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US20250027487A1 - Integrated air compressor - Google Patents

Integrated air compressor Download PDF

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Publication number
US20250027487A1
US20250027487A1 US18/354,202 US202318354202A US2025027487A1 US 20250027487 A1 US20250027487 A1 US 20250027487A1 US 202318354202 A US202318354202 A US 202318354202A US 2025027487 A1 US2025027487 A1 US 2025027487A1
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United States
Prior art keywords
cylinder
air compressor
air
motor
pistons
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Pending
Application number
US18/354,202
Inventor
Weidong Lu
Daisy KWOK
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Individual
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Individual
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Publication date
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Priority to US18/354,202 priority Critical patent/US20250027487A1/en
Publication of US20250027487A1 publication Critical patent/US20250027487A1/en
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B27/00Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders
    • F04B27/005Multi-cylinder pumps specially adapted for elastic fluids and characterised by number or arrangement of cylinders with two cylinders
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B35/00Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for
    • F04B35/01Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for the means being mechanical
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04BPOSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B35/00Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for
    • F04B35/04Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for the means being electric

Definitions

  • the present invention relates to an air supply unit of a vehicle air suspension system, and in particular relates to an integrated air compressor.
  • air suspension mainly includes air compressor, air tank, different valves and compressed air pipelines. These components are connected by independent, non-space-saving pneumatic and electrical pipelines, which are not integrated or compact enough.
  • single-stage or two-stage compressor concepts with linear pistons are often used as air compressors in air supply devices for air suspension systems of motor vehicles.
  • the air compressor described above is usually driven by an electric motor and includes a pump head made of plastic or die-cast aluminum; the single-stage air compressor has the obvious disadvantage that it has only one pump head and one pressure stage, resulting in a disadvantage that the inflation efficiency is low, so it is not widely in use.
  • the two-stage compressor has two piston heads and two pressure stages, which increases the pumping efficiency, but the two pump heads are located on both sides of the radial direction of the motor drive shaft, which occupies a certain space and is not compact enough;
  • both the single-stage as well as the two-stage air compressor described above need to be connected by lines having a certain length to the distributing valve unit and from there to the corresponding air spring, that is to say the distributing valve unit and the air compressor are connected by separate, non-space-saving pneumatic lines, in which case the individual components have to be laboriously connected.
  • one embodiment discloses an air compressor.
  • the air compressor comprises at least two separate cylinder housings, a pair of pistons, a motor, a pair of head members, and a distribution valve unit.
  • Each cylinder housing may define a cylinder with an axis. The axes are parallel and spaced apart.
  • the pair of pistons has each piston being reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder.
  • the motor may be positioned between the two axes of the corresponding cylinders and drives the pistons so as to reciprocate the pistons.
  • the pair of head members have each head member being fastened to a different one of the cylinder housings.
  • the distribution valve unit may be positioned in between and next to the cylinder housings.
  • the air compressor may further comprise an air drier connected to and positioned next to the distribution unit.
  • the air compressor further comprises an air input unit configured to introduce air into the cylinder.
  • the air compressor further comprises an air output unit configured to move a compressed air out of the cylinder.
  • the motor is configured to connect to and positioned to be next to the distribution valve unit.
  • the motor comprise a brushless motor.
  • the air compressor further comprises a crank shaft, a connecting rod, and a piston head assembly.
  • the piston head assembly is configured to connect to one end of the connecting rod.
  • the motor further comprises a driving shaft, wherein the connecting rods connected to the driving shaft along both sides of an axis of the motor driving shaft.
  • one embodiment discloses an air compressor.
  • the air compressor comprises at least two separate cylinder housings, a pair of pistons, a motor.
  • the at least two separate cylinder housings have each cylinder housing defining a cylinder with an axis. The axes are parallel and spaced apart.
  • the pair of pistons with each piston is reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder.
  • the motor has a driving shaft and positioned between the two axes of the corresponding cylinders and driving the pistons so as to reciprocate the pistons.
  • the piston is connected to the driving shaft along both side of an axis of the motor driving shaft.
  • the air compressor further comprises a distribution valve unit positioned in between and next to the cylinder housings.
  • the air compressor further comprises a pair of head members with each head member being fastened to a different one of the cylinder housings.
