FIELD OF THE INVENTION

The field of the invention relates to vacuum pumps.

BACKGROUND

Vacuum pump systems may be made up of different components, the vacuum generator, the motor and in some cases control circuitry and a lubricant reservoir. Vacuum pumps are often heavy and may be unwieldy and parts of them may be sensitive to shocks and tilting. They also need to be secured in use due to the vibrations that they produce.

It would be desirable to provide a vacuum pump system that is compact, easy to secure and move.

SUMMARY

One aspect provides a modular system comprising a vacuum pump system and a support frame for supporting said vacuum pump system above a surface, said vacuum pump system comprising: a vacuum generator; and a motor for driving said vacuum generator; said support frame comprising an upper mounting means configured for supporting said vacuum generator and said motor; and a lower level; wherein said support frame is configured to receive control circuitry for controlling operation of said vacuum generator between said upper mounting means and said lower level, wherein said support frame comprises side walls connecting said upper mounting means and lower level and at least one open face for receiving said control circuitry, said upper mounting means, lower level and said side walls are formed from a single piece of metal deformed to form said mounting means and said side walls.

It was recognised that vacuum generators tend to generate significant vibrations and need to be mounted securely. It was also recognised that where there is circuitry associated with them for controlling the vacuum generator then this should be at least partially enclosed and protected where possible. Both of these issues have been addressed by the provision of a support structure or frame for supporting the different components of the vacuum pump in a stack like arrangement, such that there is a location under the mounting means below the vacuum generator for the control circuitry. This allows the vacuum system to be supported and moved as a modular system and provides for a compact arrangement and some protection for any control circuitry. In some embodiments the control circuitry is mounted between the lower level and upper mounting means.

It is also advantageous if much of the support frame is formed of a single piece of metal bent to form the upper mounting means, in some cases the lip and the lower level. This provides a strong support frame for supporting significant a weight, that is easy to manufacture.

In some embodiments, said lower level of said support frame comprises at least one support protrusion extending away from the upper mounting means for mounting said lower level of said support frame above said surface.

In some embodiments the support frame is supported above a surface by protrusions extending from the lower level. These may protect the lower level of the support frame and protect the components.

In some embodiments said upper mounting means comprises at least one protrusion extending away from said lower level, said at least one protrusion comprising retaining means for retaining at least one of said motor and said vacuum generator.

In some embodiments the upper mounting means may comprise a surface on which the vacuum generator and/or motor are mounted. In other embodiments, the upper mounting means may comprise a frame like structure for mounting the components. In some cases the upper mounting means may have at least one protrusion extending up from the upper mounting means to which the motor and/or vacuum generator may be attached to hold them in position. The attachments may be by bolts or other attaching means.

In some embodiments the lower level may comprise a surface, or it may comprise a portion of a surface. The lower level and upper mounting means may be configured to extend substantially parallel to each other and parallel to the surface that the vacuum system is mounted above by the support frame.

In some embodiments, said at least one upwardly extending protrusion comprises an upwardly extending lip at at least one edge of said upper mounting means, said upwardly extending lip comprising said retaining means for retaining said vacuum generator.

An upwardly extending lip that is one extending away from the lower level along at least one side or edge of the upper mounting means may increase its rigidity and stability which may be important where the modular vacuum system is heavy and in some embodiments, provides a site for retaining means for holding the vacuum generator or motor in position. These retaining means may simply be an aperture for receiving a bolt for bolting the module to the support frame.

In some embodiments, said system further comprises said control circuitry mounted below said upper mounting means between said upper mounting means and said lower level.

The support frame is configured for supporting a modular vacuum system. In some cases this may comprise a control circuitry module for controlling the vacuum generator that may slot into a space between the upper mounting means and lower level. However, the support frame may also support a modular vacuum system that does not have complex control circuitry in which case the space between the upper mounting means and lower level may be empty. The modular nature allows the support frame to be used for different vacuum systems, having different capacities, thereby reducing manufacturing costs and increasing uniformity of products.

The control circuitry is used to control the vacuum generator and in some embodiments comprises a frequency convertor for controlling a speed of said motor driving said vacuum generator.

In some embodiments, said control circuitry further comprise diagnostic circuitry configured to receive signals from sensors associated with said vacuum system.

In some embodiments, said modular system comprises a protective cover mounted to protect at least a portion of cabling for transmitting signals between said control circuitry and at least one of said vacuum generator and motor, said at least a portion being a portion extending from said control circuitry, said protective cover being arranged between said upper mounting means and said lower surface of said support frame.

