Five-in-one high-power electric hydraulic pump assembly for supplying energy to active suspension system

Abstract

A five-in-one high-power electric hydraulic pump assembly for supplying energy to an active suspension system belongs to the technical field of vehicle chassis and comprises two motors, two hydraulic pumps and a motor controller, the two motors are arranged back to back, the two hydraulic pumps are respectively arranged at shaft ends of the two motors, motor shells of the two motors are connected into a whole, and the motor controller is connected with the two motors. The motor controller is arranged on the side surfaces of the two motors, through integration and optimization design, the number of structural units in the motor controller is reduced, the manufacturing cost is reduced, the overhaul and maintenance difficulty is reduced, the PCB lower board structure is specially designed, the circuit safety is guaranteed, meanwhile, the depth of heat transfer and heat dissipation of the motors is further deepened, and the service life of the motors is prolonged. And meanwhile, the temperature sensor arranged in the stator also realizes real-time monitoring on the temperature condition of the motor.

Description

Technical Field

[0001] This utility model belongs to the field of vehicle chassis technology, and particularly relates to active suspension systems, specifically a five-in-one high-power electric hydraulic pump assembly that supplies power to the active suspension system. Background Technology

[0002] Traditional shock absorbers have poor vibration filtering performance, resulting in mediocre ride comfort. While semi-active suspension improves this to some extent, as its damping can be continuously adjusted, it still falls short of active suspension in terms of adjustment precision and response speed. As market demands for smoothness and handling continue to rise, the market share of electronically controlled shock absorbers is gradually increasing, and active suspension, as a superior technical solution, is gradually becoming the mainstream.

[0003] In an active suspension system, the electric hydraulic pump is a crucial component, serving as the power supply unit for the shock absorbers. Through this unit, the fully active suspension system can actively apply force in real time to counteract road impacts or vehicle movements (such as roll and pitch). Compared to the passive buffering of traditional suspensions or the damping adjustment of semi-active suspensions, the fully active suspension system can more directly control the vehicle's attitude. Furthermore, thanks to the millisecond-level high-speed response characteristics of the hydraulic system, it can respond to complex road conditions more promptly, significantly improving ride comfort.

[0004] In practical applications, to provide sufficient pressure to the hydraulic cylinders of the shock absorbers in an active suspension system, the electro-hydraulic pump assembly, as the power supply unit, often requires a combination of more than one motor and hydraulic pump. This necessitates leaving sufficient space for the active suspension system, severely impacting its performance. To save space, integrated design solutions have been developed, combining two motors, two hydraulic pumps, and a motor controller into a five-in-one structure, as shown in the structure presented in "Motor Assembly, Hydraulic Power Supply System, Chassis System and Vehicle" (CN 222602153 U). However, this integrated design also has significant problems: firstly, the structure is complex, making maintenance difficult and posing challenges to reliability and durability; secondly, as the motor is a high-heat-generating unit, the integrated design's heat dissipation scheme, in addition to heat dissipation through the motor housing, also includes a heat dissipation structure in the direction of the controller. However, multiple PCBs with poor heat transfer are stacked on top of the heat dissipation structure, severely affecting its heat dissipation effect. Furthermore, the high temperatures emanating from the heat dissipation can even affect the lifespan of electronic components on the PCBs. Therefore, there is a need for an integrated electric hydraulic pump assembly design with a relatively simple structure, excellent layout, and good heat dissipation to meet the requirements of high-performance active suspension systems. Utility Model Content

[0005] To address the shortcomings of existing technologies, this invention proposes a five-in-one high-power electric hydraulic pump assembly for powering an active suspension system, thereby meeting the requirements of high-performance active suspension systems.

