Five-in-one water-cooled full active suspension control system

Abstract

The application discloses a five-in-one water-cooling full active suspension control system, belongs to the technical field of electric vehicles, and aims to solve the problems of high cost, large size and complex arrangement of the existing dispersed architecture. The five-in-one water-cooling full active suspension control system comprises a controller, a first motor, a second motor, a first electric pump and a second electric pump, the power output ends of the controller are connected with the power input ends of the first motor and the second motor respectively, the first motor and the second motor are used for driving the first electric pump and the second electric pump respectively, and the first electric pump and the second electric pump are used for cooperating with the valve group of the automobile to adjust the full active suspension. The water-cooling devices are arranged on the housings of the first motor and the second motor respectively and used for cooling the first motor, the second motor and the controller. The application is suitable for the full active suspension of the automobile, can realize that the structural parts are assembled into a whole, and has the effects of low cost, small size and simple arrangement.

Description

Technical Field

[0001] This invention belongs to the field of electric vehicle technology, and in particular relates to a five-in-one water-cooled fully active suspension control system. Background Technology

[0002] With the rapid development of the new energy vehicle industry, higher demands are being placed on the comfort, handling, and integration of the chassis system. Traditional passive suspensions, with their non-adjustable stiffness and damping, struggle to adapt to complex and changing road conditions. In contrast, fully active suspensions can efficiently decouple vehicle body and road surface excitations, providing a smooth driving experience while significantly improving vehicle handling limits. Furthermore, traditional suspensions often employ a distributed architecture, resulting in high cost, large size, and complex layout. Summary of the Invention

[0003] The purpose of this invention is to provide a five-in-one water-cooled fully active suspension control system. The structural components are assembled into a whole, which has the advantages of low cost, small size and simple layout. The five-in-one integration makes the suspension response faster, more compact and reliable, while water cooling ensures that there is no thermal decay during long-term high-intensity operation and that it is more stable and durable.

[0004] To achieve the above objectives, the present invention is implemented using the following technical solution:

[0005] This invention provides a five-in-one water-cooled fully active suspension control system, which is installed on a car and includes a controller, a first motor, a second motor, a first electric pump, and a second electric pump. The power output terminal of the controller is connected to the power input terminals of the first motor and the second motor, respectively. The first motor and the second motor are used to drive the first electric pump and the second electric pump, respectively. The first electric pump and the second electric pump are used to cooperate with the valve group of the car to adjust the fully active suspension.

[0006] The controller includes a controller cover, which is connected to the housings of the first motor and the second motor in pairs. The housings of the first electric pump and the second electric pump are respectively connected to the housings of the first motor and the second motor.

[0007] Water cooling devices are respectively installed on the housings of the first motor and the second motor to dissipate heat from the first motor, the second motor and the controller.

[0008] In the above technical solution, the internal controller controls the power transmission of the motor, and the motor drives the electric pump, which in turn works with the valve group of the car to adjust the fully active suspension. The external housings are connected to form a whole, forming a five-in-one integrated structure. It is low in cost, small in size, simple in layout, and easy to install. A water cooling device is set on the motor to dissipate heat, ensuring that the motor and controller do not experience heat decay during long-term high-intensity operation and are more stable and durable.

[0009] Furthermore, the controller also includes a power board and a control board. The first motor and the second motor are respectively installed inside the first motor housing and the second motor housing. The controller cover is connected to the upper housing of the first motor housing and the second motor housing. The power board and the control board are sealed between the controller cover and the two motor housings. The control board is installed on the controller cover, and the power board is connected to the first motor housing and the second motor housing. The power board and the control board are electrically connected. The first electric pump and the second electric pump are respectively installed inside the first electric pump housing and the second electric pump housing. The sides of the first motor housing and the second motor housing that are far apart from each other are respectively connected to the first electric pump housing and the second electric pump housing.

[0010] In the above technical solution, the controller box cover is installed above the two motor housings, enclosing the power board and control board. The two motor housings are connected to the two electric pump housings as one unit, and the internal structure is electrically connected according to function to form an integral plug-in, which is convenient for assembly.

[0011] Furthermore, the power board is provided with silicon carbide power devices and ceramic plates. The silicon carbide power devices are located on the side of the power board closer to the control board, and the ceramic plates are located on the other side of the power board at the same position as the silicon carbide power devices.

[0012] In the above technical solution, silicon carbide power devices are used for power conversion in the power control system, which can reduce switching losses, improve working efficiency and power density, achieve precise control of power output, and at the same time, they are resistant to high temperature and have high reliability. The ceramic plate can effectively dissipate heat for the silicon carbide power devices.

