New energy vehicle brake system air compressor and air compressor mounting rack

Abstract

The present application relates to a kind of new energy vehicle brake system air compressor and air compressor mounting rack, belong to automobile brake system technical field, air compressor includes air compressor body and the air inlet filter assembly being communicated with its air inlet end, air inlet filter assembly is equipped with inclined guide vane and multiple resistance flow baffle, resistance flow baffle forms circuitous air inlet flow channel between, for water vapor separation and discharge through automatic blow-off port, air compressor further includes universal joint assembly, and through universal ball head assembly cooperation flexible bellows realizes pipeline self-adapting deflection, air compressor mounting rack includes mounting bracket, damping shock attenuation component and heat conduction component, damping shock attenuation component is vibrated by elastic shock attenuation ring and washer buffering, heat conduction component is conducted to the heat dissipation of vehicle frame by phase-change heat pipe, the present application solves the existing air compressor air inlet water, pipeline stress concentration, poor heat dissipation and damping effect problem, applicable to new energy commercial vehicle and passenger car brake air supply system.

Description

Technical Field

[0001] This invention belongs to the field of automotive braking system technology, and relates to an air compressor and air compressor mounting bracket for a braking system of new energy vehicles. Background Technology

[0002] New energy vehicles generally adopt air-assisted braking systems. As the core supply equipment for the vehicle's braking air, the air compressor's operational stability, intake air cleanliness, and structural reliability directly affect the vehicle's braking safety factor. Currently, air compressors and their mounting brackets used in new energy vehicle braking systems generally have multiple structural defects during actual vehicle use, making them unsuitable for the harsh working conditions of complex chassis bumps, enclosed high temperatures, and mud and water splashes.

[0003] Most existing air compressors use a straight-through intake or an external flexible hose intake structure. During intake, a large amount of water mist and fine water droplets carried in the air can easily enter the air compressor body directly with the intake airflow. Long-term intake of water-containing air will cause corrosion of the inner wall of the air compressor cylinder, internal scale buildup, and accelerated wear. This will not only reduce the air compressor's compression efficiency, cause slow pressure build-up, and reduce pressure stabilization accuracy, but in severe cases, it can also cause internal jamming, air leakage, and failure, directly resulting in insufficient air supply to the braking system, posing a significant driving safety hazard. Furthermore, conventional high-level air intake pipelines also have problems such as easy aging of hoses, bending and collapse, occupation of chassis layout space, and inconvenience of disassembly and maintenance.

[0004] Secondly, existing air compressors generally adopt a suspension installation method with shock-absorbing pads. During the operation of the equipment, high-frequency vibrations will be generated continuously. When the vehicle is driving and bumping, multi-dimensional low-frequency impact displacement will also be generated. The air intake pipes connected to the air compressor are mostly rigidly fixed to the vehicle frame with cable ties and buckles. The structural contradiction between the floating vibration of the equipment and the fixed static position of the pipes will cause the air intake connection pipes to be subjected to repeated pulling, bending and shear stress for a long time.

[0005] Furthermore, traditional air compressor mounting brackets are mostly single rigid support structures that only serve a fixed load-bearing function. During the continuous compression of air, air compressors generate a large amount of compression heat and mechanical working heat. However, the mounting space of new energy vehicle chassis is enclosed and small, making it easy for heat to accumulate and unable to dissipate quickly. Long-term high-temperature heat accumulation will lead to the deterioration of the internal lubrication performance of the air compressor, accelerated aging of seals, and deterioration of the overall performance of the machine, significantly shortening the service life of the equipment. Traditional heat dissipation solutions mostly rely on external cooling fans, which not only increases the number of parts, energy consumption and noise, but also increases the number of failure points, resulting in poor reliability.

[0006] Therefore, we propose an air compressor and air compressor mounting bracket for the braking system of new energy vehicles to solve the problems mentioned above. Summary of the Invention

[0007] This invention addresses the problems encountered by new energy vehicle chassis under enclosed operating conditions, including cylinder wear due to water in the intake air of the brake air compressor, easy cracking of pipelines due to vibration and pulling, abnormal noise caused by high and low frequency vibrations transmitted to the vehicle body, heat accumulation in the enclosed space shortening lifespan, and difficulties in disassembly and maintenance in confined spaces. During the research and development process, it was found that existing technologies can only achieve basic fixing functions, following the design concept of open spaces in traditional fuel vehicles, and have not been integrated and optimized for the operating conditions of new energy vehicle chassis: intake air dehydration relies on an external independent dryer; pipelines are conventional rubber hoses that are easily damaged by pulling; shock absorption uses a single rubber pad that cannot handle both high and low frequency vibrations; heat dissipation relies on natural ventilation, which easily accumulates heat; and installation involves multiple bolts for blind mounting, making operation difficult and prone to falling.

[0008] This invention integrates an integrated gravity vapor-water ionization system, a universal ball joint stress compensation subsystem, a high- and low-frequency two-stage vibration damping subsystem, a phase change heat pipe passive heat dissipation subsystem, and a dovetail sliding quick-assembly anti-fall subsystem, achieving full-chain optimization of air intake purification, stress compensation, vibration isolation, passive heat dissipation, and rapid assembly, and provides an air compressor and air compressor mounting bracket for a new energy vehicle braking system.

