Lubrication system for pump drive

Abstract

To provide a pump drive system that can increase operational efficiency of a pump and / or reduce wear of a pump drive, thereby inhibiting reduction of the lifespan of the pump drive part.SOLUTION: A pump drive system includes: a housing; an electric motor disposed within the housing, the electric motor being configured to drive a piston of a pump; a lubricant reservoir configured to store a lubricant; a conduit configured to direct lubricant from the lubricant reservoir into the housing to submerge the electric motor in the lubricant; and a sensor configured to monitor the level of the lubricant in the lubricant reservoir.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a pump, and more particularly to a lubrication system for a pump drive unit.

Background Art

[0002] A booster pump can be used to increase the pressure of a fluid - for example, a gas. A booster pump generally has one or more stages driven by a piston housed inside a cylinder. The booster has a pump drive unit configured to increase the pressure of the fluid by compressing the fluid in the cylinder by moving the piston. The pump drive unit may have various members configured to drive the corresponding piston movement by moving relative to each other. For example, the pump drive unit may have a motor (e.g., an electric motor) configured to drive the piston movement by moving inside a housing.

Summary of the Invention

Problems to be Solved by the Invention

[0003] However, a direct connection between the motor and the housing can sometimes be detrimental because it reduces the operating efficiency of the pump and / or reduces the life of the pump drive unit by increasing wear of the pump drive unit.

Means for Solving the Problems

[0004] In one embodiment, the present application relates to a pump drive system. The pump drive system includes a housing, an electric motor provided inside the housing and configured to drive a piston of the pump, a lubricant storage unit configured to store a lubricant, a conduit, and a sensor. The conduit is configured to guide the lubricant from the lubricant storage unit to the housing to immerse the electric motor in the lubricant, and the sensor is configured to monitor the level of the lubricant in the lubricant storage unit.

[0005] In other embodiments, the present application relates to a booster pump system. The booster pump system includes a cylinder having a chamber, a piston provided inside the chamber of the cylinder, and an electric motor configured to pressurize a fluid inside the chamber and discharge the pressurized fluid from the chamber by driving the movement of the piston with respect to the chamber of the cylinder. The electric motor is provided inside a housing. The booster pump system also includes a lubricant storage unit, a conduit fluidly connected to the lubricant storage unit and configured to guide lubricant from the lubricant storage unit into the housing, and a sensor configured to monitor the level of the lubricant in the lubricant storage unit.

[0006] In a further embodiment, the non-transitory computer-readable medium includes instructions configured to cause the one or more processors to monitor the level of lubricant contained inside the lubricant storage unit when executed by the one or more processors. The lubricant storage unit is configured to store lubricant and guide the lubricant into a housing including a motor of the booster pump. The motor is configured to drive the movement of the piston of the booster pump to pressurize the fluid inside the cylinder of the booster pump. The instructions are also configured to cause the one or more processors to determine whether the level of lubricant in the lubricant storage unit is below a threshold level and to reduce the operation of the motor in response to a determination that the level of lubricant in the lubricant storage unit is below the threshold level.

Brief Description of the Drawings

[0007] To make the specification complete and to better understand the present disclosure, a set of multiple drawings is provided. The drawings form an essential part of this specification and represent embodiments of the present disclosure, but should not be construed as limiting the technical scope of the present disclosure, which are merely examples of how the present invention can be implemented.

Figure 1

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[0008] The same numbers are used throughout all the drawings.

Mode for Carrying Out the Invention

[0009] The present disclosure relates to smoothing a pump drive part of a pump such as a booster. During operation, the booster increases the pressure of the fluid. For example, the booster includes a cylinder that defines a chamber and a piston disposed within the chamber and movable within the chamber. The fluid is introduced into the chamber, and the piston moves within the chamber to reduce the volume of the chamber in which the fluid is contained, thereby pressurizing the fluid. The pressurized fluid is then discharged from the chamber.

[0010] In some embodiments, the pump includes a motor configured to drive the movement of a piston. As an example, the piston may be connected to a drive shaft, and the motor may be configured to cause movement of the drive shaft, and thus the piston within a chamber corresponding to the movement of the motor. The motor may be housed within a housing configured to shield the motor from the external environment. However, the motor may be in direct contact with the housing. The direct contact between the motor and the housing may negatively affect the operation of the motor, such as by reducing the movement of the motor relative to the housing and / or reducing the useful life of the motor. As a result, the operation of the pump for pressurizing the fluid may also be negatively affected.

[0011] Accordingly, avoiding direct contact between the motor and the housing can improve the operation of the pump, such as moving the piston and pressurizing the fluid. Thus, according to embodiments of the present disclosure, the pump includes a lubrication system configured to direct a lubricant into the housing, and the motor is disposed therein to provide lubrication between the motor and the housing. For example, the lubricant can fill the housing and flow at the interface between the motor and the housing. As a result, the lubricant can prevent or at least deter the motor and the housing from directly contacting each other. That is, instead of the motor moving or colliding (e.g., wearing against) the housing, the motor may be positioned within the lubricant. As a result, the motor can more easily and / or immediately drive the corresponding piston movement and pressurize the fluid.

[0012] Furthermore, the pump includes a sensor configured to monitor a parameter indicative of the level of lubricant within the lubricant reservoir. In at least some of these instances, the pump may also include a control system communicatively coupled to the sensor and configured to receive sensor data indicative of the monitored parameter. The control system is configured to determine the level of lubricant within the lubricant reservoir based on the sensor data and to operate accordingly. For example, the control system can compare the level of lubricant to a threshold level and reduce the operation of the pump (e.g., the motor) in response to the level of lubricant being below the threshold level. In fact, a level of lubricant below the threshold level may indicate that the lubricant cannot be easily guided into the housing to provide a barrier between the motor and the housing. Thus, since there is an increased risk of direct contact between the motor and the housing, the control system can prevent or deter direct contact between the motor and the housing by reducing the operation of the pump.

