U.S. patent application number 11/005887 was filed with the patent office on 2006-05-18 for air compressor including a disk oil slinger assembly.
Invention is credited to Robert F. Burkholder.
Application Number | 20060104839 11/005887 |
Document ID | / |
Family ID | 46321711 |
Filed Date | 2006-05-18 |
United States Patent
Application |
20060104839 |
Kind Code |
A1 |
Burkholder; Robert F. |
May 18, 2006 |
Air compressor including a disk oil slinger assembly
Abstract
A "splash" lubrication system having an oil slinger capable of
providing an increased flow rate of lubricating and cooling oil to
lubricated components of the system compared to conventional dip
stick oil slingers while reducing oil atomization and oil loss
through the crankcase vent is disclosed. In embodiments of the
invention, the oil slinger is comprised of a disk coupled to the
crankshaft assembly of a direct drive oil-lube air compressor. The
air compressor includes a universal electric motor which drives the
crankshaft assembly, thereby causing the crankshaft assembly to
rotate, which in turn, rotates the disk for splashing lubricating
oil from the crankcase's oil sump onto the moving parts of the air
compressor being lubricated by the lubricating system.
Inventors: |
Burkholder; Robert F.;
(Jackson, TN) |
Correspondence
Address: |
THE BLACK & DECKER CORPORATION
701 EAST JOPPA ROAD, TW199
TOWSON
MD
21286
US
|
Family ID: |
46321711 |
Appl. No.: |
11/005887 |
Filed: |
December 7, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10118675 |
Apr 9, 2002 |
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11005887 |
Dec 7, 2004 |
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09861285 |
May 18, 2001 |
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10118675 |
Apr 9, 2002 |
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Current U.S.
Class: |
417/416 ;
417/415 |
Current CPC
Class: |
F16N 7/26 20130101; F01M
9/06 20130101; F04B 39/0094 20130101; F04B 39/0223 20130101; F04B
39/0284 20130101; F04B 41/02 20130101 |
Class at
Publication: |
417/416 ;
417/415 |
International
Class: |
F04B 35/04 20060101
F04B035/04; F04B 17/00 20060101 F04B017/00 |
Claims
1. An air compressor assembly, comprising: an air storage tank for
storing at a first pressure; an air compressor for compressing air
from a second pressure to the first pressure for storage in the air
storage tank, the air compressor including a cylinder, a piston
disposed within the cylinder, a crankcase housing a crankshaft
assembly for reciprocating the piston within the cylinder, an oil
sump formed in the crankcase for containing lubricating oil for
lubricating the cylinder and piston, and a generally disk shaped
oil slinger positioned below the cylinder and co-planer with a
plane passing though the cylinder, the generally disk shaped oil
slinger being coupled to the crankshaft assembly; and, a motor for
driving the crankshaft assembly for reciprocating the piston within
the cylinder; wherein rotation of the crankshaft assembly by the
motor rotates the oil slinger for splashing lubricating oil from
the oil sump onto the cylinder and piston.
2. The air compressor assembly as claimed in claim 1, further
comprising a pressure regulator for regulating the pressure of air
in the air storage tank to at least approximately the first
pressure by starting and stopping the motor.
3. The air compressor assembly as claimed in claim 1, wherein the
air compressor assembly is a direct drive air compressor
assembly.
4. The air compressor assembly as claimed in claim 1, wherein the
air compressor assembly is a belt drive air compressor
assembly.
5. The air compressor assembly as claimed in claim 1, wherein the
motor is a universal motor.
6. The air compressor assembly as claimed in claim 1, further
comprising a safety valve for releasing pressure within the air
storage tank.
7. The air compressor assembly as claimed in claim 1, further
comprising a check valve.
8. The air compressor assembly as claimed in claim 1, further
comprising a drain plug.
9. An air compressor assembly, comprising: an air storage tank for
storing at a first pressure; an air compressor for compressing air
from a second pressure to the first pressure for storage in the air
storage tank, the air compressor including a cylinder, a piston
disposed within the cylinder, a crankcase housing a crankshaft
assembly for reciprocating the piston within the cylinder, an oil
sump formed in the crankcase for containing lubricating oil for
lubricating the cylinder and piston, and a generally disk shaped
oil slinger positioned below the cylinder and co-planer with a
plane passing though the cylinder, the generally disk shaped oil
slinger being coupled to the crankshaft assembly; and, a motor for
driving the crankshaft assembly for reciprocating the piston within
the cylinder; wherein rotation of the crankshaft assembly by the
motor rotates the oil slinger for splashing lubricating oil from
the oil sump onto the cylinder and piston; wherein the air
compressor assembly is a direct drive air compressor assembly.