[0009] To achieve the above objectives, the present invention provides the following technical solution: an air compressor for a braking system of a new energy vehicle, comprising an air compressor body, wherein the air intake end of the air compressor body is sealed and connected to an air intake filter assembly; The air intake filter assembly includes a filter housing disposed on one side of the air compressor body. The filter housing has an exhaust port and a negative pressure air intake port on both sides respectively. The exhaust port is sealed and connected to the air intake end of the air compressor body. A guide plate is fixedly installed at an inclination inside the filter housing. Multiple flow-blocking baffles I are fixed between the top of the guide plate and the inner wall of the filter housing. The multiple flow-blocking baffles I form a meandering air intake channel. A drain port is opened at the bottom of the outer side of the filter housing. A gravity-type one-way drain valve is installed at the port. The liquid inlet of the gravity-type one-way drain valve is positioned opposite to the water accumulation area at the bottom of the guide plate. After the accumulated water reaches the set liquid level, it can be automatically discharged outside the housing through the gravity-type one-way drain valve, while preventing external air from entering the air passage in reverse. It also includes a universal connector and a rigid air intake guide tube, wherein the rigid air intake guide tube is sealed and connected to the negative pressure air intake port through the universal connector; After being introduced through the rigid air intake duct, external air enters the filter housing through the universal connection assembly and flows back and forth along the meandering air intake channel. Water vapor in the air adheres to and precipitates on the surface of the flow baffle I and the guide plate, gathers at the bottom of the guide plate and is discharged from the automatic drain port. The separated air enters the air compressor body through the exhaust port.

[0010] As a further improvement to the above technical solution: The universal joint assembly includes a ball socket base fixedly sleeved on the outer end of the negative pressure air intake port. A covering cover is fixedly connected to the outer side of the ball socket base by multiple sets of fastening bolts I and locking nut rings. A universal ball joint assembly is provided between the covering cover and the ball socket base. A flexible bellows is provided inside the universal ball joint assembly. The other end of the flexible bellows is sealed and connected to the negative pressure air intake port. The rigid air intake guide pipe is fixed to the vehicle frame, and one end is connected to the universal ball joint assembly.

[0011] Turbulence suppression plates are fixedly provided on one side of the flow-blocking baffle I on both sides and on both sides of the flow-blocking baffle I in the middle. The turbulence suppression plates are used to increase the contact area between air and the plate and prolong the contact and residence time of water vapor with the plate.

[0012] An air compressor mounting bracket is used in the aforementioned air compressor for the braking system of a new energy vehicle. It includes a mounting bracket, two vehicle body mounting brackets fixedly mounted on the vehicle frame, and four damping shock absorbers. The mounting bracket is detachably connected to the two vehicle body mounting brackets. All four damping shock absorbers are located on the top of the mounting bracket. The air compressor body is fixed to the top of the four damping shock absorbers, and the damping shock absorbers provide cushioning and shock absorption for the air compressor body. It also includes a heat-conducting component disposed within the mounting bracket, which directs the heat from the air compressor body to the vehicle frame.

[0013] As a further improvement to the above technical solution: The mounting bracket includes a mounting base plate, and the heat-conducting component includes four clearance openings on the top of the mounting base plate. The middle part of the mounting base plate is bent to form a structural bending section. The inner contour of the structural bending section is adapted to the bottom of the air compressor body. The structural bending section has an assembly mounting hole II, and the mounting base plate has an assembly mounting hole I corresponding to the assembly mounting hole II. Each set of assembly mounting holes II and assembly mounting holes I is interference-fitted with a phase change heat pipe.

[0014] The inner wall of the bending section of the structure is provided with a graphite pad, which is attached to the bottom outer wall of the air compressor body. The graphite pad is used to uniformly collect the working heat of the air compressor body and conduct it directionally to the mounting base plate and the frame through the phase change heat pipe.

[0015] The damping and shock absorption assembly includes a lower shock absorption housing, with an upper shock absorption housing fitted onto the top of the lower shock absorption housing. An elastic shock absorption ring is provided inside both the upper and lower shock absorption housings. Both ends of the elastic shock absorption ring are fixedly connected to the lower and upper shock absorption housings, respectively. A washer is fixedly provided inside the elastic shock absorption ring, and a buffer gap is reserved between the two ends of the washer and the two ends of the elastic shock absorption ring. The elastic shock absorption ring is used to absorb high-frequency, small-amplitude vibrations, and the washer is used to limit and buffer low-frequency, large-amplitude impacts when the elastic shock absorption ring is compressed to its limit.

[0016] The top of the upper shock-absorbing housing is fixedly provided with a positioning and fastening stud, and the bottom of the lower shock-absorbing housing is fixedly provided with a positioning and fastening stud. The upper shock-absorbing housing and the lower shock-absorbing housing are respectively fixed to the corresponding air compressor body and mounting bracket by positioning and fastening studs and nuts.

[0017] It also includes two sets of sliding assembly components, which are disposed between the vehicle body fixing bracket and the mounting bracket; The sliding assembly includes a sliding mounting base fixed to the top of the vehicle body mounting bracket. The top of the sliding mounting base is provided with a dovetail guide groove, and a dovetail sliding block is inserted into the dovetail guide groove. The dovetail sliding block is fixed to the bottom of the mounting bracket. A positioning pin is fixed to the outer end of the sliding mounting base. A pressure plate is sleeved on the outer wall of the positioning pin. A fastening bolt II is threaded through the other end of the pressure plate and is threaded to the sliding mounting base. The mounting bracket can be detachably assembled to the vehicle body fixing bracket through the insertion and engagement of the dovetail sliding block and the dovetail guide groove. The pressure plate can be tightened or loosened by screwing on the fastening bolt II.

[0018] The top of the sliding mounting base is provided with multiple rectangular clearance through holes that are connected to the dovetail guide groove. The number of dovetail sliding blocks corresponds to the number of rectangular clearance through holes. A wedge-shaped locking block is inserted into the outer end of the dovetail guide groove. The two ends of the wedge-shaped locking block abut against one end of the outer dovetail sliding block and the inner side of the pressure plate, respectively. The wedge-shaped locking block is used to limit and lock the dovetail sliding block when the pressure plate is pressed.

