An active suspension electro-hydraulic pump assembly motor and a stator module thereof

Abstract

The utility model discloses a kind of stator modules for active suspension electro-hydraulic pump assembly motor, including stator tooth component, stator yoke, stator winding, potting layer and injection layer.Stator tooth component includes several stator teeth, and strengthening rib is equipped between adjacent two stator teeth to connect.Stator yoke sleeve is connected in stator tooth component outside.Stator winding is connected in stator tooth component.Potting layer fills the gap between stator tooth component, stator yoke and stator winding and forms preliminary stator piece.Injection layer injection is formed in the inner side wall of preliminary stator piece;The inner side wall of injection layer forms the stator inner wall of stator module.The utility model also discloses a kind of active suspension electro-hydraulic pump assembly motor, including preceding stator module.The utility model is by setting strengthening rib between adjacent two stator teeth and setting potting layer to form preliminary stator piece, to make the stator inner wall can withstand greater pressure.And, stator tooth can also form stator inner wall on injection layer and play the supporting role.

Description

Technical Field

[0001] This utility model belongs to the field of electro-hydraulic pump technology, and in particular relates to an active suspension electro-hydraulic pump assembly motor and its stator module. Background Technology

[0002] The suspension system connects the wheels and the vehicle body, primarily functioning to cushion vibrations from uneven road surfaces, improving ride comfort and handling. Common suspension types include passive suspension, semi-active suspension, and active suspension. Passive suspension is a traditional combination of springs and shock absorbers, simple in structure but unable to adjust in real time according to road conditions. Semi-active suspension allows adjustment of shock absorber damping, while active suspension goes a step further, actively applying force to adjust the suspension's state.

[0003] Active suspension specifically comprises sensors, controllers, and actuators. Sensors are responsible for detecting the vehicle's state, such as vehicle acceleration, suspension displacement, and wheel speed. The controller processes this data and then uses algorithms to calculate the force to be applied or the parameters to be adjusted. Finally, actuators (such as electro-hydraulic pumps) actually adjust the suspension.

[0004] An electro-hydraulic pump is a power device that converts electrical energy into hydraulic energy. An electric motor module drives a hydraulic pump module, converting mechanical energy into fluid pressure energy. The stator is a crucial component of the motor in an electro-hydraulic pump. Traditional stator structures are divided into integral and segmented types. Integral stators, due to their lower slot fill factor, result in a larger motor size and are unsuitable for electro-hydraulic pumps in active suspension systems. Segmented stators employ an outer circle welding process, but because the stator cavity of a suspension pump needs to withstand significant pressure, traditional segmented stators are unsuitable for this operating environment. Utility Model Content

[0005] The purpose of this utility model is to provide an active suspension electro-hydraulic pump assembly motor and its stator module, so as to solve the problem that the traditional stator structure in the prior art is not suitable for active suspension electro-hydraulic pumps.

[0006] The technical solution of this utility model is as follows:

[0007] A stator module for an active suspension electro-hydraulic pump assembly motor, comprising:

[0008] The stator tooth component includes a plurality of stator teeth, with reinforcing ribs connecting adjacent stator teeth;

[0009] The stator yoke is fitted and connected to the stator gear component;

[0010] Stator windings are connected to the stator gear assembly;

[0011] A potting layer is used to fill the gaps between the stator tooth components, the stator yoke, and the stator windings to form a preliminary stator component;

[0012] An injection-molded layer is formed on the inner wall of the initial stator component; the inner wall of the injection-molded layer forms the inner wall of the stator module.

[0013] Optionally, the outer sidewall of the injection molding layer is provided with a plurality of first protrusions, and the inner sidewall of the potting layer is provided with a plurality of corresponding first grooves, wherein the first protrusions are accommodated in the corresponding first grooves.

[0014] Optionally, the stator teeth include:

[0015] The stator winding is connected to the tooth section;

[0016] A connecting portion, wherein the radially inner side of the tooth is connected to the connecting portion;

[0017] There is a gap between the connecting portions of two adjacent stator teeth, the reinforcing rib is located in the gap, and the two ends of the reinforcing rib are respectively connected to the connecting portions of the stator teeth on both sides.

