Two-stage piston air suspension compressor intelligently controlled by brushless motor

Abstract

The brushless motor intelligent control two-stage piston air suspension compressor comprises a compressor body, a first-stage piston and a second-stage piston are arranged in a working cavity of the compressor body in a sliding mode, a first air channel communicating with a first-stage compression cavity and a second-stage compression cavity is formed in the compressor body, the first-stage piston is provided with an air inlet hole communicating with the first-stage compression cavity, and the second-stage piston is provided with an air outlet hole communicating with the second-stage compression cavity; a second air hole communicating with the second-stage compression cavity is formed in the side face of the other side of the compressor body. The first end of the brushless motor is installed on the side face of one side of the compressor body, an air inlet is formed in the second end of the brushless motor, and an output shaft of the brushless motor rotatably penetrates through the first air hole and is in transmission connection with the piston frame to drive the first-stage piston and the second-stage piston to reciprocate up and down; the controller is installed in the second end, and the controller is in signal connection with the brushless motor; and the drying cylinder is used for drying the compressed high-pressure gas. The problems that a piston leather cup is easy to damage and a commutator is easy to ablate due to accumulation of carbon powder of an electric brush in an air path of an existing air suspension compressor are solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of compressor, in particular to a two-stage piston air suspension compressor with intelligent control of brushless motor. BACKGROUND

[0002] With the continuous improvement of living standards, people's requirements for cars are also getting higher and higher, especially the comfort, operability and quietness of the automobile chassis suspension. The automobile intelligent suspension-air suspension compressor, which is comfortable, light, low noise, energy-saving, efficient and dry running, is favored by the market. Air suspension compressor. The air suspension compressor is the core power component of the air suspension system, responsible for providing compressed air to the air spring to adjust the height and damping performance of the vehicle body. The existing air suspension compressor has the problems of carbon powder accumulation in the air path, easy damage of the piston leather bowl and easy ablation of the commutator. SUMMARY

[0003] In order to overcome the defects of the prior art, a two-stage piston air suspension compressor with intelligent control of brushless motor is provided to solve the problems of carbon powder accumulation in the air path of the existing air suspension compressor, easy damage of the piston leather bowl and easy ablation of the commutator.

[0004] In order to achieve the above-mentioned purpose, a two-stage piston air suspension compressor with intelligent control of brushless motor is provided, comprising: A compressor body, a vertical working cavity is formed on one side of the compressor body, a first air hole is formed on the side of one side of the compressor body and communicated with the working cavity, a first-stage piston and a second-stage piston are slidably arranged in the working cavity, a first-stage leather bowl is arranged on the first-stage piston, a second-stage leather bowl is arranged on the second-stage piston, a first-stage compression chamber is formed between the first-stage piston and the bottom of the working cavity, a second-stage compression chamber is formed between the second-stage piston and the top of the working cavity, a first air passage is formed in the compressor body and communicated with the first-stage compression chamber and the second-stage compression chamber, a piston holder is connected between the first-stage piston and the second-stage piston, an air inlet hole is formed in the first-stage compression chamber, and a second air hole is formed on the side of the other side of the compressor body and communicated with the second-stage compression chamber; A brushless motor, the brushless motor has opposite first and second ends, the first end is installed on the side of one side of the compressor body, the second end is formed with an air inlet, the output shaft of the brushless motor is rotatably arranged in the first air hole, and the output shaft is drivingly connected to the piston holder through a transmission structure to drive the first-stage piston and the second-stage piston to reciprocate up and down; A controller is installed in the second end, and the controller is signal-connected to the brushless motor; A drying cylinder is installed on the other side of the compressor body, a containing hole is formed in the drying cylinder, one end of the containing hole is connected to the second air hole, a drying agent is installed in the containing hole, a second air passage is formed in the compressor body and connected to the other end of the containing hole, and the second air passage is connected to the automobile air cylinder.