[0019] The beneficial effects of this invention are as follows: 1. The air compressor and air compressor mounting bracket for the braking system of new energy vehicles disclosed in this invention form a tortuous air intake channel through the inclined guide plate and multi-layer staggered flow-blocking baffle inside the filter housing, and increase the water vapor contact area with the turbulence suppression plate. The efficient separation of water mist and impurities in the intake air is achieved by utilizing the principle of airflow inertia and gravity settling. The separated water can be automatically discharged through the bottom automatic drain port without manual maintenance. 2. The air compressor and air compressor mounting bracket for the braking system of new energy vehicles disclosed in this invention adopts a ball cage universal connection component in combination with an independent sealed bellows structure. Relying on the multi-dimensional deflection characteristics of the universal ball head assembly, it adaptively offsets the three-dimensional relative displacement caused by the shock-absorbing and suspended installation of the air compressor, which can alleviate the problems of pipeline pulling and shear stress caused by equipment vibration and vehicle body bumps. 3. The air compressor and air compressor mounting bracket for the braking system of new energy vehicles disclosed in this invention achieve flexible absorption of high-frequency small-amplitude vibrations through elastic damping rings, and achieve limit buffering of low-frequency large impacts in conjunction with the gap limiting structure of the internal gaskets. It can adapt to the high and low frequency composite vibration conditions during air compressor start-up and shutdown and vehicle driving, effectively isolate the air compressor working vibration from being transmitted to the vehicle frame, reduce vehicle resonance and abnormal noise, and limit excessive shaking of the equipment to avoid damage to pipelines and lines, further improving the overall machine operation stability and structural durability. 4. The air compressor and air compressor mounting bracket for the braking system of new energy vehicles disclosed in this invention achieve full coverage heat collection of the heat-generating area of ​​the machine body through a high-adhesion graphite pad, and in conjunction with multiple sets of phase change heat pipes, the working heat of the machine body is quickly and directionally transferred to the large-volume metal structure of the vehicle frame for full-area heat dissipation. There is no need to configure an additional cooling fan, reducing equipment failure points, reducing energy consumption and operating noise.

[0020] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0021] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein: Figure 1 This is a three-dimensional structural schematic diagram of an air compressor and air compressor mounting bracket for a braking system of a new energy vehicle according to the present invention; Figure 2 This is a cross-sectional view of the air intake filter assembly of an air compressor for a new energy vehicle braking system according to the present invention. Figure 3 This is a cross-sectional view of the universal connection assembly of an air compressor for a new energy vehicle braking system according to the present invention. Figure 4 This is a schematic diagram of the mounting bracket and vehicle body fixing bracket structure of an air compressor and air compressor mounting frame for a new energy vehicle braking system according to the present invention. Figure 5 This is a partial cross-sectional view of the mounting bracket for an air compressor and air compressor mounting frame used in a braking system for new energy vehicles according to the present invention. Figure 6 This is a cross-sectional schematic diagram of the damping and shock absorption components of an air compressor and air compressor mounting bracket for a new energy vehicle braking system according to the present invention. Figure 7 This is a partial cross-sectional view of the sliding assembly of an air compressor and air compressor mounting bracket for a new energy vehicle braking system according to the present invention.

[0022] Reference numerals: 1. Air compressor body; 2. Intake filter assembly; 21. Filter housing; 22. Baffle I; 23. Guide plate; 24. Detour-type intake air passage; 25. Automatic drain port; 26. Exhaust port; 27. Negative pressure intake port; 28. Turbulence suppression plate; 3. Universal joint assembly; 31. Ball socket base; 32. Covering gland; 33. Universal ball joint assembly; 34. Fastening bolt I; 35. Locking nut ring; 36. Flexible bellows; 4. Rigid intake guide pipe; 5. Damping and vibration reduction assembly; 51. Vibration-damping lower housing; 52. 53. Upper housing for shock absorption; 54. Positioning and fastening studs; 55. Elastic shock-absorbing ring; 6. Washer; 7. Mounting bracket; 8. Mounting base plate; 9. Clearance opening; 10. Structural bending section; 11. Graphite pad; 12. Assembly mounting hole I; 13. Assembly mounting hole II; 14. Phase change heat pipe; 15. Body fixing bracket; 26. Sliding assembly assembly; 17. Sliding mounting base; 18. Dovetail guide groove; 19. Dovetail sliding block; 20. Rectangular clearance through hole; 21. Positioning pin; 22. Pressure plate; 33. Fastening bolt II; 44. Wedge-shaped locking block. Detailed Implementation

[0023] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0024] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0025] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0026] Example 1

[0027] like Figures 1-3 As shown, an air compressor for a new energy vehicle braking system includes an air compressor body 1 as the core air supply device. An intake filter assembly 2 is fitted to the air intake end of the air compressor body 1. The intake filter assembly 2 is positioned on the outer side of the air compressor body 1, allowing for slight vibrations synchronized with the vehicle without interfering with the surrounding chassis structure. The filter housing 21 serves as the external load-bearing housing for the intake filter assembly 2. It is integrally injection molded from high-strength glass fiber modified engineering plastic, possessing corrosion resistance, aging resistance, and lightweight properties. It also exhibits good structural rigidity, making it resistant to deformation and cracking. Sealing strips are used to seal the joints of the housing, ensuring excellent overall sealing performance. This effectively prevents external mud, water, dust, and sand impurities from directly entering the air intake channel, reducing the probability of air pollution at the source. The filter housing 21 has an exhaust port 26 and a negative pressure air inlet port 27 respectively through the left and right sides. The exhaust port 26 is pressed and sealed to the air inlet end of the air compressor body 1 through an integrated sealing flange structure. The flange contact surface is flat and fits well to ensure that the air intake airflow is introduced into the air compressor body 1 without leakage or pressure loss. The negative pressure air inlet port 27 serves as an external air inlet port to connect to the external air intake pipeline to complete the continuous supply of normal pressure air.

