Brushless synchronous motor integrated ECU (Electronic Control Unit) compression air suspension air pump assembly

Abstract

The utility model relates to a brushless synchronous motor integrated ECU (Electronic Control Unit) compression air suspension air pump assembly, which comprises an air compressor, a brushless synchronous motor for driving the air compressor to work, valve elements arranged on each air path, and an ECU in control connection with the brushless synchronous motor and each valve element, a rotor of the brushless synchronous motor is an eccentric rotor, and the eccentric parameter of the eccentric rotor is determined according to the imbalance rule of the whole structure of the air compressor caused by the dynamic change of the load so as to meet the balance requirement of the whole structure. The brushless synchronous motor is adopted to replace a brush motor, noise is low, soft start can be achieved, control is more accurate, power consumption is lower, and the stability of the whole structure can be improved.

Description

Technical Field

[0001] The utility model relates to the technical field of vehicle control, in particular to a brushless synchronous motor integrated ECU compressed air suspension air pump assembly. Background Art

[0002] With the continuous improvement of living standards, people's requirements for cars are getting higher and higher, and comfortable and adjustable air suspension is more popular in the market.

[0003] Existing air suspensions usually use brushed motors to drive air compressors. Although brushed motors can be directly set up and debugged without the need for electronic controllers, and their structure and control are relatively simple, brushed motors cannot compensate for the structural imbalance caused by dynamic changes in the load of the air compressor, resulting in poor overall structural stability. Brushed motors also have high noise levels and high power consumption due to the inability to accurately control them. Utility Model Content

[0004] In order to solve the above problems, the utility model provides a brushless synchronous motor integrated ECU compressed air suspension air pump assembly, which uses a brushless synchronous motor instead of a brush motor, has low noise, can achieve soft start, has more precise control, lower power consumption, and can improve the stability of the overall structure.

[0005] The utility model is realized through the following scheme: a brushless synchronous motor integrated ECU compressed air suspension air pump assembly, including an air compressor, a brushless synchronous motor for driving the air compressor, valve elements installed on each air path, and an ECU connected to the brushless synchronous motor and each of the valve elements for control, the rotor of the brushless synchronous motor is an eccentric rotor, the eccentricity parameter of the eccentric rotor is determined according to the imbalance law of the overall structure of the air compressor caused by dynamic load changes, so as to meet the balance requirement of the overall structure.

[0006] A further improvement of the brushless synchronous motor integrated ECU compressed air suspension air pump assembly of the utility model is that at least one crankshaft is arranged on the rotor shaft of the rotor, and the eccentricity parameters include the shape, weight, number and layout angle of the crankshaft.

[0007] A further improvement of the brushless synchronous motor integrated ECU compressed air suspension air pump assembly of the utility model is that the ECU is integrated on a PCB board, and the PCB board is installed between the stator housing and the stator end cover of the brushless synchronous motor.

[0008] A further improvement of the brushless synchronous motor integrated ECU compression air suspension air pump assembly of the utility model is that the PCB board and the stator end cover are both square, the end of the stator housing is sleeved with a square frame, and the PCB board is connected between the stator end cover and the square frame by screws.

[0009] A further improvement of the brushless synchronous motor integrated ECU compressed air suspension air pump assembly of the utility model is that the PCB board and the stator end cover are both circular, and a connecting sleeve extending axially is provided on the outer periphery of the end of the stator housing, and the PCB board is connected between the stator end cover and the connecting sleeve by screws.

[0010] The utility model adopts a brushless synchronous motor instead of a brushed motor, which has low noise, can realize soft start, more precise control, and lower power consumption. Moreover, on the one hand, through the setting of the eccentric rotor, the structural imbalance caused by the dynamic change of the load of the air compressor can be compensated as much as possible in the structure, thereby improving the stability of the overall structure. On the other hand, the brushless synchronous motor can realize dynamic control by ECU, which provides a basis for improving the structural stability in software. In turn, noise and power consumption can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 The overall structural schematic diagram of the brushless synchronous motor integrated circular ECU compression air suspension air pump assembly is shown.

[0012] Figure 2 A schematic diagram of the exploded structure of a brushless synchronous motor integrated circular ECU compressed air suspension air pump assembly is shown.

[0013] Figure 3 The overall structural schematic diagram of the brushless synchronous motor integrated square ECU compressed air suspension air pump assembly is shown.

[0014] Figure 4 A schematic diagram of the exploded structure of a brushless synchronous motor integrated square ECU compressed air suspension air pump assembly is shown.