[0018] Optionally, the reinforcing rib is located in the region of the gap near the radially outer side.

[0019] Optionally, it also includes two support sleeves, which are inserted from both ends of the stator module and connected between the injection molding layer and the potting layer.

[0020] Optionally, it also includes two support sleeves, which are respectively inserted from both ends of the stator module and connected between the injection molding layer and the potting layer;

[0021] Furthermore, one axial end face of the support sleeve abuts against the connecting portion in the stator gear component.

[0022] Optionally, one of the radially outward-facing surfaces of the stator teeth and the inner wall of the stator yoke has a second protrusion, and the other has a corresponding second groove, with the second protrusion accommodated in the second groove.

[0023] Optionally, a temperature sensor may also be included, which is located in the coil of the stator winding.

[0024] Optionally, it may also include a rotor base, which is connected to one axial end of the injection-molded layer.

[0025] Based on the same concept, this utility model also provides an active suspension electro-hydraulic pump assembly motor, including a stator module for an active suspension electro-hydraulic pump assembly motor as described in any of the above claims.

[0026] Because of the adoption of the above technical solution, this utility model has the following advantages and positive effects compared with the prior art:

[0027] The active suspension electro-hydraulic pump assembly motor and its stator module provided by this utility model form a preliminary stator component by setting reinforcing ribs between adjacent stator teeth and setting a potting layer to integrate the components (stator tooth components, stator yoke, stator windings, etc.) in the stator module into a whole. This allows the inner wall of the stator module of this utility model to withstand greater pressure. Furthermore, the radially inward-facing surfaces of the stator teeth also provide support for the inner wall of the stator formed on the injection-molded layer. Therefore, the active suspension electro-hydraulic pump assembly motor and its stator module of this utility model are applicable to active suspension electro-hydraulic pumps. Attached Figure Description

[0028] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of the invention.

[0029] Figure 1 This is an exploded schematic diagram of a stator module (without rotor base and sealing ring) for an active suspension electro-hydraulic pump assembly motor according to the present invention.

[0030] Figure 2 This is an axial cross-sectional schematic diagram of a stator module for an active suspension electro-hydraulic pump assembly motor according to the present invention.

[0031] Figure 3 This is a radial cross-sectional schematic diagram of a stator module (without rotor base and sealing ring) for an active suspension electro-hydraulic pump assembly motor according to the present invention.

[0032] Figure 4 for Figure 1 Schematic diagram of the insulating frame;

[0033] Figure 5 This is a structural schematic diagram of a stator gear component according to the present invention;

[0034] Figure 6 for Figure 1 Schematic diagram of the middle stator yoke;

[0035] Figure 7 This is a schematic diagram of the structure of a potting layer according to the present invention;

[0036] Figure 8 for Figure 1 A schematic diagram of the middle injection layer.

[0037] Explanation of reference numerals in the attached figures:

[0038] 1: Stator gear component; 11: Stator tooth; 111: Tooth portion; 112: Connecting part; 113: Second protrusion; 12: Reinforcing rib; 2: Stator yoke; 21: Second groove; 3: Insulating frame; 4: Coil; 5: Encapsulation layer; 51: First groove; 6: Injection molding layer; 61: First protrusion; 62: Injection molding chamfer; 7: Temperature sensor; 8: Support sleeve; 9: Rotor base; 10: Sealing ring. Detailed Implementation

[0039] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the specific implementation methods of this utility model will be described below with reference to the accompanying drawings. Obviously, the drawings described below are merely some embodiments of this utility model. For those skilled in the art, other drawings and other implementation methods can be obtained based on these drawings without any creative effort.

[0040] To keep the drawings concise, only the parts relevant to this invention are shown schematically in each figure, and they do not represent the actual structure of the product. Furthermore, for ease of understanding, in some figures, only one of the components with the same structure or function is schematically depicted, or only one is labeled. In this document, "one" not only means "only one," but can also mean "more than one."

[0041] Example 1

[0042] See Figures 1 to 8 This embodiment provides a stator module for an active suspension electro-hydraulic pump assembly motor, including a stator gear component 1, a stator yoke 2, a stator winding, a potting layer, and an injection molding layer.