  • the air compressor further comprises an air drier connected and positioned next to the distribution unit.
  • the air compressor further comprises an air input unit configured to introduce air into the cylinder.
  • the air compressor may further comprise an air output unit configured to release a compressed air out of the cylinder.
  • the motor may be configured to connect to and positioned to be next to the distribution valve unit.
  • one embodiment discloses an air compressor.
  • the air compressor comprises at least two separate cylinder housings, a pair of pistons, a distribution valve unit.
  • Each cylinder housing may define a cylinder with an axis. The axes are parallel and spaced apart.
  • Each piston is reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder.
  • the distribution valve unit positioned in between and next to the cylinder housings.
  • the air compressor further comprises a motor positioned between the two axes of the corresponding cylinders and driving the pistons so as to reciprocate the pistons.
  • the motor is configured to connect to and positioned to be next to the distribution valve unit.
  • FIG. 1 is a perspective view of an air compressor on motor vehicles according to one exemplary embodiment
  • FIG. 2 is a cross-sectional view of an air compressor shown in A-A′ of FIG. 1 according to one exemplary embodiment
  • FIG. 3 illustrates an enlarged schematic view of that piston head assembly of FIG. 2 .
  • Embodiments of the present invention are directed to an air compressor for a source of compressed air on motor vehicles, and method for designing a more efficient reciprocating piston compressor.
  • the present disclosure relates to a two-cylinder piston compressor for generating compressed air.
  • the piston compressor has a crankcase for rotatably mounting a crankshaft on which a number of connecting rods are rotatably mounted so as to run counter to one another.
  • the number of connecting rods corresponds to the number of pistons with associated cylinders.
  • Means is provided for generating a cooling air flow which passes through the interior of the crankcase as a result of a pumping effect caused by the movement cycle of the piston.
  • a piston compressor of the above type is used, for example, within a compressed air supply system of a utility vehicle or of a rail vehicle.
  • the compressed air generated by the piston compressor may also be utilized for operating the air spring system, as well as for operating the brake system.
  • two-stage piston compressors are usually used here, which are correspondingly of two-cylinder design. With two-cylinder piston compressors of the above type, the required compressed air demand can be generated within short periods of time.
  • the present disclosure relates to a two-cylinder piston compressor for generating compressed air.
  • the piston compressor includes a crankcase having an interior, and a crankshaft rotatably mounted in the crankcase. Also included are two connecting rods mounted in the crankshaft and configured to run counter to one another. Further included are two cylinders mounted in the crankcase and a piston arranged at an end of each of the connecting rods and configured to run in a respective one of the two cylinders.
  • each piston operates in a separate chamber.
  • the separate chambers are generated by separating means which are arranged in the crankcase and which surround the crankshaft, so that different pressure conditions are generated in the chambers.
  • an air compressor 100 for a source of compressed air on vehicles comprises at least two separate cylinder housings 110 a and 110 b .
  • a distribution valve unit 130 may be positioned in between and next to the cylinder housings 110 a and 110 b .
  • the air compressor 100 may further comprise a motor housing 140 .
  • the motor housing 140 may have a motor 210 .
  • the air compressor 100 may further comprise an air drier 120 connected to and positioned next to the distribution valve unit 130 .
  • the distribution valve unit 130 is internally provided with a pressure sensor and a plurality of electromagnetic valves capable of controlling the on-off of a gas path.
  • the air drier 120 may be above the distribution valve unit 130 , for example.
  • the motor housing 140 may include an air opening 160 located at an outside surface of the distribution valve unit 130 .
  • the air opening 160 may help to introduce air into the air compressor 100 .
  • the motor housing 140 may help protect the motor 210 from outside damages, preventing dust from getting into the motor 210 .
  • the motor 210 may be an electric motor.
  • An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate force in the form of torque applied on the motor's shaft.
  • Electric motors may be powered by direct current (DC) sources, such as from batteries, or rectifiers, or by alternating current (AC) sources, such as a power grid, inverters or electrical generators.
  • DC direct current
  • AC alternating current
  • Electric motors may be classified by considerations such as power source type, construction, application and type of motion output. They can be powered by AC or DC, be brushed or brushless, single-phase, two-phase, or three-phase, axial or radial flux, and may be air-cooled or liquid-cooled.