The cabling extending from the control circuity to the vacuum generator and/or motor may be at risk of damage, as it passes between the different modular portions of the system and around the frame, particularly when the frame is being moved. A protective cover for protecting the cabling may mitigate these problems and allow the signals to be sent between the levels of the support frame with the cabling being protected.

In some embodiments, said protective cover is mounted to cover at least a portion of a face of said control circuitry, said at least a portion of said face comprising ports for attachment of said cabling.

In some embodiments, said protective cover is configured to be detachably attached such that said protective cover can be selectively removed to access said ports. Having a protective covering that is also removable and that covers the ports of the control circuitry allows them to be accessed and then the ports and any cabling that is attached to them to be protected by the cover when replaced.

In some embodiments, said system further comprises a fan forming part of said modular system and arranged for cooling said vacuum generator and said control circuitry and optionally said motor.

A further advantage of having a support frame for mounting the components in a predetermined fixed manner and in some cases as a stack, means that a single fan may be used for cooling the control circuitry and vacuum generator and in some cases the motor too.

In some embodiments, said system further comprises a housing at least partially surrounding said fan, said housing being configured to direct air flow from said fan over an outer surface of said control circuitry and said vacuum generator and in some cases said motor.

A housing around the fan may help both shield and protect the fan and if suitably arranged direct the air flow to the required modular components.

In some embodiments, said support frame comprises side walls connecting said upper mounting means and lower level and at least one of an open face for receiving said circuitry.

In some embodiments, the open face of the support frame helps allow air flow over the control circuitry, the fan being mounted to point towards the open face.

In some embodiments, said modular system further comprises a fluid communication path between said control circuitry and said pump system, such that cooling air flowing over said outer surface of said control circuitry is exhausted via an outer surface of said pump system. Directing the flow over the control circuitry back towards the pump system helps increase the flow over the pump system and may allow the control circuitry to be protected by housing without accessible holes For exhausting gases, which holes might allow ingress of other objects such as fingers.

In some embodiments, said fluid communication path comprises: at least one aperture in an upper surface of a housing of said control circuitry and in some embodiments at least one corresponding aperture in said upper mounting means.

Having a flow path in an upper surface of the control circuitry housing allows this aperture to be inaccessible when the control circuitry is mounted in the support frame. Control circuitry should have its electronics protected and requires particularly small holes in accessible regions to prevent the ingress of fingers for example. Providing the air flow through an aperture at the top of the housing facing the lower surface of the pump system means that it is inaccessible and the limitation on size of aperture does not apply.

In some embodiments, said side walls comprise retaining means for cooperating with latching means on said control circuitry for retaining said control circuitry on said support frame

The control circuitry may be slid into position between the upper mounting means and lower level and may be retained in position by retaining means such as clips on the side walls.

In some embodiments, said at least one support protrusion comprises at least one flexible foot extending from said lower level, said at least one flexible foot being configured to support said support frame above said surface and to distort in response to vibrations generated by said vacuum generator. The support protrusion(s) may be used not just to support the lower level above a surface but also to absorb some of the vibrations generated by the vacuum generator in operation.

In some embodiments, said at least one support protrusion comprises at least one wheel extending from said lower level of said support frame and configured to support said support frame above said surface.

The support protrusion(s) may alternatively and/or additionally comprise wheels, wheels allow the modular system to be moved in a simple way, which maintains a certain orientation of the components and reduces shocks to the components which may occur when they are placed on surfaces.

In some embodiments, said at least one wheel comprises a flexible coating configured to distort in response to vibrations generated by said vacuum generator.

The wheel(s) may comprise coatings for absorbing vibrations due to operation of the vacuum generator.

In some embodiments, said support frame comprises two wheels and two flexible feet for supporting said lower level above a surface.

One arrangement may be for the support frame to be supported on two wheels and two flexible feet, allowing the frame to be moved by tilting such that the wheels support the frame but having feet for more stability and better vibration absorption when the vacuum generator is not being moved and is in use.

In some embodiments, said vacuum generator comprises a lubricant sealed vacuum generator comprising a lubricant reservoir for supplying lubricant to and receiving exhaust from said vacuum generator, said upper mounting means supporting said lubricant sealed vacuum generator. The vacuum system may be a lubricant sealed vacuum pump system and in this case the lubricant reservoir may also be mounted on the upper mounting means. This has the advantage of the reservoir being raised above the surface on which the support frame rests, such that the drain outlet for draining the reservoir is elevated above this surface allowing a receptacle to be placed under it when the lubricant is to be changed, this allowing lubricant to be collected without the need to manipulate the vacuum pump system.