[0006] The technical problem to be solved by this utility model is achieved through the following technical solution:

[0007] A five-in-one high-power electric hydraulic pump assembly for powering an active suspension system includes two motors, two hydraulic pumps, and a motor controller. The two motors are arranged back-to-back, and the two hydraulic pumps are respectively mounted on the shaft ends of the two motors. The motor housings of the two motors are connected as one unit. The motor controller is located on the side of the two motors. In this utility model, the motor controller includes a controller housing, and an upper PCB board and a lower PCB board are arranged sequentially inside the controller housing. The lower PCB board covers the two motors, with a circuit area in the middle and heat dissipation areas on both sides. SiC components penetrating the lower PCB board are distributed in the heat dissipation areas. A water-cooled cover plate is provided near the motor controller on the motor housing. Heat dissipation protrusions are distributed on the upper surface of the water-cooled cover plate, and the heat dissipation protrusions contact and correspond one-to-one with the SiC components on the lower PCB board.

[0008] In this utility model, the upper PCB board is a low-voltage PCB board, which is fixed to the controller housing above it by bolts. The lower PCB board is a high-voltage PCB board, which is fixed to the motor housing below it by bolts. There is a gap between the upper PCB board and the lower PCB board. The circuit areas of both the upper PCB board and the lower PCB board are provided with snap-fit ​​interfaces, and they are connected by wires.

[0009] Furthermore, the low-voltage PCB board is connected to low-voltage connectors by soldering, and the high-voltage PCB board is connected to high-voltage connectors by plugging.

[0010] In this invention, the lower surface of the water-cooled cover plate is evenly distributed with heat dissipation feet, and the arrangement of the heat dissipation feet forms a heat dissipation channel to absorb the heat emitted from the motor.

[0011] In this invention, a temperature and pressure detection assembly is provided at the connection between the motor housing and the hydraulic pump. This assembly includes a temperature and pressure PCB board integrating a temperature and pressure sensor and a stator temperature sensor. The temperature and pressure sensor is press-fitted into the hydraulic pump body to detect the temperature and pressure of the hydraulic pump. It is connected to the low-voltage PCB board via a connector harness. The stator temperature sensor extends into the stator assembly of the motor to detect the stator temperature. The stator temperature sensor is connected to the high-voltage PCB board via a connector harness.

[0012] In this utility model, the end of the electric hydraulic pump assembly is provided with a rubber bushing, and the electric hydraulic pump assembly is connected to the vehicle body through the rubber bushing, which can play the role of vibration isolation and buffering.

[0013] Compared with the prior art, the present invention has the following advantages:

[0014] This application further transfers heat by setting silicon carbide components on the PCB adjacent to the water-cooling cover plate that cooperate with the heat dissipation protrusions on the water-cooling cover plate, thereby avoiding the isolation of heat by the insulating and heat-insulating PCB board, effectively expanding the heat dissipation surface and improving the heat dissipation effect.

[0015] This application improves heat dissipation by simplifying the internal structure of the controller, providing sufficient space for heat flow and dissipation;

[0016] This application divides the PCB board into functional zones, with heat dissipation zones assisting in heat transfer and dissipation, and circuit zones achieving their adjustment and control effects. The heat dissipation zones and circuit zones are separated by the good insulation effect of the PCB material, but the poor heat transfer effect. This effectively prevents the heat dissipation zones from rapidly transferring high temperatures to the circuit zones and affecting the performance of high voltage components.

[0017] This application monitors the hydraulic pump status in real time by installing a temperature and pressure sensor on the hydraulic pump and monitors the motor temperature status in real time by installing a stator temperature sensor on the motor stator, thereby determining whether the cooling and heat dissipation structure is working properly and effectively avoiding failures caused by high motor temperature.

[0018] This application provides rubber bushings at both ends of the electric hydraulic pump assembly, which separate the connection between the electric hydraulic pump assembly and the vehicle body, effectively providing vibration isolation and buffering. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the external shape of the electric hydraulic pump assembly of this utility model;

[0020] Figure 2 This is an exploded view of the electric hydraulic pump assembly structure of this utility model (including the motor controller and the single-sided motor hydraulic pump).

[0021] Figure 3 This is a schematic diagram of the controller housing and PCB upper board structure of this utility model;

[0022] Figure 4 This is a schematic diagram of the motor controller and motor housing structure of this utility model;

[0023] Figure 5 This is a schematic diagram showing the installation position of the temperature and pressure detection component of this utility model;

[0024] Figure 6 This is a schematic diagram of the installation of the temperature and pressure sensor of this utility model.