[0013] In certain embodiments, the sensor data received from the sensor includes an image or image data of the lubricant visible within the lubricant reservoir. For example, the lubricant reservoir can include a wall that is at least partially transparent or translucent, and the captured image can include the wall and the lubricant visible through the wall. Thus, the image can directly indicate the amount of lubricant within the lubricant reservoir (e.g., the height of the lubricant relative to the wall). In additional or alternative embodiments, the sensor data is based on the refractive properties of the lubricant reservoir (e.g., detected within the lubricant reservoir through a wall that is at least partially transparent or translucent) and / or the capacitance of the lubricant reservoir. Further, in some embodiments, the sensor data indicates the flow rate of the lubricant (e.g., through a conduit fluidly coupled to the lubricant reservoir and configured to direct the lubricant into the housing). In any of these embodiments, the sensor may be disposed outside of the lubricant reservoir. Thus, the sensor does not come into direct contact with the lubricant stored in the lubricant reservoir, and the structural integrity of the sensor is not affected by interaction with the lubricant. Further, an externally disposed sensor does not adversely affect (e.g., reduce) the storage capacity of the lubricant within the lubricant reservoir and / or otherwise adversely affect the flow of lubricant towards the housing. Thus, the pump and / or sensor can continue to operate effectively.

[0014] Figure 1 is a cross-sectional view of a pump system 100. The pump system 100 is a booster configured to increase the pressure of a fluid such as a gas. The pump system 100 includes a first cylinder 102 that defines a first chamber 104 in which at least one working fluid can be pumped / pressurized. More specifically, a first piston 106 is disposed within the first chamber 104 and is configured to move within the first chamber 104 to pressurize one or more fluids. The pump system 100 also includes a second cylinder 112 that defines a second chamber 114 in which at least one working fluid (e.g., the same or a different fluid as the fluid within the first chamber 104) can be pumped / pressurized. A second piston 116 is disposed within the second chamber 114 and is configured to move within the second chamber 114 to pressurize the fluid.

[0015] In some embodiments, the first chamber 104 defined by the first cylinder 102 is divided into two pumping chambers. One of the two pumping chambers is located on either side of the first piston 106, and / or the second chamber 114 defined by the second cylinder 112 is divided into two pumping chambers. One of the two pumping chambers is located on either side of the second piston 116. For example, the working fluid can enter the first cylinder 102 in a first pumping chamber 104A between the first piston 106 and the first end wall 108 of the first end cap 103 and / or in a second pumping chamber 104B between the first piston 106 and the outer wall 105 of the first inner cap 107. Additionally or alternatively, the working fluid can enter the second cylinder 112 in a third pumping chamber 114A between the second piston 116 and the second end wall 113 of the second end cap 115 and / or in a fourth pumping chamber 114B between the second piston 116 and the outer wall 119 of the second inner cap 117.

[0016] Accordingly, in the illustrated embodiment, the working fluid can be pumped / pressurized within each of the pumping chambers 104, 114. For this purpose, although not shown, the first end cap 103 and the second end cap 115 may include passages and valves (e.g., check valves) to allow the working fluid to enter and exit the first pumping chamber 104A and the third pumping chamber 114A, respectively. Further, the first inner cap 107 and the second inner cap 117 can include passages and valves to allow the working fluid to enter and exit the second pumping chamber 104B and the fourth pumping chamber 114B, respectively. By way of example, the movement of the first piston 106 in the first direction 110 towards the first end wall 108 decreases the volume of the first pumping chamber 104A, increases the pressure of the working fluid within the first pumping chamber 104A, and discharges the working fluid from the first pumping chamber 104A while increasing the volume of the second pumping chamber 104B and drawing the working fluid into the second pumping chamber 104B. The movement of the first piston 106 in the second direction 118 away from the first end wall 108 increases the volume of the first pumping chamber 104A and draws the working fluid into the first pumping chamber 104A while decreasing the volume of the second pumping chamber 104B, increasing the pressure of the working fluid within the second pumping chamber 104B, and discharging the working fluid from the second pumping chamber 104B. Similarly, the movement of the second piston 116 in the second direction 118 towards the second end wall 113 decreases the volume of the third pumping chamber 114A, increases the pressure of the working fluid within the third pumping chamber 114A, and discharges the working fluid from the third pumping chamber 114A while increasing the volume of the fourth pumping chamber 114B and drawing the working fluid into the fourth pumping chamber 114B.When the second piston 116 moves in a first direction 110 away from the second end wall 113, the volume of the third pumping chamber 114A increases to draw the working fluid into the third pumping chamber 114A, while the volume of the fourth pumping chamber 114B decreases to increase the pressure of the working fluid in the fourth pumping chamber 114B and discharge the working fluid from the fourth pumping chamber 114B.

[0017] Additionally or alternatively, each of the first chamber 104 and / or the second chamber 114 may have a single pumping chamber for pressurizing the working fluid. That is, the working fluid can be sucked in and pressurized on the side of the first piston 106 (e.g., the first pumping chamber 104A) and / or the second piston 116 (e.g., the third pumping chamber 114A), while the different fluids can be sucked in on the other side of the first piston 106 (e.g., the second pumping chamber 104B) and / or the second piston 116 (e.g., the fourth pumping chamber 114B) to facilitate the movement of the pistons 106, 116. For example, when the first piston 106 is moved in the first direction 110 towards the first end cap 103 to reduce the volume of the first pumping chamber 104A and increase the volume of the second pumping chamber 104B, the working fluid in the first pumping chamber 104A is pressurized, while ambient air, lubricant, or any other such fluid can fill the second pumping chamber 104B to provide "breathing" or venting (e.g., between the strokes of the first piston 106) of the first piston 106. Similarly, when the second piston 116 is moved in the second direction 118 towards the second end cap 115 to reduce the volume of the third pumping chamber 114A and increase the volume of the fourth pumping chamber 114B, the working fluid in the third pumping chamber 114A is pressurized, while ambient air, lubricant, or any other such fluid can fill the fourth pumping chamber 114B to provide "breathing" or venting (e.g., between the strokes of the second piston 116) of the second piston 116.

[0018] In some embodiments, the fluid flow directed through the pump system 100 is pressurized by each of the first piston 106 and the second piston 116. For example, the fluid flow is first pressurized by the first piston 106 (e.g., low-pressure piston) within the first chamber 104 (e.g., low-pressure chamber), and the fluid flow is directed from the first chamber 104 to the second chamber 114 (e.g., high-pressure chamber) for further pressurization by the second piston 116 (e.g., high-pressure piston). In such embodiments, the pump system 100 is a two-stage booster that pressurizes the same fluid flow through each of the pistons 106, 116. In additional or alternative embodiments, each different fluid flow is pressurized by the pistons 106, 116. That is, separate fluid flows are directed into the first chamber 104 and into the second chamber 114 for pressurization. In such embodiments, the pump system 100 is a single-stage booster. The pump system can also operate in any other stage configuration known now or developed in the future.