  • the air compressor 100 further comprises an electronic control board 150 .
  • the electronic control board 150 lays parallel to and connects next to the air dryer 120 , the distribution valve unit 130 , the cylinder housings 110 a and 110 b , and the motor housing 140 .
  • the electronic control board 150 may control an operation of the air compressor 100 .
  • an electronic control board 150 may be disposed on a coil side of a solenoid valve. This saves the length of the electrical connection between the solenoid and the electronic control board 150 .
  • the matching mode has the advantages of compact structure and space saving, and can achieve the technical effect.
  • air drier 120 is arranged on the distribution valve unit 130 , the installation between them is compact, and no additional air pipeline connection is need.
  • the pistons 270 a and 270 b are synchronously driven by the motor 210 via driving shaft 220 , so that one piston 270 a is driven to be in a compression state while the other piston 270 b is driven to be in a suction state, vice versa.
  • the overall inertia force of the air compressor 100 can be balanced, the load torque fluctuation of the motor 210 is small, and the rotation speed fluctuation of the motor 210 is also small, so that the noise can be effectively reduced.
  • the two cranks 230 a and 230 b are respectively held on the two shaft ends of the driving shaft 220 , and the two connecting rods 260 a and 260 b are respectively fitted on the two crank connecting shafts 240 a and 240 b through bearings 250 a and 250 b , respectively.
  • the axes of the two crank connecting shafts 240 a and 240 b are arranged eccentrically to the axis of the driving shaft 220 , and the axes of the two crank connecting shafts are located on both sides of the axis of the driving shaft 220 .
  • the two eccentricities d are located on both sides of the axis of driving shaft 220 .
  • one piston 270 a is driven to be in a compression state while the other piston 270 b is in a suction state; the other two crankshafts 230 a and 230 b are only subjected to the force of one connecting rod respectively when working, and the stress and the shearing stress of the crankshafts 230 a and 230 b are small, so that the overall fatigue strength of the crankshafts can be improved.
  • each cylinder housing 110 a and 110 b defining a cylinder 290 a and 290 b with axes B-B′ and C-C′, axes B-B′ and C-C′ being parallel and spaced apart.
  • Each of pistons 270 a and 270 b is reciprocable in a corresponding one of the cylinders 290 a and 290 b so as to reciprocate along the axes B-B′ and C-C′ of the corresponding cylinder 290 a and 290 b to vary a working volume of the cylinder 290 a and 290 b.
  • the motor 210 may be positioned between the two axes B-B′ and C-C′ of the corresponding cylinders 290 a and 290 b and driving the pistons 270 a and 270 b so as to reciprocate the pistons 270 a and 270 b , respectively.
  • the air compressor 100 further comprises a distribution valve unit 130 positioned in between and next to the cylinder housings 110 a and 110 b .
  • the air compressor 100 may further comprise an air drier 120 connected to and positioned next to the distribution valve unit 130 .
  • the air compressor 100 may further comprise an air input unit 282 a and 282 b configured to introduce air into the cylinders 290 a and 290 b , respectively.
  • the air input unit 282 a and 282 b may further include an air inlet opening 160 as shown in FIG. 1 .
  • the air compressor 100 may further comprise an air output unit 286 a and 286 b configured to move a compressed air out of the cylinders 290 a and 290 b .
  • the air output unit 286 a and 286 b may further include gas valves 280 a and 280 b respectively.
  • the gas valves 280 a and 280 b may further include springs 284 a and 284 b respectively. The pressure inside the cylinders 290 a and 290 b builds up so that the pressed air can push the valves 280 a and 280 b open and release the air out.
  • the air compressor 100 further comprise crank shafts 230 a and 230 b , connecting rods 260 a and 260 b , and pistons 270 a and 270 b , respectively.
  • the pistons 270 a and 270 b may be configured to connect to one end of the connecting rod 260 a and 260 b.
  • the motor 210 may further comprise a driving shaft 220 .
  • the driving shaft 220 may be supported by the bearings 250 a and 250 b , respectively.
  • the two connecting rods 260 a and 260 b may be arranged along the axial direction of the motor driving shaft 220 .
  • the piston 270 a may comprise an annular hollow pressure plate 350 a , a piston ring 320 a , a column 360 a , a valve plate 310 a and a screw 340 a .