[0005] Further, a third air passage connected to the automobile air cylinder and a fourth air passage connected to the other end of the containing hole are formed in the compressor body, one end of the fourth air passage is connected to the outside of the compressor body, an electromagnetic valve is installed in the third air passage and the fourth air passage, and the electromagnetic valve is signal connected to the controller.

[0006] Further, the controller is a circuit board, and the circuit board is provided with a flow guide hole.

[0007] Further, the piston frame includes connecting plates, the connecting plates are oppositely extended from the opposite sides of the first-stage piston and the second-stage piston, the two connecting plates are abutted to each other, one end of one connecting plate is pivotally connected to the middle part of the other connecting plate, the middle part of the one connecting plate and one end of the other connecting plate are respectively provided with insertion holes, the transmission structure is an eccentric shaft, the output shaft is eccentrically connected to the eccentric shaft, and the eccentric shaft is movably inserted into the insertion holes of the two connecting plates.

[0008] Further, the inner hole of the air inlet hole is elastically installed with a first-stage air inlet valve plate.

[0009] Further, the containing hole is in a U shape.

[0010] Further, the two ends of the containing hole are respectively provided with supports, one side of the support facing the inside of the containing hole is paved with a filter screen, and the filter screen and the other side of the compressor body are installed with an elastic supporting piece.

[0011] Further, the elastic piece is a spiral spring.

[0012] Further, the drying agent includes 80% of silicon dioxide and 20% of aluminum oxide.

[0013] The two-stage piston air suspension compressor of the brushless motor intelligent control has the advantages that the controller of the two-stage piston air suspension compressor of the brushless motor intelligent control can intelligently control the soft start, inflation speed and self-protection of the brushless motor according to the inflation load in a closed loop mode, the gas circuit of the two-stage piston air suspension compressor of the brushless motor intelligent control is designed to have no gas backflow and high inflation efficiency, the brushless compressor of the two-stage piston air suspension compressor of the brushless motor intelligent control has a long service life, there is no carbon powder accumulation in the gas circuit, and the piston cup is not damaged, thereby prolonging the service life of the compressor. BRIEF DESCRIPTION OF DRAWINGS

[0014] Other features, objects, and advantages of the application will become more apparent from the following detailed description of non-limiting embodiments when read in conjunction with the accompanying drawings: Figure 1 Structure diagram of two-stage piston air suspension compressor with brushless motor intelligent control.

[0015] Figure 2 Structure diagram of two-stage piston air suspension compressor with brushless motor intelligent control.

[0016] Figure 3 Structure diagram of two-stage piston air suspension compressor with brushless motor intelligent control.

[0017] Figure 4 Structure diagram of two-stage piston air suspension compressor with brushless motor intelligent control.

[0018] Figure 5 Structure diagram of solenoid valve when not powered.

[0019] Figure 6 Structure diagram of solenoid valve when powered.

[0020] Figure 7 Structure diagram of drying cylinder.

[0021] Figure 8 Structure diagram of two-stage piston air suspension compressor with brushless motor intelligent control.

[0022] LIST OF REFERENCE NUMERALS Compressor body 1, primary piston 11, primary intake valve plate 111, secondary piston 12, piston holder 13, connecting plate 131, pivot 132; Brushless motor 2, output shaft 21, transmission structure 22, casing 23, stator 24; Controller 3; Drying cylinder 4, drying agent 41, support 42, filter screen 43, elastic support 44; Solenoid valve 5, mechanical reversing valve assembly 51. DETAILED DESCRIPTION

[0023] The application will be further described in conjunction with the drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the related application, and are not a limitation of the application. In addition, it should be noted that only the parts related to the application are shown in the drawings for ease of description.

[0024] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict. The present application will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0025] Referring to Figures 1 to 7 The present application provides a two-stage piston air suspension compressor with intelligent brushless motor control, comprising a compressor body 1, a brushless motor 2, a controller 3 and a drying cylinder 4.