[0019] In some embodiments, the fluid flow directed through the pump system 100 is pressurized by each of the first piston 106 and the second piston 116. For example, the fluid flow is first pressurized by the first piston 106 (e.g., low-pressure piston) within the first chamber 104 (e.g., low-pressure chamber), and the fluid flow is directed from the first chamber 104 to the second chamber 114 (e.g., high-pressure chamber) for further pressurization by the second piston 116 (e.g., high-pressure piston). In such embodiments, the pump system 100 is a two-stage booster that pressurizes the same fluid flow through each of the pistons 106, 116. In additional or alternative embodiments, each different fluid flow is pressurized by the pistons 106, 116. That is, separate fluid flows are directed into the first chamber 104 and into the second chamber 114 for pressurization. In such embodiments, the pump system 100 is a single-stage booster. The pump system can also operate in any other stage configuration known now or developed in the future.

[0020] The illustrated pump system 100 further includes a pump drive system 122 configured to operate pistons 106, 116. The pump drive system 122 includes a drive shaft or rod 124 coupled to each of the first piston 106 and the second piston 116. For example, the drive shaft 124 includes a first end 126 extending toward the first cylinder 102 for coupling to the first piston 106 and a second end 128 opposite the first end 126 extending toward the second cylinder 112 for coupling to the second piston 116. Thus, the movement of the drive shaft 124 drives the movement of each of the pistons 106, 116, at least in the illustrated embodiment. However, in other embodiments, the pump drive system 122 may be connected to a single cylinder and, thus, may drive a single piston.

[0021] In the embodiment shown in FIG. 1, the movement (e.g., translation) of the drive shaft 124 in the first direction 110 drives the movement of the first piston 106 toward the first end wall 108 and the movement of the second piston 116 away from the second end wall 113. Thus, the movement of the drive shaft 124 in the first direction 110 decreases the volume of the first pumping chamber 104A, pressurizes the fluid within the first pumping chamber 104A, increases the volume of the third pumping chamber 114A, and draws the fluid into the third pumping chamber 114A. The movement of the drive shaft 124 in the second direction 118 (e.g., translation) drives the movement of the first piston 106 away from the first end wall 108 and the movement of the second piston 116 toward the second end wall 113. As a result, the movement of the drive shaft 124 in the second direction 118 increases the volume within the first pumping chamber 104A, draws the fluid into the first pumping chamber 104A, decreases the volume of the third pumping chamber 114A, and pressurizes the fluid within the third pumping chamber 114A. The drive shaft 124 can alternately switch the movement in the first direction 110 and the second direction 118 to alternately pressurize the fluids within the first pumping chamber 104A and the third pumping chamber 114A.

[0022] The illustrated pump drive system 122 includes a motor 130 configured to move the drive shaft 124. In the illustrated embodiment, the motor 130 is an electric motor configured to convert electrical energy into linear motion to move the drive shaft 124 in the first direction 110 and the second direction 118. For example, the motor 130 can include a ball screw, magnets, windings (e.g., rotor, stator), etc., and can convert electrical energy into rotational motion and then into linear motion. The motor 130 is schematically shown for visualization purposes. However, it should be noted that the motor 130 can include any suitable components for driving the movement of the drive shaft 124, and the motor 130 need not be electrical.

[0023] The pump drive system 122 also includes a housing 132 that defines an interior 134. The drive shaft 124 extends through the interior 134, and the motor 130 is disposed within the interior. Thus, the housing 132 shields the motor 130 from the external environment and protects the motor 130 from dust, debris, or other contaminants within the external environment. The housing 132 of the illustrated embodiment couples the drive shaft 124 (e.g., first end 126, second end 128) to each of the first cylinder 102 and the second cylinder 112 via respective adapters 121, 123 to align the drive shaft 124 with the first chamber 104 and the second chamber 114. For example, the first adapter 121 is coupled to the housing 132 and the first inner cap 107, and the first inner cap 107 (e.g., outer wall 105) is coupled to the first cylinder 102 to couple and align the housing 132 and the first cylinder 102. The second adapter 123 is also coupled to the housing 132 and the second inner cap 117, and the second inner cap 117 (e.g., outer wall 119) is coupled to the second cylinder 112 to couple and align the housing 132 and the second cylinder 112. Further, the first end cap 103 (e.g., first end wall 108) is coupled to the first cylinder 102, and the first stay rod 125 is coupled to the first adapter 121 and the first end cap 103, thereby further securing between the housing 132 coupled to the first adapter 121 and the first cylinder 102 coupled to the first end cap 103. The second end cap 115 (e.g., second end wall 113) is coupled to the second cylinder 112, and the second stay rod 127 is coupled to the second adapter 123 and the second end cap 115, thereby further securing between the housing 132 coupled to the second adapter 123 and the second cylinder 112 coupled to the second end cap 115. However, in other embodiments, the housing 132 may be coupled to one or more cylinders in any manner currently known or hereafter developed.In any case, the motor 130 operates within the interior 134 and is configured to move (i.e., convert power into motion) and drive the movement of the drive shaft 124 relative to the housing 132 to move the pistons 106, 116.

[0024] For this reason, it is desirable to ensure that the motor 130 can move freely relative to the housing 132. As an example, it may be desirable to prevent or inhibit direct contact of a portion of the motor 130 with the housing 132. Direct contact between the motor 130 and the housing 132 can cause the motor 130 to collide with (e.g., wear, rub against) the housing 132, reducing the efficiency of the motor 130 (e.g., driving the movement of the drive shaft 124), increasing wear of the motor 130 and / or the housing 132, or degrading the desired operation of the pump drive system 122.