[0015] Figure 5 A schematic diagram of the pneumatic principle of a brushless synchronous motor integrated with an ECU to compress an air suspension air pump assembly is shown. DETAILED DESCRIPTION

[0016] Traditional air suspension usually includes an air compressor and a brushed motor for driving the air compressor. The rotation of the brushed motor drives the piston of the air compressor to make linear reciprocating motion, thereby compressing the air. The compressed high-pressure air is then used to push the air control assembly to lift the vehicle body. However, since the amount of air in the air compressor is dynamic, that is, the load curve is unbalanced, which leads to the inevitable structural imbalance problem for each air compressor. The traditional brushed motor drive structure does not solve this problem, but directly sets the theoretical value to drive the air compressor, which not only leads to the instability of the entire structure, high noise, and high power consumption.

[0017] Based on the above problems, the utility model provides a brushless synchronous motor integrated ECU compressed air suspension air pump assembly, which adopts a brushless synchronous motor instead of a brushed motor, and according to the imbalance law of the overall structure caused by the dynamic change of the load of the air compressor, the rotor of the brushless synchronous motor is set to an eccentric rotor with a certain eccentricity, so as to structurally compensate for the structural imbalance caused by the air compressor. The brushless synchronous motor integrated ECU compressed air suspension air pump assembly is further described below with specific embodiments combined with the accompanying drawings.

[0018] See also Figure 1 and Figure 2 As shown, a brushless synchronous motor integrated ECU compressed air suspension pump assembly includes an air compressor 2, a brushless synchronous motor 1 for driving the air compressor 2, valve elements installed on each air path, and an ECU (i.e., an electronic controller) connected to the brushless synchronous motor 1 and each valve element. The brushless synchronous motor 1 specifically includes a stator housing 15, a rotor 16 disposed in the stator housing 15, and a stator end cover 11 disposed at the end of the stator housing 15, wherein the rotor 16 is an eccentric rotor, which achieves an eccentric effect by arranging a crankshaft 161 on the rotor shaft. Since the eccentric rotor needs to compensate for the structural imbalance of the air compressor in structure, when arranging the crankshaft 161, it is necessary to comprehensively consider the shape, weight, quantity, and layout angle of the crankshaft according to the imbalance law of the overall structure of the air compressor 2 caused by the dynamic change of the load, so that the eccentric rotor can balance the structural imbalance of the air compressor 2 to the greatest extent in structure, so that the overall structure is more stable and balanced, the noise is reduced, and the service life is increased. In addition, the brushless synchronous motor can achieve soft start through the ECU, with more precise control and lower power consumption, and can also dynamically control the speed of the brushless synchronous motor 1 in conjunction with the eccentric rotor to keep the load curve in the air compressor 2 in a balanced state.

[0019] In order to make the entire structure more compact, the ECU and the brushless synchronous motor 1 can be integrated together. Two integrated structures are provided below:

[0020] Example 1: See Figure 1 and Figure 2 As shown, since the stator housing 15 and the stator end cover 11 of the brushless synchronous motor 1 are usually circular, the ECU is integrated on a circular PCB board 3, and then the circular PCB board 3 is installed between the stator housing 15 and the stator end cover 11 and located at the outer end of the magnetic ring 14. Specifically, the outer periphery of the end of the stator housing 15 is provided with a connecting sleeve 42 extending in the axial direction, and the circular PCB board 3 is connected between the stator end cover 11 and the connecting sleeve 42 by screws 41. Among them, a wire hole can be set on the stator end cover 11, so that the power supply 13 can penetrate and supply power to the ECU. Similarly, in order to achieve circuit connection, other hardware structures can be appropriately opened and avoided as needed.

[0021] Example 2: See Figure 3 and Figure 4 As shown, due to the limited area of ​​the circular PCB board, it may not be possible to integrate the ECU on it, so this embodiment integrates the ECU on a square PCB board 3, and then the square PCB board 3 is installed between the stator housing 15 and the stator end cover 11 and is located at the outer end of the magnetic ring 14. Specifically, the end of the stator housing 15 is sleeved with a square frame 42 that is adapted to the size of the square PCB board 3, and then the square PCB board 3 is connected between the stator end cover 11 and the square frame 42 at the four corners by screws 41. Preferably, the screw 41 can be a long screw that can pass through the connection hole of the square frame 42 and then be fixed to the air compressor assembly to ensure the connection reliability of the entire structure. As for the circuit connection, it is the same as Example 1 and will not be repeated here.