[0013] Optionally, the silicon carbide power device is a surface-mount type.

[0014] In the above technical solution, the surface-mount silicon carbide power device is soldered onto the control board, with a large solder pad area, tight fit, and strong vibration resistance.

[0015] Furthermore, a heat-dissipating adhesive is applied between the ceramic plate and the water-cooling device.

[0016] Optionally, the ceramic sheet is provided with a coating, which is in contact with the power board.

[0017] In the above technical solutions, the coating can improve heat dissipation, shock resistance, and insulation performance.

[0018] Furthermore, a partition is provided between the power board and the control board, and an insulating block is provided on the side of the partition closest to the power board.

[0019] In the above technical solution, the partition prevents mutual interference between the power board and the control board, and the insulating block is used to insulate the silicon carbide power devices.

[0020] Furthermore, the water-cooling device includes a water-cooling cover plate and a water-cooling pipe. The water-cooling cover plate is connected to the first motor housing and the second motor housing respectively. The first motor housing and the second motor housing are provided with water storage grooves, which together with the water-cooling cover plate form a water storage cavity. The inlet and outlet of the water storage cavity are connected to the water-cooling circuit of the vehicle through the water-cooling pipe.

[0021] In the above technical solution, the coolant enters and exits the water storage chamber through the water cooling pipe to dissipate heat for the controller and motor. The inlet and outlet of the water storage chamber can be set on the water cooling cover plate or the motor housing.

[0022] Optionally, a waterproof and breathable valve is provided on the side of the controller box cover.

[0023] In the above technical solution, water and dust can be isolated, the pressure difference in the cavity can be balanced, and moisture can be discharged by adjusting the waterproof and breathable valve.

[0024] Furthermore, the controller box cover is provided with a low-voltage connector and a high-voltage connector. The low-voltage connector is connected to the first signal input terminal of the controller, and the high-voltage connector is connected to the power input terminal of the controller.

[0025] In the above technical solution, the controller connects to the car through a low-voltage connector to receive CAN communication signals and connects to the car through a high-voltage connector to obtain high-voltage DC power. The five-in-one water-cooled fully active suspension controller connects to the car through high-voltage and low-voltage connectors. The internal wiring controls the motor to drive the electric pump to control the suspension. The structure is simple and the connection and assembly are convenient.

[0026] Furthermore, a magnetic braiding plate is provided on the housing of the motor, and the signal output terminal of the magnetic braiding plate is connected to the second signal input terminal of the controller.

[0027] In the above technical solution, the magnetic braiding board collects the rotor position information of the motor and sends it to the controller. The controller calculates the motor speed, determines the output voltage power based on the motor speed, and performs control. The magnetic braiding board is installed on the motor housing and accurately identifies the rotor angle position by detecting changes in the magnetic field, thereby controlling the motor speed more precisely.

[0028] Optionally, the magnetic braiding plate is provided with silicon steel sheets.

[0029] In the above scheme, the silicon steel sheet is placed over the magnetic braiding plate to prevent the signals between the two magnetic braiding plates from interfering with each other.

[0030] Furthermore, temperature sensors are respectively installed on the first motor and the second motor, and the signal output terminal of the temperature sensor is connected to the third signal input terminal of the controller.

[0031] In the above technical solution, the temperature sensor collects the temperature information of the motor stator and transmits it to the controller. The controller then combines the temperature information to control the motor power.

[0032] Furthermore, the first electric pump and the second electric pump are respectively equipped with temperature and pressure sensors, and the signal output terminal of the temperature and pressure sensors is connected to the fourth signal input terminal of the controller.

[0033] In the above technical solution, the temperature and pressure sensor is used to measure the temperature and pressure of the medium inside the electric pump.

[0034] Optionally, the power output terminal of the controller is connected to the power input terminals of the first motor and the second motor respectively via three-phase terminals.

[0035] Beneficial effects

[0036] The present invention provides a five-in-one water-cooled fully active suspension control system, which integrates two electric pumps, two motors and a controller into one unit. It drives the fully active suspension through internal connection, and the external shell is connected as a whole component. Compared with the traditional separate suspension, it can reduce cost and size. The motor housing is equipped with a water cooling device to ensure that it does not heat decay during long-term high-intensity operation and is more stable and durable.