[0025] Accordingly, the pump drive system 122 includes a lubricant system 136 configured to direct a lubricant (e.g., oil, liquid) into the interior 134 of the housing 132. The lubricant can flow between the motor 130 and the housing 132 to prevent or at least inhibit direct contact between the motor 130 and the housing 132 and facilitate movement of the motor 130 within the housing 132. That is, the lubricant can create a buffer or cushion between the motor 130 and the housing 132. As a result, the lubricant enables the motor 130 to drive the movement of the pistons 106, 116 via the drive shaft 124 to pressurize the fluid. The lubricant can also reduce the temperature of the motor 130. For example, when the lubricant contacts the motor 130, it can absorb heat from the motor 130. By reducing the temperature of the motor 130, the lubricant can reduce wear of the motor 130 and extend the useful life of the motor 130.

[0026] In certain embodiments, the lubricant can flow continuously into and out of the interior 134 of the housing 132. As an example, one or more lubricant conduits 138 can direct lubricant from a lubricant source 146 into the interior 134 of the housing 132. Additionally or alternatively, the lubricant conduits 138 can direct lubricant out of the interior 134. For example, the use of the lubricant within the interior 134 can raise the temperature of the lubricant, contaminate the lubricant (e.g., by absorbing particles emitted by the motor 130 and / or the housing 132), change the viscosity of the lubricant, or reduce the effectiveness of the lubricant in a way that can affect the ability of the lubricant to facilitate movement and / or reduce the temperature of the motor 130. For this reason, the lubricant may be directed out of the interior 134 via one or more lubricant outlet conduits 138 for processing such as filtering and / or cleaning, and additional lubricant may be introduced into the interior 134 by the lubricant system 136. As a result, the lubricant within the interior 134 can continue to enable effective operation of the motor 130. As another example, the lubricant may leak or otherwise be directed from the interior 134 (e.g., toward the cylinders 102, 112) through an opening 140 through which the drive shaft 124 passes for positioning within the cylinders 102, 112. In either case, the lubricant system 136 operates to replenish the lubricant within the interior 134, thereby ensuring that there is a sufficient amount of lubricant present to flow between the motor 130 and the housing 132.

[0027] For this purpose, the lubricant system 136 includes a lubricant storage or container 144 configured to store lubricant and discharge the lubricant towards the housing 132. In some embodiments, the lubricant storage 144 is fluidly coupled to a lubricant source 146 and configured to receive lubricant from the lubricant source 146. For example, oil is directed into the housing 132 through the lubricant storage 144 or pumped in. Additionally or alternatively, the lubricant system 136 may be a closed-loop system, and the lubricant may circulate between the lubricant system 136 and the housing 132 such that it results from the movement of the pump drive system 122 (e.g., the drive shaft 124 within the housing 132). In any embodiment, the presence of lubricant within the lubricant storage 144 indicates that the housing 132 is sufficiently filled or overfilled with lubricant, allowing the lubricant to flow from the housing 132 into the lubricant storage 144.

[0028] In the illustrated embodiment, the lubricant storage 144 is also fluidly coupled to a conduit system 148 and configured to direct the lubricant to the conduit system 148. The conduit system 148 is fluidly coupled to the interior 134 of the housing 132 and configured to direct the lubricant received from the lubricant storage 144 to the interior 134. Accordingly, the lubricant system 136 is configured to direct lubricant from the lubricant source 146 into the housing 132 via the lubricant storage 144 and the conduit system 148. However, in other embodiments, the lubricant storage 144 can be directly connected to the housing 132.

[0029] Referring further to FIG. 1, the pump drive system 122 of the illustrated embodiment includes a control system 150 configured to operate various components of the pump drive system 122. For example, the control system 150 is configured to operate the motor 130. Further, the control system 150 is configured to monitor the lubricant level within the lubricant reservoir 144. In fact, it is desirable to ensure that a sufficient amount of lubricant is stored within the lubricant reservoir 144 to indicate that the housing 132 is sufficiently or overly filled with lubricant for the desired operation of the motor 130. However, the lubricant level in the lubricant reservoir 144 may fall below a desired or threshold level. In some situations, the lubricant level within the lubricant reservoir 144 may be insufficient as a result of air accumulating within the housing 132. More specifically, the air accumulated within the housing 132 first pushes the lubricant out of the housing 132 and into the lubricant reservoir 144, and then, for example, as subsequent lubricant (driven by the operation of the pump drive system 122) moves, the accumulated air is filled, and the lubricant may flow from the lubricant reservoir 144 back into the housing 132, resulting in a decrease in the lubricant level within the lubricant reservoir 144. Similarly, an insufficient amount of lubricant may initially be supplied to the pump drive system 122 via improper filling procedures (e.g., during maintenance), causing the housing 132 to be improperly filled or overfilled, which can limit the lubricant level within the lubricant reservoir 144. Additionally or alternatively, the lubricant may undesirably leak out of the pump drive system 122 during operation, such as through seals, to reduce the total amount of lubricant available for filling the housing 132 and the lubricant reservoir 144. The control system 150 is configured to monitor the lubricant level within the lubricant reservoir 144 to enable the desired operation of the motor 130. However, other embodiments may not include the control system 150 and may instead be configured to connect to a separate or external control system via, for example, a wired or wireless connection.

[0030] The control system 150 includes a memory 152 and a processor 154 (e.g., a processing circuit). The memory 152 includes a read-only memory (ROM), a random access memory (RAM), a magnetic disk storage media device, an optical storage media device, a flash memory device, an electrical, optical, or other physical / tangible (e.g., non-transitory) memory storage device. Thus, generally, the memory 152 includes one or more computer-readable storage media (e.g., storage devices) encoded with software using computer-executable instructions that can be executed to achieve the operations described herein. For example, the memory 152 stores or is encoded with instructions for monitoring the level of lubricant within the lubricant reservoir 144. The processor 154 includes, for example, a set of one or more microcontrollers and / or microprocessors configured to execute respective software instructions each stored in the memory 152. The processor 154 is configured to execute instructions stored in the memory 152 to monitor the level of lubricant within the lubricant reservoir 144.

[0031] As an example, control system 150 is communicatively coupled to a sensor 156 configured to provide a parameter indicative of the level of lubricant within lubricant reservoir 144. Accordingly, control system 150 is configured to receive data related to the parameter from sensor 156 and determine the level of lubricant within lubricant reservoir 144 based on the data. Control system 150 can then perform an operation based on the determined level of lubricant within lubricant reservoir 144. For example, control system 150 can be configured to reduce or temporarily stop the operation of motor 130 in response to determining that the level of lubricant within lubricant reservoir 144 is below a threshold level to avoid the potential operation of pump system 100 where motor 130 is in direct contact with housing 132. Control system 150 can be additionally or alternatively configured to perform different operations - such as directing lubricant from lubricant source 146 into lubricant reservoir 144 (e.g., by operating a lubricant pump) and / or providing a notification to a user (e.g., an operator, a technician) to prompt user action to address a small amount of lubricant within lubricant reservoir 144 - in response to determining that the level of lubricant within lubricant reservoir 144 is less than a threshold level.