10. The air compressor assembly as claimed in claim 9, further
comprising a pressure regulator for regulating the pressure of air
in the air storage tank to at least approximately the first
pressure by starting and stopping the motor.
11. The air compressor assembly as claimed in claim 9, wherein the
motor is a universal motor.
12. The air compressor assembly as claimed in claim 9, further
comprising a safety valve for releasing pressure within the air
storage tank.
13. The air compressor assembly as claimed in claim 9, further
comprising a check valve.
14. The air compressor assembly as claimed in claim 9, further
comprising a drain plug.
15. An air compressor assembly, comprising: an air storage tank for
storing at a first pressure; an air compressor for compressing air
from a second pressure to the first pressure for storage in the air
storage tank, the air compressor including a cylinder, a piston
disposed within the cylinder, a crankcase housing a crankshaft
assembly for reciprocating the piston within the cylinder, an oil
sump formed in the crankcase for containing lubricating oil for
lubricating the cylinder and piston, and a generally disk shaped
oil slinger positioned below the cylinder and co-planer with a
plane passing though the cylinder, the generally disk shaped oil
slinger being coupled to the crankshaft assembly; and, a universal
motor for driving the crankshaft assembly for reciprocating the
piston within the cylinder; wherein rotation of the crankshaft
assembly by the motor rotates the oil slinger for splashing
lubricating oil from the oil sump onto the cylinder and piston;
wherein the air compressor assembly is a direct drive air
compressor assembly.
16. The air compressor assembly as claimed in claim 15, further
comprising a pressure regulator for regulating the pressure of air
in the air storage tank to at least approximately the first
pressure by starting and stopping the motor.
17. The air compressor assembly as claimed in claim 15, further
comprising a safety valve for releasing pressure within the air
storage tank.
18. The air compressor assembly as claimed in claim 15, further
comprising a check valve.
19. The air compressor assembly as claimed in claim 15, further
comprising a drain plug.
20. The air compressor assembly as claimed in claim 15, further
comprising one or more gauges.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S.
patent application Ser. No. 10/118,675 filed Apr. 9, 2002, which is
a continuation-in-part of U.S. patent application Ser. No.
09/861,285 filed May 18, 2001. U.S. patent application Ser. No.
10/118,675 and U.S. patent application Ser. No. 09/861,285 are
herein incorporated by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the field of oil
lubrication devices for air compressors, and more particularly to
an air compressor including a disk oil slinger suitable for use in
oil lubricated air compressors.
BACKGROUND OF THE INVENTION
[0003] Typically, lower cost oil lubricated air compressors have
employed a "splash" lubrication system to distribute oil from the
oil sump to the mechanical bearings, seals, valves, pistons and
other parts that require lubrication and oil cooling. A small
protruding piece of material or "dip stick" is attached to one or
more of the moving components such that during each revolution of
the crankshaft, the dip stick dips into the oil sump at sufficient
velocity to cause oil to splash onto the components requiring
lubrication. The size, shape and velocity of the dip stick must be
engineered to assure sufficient lubrication and oil cooling for all
components while minimizing atomization of the oil in the crankcase
so as to reduce oil loss through the crankcase vent. A higher
velocity or larger profile dip stick will improve lubrication and
oil cooling but will increase oil atomization and oil loss through
the crankcase vent. A less aggressive dipstick velocity or profile
will reduce lubrication and oil cooling but also reduce oil loss
through the vent. These conflicting phenomena require designers to
compromise their design by reducing the positive benefits of
lubrication and oil cooling in order to reduce the negative effects
of oil loss.
[0004] Another problem with such traditional splash oil lubrication
systems is that a number of the air compressors in which such
systems are used are portable and are regularly moved by hand from
one work site to another. If such portable air compressors are not
properly leveled prior to operation, the dip stick splash
lubricator may not reach the oil sump causing a lack of needed
lubrication and cooling, possibly leading to subsequent component
failure.