  • the piston 270 a is substantially similar to the piston 270 b , so only piston 270 a is discussed here.
  • the annular hollow pressure plate 350 a may be an interference fit with the column 360 a on one end of the connecting rod 260 a .
  • the valve plate 310 a is arranged on the screw 340 a in a penetrating manner, one end of the screw 370 a may be fixed in the column 360 a .
  • the valve plate 310 a is provided with a movable space between the screw cap 370 of the screw 340 a and the upper surface of the column 360 a .
  • the opening and closing of the air inlet 330 a in the column 360 a are controlled by the pressure difference formed by the upper surface and the lower surface of the valve plate 310 a . And that traditional opening and closing fastener is replaced by the valve plate 310 a , and the service life of the valve plate is prolonged.
  • the air input unit 282 a or 282 b may further include the air inlet 330 a , an air space 288 (shown in FIG. 2 ) and an air channel or space between the air space 288 and the air inlet 330 .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Compressor (AREA)
  • Compressors, Vaccum Pumps And Other Relevant Systems (AREA)

Abstract

The patent application discloses an air compressor. The air compressor comprises at least two separate cylinder housings, a pair of pistons, a motor, a pair of head members, and a distribution valve unit. Each cylinder housing may define a cylinder with an axis. The axes are parallel and spaced apart. The pair of pistons has each piston being reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder. The motor may be positioned between the cylinder housings and drives the pistons so as to reciprocate the pistons. The pair of head members has each head member being fastened to a different one of the cylinder housings. The distribution valve unit may be positioned in between and next to the cylinder housings.

Description

    TECHNICAL FIELD
  • The present invention relates to an air supply unit of a vehicle air suspension system, and in particular relates to an integrated air compressor.
  • BACKGROUND
  • As an important part of the active suspension system, air suspension mainly includes air compressor, air tank, different valves and compressed air pipelines. These components are connected by independent, non-space-saving pneumatic and electrical pipelines, which are not integrated or compact enough.
  • In particular, single-stage or two-stage compressor concepts with linear pistons are often used as air compressors in air supply devices for air suspension systems of motor vehicles. The air compressor described above is usually driven by an electric motor and includes a pump head made of plastic or die-cast aluminum; the single-stage air compressor has the obvious disadvantage that it has only one pump head and one pressure stage, resulting in a disadvantage that the inflation efficiency is low, so it is not widely in use. The two-stage compressor has two piston heads and two pressure stages, which increases the pumping efficiency, but the two pump heads are located on both sides of the radial direction of the motor drive shaft, which occupies a certain space and is not compact enough; On the other hand, both the single-stage as well as the two-stage air compressor described above need to be connected by lines having a certain length to the distributing valve unit and from there to the corresponding air spring, that is to say the distributing valve unit and the air compressor are connected by separate, non-space-saving pneumatic lines, in which case the individual components have to be laboriously connected.
  • Therefore, there is a need to have a better and efficient compressed air control device with a high pressure air output.
  • SUMMARY
  • In one aspect, one embodiment discloses an air compressor. The air compressor comprises at least two separate cylinder housings, a pair of pistons, a motor, a pair of head members, and a distribution valve unit. Each cylinder housing may define a cylinder with an axis. The axes are parallel and spaced apart. The pair of pistons has each piston being reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder. The motor may be positioned between the two axes of the corresponding cylinders and drives the pistons so as to reciprocate the pistons. The pair of head members have each head member being fastened to a different one of the cylinder housings. The distribution valve unit may be positioned in between and next to the cylinder housings.
  • Optionally in any aspect, the air compressor may further comprise an air drier connected to and positioned next to the distribution unit.
  • Optionally in any aspect, the air compressor further comprises an air input unit configured to introduce air into the cylinder.
  • Optionally in any aspect, the air compressor further comprises an air output unit configured to move a compressed air out of the cylinder.
  • Optionally in any aspect, the motor is configured to connect to and positioned to be next to the distribution valve unit.
  • Optionally in any aspect, the motor comprise a brushless motor.
  • Optionally in any aspect, the air compressor further comprises a crank shaft, a connecting rod, and a piston head assembly.