[0032] FIG. 2 is a perspective view of a pump drive system 122 having a lubricant system 136. Lubricant system 136 includes a first lubricant inlet conduit 200 (e.g., an inner tube or pipe of a structure labeled 200) fluidly communicating lubricant reservoir 144 and housing 132. First lubricant inlet conduit 200 is directly coupled (e.g., attached thereto) to lubricant reservoir 144 so as to receive lubricant stored within lubricant reservoir 144. First lubricant inlet conduit 200 is configured to direct lubricant received from lubricant reservoir 144 into housing 132.

[0033] The lubricant system 136 also includes an intermediate conduit 202 (e.g., a pipe) in fluid communication with a first lubricant inlet conduit 200, and a second lubricant inlet conduit 204 in fluid communication with the intermediate conduit 202 and the housing 132. The intermediate conduit 202 is configured to direct lubricant from the first lubricant inlet conduit 200 to the second lubricant inlet conduit 204, and then the second lubricant inlet conduit 204 is configured to direct the lubricant received from the intermediate conduit 202 to the housing 132. As such, the lubricant system 136 is configured to direct lubricant from the lubricant reservoir 144 into the housing 132 via both the first lubricant inlet conduit 200 and the second lubricant inlet conduit 204. Thus, the lubricant system 136 may be able to supply lubricant into the housing 132 at a higher flow rate compared to the use of a single lubricant inlet conduit. By way of example, movement of the pump drive system 122 (e.g., of the drive shaft 124 within the housing 132) can reciprocate lubricant between the interior 134 of the housing 132 (e.g., near the motor 130) and the lubricant reservoir 144, and one of the first lubricant inlet conduit 200 or the second lubricant inlet conduit 204 can direct lubricant into the lubricant reservoir 144, while the other of the first lubricant inlet conduit 200 or the second lubricant inlet conduit 204 can direct lubricant into the housing 132 to maintain a certain amount of lubricant within the housing 132. However, the lubricant system 136 can have any suitable number of lubricant inlet conduits in alternative embodiments, such as a single lubricant inlet conduit (e.g., the first lubricant inlet conduit 200) or more than two lubricant inlet conduits configured to direct lubricant into the housing 132.

[0034] The lubricant storage portion 144 also includes a relief valve or overfill valve 206 configured to discharge lubricant from the lubricant storage portion 144. For example, the relief valve 206 can be actuated to avoid storage of an excessive amount of lubricant in the lubricant storage portion 144 (e.g., caused by substantial overfilling of the housing 132 for allowing an excessive amount of lubricant to flow into the lubricant storage portion 144) when the pressure in the lubricant storage portion 144 exceeds a threshold pressure. Thus, the relief valve 206 can help maintain the structural integrity of the lubricant storage portion 144 by avoiding accumulation of lubricant in the lubricant storage portion 144. Another valve such as a bleed valve can be additionally or alternatively used to reduce the excessive amount of lubricant in the lubricant storage portion 144 and maintain the structural integrity of the lubricant storage portion 144.

[0035] Figure 3 is a cross-sectional side view of the pump drive system 122. The lubricant storage portion 144 of the lubricant system 136 of the pump drive system 122 defines an interior 250 of the storage portion in which lubricant is contained. The lubricant storage portion 144 includes a storage outlet 252 that is in fluid communication with the interior 250 of the storage portion and is configured to discharge lubricant from the lubricant storage portion 144 to the interior 250 of the storage portion. The first lubricant inlet conduit 200 defines an interior 254 of the first conduit having a first conduit inlet 256, a first conduit outlet 258, and a second conduit outlet 260. The first lubricant inlet conduit 200 is mounted on the lubricant storage portion 144 and aligns the first conduit inlet 256 of the first lubricant inlet conduit 200 with the storage outlet 252 of the lubricant storage portion 144, thereby fluidly connecting the first lubricant inlet conduit 200 and the lubricant storage portion 144 to each other. Further, the first lubricant inlet conduit 200 is mounted on the housing 132 such that the first conduit outlet 258 is aligned with the first housing inlet 262 of the housing 132. Thus, lubricant can be directed to flow from the interior 250 of the storage portion, through the storage outlet 252, through the first conduit inlet 256, through the first conduit outlet 258, through the first housing inlet 262, and into the housing 132 from the lubricant system 136.

[0036]

[0042] The intermediate conduit 202 defines an inner second conduit 264, and the intermediate conduit 202 is attached to the first lubricant inlet conduit 200 such that the inner second conduit 264 is aligned with the second conduit outlet 260 of the first lubricant inlet conduit 200. Further, the second lubricant inlet conduit 204 defines an inner second conduit 266 having a second conduit inlet 268 and a third conduit outlet 270. The intermediate conduit 202 is attached onto the second lubricant inlet conduit 204 such that the inner second conduit 264 of the intermediate conduit 202 is aligned with the second conduit inlet 268 of the second lubricant inlet conduit 204, whereby the intermediate conduit 202 and the second lubricant inlet conduit 204 are in fluid communication with each other. The second lubricant inlet conduit 204 is attached onto the housing 132 such that the third conduit outlet 270 of the second lubricant inlet conduit 204 is aligned with the second housing inlet 272 of the housing 132. Thus, the lubricant may also be directed to flow into the housing 132 through the second conduit outlet 260, through the inner second conduit 264, through the second conduit inlet 268, through the third conduit outlet 270, through the second housing inlet 272, and through the second lubricant inlet conduit 204. Whether the lubricant is directed into the housing 132 via the first lubricant inlet conduit 200 or via the second lubricant inlet conduit 204, the lubricant fills the interior 134 of the housing 132 to provide a cushion or buffer between the motor 130 and the housing 132 (e.g., by immersing the motor 130).