[0028] A guide plate 23 is fixedly installed at an angle inside the filter housing 21. The guide plate 23 and the filter housing 21 are integrally formed without assembly gaps, resulting in strong structural stability. The guide plate 23 adopts a fixed inclined arrangement, and the inclination angle is perfectly adapted to the liquid flow, which can guide impurities and water droplets and prevent impurities and water droplets from remaining inside the filter housing 21. Multiple sets of flow-blocking baffles I 22 are fixedly installed between the top of the guide plate 23 and the inner side wall of the filter housing 21. The multiple sets of flow-blocking baffles I 22 are arranged in parallel and equidistantly, and the gaps between adjacent flow-blocking baffles I 22 are staggered and blocked, with no straight airflow channel. They form a continuous and tortuous meandering airflow channel 24 inside the filter housing 21, forcing the airflow to turn back multiple times and flow in layers. After external air enters the filter housing 21 through the negative pressure air inlet port 27, it flows slowly back and forth along the meandering air inlet channel 24. The water mist, tiny water droplets and light impurity particles mixed in the airflow will continuously impact the surface of the baffle plate I 22 and the guide plate 23 under the action of inertia. Water vapor gradually adheres to the surface of the plate and continuously gathers into liquid water droplets. Under the action of gravity, the water droplets slowly flow down along the side of the baffle plate I 22 and the slope of the guide plate 23, and finally all of them gather in the low-level water accumulation area at the bottom of the guide plate 23. A drain port is provided at the bottom outer side of the filter housing 21. A gravity-type one-way drain valve 25 is installed at the port. The inlet end of the gravity-type one-way drain valve 25 is positioned opposite to the water accumulation area at the bottom of the guide plate 23. Specifically, the gravity-type one-way drain valve 25 is configured such that a rotating shaft is rotatably connected to the outside of the drain port via a bearing. A sealing plate is press-fitted onto the outer wall of the rotating shaft, and a rubber gasket is installed on the side of the sealing plate near the drain port. Under normal conditions, the sealing plate droops down under its own weight, working with the rubber gasket to seal the drain port. Once the accumulated water reaches a set level, the water... The gravity can overcome the weight of the sealing plate, driving the sealing plate to flip. After the sealing plate flips, the accumulated water is automatically discharged to the outside of the housing, while preventing the outside air from entering the air passage in reverse. In order to ensure that the sealing plate does not swing back and forth with vibration during operation, a torsion spring is sleeved on the rotating shaft. The two ends of the torsion spring abut against the sealing plate and the housing respectively to ensure the stability of the sealing plate. This effectively prevents water vapor from continuously accumulating and flowing back into the air compressor body 1, greatly reducing the probability of failure such as corrosion, scale buildup and abnormal wear on the cylinder inner wall, and effectively extending the service life of the air compressor.

[0029] Multiple sets of turbulence suppression plates 28 are fixedly installed on the inner wall of the filter housing 21 and the surface of the baffle plate I 22. The turbulence suppression plates 28 and the corresponding baffle plates I 22 are fixed together by heat fusion, which is firm and not easy to fall off. The turbulence suppression plates 28 are made of thin sheet plastic material and are evenly distributed in the core area through which the airflow passes. This can effectively increase the overall contact area between the airflow and the plate structure, prolong the contact and residence time between water vapor and the plate, and allow the fine water mist suspended in the airflow to fully adhere and precipitate, further improving the separation and purification efficiency of water mist inside the airflow. At the same time, the turbulence suppression plates 28 can regulate and sort the turbulent airflow generated by high-speed air intake, weaken the airflow turbulence and eddy phenomenon, reduce intake wind noise and airflow impact noise, ensure that the intake airflow entering the air compressor is continuous, stable and uniform in velocity, and improve the air compressor's air pressure stabilization accuracy.

[0030] A universal connector 3 is installed at the outer end of the negative pressure air inlet port 27. The rigid air inlet guide pipe 4 is sealed and connected to the negative pressure air inlet port 27 through the universal connector 3, so as to achieve stable and leak-free introduction of external clean air. The universal connector 3 includes a ball socket base 31, a covering cover 32, a universal ball head assembly 33, and a flexible bellows 36. The ball socket base 31 is made of hard aluminum alloy and is integrally formed, with high structural strength and not easy to deform. It is fixedly sleeved on the outer wall of the negative pressure air inlet port 27 and maintains a fixed relative position with the filter housing 21, so that it will not shift or loosen due to equipment vibration. The outer side of the ball socket base 31 is fixedly fitted with the covering cover 32 by a matching locking structure of multiple sets of fastening bolts I 34 and locking nut rings 35. The fastening bolts I 34 are made of high-strength galvanized carbon steel, which has rust and corrosion resistance. The locking nut rings 35 adopt an annular integral locking structure, which can achieve uniform compression and avoid sealing failure caused by single-point force. The fastening bolts I 34 and locking nut rings 35 are matched and pressed one-to-one to ensure the assembly sealing and structural tightness between the covering cover 32 and the ball socket base 31, and the enclosed cavity is regular and without gaps.

[0031] The covering cap 32 and the ball socket base 31 together form a complete closed spherical receiving cavity. A universal ball joint assembly 33 is movably assembled inside the spherical receiving cavity. The universal ball joint assembly 33 is made of wear-resistant copper alloy, with a smooth and wear-resistant surface. It can deflect in multiple directions within the spherical receiving cavity, with a maximum deflection angle controlled within 15 degrees. This allows it to fully adapt to the multi-directional vibration offset and slight relative displacement during the start-up and shutdown of the air compressor body 1 and during road bumps, achieving dynamic adaptive compensation. One end of the universal ball joint assembly 33 is internally fixedly connected to a flexible bellows 36, and the other end is connected to an external rigid air intake guide pipe 4. The flexible bellows 36 is integrally molded from high-purity polytetrafluoroethylene (PTFE), which has excellent resistance to high and low temperatures, corrosion, and aging. It also has a low coefficient of friction and strong sealing stability, and will not harden, crack, or age even after long-term contact with air, moisture, and oil. The other end of the flexible bellows 36 is internally sealed and connected to the negative pressure air intake port 27, forming a completely sealed and leak-free air intake channel. During equipment operation, when the air compressor body 1 experiences high-frequency vibration and slight displacement due to the shock absorption structure, the rigid air intake guide pipe 4 remains stationary on the side of the frame. The air intake end of the body continues to shake, and the universal ball joint assembly 33 can adaptively match the equipment displacement to complete multi-angle deflection, completely offsetting the tension, bending, and shear stress of the pipeline. The flexible corrugated pipe 36 only independently undertakes the functions of air passage sealing and airflow conduction, and does not bear any mechanical tension load or shear load throughout the process. It can maintain the integrity of the seal for a long time, avoiding the problems of rigid tension of rigid pipelines, fatigue cracking of ordinary rubber hoses, and air leakage caused by detachment in traditional structures. It continuously ensures the stable operation of the vehicle's braking air supply system and eliminates the safety hazards of brake failure.