[0025] In the diagram: motor controller 100, controller housing 101, low-voltage connector 102, low-voltage connector bolt 102a, high-voltage connector 103, high-voltage connector bolt 103a, PCB upper board 104, PCB upper board bolt 104a, snap-fit ​​interface 105, SiC components 106, PCB lower board 107, (PCB lower board) circuit area 107a, (PCB lower board) heat dissipation area 107b, PCB lower board bolt 107c, wire 108, connector harness 109;

[0026] Hydraulic pump 110, rubber bushing 111, pump cover 112, pump body 113, temperature and pressure sensor 114, spring pin 114a, temperature and pressure PCB board 115, temperature and pressure PCB board bolt 115a, conductive copper sheet 115b;

[0027] Motor 120, water-cooled cover plate 121, heat dissipation protrusion 121a, motor housing 122, stator 123, stator temperature sensor 124, motor shaft and rotor 125. Detailed Implementation

[0028] The present invention will be further described below with reference to the accompanying drawings and specific preferred embodiments, but this does not limit the scope of protection of the present invention.

[0029] A five-in-one high-power electro-hydraulic pump assembly that powers a fully active suspension system, such as Figure 1 As shown, it includes two motors 120, two hydraulic pumps 110, and a motor controller 100. The two motors 120 are arranged back to back, and the hydraulic pumps 110 are respectively installed on the shaft ends of the motors 120. The motor housings 122 of the two motors 120 are connected as one unit. The motor controller 100 is installed on the side of the two motors 120. A rubber bushing 111 is provided on the outside of the hydraulic pump 110. The electric hydraulic pump assembly is connected to the vehicle body through the rubber bushing 111.

[0030] like Figure 2 As shown, the motor controller 100 includes a controller housing 101 and an upper PCB board 104 and a lower PCB board 107 disposed within the controller housing 101. Figure 3 In the middle, the upper PCB board 104 is fixed to the controller housing 101 by PCB upper board bolts 105. A gap is left between the upper PCB board 104 and the lower PCB board 107. Both the circuit area 107a of the upper PCB board 104 and the circuit area 107a of the lower PCB board 107 are provided with snap-fit ​​interfaces 105, and they are connected by wires 108. Figure 4In the middle, the PCB lower plate 107 is fixed to the motor housing 122 by PCB lower plate bolts 107c. The PCB lower plate 107 covers the two motors 120 on the left and right. The middle part is the circuit area 107a, and the two sides are heat dissipation areas 107b. The heat dissipation areas 107b are distributed with SiC components 106 that penetrate the PCB lower plate 107. Correspondingly, a water-cooling cover plate 121 is provided on the motor housing 122 near the motor controller 100. The lower surface of the water-cooling cover plate 121 has heat dissipation feet evenly distributed. The arrangement of the heat dissipation feet forms a heat dissipation channel. The heat dissipation feet face into the motor housing 122 or contact the motor housing 122 for heat transfer. The upper surface of the water-cooled cover plate 121 has heat dissipation protrusions 121a. The heat dissipation protrusions 121a contact and correspond one-to-one with the SiC components 106 on the lower PCB board 107. The heat dissipation protrusions 121a absorb the heat from the motor 120 and transfer part of it through the SiC components 106, so that the gap between the lower PCB board 107 and the upper PCB board 104 can also dissipate heat.

[0031] The controller housing 101 of the motor controller 100 is provided with a high-voltage connector 103 and a low-voltage connector 102, which are respectively located on both sides of the motor controller 100. The high-voltage connector 103 is fixed by a high-voltage connector bolt 103a, and the low-voltage connector 102 is fixed by a low-voltage connector bolt 102a. The low-voltage connector 102 is electrically connected to the upper PCB board 104 through its pins. The high-voltage connector 103 is electrically connected to the lower PCB board 107 through a connector.