[0037] FIG. 4 is a perspective view of a lubricant system 136 and a control system 150 configured to monitor the level of lubricant within a lubricant reservoir 144. In the illustrated embodiment, sensor 156 is an optical sensor, such as a camera, configured to determine a visual parameter indicative of the level of lubricant within lubricant reservoir 144. For this purpose, lubricant reservoir 144 includes a wall or panel 350 (e.g., a sight glass) that is at least partially transparent or at least partially translucent to enable viewing therethrough. Thus, the lubricant is contained within lubricant reservoir 144, and thus the level of lubricant within the internally contained lubricant reservoir 144 can be viewed through wall 350. However, sensor 156 need not be an optical sensor and can include any other type of sensor capable of providing data regarding the amount of lubricant within lubricant system 136.

[0038] In embodiments where sensor 156 is an optical sensor, sensor 156 can be positioned to face panel 350 to enable determination of a visual parameter indicative of the level of lubricant within lubricant reservoir 144. As illustrated, in some examples, this can be accomplished by attaching sensor 156 to intermediate conduit 202 and / or wall 350. Additionally or alternatively, sensor 156 may be attached to second lubricant inlet conduit 204 and / or housing 132. The parameter determined by sensor 156 can include an image of one or more walls 350 and an image (e.g., a video) of the lubricant visible through wall 350, refraction or deflection of light through (and e.g., through the lubricant) wall 350, or any other suitable visual parameter indicative of the lubricant level relative to wall 350.

[0039] The control system 150 is configured to receive data captured by the sensor 156 (e.g., an image showing the lubricant meniscus visible through the wall 350, or image data representing the same), and determine the lubricant level within the lubricant reservoir 144 based on the data. For example, the control system 150 is configured to determine whether the lubricant level exceeds a threshold level 352 of the wall 350 to indicate a sufficient amount of lubricant within the lubricant reservoir 144, and the control system 150 is configured to perform an operation to address a small amount of lubricant within the lubricant reservoir 144 in response to determining that the lubricant level is below the threshold level 352.

[0040] In additional or alternative embodiments, the sensor 156 is configured to determine a non-visible parameter indicative of the amount of lubricant within the lubricant reservoir 144. As an example, the parameter can include capacitance through the wall 350. In such embodiments, the sensor 156 may be mounted on the wall 350, and the wall 350 may have a specific thickness and / or material that allows the sensor 156 to determine a capacitance that changes based on whether the lubricant within the lubricant reservoir 144 is at least as high as the sensor 156. That is, the sensor 156 can detect a first capacitance while the lubricant does not overlap the sensor 156 across the wall 350 (e.g., the first capacitance is provided by the wall 350 without being affected by the presence of the lubricant). Thus, the first capacitance indicates that the lubricant has not reached the sensor 156 and, therefore, the lubricant level is insufficient.

[0041] Next, sensor 156 can detect a second capacitance that is different from (e.g., smaller than) the first capacitance. On the other hand, the lubricant overlaps sensor 156 across wall 350 (e.g., the presence of the lubricant adjusts the detected capacitance from the first capacitance provided by wall 350 such that the second capacitance is provided by both wall 350 and the lubricant). Thus, the second capacitance indicates that the lubricant has reached the location (e.g., height) of sensor 156 on wall 350 and is at a sufficient level within lubricant reservoir 144. Thus, sensor 156 can be mounted on wall 350 near threshold level 352 of wall 350 such that the capacitance detected by sensor 156 indicates whether the lubricant level is at threshold level 352 (e.g., whether the lubricant overlaps sensor 156 with respect to threshold level 352). Control system 150 is configured to receive the capacitance detected by sensor 156 and operate based on the received capacitance. For example, control system 150 is configured to execute an operation in response to determining that the capacitance exceeds a threshold for dealing with a low amount of lubricant within lubricant reservoir 144.

[0042] In any of the embodiments, sensor 156 is external to lubricant reservoir 144. Thus, sensor 156 does not contact the lubricant within lubricant reservoir 144. As a result, sensor 156 does not reduce the storage capacity of lubricant reservoir 144, does not affect (e.g., impede) the flow of lubricant in and out of housing 132, and / or does not contaminate the lubricant. This ensures that lubricant system 136 can operate effectively and continuously deliver lubricant into housing 132. Further, the separation of the lubricant from sensor 156 can maintain the structural integrity of sensor 156, thereby enabling sensor 156 to operate effectively and / or extending the useful life of sensor 156.

[0043] FIG. 5 is a cross-sectional side view of a portion of the lubricant system 136, showing an embodiment in which the sensor 156 is configured to monitor the lubricant within the intermediate conduit 202. That is, the sensor 156 is configured to monitor the flow of lubricant between the first lubricant inlet conduit 200 and the second lubricant inlet conduit 204. In some embodiments, the parameters detected by the sensor 156 include the flow rate of the lubricant. The control system 150 can receive data indicative of the flow rate and compare the flow rate to a threshold flow rate. A flow rate above the threshold flow rate can indicate that the lubricant is flowing sufficiently into the housing 132 (e.g., via the second lubricant inlet conduit 204 configured to receive lubricant from the intermediate conduit 202). This can then indicate that the lubricant level within the lubricant reservoir 144 is also sufficient (e.g., this lubricant level can allow lubricant to flow through the intermediate conduit 202 at a flow rate above the threshold flow rate). However, a flow rate below the threshold flow rate can indicate that the lubricant level within the lubricant reservoir 144 is insufficient. Accordingly, the control system 150 can perform an operation to address the low lubricant level within the lubricant reservoir 144 in response to determining that the flow rate is less than the threshold flow rate.

[0044] In additional or alternative embodiments, different parameters can be detected by the sensor 156. As an example, the sensor 156 can be configured to determine the presence of lubricant within the intermediate conduit 202. In certain embodiments, the sensor 156 can be disposed external to the intermediate conduit 202 to avoid contact with the lubricant flowing through the second conduit interior 264 of the intermediate conduit 202. For example, the lubricant system 136 can include a sensor housing 400 mounted on the intermediate conduit 202 (e.g., on the exterior of the intermediate conduit 202), and the sensor 156 can be at least partially disposed within the sensor housing 400. Accordingly, the sensor housing 400 can shield at least a portion of the sensor housing 400 from external members such as dust and debris and can secure the sensor 156 to the intermediate conduit 202.