[0032] Example 2

[0033] Reference Figure 1 , Figures 4-7 An air compressor mounting bracket is disclosed. The air compressor body 1 is fixedly mounted on top of the air compressor mounting bracket. The air compressor mounting bracket consists of a mounting bracket 6 and two sets of vehicle body fixing brackets 7. The two sets of vehicle body fixing brackets 7 are symmetrically fixedly installed at the preset installation positions on the vehicle chassis frame, and are rigidly connected to the frame without loosening. The mounting bracket 6 is detachably mounted between the two sets of vehicle body fixing brackets 7. The overall assembly position is centered, the force is evenly distributed, the structural load-bearing stability is good, and the disassembly, assembly, maintenance and operation space is highly adaptable. Four sets of damping shock absorption components 5 are evenly arranged on the top of the mounting bracket 6. The four sets of damping shock absorption components 5 are distributed in a rectangular array, and the force is evenly distributed at four points, which can effectively disperse the self-weight of the machine body and the vibration load. The bottom feet of the air compressor body 1 are fixed to the top of the four sets of damping shock absorption components 5. The damping shock absorption components 5 realize the fully flexible connection between the air compressor body 1 and the mounting bracket 6, completely isolate the vibration impact transmitted from the machine body to the bracket and the frame, effectively buffer the high-frequency vibration of the equipment during operation and the low-frequency impact of vehicle bumps, and take into account the NVH performance of the whole vehicle and the stability of the equipment operation.

[0034] The single-unit damping shock absorber assembly 5 includes a lower damping shell 51, an upper damping shell 52, an elastic damping ring 54, and a washer 55. Both the lower and upper damping shells 51 and 52 are integrally molded from rigid engineering plastic, exhibiting a hard texture, resistance to pressure and deformation, and the ability to maintain their structural shape over a long period. The lower damping shell 51 is fixed to the top of the mounting bracket 6, and the upper damping shell 52 is fitted onto the outer side of the top of the lower damping shell 51. Together, they form a nested protective structure capable of slight relative expansion and contraction, providing dustproof, waterproof, and impact-resistant protection for the internal damping structure. The elastic damping ring 54 is made of highly elastic polyurethane material with a hollow "C"-shaped cross-section. It exhibits good toughness, fatigue resistance, and resistance to aging, and will not loosen or fail even after long-term repeated deformation. The elastic damping ring 54 is nested and fixed inside the enclosed cavity of the lower and upper damping shells 51 and 52, with its upper and lower ends tightly fixed to the inner walls of the lower and upper damping shells 51 and 52, respectively, without any gaps or detachment. The washer 55 is made of corrugated pressed metal wire mesh and is fixedly installed in the central cavity of the elastic damping ring 54 (only the middle part of the washer 55 is bonded to the elastic damping ring 54, and its two ends can be displaced relative to the inner wall of the elastic damping ring 54). A fixed buffer gap is reserved between the upper and lower end faces of the washer 55 and the inner end face of the elastic damping ring 54. This gap is reserved for deformation space for equipment vibration. When the equipment operates smoothly and generates high-frequency small-amplitude vibrations, the flexible micro-deformation of the elastic damping ring 54 can fully absorb the high-frequency vibration energy, weaken the vibration transmission, and avoid vehicle body resonance and abnormal noise. When the vehicle bumps or the equipment starts and stops and generates low-frequency large impacts and large-amplitude shaking, after the elastic damping ring 54 is compressed and deformed to its limit, the washer 55 can quickly assist in limiting and buffering, restricting the excessive shaking of the equipment, and avoiding pulling damage to the air intake pipe and wiring position. It achieves full-range buffering adaptation for high and low frequency vibrations and large and small impacts, solving the defect of traditional single-hardness damping pads that cannot take into account both high-frequency noise reduction and low-frequency anti-shaking.

[0035] Positioning and fastening studs 53 are fixedly installed at the top of the upper housing 52 and the bottom of the lower housing 51. The positioning and fastening studs 53 are made of stainless steel, which is rust-proof, corrosion-resistant, and has high structural strength. The top positioning and fastening stud 53 is locked to the bottom support of the air compressor body 1 with a nut, and the bottom positioning and fastening stud 53 is locked to the top surface of the mounting bracket 6 with a nut. The corresponding positioning and fastening studs 53 at the top and bottom can realize the precise alignment and limiting fixation of the damping and shock absorption components 5, effectively avoiding the displacement, torsion, and loosening of the shock absorption structure due to long-term vibration, ensuring that the four sets of shock absorption components are evenly stressed and have a stable and consistent shock absorption effect, and avoiding the problem of pipeline stress concentration caused by unilateral tilting of the machine body and uneven stress.