  • Optionally in any aspect, the piston head assembly is configured to connect to one end of the connecting rod.
  • Optionally in any aspect, the motor further comprises a driving shaft, wherein the connecting rods connected to the driving shaft along both sides of an axis of the motor driving shaft.
  • In further another aspect, one embodiment discloses an air compressor. The air compressor comprises at least two separate cylinder housings, a pair of pistons, a motor. The at least two separate cylinder housings have each cylinder housing defining a cylinder with an axis. The axes are parallel and spaced apart. The pair of pistons with each piston is reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder. The motor has a driving shaft and positioned between the two axes of the corresponding cylinders and driving the pistons so as to reciprocate the pistons. The piston is connected to the driving shaft along both side of an axis of the motor driving shaft.
  • Optionally in any aspect, the air compressor further comprises a distribution valve unit positioned in between and next to the cylinder housings.
  • Optionally in any aspect, the air compressor further comprises a pair of head members with each head member being fastened to a different one of the cylinder housings.
  • Optionally in any aspect, the air compressor further comprises an air drier connected and positioned next to the distribution unit.
  • Optionally in any aspect, the air compressor further comprises an air input unit configured to introduce air into the cylinder.
  • Optionally in any aspect, the air compressor may further comprise an air output unit configured to release a compressed air out of the cylinder.
  • Optionally in any aspect, the motor may be configured to connect to and positioned to be next to the distribution valve unit.
  • In still further another aspect, one embodiment discloses an air compressor. The air compressor comprises at least two separate cylinder housings, a pair of pistons, a distribution valve unit. Each cylinder housing may define a cylinder with an axis. The axes are parallel and spaced apart. Each piston is reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder. The distribution valve unit positioned in between and next to the cylinder housings.
  • Optionally in any aspect, the air compressor further comprises a motor positioned between the two axes of the corresponding cylinders and driving the pistons so as to reciprocate the pistons.
  • Optionally in any aspect, the motor is configured to connect to and positioned to be next to the distribution valve unit.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • In order to illustrate the technical solutions more clearly in the embodiments of the present disclosure or the exemplary techniques, the drawings to be used in the embodiments or the description of the exemplary embodiments will be briefly described below. Obviously, the drawings in the following description are only certain embodiments of the present disclosure, and other drawings may be obtained according to the structures shown in the drawings without any creative work for those skilled in the art.
  • FIG. 1 is a perspective view of an air compressor on motor vehicles according to one exemplary embodiment;
  • FIG. 2 is a cross-sectional view of an air compressor shown in A-A′ of FIG. 1 according to one exemplary embodiment; and
  • FIG. 3 illustrates an enlarged schematic view of that piston head assembly of FIG. 2 . The implementation, functional features and advantages of the present disclosure will be further described with reference to the accompanying drawings.
  • DETAILED EMBODIMENTS
  • The invention is not limited to the particular methodology, protocols, and reagents described herein because they may vary. Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention. As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise.
  • Unless defined otherwise, all technical and scientific terms and any acronyms used herein have the same meanings as commonly understood by one of ordinary skill in the art in the field of the invention. Although any methods and materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred methods, devices, and materials are described herein. The technical means, creative features, objectives, and effects of the patent application may be easy to understand, the following embodiments will further illustrate the patent application. However, the following embodiments are only the preferred embodiments of the utility patent application, not all of them. Based on the examples in the implementation manners, other examples obtained by those skilled in the art without creative work shall fall within the protection scope of the present invention. The experimental methods in the following examples are conventional methods unless otherwise specified. The materials used in the following examples can be obtained from commercial sources unless otherwise specified.
  • Embodiments of the present invention are directed to an air compressor for a source of compressed air on motor vehicles, and method for designing a more efficient reciprocating piston compressor.
  • The present disclosure relates to a two-cylinder piston compressor for generating compressed air. The piston compressor has a crankcase for rotatably mounting a crankshaft on which a number of connecting rods are rotatably mounted so as to run counter to one another. The number of connecting rods corresponds to the number of pistons with associated cylinders. Means is provided for generating a cooling air flow which passes through the interior of the crankcase as a result of a pumping effect caused by the movement cycle of the piston.