[0045] Furthermore, the intermediate conduit 202 may be constructed of a specific material to enable the sensor 156 to monitor parameters related to the lubricant. For example, the intermediate conduit 202 may be constructed of glass or other materials that are at least partially translucent or transparent to enable the sensor 156 to visually monitor the lubricant within the intermediate conduit 202 and / or to enable determination of the capacitance through the intermediate conduit 202. Alternatively, the sensor 156 may be disposed within the second conduit interior 264 of the intermediate conduit 202 to monitor parameters related to the lubricant within the second conduit interior 264. For example, the sensor 156 may include a flow meter through which the lubricant flows for supply into the housing 132, and the sensor 156 may be configured to determine the flow rate of the lubricant flowing through the flow meter.

[0046] The illustrated sensor 156 is configured to detect the lubricant within the intermediate conduit 202, but in additional or alternative embodiments, the sensor 156 may be configured to detect the lubricant within various portions of the conduit system 148 of the lubricant system 136, such as within the first lubricant inlet conduit 200 and / or the second lubricant inlet conduit 204. In fact, the flow of the lubricant within any suitable portion of the conduit system 148 indicates the level of the lubricant within the lubricant reservoir 144 and can be readily supplied into the housing 132.

[0047] FIG. 6 is a perspective view of another pump system 420 including a plurality of housings 132 and respective lubricant systems 136 configured to direct lubricant into the housings 132. The illustrated lubricant reservoir 144 of the lubricant system 136 is directly coupled (e.g., attached) to a corresponding first lubricant inlet conduit 200 and a corresponding second lubricant inlet conduit 204. For example, each lubricant reservoir 144 can be extended or elongated to enable direct coupling to the first lubricant inlet conduit 200 and the second lubricant inlet conduit 204. Thus, the lubricant reservoir 144 is configured to direct lubricant into the housing 132 without an intermediate conduit 202. For example, movement of the pump drive system 122 can urge lubricant back and forth between the housing 132 and the lubricant reservoir 144, and one of each first lubricant inlet conduit 200 or each second lubricant inlet conduit 204 can direct lubricant into the corresponding lubricant reservoir 144, while the other of each first lubricant inlet conduit 200 or each second lubricant inlet conduit 204 can direct lubricant into the corresponding 132. Thus, a certain amount of lubricant within the housing 132 can be maintained.

[0048] The sensor 156 is configured to monitor the amount of lubricant within the lubricant reservoir 144. In some embodiments, the sensor 156 is configured to determine the amount of lubricant passing through the wall 350 (e.g., the sensor 156 is mounted on the wall 350 and / or on the housing 132 so as to face the wall 350). In additional or alternative embodiments, the sensor 156 is configured to determine the flow rate of lubricant through the lubricant system 136, such as through the first lubricant inlet conduit 200 and / or the second lubricant inlet conduit 204.

[0049] Figure 7 is a flowchart of a method 450 for operating a pump drive system 122. In some embodiments, a single component (e.g., control system 150) may perform the operations of method 450. In additional or alternative embodiments, the operations of method 450 may be performed by separate entities. It should also be noted that method 450 may be performed differently than shown. For example, additional operations may be performed, and / or any of the depicted operations may be performed differently, in a different order, and / or not at all.

[0050] At block 452, the amount of lubricant contained within lubricant reservoir 144 is monitored. For example, sensor 156 can determine a parameter indicative of the level of lubricant. In certain embodiments, the parameter includes the height of the lubricant contained within lubricant reservoir 144 and visible through wall 350 (e.g., captured via an image indicative of refractive properties through lubricant reservoir 144). In additional or alternative embodiments, the parameter includes the capacitance detected through wall 350. In further embodiments, the parameter includes the flow rate of the lubricant (e.g., within first lubricant inlet conduit 200, intermediate conduit 202, second lubricant inlet conduit 204).

[0051] At block 454, it is determined that the level of lubricant is below a threshold level. For example, a lubricant level below the threshold level can be indicated by a height of the lubricant below a threshold height, a capacitance through wall 350 below a threshold capacitance, and / or a flow rate of the lubricant through intermediate conduit 202 below a threshold flow rate. A low level of lubricant within lubricant reservoir 144 may indicate that the lubricant is not readily available within housing 132.

[0052] In block 456, in response to determining that the level of lubricant is below a threshold level, the operation of motor 130 can be reduced. This is because while the lubricant may not be easily supplied into housing 132, the potential of motor 130 that directly contacts housing 132 may increase. The direct contact between motor 130 and housing 132 during the operation of motor 130 (e.g., the resulting movement of motor 130 relative to housing 132) can be detrimental to the operation of pump system 100. Thus, by reducing the operation of motor 130, the impact on the operation of pump system 100 can be avoided. In some embodiments, the operation of motor 130 is interrupted by cutting off the power supply directed to motor 130. In additional or alternative embodiments, some operations of motor 130 can be enabled so that pump system 100 can continue to pressurize fluid (e.g., with limited capacity).

[0053] In additional or alternative embodiments, operations can be performed in response to determining that the level of lubricant in lubricant reservoir 144 exceeds a higher threshold level, which may indicate an excessive amount of lubricant in lubricant reservoir 144. Such determination can be made using similar techniques as described for the determination of low levels of lubricant, such as using image data, refractive properties, capacitance, and / or flow rate. In such situations, it may be desirable to avoid increasing the amount of lubricant in lubricant reservoir 144. For example, relief valve 206 may be actuated to discharge lubricant from lubricant reservoir 144. Additionally or alternatively, the operation of lubricant system 136 and / or lubricant source 146 can be stopped or reduced to avoid further accumulation of lubricant in lubricant reservoir 144. Thus, a desired amount of lubricant in lubricant reservoir 144 can be maintained.

[0054] As used herein, unless explicitly stated otherwise, the use of phrases such as "at least one of", "one or more of", "and / or, or variations thereof", etc., is an unrestricted expression that is both conjunctive and disjunctive for any and all possible combinations of the relevant listed items. For example, each of the expressions "at least one of X, Y, and Z", "at least one of X, Y, or Z", "one or more of X, Y, and Z", "one or more of X, Y, or Z", and "X, Y, and / or Z" can mean 1) X but neither Y nor Z, 2) Y but neither X nor Z, 3) Z but neither X nor Y, 4) X and Y but not Z, 5) X and Z but not Y, 6) Y and Z but not X, or 7) any of X, Y, and Z.

