Pump drive system

A fluid sprayer assembly comprising:

• an electric motor comprising a stator and a rotor, the stator and rotor disposed on an axis;
• a drive coupled to the rotor and configured to convert a rotational output of the rotor into reciprocating linear motion;
• a pump comprising a fluid displacement member mechanically coupled to the drive to be reciprocated by the drive;
• a fluid outlet that sprays the fluid output by the pump;
• a controller configured to output driving electrical energy to the electric motor to control operation of the electric motor, wherein the controller is configured to receive a pressure setting that is set by a user and control a level of power provided to the electric motor based on the pressure setting such that the rotor stalls while power is delivered to the electric motor to control output spray pressure relative to the pressure setting;
• and
• a motor sensor configured to sense rotation of the rotor on the axis, wherein the controller is configured to control the level of power provided to the electric motor based on an output from the motor sensor regarding a rotational status of the rotor.

A fluid sprayer assembly comprising:

• an electric motor comprising a stator and a rotor, the stator and rotor disposed on an axis;
• a drive coupled to the rotor and configured to convert a rotational output of the rotor into reciprocating linear motion;
• a pump comprising a fluid displacement member mechanically coupled to the drive to be reciprocated by the drive;
• a fluid outlet that sprays the fluid output by the pump;
• a controller configured to output driving electrical energy to the electric motor to control operation of the electric motor;
• wherein the controller is configured to receive a pressure setting that is set by a user and control a level of power provided to the electric motor based on the pressure setting such that the rotor stalls while power is delivered to the electric motor to control output spray pressure relative to the pressure setting;
• and
• wherein the controller is configured to initiate a count based on the rotor stalling, and wherein the controller is configured to stop providing the driving electrical energy to the electric motor based on the count reaching a count threshold.

A fluid sprayer comprising:

• an electric motor comprising a stator and a rotor, the stator and rotor disposed on an axis;
• a drive coupled to the rotor and configured to convert a rotational output of the rotor into reciprocating linear motion;
• a pump comprising a fluid displacement member mechanically coupled to the drive to be reciprocated by the drive;
• a fluid outlet that sprays the fluid output by the pump;
• a controller configured to output driving electrical energy to the electric motor to control operation of the electric motor;
• wherein the controller is configured to receive a pressure setting that is set by a user and control a level of power provided to the electric motor based on the pressure setting such that the rotor stalls while power is delivered to the electric motor to control output spray pressure relative to the pressure setting;
• and
• wherein:
• the electric motor includes a first axial end and a second axial end;
• the rotor includes a housing with an opening at the second axial end;
• the stator is located at least partially inside of the rotor;
• a support frame supports the electric motor;
• a stator support extends through the opening of the housing and holds the stator stationary relative to the support frame;
• and
• the pump is located closer to the first end of the electric motor than to the second end of the electric motor.

A method of spraying fluid by a fluid sprayer, the method comprising:

• receiving, by a controller of an electric motor, a pressure setting that is set by a user, the pressure setting corresponding to a set output pressure for a pump, the pump connected to the electric motor by a drive to be driven by the electric motor via the drive and pump fluid downstream to a fluid outlet for spraying, the electric motor including a stator and a rotor configured to rotate on an axis;
• providing, by the controller, driving electrical energy to the electric motor to power the electric motor;
• and
• controlling, by the controller, a level of electric current provided to the electric motor based on the pressure setting such that the rotor stalls while power is delivered to the electric motor to control output spray pressure relative to the pressure setting;
• and
• reducing the level of electric current provided to the electric motor while the rotor stalls to reduce a force applied by the rotor while continuing to urge the rotor by the reduced level of electric current;
• and
• increasing the level of electric current provided to the electric motor after reducing the level of electric current to increase the force applied by the rotor and cause pumping by the pump.

A method of spraying fluid by a fluid sprayer, the method comprising:

• receiving, by a controller of an electric motor, a pressure setting that is set by a user, the pressure setting corresponding to a set output pressure for a pump, the pump connected to the electric motor by a drive to be driven by the electric motor via the drive and pump fluid downstream to a fluid outlet for spraying, the electric motor including a stator and a rotor configured to rotate on an axis;
• providing, by the controller, driving electrical energy to the electric motor to power the electric motor;
• and
• controlling, by the controller, a level of power provided to the electric motor based on the pressure setting such that the rotor stalls while power is delivered to the electric motor to control output spray pressure relative to the pressure setting;
• stopping, by the controller, delivery of the driving electrical energy to the electric motor based on the rotor being stalled for a period of time, wherein stopping, by the controller, delivery of the driving electrical energy to the electric motor based on the rotor being stalled for a period of time comprises:
• initiating a count based on the rotor stopping rotation while the controller continues providing the driving electrical energy;
• and
• stopping, by the controller, of the delivery of the driving electrical energy to the electric motor based on the count reaching a count threshold.