Compressor Gearbox Lubrication Layout With Single Pump Module
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Solution Overview
Problem
Split gearbox compressors and blowers are often large and expensive due to their extensive lubrication systems and expansive couplings, requiring a large baseplate and increased production and securing costs.
Innovation Solution
A compressor or blower design featuring a streamlined lubrication system with a single pump module and a direct engagement between the impeller and motor, utilizing hydrodynamic bearings and a mechanical pump to lubricate bearings before startup, eliminating the need for auxiliary pumps and reducing the overall footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional extensive lubrication systems and expansive couplings are used, then reliable lubrication is achieved, but device complexity and footprint increase
Solution Approach 1:
The patent combines the lubrication pump and motor into a single integrated unit, eliminating the need for separate auxiliary pumps and extensive lubrication systems. The motor shaft directly drives both the impeller and the lubrication pump, merging multiple functions into one compact assembly that reduces device complexity while maintaining reliable lubrication.
Solution Approach 2:
The motor shaft serves multiple functions simultaneously: it drives the impeller for compression, drives the lubrication pump for bearing lubrication, and provides structural support. This multi-functionality eliminates the need for separate dedicated components, reducing overall device complexity while ensuring reliable lubrication delivery.
2Reliability
If traditional expansive couplings are used, then reliable power transmission is achieved, but footprint and manufacturing cost increase
Solution Approach 1:
The patent removes traditional expansive couplings from the power transmission system and replaces them with a direct-drive configuration where the motor shaft directly connects to and drives the impeller. This extraction of unnecessary intermediate components reduces the footprint and eliminates the need for a large baseplate while maintaining reliable power transmission.
3Reliability
If traditional extensive lubrication systems are used, then adequate bearing lubrication is achieved, but production cost and baseplate requirements increase
Solution Approach 1:
The lubrication pump is merged with the motor assembly, sharing the same shaft and housing space. This integration eliminates the need for separate auxiliary pumps, extensive lubrication piping, and large baseplates, significantly reducing production costs while ensuring adequate bearing lubrication through the combined unit.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves a smaller form factor and enhanced efficiency by eliminating unnecessary components, reducing manufacturing costs, and allowing easy maintenance access while maintaining reliable lubrication.
Implementation Method 1
a mechanically driven pump that is disposed on the motor shaft
Implementation Method 2
the pump module includes an injector that wets the bearings
Implementation Method 3
the high-speed shaft is supported by hydrodynamic bearings
Data Source
AI summary
A compressor or blower includes an impeller disposed on a high-speed shaft, a motor shaft that extends from an end shield of a motor, a gearbox, and a lubrication system. The gearbox is disposed between the motor and the impeller and includes a pinion disposed on the high-speed shaft and a bull gear disposed directly on the motor shaft in engagement with the pinion. The lubrication system includes a single pump module that is configured to wet bearings on the high-speed shaft prior to starting the motor and to mechanically pump oil to the bearings during operation of the motor.