Portable Reciprocating Air Compressor Direct Drive Design
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Solution Overview
Problem
Existing portable air pumps for cyclists are either too large and heavy, slow to use, or require external power sources, and struggle to achieve high pressures efficiently, with manufacturing costs increased by the need for precise CNC machining for high compression ratios.
Innovation Solution
A compact, battery-powered reciprocating air compressor with a brushless DC motor and optimized dimensions for a small, lightweight design that can fit in a cyclist's pocket, using a thermally conductive aluminum housing and direct drive mechanism to achieve high pressures without a hose, and utilizing a rechargeable lithium polymer battery for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a reciprocating air compressor with gear assembly is used, then high pressure compression is achieved, but the device size and weight increase making it impractical for portable use
Solution Approach 1:
The patent removes the gear assembly from the compressor design, extracting the unnecessary mechanical transmission component. This direct-drive configuration eliminates the gear train while maintaining compression capability through optimized piston-cylinder geometry and high-speed electric motor operation.
Solution Approach 2:
The patent replaces the mechanical gear transmission system with an electrically-driven direct-drive system. The electric motor directly drives the piston through a simplified crank mechanism, substituting complex mechanical gearing with electrical control and streamlined mechanics.
2Productivity
If high compression ratios are used to reduce inflation time, then pumping speed improves, but manufacturing precision requirements increase due to smaller clearances
Solution Approach 1:
The patent changes the operational parameters by increasing motor speed and adjusting piston stroke length rather than relying solely on high compression ratios. This allows for larger, more manufacturable clearances while maintaining fast inflation performance through higher operational RPM and optimized displacement volume.
3Productivity
If a larger pump unit is used to achieve fast inflation, then pumping speed improves, but portability deteriorates
Solution Approach 1:
The patent employs a dynamically controlled electric motor that can vary its operating speed and power output. This allows the compact compressor to achieve high inflation speeds when needed while consuming less energy during operation, maintaining portability without sacrificing performance capability.
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 solution enables a portable, lightweight pump that can inflate a bicycle tire to 100 psi in under a minute, is less sensitive to compression ratio, and can be manufactured using cost-effective processes, while maintaining high efficiency and durability.
Implementation Method 1
an electric motor to a drive shaft, with the drive shaft rotatable about a drive shaft axis
Implementation Method 2
The crank is provided to actuate the piston in a reciprocating motion within and relative to the cylinder so as to compress air within the cylinder
Implementation Method 3
The components are all contained within a thermally conductive housing thereby improving the thermal efficiency of the compressor
Data Source
AI summary
Disclosed is a portable pump including a reciprocating air compressor arrangement with a crank driving a connecting rod and a piston within a cylinder, the connecting rod being connected to the crank and piston, the crank actuating the piston in a reciprocating motion within and relative to the cylinder, an electric motor having a drive shaft mounted to the crank and rotatable about a drive shaft axis, the drive shaft axis being at least substantially coaxially aligned with an axis of rotation of the crank, a control unit communicating with the electric motor to control the pump, a power supply communicating with the control unit to power the control unit and electric motor, a common housing containing the electric motor, reciprocating air compressor arrangement, control unit, and power supply, and an outlet fluidly connected to the reciprocating air compressor arrangement for fluidly engaging with an pumpable object.