Motor controller of automobile five-in-one electric pump assembly

Abstract

A motor controller of an automobile five-in-one electric pump assembly belongs to the technical field of vehicle chassis and comprises a controller shell, the controller shell is fixed on a shell of a motor through shell bolts, a closed mounting space is formed between the controller shell and the motor shell, an upper PCB (printed circuit board) and a lower PCB are sequentially arranged in the mounting space, and the upper PCB and the lower PCB are arranged in the controller shell. A high-voltage connector and a low-voltage connector are arranged on the controller shell, the high-voltage connector is connected to a high-voltage plug-in in a rapid plug-in mode, high-voltage alternating current is input into the electric pump assembly, and a vent plug is arranged on the controller shell. Through the integrated and optimized design, the occupied space is reduced, the manufacturing cost is reduced, the weight is reduced, the convenient plug-in connection design is adopted, the installation convenience and the assembly economical efficiency are remarkably improved, and the structure is suitable for a vehicle active suspension system.

Description

Technical Field

[0001] The present invention belongs to the technical field of vehicle chassis, and particularly relates to an active suspension system, specifically a motor controller for an integrated five-in-one electric pump assembly. Background Art

[0002] The shock absorption performance of traditional shock absorbers is poor, resulting in average ride comfort. Although semi-active suspensions improve this problem to a certain extent and their damping can be continuously adjusted, they are still inferior to active suspensions in terms of adjustment accuracy and response speed. With the continuous improvement of market requirements for vehicle ride comfort and handling performance, the market share of electronically controlled shock absorbers is gradually increasing. As a better technical solution, active suspensions are gradually becoming the mainstream.

[0003] In an active suspension system, the motor controller is an important part of the electric pump assembly. The electric pump assembly generally includes a motor, a controller, and a hydraulic pump. Existing motor controllers are usually large in size, high in manufacturing cost, heavy in weight, difficult to produce and process, and complex to install. These problems limit the wide application of active suspension systems. Summary of the Invention

[0004] In order to solve the deficiencies of the prior art, the present invention proposes a motor controller for a vehicle five-in-one electric pump assembly to meet the requirements of a high-performance active suspension system.

[0005] The technical problems to be solved by the present invention are achieved through the following technical solutions: A motor controller for a vehicle five-in-one electric pump assembly includes a controller housing. In the present invention, the controller housing is fixed to the housing of the motor through housing bolts, and a sealing glue is applied to the mating surface. A closed installation space is formed between the controller housing and the motor housing. A PCB upper board and a PCB lower board are sequentially arranged in the installation space. A high-voltage connector and a low-voltage connector are provided on the controller housing. The high-voltage connector is connected to a high-voltage mating connector through quick plug-in connection to input high-voltage alternating current to the electric pump assembly. A breather plug is provided on the controller housing.

[0006] In the present invention, the PCB upper board is fixed to the controller housing through upper board bolts, the PCB lower board is fixed to the motor housing through lower board bolts, and the high-voltage plug-in connector is fixed to the controller housing through high-voltage plug-in connector bolts.

[0007] Further, an electrical connection is achieved between the PCB upper board and the controller housing through welding pins.

[0008] In the present invention, the controller includes a temperature and pressure PCB. The temperature and pressure PCB integrates a temperature sensor and a pressure sensor, and is connected to the low-voltage connector through a flexible wire jumper to communicate with the control end through the low-voltage connector, realizing temperature closed-loop control within the electric pump assembly.

[0009] Further, the low-voltage connector is connected to the flying wire harness through a snap-in interface.

[0010] In the present invention, the breather plug is located at the top of the controller housing, and includes a breather window opened in the controller housing and a waterproof breathable membrane embedded in the breather window, for waterproofing and breathing to prevent condensation.

[0011] In the present invention, the controller is longitudinally arranged on the side of the motor.

[0012] A vehicle active suspension system includes a five-in-one electric pump assembly, and the five-in-one electric pump assembly includes two motors, two hydraulic pumps and a motor controller as described above, for adjusting the suspension stiffness and damping in real time.

[0013] Compared with the prior art, the present invention has the following advantages: In this application, the longitudinal integration and compact layout of the controller and the motor are realized through bolt connection, reducing the number of parts used, effectively reducing the space occupied by the electric pump assembly by more than 30%, and greatly reducing the cost; In this application, the modularization of the controller is realized by independently fixing the upper PCB board and the lower PCB board, which is convenient for the maintenance and repair of the controller; In this application, a high-voltage connector is used to connect to the high-voltage connector of the battery through a quick plug-in connection, reducing the installation complexity and effectively improving the assembly efficiency; In this application, the connection between the temperature and pressure sensor and the low-voltage connector is realized by means of a flexible flying wire, avoiding the influence on detection caused by the sensitivity to vibration brought by hard wire connection or rigid connection; The motor controller structure of this application can continuously output sufficient pressure for the shock absorber of the vehicle active suspension system to drive the hydraulic pump to adjust the suspension damping; In this application, waterproof and breathable are effectively realized through the breather plug opened on the controller, avoiding the influence of water droplets caused by condensation on electrical parts. Description of the Drawings

[0014] Figure 1 is a schematic external view of the motor controller of the present invention; Figure 2 is an exploded view of the structure of the motor controller of the present invention.