[0026] A working chamber is formed on one side of the compressor body 1. A first air hole is formed on the side surface of the one side of the compressor body 1 and is communicated with the working chamber. A first-stage piston 11 and a second-stage piston 12 are slidably arranged in the working chamber. A first-stage leather cup is arranged on the outside of the first-stage piston. A second-stage leather cup is arranged on the outside of the second-stage piston. A first-stage compression chamber is formed between the first-stage piston 11 and the bottom of the working chamber. A second-stage compression chamber is formed between the second-stage piston 12 and the top of the working chamber. An inter-stage chamber is formed between the first-stage piston and the second-stage piston. A first air passage is formed in the compressor body 1 and is communicated with the first-stage compression chamber and the second-stage compression chamber. In this embodiment, the first air passage is formed in the compressor cylinder head. A piston frame 13 is connected between the first-stage piston 11 and the second-stage piston 12. The first-stage piston 11 is provided with an air inlet hole communicated with the first-stage compression chamber. A second air hole is formed on the side surface of the other side of the compressor body 1 and is communicated with the second-stage compression chamber.

[0027] Referring to Figure 2 and Figure 3 The working chamber is arranged on the right side of the compressor body. Various air passages are formed in the left side of the compressor body. The first-stage piston and the second-stage piston can slide in the working chamber in the vertical direction. When the first-stage piston moves downward, the air in the first-stage compression chamber is compressed; when the second-stage piston moves upward, the air in the second-stage compression chamber is compressed. The size of the first-stage piston is larger than that of the second-stage piston.

[0028] The brushless motor 2 comprises a housing 23, a stator 24, a rotor and other components. The housing is cylindrical. The housing is arranged in the horizontal direction. The brushless motor 2 has opposite first and second ends. The first end of the brushless motor 2 is mounted on the side surface of the one side of the compressor body 1. The second end of the brushless motor 2 is formed with an air inlet. The output shaft 21 of the brushless motor 2 is rotatably arranged in the first air hole. The output shaft 21 of the brushless motor 2 is drivingly connected to the piston frame 13 through a transmission structure 22 to drive the first-stage piston and the second-stage piston to move up and down.

[0029] The controller 3 is mounted in the second end of the brushless motor 2. The controller 3 is signal connected to the brushless motor 2. In this embodiment, referring to Figure 2The controller 3 is a circuit board, and the circuit board is provided with a flow guide hole. A gap is formed between the circuit board and the inner wall of the brushless motor. The inter-stage cavity in the compressor body is connected to the inside of the brushless motor.

[0030] The drying cylinder 4 is installed on the other side of the compressor body 1. The drying cylinder 4 is formed with a receiving channel. One end of the receiving channel is connected to the second air hole. The drying agent 41 is installed in the receiving channel. The second air channel is formed in the compressor body 1 and connected to the other end of the receiving channel. The second air channel pipeline is connected with the automobile air cylinder.

[0031] In this embodiment, the third air channel and the fourth air channel are formed in the compressor body 1. One end of the third air channel is connected to the other end of the receiving channel. The other end of the third air channel is connected to the automobile air cylinder. One end of the fourth air channel is connected to the receiving channel. The other end of the fourth air channel, which is away from the receiving channel, is connected to the outside of the compressor body 1. The third air channel and the fourth air channel are installed with the electromagnetic valve 5. The controller 3 is signal connected with the electromagnetic valve 5. Specifically, the third air channel and the fourth air channel are installed with the mechanical reversing valve, and the controller controls the mechanical reversing valve to realize reversing exhaust through the electromagnetic valve.

