This invention relates to a multi-piston axial machine that operates as a pump or compressor. Throughout this application the terms axial pump, axial pump/compressor or pump will refer to and include both an axial pump and an axial compressor.
Axial pumps for liquids or gases employ a plurality of cylinders and reciprocating pistons that are aligned parallel to and disposed around a central axis. The pistons reciprocate successively within the cylinders with their strokes overlapping in time to provide continuous pumping of the working fluid. The distance a piston travels within the cylinder, i.e., travel, controls the amount of working fluid taken in and expelled in one complete cycle of a piston. The greater the distance traveled, the greater the amount of fluid pumped in one cycle. The product of the distance a piston travels in one-half of the cycle, the area of the cylinder and the number of cylinders equals the displacement of the pump. One or more valves allow flow of the working fluid in to and out of each cylinder on the intake and output strokes, respectively.
One method and means of actuating the pistons in an axial pump is to provide a plate, typically a swash or wobble plate, which is tilted relative to the pump axis. The plate engages the pistons so as to actuate each piston successively as rotation takes place. Depending on the design of the axial pump, either the plate or the cylinders and pistons are rotated such that there is relative rotation between the plate and the cylinders.
In an axial pump with a wobble plate, the plate rotates while the cylinders are stationary. In this type of pump, travel is typically fixed. Because travel is fixed, output from each cylinder is also typically fixed. A wobble plate axial pump typically has at least two valves allowing flow of the working fluid, one for intake and the other for output.
In an axial pump with a swash plate, the plate does not rotate while the cylinders and pistons rotate around the axis of the pump. However, in this type of pump it is possible to change the angle of the tilt to the swash plate. As the tilt of the swash plate is changed the travel of the piston, and therefore the amount of fluid pumped with each stroke, is changed. A swash plate axial pump typically has a port plate in contact with the top of the cylinder barrel that allows separate intake and output of the working fluid.
The port plate typically has at least two kidney-shaped openings, one that is open to each cylinder in which the piston is being retracted from the cylinder during rotation of the cylinder barrel, i.e., the intake stroke, and the other that is open to each cylinder in which the piston is being pushed into the cylinder during rotation of the cylinder barrel, i.e., the output stroke. Each end of the intake opening is separated from each end of the output opening by a distance equal to the diameter of a cylinder. One such separation, or “blocked bridge,” is at top-dead-center, or “TDC;” the other is at bottom-dead-center, or “BDC.” At TDC, a piston has finished the output stroke and is beginning the intake stroke. At BDC, a piston has finished the intake stroke and is beginning the output stroke. At TDC of the swash plate, and any output greater than zero, the distance between the swash plate surface and the top of the cylinder is at its shortest. At BDC of the swash plate, and any output greater than zero, the distance between the swash plate surface and the top of the cylinder is at its longest.
In a swash plate axial pump, TDC for the port plate and the swash plate are typically the same and fixed, i.e., the swash plate and port plate are “on time”. The output of the pump is controlled by changing the distance a piston travels during a cycle, i.e., by changing the tilt angle of the swash plate. If the swash plate is rotated about the axis, the dead-center positions for the swash plate and port plate are no longer the same, i.e., they are “off time”. This means that at TDC of the port plate a piston is either continuing its input stroke or is in the middle of its output stroke, depending on the direction of rotation of the swash plate.
One example of a swash plate that has its angled driving surface tilted to adjust the flow rate is in U.S. Pat. No. 4,455,920 issued Jun. 26, 1984 to Shaw. This patent discloses a conventional axial pump with an adjustable angle swash plate. Another is U.S. Pat. No. 5,724,879 issued Mar. 10, 1998 to Hugelman. This patent discloses a mechanism to vary the flow rate by using a double wedge system that rotates the wedges with respect to each other to vary the flow rate by increasing or decreasing the travel of the pistons while not altering the TDC positions of the swash plate and port plate.