[0037] The controller box cover and the motor housing are sealed with adhesive, providing excellent sealing performance at a low cost. The ceramic plate has a coating that contacts the power board, and thermal adhesive is applied between the ceramic plate and the controller box cover to improve the heat dissipation performance of the device. A water-cooling cover is arranged below the ceramic plate to assist in heat dissipation through water cooling, ensuring that there is no thermal decay during long-term high-intensity operation and that the device is more stable and durable. The silicon carbide power devices are surface-mount type and are mounted on the control board, providing good shock resistance. Attached Figure Description

[0038] To more clearly illustrate the technical solutions in the embodiments of this disclosure or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0039] Figure 1 These are schematic diagrams of some embodiments provided by the present invention;

[0040] Figure 2 These are schematic diagrams of the side view structure of some embodiments provided by the present invention;

[0041] Explanation of reference numerals in the attached figures:

[0042] 1. Controller box cover; 2. First motor housing, 2-1. Three-phase adapter board, 2-2. Water-cooled cover plate; 3. First electric pump housing; 4. High-voltage connector; 5. Low-voltage connector; 6. Control board, 6-1. Temperature and pressure sensor connector, 6-2. Magnetic braided connector, 6-3. Interlock connector; 7. Partition plate; 8. Insulating block; 9. Power board, 9-1. Temperature sensor, 9-2. Silicon carbide power device, 9-3. Ceramic sheet, 9-4. Three-phase terminal; 10. Magnetic braided board, 10-1. Silicon steel sheet; 11. Temperature and pressure adapter board; 12. Waterproof and breathable valve; 13. Second motor housing; 14. Second electric pump housing;

[0043] In the diagram, the black lines represent board-to-board connector connections, the yellow lines represent magnetic braided board connections, the pink lines represent interlock connector connections, the blue lines represent temperature and pressure sensor connections, and the green lines represent temperature sensor connections. Detailed Implementation

[0044] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use.

[0045] Example 1

[0046] This embodiment provides a five-in-one water-cooled fully active suspension control system, which is installed on a car, such as... Figure 1 and Figure 2 As shown, it includes a controller, a first motor, a second motor, a first electric pump, and a second electric pump. The power output terminal of the controller is connected to the power input terminals of the first motor and the second motor, respectively. The first motor and the second motor are used to drive the first electric pump and the second electric pump, respectively. The first electric pump and the second electric pump are used to cooperate with the valve group of the car to adjust the fully active suspension.

[0047] The controller includes a controller cover 1, which is connected to the housings of the first motor and the second motor in pairs. The housings of the first electric pump and the second electric pump are respectively connected to the housings of the first motor and the second motor.

[0048] Water cooling devices are respectively installed on the housings of the first motor and the second motor to dissipate heat from the first motor, the second motor and the controller.

[0049] Example 2

[0050] This embodiment provides a five-in-one water-cooled fully active suspension control system, which is installed on a car, such as... Figure 1 and Figure 2As shown, the system includes a controller, a first motor, a second motor, a first electric pump, and a second electric pump. The power output terminal of the controller is connected to the power input terminals of the first motor and the second motor, respectively. The first motor and the first electric pump are coaxially driven and connected, and the second motor and the second electric pump are coaxially driven and connected, respectively, to drive the first electric pump and the second electric pump. The first electric pump and the second electric pump are respectively connected to the corresponding fully active suspension control valve group on the vehicle, and are used to coordinate with the valve group of the vehicle to adjust the fully active suspension.

[0051] The controller includes a power board 9, a control board 6, and a controller cover 1. The first motor and the second motor are respectively installed in the first motor housing 2 and the second motor housing 13. The first electric pump and the second electric pump are respectively installed in the first electric pump housing 3 and the second electric pump housing 14. The controller cover 1 is connected to the first motor housing 2 and the second motor housing 13 in pairs. The controller cover 1 connects to the upper housing of the first motor housing 2 and the second motor housing 13. The two motor housings are sealed to the controller cover 1 by applying glue, which is low-cost and improves the overall sealing performance of the device. The first motor housing 2 and the second motor housing 13 are symmetrically connected. The power board 9 and the control board 6 are sealed between the controller cover 1 and the two motor housings. The control board 6 is installed on the controller cover 1. The power board 9 is connected to the first motor housing 2 and the second motor housing 13. The sides of the first motor housing 2 and the second motor housing 13 that are close to each other are connected, and the sides that are far from each other are connected to the first electric pump housing 3 and the second electric pump housing 14, respectively. The power board 9 and the control board 6 are electrically connected.