[0032] like Figure 2 and 5 As shown, the motor 120 includes a motor housing 122, a stator 123, a motor shaft, and a rotor 125. The stator 123 is fixedly connected to the motor housing 122. The motor shaft is located at the center of the rotor and rotates synchronously with the rotor. The motor shaft and the rotor 125 are located at the central axis of the stator 123. The end of the motor shaft is inserted into the hydraulic pump 110. The hydraulic pump 110 includes a pump body 113 and a pump cover 112. The rubber bushing 111 is disposed on the pump cover 112.

[0033] A temperature and pressure detection component is provided at the connection between the motor housing 122 and the hydraulic pump 110, such as... Figure 6As shown, the temperature and pressure detection assembly includes a temperature and pressure PCB board 115 integrating a temperature and pressure sensor 114 and a stator temperature sensor 124. The temperature and pressure sensor 114 is press-fitted into the pump body 113 of the hydraulic pump 110. The temperature and pressure PCB board 115 is fixed to the pump body 113 by temperature and pressure PCB board bolts 115a. The temperature and pressure sensor 114 is soldered to the conductive copper sheet 115b reserved on the temperature and pressure PCB board 115 through spring pins 114a, and connected to the low-voltage connector 102 through a connector harness 109. The stator temperature sensor 124 extends into the stator 123 of the motor 120 to detect the temperature of the motor stator 123. The stator temperature sensor 124 is connected to the lower PCB board 107 through the connector harness 109.

[0034] In summary, this application reduces the number of structural units within the motor controller through integrated and optimized design, thereby lowering manufacturing costs and reducing the difficulty of inspection and maintenance. The specially designed PCB lower board structure, while ensuring circuit safety, further deepens the heat transfer and dissipation of the motor, making the heat dissipation effect more obvious. At the same time, the temperature sensor installed in the stator enables real-time monitoring of the motor temperature.

Claims

1. A five-in-one high-power electric hydraulic pump assembly for powering an active suspension system, comprising two motors, two hydraulic pumps, and a motor controller; the two motors are arranged back-to-back; the two hydraulic pumps are respectively mounted on the shaft ends of the two motors; the motor housings of the two motors are integrated; and the motor controller is located on the sides of the two motors, characterized in that: The motor controller includes a controller housing, inside which a PCB upper board and a PCB lower board are arranged in sequence. The PCB lower board covers two motors, with the central part being the circuit area and the two sides being heat dissipation areas. The heat dissipation areas are distributed with SiC components that penetrate the PCB lower board. A water-cooling cover is provided on the motor housing near the motor controller. The upper surface of the water-cooling cover is distributed with heat dissipation protrusions, which contact and correspond one-to-one with the SiC components on the PCB lower board.

2. The electro-hydraulic pump assembly of claim 1, wherein: The upper PCB is a low-voltage PCB, which is fixed to the controller housing above it by bolts. The lower PCB is a high-voltage PCB, which is fixed to the motor housing below it by bolts. There is a gap between the upper and lower PCBs. Both the circuit areas of the upper and lower PCBs are equipped with snap-fit ​​interfaces, and they are connected by wires.

3. The electro-hydraulic pump assembly of claim 2, wherein: The low-voltage PCB board is connected to low-voltage connectors by soldering, and the high-voltage PCB board is connected to high-voltage connectors by plugging.

4. The electro-hydraulic pump assembly of claim 1, wherein: The lower surface of the water-cooled cover plate is evenly distributed with heat dissipation feet, and the arrangement of the heat dissipation feet forms a heat dissipation channel.

5. The electro-hydraulic pump assembly of claim 1, wherein: A temperature and pressure detection assembly is provided at the connection between the motor housing and the hydraulic pump, including a temperature and pressure PCB board integrating a temperature and pressure sensor and a stator temperature sensor. The temperature and pressure sensor is press-fitted into the hydraulic pump body and connected to the low-voltage PCB board through a connector harness. The stator temperature sensor extends into the stator assembly of the motor and is connected to the high-voltage PCB board through a connector harness.

6. The electro-hydraulic pump assembly of claim 1, wherein: The end of the electric hydraulic pump assembly is provided with a rubber bushing, and the electric hydraulic pump assembly is connected to the vehicle body through the rubber bushing.

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