  • A piston compressor of the above type is used, for example, within a compressed air supply system of a utility vehicle or of a rail vehicle. When used in a utility vehicle, the compressed air generated by the piston compressor may also be utilized for operating the air spring system, as well as for operating the brake system. On account of the associated very high compressed air demand, two-stage piston compressors are usually used here, which are correspondingly of two-cylinder design. With two-cylinder piston compressors of the above type, the required compressed air demand can be generated within short periods of time.
  • The present disclosure relates to a two-cylinder piston compressor for generating compressed air. The piston compressor includes a crankcase having an interior, and a crankshaft rotatably mounted in the crankcase. Also included are two connecting rods mounted in the crankshaft and configured to run counter to one another. Further included are two cylinders mounted in the crankcase and a piston arranged at an end of each of the connecting rods and configured to run in a respective one of the two cylinders.
  • The present disclosure encompasses the technical teaching that, in order to assist the pumping effect, each piston operates in a separate chamber. The separate chambers are generated by separating means which are arranged in the crankcase and which surround the crankshaft, so that different pressure conditions are generated in the chambers.
  • Referring first to FIGS. 1 and 2 , an air compressor 100 for a source of compressed air on vehicles comprises at least two separate cylinder housings 110 a and 110 b. A distribution valve unit 130 may be positioned in between and next to the cylinder housings 110 a and 110 b. The air compressor 100 may further comprise a motor housing 140. The motor housing 140 may have a motor 210. The air compressor 100 may further comprise an air drier 120 connected to and positioned next to the distribution valve unit 130. In this embodiment, the distribution valve unit 130 is internally provided with a pressure sensor and a plurality of electromagnetic valves capable of controlling the on-off of a gas path.
  • In one embodiment, the air drier 120 may be above the distribution valve unit 130, for example.
  • The motor housing 140 may include an air opening 160 located at an outside surface of the distribution valve unit 130. The air opening 160 may help to introduce air into the air compressor 100.
  • The motor housing 140 may help protect the motor 210 from outside damages, preventing dust from getting into the motor 210. In one embodiment, the motor 210 may be an electric motor. An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate force in the form of torque applied on the motor's shaft.
  • Electric motors may be powered by direct current (DC) sources, such as from batteries, or rectifiers, or by alternating current (AC) sources, such as a power grid, inverters or electrical generators.
  • Electric motors may be classified by considerations such as power source type, construction, application and type of motion output. They can be powered by AC or DC, be brushed or brushless, single-phase, two-phase, or three-phase, axial or radial flux, and may be air-cooled or liquid-cooled.
  • The air compressor 100 further comprises an electronic control board 150. The electronic control board 150 lays parallel to and connects next to the air dryer 120, the distribution valve unit 130, the cylinder housings 110 a and 110 b, and the motor housing 140. The electronic control board 150 may control an operation of the air compressor 100. In this embodiment, an electronic control board 150 may be disposed on a coil side of a solenoid valve. This saves the length of the electrical connection between the solenoid and the electronic control board 150.
  • Still in FIG. 1 , the cylinder housings 110 a and 110 b at the higher positions on both sides, and the motor 4-1 is at the bottom; The matching mode has the advantages of compact structure and space saving, and can achieve the technical effect. And that air drier 120 is arranged on the distribution valve unit 130, the installation between them is compact, and no additional air pipeline connection is need.
  • In one embodiment of the present invention, the pistons 270 a and 270 b are synchronously driven by the motor 210 via driving shaft 220, so that one piston 270 a is driven to be in a compression state while the other piston 270 b is driven to be in a suction state, vice versa. As shown in FIG. 3 , the overall inertia force of the air compressor 100 can be balanced, the load torque fluctuation of the motor 210 is small, and the rotation speed fluctuation of the motor 210 is also small, so that the noise can be effectively reduced.
  • Furthermore, the two cranks 230 a and 230 b are respectively held on the two shaft ends of the driving shaft 220, and the two connecting rods 260 a and 260 b are respectively fitted on the two crank connecting shafts 240 a and 240 b through bearings 250 a and 250 b, respectively. The axes of the two crank connecting shafts 240 a and 240 b are arranged eccentrically to the axis of the driving shaft 220, and the axes of the two crank connecting shafts are located on both sides of the axis of the driving shaft 220.