[0036] The mounting bracket 6 is formed by bending an entire aluminum alloy sheet, which has a high thermal conductivity, light weight, strong structural rigidity, and is not easy to deform or rust. It is suitable for long-term and complex working conditions of the chassis. The top surface of the mounting base plate 61 has four evenly distributed clearance openings 62. The clearance openings 62 are regularly distributed. The middle of the mounting base plate 61 is bent upward to form a structural bending section 63. The bending arc is formed in one step without stress residue. The inner contour of the structural bending section 63 fits perfectly with the outer contour of the bottom of the air compressor body 1, which can cover a large area of ​​the heat-generating area at the bottom of the machine body and improve heat collection efficiency. A graphite pad 64 is fitted to the inner wall of the structural bending section 63. The graphite pad 64 is made of highly thermally conductive flexible graphite material. It is soft and can fit irregular curved surfaces. It fits tightly without gaps and can fit the heat-generating area of ​​the outer wall of the air compressor body 1 in all directions. It can quickly and evenly absorb the accumulated heat generated by the machine body during operation and avoid local high temperature accumulation. At the same time, the soft graphite pad 64 can adapt to fit irregular curved surfaces of the machine body, eliminate fitting gaps, ensure heat conduction effect throughout the entire area, and help disperse local stress of the machine body to avoid rigid compression and wear. It is always tightly fitted to the bottom of the air compressor body 1.

[0037] Assembly and installation holes II 66 are formed inside the structural bending section 63 along the bending trajectory. Assembly and installation holes I 65 are correspondingly formed inside the mounting base plate 61. Assembly and installation holes I 65 and II 66 are precisely aligned vertically and completely connected. Each set of aligned holes is fitted with a phase change heat pipe 67 using an interference fit. The phase change heat pipe 67 has a copper outer shell and is filled with a highly efficient phase change heat transfer medium. It has fast heat transfer speed, no thermal resistance, and requires no electrical drive, achieving rapid heat transfer through physical phase change. The upper end of the phase change heat pipe 67 is tightly attached to the heat collection area of ​​the graphite pad 64, and the lower end extends to the bottom surface of the mounting base plate 61, forming a large-area rigid thermal contact with the vehicle body fixing bracket 7 and the chassis frame metal structure. The heat generated by the equipment is transferred to the graphite pad 64 through the outer casing to achieve uniform heat collection. Then, it is quickly and directionally conducted to the mounting base plate 61 through multiple sets of phase change heat pipes 67, and finally diffused to the large-volume chassis frame metal structure to complete passive heat dissipation. At the same time, it effectively solves the problems of poor heat dissipation of the air compressor in the enclosed chassis space, excessive temperature rise leading to performance degradation and shortened life. During long-term operation, the phase change heat pipes and the contact surfaces can be regularly dusted and maintained to ensure stable heat conduction and heat dissipation efficiency.

[0038] Two sets of sliding assembly components 8 are symmetrically assembled between the mounting bracket 6 and the vehicle body fixing bracket 7. The two sets of sliding assembly components 8 are symmetrically arranged and evenly stressed, specifically designed for assembly conditions in new energy vehicles where the chassis is narrow, visibility is obstructed, and operating space is limited. This allows for rapid blind assembly and alignment, self-locking anti-fall, significantly improving assembly and maintenance safety. Each set of sliding assembly components 8 includes a sliding mounting base 81, a dovetail guide groove 82, a dovetail sliding block 83, a positioning pin 85, a pressure plate 86, fastening bolts II 87, and a wedge-shaped locking block 88. The sliding mounting base 81 is fixedly installed on the top surface of the vehicle body fixing bracket 7, and is a single-piece machined metal structure with strong load-bearing capacity and resistance to deformation. The top surface of the sliding mounting base 81 has a dovetail guide groove 82, which adopts a standard dovetail structure that is narrower at the top and wider at the bottom. This provides automatic centering alignment, prevents lateral deviation, and prevents vertical disengagement, allowing for smooth assembly without the need for precise manual alignment.

[0039] The bottom surface of the mounting bracket 6 is fixedly fitted with a dovetail sliding block 83. The shape, dimensions, and tilt angle of the dovetail sliding block 83 are precisely matched with the dovetail guide groove 82. During assembly, no visual observation is required; it can be directly slid into the dovetail guide groove 82 from the outside. Relying on the inclined surface for automatic correction and centering, the mounting bracket 6 and the vehicle body fixing bracket 7 can be quickly and blindly aligned. The top surface of the sliding mounting base 81 has multiple sets of rectangular clearance through holes 84, which are interconnected with the dovetail guide groove 82. The number of rectangular clearance through holes 84 corresponds one-to-one with the dovetail sliding block 83, which greatly improves the smoothness of the sliding assembly and avoids jamming and hard-hitting assembly.

[0040] A positioning pin 85 is fixedly installed on the outer end of the sliding mounting base 81. The positioning pin 85 is made of stainless steel that has been quenched and tempered, making it wear-resistant and deformation-resistant. A pressure plate 86 is movably sleeved on the outer side of the positioning pin 85. The pressure plate 86 can rotate slightly around the positioning pin 85 to achieve adaptive angle fitting. A fastening bolt II 87 is installed through the outer end of the pressure plate 86. The fastening bolt II 87 is precisely matched with the threaded hole at the end of the sliding mounting base 81. The tightening and loosening state of the pressure plate 86 can be controlled by turning the bolt. A wedge-shaped locking block 88 is inserted into the outer port of the dovetail guide groove 82. The wedge-shaped locking block 88 is made of hard alloy, which is wear-resistant, pressure-resistant, and not easily deformed. The two ends of the wedge-shaped locking block 88 are respectively tightly abutting against the end of the outermost dovetail sliding block 83 and the inner wall of the pressure plate 86. After the equipment is assembled, tightening the fastening bolt II 87 pushes the pressure plate 86 inward to press the wedge-shaped locking block 88. The wedge-shaped locking block 88 presses against the dovetail sliding block 83, locking the sliding gap and achieving rigid locking and fixing of the sliding structure. This prevents the mounting bracket 6 from slipping, loosening, or making abnormal noises due to vehicle bumps and vibrations. During later maintenance and disassembly, simply loosen the fastening bolt II 87 to release the pressure limit of the pressure plate 86, then remove the wedge-shaped locking block 88 to release the sliding lock. The mounting bracket 6 can then be smoothly slid outward along the dovetail guide groove 82 and pulled out. The overall disassembly and assembly operation is simple and efficient. Simultaneously, the physical limiting structure of the wedge-shaped locking block 88 prevents the equipment from slipping during disassembly, avoiding the unrestrained fall of the heavy air compressor and significantly improving the safety of disassembly and assembly operations in confined spaces.