[0005] Consequently, it would be advantageous to provide a "splash"
lubrication system designed to increase the flow rate of
lubricating and cooling oil to lubricated components of an air
compressor while reducing oil atomization and oil loss through the
crankcase vent. Further, it would be desirable to provide such a
lubrication system that is capable of functioning properly while
the crankcase is tilted, providing an increased tolerance of
operation on non-level surfaces. Further it would be desirable to
provide a lubrication system for implementation within an air
compressor having a universal motor, said lubrication system
providing improved lubrication for the universal motor, which
typically operates at higher rates of speed than other conventional
air compressor motors.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention is directed to a "splash"
lubrication system having an oil slinger capable of providing an
increased flow rate of lubricating and cooling oil to lubricated
components of an air compressor compared to conventional dip stick
oil slingers, while reducing oil atomization and oil loss through
the crankcase vent. In embodiments of the invention, the oil
slinger is comprised of a disk coupled to the crankshaft assembly
of the air compressor being lubricated, so that rotation of the
crankshaft assembly rotates the disk for splashing lubricating oil
from the crankcase's oil sump onto components of the air
compressor. Preferably, at least a portion of the oil slinger is
continuously submerged in the lubricating oil contained in the oil
sump as it is rotated by the crankshaft assembly, thereby
decreasing atomization of oil from the oil sump. Further, the oil
slinger may be designed to remain at least partially submerged in
the oil sump even if the crankcase is tilted providing increased
tolerance of operation on non-level surfaces.
[0007] In one embodiment the lubrication system may be implemented
in an air compressor having two or more cylinder/piston assemblies.
In such embodiments, the cylinders of the air compressor are
oriented (e.g., may overlap) so that a single oil slinger may
provide lubrication to both assemblies.
[0008] In a further embodiment the lubrication system may be
implemented in an oil-lube direct drive air compressor having a
universal motor. The lubrication system of the present invention
providing an increased level of lubrication for meeting the demands
of a universal motor, which typically operates at higher rates of
speed than a conventional air compressor motor.
[0009] It is to be understood that both the forgoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention as
claimed. The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate an embodiment of
the invention and together with the general description, serve to
explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The numerous advantages of the present invention may be
better understood by those skilled in the art by reference to the
accompanying figures in which:
[0011] FIG. 1 is an isometric view illustrating a lubrication
system in accordance with an exemplary embodiment of the present
invention;
[0012] FIG. 2 is a side elevational view illustrating the oil
slinger of the lubrication system shown in FIG. 1;
[0013] FIGS. 3 and 4 are side elevational views illustrating
tilting of the crankcase;
[0014] FIG. 5 is an isometric view illustrating a shaped disk oil
slinger having edge and/or surface features in accordance with an
exemplary embodiment of the present invention;
[0015] FIG. 6 is an isometric view illustrating an auger oil
slinger in accordance with an exemplary embodiment of the present
invention;
[0016] FIG. 7 is an isometric view illustrating an oil slinger in
accordance with an exemplary embodiment of the present invention
wherein the oil slinger is not a continuous disk;
[0017] FIG. 8 is a partial cross-sectional side elevational view
illustrating an air compressor having two cylinder/piston
assemblies, wherein the air compressor employs the lubrication
system of the present invention;
[0018] FIG. 9 is an isometric view of a belt drive air compressor
assembly including the lubrication system of the present
invention;
[0019] FIG. 10 is a cross-sectional view of the lubrication system
of the air compressor assembly shown in FIG. 10;
[0020] FIG. 11 is an isometric view of a direct drive air
compressor assembly including the lubrication system of the present
invention; and,
[0021] FIG. 12 is a cross-sectional view of the lubrication system
of the air compressor assembly shown in FIG. 11.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Reference will now be made in detail to the presently
preferred embodiments of the invention, examples of which are
illustrated in the accompanying drawings.
[0023] Referring now to FIGS. 1, 2, 3 and 4, an exemplary "splash"
lubrication system suitable for providing lubrication to the moving
components of an air compressor in accordance with the present
invention is described. The lubrication system 100 includes an oil
sump 102 formed in the crankcase 104 of the air compressor 106 in
which the lubrication system 100 is employed and an oil slinger 108
coupled to the air compressor's crankshaft assembly 110.
[0024] In one embodiment, the oil slinger 108 is comprised of a
continuous disk 112 attached to the crankshaft assembly 110.
