Hybridized compressor

Abstract

An air compressor includes a first compressor stage and at least one motor. The first compressor stage includes a first housing, a first drive plate, and a plurality of first pistons. The first drive plate is positioned in the first housing and includes an odd number of first lobes. The plurality of first pistons each contact the first drive plate at different locations relative to top dead center on the first lobes. The at least one motor is operable to rotate the first drive plate to move the plurality of first pistons to generate a volume of compressed air in the first housing.

What is claimed is: 
     
         1 . An air compressor, comprising:
 a first compressor stage comprising:
 a first housing; 
 a first drive plate positioned in the first housing and comprising an odd number of first lobes; 
 a plurality of first pistons each contacting the first drive plate at different locations relative to top dead center on the first lobes; 
   at least one motor operable to rotate the first drive plate to move the plurality of first pistons to generate a volume of compressed air in the first housing.   
     
     
         2 . The air compressor of  claim 1 , wherein the at least one motor comprises an electrically driven motor, a mechanically driven motor, and a controller, the controller being operable to switch between the electrically driven motor and the mechanically driven motor depending on an operation state of the mechanically driven motor. 
     
     
         3 . The air compressor of  claim 1 , wherein the at least one motor comprises an electrically driven motor and a mechanically driven motor, the air compressor further comprising a clutch operably positioned between the mechanically driven motor and the first drive plate. 
     
     
         4 . The air compressor of  claim 1 , wherein only one of the plurality of first pistons is positioned at top dead center position at a time. 
     
     
         5 . The air compressor of  claim 1 , wherein the plurality of first pistons are evenly spaced apart circumferentially and the first lobes are evenly spaced apart circumferentially. 
     
     
         6 . The air compressor of  claim 1 , wherein the plurality of first pistons are oriented radially outward. 
     
     
         7 . The air compressor of  claim 1 , further comprising:
 a second compressor stage comprising:
 a second housing; 
 a second drive plate positioned in the second housing and comprising an odd number of second lobes; 
 a plurality of second pistons each contacting one of the second lobes at different locations relative to top dead center on the second lobes; 
   wherein the at least one motor is operable to rotate the second drive plate to move the plurality of second pistons to generate a volume of compressed air in the second housing.   
     
     
         8 . The air compressor of  claim 7 , wherein only one of the plurality of first pistons and the plurality of second pistons are positioned at top dead center at a time. 
     
     
         9 . The air compressor of  claim 7 , wherein the first and second compressor stages are arranged coaxially. 
     
     
         10 . The air compressor of  claim 7 , wherein the at least one motor operates the first and second compressor stages concurrently. 
     
     
         11 . The air compressor of  claim 7 , wherein the first and second housings are coupled in flow communication with a single outlet of the air compressor. 
     
     
         12 . An air compressor system, comprising:
 a first drive plate having a plurality of lobes arranged circumferentially;   a plurality of first pistons circumferentially spaced apart and in contact with the plurality of lobes;   an air chamber arranged to collect a volume of compressed air created by reciprocal motion of the plurality of first pistons when rotating the first drive plate;   an electrically driven motor operable to rotate the first drive plate;   a mechanically driven motor operable to rotate the first drive plate;   a motor selection member configured to switch between the electrically driven motor and the mechanically driven motor.   
     
     
         13 . The air compressor of  claim 12 , wherein the motor selection member is configured to control a clutch. 
     
     
         14 . The air compressor of  claim 12 , wherein the plurality of first pistons are positioned on separate ones of the plurality of lobes at different locations relative to top dead center on the plurality of lobes. 
     
     
         15 . The air compressor of  claim 12 , further comprising:
 a second drive plate having a plurality of lobes arranged circumferentially;   a plurality of second pistons circumferentially spaced apart and in contact with the plurality of lobes of the second drive plate;   wherein the second drive plate is driven by one of the electrically driven motor and the mechanically driven motor.   
     
     
         16 . A method of generating compressed air, comprising:
 providing a housing, at least one drive plate comprising a plurality of lobes arranged circumferentially, a plurality of pistons each contacting one of the plurality of lobes at different locations relative to top dead center, and at least one motor;   rotating the at least one drive plate to move the plurality of pistons radially to generate a volume of compressed air in the housing.   
     
     
         17 . The method of  claim 16 , wherein the at least one motor comprises an electrically driven motor and a mechanically driven motor, the method comprising switching between the electrically driven motor and the mechanically driven motor based on a rotation speed of the mechanically driven motor. 
     
     
         18 . The method of  claim 17 , further comprising a pulley and drive shaft coupled to the at least one drive plate, wherein the mechanically driven motor is coupled to the pulley with a belt. 
     
     
         19 . The method of  claim 17 , wherein the electrically driven motor is coupled to the at least one motor with a drive shaft. 
     
     
         20 . The method of  claim 17 , further comprising a controller and a clutch, the controller operating the clutch to switch between the electrically driven motor and the mechanically driven motor as a power source for rotating the at least one drive plate.