The present invention relates to a compressor, in particular to a compressor having a reciprocating piston compressor.
Mobile compressors are used for example on construction sites for manual work in which compressed air is required for connected compressed-air tools. One type of compressor that is often used is the piston compressor, in which air is sucked into one or more cylinders, compressed by a piston and discharged again as compressed air. The amount of air delivered from the piston compressors is usually adapted to the compressed air required in each case by adjusting the drive speed of the machine driving the compressor. DE 10 2004 007 882 B4 discloses for example a compressor having a compressed-air sensor, depending on the measured value of which the speed of a piston compressor is adjusted.
Due to the clocked operation thereof, piston compressors do not discharge compressed air continuously but rather generate compressed air in pulses. Conventionally, a specific compressed-air buffer volume is therefore retained in order to damp the compressed-air pulses by means of the compressor. This buffer volume is conventionally retained in separate storage containers so that compressed air at equally high pressure can be provided to a compressed-air consumer connected to the storage containers. DE 10 2009 052 510 A1 for example relates to a speed-variable piston compressor that has a lightweight and compact compressed-air tank made of plastics material.
Various other attachments are provided for the design of compressed-air tanks for piston compressors: U.S. Pat. No. 6,089,835 A for example discloses a piston compressor having a compressed-air tank that is formed by a cover housing placed on the outside of the motor housing. U.S. Pat. No. 5,370,504 A discloses a piston compressor in which the compressor cylinders are completely embedded in a storage tank for compressed air.
However, there is a need for solutions for compressors that have a lower weight and smaller dimensions so that they better suit manual transport.
According to one aspect of the invention, a compressor is therefore provided, comprising a motor, a drive shaft driven by the motor and connected thereto, a crank mechanism connected to the drive shaft, at least one compressed-air generation apparatus that is driven by the crank mechanism and is designed to generate compressed air, a crankcase that has an inner chamber wall in the shape of a hollow body, which receives the drive shaft at least in portions, an outer chamber wall that is spaced apart from the inner chamber wall radially with respect to the drive shaft, an end wall, and a dividing wall, and a compressed-air storage container that is designed to receive compressed air generated by the compressed-air generation apparatus, wherein the compressed-air storage container is formed by the inner chamber wall, the outer chamber wall, the end wall and the dividing wall.
The basic concept of the invention is that of embedding the storage container for compressed air generated by the compressor in the crankcase of the compressor by using the space around the drive shaft. In this case, it is highly advantageous that a separate storage container can be omitted, which in turn contributes to a considerable saving in terms of weight and cost. The entire structure of the compressor is more compact, and therefore the compressor remains easy to handle and portable despite having a large storage volume.
In addition, by integrating the compressed-air storage container in the crankcase, the amount of components required is reduced, which in turn simplifies assembly of the compressor. By supporting the drive shaft in an integral crankcase portion, there is also no need for the complex adjustment of the individual bearing points with respect to one another. Furthermore, components that are required for operating the compressor, for example a pressure sensor, pressure indicator, safety valve, non-return valve or drain valve can be connected to the integrated compressed-air storage container in a cost-effective manner and without additional pipes.
According to one embodiment of the compressor according to the invention, the compressor may also comprise a motor mount that receives and retains the motor and is connected to the crankcase by forming the end wall between the crankcase and the motor.
According to another embodiment of the compressor according to the invention, the compressor may also comprise at least one first bearing that supports the drive shaft and is arranged within the hollow body formed by the inner chamber wall.
In this case, the compressor may comprise at least one second bearing that supports the drive shaft. According to one variant, the second bearing may be arranged between the motor and the first bearing within the hollow body formed by the inner chamber wall. According to another variant, the second bearing may be arranged in the motor outside the hollow body formed by the inner chamber wall. The first and/or second bearing may for example be grease-lubricated rolling bearings.
According to another embodiment of the compressor according to the invention, the crankcase may be monolithically formed with the inner chamber wall, the outer chamber wall and the dividing wall. In this case, the monolithic crankcase may be designed as a light metal cast part.