Rotation of the crankshaft assembly 110 rotates the disk for
splashing lubricating oil 114 from the oil sump 102 onto components
of the air compressor 106 being lubricated (e.g., crankshaft
assembly 110, journal 116, piston 118, cylinder wall 120, and the
like). Preferably, the disk 112 is positioned along the crankshaft
immediately adjacent to journal 116 so that oil may be slung from
the oil sump 102 onto the piston 118 and cylinder wall 120. For
instance, in one embodiment, shown in FIGS. 1 and 2, the disk 112
is bolted to a counterweight 122 of the crankshaft assembly 108 so
that it is centered coaxially with the center of rotation 124 of
the crankshaft assembly 110. The disk 112 may have an aperture 126
sized and shaped to fit over the crankshaft assembly 110 so that
the disk 112 and crankshaft assembly 110 may be assembled together.
However, it will be appreciated that other fabrication methods may
be employed without departing from the scope and spirit of the
present invention. For example, the disk 112 may be formed as an
integral part of the crankshaft assembly 110, or the crankshaft
assembly 110 may be formed in two or more sections that are joined
together around the disk 112, thereby clamping the disk 112 in
place.
[0025] During operation of the air compressor 106, rotation of the
crankshaft assembly 110 rotates the oil slinger 108 for splashing
lubricating oil 114 from the oil sump 102 onto components of the
air compressor 106 being lubricated (e.g., crankshaft assembly 110,
journal 116, piston 118, cylinder wall 120, and the like). As
shown, the disk 112 of oil slinger 108 is generally centered
coaxially with the center of rotation 124 of the crankshaft
assembly 110 so that rotation of the crankshaft assembly 110 causes
the disk 112 to rotate 360 degrees about the center of rotation of
the crankshaft 124. Thus, during operation, the lower portion of
disk 112 is continuously submerged in lubricating oil 114 contained
in the oil sump 102. Because the disk 112 remains in the oil 114
instead of cyclically entering and exiting the oil 114, as does a
conventional dip stick or dipper oil slinger, the volume of oil 114
in the oil sump 102 that the disk 112 displaces does not change
during each revolution of the crankshaft 110. Further, the oil
slinger 108, being a continuous disk 112, does not have a high
speed advancing edge that must pass through the lubricating oil 114
as do dipper slingers. Thus, the flow of lubricating oil 114 over
the surface of the oil slinger 108 as it advances through the oil
sump 102 is substantially more laminar than is possible with
intermittent dipper slingers. As a result, the disk oil slinger 108
of the present invention is capable of moving lubricating oil 114
about the crankcase 104 with substantially less atomization of the
oil 114.
[0026] The amount of oil flow generated by an oil slinger is
proportional to the surface area of the submerged portion of the
slinger, and proportional to the amount of time that the slinger is
submerged during each revolution of the crankshaft. Because the
lower portion of the disk oil slinger 108 is continuously submerged
in the lubricating oil 114 contained in the oil sump 102, and the
submerged surface area of the disk 112 is substantially larger than
that of the dipper of a dipper oil slinger, the oil flow rate of
the disk oil slinger 108 of the present invention is significantly
greater than that of an intermittent dipper slinger. For example,
lubrication systems 100 in accordance with the present invention
have been found to be capable of providing oil flows that are 50 to
100 times greater than lubrication systems utilizing dipper
slingers, while at the same time reducing atomization of the
lubricating oil 114 from the oil sump 102.
[0027] Turning now to FIGS. 3 and 4, the air compressor 106 shown
in FIGS. 1 and 2 is illustrated as being tilted at an angle to the
horizontal, for example, as if it were set on a non-level surface.
As shown, when the crankcase 104 is tilted, the surface of the
lubricating oil 114 in oil sump 102 remains substantially
horizontal. As shown, the disk 112 of oil slinger 108 is generally
centered coaxially with the center of rotation 124 of the
crankshaft assembly 110 so that rotation of the crankshaft assembly
110 causes the disk 112 to rotate 360 degrees about the center of
rotation of the crankshaft 124. As a result, the disk 112 remains
at least partially submerged in the oil sump 102 if the crankcase
104 is tilted providing an increased tolerance to unit operation on
non-level surfaces. It will be appreciated that the degree of tilt
(.alpha.) tolerated by lubrication system 100 may vary depending on
the design of crankcase 104, and is limited only by the possibility
of lubricating oil 114 from the oil sump 102 entering cylinder 118.