Typical adjustable swash plate designs for axial pumps generally make use of a tilt platform with a pin-ended bearing support along the tilt axis. An external mechanism is then used to rotate the pin-ended platform. This configuration requires the tilt platform and pin-ended bearing structures to support the full pump thrust loads. Under high pressures the pivoting assembly will flex between the bearings so that at short stroke and high pressures the degree of flexure may be of the same order of magnitude as the stroke itself. As a result, stroke adjustment becomes unstable. For these reasons high pressure hydraulic pumps are only adjustable over a limited range. Structural rigidity and dynamic performance are compromised with an accompanying increase in pump vibration, noise, and small stroke dynamic stability. Furthermore the flexing of the swash plate support contributes to the noise of a working pump. An unnecessarily large pump housing is required to accommodate this approach adding to pump cost and size while further exacerbating rigidity and noise problems. These large pump housings often dwarf the size of the actual working parts of the pump. The pumps continue increasing in size as the need for higher pressures continues putting increasing demands on the pumps.
In a conventional pivoting swash plate axial pump, reducing the stroke extracts the piston assembly from the cylinder barrel reducing the piston/cylinder contact length and increasing clearance volume. To correct for this reduced contact length, the pistons are lengthened to maintain sufficient contact length at the shortest stroke. As a result, the cylinders and pistons are longer than necessary which adds to pump size, weight and cost.
Applicant's axial pump is configured as a multi-piston pump with a rotating cylinder barrel where the pistons are actuated by a tilted swash plate. In this it is similar to and uses basic parts common to conventional pumps. However, applicant's pump differs in how the swash plate is supported and how variable output is achieved.
Applicant's axial pump uses a single solid wedge as a swash plate with the base of the wedge buttressed against the pump housing or case. The tilt angle of the wedge is fixed. Thus there is no pin-ended bearing support to flex. This design provides for a very compact design tightly wrapped around the internal working parts resulting in low noise and increased pressure capacity.
The output is controlled and varied by rotation of the wedge. The rotation puts the pump “off time” relative to the fixed port plate. This rotation changes the timing of the piston strokes with respect to TDC and BDC of the fixed port plate so that a portion of the intake charge is breathed back up stream through the intake port and a portion of the output charge is breathed back up stream through the output port. The net result is that pistons do not pull in a full charge nor pump out a full charge. The greater the degree of rotation of the wedge, the more of the charge in each cycle is breathed back into its respective port. At 90 degrees rotation of the wedge, one half of each cycle is breathed back. That is, the same amount of fluid is taken in and breathed back out on the input side of the pump. Likewise, the same amount of fluid is pushed out and breathed back in on the output side of the pump. The net result is zero fluid flow into and out of the pump. Thus rotation of the wedge varies the flow rate of the pump.
In one embodiment the wedge is a solid wedge maintained in one axial position with respect to the cylinder barrel so that the clearance volume remains constant. In a second embodiment the wedge, although still solid, is allowed to move axially so that the clearance volume can be varied. In this way, the compression ratio of a gas compressor can be varied independently of piston travel distance in the compressor.
It is an object to provide an axial pump that is smaller in size yet delivers the same or higher pump capacity than previous designed axial pumps that used a pivoting swash plate to vary the flow rate.
It is another object to eliminate the pivoting swash plate of prior art axial pumps that was used to vary the flow rate and use a wedge that maintains the same tilt angle with respect to the pistons.
It is another object to eliminate the pin-ended large bearing supported swash plate of the prior art axial pumps and instead use a solid wedge that is supported by the pump case or housing. An advantage of using a solid wedge supported by the housing is that it results in a smaller size pump for the same volume of fluid flow.
It is still another object of this invention to provide an axial pump that provides a variable flow rate by means of breathing portions of the intake and output charges back into their respective ports resulting in a reduced charge delivered from the output. A related object is to vary the flow rate of a fluid from an axial pump by rotating the wedge to change the timing of the pistons with respect to the inlet and outlet ports, thus varying the amount of fluid drawn into the cylinder from the inlet port and the amount of fluid exhausted into the outlet port
These and other objects and advantages will be apparent from the following Description of the Drawings and Description of the Preferred Embodiment.
a-8d are schematic views of the orientation of the rotating cylinders to the port plate during rotation of the wedge from 0° to 90°.