[0055] Furthermore, unless otherwise specified, terms such as "first", "second", "third", etc., are not intended to indicate a changed order, rank, importance, time series, or any kind of order of the nouns, unless explicitly stated otherwise. For example, "the first X" and "the second X" are intended to designate two "X" elements that are not necessarily limited by the order, rank, importance, time series, or order of the two elements. As further mentioned herein, "at least one of" and "one or more of" can be represented using the "(one or more of)" nomenclature (e.g., one or more elements).

[0056] Each exemplary embodiment disclosed herein is included to present one or more different features. However, all of the disclosed exemplary embodiments are designed to function together as part of a single larger system or method. The present disclosure explicitly contemplates compound embodiments that combine multiple of the aforementioned features in different exemplary embodiments into a single system or method.

[0057] One or more of the advantages described in this specification do not imply that any one of the embodiments described in this specification necessarily provides all of the described advantages, or that all embodiments of the disclosure necessarily provide any one of the described advantages. Numerous other variations, substitutions, modifications, alterations, and / or revisions may be apparent to those skilled in the art, and the disclosure is intended to encompass all such variations, substitutions, modifications, alterations, and / or revisions that fall within the scope of the appended claims.

Claims

1. A housing and an electric motor disposed within the housing and configured to drive a piston of the pump; a lubricant reservoir configured to store a lubricant; a conduit configured to conduct lubricant from the lubricant reservoir to the housing so as to submerge the electric motor in the lubricant; a sensor configured to monitor a level of lubricant in the lubricant reservoir; A pump drive system comprising:

2. 2. The pump drive system of claim 1, further comprising a control system in communication with the sensor, the control system comprising: determining that the level of lubricant in the lubricant reservoir is below a threshold level; interrupting operation of the electric motor in response to determining that the level of lubricant in the lubricant reservoir is below a threshold level. It is configured as follows: Pump drive system.

3. 3. The pump drive system of claim 2, wherein the control system is configured to interrupt operation of the electric motor in response to determining that the level of lubricant in the lubricant reservoir is below a threshold level by interrupting the supply of power to the electric motor.

4. 2. The pump drive system of claim 1, the lubricant reservoir has a wall; and the sensor is configured to monitor a level of lubricant in the lubricant reservoir by determining a capacitance of the wall. Pump drive system.

5. The pump drive system of claim 4 , wherein the sensor is mounted to the wall.

6. 2. The pump drive system of claim 1, the lubricant reservoir has an at least partially transparent or translucent wall; and the sensor includes an optical sensor configured to monitor the level of lubricant in the lubricant reservoir relative to the wall; Pump drive system.

7. 7. The pump drive system of claim 6, wherein the optical sensor is configured to monitor the level of lubricant in the lubricant reservoir relative to the wall by determining refractive properties associated with the wall.

8. 2. The pump drive system of claim 1, wherein the sensor is configured to determine a parameter of lubricant channeled through the conduit that is indicative of the level of lubricant in the lubricant reservoir.

9. 9. The pump drive system of claim 8, wherein the parameter comprises a flow rate.

10. 9. The pump drive system of claim 8, wherein the conduit is a first conduit: a second conduit attached to the lubricant reservoir and to the housing and configured to conduct lubricant from the lubricant reservoir to the housing; a third conduit attached to the housing; Equipped with the first conduit is configured to be fluidly connected to the second conduit and the third conduit to conduct lubricant from the second conduit to the third conduit; and the third conduit is configured to conduct lubricant from the first conduit to the housing. Pump drive system.

11. a cylinder having a chamber; a piston disposed within the chamber of the cylinder; an electric motor disposed within the housing and configured to drive movement of the piston relative to the chamber of the cylinder to pressurize fluid within the chamber and expel pressurized fluid from the chamber; a lubricant reservoir; a conduit fluidly connected to the lubricant reservoir and configured to direct lubricant from the lubricant reservoir into the housing; a sensor configured to monitor a level of the lubricant in the lubricant reservoir; A booster pump system comprising:

12. 12. The booster pump system of claim 11, wherein the sensor is external to the lubricant reservoir.

13. 13. The booster pump system of claim 12, wherein the sensor is coupled to the conduit.

14. 14. The booster pump system of claim 13, the lubricant reservoir has an at least partially transparent or translucent wall; and the sensor including an optical sensor configured to determine a parameter of the lubricant channeled through the conduit indicative of the level of lubricant in the lubricant reservoir; Booster pump system.

15. 15. The booster pump system of claim 14, wherein the parameter comprises a flow rate.

16. 14. The booster pump system of claim 13, the lubricant reservoir has an at least partially transparent or translucent wall; and the sensor is configured to monitor the level of lubricant within the lubricant reservoir by acquiring an image of the lubricant contained within the lubricant reservoir and visible through the wall. Booster pump system.

17. When executed by one or more processors, the one or more processors are monitoring a level of lubricant contained within a lubricant reservoir configured to store the lubricant and direct the lubricant into a housing including a motor of the booster pump configured to drive movement of a piston of the booster pump; determining whether the level of lubricant in the lubricant reservoir is below a threshold level; reducing operation of the motor in response to determining that the level of lubricant in the lubricant reservoir is below the threshold level; A non-transitory computer readable medium comprising instructions for performing operations including:

18. 20. The non-transitory computer readable medium of claim 17, The instructions, when executed by the one or more processors, cause the one or more processors to: receiving sensor data from a sensor disposed outside the lubricant reservoir; determining the level of lubricant contained within the lubricant reservoir based on the sensor data; A non-transitory computer-readable medium configured to cause a computer to perform operations including:

19. 20. The non-transitory computer readable medium of claim 18, the lubricant reservoir has an at least partially transparent or translucent wall, the wall being at least partially transparent or translucent such that the lubricant contained within the lubricant reservoir is visible through the wall; the sensor data includes an image of the wall of the lubricant reservoir; Non-transitory computer-readable medium.

20. 20. The non-transitory computer readable medium of claim 17, The instructions, when executed by the one or more processors, are configured to cause the one or more processors to reduce operation of the motor in response to determining that the level of lubricant in the lubricant reservoir has fallen below the threshold level by interrupting the supply of power to the motor. Non-transitory computer-readable medium.

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