According to another embodiment of the compressor according to the invention, the compressor may also have at least one brace that extends axially with respect to the drive shaft between the inner chamber wall and the outer chamber wall and divides the compressed-air storage container into at least two storage portions.
According to another embodiment of the compressor according to the invention, the at least two storage portions may be fluidically interconnected by compressed-air lines, valves and/or constrictions.
According to another embodiment of the compressor according to the invention, the compressor may also have at least one longitudinal rib that is formed integrally with the crankcase on the outside of the compressed-air storage container.
According to another embodiment of the compressor according to the invention, the compressor may also comprise a motor mount that receives and retains the motor, wherein the crankcase is formed around the motor so as to be spaced apart from the motor mount, and wherein the compressed-air storage container extends at least in part around the motor between the crankcase and the motor mount.
According to another embodiment of the compressor according to the invention, the compressed-air storage container may enclose the drive shaft within an angular range of 360°.
According to another embodiment of the compressor according to the invention, the ratio of the distance between the axis of rotation of the drive shaft and the point on the inner wall of the compressed-air storage container that is furthest perpendicularly from the drive shaft to the distance between the axis of rotation of the drive shaft and the upper dead centre of a piston of the compressed-air generation apparatus may be between 0.2 and 1.
According to another embodiment of the compressor according to the invention, the ratio of the distance between the axis of rotation of the drive shaft and the point on the inner wall of the compressed-air storage container that is furthest perpendicularly from the drive shaft to the maximum axial extent of the compressed-air storage container 25 may be between 0.3 and 2.5.
According to another embodiment of the compressor according to the invention, the compressed-air generation apparatus may have at least one compressor chamber and the volume ratio between the volume of the compressed-air storage container and the sum of the geometric working volumes of the compressor chambers of the compressed-air generation apparatus may be between 5 and 25.
The invention will be described in more detail below with reference to the embodiments and the accompanying drawings.
The accompanying drawings are used in order to better understand the present invention and show variants of the invention. They are used to explain principles, advantages, technical effects and possible variations. Of course, other embodiments and many of the intended advantages of the invention are likewise conceivable, in particular with reference to the detailed description of the invention set out below. The elements in the drawings are not necessarily shown to scale and are simplified in part or shown schematically for reasons of clarity. Like reference signs denote like or similar components or elements.
Although specific embodiments are described and shown herein, it is clear to a person skilled in the art that an abundance of other, alternative and/or equivalent implementations can be selected for the embodiments, essentially without departing from the basic concept of the present invention. In general, all of the variations, modifications and deviations of the embodiments described herein should likewise be considered to be covered by the invention.
The compressed-air storage container 25, which is formed as an integral component of the crankcase 20 in
In addition, an additional bearing 28a may be formed in a second bearing seat inside the chamber wall 26a and may support a motor-side part of the drive shaft 24 between the motor 40 and crank mechanism 6, i.e. the bearing 28a supports the motor 40 in a floating manner. Because the two bearings 28a and 28b are in the portion of the crankcase 20 that forms the compressed-air storage container 25, the bearing seats of the bearings 28a and 28b can be better aligned to one another. This enables improved concentricity of the bearing seats with respect to one another. It is in this case possible for the two bearing seats of the bearings 28a and 28b in the crankcase 20 to be accessed from one side, in particular if the radial extent of the bearing 28a is less than that of the bearing 28b.
In order to illustrate the geometry of the compressed-air storage container 25,
The outer chamber wall 26b is an outer wall of the crankcase 20 that completely receives the inner chamber wall 26a in its interior. In other words, the topology of the case formed by the outer chamber wall 26b and the inner chamber wall 26a substantially resembles two cylinders mounted inside one another, for example circular cylinders, prismatic cylinders or cylinders having a polygonal cross-sectional area. The cover areas of the cylinder shell surfaces formed between the by the outer chamber wall 26b and the inner chamber wall 26a may be enclosed by one or more dividing walls 34 on the other side or one or more end walls 23 on the other side in order to form the volume of the compressed-air storage container 25.
