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High pressure pump, frame and housing assemblyHigh pressure pump, frame and housing assembly description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20080044298, High pressure pump, frame and housing assembly. Brief Patent Description - Full Patent Description - Patent Application Claims
TECHNICAL FIELD OF THE INVENTION [0001]This invention relates to a pump, frame, and housing assembly for a motorized, high pressure pump producing an output of at least 4 gpm and 2,000 psi of hydraulic pressure, where the assembly suppresses motor and pump vibrations, reduces noise to 77 decibels or less, and allows safe viewing of internal components during operation. BACKGROUND OF THE INVENTION [0002]Manufacturing systems and processes that require a source of high pressure fluid are well known. These systems increase manufacturing efficiency, reduce waist and improve the quality of goods. Many of these systems are computer controlled robotic systems that use a robotic arm to control and aim a high pressure stream of fluid. Washing, deburring and cutting systems are but a few examples of the many types of systems that require fluid pressures of 2,000 psi (pounds per square inch) or greater. Each year, the various uses and needs for these systems and processes continues to grow. These manufacturing systems incorporate high pressure pumps and relatively powerful motors that can pressurize a working fluid such as water to a desired hydraulic pressure at a flow rate needed to properly perform the system. Most manufacturing systems require a flow rate of at least 4 gpm (gallons per minute). An example of a conventional high pressure pump, electric motor and frame assembly is shown in FIGS. 1-4. [0003]A problem with conventional high pressure pump and motor assemblies is excessive noise. High pressure pumps capable of producing the required pressures and volumetric flow rates needed for most manufacturing systems are noisy. The electric motor and pulley drive assembly only add to this noise level. In many conventional cases, the noise level of the motorized pump and frame assembly exceeds 90 decibels. Yet, prolonged exposure to this level of noise is known to cause hearing loss. This noise level can also lead to accidents because workers cannot hear each other talk, as human speech is typically about 75 decibels and is drowned out by the pumping unit. Workers may also be unable to hear other heavy equipment or vehicles in the area. Still, locating high pressure pumping units in remote parts of a plant or constructing a room for them is costly and often impractical. [0004]Another problem with conventional high pressure pumps and motors is vibration. The high rates of speed and cyclical motion of the pump, motor and drive assembly generate vibrations that shake their supporting frame and the components attached to that frame. Industrial high pressure pumps typically take the form of positive displacement pumps. These pumps generate large pulses of energy and vibrations each time their piston or pistons are stroked to pressurize the working hydraulic fluid such as water. The pumps typically operate at several hundred rotations per minute (rpm). The electric motors typically used to drive the pumps rotate at even higher rates of speed. The various cyclical pulses and rotational vibrations of the motorized pump assembly can combine to harmonically excite the frame and produce even larger amplitude vibrations and shaking. These vibrations create excessive wear and tear on the equipment, can lead to malfunctions, and result in increased maintenance requirements for the equipment. These vibrations and shaking of components also increase the level of noise. [0005]A still further problem with high pressure pumps and motors is visibility and lighting. The expensive, high speed equipment must be routinely inspected to ensure proper operation. Abnormalities that can lead to the rapid deterioration or degeneration of the equipment should be easily detected. For example, periodic visual checks for smoke, excessive shaking, or loosening or flaking of the drive belt, help indicate if service is required. Active components such as the motor, pump and drive assembly should be located where they are not visually obstructed by other components and are properly illuminated by light so that any abnormalities can be easily seen. Visibility and proper lighting are important because even trace amounts of smoke, belt ware or leaks can lead to rapid deterioration and even dangerous and costly disintegration of the high speed equipment. Yet, an acoustic housing that surrounds the active equipment tends to block visibility and lighting, and renders proper inspection and maintenance problematic. [0006]A still further problem with high pressure pump and motor assemblies is ventilation. High pressure pumps and their motors need cooling. Using the air in the building to cool the equipment is common and economical. Higher horsepower electric motors typically include a fan to draw air into the housing to cool its internal components and prevent them from overheating. High pressure pumps also need air flow around them to prevent overheating. Enclosing a high pressure pump in a sealed housing can result in overheating, malfunction or reduced life of the pump or motor unless proper ventilation is provided. Yet, vent openings provide pathways for transmitting noise, and can render other noise attenuating methods ineffective. [0007]A still further problem with high pressure pump and motor assemblies is safety. The shafts of the motor and pump spin at several hundred revolutions per minute (rpm). The drive belt and pulleys that join the drive and driven shafts of the motor and pump also turn at a high rate of speed. Any worker that inadvertently comes in contact with these components during operation