Five-in-one electric pump assembly applied to full-active suspension of vehicle

Abstract

The utility model belongs to the technical field of electric pump devices, and particularly relates to a five-in-one electric pump assembly applied to a full-active suspension of a vehicle, which comprises a controller, two bidirectional internal gear pumps and two motor assemblies, the motor assembly comprises two motors, the two-way internal gear pump is connected to the ends of the motors, the controller is arranged above the two motors, a motor shaft extending out of the motor assembly is coaxially provided with a pentagonal spline, the pentagonal spline comprises five outer acting surfaces and an outer transition surface, and the outer acting surfaces are arc-shaped surfaces protruding outwards; an inner pentagonal hole matched with the pentagonal spline in an engaged mode is coaxially formed in an outer gear of the two-way internal gear pump. The electric pump is used for solving the technical problems that a motor and a pump in an existing electric pump are in transmission connection through a flat key or an involute spline, the positioning gap and the repeated impact resistance are poor, and the response capacity to real-time flow is affected.

Description

A five-in-one electric pump assembly applied to a fully active vehicle suspension Technical Field

[0001] This utility model belongs to the technical field of electric pump devices, specifically relating to a five-in-one electric pump assembly applied to a vehicle's fully active suspension. Background Technology

[0002] As market customers demand increasingly higher levels of smoothness and handling from their vehicles, the market share of electronically controlled shock absorbers is gradually increasing, and active suspension, as a superior technical solution, is gradually becoming the mainstream in the market. The electric pump unit is a crucial and indispensable actuator in active suspension. It uses a high-performance permanent magnet motor to drive a four-quadrant internal gear pump, supporting both forward and reverse rotation, continuously supplying high-pressure oil to the shock absorbers. This enables a wider adjustment bandwidth and faster response speed for the suspension, truly improving vehicle smoothness and handling, and providing passengers with a better driving experience.

[0003] Currently, the main connection methods used for motors and pumps in China are fixed connections and direct connections. Transmission is primarily accomplished through flat keys and involute splines. Flat keys are generally used for connections between components, while involute splines offer better centering and load-bearing capacity, but their positioning clearances are larger and their resistance to repeated impacts is poor. Therefore, electric pumps connected using flat keys or involute splines exhibit poor real-time flow response. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the purpose of this utility model is to provide a five-in-one electric pump assembly for use in fully active vehicle suspensions. This assembly solves the technical problem that current electric pumps use a key or involute spline drive connection between the motor and pump, resulting in poor positioning clearance and resistance to repeated impacts, which affects the responsiveness to real-time flow.

[0005] To achieve the above objectives, the technical solution of this utility model is as follows: a five-in-one electric pump assembly applied to a fully active suspension of a vehicle. This electric pump assembly includes an integrated controller, two bidirectional internal gear pumps, and two motor assemblies. The two motor assemblies are arranged back-to-back. The bidirectional internal gear pumps are connected to the ends of the motors furthest from the other motor. The controller is positioned above the two motors. A penta-spindle is coaxially arranged on the shaft extending from the motor assembly. The penta-spindle includes five circumferentially evenly arranged external action surfaces and an external transition surface connecting two adjacent external action surfaces. The external action surfaces are outwardly convex arc-shaped surfaces. An internal penta-spindle hole is coaxially arranged on the external gear of the bidirectional internal gear pump, meshing with the penta-spindle. The shaft extends through the penta-spindle portion into the internal penta-spindle hole, realizing the transmission connection between the motor assembly and the bidirectional internal gear pump.

[0006] Preferably, the outer transition surface is an outwardly convex arc-shaped surface.

[0007] Preferably, the inner pentagonal hole includes an inner working surface that is close to the outer working surface and an inner transition surface that is close to the outer transition surface.

[0008] Preferably, the gap between the inner working surface and the outer working surface is set between 0.01 and 0.03 mm.

[0009] Preferably, the ends of the pentagonal spline and the inner pentagonal hole are chamfered to facilitate assembly.

[0010] Preferably, the shaft includes a first connecting portion connected to the rotor inside the motor assembly, a second connecting portion connected to the housing of the double inward meshing gear pump, and a third connecting portion connected to the end of the second connecting portion away from the first connecting portion, wherein the pentagonal spline is disposed on the third connecting portion.

[0011] Preferably, the diameter of the circumscribed circle of the five transition surfaces on the pentagonal spline is not greater than the diameter of the second connecting portion, and the diameter of the inscribed circle of the five functional surfaces is not less than the diameter of the third connecting portion.

[0012] Preferably, the connection between the machine shaft and the inner patented connection of the motor assembly is provided with knurling.