[0041] If the equipment operates under harsh conditions of mud, dust, and vibration for extended periods, it is necessary to regularly clean the automatic drain port 25, the meandering air intake channel 24, and the sliding assembly gaps to remove impurities. Simultaneously, the fit of the phase change heat pipe 67, the sealing performance of the universal joint assembly 3, and the deformation of the shock-absorbing structure should be checked periodically to ensure long-term stable operation. The complete workflow of the overall equipment of this invention during vehicle assembly and actual operation is as follows: During the factory assembly stage, two sets of body fixing brackets 7 are first fixedly installed in the preset positions of the new energy vehicle chassis frame to complete the benchmark fixing. Then, the damping shock absorption component 5 is pre-assembled on the top surface of the mounting bracket 6 and the bottom of the air compressor body 1 respectively through the upper and lower positioning fastening studs 53, realizing the flexible pre-assembly of the body and the bracket. After the pre-assembly is completed, the dovetail sliding block 83 at the bottom of the mounting bracket 6 is aligned with the dovetail guide groove 82 at the top of the sliding mounting base 81 to complete the blind insertion sliding assembly. After it is in place, the wedge-shaped locking block 88 is inserted and the pressure plate 86 is pressed by the fastening bolt II 87 to complete the overall locking and fixing, realizing the whole machine without deviation and with high safety assembly.

[0042] After the equipment is assembled and put into use in the vehicle, when the vehicle braking system needs to build up pressure for air supply, external atmospheric pressure air is introduced through the rigid intake guide pipe 4 and smoothly delivered to the intake filter assembly 2 through the flexible corrugated pipe 36 inside the universal connection assembly 3. After the airflow enters the filter housing 21, it flows back and forth multiple times along the meandering intake air passage 24. Water mist and tiny water droplets mixed in the airflow are continuously released under the combined action of inertia and gravity, adhering to the surfaces of the guide plate 23, the flow baffle I 22, and the turbulence suppression plate 28. The accumulated water is automatically discharged from the automatic drain port 25, completing the intake air dewatering and purification. The clean and dry air finally enters the air compressor body 1 through the exhaust port 26 to complete the compression and air production, providing a stable high-pressure air source for the vehicle braking system. During continuous operation of the equipment, the air compressor body 1 continuously operates and generates high-frequency vibration. At the same time, the vehicle's bumpy ride will bring low-frequency impact vibration. All kinds of vibration loads are absorbed and buffered in stages by four sets of damping shock absorption components 5. High-frequency vibration is offset by the flexible deformation of the elastic shock absorption ring 54, and low-frequency large-scale shaking is suppressed by the limit of the washer 55, effectively preventing the body from violently shaking and pulling the air intake pipe.

[0043] Meanwhile, the continuous heat generated by the machine body during operation is quickly collected by the graphite pad 64 on the inner side of the structural bending section 63, and then directionally conducted to the mounting bracket 6 and chassis frame through multiple sets of phase change heat pipes 67. Relying on the large-volume metal structure of the chassis for continuous passive heat dissipation, the operating temperature of the machine body is stabilized within a reasonable range, avoiding high temperature heat accumulation that could affect the performance and lifespan of the equipment.

[0044] The relative displacement between the machine body and pipelines generated during equipment operation is entirely compensated by the multi-angle deflection adaptive compensation of the universal ball joint assembly 33. The flexible bellows 36 is only responsible for sealing and guiding air throughout the entire process, and is not subject to mechanical stress, thus avoiding pipeline fatigue damage. During subsequent vehicle maintenance and repair, simply loosen the fastening bolts II 87 and remove the wedge-shaped locking block 88 in sequence, and the entire machine can be smoothly slid out along the dovetail guide groove 82 without complicated disassembly and assembly operations. It also has structural anti-fall protection throughout the process, effectively adapting to maintenance conditions in narrow chassis spaces. The entire set of equipment recurs steadily and reliably completes the vehicle's braking air supply work.

[0045] However, as is well known to those skilled in the art, the working principle and wiring method of the air compressor body 1 are commonplace and are all conventional methods or common knowledge. They will not be described in detail here. Those skilled in the art can make any selections according to their needs or convenience.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. An air compressor for a braking system of a new energy vehicle, comprising an air compressor body (1), characterized in that, The air compressor body (1) has an air intake filter assembly (2) sealed and connected to the air intake end. The air intake filter assembly (2) includes a filter housing (21) disposed on one side of the air compressor body (1). The filter housing (21) is provided with an exhaust port (26) and a negative pressure air intake port (27) on both sides respectively. The exhaust port (26) is sealed and connected to the air intake end of the air compressor body (1). A guide plate (23) is fixedly and inclined inside the filter housing (21). Multiple flow-blocking baffles I (22) are fixed between the top of the guide plate (23) and the inner wall of the filter housing (21). A meandering air intake channel (24) is formed between the multiple flow-blocking baffles I (22). It also includes a universal connector assembly (3) and a rigid air intake guide pipe (4), wherein the rigid air intake guide pipe (4) is sealed and connected to the negative pressure air intake port (27) through the universal connector assembly (3); After external air is introduced through the rigid air intake guide pipe (4), it enters the filter housing (21) through the universal connection assembly (3) and flows back along the meandering air intake channel (24). Water vapor in the air adheres to and precipitates on the surface of the flow baffle I (22) and the guide plate (23), gathers at the bottom of the guide plate (23) and is discharged from the automatic sewage discharge port (25). The separated air enters the air compressor body (1) through the exhaust port (26).