[0015] In the figure: breather plug 1, high-voltage connector 2, housing bolt 3, upper board bolt 4, high-voltage plug-in bolt 5, controller housing 6, upper PCB board 7, lower PCB board 8, lower board 9, low-voltage connector 10, temperature and pressure PCB 11, high-voltage connector 12. Detailed Embodiments

[0016] The present invention will be further described below in conjunction with the accompanying drawings of the specification and specific preferred embodiments, but the protection scope of the present invention is not limited thereby. Embodiment

[0017] The motor controller of the five-in-one electric pump assembly for an automobile is longitudinally arranged on the side of the motor, and includes a controller housing 6, and a PCB upper board 7 and a PCB lower board arranged in the controller housing 6. The controller housing 6 is fixed to the motor housing by housing bolts 3 arranged on the edge. The PCB upper board 7 is fixed to the controller housing 6 by upper board bolts 4. The PCB lower board is fixed to the motor housing by lower board bolts. The PCB upper board 7 and the controller housing 6 are electrically connected through welding pins.

[0018] A high-voltage connector 12 and a low-voltage connector 10 are arranged on the top of the controller housing 6. The high-voltage connector 12 is located at the top of the controller housing 6 and is connected to the high-voltage pair plug 2 through quick plug-in connection, which is convenient for installation. The high-voltage plug-in is fixed to the controller housing 6 by high-voltage plug-in bolts 5. The low-voltage connector 10 is connected with a temperature and pressure PCB 11 through a flexible wire. The temperature and pressure PCB 11 is integrated with a temperature sensor and a pressure sensor, and is arranged in the electric pump assembly to realize the temperature and pressure monitoring of the electric pump, improving the stability and reliability of the system.

[0019] A breather plug 1 is arranged on the top of the controller housing 6. The breather plug 1 includes a breather window opened on the controller housing 6 and a waterproof breathable membrane embedded in the breather window, avoiding the controller housing 6 from generating condensation and affecting the electrical circuit. Embodiment

[0020] A vehicle active suspension system includes a five-in-one electric pump assembly. The five-in-one electric pump assembly includes two motors, two hydraulic pumps and a motor controller as described in Embodiment 1. The integrated design and longitudinally arranged motor controller reduce the space occupied by the electric pump assembly, and reduce the manufacturing cost and weight.

[0021] In summary, through the integrated and optimized design, the present application reduces the space occupation, reduces the manufacturing cost, reduces the weight, and adopts a convenient plug-in connection design, significantly improving the installation convenience and the economy of the assembly, and is applicable to the vehicle active suspension system.

Claims

1. The motor controller of the five-in-one electric pump assembly for an automobile, including a controller housing, is characterized in that: The controller housing is fixed to the housing of the motor by housing bolts, and the mating surface is coated with sealant. A closed installation space is formed between the controller housing and the motor housing. A PCB upper board and a PCB lower board are sequentially arranged in the installation space. A high-voltage connector and a low-voltage connector are arranged on the controller housing. The high-voltage connector is connected to the high-voltage mating connector through quick plug-in connection. A breather plug is arranged on the controller housing.

2. The motor controller according to claim 1, characterized in that: The PCB upper board is fixed to the controller housing by upper board bolts, the PCB lower board is fixed to the motor housing by lower board bolts, and the high-voltage plug-in connector is fixed to the controller housing by high-voltage plug-in connector bolts.

3. The motor controller according to claim 1, characterized in that: The controller includes a temperature and pressure PCB, which integrates a temperature sensor and a pressure sensor, and is connected to the low-voltage connector through a flexible wire jumper, and communicates with the control end through the low-voltage connector.

4. The motor controller according to claim 2, wherein: The low-voltage connector is connected to the jumper wire harness through a snap-in interface.

5. The motor controller according to claim 1, characterized in that: The breather plug is located at the top of the controller housing and includes a breather window opened in the controller housing and a waterproof breathable membrane embedded in the breather window.

6. The motor controller according to claim 1, characterized in that: The controller is longitudinally arranged on the side of the motor.

7. An active vehicle suspension system, characterized in that: It includes a five-in-one electric pump assembly, and the five-in-one electric pump assembly includes two motors, two hydraulic pumps and a motor controller according to any one of claims 1-6.

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