However, it is contemplated that degrees of tilt (.alpha.) of up to
or even greater than 90 degrees (i.e., the crankcase 102 is tilted
on its side) are possible.
[0028] Referring now to FIG. 5, a shaped oil slinger for a
lubrication system in accordance with an exemplary embodiment of
the invention is described. Shaped oil slinger 128 is comprised of
a disk 130 including an edge portion 132 shaped for generating
additional oil flow and/or for directing the oil flow at angles to
the side of the disk 130, thereby distributing the oil more
uniformly within the crankcase than conventional dipper type
lubrication systems. Further, the edge portion 132 may be shaped so
that it is capable of providing such advantages without
unnecessarily interrupting the laminar flow of the lubricating oil
around the disk 130, thus preventing unnecessary atomization of
lubricating oil from the oil sump (see FIG. 1). For instance, in
the embodiment shown in FIG. 4, edge portion 132 may be formed so
as to have a contour that is generally sinusoidal or curvilinear in
shape as viewed along an edge of the disk 130. Alternately, edge
portion 132 may be shaped to have other contours such as fins,
slots, grooves, or the like, depending on the requirements of the
particular application in which the lubrication system is
employed.
[0029] In addition to (or in place of) shaped edge portion 132,
features 134 may be formed on the surfaces of either or both sides
of disk 130 for providing additional oil flow and/or for directing
the oil flow at lateral angles to the disk 130. It will be
appreciated that the shape of such surface features 134 may vary
depending on the requirements (desired oil flow rate, splash
pattern, etc.) of the particular air compressor in which the
lubrication system is employed. However, exemplary surface features
134 include circumferential or spiraled ridges or grooves (shown),
spaced bumps, indentations, or slots, vanes, and the like.
Additionally, surface features 134 may be shaped so they do not
create unnecessary turbulence thereby interrupting the
substantially laminar flow of lubricating oil around the disk 130
and increasing atomization of lubricating oil from the oil sump
(see FIG. 1).
[0030] Referring now to FIG. 6, an auger oil slinger in accordance
with an exemplary embodiment of the present invention is shown. Oil
slinger 136 is comprised of a disk 138 having a slit 140 radially
formed therein from edge portion 142 toward the disk center 144.
The ends 146 & 148 of edge portion 142 adjacent to the slit 140
are separated laterally so that edge portion 142 assumes a
generally spiral shape. In this manner, disk 138 is formed into a
simple auger capable of generating substantially greater oil flow
than the dip stick slingers of conventional dipper lubrication
systems. The spiral shape of edge portion 142 may further direct
the oil flow at angles to disk 138 thereby distributing the oil
more uniformly within the crank case and providing greater coverage
of components of the air compressor (see FIG. 1). Because disk 138
remains substantially continuous except for leading and trailing
edges 150 & 152 caused by slit 140, oil flow over the surface
of the disk 138 is generally laminar. Thus, atomization of
lubricating oil may be held to rates that are substantially equal
to or less than that of conventional dipper lubrication
systems.
[0031] Based on the discussion of the disk oil slingers shown in
FIG. 1 through 6, it should now be appreciated that a substantial
advantage is obtained by increasing the surface area of the oil
slinger so that area of laminar flow is enlarged. In this manner,
cohesion of oil to the surface of the oil slinger is improved so
that the volume of oil "splashed" by the oil slinger as it rotates
is increased while atomization of the oil remains substantially
unchanged or is reduced. Thus, it should also be appreciated that
in accordance with the present invention, lubrication systems may
be provided that, while not utilizing continuous disk oil slingers,
provide enhanced performance compared to conventional "dip stick"
or dipper systems by substantially increasing the surface area of
the oil slinger to provide for more laminar flow of the lubricating
oil over the slinger as it is rotated.
[0032] Referring now to FIG. 7, an oil slinger in accordance with
such an alternate embodiment of the present invention is described.