In some embodiments, said system further comprises damping means for absorbing vibrations mounted between said vacuum generator and said upper mounting means.

Mounting the vacuum generator on the support frame provides a location for damping means to be placed allowing at least some of the vibrations due to operation of the vacuum generator to be absorbed.

A further aspect provides a method of .manufacturing a modular vacuum pump system comprising: deforming a sheet of metal to form a support frame comprising said upper mounting means, lower level and said side walls; mounting a vacuum generator and motor to said upper mounting means of said support frame; mounting a fan for cooling said circuitry and at least one of said vacuum generator and said motor to form part of said modular vacuum pump system supported by said support frame; and sliding control circuitry between said upper mounting means and a lower level of said support frame.

Further particular and preferred aspects are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with features of the independent claims as appropriate, and in combinations other than those explicitly set out in the claims. Where an apparatus feature is described as being operable to provide a function, it will be appreciated that this includes an apparatus feature which provides that function or which is adapted or configured to provide that function.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described further, with reference to the accompanying drawings, in which:

Figure 1 schematically shows a front and side view of a modular system according to an embodiment;

Figure 2 schematically shows the air flow from the fan over the modular system of Figure 1 ;

Figure 3 schematically shows a front view of a modular system according to an embodiment;

Figure 4 schematically shows a further front view of a modular system according to an embodiment;

Figure 5 shows the support frame;

Figure 6 shows a flow chart showing steps in a method according to an embodiment:

Figure 7 shows a support frame and control circuitry according to an embodiment;

Figure 8 shows a support frame according to an embodiment; and Figure 9 shows a modular system according to an embodiment.

DESCRIPTION OF THE EMBODIMENTS

Before discussing the embodiments in any more detail, first an overview will be provided.

A modular system for supporting the different components of a vacuum system on a support frame is provided. The support frame has different levels for supporting different components. There is an upper level or mounting means, which may comprise a surface and on which the vacuum generator, and other components such as the motor and oil reservoir may be mounted. There is a lower level connected to the upper level by side walls. The lower level may comprise support protrusions extending from a lower surface, and this lower level may be a partial surface extending from the side walls, but only for a portion of the width of the support frame.

The support frame may have an open front for receiving a control circuitry module for controlling the vacuum generator between the upper and lower levels, and an at least partially open back, which allows air flow from the fan to pass over the control circuitry. The control circuitry is mounted below the upper mounting means in some embodiments it is mounted by fixing it to the side walls.

Figure 1 schematically shows a modular system according to an embodiment. The modular system comprises support frame 5 having a lower level 6 and an upper mounting means 8. Extending from the lower level 6 of the support frame are mounting protrusions 7 in the form of feet 7a or wheels 7b. Also mounted to the vacuum system is fan 50 which is configured for cooling both the vacuum generator 20 and in some cases a motor associated with the vacuum generator and the control circuitry 10. There is a housing 52 associated with the fan and the vacuum system for directing the air flow from the fan over the vacuum generator 20 and the control circuitry 10. The housing 52 obscures the side walls of the support frame in this embodiment.

Figure 2 shows the air flow from fan 50 to cool the control circuitry and the vacuum generator. The air flow to the control circuitry flows through an open face of the support frame at the rear of the support frame. In this regard, the support frame has an open front and back face between side walls (not shown). The open front face allows a control circuitry module 10 to be inserted and removed from the support frame while the open back allows air flow from fan 50 to cool the control circuitry at the same time as it cools the vacuum generator 20. Figure 3 shows a front view of the support frame having protrusions 7 in the form of flexible feet 7a extending from the lower level 6 of support frame 5. The frame has side walls 9 extending between the upper mounting means 8 and the lower level 6. In this embodiment upper mounting means 8 supports a vibration damping means 40 mounted between the frame and the vacuum generator, which vibration damping means absorbs vibrations from the vacuum generator 20 when operating.

Adjacent to the vacuum generator in this embodiment is lubricant reservoir 30. The vacuum generator 20 is in this embodiment an oil sealed rotary vacuum pump and the lubricant reservoir contains the oil for this pump. The lubricant reservoir 30 has a drain 32 allowing the oil to be drained from the reservoir when it needs to be changed. The support frame 5 mounts the vacuum system above a surface which facilitates draining of the lubricant from the lubricant reservoir by allowing a collection receptable to be placed under the drain means 32 without the need to move or raise the vacuum system.