can be severely injured. Although some designs include a cabinet that encloses the pulley and belt as in FIG. 3, this cabinet obstructs the view of these and other components during operation. The cabinet also requires workers to come close to the unit, open the cabinet, and even lean over the high speed components to inspect them during operation. [0008]A further problem with motorized, high pressure pump assemblies is their bulky size. Although floor space in most manufacturing settings is at a premium, the components are typically arranged on a skid type frame having a large footprint as in FIG. 1. The pump, motor and pulley drive are mounted close to the floor to dampen vibrations and minimize their transmission to each other, as well as other static components such as the fluid storage tanks. Designs that rely on the dampening effect of the floor to reduce vibrations increase the footprint of the unit. The actively rotating components, as well as other relatively static components, are simply spread out over the length and width of the frame. This large footprint also increases the difficulty and cost of enclosing the components in a housing. [0009]A still further problem with motorized high pressure pump assemblies is maintenance. For example, the oil level of the pump must be routinely checked and maintained. Yet, the frame sets on the floor and the active components are located near the floor. Workers must bend over or kneel down, open access doors or remove obstructions to inspect or perform routine maintenance on various components. Dirt and debris also collect under the unit which is at best difficult to clean, particularly during operation. This dirt and debris can be drawn into the motor or pump and cause damage, or be picked up by the drive belt and result in unnecessary injury or damage. [0010]The present invention is intended to solve these and other problems. BRIEF DESCRIPTION OF THE INVENTION [0011]This invention relates to a high pressure pump, frame and housing assembly including a high pressure pump, electric motor, drive belt assembly, metal frame, plastic housing and noise absorbing sheets that combine to suppress vibration, reduce noise, and allow viewing of the motorized pump assembly. The motorized pump produces a flow rate of at least 4 gpm and hydraulic pressure of at least 2,000 psi, while keeping the noise level at or below about 77 decibels. Vibrations are suppressed by the frame and housing, which are formed by frame members, segments and panels having different sizes and shapes so that they do not vibrate at the same natural frequency, and tend to cancel or attenuate vibrations passing from one frame or panel member to another. Thin acoustic insulation sheets combine with the housing panels to form dead zones that absorb noise. The sheets and dead zones are compactly arranged inside the frame segments so that the size and footprint of the assembly is kept to a minimum. Two transparent housing panels form dual opposed windows that provide the lighting to and allow the viewing of the motorized pump assembly and other internal components. [0012]One advantage of the present motorized pump assembly is its reduced noise level. Although the motorized high pressure pump produces hydraulic pressures of about 2,000 to 10,000 psi or more at flow rates of 4 to 18 gpm or more, the noise level of the assembly at a distance of three feet from the unit is kept to about 75 to 77 decibels or less. This noise reduction is a result of reduced vibration and the use and arrangement of noise absorbing sheets placed in the windows of the frame segments. The thin, plastic, sound absorbing sheets have a porous surface that dampens noise. The sheets are sonically welded to the inside surface of the plastic housing. The sheets are folded to form a box shape. The sheets have a flat main portion that is spaced from the housing to form a dead zone of air between the sheet and the housing. The sheets and dead zones are compactly arranged to fit within the windows of the frame segment. A bottom sheet is also located along the bottom of the frame. The motor intake air vent and the exhaust vent at the top of the frame include noise insulation and baffles. The dramatic reduction in noise of the present motorized pump assembly meets the noise level requirements for machinery and equipment used in many industrial setting such as Ford Motor Company manufacturing plants. [0013]Another advantage of the present motorized pump assembly is vibration suppression. High pressure pumps generate large pulses of energy and vibrations. The drive motor also generates vibrations. The structure of the frame inhibits the transmission and multiplication or excitement of these vibrations. The frame is composed of upper and lower portions. The upper portion is formed by frame members with different cross sectional sizes than the lower portion. The frame is also formed by several frame segments. These segments have different shapes and sizes, and do not form a square. The platforms on which the motor and pump are mounted are also constructed differently and include plates having different thicknesses. This construction produces frame segments and parts with different natural frequencies that inhibit the multiplication or excitement of vibrations. The construction also helps attenuate and minimize the propagation of the motor and pump vibrations through the frame. The shafts of the motor and pump are also offset from the center of the housing, and flex hose and shock absorbing rubber mounting pads are used to reduce vibration excitement and propagation. This vibration suppression reduces the wear and tear on the frame, housing and internal components attached to the frame. The reduced vibration also reduces the noise level of the overall assembly. [0014]A still further advantage of the present motorized pump assembly