[0013] The beneficial effects of adopting the technical solution of this utility model are as follows:

[0014] This utility model integrates two motors, two gear pumps, and a controller into one unit. The controller is placed above the two back-to-back motor assemblies, which is a reasonable design that reduces the space occupied. By connecting the motors and gear pumps through a five-point spline and an inner five-point hole, the motor assembly and gear pumps are centrally positioned and torque is transmitted. The five-point spline includes five external working surfaces and an external transition surface connecting two adjacent external working surfaces. The external working surfaces are outwardly convex arc surfaces, which have a large pressure area during torque transmission, strong impact resistance, and good real-time flow response. Attached Figure Description

[0015] Figure 1 is an overall schematic diagram of an embodiment of a five-in-one electric pump assembly applied to a fully active vehicle suspension;

[0016] Figure 2 is a schematic cross-sectional view of the motor assembly and the bidirectional internal gear pump assembly.

[0017] Figure 3 is a schematic diagram of the fit between the external gear, the machine shaft and the rotor;

[0018] Figure 4 is a schematic diagram of the cross-section of the pentagonal spline.

[0019] In Figures 1-4, 1-motor assembly, 11-shaft, 111-first connecting part, 112-second connecting part, 113-third connecting part, 114-pentagonal spline, 1141-outer working surface, 1142-outer transition surface, 1143-chamfer, 12-rotor, 2-double internal meshing gear pump, 21-housing, 22-external gear, 221-inner pentagonal hole, 23-gear ring, 24-pump cover, 31-high voltage PCB, 32-low voltage PCB, 33-controller cover, 34-high voltage connector, 35-low voltage connector, 4-first positioning pin, 5-second positioning pin. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, not all embodiments, and do not limit the scope of the present utility model.

[0021] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model 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, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0022] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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 can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0023] The specific implementation method is as follows:

[0024] Example 1, as shown in Figures 1-4, describes a five-in-one electric pump assembly applied to a fully active vehicle suspension. This electric pump assembly includes two motor assemblies 1, two bidirectional internal gear pumps 2, and a controller. The two motor assemblies 1 are arranged back-to-back, positioned by a first locating pin 4 and connected by bolts. The mating joint of the two motor assemblies 1 is sealed with sealant. A rotor 12 inside each motor assembly 1 is press-fitted with a shaft 11, which is connected to the housing of the motor assembly 1 via bearings. The shaft 11 extends from one end of the motor assembly 1 and connects to the bidirectional internal gear pump 2. The bidirectional internal gear pump 2 includes a housing 21, a gear ring 23 housed within the housing 21, an external gear 22 eccentrically meshing with the gear ring 23, and a pump cover 24 connecting to the end of the housing 21. The shaft 11 is connected to the external gear 22. The motor assembly 1 and the housing 21 are positioned by a second locating pin 5 and connected by bolts. A cavity is formed at the upper end of the two motor assemblies 1 to house the controller. The controller includes a high-voltage PCB 31 and a low-voltage PCB 32 placed within the cavity. The high-voltage PCB is fixed to the housing of the motor assembly 1 with bolts. The controller also includes a controller cover 33 for protecting the high-voltage PCB 31 and low-voltage PCB 32 and connecting to the upper cavity of the motor assembly 1. The low-voltage PCB is fixed to the controller cover 33 with six bolts, and the controller cover 33 is fixed to the motor assembly 1 with twelve bolts and sealed with sealant. A high-voltage connector 34 connected to the high-voltage PCB 31 and a low-voltage connector 35 connected to the low-voltage PCB are provided on the controller cover 33. Based on this, the two electric pumps (including the motor assembly and gear pump) are arranged back-to-back, and the controller is positioned above the two motor assemblies 1, completing the integrated setup. The entire arrangement is reasonable, occupies little space, and saves space in the vehicle body.

[0025] A pentagram spline 114 is coaxially mounted on the machine shaft 11, and an inner pentagram hole 221 is coaxially mounted on the external gear 22. The pentagram spline 114 is meshed within the inner pentagram hole 221. The pentagram spline 114 includes five external working surfaces 1141 and five external transition surfaces 1142. The five external working surfaces 1141 are evenly arranged along the circumference of the machine shaft 11. The five external transition surfaces 1142 are respectively located between two adjacent external working surfaces 1141 and are connected to the external working surfaces 1141. The inner pentagram hole 221 is a hole that meshes with the pentagram spline 114, realizing the center positioning and torque transmission between the motor assembly 1 and the bidirectional internal meshing gear pump 2. More specifically, the outer working surface 1141 is an arc-shaped surface that bulges outward relative to the machine shaft 11, and the outer transition surface 1142 is also an arc-shaped surface that bulges outward relative to the machine shaft 11, which makes the pressure area larger during torque transmission, improves the impact resistance of the five-sided spline 114, and thus improves the responsiveness to real-time flow.

[0026] This embodiment describes a five-in-one electric pump assembly applied to a fully active vehicle suspension. When in use, the assembly of two motor assemblies 1, two bidirectional internal gear pumps 2, and a controller results in high integration and a small footprint. The motor assemblies 1 and the bidirectional internal gear pumps 2 mesh via a pentagonal spline 114 on the shaft 11 and an inner pentagonal hole 221 on the external gear 22. Both the outer working surface 1141 and the outer transition surface 1142 of the pentagonal spline 114 are arc-shaped surfaces convex outwards relative to the shaft 11, thereby increasing the pressure-bearing area during torque transmission, improving the impact resistance of the pentagonal spline 114, and ultimately enhancing the responsiveness to real-time flow.