[0043] The stator winding includes several insulating frames 3 and coils 4. Several insulating frames 3 (specifically, 12 insulating frames 3 in this embodiment) are laid flat on a winding fixture, and then the coils 4 are wound around the insulating frames 3 to form the stator winding. The insulating frames 3 can be plastic frames.

[0044] The stator tooth component 1 includes a plurality of stator teeth 11, which are evenly distributed along the circumferential direction of the stator module (unless otherwise specified in this document, the circumferential direction refers to the circumferential direction of the specified sub-module), and are connected by reinforcing ribs 12 between adjacent stator teeth 11. Specifically, as shown... Figure 5 As shown, the stator tooth 11 includes a tooth portion 111 and a connecting portion 112. The radially inner side of the tooth portion 111 is connected to the connecting portion 112. There is a gap between the connecting portions 112 of two adjacent stator teeth 11, and a reinforcing rib 12 is located in the gap. The two ends of the reinforcing rib 12 are respectively connected to the connecting portions 112 of the stator teeth 11 on both sides. The design of the reinforcing rib 12 strengthens the structural strength of the entire stator tooth component 1.

[0045] The gap formed between the connecting portions 112 of two adjacent stator teeth 11 has multiple reinforcing ribs 12 spaced apart along the axial direction of the stator module. The width of the reinforcing ribs 12 (e.g., ...) Figure 3 As shown in the figure, within the cross-section shown, the arc length of the reinforcing rib 12 on the circle is equal to the width of the reinforcing rib 12 (i.e., the distance between the two connecting parts 112 connected to the reinforcing rib 12 is also equal to the width of the reinforcing rib 12). This width can be designed to be relatively small, in this embodiment, approximately 0.5 mm. The vertical spacing of the reinforcing ribs 12 between adjacent connecting parts 112, and the smaller width of the reinforcing ribs 12, both contribute to reducing stator leakage flux.

[0046] In the gap formed between the connection portion 112 of two adjacent stator teeth 11, the reinforcing rib 12 is located in the region near the radial outer side of the gap.

[0047] The stator winding is connected to the stator tooth component 1, specifically the teeth 111 on the stator teeth 11 in the stator tooth component 1. During assembly, the wound insulating frame 3 is inserted into the stator teeth 11 in the stator tooth component 1 by rolling it into a circle, thereby assembling the stator winding onto the stator tooth component 1. Ideally, there should be no gap between the insulating frame 3 and the stator teeth 11 after assembly, but for ease of assembly, in this embodiment, the gap between the insulating frame 3 and the stator teeth 11 is designed to be approximately 0.01 mm.

[0048] The stator yoke 2 is sleeved and connected to the stator tooth component 1. The stator teeth 11 have radially outward-facing surfaces (unless otherwise specified, radially inward-facing or radially outward-facing surfaces refer to the radial direction of the specified submodule) and inner walls of the stator yoke 2. One of the teeth has a second protrusion 113, and the other has a corresponding second groove 21. The second protrusion 113 is accommodated within the second groove 21. Specifically, in this embodiment, the second protrusion 113 is provided on the radially outward-facing surface of the stator tooth 11, and a corresponding second groove 21 is provided on the inner wall of the stator yoke 2. Furthermore, the second protrusion 113 can be configured such that its length in the circumferential direction increases radially outward, and the shape of the second groove 21 is adapted to the second protrusion 113. This allows for a tighter connection between the stator teeth 11 and the stator yoke 2. Furthermore, the shape of one of the second protrusions 113 is designed to be different, and the shape of the second groove 21 corresponding to the second protrusion 113 is changed accordingly, so that the stator yoke 2 and stator tooth component 1 can be positioned in the circumferential direction.

[0049] After the stator winding is assembled onto the stator tooth component 1, the stator yoke 2 and the stator tooth component 1 can be assembled by press fitting. The second protrusion 113 and the second groove 21 further ensure the alignment of the stator tooth component 1 and the stator yoke 2. Ideally, there should be no gap between the second protrusion 113 and the second groove 21 after the stator yoke 2 and the stator tooth component 1 are assembled. However, for ease of assembly, in this embodiment, the mating gap between the second protrusion 113 and the second groove 21 is designed to be approximately 0.05 mm.

