Integrated power unit

Abstract

The invention discloses an integrated power unit which comprises a shell, an oil storage tank, a motor assembly and a pump core assembly. The shell is of an integrally-formed structure, and a valve mounting hole, a pump body mounting cavity and an internal oil way are formed in the shell in a casting mode. A reversing valve assembly is arranged in the valve mounting hole, a first one-way valve structure and a second one-way valve structure which are arranged on a first oil channel set and a second oil channel set which are isolated from each other and staggered in space are integrated in the internal oil way, and the first one-way valve structure and the second one-way valve structure are in fluid communication with the circumferential sealing face of the reversing valve assembly. By means of the collaborative design of the integrated shell and the built-in double one-way valves, the technical problems that a traditional split type combined oil pump is large in oil leakage point number, complex in oil way, large in size and poor in reliability are solved, and the beneficial effects of being compact in structure, light in weight, low in cost and high in reliability are achieved.

Description

Technical Field

[0001] This invention relates to the field of hydraulic lifting technology, and more particularly to an integrated power unit. Background Technology

[0002] In new energy heavy-duty trucks, the hydraulic tilting system for the cab remains an indispensable feature due to its comfort, with the electric combined oil pump as its core component. Currently, the combined oil pumps used in the market generally employ a separate design for the pump base, pump body, and valve seat, connected by external oil pipes. This separate layout has inherent drawbacks: firstly, the numerous connection points between components increase the potential risk of oil leakage, reducing reliability; secondly, the complex external oil circuitry makes the overall structure less compact, occupying a large space and causing inconvenience for vehicle layout and maintenance; finally, the separate structure has a large number of parts, making processing and assembly procedures cumbersome and production costs high. Therefore, there is an urgent need for a power unit solution with a highly integrated structure that fundamentally eliminates the risk of leakage and reduces manufacturing costs. Summary of the Invention

[0003] To address the problems of multiple oil leakage points, complex oil circuits, large size, and high cost of existing split-type combined oil pumps, this invention proposes an integrated power unit.

[0004] The specific technical solution is as follows: An integrated power unit includes: a housing, an oil storage tank disposed on the housing, a motor assembly, and a pump core assembly;

[0005] The housing is a one-piece molded structure. The housing has valve mounting holes, pump body mounting cavities, and internal oil passages that connect the oil storage tank, pump core assembly, and external actuators.

[0006] A reversing valve assembly is rotatably disposed within the valve mounting hole;

[0007] The internal oil circuit integrates a first check valve structure and a second check valve structure.

[0008] The first and second one-way valve structures are respectively disposed inside the housing on a first oil passage group and a second oil passage group that are isolated from each other and spatially offset, and both are in fluid communication with the circumferential sealing surface of the reversing valve assembly. This unit fundamentally eliminates the risk of oil leakage at the connection between the pump body, valve seat and oil passage, significantly improving the sealing reliability and service life of the unit; it simplifies the external oil pipe connection, making the overall structure extremely compact and significantly reducing the volume, which is convenient for layout and installation in the narrow space of the vehicle; it reduces the number of parts and subsequent processing and assembly steps, effectively reducing production and manufacturing costs.

[0009] Furthermore, the first check valve structure is disposed in the first oil passage group, which is connected to the pressure oil outlet of the pump core assembly; the second check valve structure is disposed in the second oil passage group, which is connected to the oil outlet of the plunger assembly. By disposing of the two check valve structures in independent oil passage groups corresponding to the electric pump and the manual plunger, physical isolation and functional independence of the electric and manual oil supply circuits are achieved, avoiding hydraulic interference between them and ensuring the stability and reliability of operation in both modes.

[0010] Furthermore, the first check valve structure includes a third check valve ball, a spring, and a valve seat assembly installed in the first oil passage assembly; the second check valve structure includes a first check valve ball, a spring, and a valve seat assembly installed in the second oil passage assembly. This built-in design avoids the complexity and potential leakage associated with external check valves.

[0011] Furthermore, the housing is also cast with a plunger hole, a plunger assembly is disposed in the plunger hole, and a bottom valve structure is provided at the bottom of the plunger hole. The bottom valve structure includes a fourth one-way valve ball and a ball plug located below the fourth one-way valve ball.

[0012] Furthermore, the ball plug is fixed to the bottom of the plunger hole, and the inner diameter of the ball plug is smaller than the diameter of the fourth one-way valve ball. By limiting the inner diameter of the ball plug to be smaller than the diameter of the one-way valve ball, it is possible to effectively prevent the one-way valve ball from being sucked into the plunger hole during operation, thereby completely avoiding the risk of plunger jamming and greatly improving the operational safety and component durability in manual mode.