[0052] Water cooling devices are respectively provided on the first motor housing 2 and the second motor housing 13 for heat dissipation of the first motor, the second motor and the controller. The water cooling device includes a water cooling cover plate 2-2 and a water cooling pipe. The water cooling cover plate 2-2 is respectively connected to the first motor housing 2 and the second motor housing 13. Water storage grooves are provided on the first motor housing 2 and the second motor housing 13, forming a water storage cavity with the water cooling cover plate 2-2. The inlet and outlet of the water storage cavity are connected to the water cooling circuit of the car through the water cooling pipe. The inlet and outlet of the water storage cavity are located on the motor housing. The coolant circulates in the water storage cavity to dissipate heat from the motor and the controller.

[0053] The power board 9 is equipped with a silicon carbide power device 9-2 and a ceramic plate 9-3. The silicon carbide power device 9-2 is located on the side of the power board 9 near the control board 6, and the ceramic plate 9-3 is located on the other side of the power board 9 at the same position as the silicon carbide power device 9-2. The silicon carbide power device 9-2 is a surface mount type. Thermal adhesive is applied between the ceramic plate 9-3 and the water-cooling cover plate 2-2 to improve the heat dissipation performance of the ceramic plate 9-3. A plating layer is provided on the ceramic plate 9, which is in contact with the power board 9. The plating layer is nickel plating, silver plating, gold plating, or tin plating and is soldered to the power board 9. The number of silicon carbide power devices 9-2 and ceramic plates 9-3 is several and can be selected according to actual needs.

[0054] A partition 7 is provided between the power board 9 and the control board 6, and an insulating block 8 is provided on the side of the partition 7 closest to the power board 9.

[0055] The controller cover 1 has a waterproof and breathable valve 12 on its side to balance air pressure and provide waterproofing and breathability. The controller cover 1 is equipped with a low-voltage connector 5 and a high-voltage connector 4. The low-voltage connector 5 connects to the controller's first signal input terminal, and the high-voltage connector 4 connects to the controller's power input terminal. Both connectors are waterproof and achieve good sealing performance through plug-and-play connection with the vehicle's transmission harness. A groove is provided on the housing of the first and second motors on their adjacent sides, and a magnetic braided plate 10 is installed in the groove. The signal output terminal of the magnetic braided plate 10 connects to the controller's second signal input terminal. A silicon steel sheet 10-1 is provided on the magnetic braiding plate 10; a temperature sensor 9-1 is provided on the first motor and the second motor respectively, and the signal output terminal of the temperature sensor 9-1 is connected to the third signal input terminal of the controller; a temperature and pressure sensor is provided on the first electric pump and the second electric pump respectively, and the signal output terminal of the temperature and pressure sensor is connected to the fourth signal input terminal of the controller; the power output terminal of the controller is connected to the power input terminals of the first motor and the second motor respectively through the three-phase terminal 9-4; the signal input terminal of the controller is the signal input terminal of the control board 6, and the power output terminal of the controller is the power output terminal of the power board 9.

[0056] Example 3

[0057] This embodiment provides a five-in-one water-cooled fully active suspension control system. Based on embodiment 2, the power board 9 and the control board 6 are connected through a set of board-to-board connectors and interlock connectors 6-3.

[0058] The control board 6 is equipped with a temperature and pressure sensor connector 6-1 and a magnetic braided connector 6-2. The temperature and pressure sensor is connected to the fourth signal input terminal of the control board 6 through the temperature and pressure sensor connector 6-1, and the magnetic braided board 10 is connected to the second signal input terminal of the control board 6 through the magnetic braided connector 6-2. The first electric pump housing 3 and the second electric pump housing 14 are provided with grooves, in which a temperature and pressure adapter board 11 is placed. The temperature and pressure sensor is connected to the temperature and pressure adapter board 11, and then connected to the temperature and pressure sensor connector 6-1 through the temperature and pressure adapter board 11. The three-phase terminal 9-4 is connected to the power input terminal of the motor through the three-phase adapter board 2-1.

[0059] The control board 6 is connected to the controller cover 1, the first motor housing 2 and the second motor housing 13, the power board 9 and the first motor housing 2 and the second motor housing 13, the controller cover 1 and the first motor housing 2 and the second motor housing 13, the two magnetic braiding plates 10 and the first motor housing 2 and the second motor housing 13, the two temperature and pressure adapter plates 11 and the first motor housing 2 and the second motor housing 13, the first motor housing 2 and the first electric pump housing 3, the second motor housing 13 and the second electric pump housing 14, and the two three-phase adapter plates 2-1 and the first motor housing 2 and the second motor housing 13 by bolts.