The dividing wall 34 or the dividing walls 34 each have a main direction of extension that substantially extends perpendicularly to the axial direction of the drive shaft 24. The end wall 23 likewise has a main direction of extension that substantially extends perpendicularly to the axial direction of the drive shaft 24 and is spaced apart from the dividing wall 34 or the dividing walls 34 by a length that substantially corresponds to the longitudinal extent of the compressed-air storage container 25.
In the lateral direction, the compressed-air storage container 25 may be divided by one or more braces 33. In this way, the compressed-air storage container 25 can be stabilised on the one hand and can be divided into a plurality of partial storage volumes on the other hand. Said partial storage volumes may be interconnected via compressed-air lines or other connection lines such as constrictions. Advantageously, compressed-air coolers and/or valves may also be arranged in the connection lines. In the example in
The compressor according to
The linear working movement for the piston 5 is produced by a crank mechanism 6 that is connected to the rotor 43 of the motor 40 by means of a drive shaft 24. The drive shaft 24 may be mounted so as to rotate relative to the crankcase 20 by means of two bearings 28a and 28b, for example prelubricated rolling bearings having fixed/floating bearings. The crankcase 20 has a crank mechanism portion 21 that encloses the crank mechanism 6 at least in part and has a storage portion 22 that adjoins the crank mechanism portion 21 and is arranged axially between said portion and the motor 40.
It is preferably provided for the dividing wall 34 to separate the compressed-air storage container 25 from the crank mechanism 21 inside the crankcase 20, i.e. the crank mechanism 6 itself is not located in the air storage volume of the compressed-air storage container 25. The storage portion 22 is therefore disjointedly formed with the crank mechanism portion 21. In particular, it is also provided for the cylinder 5 and the piston 4 not to be arranged inside the storage portion 22, i.e. for the volume of the compressed-air storage container not to include the cylinder 5 and the piston 4.
The storage portion 22 has an inner chamber wall 26a that is hollow or tubular in order to be arranged around the drive shaft 24 and receives the region of the drive shaft 24 leading through the storage portion 22 and at least one of the two bearings 28a and 28b. The inner chamber wall 26a may have recesses for one or more bearing seats of the bearings 28a and 28b. Furthermore, more than two bearings 28a and 28b may be provided.
Furthermore, the storage portion 22 has an outer chamber wall 26b that may be arranged so as to be concentric around the inner chamber wall 26a and spaced apart therefrom. Preferably, the inner chamber wall 26a and the outer chamber wall 26b are integrally formed with the crankcase 20, i.e. formed as an integral portion of the crankcase 20.
The inner chamber wall 26a and the outer chamber wall 26b define, together with one or more dividing walls 34, the extension plane of which extends substantially perpendicularly to the axis of rotation of the drive shaft 24, a compressed-air storage container 25 of the compressor 100. The compressed-air storage container 25 is arranged annularly around the inner chamber wall 26a at least in portions so as to be concentric with the drive shaft 24. In other words, the compressed-air storage container 25 therefore surrounds the drive shaft 24 at least in a partial angular range. In the example in
The motor mount 41 may assume the function of supporting the torque between the rotor and stator of the motor 40. The motor mount 41 may be a component that completely or only partially surrounds the motor 40 and may have closed bordering walls having braces, columns or the like. In this case, the motor mount 41 may also act as a completely closed motor housing.
The motor mount 41 may in addition form the end wall 23, which is arranged between the motor 40 and the storage portion 22 in the example in
After a suction cycle of the piston 4, the sucked-in air is compressed in the compression chamber 11 in a compression cycle when the piston 4 moves upwards and is output via the outlet opening 7 and an outlet valve arranged therein. The compressed air that is discharged via the outlet opening 7 may be output into a compressed-air line 8 that may comprise a region having a cooling line 9 for cooling purposes. The compressed air passes via the cooling line 9 through the non-return valve 10 to reach a compressed-air storage container 25 of the compressor 100.
Sealing with respect to the surroundings may expediently take place by means of seals 29 and 30, for example O-rings. Both the crankcase 20 and the motor mount 41 may be reinforced by ribs 32. Said ribs 32, which can be attached to the outside of the crankcase 20 and/or of the motor mount 41 in a similar manner, contribute to better heat dissipation from the compressed air. In addition, it is possible to optimise the mechanical stability of the compressor 100 in this way.