[0032] Continuing to refer to Figure 2 and Figure 3 The piston frame 13 includes a connecting plate 131 and a pivot 132. The opposite sides of the first-stage piston 11 and the second-stage piston 12 are formed with the connecting plate 131. The two connecting plates 131 are in close contact with each other. One end of one connecting plate 131 is pivotally connected to the middle part of the other connecting plate 131 through the pivot 132. The middle part of one connecting plate 131 and one end of the other connecting plate 131 are respectively provided with a socket. The end of the second-stage piston is provided with a larger socket. The transmission structure 22 is an eccentric shaft. The output shaft 21 is eccentrically connected to the eccentric shaft. The eccentric shaft is movably inserted into the sockets of the two connecting plates 131.

[0033] In this embodiment, the inner hole of the intake hole of the first-stage piston is elastically installed with the first-stage intake valve plate 111. Correspondingly, the two ends of the first air channel are installed with the first-stage exhaust valve plate, the second-stage intake valve plate, and the second air hole is installed with the second-stage exhaust valve plate, so as to realize the function of the one-way valve.

[0034] Referring to Figure 4 and Figure 7 The receiving channel in the drying cylinder in this embodiment is in a U shape.

[0035] The two ends of the receiving channel are respectively provided with a bracket 42. The side of the bracket 42, which faces the inside of the receiving channel, is paved with a filter screen 43. The filter screen 43 and the other side of the compressor body 1 are installed with an elastic support 44.

[0036] The elastic member is a spiral spring.

[0037] The drying agent 41 comprises 80% of silicon dioxide and 20% of aluminum oxide.

[0038] Referring to Figure 8 As shown in the figure, the internal structure of the two-stage piston air suspension compressor of the brushless motor intelligent control is formed with an inflation gas path, a regeneration gas path and a control gas path.

[0039] The specific structure of the inflation gas path is as follows: In this embodiment, in combination with Figure 4 When the two-stage piston air suspension compressor of the brushless motor intelligent control inflates the automobile gas tank, the brushless motor drives the piston frame to realize the linear reciprocating motion of the first-stage piston and the second-stage piston, the air outside the brushless motor is sucked in through the air inlet (01), the sucked air passes through the flow guide hole on the controller circuit board, the stator of the motor (02) and the rotor core air gap hole, and finally enters the working cavity through the first gas hole. The inside of the first-stage piston is provided with a first-stage air inlet valve plate, and the air in the working cavity is sucked into the first-stage compression cavity (04) through the air inlet hole. After being compressed in the first-stage compression cavity, the air enters the second-stage compression cavity through the first gas channel (05, 06, 07, 08). After being compressed in the second-stage compression cavity, the air is discharged into the containing hole (09, 10) through the second gas hole. After being dried in the containing hole, the compressed air is input into the automobile gas tank through the second gas channel.

[0040] The above-mentioned inflation is directly sucked from the air, and after passing through the drying agent, the moisture in the air is removed. When a certain volume of air is sucked, the drying agent in the drying cylinder is saturated after absorbing enough moisture and has no drying capacity. At this time, it is necessary to discharge the air (high-pressure gas) from the automobile gas cylinder on the vehicle to reversely charge the moisture in the drying agent into the atmosphere. At this time, the regeneration of the drying agent is completed.

[0041] The specific structure of the regeneration gas path is as follows: Referring to Figure 5 and Figure 6 As shown in the figure, after the solenoid valve is energized, the magnetic force generated by the coil in the solenoid valve overcomes the spring force to attract the moving iron core in the valve, the introduced high-pressure gas pushes open the mechanical valve, and the third gas channel and the fourth gas channel are opened (when the solenoid valve is de-energized, the moving iron core in the solenoid valve returns to the original position under the action of the spring force, and the third gas channel and the fourth gas channel are closed, the exhaust is closed, and the inflation gas path is prepared). At this time, the high-pressure gas in the automobile gas tank enters the containing hole through the third gas channel, reversely takes away the moisture in the drying agent, and is discharged into the atmosphere outside the compressor body through the fourth gas channel.