[0060] The signal and power transmission between the magnetic braided connector 6-2 and the magnetic braided board 10, the temperature and pressure adapter board 11 and the temperature and pressure sensor connector 6-1, and other electrical structures are connected by wire harnesses.

[0061] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "up," "down," "front," "rear," "left," "right," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to explain the relative positional relationship and movement between components in a specific posture. If the specific posture changes, the directional indication will also change accordingly. These terms are used only for the convenience of describing the invention and for simplifying the description, and are not intended to 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, they should not be construed as limiting the invention.

[0062] Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0063] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0064] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A five-in-one water-cooled full active suspension control system installed on a vehicle, characterized by, It includes a controller, a first motor, a second motor, a first electric pump, and a second electric pump. The power output terminal of the controller is connected to the power input terminals of the first motor and the second motor, respectively. The first motor and the second motor are used to drive the first electric pump and the second electric pump, respectively. The first electric pump and the second electric pump are used to coordinate with the valve group of the car to adjust the fully active suspension. The controller includes a controller cover (1), which is connected to the housings of the first motor and the second motor in pairs. The housings of the first electric pump and the second electric pump are respectively connected to the housings of the first motor and the second motor. Water cooling devices are respectively installed on the housings of the first motor and the second motor to dissipate heat from the first motor, the second motor and the controller.

2. The five-in-one water-cooled fully active suspension control system according to claim 1, characterized by, The controller also includes a power board (9) and a control board (6). The first motor and the second motor are respectively installed in the first motor housing (2) and the second motor housing (13). The controller cover (1) is connected to the upper housing of the first motor housing (2) and the second motor housing (13). The power board (9) and the control board (6) are sealed between the controller cover (1) and the two motor housings. The control board (6) is installed on the controller cover (1). The power board (9) is connected to the first motor housing (2) and the second motor housing (13). The power board (9) and the control board (6) are electrically connected. The first electric pump and the second electric pump are respectively installed in the first electric pump housing (3) and the second electric pump housing (14). The sides of the first motor housing (2) and the second motor housing (13) that are far apart from each other are respectively connected to the first electric pump housing (3) and the second electric pump housing (14).

3. The five-in-one water-cooled fully active suspension control system according to claim 2, characterized by, The power board (9) is provided with a silicon carbide power device (9-2) and a ceramic plate (9-3). The silicon carbide power device (9-2) is located on the side of the power board (9) close to the control board (6), and the ceramic plate (9-3) is located on the other side of the power board (9) at the same position as the silicon carbide power device (9-2).

4. The five-in-one water-cooled fully active suspension control system according to claim 3, characterized by, A heat dissipation adhesive is applied between the ceramic sheet (9-3) and the water cooling device.

5. The five-in-one water-cooled fully active suspension control system according to claim 2, wherein, A partition (7) is provided between the power board (9) and the control board (6), and an insulating block (8) is provided on the side of the partition (7) near the power board (9).

6. The five-in-one water-cooled fully active suspension control system according to claim 2, characterized in that, The water cooling device includes a water cooling cover plate (2-2) and a water cooling pipe. The water cooling cover plate (2-2) is connected to the first motor housing (2) and the second motor housing (13) respectively. The first motor housing (2) and the second motor housing (13) are provided with water storage grooves, which together with the water cooling cover plate (2-2) form a water storage cavity. The inlet and outlet of the water storage cavity are connected to the water cooling circuit of the car through the water cooling pipe.

7. The five-in-one water-cooled fully active suspension control system according to claim 1, characterized in that, The controller box cover (1) is provided with a low-voltage connector (5) and a high-voltage connector (4). The low-voltage connector (5) is connected to the first signal input terminal of the controller, and the high-voltage connector (4) is connected to the power input terminal of the controller.

8. The five-in-one water-cooled fully active suspension control system according to claim 1, characterized in that, A magnetic braiding plate (10) is provided on the housing of the motor, and the signal output terminal of the magnetic braiding plate (10) is connected to the second signal input terminal of the controller.

9. The five-in-one water-cooled fully active suspension control system according to claim 1, characterized in that, Temperature sensors (9-1) are respectively installed on the first motor and the second motor, and the signal output terminal of the temperature sensor (9-1) is connected to the third signal input terminal of the controller.

10. The five-in-one water-cooled fully active suspension control system according to claim 1, characterized in that, The first electric pump and the second electric pump are respectively equipped with temperature and pressure sensors, and the signal output terminal of the temperature and pressure sensors is connected to the fourth signal input terminal of the controller.

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