[0050] The potting layer 5 fills the gap between the stator tooth component 1, the stator yoke 2, and the stator windings, forming a preliminary stator component. The potting layer 5 can be made of epoxy resin with high thermal conductivity, which provides better heat dissipation for the active suspension electro-hydraulic pump assembly motor, thereby increasing the power density of the active suspension electro-hydraulic pump assembly motor. The injection molding layer 6 is formed on the inner wall of the preliminary stator component through injection molding, and the inner wall of the injection molding layer 6 forms the stator inner wall of the stator module.

[0051] The stator module in this embodiment also includes a temperature sensor 7 and two support sleeves 8. The temperature sensor 7 is located in the coil 4 of the stator winding, and the cable electrically connected to the temperature sensor 7 extends out of the potting layer 5. Figure 2 (Note 7 in the attached diagram actually refers to the cable connected to the temperature sensor 7); the temperature sensor 7 is used to detect the temperature of the stator phase line (i.e., coil 4). Two support sleeves 8 are inserted from both ends of the stator module and connected to the stator module (specifically between the potting layer 5 and the injection molding layer 6).

[0052] After the stator yoke 2 and stator gear component 1 are assembled, one of the support sleeves 8 is press-fitted from one end of the stator module into the insulating frame 3, with the axial end face of the support sleeve 8 abutting against the connecting part 112 in the stator gear component 1. Then, the detection end of the temperature sensor 7 is embedded in the coil 4 (in this embodiment, two temperature sensors 7 are included, and the detection ends of the two temperature sensors 7 are respectively embedded in the coil 4 in the two insulating frames 3). Then, the stator gear component 1 and stator yoke 2 are filled by potting to ensure structural strength; this potting forms the potting layer 5. Then, another support sleeve 8 is press-fitted from the other end of the stator module onto the potted whole, and then the injection layer 6 is formed by injection molding. In this embodiment, the injection molding material is preferably PPS+GF40 (other injection molding materials can also be used in other embodiments).

[0053] After injection molding, the following is observed: two support sleeves 8 are inserted from both ends of the stator module and connected between the potting layer 5 and the injection molding layer 6. The support sleeves 8 are located between the injection molding layer 6 and the potting layer 5, and one axial end face of the support sleeve 8 abuts against the connecting portion 112 in the stator gear component 1. When other parts in the active suspension electro-hydraulic pump assembly motor are assembled with the stator module of this embodiment, the main connection points are the two ends of the inner wall of the stator. The two support sleeves 8 provide support for the injection molding layer 6 (the inner wall of the stator is formed by the injection molding layer 6), thereby improving the structural strength of the stator module. In this embodiment, the support sleeves 8 can be made of steel, but in other embodiments, the support sleeves 8 can also be made of other materials.

[0054] Because the reinforcing rib 12 is located in the region near the radially outer side of the gap formed between the connecting portions 112 of two adjacent stator teeth 11, the region near the radially inner side of the gap is left empty. This empty portion can be used to form a first groove 51 on the inner wall of the potting layer 5 during the potting process, i.e., a plurality of first grooves 51 are provided on the inner wall of the potting layer 5. Thus, during the injection molding process to form the injection layer 6, a first protrusion 61 can be formed in the first groove 51, i.e., a plurality of first protrusions 61 corresponding to the plurality of first grooves 51 are provided on the outer wall of the injection layer 6, and the first protrusions 61 are accommodated in the corresponding first grooves 51. The arrangement of the first protrusions 61 and the first grooves 51 ensures that circumferential rotation does not occur between the injection layer 6 and the potting layer 5 after injection molding.

