Diaphragm pump with sensor mount

Abstract

Illustrative embodiments of diaphragm pumps including a sensor mount are disclosed. In one illustrative embodiment, a diaphragm pump may include a shaft disposed within a pump housing and coupled to at least one diaphragm, a mount removably attached to the pump housing and having a sensor receptacle, and a proximity sensor received in the sensor receptacle of the mount such that a sensing end of the proximity sensor is flush with an end of the sensor receptacle nearest the shaft.

1 .- 11 . (canceled) 
     
     
         12 . A method of assembling a diaphragm pump comprising a shaft coupled to at least one diaphragm, the method comprising:
 inserting a proximity sensor into a sensor receptacle defined in a mount of the diaphragm pump such that a sensing end of the proximity sensor is flush with an end of the sensor receptacle; and   attaching the mount to a pump housing of the diaphragm pump such that the end of the sensor receptacle is positioned at a predetermined distance from the shaft of the diaphragm pump.   
     
     
         13 . The method of  claim 12 , wherein the method comprises first inserting the proximity sensor into the sensor receptacle, and second attaching the mount to the pump housing. 
     
     
         14 . The method of  claim 12 , wherein the predetermined distance is a distance that requires no additional mechanical calibration of the position of the sensing end of the proximity sensor relative to the shaft. 
     
     
         15 . The method of  claim 12 , wherein inserting the proximity sensor into the sensor receptacle comprises:
 aligning the proximity sensor with the sensor receptacle; and   pressing the proximity sensor into the sensor receptacle until the sensing end of the proximity sensor is flush with the end of the sensor receptacle.   
     
     
         16 . The method of  claim 15 , wherein pressing the proximity sensor comprises forming an interference fit between at least one protrusion of the sensor receptacle and an exterior surface of the proximity sensor. 
     
     
         17 . The method of  claim 12 , further comprising attaching an inlet of a muffler to the pump housing of the diaphragm pump such that the inlet of the muffler is fluidly connected with an exhaust chamber of the diaphragm pump. 
     
     
         18 . The method of  claim 17 , wherein attaching the inlet of the muffler to the pump housing comprises inserting the inlet of the muffler into a muffler receptacle defined in the mount. 
     
     
         19 .- 21 . (canceled) 
     
     
         22 . A method of assembling a diaphragm pump comprising a shaft coupled to at least one diaphragm, the method comprising:
 coupling a proximity sensor to a mount of the diaphragm pump such that a sensing end of the proximity sensor extends a predetermined length from a first side of the mount; and   coupling the mount to a pump housing of the diaphragm pump such that first side of the mount faces the pump housing, and such that the sensing end of the proximity sensor is positioned at a predetermined distance from the shaft of the diaphragm pump.   
     
     
         23 . The method of  claim 22 , wherein the mount includes a sensor receptacle that at least partially extends from the first side of the mount. 
     
     
         24 . The method of  claim 23 , wherein coupling the proximity sensor to the mount comprises:
 aligning the proximity sensor with the sensor receptacle; and   pressing the proximity sensor into the sensor receptacle until the sensing end of the proximity sensor is flush with an end of the sensor receptacle.   
     
     
         25 . The method of  claim 24 , wherein pressing the proximity sensor comprises forming an interference fit between at least one protrusion of the sensor receptacle and an exterior surface of the proximity sensor. 
     
     
         26 . The method of  claim 22 , wherein the pump housing includes an exhaust chamber. 
     
     
         27 . The method of  claim 26 , wherein the mount has a complimentary shape to the exhaust chamber such that the mount is in a predetermined orientation with respect to the pump housing when coupled to the exhaust chamber of the pump housing, the predetermined orientation positioning the sensing end of the proximity sensor the predetermined distance from the shaft of the diaphragm pump. 
     
     
         28 . The method of  claim 27 , wherein the proximity sensor is collinear with a longitudinal axis of the mount and a longitudinal axis of the exhaust chamber when the proximity sensor is coupled to the mount and the mount is coupled to the exhaust chamber. 
     
     
         29 . A method of assembling a diaphragm pump comprising a shaft coupled to at least one diaphragm, the method comprising:
 securing a proximity sensor to a mount of the diaphragm pump such that a sensing end of the proximity sensor is flush with an end of the mount; and   installing the mount to a pump housing of the diaphragm pump such that the end of the mount and the sensing end of the proximity sensor are positioned at a predetermined distance from the shaft of the diaphragm pump.   
     
     
         30 . The method of  claim 29 , wherein the proximity sensor is configured to detect movement of the shaft of the diaphragm pump. 
     
     
         31 . The method of  claim 29 , wherein securing the proximity sensor to the mount comprises:
 aligning the proximity sensor with a sensor receptacle disposed within the mount; and   pressing the proximity sensor into the sensor receptacle until the sensing end of the proximity sensor is flush with an end of the sensor receptacle, the end of the sensor receptacle being the end of the mount.   
     
     
         32 . The method of  claim 31 , wherein pressing the proximity sensor comprises forming an interference fit between at least one protrusion of the sensor receptacle and an exterior surface of the proximity sensor. 
     
     
         33 . The method of  claim 29 , the method further comprises coupling a muffler to the pump housing of the diaphragm pump such that the muffler is fluidly connected with an exhaust chamber of the diaphragm pump. 
     
     
         34 . The method of  claim 33 , wherein the mount includes a muffler receptacle, and the muffler is coupled to the pump housing by securing the muffler to the muffler receptacle of the mount and by the installing of the mount to the pump housing.