Electric air compressor system and power regulator therefor

Inventors: Kai Justice (Wheatfield, IN); Trenton Rhodes (Valparaiso, IN); Devin Royce (Chesterton, IN); Lucas Bencze (Valparaiso, IN); Ralph Kokot (Crown Point, IN)

Assignee: VANAIR MANUFACTURING, INC.

F04B49/06 F04B35/04

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Quick Facts

Patent No.: US 12669117
App. No.: 17/818,030
Granted: Jun 30, 2026
Kind: B2

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Abstract

An electric air compressor system includes an air compressor and an electric motor configured for driving the air compressor. An electric power storage device provides electric power to the electric motor. An electric generator provides electric power to the electric power storage device and/or to the electric motor. A power regulator including a processor controls operation of the electric generator. The power regulator controls operation of the electric generator based on at least one of an on/off operational state of the electric generator, the temperature of the electric generator, the temperature of the electric power storage device, the electrical current output of the electric generator, and the speed of the electric generator.

Claims (24)

1 . An electric air compressor system comprising:

an air compressor operable to produce compressed air, the air compressor being operable at variable speeds to match air demand of multiple varying loads on the electric air compressor system with the compressed air produced by the air compressor;

an electric motor configured for driving the air compressor;

a motor controller that controls operation of the electric motor;

an electric power storage device configured for providing electric power to the electric motor;

an electric charging system operatively coupled to the electric power storage device and to the electric motor, the electric charging system comprising an alternator, driven by an internal combustion engine, and configured for providing electric power to the electric power storage device to recharge the electric power storage device and to the electric motor to drive the air compressor;

a contactor located along an electrical circuit leg that extends from the alternator to both of the electric power storage device and the motor controller, and

a power regulator operatively coupled to the electric charging system and comprising a processor configured to control operation of the alternator, the processor controlling the electric power produced by the alternator based on sensed operating parameters of the electric charging system and the electric power storage device to prevent or minimize failures in the electric air compressor system, the sensed operating parameters including:

a sensed electrical current output of the alternator to the electric power storage device and/or the electric motor, and a sensed temperature of the alternator wherein the power regulator reduces power output of the alternator when the sensed temperature of the alternator exceeds a predetermined threshold, and further wherein the power regulator controls operation of the contactor, based on the sensed temperature of the alternator, to open the contactor and block the electrical current output of the alternator from both of the electric power storage device and the motor controller.

2 . A power regulator operatively coupled to an electric charging system for controlling operation of an air compressor system having an alternator, driven by an internal combustion engine, that provides electrical power to an electric power storage device and to an electric motor to drive an air compressor that is operable at variable speeds to match air demand of multiple varying loads on the air compressor system with compressed air produced by the air compressor, the power regulator comprising:

a processor configured to control operation of the alternator and control the electric power provided thereby to match the air demand of the multiple varying loads on the air compressor system with the compressed air produced by the compressor, the processor controlling the electric power produced by the alternator based on sensed operating parameters of the electric charging system and the electric power storage device to prevent or minimize failures in the air compressor system, the sensed operating parameters including:

wherein the air compressor system includes a motor controller that controls operation of the electric motor, and a contactor located along an electrical circuit leg that extends from the alternator to both of the electric power storage device and the motor controller, and further wherein the power regulator controls operation of the contactor, based on the sensed temperature of the alternator, to open the contactor and block the electrical current output of the alternator from both of the electric power storage device and the motor controller.

3 . The electric air compressor system of claim 1 , wherein the power regulator reduces power output of the alternator based on a predicted load verses a sensed speed of the alternator in anticipation of slippage of a drive belt that drives the alternator to reduce or prevent slippage of the drive belt.

4 . The electric air compressor system of claim 1 , wherein, based on the sensed electrical current output, the power regulator regulates the electrical current output from the alternator to prevent full power from the alternator from being provided to the electric power storage device when a sensed temperature of the electric power storage device is below a first selected temperature threshold.

5 . The electric air compressor system of claim 4 , wherein the power regulator regulates the electrical current output from the alternator to decrease output charge from the alternator when a sensed temperature of the electric power storage device is above a second selected temperature threshold.

6 . The power regulator of claim 2 , wherein the power regulator reduces power output of the alternator based on a predicted load verses a sensed speed of the alternator in anticipation of slippage of a drive belt that drives the alternator to reduce or prevent slippage of the drive belt.

7 . The power regulator of claim 2 , wherein, based on the sensed electrical current output, the power regulator regulates the electrical current output from the alternator to prevent full power from the alternator from being provided to the electric power storage device when a sensed temperature of the electric power storage device is below a first selected temperature threshold.

8 . The power regulator of claim 7 , wherein the power regulator regulates the electrical current output from the alternator to decrease output charge from the alternator when a sensed temperature of the electric power storage device is above a second selected temperature threshold.

9 . The electric air compressor system of claim 1 , wherein the processor is configured to the control the electric power produced by the alternator to match the air demand of the multiple varying loads on the electric air compressor system with the compressed air produced by the compressor.

10 . The electric air compressor system of claim 9 , wherein the sensed operating parameters further include:

a sensed temperature of the electric power storage device; and

a sensed speed of the alternator.

11 . The power regulator of claim 2 , wherein the sensed operating parameters further include a sensed temperature of the electric power storage device, and a sensed speed of the alternator.