  • According to the eccentricity d shown in FIG. 2 , the two eccentricities d are located on both sides of the axis of driving shaft 220. In the working process, one piston 270 a is driven to be in a compression state while the other piston 270 b is in a suction state; the other two crankshafts 230 a and 230 b are only subjected to the force of one connecting rod respectively when working, and the stress and the shearing stress of the crankshafts 230 a and 230 b are small, so that the overall fatigue strength of the crankshafts can be improved.
  • Further in FIG. 2 , each cylinder housing 110 a and 110 b defining a cylinder 290 a and 290 b with axes B-B′ and C-C′, axes B-B′ and C-C′ being parallel and spaced apart. Each of pistons 270 a and 270 b is reciprocable in a corresponding one of the cylinders 290 a and 290 b so as to reciprocate along the axes B-B′ and C-C′ of the corresponding cylinder 290 a and 290 b to vary a working volume of the cylinder 290 a and 290 b.
  • The motor 210, a brushless motor, for example, may be positioned between the two axes B-B′ and C-C′ of the corresponding cylinders 290 a and 290 b and driving the pistons 270 a and 270 b so as to reciprocate the pistons 270 a and 270 b, respectively. The air compressor 100 further comprises a distribution valve unit 130 positioned in between and next to the cylinder housings 110 a and 110 b. In one embodiment, the air compressor 100 may further comprise an air drier 120 connected to and positioned next to the distribution valve unit 130.
  • In one embodiment, the air compressor 100 may further comprise an air input unit 282 a and 282 b configured to introduce air into the cylinders 290 a and 290 b, respectively. The air input unit 282 a and 282 b may further include an air inlet opening 160 as shown in FIG. 1 .
  • In one embodiment, the air compressor 100 may further comprise an air output unit 286 a and 286 b configured to move a compressed air out of the cylinders 290 a and 290 b. The air output unit 286 a and 286 b may further include gas valves 280 a and 280 b respectively. The gas valves 280 a and 280 b may further include springs 284 a and 284 b respectively. The pressure inside the cylinders 290 a and 290 b builds up so that the pressed air can push the valves 280 a and 280 b open and release the air out. When the pressure inside the cylinders 290 a and 290 b becomes low after releasing the pressed air out, the springs 282 a and 282 b will force the valves 280 a and 280 b, respectively, back to the original position.
  • The air compressor 100 further comprise crank shafts 230 a and 230 b, connecting rods 260 a and 260 b, and pistons 270 a and 270 b, respectively. The pistons 270 a and 270 b may be configured to connect to one end of the connecting rod 260 a and 260 b.
  • The motor 210 may further comprise a driving shaft 220. The driving shaft 220 may be supported by the bearings 250 a and 250 b, respectively. The two connecting rods 260 a and 260 b may be arranged along the axial direction of the motor driving shaft 220.
  • As shown in FIG. 3 , the piston 270 a may comprise an annular hollow pressure plate 350 a, a piston ring 320 a, a column 360 a, a valve plate 310 a and a screw 340 a. The piston 270 a is substantially similar to the piston 270 b, so only piston 270 a is discussed here. The annular hollow pressure plate 350 a may be an interference fit with the column 360 a on one end of the connecting rod 260 a. The valve plate 310 a is arranged on the screw 340 a in a penetrating manner, one end of the screw 370 a may be fixed in the column 360 a. The valve plate 310 a is provided with a movable space between the screw cap 370 of the screw 340 a and the upper surface of the column 360 a. The opening and closing of the air inlet 330 a in the column 360 a are controlled by the pressure difference formed by the upper surface and the lower surface of the valve plate 310 a. And that traditional opening and closing fastener is replaced by the valve plate 310 a, and the service life of the valve plate is prolonged. The air input unit 282 a or 282 b may further include the air inlet 330 a, an air space 288 (shown in FIG. 2 ) and an air channel or space between the air space 288 and the air inlet 330.
  • It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.
  • The above shows and describes the basic principles, main features and advantages of the patent application. Those skilled in the industry should understand that the present patent application is not limited by the above-mentioned embodiments. The above-mentioned embodiments and the description are only preferred examples of the present patent application and are not intended to limit the present patent application, without departing from the present utility patent application. Under the premise of spirit and scope, the present utility patent application will have various changes and improvements, and these changes and improvements fall within the scope of the claimed utility patent application. The scope of protection claimed by the utility patent application is defined by the appended claims and their equivalents.