[0013] Furthermore, the plunger assembly is linked to a rocker arm shaft assembly mounted on the housing, and the rotational motion of the rocker arm shaft assembly can be converted into linear motion of the plunger assembly within the plunger bore. Through the linkage design of the rocker arm shaft assembly and the plunger assembly, rotational motion is efficiently converted into linear reciprocating motion.

[0014] Furthermore, the power unit is configured as follows:

[0015] In electric mode, the pump core assembly is driven by the motor assembly to generate hydraulic oil flow, which flows through the first check valve structure.

[0016] In manual mode, the rocker arm shaft assembly drives the plunger assembly to generate hydraulic oil flow, which passes through the second one-way valve structure. By configuring both electric and manual operating modes and clearly defining their oil circuit paths, the cab can still be raised and lowered manually in emergency situations such as power failure or motor malfunction, enhancing the product's emergency response capabilities and practicality.

[0017] Furthermore, the reversing valve assembly has multiple circumferential seals on its outer circumference, which form a sliding seal with the inner wall of the valve mounting hole; one end of the reversing valve assembly is connected to an exposed reversing handle assembly. The reversing valve assembly employs a circumferential seal and handle design, ensuring the reliability of the valve core rotation seal, while also making operation simple and intuitive (e.g., 90° rotation switching), resulting in a good user experience.

[0018] Furthermore, the housing is provided with ports A and B for connection to external actuators. Ports A and B form a circulation loop with the oil reservoir through the internal oil circuit and reversing valve assembly, wherein port B is in fluid communication with the return oil passage. By setting standardized ports A and B and forming a circulation loop with the internal oil circuit, this unit can be quickly connected to external actuators as a complete modular component, simplifying the assembly process of the vehicle's hydraulic system.

[0019] Furthermore, the housing is cast from aluminum alloy.

[0020] The above technical solution has the following advantages or technical effects:

[0021] 1. This invention adopts an integrally molded housing and integrates internal oil circuits and a dual one-way valve structure, achieving a high degree of integration of the power unit and completely solving the inherent problems of oil leakage, large size and high cost of traditional split-type oil pumps.

[0022] 2. This invention constructs a highly reliable manual backup system by setting up mutually isolated electric and manual dual oil circuits and an anti-jamming bottom valve structure, ensuring that the power unit does not fail under extreme conditions.

[0023] 3. Through modular interfaces and standardized internal component design, this invention enables the product to have excellent versatility and scalability, and can flexibly adapt to the needs of different vehicle models and hydraulic systems (such as differential / non-differential). Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall shape of the present invention;

[0025] Figure 2 This is an exploded view of the assembly of the present invention;

[0026] Figure 3 This is a schematic diagram of the outer shell of the present invention;

[0027] Figure 4 This is a cross-sectional schematic diagram of the oil passage in the assembly housing of the present invention;

[0028] Figure 5 This is a schematic diagram of the linkage between the rocker arm shaft and the plunger assembly of the present invention;

[0029] Figure 6 This is a schematic diagram of the reversing valve of the present invention;

[0030] Figure 7 This is a side cross-sectional view of the oil passage of the reversing valve of the present invention;

[0031] Figure 8 This is a schematic cross-sectional view of the oil passage of the reversing valve of the present invention.

[0032] Figure 9 This is a schematic diagram of the assembly of the present invention without the oil tank;

[0033] Figure 10 This is a schematic diagram of the hydraulic principle of the present invention. Detailed Implementation

[0034] To make the technical solution of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0035] like Figures 1 to 10 As shown, an integrated power unit is mainly composed of a housing 6 and an oil tank 1 installed on the housing 6. The structure is compact and greatly facilitates its arrangement in the narrow space around the cab of a commercial heavy truck.

[0036] like Figure 1 and Figure 2 As shown, the power unit mainly includes the following components: oil tank 1, motor assembly 2, wiring harness with relay assembly 3, oil nozzle connector assembly 4, pump core assembly 5, housing 6, limit plate 7, aluminum plate 8, reversing handle rod assembly 9, bracket 10, oil tank gasket 12, vent valve assembly 13, plunger assembly 14, rocker arm shaft assembly 15.

[0037] like Figure 3 As shown, the housing 6 is a one-piece stepped structure, cast from aluminum alloy using a mold. This one-piece design fundamentally eliminates the multiple assembly joints caused by traditional separate pump seats, valve seats, and external connecting pipelines, thus completely solving the risk of oil leakage. At the same time, this structure reduces the number of parts, improves production efficiency and product consistency, and achieves overall weight reduction.