[0042] The exhaust and regeneration process of the two-stage piston air suspension compressor of the brushless motor intelligent control is as follows: When the brushless motor intelligent control two-stage piston air suspension compressor of the present application needs to exhaust or regenerate, the control controls the brushless motor to stop working, and controls the electromagnetic valve to open. Referring to Figure 8 At this time, the rear-end gas (i.e. the gas in the automobile gas tank and the automobile air spring) passes through the third gas passage E and the fourth gas passage F, pushes the pneumatic valve in the fourth gas passage to act, at this time, the regeneration gas path D reverses through the drying cylinder, completes regeneration, and then is discharged from the gas passage C, 1.1 port, and finally is discharged into the inter-stage cavity. In this embodiment, a pressure sensor is installed in the automobile gas tank to collect the pressure value in the automobile gas tank. The exhaust and regeneration end process of the brushless motor intelligent control two-stage piston air suspension compressor of the present application: When the pressure of the rear-end system (i.e. the automobile gas tank) is lower than 12 bar (different host manufacturers, the set pressure may be different), the pressure sensor outputs a signal to the ECU (i.e. the controller). The controller controls the electromagnetic valve to close, and then the third gas passage and the fourth gas passage are disconnected by the passive core again. The fourth gas passage F is communicated with the outside of the compressor, the fourth gas passage gas is discharged, the pneumatic valve is returned to the original position, and the compressor body returns to the charging process.

[0043] When the brushless motor intelligent control two-stage piston air suspension compressor of the present application needs to exhaust or regenerate, the controller controls the brushless motor to stop working, and controls the electromagnetic valve to open, at this time, the gas path reverses through the drying cylinder to complete regeneration and is discharged from the C gas passage, 1.1 port.

[0044] The control gas path is constituted as follows: Continuing to refer to Figure 8 The automobile gas tank is provided with a pressure sensor, and the controller controls the on-off of the brushless motor and the electromagnetic valve of the air compressor. At the same time, the electromagnetic valve and the mechanical valve system of the compressor have a safety valve function (i.e. when the system reaches a certain pressure, the compressor system will safely release pressure to protect the system from being damaged). When the system pressure reaches between 20-25 bar, the exhaust system safety pressure relief exhaust is triggered. The power supply of the controller is DC 13V. The HALL probe 2 on the PCBA detects the radial angle of the pair of magnetic rings NS (the magnetic ring is hard connected with the rotor shaft), and the controller PID algorithm controls the MOS tube to connect the stator UVW three-phase winding commutation to generate electromagnetic force to drive the inner rotating permanent magnet, thereby completing the rotation and stop of the brushless motor.

[0045] The output of the brushless motor is hard connected with the eccentric shaft to drive the piston to make linear reciprocating motion to compress the gas. The gas is sucked from the air inlet nozzle at the second end of the brushless motor, and then flows through the PCBA hole, the motor stator-rotor core air gap hole, the working cavity, the first-stage air inlet valve plate, the first-stage air outlet valve plate, the second-stage air inlet valve plate, the second-stage compression cavity, the second-stage air outlet valve plate, the drying cylinder, the one-way valve, and the air outlet connector of the compressor body, thereby completing the charging function.

[0046] The controller of the two-stage piston air suspension compressor of the brushless motor intelligent control according to the air charging load, software intelligent closed-loop control of the brushless motor soft start, air charging speed, self-protection. The gas circuit of the two-stage piston air suspension compressor of the brushless motor intelligent control is designed without gas backflow, and the air charging efficiency is high. The two-stage piston air suspension compressor of the brushless motor intelligent control has a long service life of the brushless compressor, and there is no carbon powder accumulation of the electric brush in the gas circuit, thereby avoiding damage to the piston cup and prolonging the service life of the compressor.