Claims (20)

We claim:
1. An air compressor, comprising:
at least two separate cylinder housings, each cylinder housing defining a cylinder with an axis, the axis being parallel and spaced apart;
a pair of pistons, each piston being reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder;
a motor positioned between the two axes of the corresponding cylinders and driving the pistons so as to reciprocate the pistons; and
a distribution valve unit positioned in between and next to the cylinder housings.
2. The air compressor of claim 1 further comprising an air drier connected to and positioned next to the distribution valve unit.
3. The air compressor of claim 1 further comprising an air input unit configured to introduce air into the cylinder.
4. The air compressor of claim 1, further comprising an air output unit configured to move a compressed air out of the cylinder.
5. The air compressor of claim 1, wherein the motor is configured to connect to and positioned to be next to the distribution valve unit.
6. The air compressor of claim 1 wherein the motor comprise a brushless motor.
7. The air compressor of claim 1 further comprising a crank shaft, a connecting rod, and a piston.
8. The air compressor of claim 7 wherein the piston is configured to connect to one end of the connecting rod.
9. The air compressor of claim 7, wherein the motor further comprises a driving shaft, wherein the connecting rods connected to the driving shaft along both sides of an axis of the driving shaft.
10. An air compressor, comprising:
at least two separate cylinder housings, each cylinder housing defining a cylinder with an axis, the axes being parallel and spaced apart;
a pair of pistons, each piston being reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder; and
a motor having a driving shaft and positioned between the two axes of the corresponding cylinders and driving the pistons so as to reciprocate the pistons;
wherein the piston is connected to the driving shaft along both sides of an axis of the driving shaft.
11. The air compressor of claim 10 further comprising a distribution valve unit positioned in between and next to the cylinder housings.
12. The air compressor of claim 10 further comprising a pair of head members, each head member being fastened to a different one of the cylinder housings.
13. The air compressor of claim 10, further comprising an air drier connected to and positioned next to the distribution unit.
14. The air compressor of claim 10 further comprising an air input unit configured to introduce air into the cylinder.
15. The air compressor of claim 10, further comprising an air output unit configured to release a compressed air out of the cylinder.
16. The air compressor of claim 10, wherein the motor comprise a brushless motor.
17. The air compressor of claim 11, wherein the motor is configured to connect to and positioned to be next to the distribution valve unit.
18. An air compressor, comprising:
at least two separate cylinder housings, each cylinder housing defining a cylinder with an axis, the axes being parallel and spaced apart;
a pair of pistons, each piston being reciprocable in a corresponding one of the cylinders so as to reciprocate along the axis of the corresponding cylinder to vary a working volume of the cylinder; and
a distribution valve unit positioned in between and next to the cylinder housings.
19. The air compressor of claim 18, further comprising a motor positioned between the two axes of the corresponding cylinders and driving the pistons so as to reciprocate the pistons.
20. The air compressor of claim 19, wherein the motor is configured to connect to and positioned to be next to the distribution valve unit.
US18/354,202 2023-07-18 2023-07-18 Integrated air compressor Pending US20250027487A1 (en)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5266015A (en) * 1992-02-13 1993-11-30 Tecumseh Products Company Compressor suction and discharge valve assembly
US20060275160A1 (en) * 2005-05-17 2006-12-07 Leu Shawn A Pump improvements
US20180023554A1 (en) * 2015-02-24 2018-01-25 Illinois Tool Works Inc. Compressor for discharging a medium
CN113090498A (en) * 2021-03-23 2021-07-09 耐力股份有限公司 Oil-free piston type wind source device for urban rail vehicle

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5266015A (en) * 1992-02-13 1993-11-30 Tecumseh Products Company Compressor suction and discharge valve assembly
US20060275160A1 (en) * 2005-05-17 2006-12-07 Leu Shawn A Pump improvements
US20180023554A1 (en) * 2015-02-24 2018-01-25 Illinois Tool Works Inc. Compressor for discharging a medium
CN113090498A (en) * 2021-03-23 2021-07-09 耐力股份有限公司 Oil-free piston type wind source device for urban rail vehicle

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