Oil slinger 154 is comprised of a sector 156 of the full disk 112
of oil slinger 108 shown in FIG. 1 through 4, having curvilinear
leading and trailing edges 158 & 160. Preferably, the angle
(.beta.) defining sector 156 is selected to provide sufficient
surface area so that the flow of lubricating oil over the oil
slinger 154 as it is rotated is substantially laminar except for
turbulence at leading and trailing edges 158 & 160. In this
manner, the volume of oil splashed by the oil slinger 154 is
substantially increased compared to conventional dipper oil
slingers, while the amount of atomization of lubricating oil
remains substantially equal to or less than that of conventional
dipper oil slingers.
[0033] In exemplary embodiments of the invention, the oil slinger
154 may be mounted to the crankshaft assembly 110, shown in FIG. 1,
so that the disk 112 from which sector 156 is taken would be
generally centered coaxially with the center of rotation 124 of the
crankshaft assembly 110 if it were complete. In this manner,
rotation of the crankshaft assembly 110 causes the oil slinger 154
to rotate 360 degrees about the center of rotation of the
crankshaft 124. As a result, the oil slinger 154 remains capable of
being at least partially submerged in the oil sump 102 as it is
rotated even if the crankcase 104 is tilted. In this manner, the
oil slinger 154 is capable of providing an increased tolerance to
air compressor operation on non-level surfaces or in non-level
orientations.
[0034] Referring now to FIG. 8, implementation of a lubrication
system of the present invention in an air compressor having two or
more cylinder/piston assemblies is described. The lubrication
system 200 includes an oil sump 202 formed in the crankcase 204 of
the air compressor 206 and an oil slinger 208 coupled to the air
compressor's crankshaft assembly 210. Oil slinger 208 is comprised
of a generally continuous disk 212 attached to the crankshaft
assembly 210.
[0035] In the exemplary embodiment shown, air compressor 206
includes two cylinder assemblies 214 & 216 housing piston
assemblies 218 & 220 coupled to crankshaft assembly 210.
Preferably, cylinder assemblies 214 & 216 are oriented so that
a single oil slinger 208 may provide lubrication to both
assemblies. For example, as shown in FIG. 8, cylinder assemblies
214 & 216 are oriented at an angle of approximately ninety
degrees to one another and spaced so that they overlap thereby
allowing a single plane 222, generally coaxial with oil slinger
208, to intersect both cylinder assemblies 214 & 218. In this
manner, a single oil slinger may provide lubricating oil 224 from
the oil sump 202 onto each cylinder assembly for lubricating
components of each piston assembly 218 & 220 (e.g., eccentric
bearings, wrist pin sets, etc.).
[0036] During operation of the air compressor 206, rotation of the
crankshaft assembly 210 rotates the oil slinger 208 for splashing
lubricating oil 224 from the oil sump 202 for lubricating piston
assemblies 218 & 220 of both cylinder assemblies 214 & 216,
respectively. Like the embodiment shown in FIG. 1, the disk 212 of
oil slinger 208 is generally centered coaxially with the center of
rotation of the crankshaft assembly 210 so that rotation of the
crankshaft assembly 210 causes the disk 212 to rotate 360 degrees
about the center of rotation of the crankshaft 230.
[0037] Referring generally to FIGS. 9-12, an oil-lube air
compressor assembly including a lubrication system of the present
invention is shown. In a present embodiment, the air compressor
assembly 900, is an oil-lube, direct-drive air compressor including
an air storage tank 902 for storing compressed air. (Shown in FIGS.
11-12). In further embodiments, the air compressor assembly is a
belt drive assembly. (Shown in FIGS. 9-10). For example, the air
storage tank 902 holds a quantity of air at a predetermined
pressure range, such as between 110 and 135 psi, said quantity of
air utilized for driving air powered tools. The lubrication system
of the present invention is implemented within the air compressor
assembly 900, the air compressor assembly having one or more
cylinder/piston assemblies. (FIGS. 9-12 illustrate an air
compressor assembly with one cylinder/piston assembly). The
lubrication system 200 includes an oil sump 202 formed in a
crankcase 204 of the air compressor 900 and an oil slinger 208
coupled to a crankshaft assembly 210 of the air compressor. Oil
slinger 208 is comprised of a generally continuous disk 212
attached to the crankshaft assembly 210.
