An electronic controller for integrated pump valve drive powered by 48V

Abstract

The utility model relates to a kind of integrated pump valve drive's electronic controller powered by 48V, it is related to the field of automotive electronics, and electronic controller is equipped with 48V direct current total power input end, and electronic controller includes: pump motor drive module, connects 48V direct current total power input end;First DCDC step-down circuit one, connects 48V direct current total power input end, and output end outputs medium voltage power supply one;Solenoid valve drive module, connects medium voltage power supply one;Second DCDC step-down circuit, connects 48V direct current total power input end, and output end outputs medium voltage power supply two;Second low voltage supply circuit, connects medium voltage power supply two, and output end outputs low voltage supply;Microcontroller module, connects low voltage supply, and control signal connects pump motor drive module and solenoid valve drive module;Communication interface module, with microcontroller module two-way signal connection.The utility model realizes 48V power supply under high-power pump motor drive efficiency and multi-channel solenoid valve comprehensive optimization by differentiating power architecture.

Description

Technical Field

[0001] This utility model relates to the field of automotive electronics, and in particular to an electronic controller for integrated pump valve drive powered by 48V. It is mainly for electronic controllers for 48V system power supply and integrated pump valve drive system applications, such as 48V system integrated air supply control unit. Background Technology

[0002] Currently, passenger vehicle low-voltage power supply systems still predominantly use a 12V voltage architecture. With the increasing electrification of vehicles, the power demands of various electric loads continue to grow. Traditional 12V systems, when facing high-power applications, suffer from large current flows in their power supply lines, leading to significant conduction losses and overheating, which has become a bottleneck limiting system energy efficiency and power density optimization. Upgrading the low-voltage power supply system to 48V can reduce the supply current to one-quarter of the original 12V system under the same output power conditions, thereby significantly reducing line voltage drop and conduction losses and improving overall energy utilization efficiency. However, the current technological maturity of 48V systems is not as advanced as that of the decades-old 12V system. In particular, there are fewer options available for high-voltage integrated driver chips suitable for 48V, and the related component supply chain and certification system are still under development.

[0003] In integrated pump and valve drive applications powered by 48V, system load characteristics exhibit significant differences. Typically, the system contains only one pump motor load, but its drive power requirements are high. To improve power transmission efficiency and fully utilize the advantages of 48V power supply, directly powering the pump motor load with 48V in the electronic controller is an ideal solution. Meanwhile, the system typically contains a large number of solenoid valves, but the operating current of a single solenoid valve is relatively small. Directly using 48V for drive not only presents a shortage of high-voltage drive integrated chips, but also leads to unnecessary power loss and heat generation for low-current loads due to excessively high drive voltage.

[0004] In existing technologies, if a 48V-powered integrated pump and valve drive system uniformly adopts a 48V drive circuit architecture within its electronic controller, the applicable drive circuit solutions for a large number of low-current solenoid valve loads are extremely limited. In the absence of suitable integrated drive chips, using discrete power devices to build multi-channel drive circuits will significantly increase circuit complexity, component count, and PCB layout area. This not only drives up material costs and manufacturing difficulties but also makes it difficult to meet the stringent design requirements of modern automotive electronic controllers for miniaturization, compactness, and high reliability, severely restricting the engineering application and market promotion of the product. Utility Model Content

[0005] The purpose of this utility model is to provide a differentiated integrated pump and valve drive power supply architecture. By combining the direct 48V high-voltage drive of the pump motor with the medium-voltage integrated chip drive of the solenoid valve, the line loss and circuit complexity are reduced, and the drive efficiency, integration and reliability are comprehensively optimized. This solves the technical problems of low drive efficiency, circuit complexity and insufficient operational reliability caused by the significant difference in load characteristics between high-power pump motors and multiple low-current solenoid valves in a 48V power supply system.

[0006] To achieve the above objectives, the present invention provides an electronic controller for an integrated pump valve driven by a 48V power supply. The electronic controller has a 48V DC main power input terminal and includes: The pump motor drive module has its power input terminal connected to the 48V DC main power input terminal to receive high-voltage power without step-down processing. The first-stage DC-DC step-down circuit is connected to the input terminal of the 48V DC main power supply and outputs a medium-voltage power supply. The solenoid valve drive module has its power input terminal connected to the medium-voltage power supply. The second primary DC-DC step-down circuit has its input terminal connected to the 48V DC main power supply input terminal and its output terminal outputting medium-voltage power supply. The secondary low-voltage power supply circuit has its input terminal connected to the secondary medium-voltage power supply and its output terminal outputting low-voltage power. The microcontroller module has its power input terminal connected to the low-voltage power supply and is connected to the pump motor drive module and the solenoid valve drive module via control signals. The communication interface module is bidirectionally connected to the microcontroller module. The electronic controller employs a differentiated power architecture to optimize drive efficiency, integration, and reliability.