[0027] Furthermore, the inner pentagonal hole 221 includes an inner working surface and an inner transition surface. The inner working surface is matched and close to the outer working surface 1141, and the inner transition surface is matched and close to the outer transition surface 1142, thereby realizing the meshing of the pentagonal spline 114 and the inner pentagonal hole 221.

[0028] In this embodiment, the gap between the inner working surface and the outer working surface 1141 is set between 0.01 and 0.03 mm to improve positioning accuracy.

[0029] Furthermore, chamfers 1143 are provided at the ends of the pentagonal spline 114 and the inner pentagonal hole 221 to ensure the ease and speed of assembly of the pentagonal spline 114 and the inner pentagonal hole 221.

[0030] Example 2, as shown in Figures 1-4, describes a five-in-one electric pump assembly applied to a vehicle's fully active suspension. Unlike Example 1, the shaft 11 consists of three parts: a first connecting part 111, a second connecting part 112, and a third connecting part 113, all coaxial and integrally formed. The first connecting part 111 connects to the rotor 12, the second connecting part 112 connects to the housing 21, and a five-pointed spline 114 is disposed on the third connecting part 113 for connecting to the external gear 22, thereby achieving a transmission connection between the shaft 11 and the external gear 22.

[0031] In this embodiment, the size of the five-sided spline 114 depends on the diameters of the second connecting part 112 and the third connecting part 113; wherein, the diameter of the inscribed circle of the five outer working surfaces 1141 should be greater than or equal to the diameter of the third connecting part 113, and the diameter of the circumscribed circle of the five outer transition surfaces 1142 should be less than or equal to the diameter of the second connecting part 112, so as to ensure the transmission function of the machine shaft 11.

[0032] Furthermore, since the assembly between the machine shaft 11 and the rotor 12 is completed by press fitting, if the machine shaft 11 is a smooth shaft, the press fitting will be more difficult. In order to reduce the press fitting difficulty between the machine shaft 11 and the rotor 12, knurling is provided on the outer wall of the second connecting part 111 connected to the rotor 12.

[0033] In this embodiment, the knurling can be straight knurling, oblique knurling, or other patterns, as long as it can reduce the difficulty of pressing.

[0034] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the technical solution of the present invention, or the direct application of the concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A five-in-one electric pump assembly for use in a fully active vehicle suspension, the electric pump assembly comprising an integrated controller, two bidirectional internal gear pumps, and two motor assemblies, the two motor assemblies being arranged back-to-back, the bidirectional internal gear pumps being connected to the ends of the motors away from the other motor, and the controller being disposed above the two motors, characterized in that, The motor assembly has a five-pointed spline coaxially arranged on its extended shaft. The five-pointed spline includes five external working surfaces evenly arranged circumferentially and an external transition surface connecting two adjacent external working surfaces. The external working surfaces are outwardly convex arc-shaped surfaces. The external gear of the bidirectional internal gear pump has an internal five-pointed hole coaxially arranged to mesh with the five-pointed spline. The motor shaft extends into the internal five-pointed hole through the five-pointed spline portion, realizing the transmission connection between the motor assembly and the bidirectional internal gear pump.

2. The five-in-one electric pump assembly applied to a fully active vehicle suspension according to claim 1, characterized in that, The outer transition surface adopts an outwardly convex arc shape.

3. The five-in-one electric pump assembly applied to a fully active vehicle suspension according to claim 2, characterized in that, The inner pentagonal hole includes an inner working surface that is close to the outer working surface and an inner transition surface that is close to the outer transition surface.

4. The five-in-one electric pump assembly applied to a fully active vehicle suspension according to claim 3, characterized in that, The gap between the inner working surface and the outer working surface is set between 0.01 and 0.03 mm.

5. A five-in-one electric pump assembly applied to a fully active vehicle suspension according to claim 4, characterized in that, Both the ends of the pentagonal spline and the inner pentagonal hole are chamfered to facilitate assembly.

6. A five-in-one electric pump assembly applied to a fully active vehicle suspension according to any one of claims 1-5, characterized in that, The shaft includes a first connecting part connected to the inner rotor of the motor assembly, a second connecting part connected to the housing of the bidirectional internal gear pump, and a third connecting part connected to the end of the second connecting part away from the first connecting part, with the pentagram spline disposed on the third connecting part.

7. A five-in-one electric pump assembly applied to a fully active vehicle suspension according to claim 6, characterized in that, The diameter of the circumscribed circle of the five transition surfaces on the pentagonal spline is not greater than the diameter of the second connecting part, and the diameter of the inscribed circle of the five functional surfaces is not less than the diameter of the third connecting part.

8. A five-in-one electric pump assembly applied to a fully active vehicle suspension according to claim 7, characterized in that, The connection between the machine shaft and the inner rotor of the motor assembly is provided with knurling.

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