parallel, serving as the core of energy storage; at least one power supply interface 402 and a charging interface 403; a battery thermal management system to maintain the battery pack within its optimal operating temperature range, ensuring its performance and lifespan; a low-voltage battery control system responsible for monitoring battery status, performing safety management, and external communication; and a battery control panel 404 located outside the housing for displaying battery status information, allowing operators to perform basic operations.

[0045] In particular, the energy supply solution of this utility model has high scalability. The mobile battery unit 400 is not limited to the aforementioned dedicated battery box. In specific application scenarios, a new energy vehicle (not shown in the figure) with external discharge (V2L / V2V, Vehicle-to-Load / Vehicle-to-Vehicle) function can also be used as a mobile battery unit. With the popularization of new energy vehicles, especially large-capacity power battery trucks, more and more vehicles are equipped with high-power external discharge functions. The integrated power supply cable 300 and its power supply nozzle 310 of this utility model can be designed to be compatible with the external discharge interface (i.e., the power supply interface in this solution) of national standard or mainstream new energy vehicles. During operation, the operator only needs to drive the new energy vehicle to the vicinity of the work point, connect one end of the power supply cable 300 to the air compressor unit 100, and directly insert the power supply nozzle 310 at the other end into the vehicle's external discharge port. The vehicle's battery management system and the low-voltage control system of the air compressor unit 100 communicate via a low-voltage control line within the cable. Once the connection is confirmed, the vehicle can function as a high-capacity "mobile power bank," providing stable and reliable power to the air compressor. This solution significantly reduces the user's additional equipment purchase costs and is particularly suitable for emergency repairs and temporary operations, truly achieving the convenience of "compressed air goes wherever the vehicle goes."

[0046] It should be noted that, in this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0047] The above descriptions are merely embodiments of this utility model. Commonly known structures and characteristics are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are knowledgeable of all existing technologies in that field, and possess the ability to apply conventional experimental methods prior to that date. Therefore, those skilled in the art can, based on the guidance provided in this application, improve and implement this solution in conjunction with their own capabilities. Typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of this utility model. These modifications and improvements should also be considered within the scope of protection of this utility model, and will not affect the effectiveness of the implementation of this utility model or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A new energy mobile air compressor, characterized in that, include: Air compressor unit (100); power supply cable (300); and A mobile battery unit (400) is provided separately from the air compressor unit (100). The air compressor unit (100) is provided with a power input interface, and the mobile battery unit (400) is provided with a charging interface (402) and a power supply interface (403). The air compressor unit (100) is electrically connected to the power supply interface (403) of the mobile battery unit (400) via the power supply cable (300); the power supply cable (300) is an integrated composite cable, which integrates a high-voltage power supply cable for transmitting the high-voltage DC power from the mobile battery unit (400) to the air compressor unit (100); and a low-voltage control cable for information communication and control between the air compressor unit (100) and the mobile battery unit (400); The air compressor unit (100) includes: Mobile chassis (110) and housing (120) disposed on the mobile chassis (110); A screw air compressor (101) mounted on the mobile chassis (110), a motor (201) for driving the screw air compressor (101), and a motor controller (202) for controlling the motor (201).

2. The new energy mobile air compressor according to claim 1, characterized in that: One end of the power supply cable (300) is provided with an integrated power supply head (310); the power supply interface (403) of the mobile battery unit (400) includes an integrated socket (410) adapted to the integrated power supply head, and the integrated power supply head (310) and the integrated socket (410) integrate high-voltage connection pins / holes and low-voltage control signal pins / holes.

3. The new energy mobile air compressor according to claim 1, characterized in that: The air compressor unit (100) further includes: a power supply cable compartment (107) installed on the mobile chassis (110), the power supply cable (300) is installed in the power supply cable compartment (107), and the outer shell (120) is provided with a door that can be opened.

4. The new energy mobile air compressor according to claim 1, characterized in that: The output shaft of the motor (201) is mechanically connected to the input shaft of the screw air compressor (101) via a coupling or a reduction gearbox.

5. The new energy mobile air compressor according to claim 1, characterized in that: The air compressor unit (100) also includes an electric drive system liquid cooling radiator (203) for cooling the motor (201) and the motor controller (202).

6. The new energy mobile air compressor according to claim 5, characterized in that: The air compressor unit (100) further includes a screw oil radiator (104), which includes a fan for generating cooling airflow; the air compressor unit (100) is also provided with a screw oil radiator fan motor (204) for driving the fan; the motor controller (202) integrates a DC / AC conversion module, and the AC output terminal of the DC / AC conversion module is electrically connected to the screw oil radiator fan motor (204) to provide power to the screw oil radiator fan motor (204).

7. The new energy mobile air compressor according to claim 6, characterized in that: The screw oil radiator (104) and the electric drive system liquid cooling radiator (203) are located on different sides of the housing (120); the screw oil radiator (104) is equipped with a cooling fan that exhausts air from the inside to the outside, and the electric drive system liquid cooling radiator (203) is equipped with a cooling fan that draws air from the outside to the inside.

8. The new energy mobile air compressor according to claim 1, characterized in that: The air compressor unit (100) also includes a low-pressure control system, which includes a low-pressure controller (206), a low-pressure battery (205), and a human-machine interface; the low-pressure controller (206) is electrically connected to the motor controller (202) and the human-machine interface.

9. The new energy mobile air compressor according to claim 8, characterized in that: The motor controller (202) integrates a DC / DC conversion module, the output of which is electrically connected to the low-voltage battery (205) for charging the low-voltage battery (205).

10. The new energy mobile air compressor according to any one of claims 1-9, characterized in that: The mobile battery unit (400) is one of the following: a) A dedicated mobile energy storage box, comprising a battery housing (401), a battery module housed within the battery housing, a battery thermal management system, and a battery low-voltage control system; or, b) A new energy vehicle with external discharge function, wherein its external discharge interface serves as the power supply interface.

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