[0055] Furthermore, the stator module in this embodiment also includes a rotor base 9, which is connected to one axial end of the injection-molded layer 6. The rotor base 9 is used to mount the rotor in the active suspension electro-hydraulic pump assembly motor. Figure 2 As shown, two sealing ring grooves are provided on the outer side wall of the rotor base 9. Two sealing rings 10 are respectively installed into the two sealing ring grooves. The sealing rings 10 and the inner side wall of the injection-molded layer 6 are sealed by an interference fit, ensuring that the compression rate of the sealing rings 10 is between 15% and 30%. After the rotor base 9 and the injection-molded part are installed, the sealing rings 10 are located at the corresponding positions of the support sleeve 8. That is, within the radial section where the sealing rings 10 are located, the support sleeve 8 is located radially outside the sealing rings 10. The support sleeve 8 provides support for the injection-molded layer 6, preventing deformation of the inner side wall of the injection-molded layer 6 due to temperature changes from affecting the compression rate of the sealing rings 10. Preferably, injection chamfers 62 are provided at both ends of the inner side wall of the injection-molded layer 6, so that the sealing rings 10 will not be cut during the press-fitting process.

[0056] Example 2

[0057] This embodiment provides an active suspension electro-hydraulic pump assembly motor, including a stator module and a rotor module as described in Embodiment 1 for the active suspension electro-hydraulic pump assembly motor, wherein the rotor module is rotatably mounted on the stator module.

[0058] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to the above embodiments. Even if various changes are made to the present invention, if these changes fall within the scope of the claims of the present invention and their equivalents, they shall still fall within the protection scope of the present invention.

Claims

1. A stator module for an active suspension electro-hydraulic pump assembly motor, characterized by, include: The stator tooth component includes a plurality of stator teeth, with reinforcing ribs connecting adjacent stator teeth; The stator yoke is fitted and connected to the stator gear component; Stator windings are connected to the stator gear assembly; A potting layer is used to fill the gaps between the stator tooth components, the stator yoke, and the stator windings to form a preliminary stator component; An injection-molded layer is formed on the inner wall of the initial stator component; the inner wall of the injection-molded layer forms the inner wall of the stator module.

2. The stator module for an active suspension electro-hydraulic pump assembly motor of claim 1, wherein, The outer sidewall of the injection molding layer is provided with a plurality of first protrusions, and the inner sidewall of the potting layer is provided with a plurality of corresponding first grooves, wherein the first protrusions are accommodated in the corresponding first grooves.

3. The stator module for the active suspension electro-hydraulic pump assembly motor according to claim 1, characterized in that, The stator teeth include: The stator winding is connected to the tooth section; A connecting portion, wherein the radially inner side of the tooth is connected to the connecting portion; There is a gap between the connecting portions of two adjacent stator teeth, the reinforcing rib is located in the gap, and the two ends of the reinforcing rib are respectively connected to the connecting portions of the stator teeth on both sides.

4. The stator module for the active suspension electro-hydraulic pump assembly motor according to claim 3, characterized in that, The reinforcing rib is located in the region near the radial outer side of the gap.

5. The stator module for the active suspension electro-hydraulic pump assembly motor according to claim 1, characterized in that, It also includes two support sleeves, which are inserted from both ends of the stator module and connected between the injection molding layer and the potting layer.

6. The stator module for the active suspension electro-hydraulic pump assembly motor according to claim 3, characterized in that, It also includes two support sleeves, which are inserted from both ends of the stator module and connected between the injection molding layer and the potting layer; Furthermore, one axial end face of the support sleeve abuts against the connecting portion in the stator gear component.

7. The stator module for the motor of the active suspension electro-hydraulic pump assembly according to claim 1, characterized in that, The stator teeth have radially outward-facing surfaces and the inner sidewalls of the stator yoke, one of which has a second protrusion and the other has a corresponding second groove, with the second protrusion accommodated in the second groove.

8. The stator module for the active suspension electro-hydraulic pump assembly motor according to claim 1, characterized in that, It also includes a temperature sensor located in the coil of the stator winding.

9. The stator module for the motor of the active suspension electro-hydraulic pump assembly according to claim 1, characterized in that, It also includes a rotor base, which is connected to one end of the injection-molded layer along its axial direction.

10. A motor for an active suspension electro-hydraulic pump assembly, characterized in that, Includes the stator module for the active suspension electro-hydraulic pump assembly motor as described in any one of claims 1 to 9.

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