[0022] The utility model can be improved on the basis of the traditional compressed air suspension pump structure. It only needs to replace the brush motor with a brushless synchronous motor, and then set the brushless synchronous motor to an eccentric rotor structure, and integrate the ECU on the PCB board, and then install it on the brushless synchronous motor. Other components and functions do not need to be changed, and the original pneumatic principle can still be met. Figure 5 Let me give you a brief explanation:

[0023] 1. Inflation process:

[0024] The air compressor 2 is driven by the brushless synchronous motor 1, and sucks air from the air inlet 12 provided on the stator end cover 11, and passes through the two-stage compression process B1 (the structure for realizing the two-stage compression process includes a piston 22 driven by the brushless synchronous motor 1 to make linear reciprocating motion, a primary leather cup 21 and a secondary leather cup 23 provided at the upper and lower ends of the piston 22, and a cylinder 24 for supporting and installing the piston 22, the primary leather cup 21 and the secondary leather cup 23. Through the linear reciprocating motion of the piston 22, the air from the air inlet 12, the rotor 16 and the cylinder 24 can be cyclically compressed). After the two-stage compression process B1, the compressed gas passes through the air path A, is dried through the drying cylinder 5, and then passes through the one-way valve to the pneumatic assembly 8 to drive the gas control spring 81 to lift the car body. The pneumatic assembly 8 is also provided with an exhaust port 82. When the car body needs to be lowered, the gas can be discharged through the exhaust port 82. The exhaust pressure of the pneumatic assembly 8 depends on the pressure value required by the back-end system, which is required to be no more than 22Bar.

[0025] 2. Exhaust and regeneration process:

[0026] When the system needs to be exhausted or regenerated, the ECU controls the brushless synchronous motor 1 to stop working and controls the solenoid valve 7 to open. At this time, the gas at the rear end of the system passes through the gas path D and the gas path E. Since the gas path E is connected to the gas path F, the pneumatic valve 9 can be pushed to operate. At this time, the gas path D passes through the drying cylinder 5 in the reverse direction to complete the regeneration, and then is discharged from the air inlet 12.

[0027] 3. Exhaust and regeneration end process:

[0028] When the rear-end system pressure is lower than 5 Bar, the pressure sensor outputs a signal to the ECU to control the solenoid valve 7 to close and the gas path E to be disconnected. At this time, the gas path F is connected to the gas path D, the gas in the gas path F is discharged, and the pneumatic valve 9 returns to its position, returning to the inflation process.

[0029] It should be noted that in order to effectively control the gas pressure in the equipment, a safety protection and control mechanism should also be set up: it is required to install a pressure sensor and a safety valve at the rear end of the gas tank, and to logically control the on and off of the air compressor, brushless drive motor and solenoid valve through the ECU. At the same time, the safety valve on the gas tank provides safety protection for the system. When the system pressure is greater than 22Bar, the safety valve opens, and the pressure sensor outputs a signal to the ECU to control the brushless drive motor to stop running. In addition, a temperature sensor 6 can be installed on the air compressor 2 to detect the air temperature.

[0030] The utility model adopts a brushless synchronous motor instead of a brushed motor and improves the rotor shaft of the brushless synchronous motor, thereby overcoming the problems of large driving noise, inaccurate control and high power consumption of the brushed motor. In addition, it specifically provides how to integrate the brushless synchronous motor and the ECU. By using the ECU to coordinate and control the improved brushless synchronous motor, the structural imbalance of the air compressor caused by the dynamic change of the load can be compensated from both hardware and software aspects, thereby improving the stability of the overall structure.

[0031] The utility model is described in detail above in conjunction with the embodiments of the drawings. A person skilled in the art can make various variations of the utility model according to the above description. Therefore, some details in the embodiments should not constitute a limitation of the utility model, and the scope of protection of the utility model shall be defined by the scope of the attached claims.

Claims

1. A brushless synchronous motor integrated ECU compressed air suspension pump assembly, characterized in that: It includes an air compressor, a brushless synchronous motor for driving the air compressor, valve elements installed on each air path, and an ECU connected to the brushless synchronous motor and each valve element. The rotor of the brushless synchronous motor is an eccentric rotor. The eccentricity parameter of the eccentric rotor is determined according to the imbalance law of the overall structure caused by the dynamic change of the load of the air compressor to meet the balance requirement of the overall structure.

2. The brushless synchronous motor integrated ECU compressed air suspension pump assembly as claimed in claim 1, characterized in that: At least one crankshaft is arranged on the rotor shaft of the rotor, and the eccentricity parameters include the shape, weight, quantity and layout angle of the crankshaft.

3. The brushless synchronous motor integrated ECU compressed air suspension pump assembly as claimed in claim 1, characterized in that: The ECU is integrated on a PCB board, and the PCB board is installed between the stator housing and the stator end cover of the brushless synchronous motor.

4. The brushless synchronous motor integrated ECU compressed air suspension pump assembly as claimed in claim 3, characterized in that: The PCB board and the stator end cover are both square in shape, a square frame is sleeved on the end of the stator housing, and the PCB board is connected between the stator end cover and the square frame by screws.

5. The brushless synchronous motor integrated ECU compressed air suspension pump assembly as claimed in claim 3, characterized in that: The PCB board and the stator end cover are both circular, and a connecting sleeve extending in the axial direction is provided on the outer periphery of the end of the stator housing. The PCB board is connected between the stator end cover and the connecting sleeve by screws.

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