is the visibility and lighting of its active internal components. Good visibility and lighting are particularly important because external noise is below 77 decibels, while the background noise of many manufacturing settings is typically about or above 80 decibels. As a result, workers cannot hear component noises inside the acoustic frame and housing assembly that would otherwise signal a need for maintenance or an impending malfunction, such as a high pitched whir of a worn drive belt. Although the frame and housing assembly surround the internal components, two panels are transparent plastic to provide windows for viewing those components. The windows are located on the front and rear of the assembly. This opposed, dual window design allows light to enter the opposite side from the line of sight of the viewer to provide backlighting for each window. A worker can view the internal components through either window without shadowing that can hide or hinder the observation of smoke, leaks, belt deterioration or loosening, excessive vibration, or other sometimes difficult to detect abnormalities. The accumulation of belt flakes or leaking fluid at the bottom of the housing is easily seen through the front window, which spans from the bottom to the top of the assembly, and which is located directly in front of and provides unobstructed viewing of the pulley and drive belt assembly. The rear window is located directly behind and allows for unobstructed viewing of the pump and motor. The rear window is angled relative to the vertical front window. This angled arrangement inhibits the reverberation of noise between the windows, and provide a clear view of both the pump and motor, which are stacked one on top the other. The dual window design utilizes ambient room light and avoids the problems of providing and maintaining a fixed internal light source, which can also produce a shadowing effect. The ergonomic design also allows workers to properly inspect the internal components without bending over, kneeling down or contorting their body into an unnatural position. As a result, the expensive, high speed equipment can be routinely inspected to ensure their proper operation. [0015]A still further advantage of the present motorized pump assembly is its ventilation. Both the pump and motor are adequately ventilated and cooled by room air so that they do not overheat. The high power electric motor and the pump are kept within design specifications during operation. The air vent openings in the housing include baffles to abate the transmission of noise, and are located where they do not obstruct visibility through the front and angled rear windows. [0016]A still further advantage of the present motorized pump assembly is its added safety. The rotating shafts, pulleys and drive belt of the motorized pump assembly are enclosed in the frame and housing of the assembly. The windows are thick panels of transparent Lexan plastic. Workers do not have to open the housing or physically handle the unit to view the motorized pump assembly 15. Checking for smoke, excessive shaking, fluid leaks, belt flaking or loosening, bulging hoses, and other maintenance inspection requirements can be easily observed. Workers remain behind the housing and away from the spinning components. [0017]A further advantage of the present motorized pump assembly is its compact size, which is achieved by a number of design features. First, the pump and motor have a stacked arrangement. The pump is located above the motor. Second, only active high speed components such as the pump, motor and pulley drive are enclosed in housing of the assembly. Static components such as tanks and control panels that do not require vibration and noise control are positioned outside the frame and housing. Third, the noise absorbing sheets are thin and effective. Bulky masses of insulation are not used. Fourth the noise absorbing sheets are located inside the openings or windows of the frame segments so that they do not increase in the overall size of the assembly. The surface area of the noise insulation actually exceeds the surface area of the interior space of the assembly. Thus, the overall assembly has a small footprint and conserves manufacturing floor space. The compact size also reduces the cost of enclosing the motorized pump in an acoustic housing. [0018]A still further advantage of the present motorized pump assembly is its ergonomic design and ease of maintenance. By elevating the frame, workers can more easily perform routine maintenance such as oil changes, applying lubricants, filter cleaning or replacement, bolt tightening, hose replacement, etc. A small access opening is provided in the rear window so that a worker can check the oil level without removing any housing panels. The opening is located directly above the oil dip stick and allows the worker to see his or her hand and the dip stick as they reach into the housing. Workers do not need to bend over or work off the floor. The elevated design also allows dirt and debris to be easily cleaned away from the floor and around the unit, even during operation. [0019]Other aspects and advantages of the invention will become apparent upon making reference to the specification, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0020]FIG. 1 is a perspective view of a conventional motorized pump assembly for a high pressure, positive displacement pump that provides discharge pressure of over 2,000 psi and has a noise level of over about 90 decibels. Continue reading about High pressure pump, frame and housing assembly... Full patent description for High pressure pump, frame and housing assembly Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this High pressure pump, frame and housing assembly patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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