Figure 4 shows a further front view showing more details of the vacuum system and support frame. In this embodiment, the support frame 5 has an upper lip 3 formed in two sections which in this case is on the front surface. This upper lip strengthens the support frame and also provides a retaining means for retaining the vacuum generator and lubricant reservoir in position. There is also a downwardly extending lip in this embodiment which also strengthens the frame and helps retain the control circuitry 10 in position. This figure also schematically shows the motor 60 for driving the vacuum generator 20. The support frame has support protrusions 7 extending from the lower level of the frame, these may be flexible and configured to absorb vibrations generated by the vacuum system in use.

The support frame 5 is formed from a single sheet of metal which is bent to form the lower level, the upper mounting means, side walls and lip. This makes for a robust frame able to support considerable mass in a limited space. Figure 5 shows a three dimensional view of the support frame 5 without the vacuum pump system mounted on it. In this embodiment, the support frame 5 has two wheels 7b at the front and two flexible feet 7a at the back extending down from and attached to a portion of the lower level 6 of the support frame. This allows the support frame to be moved on the wheels by tilting the support frame such that the flexible feet are held above the surface and the frame rests on the wheels. When in position the frame is returned to its horizontal position and rests on all four protrusions. In some embodiments the wheels may have a vibration damping coating on them, such that both the wheels 7b and flexible feet 7a absorb vibrations in use. The side walls 9 have retaining means 4 configured to cooperate with a latching means on the side wall of the control circuitry to hold it in pace when it is slid into position. The retaining means 4 may be in the form of an aperture so that the latching means can be pushed back out of the aperture to release the control circuitry when it is to be removed.

In this embodiment the upper mounting means 8 comprises retaining means 12 extending up from the surface and to which the vacuum generator and lubricant reservoir can be fixed when mounted on the support frame.

Figure 6 schematically shows a flow diagram illustrating steps in a method of manufacturing a modular system according to an embodiment. At step S10 a sheet of metal is deformed to form a support frame. At step S20 a vacuum generator is mounted on an upper mounting means of the support frame. At step S30 control circuity is slid into a gap between the lower level of the support frame and the upper mounting means. At step S340 a fan is mounted to the vacuum system to cool both the control circuitry and the vacuum generator. Step S30 and S40 can be performed in any order. In some embodiments a housing is then mounted around at least a portion of the fan and vacuum generator to direct the air flow towards the control circuitry and vacuum generator. Figure 7 shows control circuitry 20 mounted in a support frame according to an embodiment. The control circuitry is housed between the upper 8 and lower 6 levels of the support frame 5. The control circuitry 10 has ports 14 for receiving cables for transmitting and receiving signals from the motor, vacuum generator and/or fan of the pump system. There is a cable protector 18, shown in the adjacent figure, that is detachably mountable over the control circuitry ports14 to protect both them and the cabling that extends from the ports. The detachable nature of the protector allows it to be removed and replaced as access to the ports is required.

Figure 8 shows the support frame 5 with control circuitry 10 in place and with the ports 14 not currently covered by the cable protector. There is an aperture 16 in the upper housing of the control circuitry that allows the flow of air between the control circuitry and the vacuum pump system mounted on the upper surface 8 of the support frame. In this embodiment, the portion of the control circuitry 10 with the aperture 16 extends beyond the upper surface 8 of the support frame 5. However, when the pump system is mounted on the frame this aperture is located underneath a portion of the pump system (see Figure 9). In other embodiments, the upper surface or mounting means 8 may extend over the aperture 16 in the control circuitry housing and in this case, there will be a corresponding one or more apertures in the upper surface 8. The location of this aperture on the upper surface of the control circuitry is such that it is shielded by a portion of the pump system (see Figure 9) allowing the aperture to have a relatively widely spaced grid on it, rather than requiring very small apertures to protect the electronic components from the ingress of stray objects such as fingers.

Figure 9 schematically shows a modular system according to an embodiment. The modular system comprises a fan at one end to blow air towards a vacuum generator 20 and motor 60. Housing 52 directs air towards the vacuum generator and motor that are mounted on the upper surface of the support frame and also towards control circuitry 10 located between the upper and lower levels of the support frame. Aperture 16 is shown allowing the flow of air between the lower level and upper levels, such that the air flow over the control circuitry is exhausted via the outer surface of motor 60. Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiment and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention as defined by the appended claims and their equivalents.

REFERENCE SIGNS

2 downward lip

3 upward lip

4,12 retaining means

5 support frame

6 lower level

7 support protrusions

7a flexible feet

7b wheels

8 upper mounting means

9 side walls

10 control circuitry

14 control circuitry ports

16 aperture

18 protective covering

20 vacuum generator

30 lubricant reservoir

32 drain

40 vibration damper

50 fan

52 housing

60 motor