[0038] like Figure 4As shown, the housing 6 is directly cast internally with all necessary mounting cavities and flow channels, including: a valve mounting hole 66 for mounting the reversing valve assembly 21, a pump body mounting cavity for mounting the pump core assembly 5, a plunger hole 55 for accommodating the plunger assembly 14, and a complex internal oil passage connecting the oil reservoir 1, the pump core assembly 5, and external actuators. These oil passages include oil passages a1, a2 (as return oil passages), a3, a4, a5, a6, a7, a8, a21 (pressure port), and a22 (suction port). Process holes (such as...) are located around each oil passage. Figure 4 The C, D, and E holes and the oil hole F are reliably sealed by components such as the screw plug 21 and the dust cover 28. The housing 6 is also provided with an oil return hole 144, which is used in the hydraulic circuit to guide the return oil from the actuator to the vicinity of the oil suction port a22 of the pump core assembly 5.

[0039] To achieve compact and reliable oil circuit control, this embodiment integrates two independent and spatially misaligned one-way valve structures in the internal oil circuit of the housing 6.

[0040] The first one-way valve structure is installed in the first oil passage group (mainly including oil passages a1 and a3), which is connected to the pressure oil outlet a21 of the pump core assembly 5. Specifically, as shown... Figure 4 As shown, a third check valve ball 30, spring 25, copper pad 27 and spring seat 26 are installed at the upper end of oil passage a3 to achieve the one-way shut-off function.

[0041] The second one-way valve structure is installed in the second oil passage group (mainly including oil passages a5 and a7), which is connected to the oil outlet of the manual plunger assembly 14. Specifically, the first one-way valve ball 24, spring 25, copper pad 27 and spring seat 26 are installed at the upper end of oil passage a5, which together realize the one-way shut-off function.

[0042] The design of integrating the dual check valve structure into an integrated housing and placing them in different oil passage groups replaces the complex structure of integrating check valves inside the directional valve in the traditional solution. This not only simplifies the design of the directional valve assembly 21, making it shorter and easier to process, but also makes the oil circuit system of the entire power unit more compact through optimized spatial layout, and significantly reduces the risk of system failure.

[0043] like Figure 2 , Figure 4 , Figure 5 and Figure 9 As shown, the housing 6 has a plunger hole 55 cast therein, in which the plunger assembly 14 is housed. A bottom valve structure is provided at the bottom of the plunger hole 55, consisting of a fourth one-way valve ball 23 and a ball plug 22 located directly below it.

[0044] The ball plug 22 is fixed to the bottom end of the plunger hole 55 by press-fitting or welding. The inner diameter of the ball plug 22 is manufactured to be smaller than the diameter of the fourth check valve ball 23. When the plunger assembly 14 moves upward, the hydraulic oil can push open the fourth check valve ball 23 to complete the oil suction; while when the plunger assembly 14 moves downward, the ball is restricted to return to its original position above the ball plug 22, and cannot physically enter the internal cavity of the plunger hole 55, thus completely avoiding the risk of collision and jamming with the reciprocating plunger assembly 14, and greatly improving the reliability and durability of the manual mode.

[0045] like Figure 5 and Figure 9 As shown, the plunger assembly 14 and the rocker arm shaft assembly 15 mounted on the housing 6 are mechanically linked. By turning the rocker arm shaft assembly 15, the operator can convert its external rotational motion into the linear reciprocating motion of the plunger assembly 14 within the plunger bore 55, thereby achieving manual oil pumping.

[0046] like Figure 4 , Figure 6 , Figure 7 , Figure 8 and Figure 9 As shown, the directional valve assembly 21 is rotatably mounted within the valve mounting hole 66 of the housing. Multiple circumferential seals (e.g., sealing sleeves 141, 142, 143, each containing a first O-ring seal 41) are provided on the outer circumference of the directional valve assembly 21. These seals form a dynamic sliding seal with the inner wall of the valve mounting hole 66. One end of the directional valve assembly 21 is axially positioned and sealed by a retaining ring 43 and a second O-ring seal 44, while the other end is connected to an exposed directional handle assembly 9. By driving the directional handle assembly 9 to rotate 90°, the communication relationship between the internal flow channel of the directional valve assembly 21 and the oil passages (a1, a2, a3, a4) on the housing can be changed, thereby controlling the lifting and lowering actions of the actuator. The directional valve assembly 21, through its sealing sleeves 141, 142, 143, can block or connect the corresponding oil passages as needed.

[0047] like Figure 10 As shown, the complete hydraulic circuit of the power unit includes: an electric oil supply path formed by the pump core assembly 5 driven by the motor assembly 2; a manual oil supply path formed by the plunger assembly 14 driven by the rocker arm shaft assembly 15; the position and function of the first check valve structure and the second check valve structure in the oil circuit; the working principle of the directional valve assembly 21 controlling the oil circuit switching to realize the lifting cylinder (actuator) rising and falling; and the return oil path returning to the oil storage tank 1 via port B and return oil passage a2.