A compressed-air discharge line, for example a compressed-air tube for a tool operated by compressed air through which the compressed air may be extracted as required from the compressed-air storage container 25, may be connected via a compressed-air coupling 31.
When the compressor is in operation, a compressor controller 60 may retrieve the pressure of the compressed air that is measured by a pressure sensor 27 arranged on the compressed-air storage container 25 via a control line 61. If the measured target pressure in the compressed-air storage container 25 deviates from the target pressure stored in the compressor controller 60, a target speed signal for the motor 40 can be determined from the control deviation, which signal is sent by the compressor controller 60 as an actuation signal via a control line 62 to a motor controller, for example to the frequency converter 70 of an electric motor 40. The frequency converter 70 controls the speed of the motor 40 depending on the sent actuation signal.
When the speed of the motor 40 is adjusted and the amount of delivered air from the compressor 100 is adapted as a result, it is advantageous for the size of the compressed-air storage container 25 to be able to be reduced while the switching frequency remains the same. As an alternative, it is likewise possible to reduce the switching frequency while the size of the compressed-air storage container 25 remains the same. By adjusting the speed, it is moreover advantageously possible to reduce the minimum amount of delivered air from the compressor, which in turn can lead to a smaller size of the compressed-air storage container 25 or a lower switching frequency. Finally, it is also possible to fill the compressed-air storage container 25 more rapidly after an idle phase, in particular if the compressor 100 is operated in a speed-adjusted manner and can provide a greater amount of delivered air at a low pressure.
In the example in
Both for the compressor 100 in
The maximum radial extent L2 may also be in a specific ratio to the maximum axial extent L3 of the compressed-air storage container 25. If the compressed-air storage container 25 is arranged between the crank mechanism 6 and the motor 40, the ratio L2/L3 may be between 0.3 and 2.5, preferably between 0.5 and 1.33.
In addition, the volume ratio between the volume VR of the compressed-air storage container 25 and the geometric working volume VH of the compressor chamber 11 (or the sum VH of all the working volumes VHi of all the compressor chambers 11 in the case of a plurality of cylinder 5) can be set in order to be able to eliminate the damping of the compressed-air pulses in an optimum manner. The ratio VR/VH may in this case be between 5 and 25.
The crankcase 20 including all the chamber walls 26a, 26b and end walls 23 and dividing walls 34 may be entirely formed in one piece in
The compressed-air storage container 25 may enclose the motor 40 in a partial angular range of less than 360° or completely, i.e. over a circumference of 360°. It may also be possible for the compressed-air storage container 25 to completely enclose the motor 40 relative to the angular range around the drive shaft 24, but to only partially enclose the motor 40 in the axial direction of the axis of rotation of the motor, i.e. is not completely formed up to the non-crankcase-end of the motor mount 40.
Number | Date | Country | Kind |
---|---|---|---|
13197728 | Dec 2013 | EP | regional |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/EP2014/078112 | 12/17/2014 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2015/091587 | 6/25/2015 | WO | A |
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4854829 | Stanzani | Aug 1989 | A |
5370504 | Nagashima | Dec 1994 | A |
6089835 | Suzuura et al. | Jul 2000 | A |
6148716 | Swank | Nov 2000 | A |
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20070075673 | Nakazawa | Apr 2007 | A1 |
20080173171 | Brower | Jul 2008 | A1 |
20090220338 | Ietka | Sep 2009 | A1 |
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20110007990 | Kawamura | Jan 2011 | A1 |
Number | Date | Country |
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2007041818 | Apr 2007 | WO |
Entry |
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International Search Report dated Mar. 23, 2015 issued in corresponding PCT/EP2014/078112 application (2 pages). |
Office Action in corresponding Brazil application BR112016013952-6 dated Apr. 7, 2020 (pp. 1-4 and English translation of relevant portion (pp. 1). |
Number | Date | Country | |
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20160319809 A1 | Nov 2016 | US |