2. The air compressor for the braking system of new energy vehicles according to claim 1, characterized in that, The universal connection assembly (3) includes a ball socket base (31) fixedly sleeved on the outer end of the negative pressure air intake port (27). The outer side of the ball socket base (31) is fixedly connected to a cover (32) by multiple sets of fastening bolts I (34) and locking nut rings (35). A universal ball head assembly (33) is provided between the cover (32) and the ball socket base (31). A flexible corrugated tube (36) is provided inside the universal ball head assembly (33). The other end of the flexible corrugated tube (36) is sealed and connected to the negative pressure air intake port (27). The rigid air intake guide tube (4) is fixed to the frame and one end is connected to the universal ball head assembly (33).

3. The air compressor for the braking system of new energy vehicles according to claim 1, characterized in that, Turbulence suppression plates (28) are fixedly provided on one side of the flow-blocking baffle I (22) on both sides and on both sides of the flow-blocking baffle I (22) in the middle. The turbulence suppression plates (28) are used to increase the contact area between air and the plate and prolong the contact and residence time of water vapor with the plate.

4. An air compressor mounting bracket, applied to the air compressor for the braking system of a new energy vehicle as described in claim 3, characterized in that, It includes a mounting bracket (6), two body mounting brackets (7) fixedly mounted on the vehicle frame, and four damping shock absorbers (5). The mounting bracket (6) is detachably connected to the two body mounting brackets (7). The four damping shock absorbers (5) are all located on the top of the mounting bracket (6). The air compressor body (1) is fixed on the top of the four damping shock absorbers (5). The damping shock absorbers (5) buffer and damp the air compressor body (1). It also includes a heat-conducting component disposed within the mounting bracket (6), which directs the heat from the air compressor body (1) to the vehicle frame.

5. The air compressor mounting bracket according to claim 4, characterized in that, The mounting bracket (6) includes a mounting base plate (61), and the heat-conducting component includes four clearance openings (62) on the top of the mounting base plate (61). The middle part of the mounting base plate (61) is bent to form a structural bending section (63). The inner contour of the structural bending section (63) is adapted to the bottom of the air compressor body (1). The structural bending section (63) is provided with an assembly mounting hole II (66). The mounting base plate (61) is provided with an assembly mounting hole I (65) corresponding to the assembly mounting hole II (66). Each set of assembly mounting holes II (66) and assembly mounting holes I (65) is fitted with a phase change heat pipe (67).

6. The air compressor mounting bracket according to claim 5, characterized in that, The inner wall of the bending section (63) of the structure is provided with a graphite pad (64). The graphite pad (64) is attached to the bottom outer wall of the air compressor body (1). The graphite pad (64) is used to uniformly collect the working heat of the air compressor body (1) and conduct it to the mounting base plate (61) and the frame through the phase change heat pipe (67).

7. The air compressor mounting bracket according to claim 4, characterized in that, The damping and shock absorption assembly (5) includes a lower shock absorption housing (51), and a higher shock absorption housing (52) is fitted onto the top of the lower shock absorption housing (51). An elastic shock absorption ring (54) is provided inside the upper shock absorption housing (52) and the lower shock absorption housing (51). The two ends of the elastic shock absorption ring (54) are fixedly connected to the lower shock absorption housing (51) and the upper shock absorption housing (52) respectively. A washer (55) is fixedly provided inside the elastic shock absorption ring (54), and a buffer gap is reserved between the two ends of the washer (55) and the two ends of the elastic shock absorption ring (54). The elastic shock absorption ring (54) is used to absorb high-frequency small-amplitude vibrations, and the washer (55) is used to limit and buffer low-frequency large-amplitude impacts when the elastic shock absorption ring (54) is compressed and deformed to its limit.

8. The air compressor mounting bracket according to claim 7, characterized in that, The top of the shock-absorbing upper housing (52) is fixedly provided with a positioning fastening stud (53), and the bottom of the shock-absorbing lower housing (51) is fixedly provided with a positioning fastening stud (53). The shock-absorbing upper housing (52) and the shock-absorbing lower housing (51) are respectively fixed to the corresponding air compressor body (1) and mounting bracket (6) by positioning fastening studs (53) and nuts.

9. The air compressor mounting bracket according to claim 4, characterized in that, It also includes two sets of sliding assembly components (8), which are disposed between the vehicle body fixing bracket (7) and the mounting bracket (6); The sliding assembly (8) includes a sliding mounting base (81) fixed to the top of the vehicle body mounting bracket (7). The top of the sliding mounting base (81) is provided with a dovetail guide groove (82). A dovetail sliding block (83) is inserted into the dovetail guide groove (82). The dovetail sliding block (83) is fixed to the bottom of the mounting bracket (6). A positioning pin (85) is fixed to the outer end of the sliding mounting base (81). A pressure plate (86) is sleeved on the outer wall of the positioning pin (85). A fastening bolt II (87) is passed through the other end of the pressure plate (86). The fastening bolt II (87) is threadedly connected to the sliding mounting base (81). The mounting bracket (6) can be detachably mounted on the vehicle body fixing bracket (7) by the insertion and engagement of the dovetail sliding block (83) and the dovetail guide groove (82). The pressure plate (86) can be tightened or loosened by screwing on the fastening bolt II (87).

10. The air compressor mounting bracket according to claim 9, characterized in that, The top of the sliding mounting base (81) is provided with a plurality of rectangular clearance through holes (84) that are connected to the dovetail guide groove (82). The number of dovetail sliding blocks (83) corresponds to the number of rectangular clearance through holes (84). A wedge-shaped locking block (88) is inserted into the outer end of the dovetail guide groove (82). The two ends of the wedge-shaped locking block (88) respectively abut against one end of the outer dovetail sliding block (83) and the inner side of the pressure plate (86). The wedge-shaped locking block (88) is used to limit and lock the dovetail sliding block (83) when the pressure plate (86) is pressed.

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