[0047] The above description is merely preferred embodiments of the present application and a description of the principles of the technology used. It should be understood by those skilled in the art that the scope of the application involved in the present application is not limited to the technical solutions formed by the specific combinations of the above technical features, and also covers other technical solutions formed by any combination of the above technical features or equivalent features without departing from the inventive concept. For example, the above features are replaced with each other to form a technical solution with similar functions disclosed in the present application (but not limited to).

Claims

1. A two-stage piston air suspension compressor with intelligent control of brushless electric motor, characterized by, The utility model provides a kind of compressor and automobile air cylinder, comprising: Compressor body, the side of the compressor body is formed with vertically arranged working chamber, the side of the compressor body is opened with first gas hole communicated with the working chamber, the working chamber is slidably provided with primary piston and secondary piston, the primary piston is provided with primary leather cup, the secondary piston is provided with secondary leather cup, the primary piston and the bottom of the working chamber form primary compression chamber, the secondary piston and the top of the working chamber form secondary compression chamber, the compressor body is formed with first air duct communicated with the primary compression chamber and the secondary compression chamber, the primary piston and the secondary piston are connected with piston holder, the primary piston is opened with intake hole communicated with the primary compression chamber, the side of the other side of the compressor body is opened with second gas hole communicated with the secondary compression chamber; Brushless motor, the brushless motor has opposite first end and second end, the first end is installed on the side of the compressor body, the second end is formed with air inlet, the output shaft of the brushless motor is rotatably arranged in the first gas hole, the output shaft is drivingly connected to the piston holder through transmission structure to drive the primary piston and secondary piston reciprocating motion up and down; Controller, installed in the second end, the controller is signal connected to the brushless motor; Drying cylinder, installed on the other side of the compressor body, the drying cylinder is formed with accommodating channel, one end of the accommodating channel is connected to the second gas hole, the drying agent is installed in the accommodating channel, the second air duct connected to the other end of the accommodating channel is formed in the compressor body, and the automobile air cylinder is connected to the second air duct pipeline.

2. The two-stage piston air suspension compressor with intelligent brushless motor control of claim 1, wherein, Third air duct and fourth air duct communicated with the other end of the accommodating channel are formed in the compressor body, the third air duct is connected to the automobile air cylinder, the fourth air duct is connected to the outside of the compressor body, the third air duct and the fourth air duct are installed with electromagnetic valve, and the electromagnetic valve is signal connected with the controller.

3. The two-stage piston air suspension compressor with intelligent brushless motor control of claim 1, wherein, The controller is a circuit board, and the circuit board is opened with flow guide hole.

4. The two-stage piston air suspension compressor with intelligent brushless motor control of claim 1, wherein, The piston holder includes connecting plate, the opposite sides of the primary piston and the secondary piston are oppositely extended to form the connecting plate, the two connecting plates are attached to each other, one end of one connecting plate is pivotally connected to the middle part of the other connecting plate, the middle part of the one connecting plate and one end of the other connecting plate are respectively opened with insertion hole, the transmission structure is eccentric shaft, the output shaft is eccentrically connected to the eccentric shaft, and the eccentric shaft is movably inserted into the insertion holes of the two connecting plates.

5. The intelligent brushless motor controlled two-stage piston air suspension compressor of claim 1, wherein, The inner hole of the intake hole is elastically installed with primary air valve plate.

6. The two-stage piston air suspension compressor with intelligent brushless motor control of claim 1, wherein, The accommodating channel is U-shaped.

7. The two-stage piston air suspension compressor with intelligent brushless motor control of claim 6, wherein, Both ends of the accommodating channel are respectively supported by bracket, the side of the bracket facing the inside of the accommodating channel is paved with filter screen, and the filter screen and the other side of the compressor body are installed with elastic supporting piece.

8. The two-stage piston air suspension compressor of claim 6, wherein, The elastic member is a spiral spring.

9. The two-stage, air suspension, piston compressor with intelligent brushless motor control of claim 6, wherein, The drying agent includes 80% of silicon dioxide and 20% of aluminum oxide.

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