[0038] In an exemplary embodiment, the air compressor 900 includes
a cylinder assembly 214 housing a piston assembly 218 coupled to
crankshaft assembly 210. The air compressor further includes an
electric motor 904, which is coupled either directly (such as in a
direct drive air compressor) or by a belt system (such as with a
belt driven air compressor) with the crankshaft assembly, thereby
causing the crankshaft assembly to rotate and drive the piston
assembly. In the embodiment illustrated in FIGS. 11-12, the air
compressor assembly is a direct drive air compressor assembly
having a universal motor. For example, with a single stage air
compressor, during the downstroke of the piston assembly 218, the
piston assembly moves downward within the cylinder assemblies 214
allowing for the inlet of air into the cylinder assembly, the air
being from an external environment (i.e.--atmospheric pressure).
During the upstroke of the piston assembly 218, the piston assembly
moves upward within the cylinder assembly 214 and causes the air to
be compressed and discharged into the air storage tank 902, wherein
said air is stored. The electric motor 904 continues to drive the
crankshaft assembly, thereby causing the intake of air by the
cylinder assembly, the compression of air by the piston assembly,
and discharge of air into the tank 902 as described above until the
pressure within the tank reaches a predetermined pressure or falls
within a predetermined pressure range, such as between 115 and 135
psi. In a present embodiment, the air compressor includes a
pressure regulator 906 for monitoring the pressure within the tank
902. The pressure regulator 906 is configured to automatically
cause the electric motor 904 to cycle on and off respectively so
that the compressed air stored within the air storage tank 902 is
maintained at a predetermined pressure or within a predetermined
pressure range. In further embodiments, the air compressor 900 may
be a 2-stage compressor.
[0039] In further embodiments, the compressor assembly includes a
safety valve 908 for releasing pressure within the air storage tank
902.
[0040] In further embodiments, the compressor assembly includes a
check valve 910.
[0041] In further embodiments, the compressor assembly includes a
drain plug 912.
[0042] In embodiments with two or more cylinder/piston assemblies,
preferably, cylinder assemblies 214 & 216 are oriented so that
a single oil slinger 208 may provide lubrication to both
assemblies. For example, as shown in FIG. 8, cylinder assemblies
214 & 216 are oriented at an angle of approximately ninety
degrees to one another and spaced so that they overlap thereby
allowing a single plane 222, generally coaxial with oil slinger
208, to intersect both cylinder assemblies 214 & 218. In this
manner, a single oil slinger may provide lubricating oil 224 from
the oil sump 202 onto each cylinder assembly for lubricating
components of each piston assembly 218 & 220 (e.g., eccentric
bearings, wrist pin sets, etc.).
[0043] During operation of the air compressor 900, the electric
motor 904 drives the crankshaft assembly 210 and causes rotation of
the crankshaft assembly 210, which rotates the oil slinger 208 for
splashing lubricating oil 224 from the oil sump 202 for lubricating
piston assembly 218 of the cylinder assembly 214, respectively.
Like the embodiment shown in FIG. 1, the disk 212 of oil slinger
208 is generally centered coaxially with the center of rotation of
the crankshaft assembly 210 so that rotation of the crankshaft
assembly 210 causes the disk 212 to rotate 360 degrees about the
center of rotation of the crankshaft 230.
[0044] It will be appreciated that, based on the foregoing
discussion, an air compressor may be fabricated to comprise three
or more cylinder assemblies oriented to be lubricated by a single
oil slinger, such as oil slinger 208, without departing from the
scope and spirit of the invention. Moreover, in other embodiments,
air compressors may be provided having multiple cylinder/piston
assemblies that are lubricated by lubrication systems having two or
more oil slinger systems in accordance with the present invention.
Again, such embodiments would not depart from the scope and spirit
of the present invention.
[0045] It is contemplated that, employing the principles of the
invention discussed and illustrated herein, those of skill in the
art may now design lubrication systems utilizing oil slingers
having a wide variety of shapes (e.g., oval, eccentric, octagonal,
etc.) and/or edge and surface features other than those
specifically disclosed. Accordingly, such lubrication systems are
considered to be well within the scope and spirit of the present
invention as presently claimed. Further, it is believed that the
lubrication system of the present invention and many of its
attendant advantages will be understood by the forgoing
description, and it will be apparent that various changes may be
made in the form, construction and arrangement of the components
thereof without departing from the scope and spirit of the
invention or without sacrificing all of its material advantages,
the form herein before described being merely an explanatory
embodiment thereof. It is the intention of the following claims to
encompass and include such changes.
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