Turning to
The rotating components will now be discussed also with reference to
The drive shaft 18 is retained within needle bearings 68 in an inner end cap 70. There is an outer end cap 71 disposed at the rear of the pump 10 that is bolted to the case or main housing 14. The port plate 33, inner end cap 70, outer end cap 71 and main housing 14 are all properly positioned by O-rings 72 and lock pins 74. The case bolts 16 secure the front housing 12, main housing 14, inner end cap 70 and outer end cap 71, with all internal components securely fastened or positioned within.
The pistons 26 move through one intake and one exhaust stroke with one complete rotation of the of the cylinder barrel 20. The pistons 26 move out of cylinders 22 from a top dead center point to a bottom dead center point and into cylinders 22 from a bottom dead center point to a top dead center point. Unlike prior devices the flow control is not controlled by adjusting the angle of a swashplate which in turn varies the distance a piston travels.
Rather, the flow rate in Applicant's invention is controlled by rotation of the wedge 28. Rotating the wedge 28 by means of the worm drive assembly 40 and worm gear 42 changes the timing, or travel, of the pistons 26 with respect to the fixed port plate 33 and the inlet and outlet ports 34, 36. As seen in
b illustrates the wedge 28 rotated 30° from top dead center. TDC and BDC of the piston intake and exhaust cycles are shifted 30° while the beginnings and ends of the inlet and outlet ports 34, 36 have remained stationary. This causes the piston to delay its ending of the exhaust cycle and beginning of the intake cycle by 30°. The result is that part of the exhaust cycle is breathed back into the inlet port 34 and the start of the intake stroke is delayed causing less fluid to be drawn in from the inlet port 34. Likewise, part of the intake cycle is breathed back into the cylinder through the outlet port 36 and the start of the exhaust cycle is delayed causing less fluid to be pumped out of the outlet port 36. This “off timing” wedge position results in decreased fluid flow from the outlet of the pump.
d illustrates the wedge rotated 90°. Here fully half of the exhaust cycle is breathed back into the inlet port 34 and half of the intake cycle is breathed back from the outlet port 36. The net result is that there is no fluid flow to the pump's outlet even though the cylinder barrel 20 is still rotating at the same speed as it was during full fluid flow.
Although the preferred embodiment describes the invention as using a rotatable wedge to vary and control the timing to thereby control the fluid, the invention can also be used when the wedge remains stationary and the port plate and a portion of the end cap are rotated as a unit with respect to the wedge. This results in varying the timing as described in the preferred embodiment. The invention can also be used in a pump/compressor where the cylinder barrel is held stationary and the wedge is spun and a portion of the end cap is rotated as a unit with respect to TDC and BDC of the cylinder barrel.
The output flow rate as a function of wedge rotation is illustrated in
As described, the wedge 28 is rotated by means of the worm drive assembly 40. However, this can be replaced with a hydraulic or pneumatic cylinder with a piston operatively connected to the wedge 28 for rotation of the wedge 28.
In the inventive pump 10 the compression ratio is physically fixed since there is no change in wedge angle of axial position. However, in an alternate embodiment, the compression ratio can be changed by moving the wedge 28 and its driven piston assembly 24 axially. A plot of “Compression Ratio vs. Wedge Axial Movement” is seen in
Thus there has been provided an axial pump/compressor that fully satisfies the objects set forth above. While the invention has been described in conjunction with a specific embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and scope of the appended claims.
This patent application is a non-provisional application claiming priority from U.S. Provisional Application Ser. No. 60/586,583, entitled “Multi-Piston Pump/Compressor” filed on Jul. 10, 2004.
Number | Name | Date | Kind |
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3139037 | Budzich | Jun 1964 | A |
3208395 | Budzich | Sep 1965 | A |
4455920 | Shaw et al. | Jun 1984 | A |
5724879 | Hugelman | Mar 1998 | A |
5979294 | Hugelman | Nov 1999 | A |
6629488 | Hugelman | Oct 2003 | B2 |
Number | Date | Country | |
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20060008362 A1 | Jan 2006 | US |
Number | Date | Country | |
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60586583 | Jul 2004 | US |