[0048] To ensure complete system functionality, the following auxiliary structures are also included: Filter screen 29 is installed inside ports A and B to filter impurities in the hydraulic oil; vent valve assembly 13 is installed on the oil reservoir 1 to remove air accumulated in the hydraulic system; limit plate 7 is mounted on housing 6 via aluminum plate 8 for positioning and support during vehicle assembly; bracket 10 secures the entire power unit to the vehicle frame; oil tank gasket 12 ensures a seal between oil reservoir 1 and housing 6; and nozzle connector assembly 4 connects external oil pipes to achieve hydraulic connection between ports A and B and the actuators.

[0049] The work process is as follows:

[0050] Electric lifting mode: Move the reversing handle assembly 9 to the lifting position and connect the power. The motor assembly 2 drives the pump core assembly 5 to work. Hydraulic oil is drawn from the oil tank 1 through oil passages a8 and a22, pressurized, and output from a21, opening the third one-way valve ball 30. The oil is then output from port A through oil passages a1, a3, and a4, pushing the lifting cylinder upward. The return oil flows from port B through return oil passage a2 and return oil hole 144 into the bottom of the pump core assembly 5, and then flows back to the oil tank 1 through the suction port a22 and oil passage a8, forming a cycle.

[0051] Manual lifting mode: Keep the reversing handle assembly 9 in the raised position. Move the rocker arm shaft assembly 15 to drive the plunger assembly 14 to reciprocate. The resulting pressure oil opens the first one-way valve ball 24, and the subsequent path is the same as in electric mode, achieving lifting. The return oil path is also the same as in electric mode, flowing back to the oil storage tank 1 through the return oil hole 144.

[0052] This power unit has excellent versatility. By changing the internal flow channel design of the reversing valve assembly 21, it can be adapted to a differential oil supply system (for example, to connect oil passage a3 with oil passages a1 and a2 simultaneously during lifting) without any modifications to the main structure such as the housing 6 and the oil passage layout, demonstrating the advantages of a highly modular design.

[0053] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. An integrated power unit, characterized in that, include: The housing, the oil storage tank disposed on the housing, the motor assembly, and the pump core assembly; The housing is a one-piece molded structure. The housing has valve mounting holes, pump body mounting cavities, and internal oil passages that connect the oil storage tank, pump core assembly, and external actuators. A reversing valve assembly is rotatably disposed within the valve mounting hole; The internal oil circuit integrates a first check valve structure and a second check valve structure. The first check valve structure and the second check valve structure are respectively disposed inside the housing on the first oil passage group and the second oil passage group, which are isolated from each other and spatially misaligned, and are in fluid communication with the circumferential sealing surface of the reversing valve assembly.

2. The integrated power unit according to claim 1, characterized in that, The first check valve structure is disposed in the first oil passage group, which is connected to the oil pressure outlet of the pump core assembly; the second check valve structure is disposed in the second oil passage group, which is connected to the oil outlet of the plunger assembly.

3. The integrated power unit according to claim 2, characterized in that, The first check valve structure includes a third check valve ball, a spring, and a valve seat assembly installed in the first oil passage group; the second check valve structure includes a first check valve ball, a spring, and a valve seat assembly installed in the second oil passage group.

4. The integrated power unit according to claim 1, characterized in that, The housing is also cast with a plunger hole, and a plunger assembly is provided in the plunger hole. The bottom of the plunger hole is provided with a bottom valve structure, which includes a fourth one-way valve ball and a ball plug located below the fourth one-way valve ball.

5. The integrated power unit according to claim 4, characterized in that, The ball plug is fixed to the bottom of the plunger hole, and the inner diameter of the ball plug is smaller than the diameter of the ball of the fourth one-way valve.

6. The integrated power unit according to claim 5, characterized in that, The plunger assembly is linked to the rocker arm shaft assembly disposed on the housing, and the rotational motion of the rocker arm shaft assembly can be converted into linear motion of the plunger assembly within the plunger hole.

7. The integrated power unit according to claim 6, characterized in that, The power unit is configured as follows: In electric mode, the pump core assembly is driven by the motor assembly to generate hydraulic oil flow, which flows through the first check valve structure. In manual mode, the piston assembly is driven by the rocker arm shaft assembly to generate hydraulic oil flow, which flows through the second check valve structure.

8. The integrated power unit according to claim 1, characterized in that, The reversing valve assembly has multiple circumferential seals on its outer circumference, and the circumferential seals form a sliding seal with the inner wall of the valve mounting hole; one end of the reversing valve assembly is connected to an exposed reversing handle rod assembly.

9. The integrated power unit according to claim 1, characterized in that, The housing is provided with port A and port B for connection to external actuators. Port A and port B form a circulation loop with the oil storage tank through the internal oil circuit and reversing valve assembly, wherein port B is in fluid communication with the return oil passage.

10. The integrated power unit according to claim 1, characterized in that, The shell is cast from aluminum alloy.

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