[0007] Preferably, the power supply paths of the pump motor drive module and the solenoid valve drive module are independent of each other, and are provided by the high-voltage power supply and the medium-voltage power supply respectively, thereby reducing line conduction losses and increasing system power density.

[0008] Preferably, the pump motor drive module adopts 48V high-voltage direct drive to directly drive the compressor or pump motor load, avoiding power loss in the intermediate voltage reduction stage.

[0009] Preferably, the solenoid valve drive module receives medium-voltage power from the first-stage DC-DC step-down circuit and drives multiple solenoid valve loads.

[0010] Preferably, the solenoid valve drive module uses an integrated solenoid valve drive chip.

[0011] Preferably, the first-stage DC-DC step-down circuit one and the second-stage DC-DC step-down circuit two are connected in parallel to the 48V DC main power input terminal to form a mid-level voltage distribution architecture.

[0012] Preferably, the output voltage range of the first-stage DC-DC step-down circuit is 18V to 28V.

[0013] Preferably, the output voltage range of the second-stage DC-DC step-down circuit is 9V to 16V.

[0014] Preferably, the secondary low-voltage power supply circuit converts the 9V to 16V medium-voltage precision regulated voltage into a 3.3V or 5V standard logic level, providing a stable and low-noise power supply for the microcontroller module.

[0015] Preferably, the microcontroller module interacts with external communication signals through the communication interface module, receives external commands, and uploads status and fault diagnosis information.

[0016] Compared with the prior art, the present invention has the following beneficial technical effects: This invention's electronic controller achieves a significant improvement in drive efficiency by constructing a differentiated power supply architecture tailored to the load characteristics of pump motors and solenoid valves. Specifically, the high-power pump motor drive module directly uses 48V DC power, avoiding power loss caused by intermediate voltage reduction stages, while effectively reducing drive current and significantly minimizing line voltage drop and conduction losses caused by PCB wiring resistance and connector contact resistance. For multi-channel solenoid valve loads, a medium-voltage power supply scheme of 18V to 28V is adopted. While ensuring compatibility with integrated drive chips with a withstand voltage of 36V or higher, the drive current of a single solenoid valve is reduced by increasing the drive voltage, thereby optimizing load line losses and improving system thermal performance. Two-stage voltage reduction circuits provide differentiated voltage configurations for the power supply of the solenoid valve drive and control circuits, ensuring that each load operates within the optimal voltage window and maximizing overall energy efficiency.

[0017] This invention significantly improves product integration and operational reliability. By setting the output voltage range of the first-stage DC-DC step-down circuit to 18V to 28V, it can directly use integrated solenoid valve driver chips with a withstand voltage of 36V and above, which are maturely used in 12V systems. This eliminates the need for H-bridges or driver circuits composed of a large number of discrete components in traditional solutions, greatly simplifying the driver circuit design, achieving a more compact controller layout, and reducing the number of components and the risk of solder joint failure. At the same time, the second-stage DC-DC step-down circuit outputs a medium voltage of 9V to 16V to power the second-stage low-voltage power supply circuit, effectively reducing the input-output voltage difference of the final-stage linear power supply, improving low-voltage conversion efficiency and reducing heat generation, further enhancing the long-term stability and reliability of the system.

[0018] This invention achieves a balance between optimizing overall system performance and cost-effectiveness. The parallel and independent high-voltage direct drive and medium-voltage drive architecture ensures the isolation between the power supply paths of the pump motor and the solenoid valve, avoiding interference from high-power loads on the control circuit. Differentiated voltage configuration, while meeting the voltage tolerance compatibility requirements of existing chips, effectively reduces line losses and heat generation by lowering current, thereby increasing system power density. Furthermore, this solution fully utilizes the advantages of 48V power supply, ensuring high-power drive capability while optimizing power supply to low-current loads and control circuits through two-stage voltage reduction. This achieves excellent overall optimization in terms of drive efficiency, integration, thermal management, and component costs, significantly enhancing the product's market competitiveness. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of an electronic controller for an integrated pump valve driven by a 48V power supply according to this utility model.

[0020] Reference numerals in the attached diagram: 1. Electronic controller; 2. First-stage DC-DC step-down circuit one; 3. First-stage DC-DC step-down circuit two; 4. Second-stage low-voltage power supply circuit; 5. Communication interface module; 6. Microcontroller module; 7. Pump motor drive module; 8. Solenoid valve drive module; 9. Medium-voltage power supply one; 10. Medium-voltage power supply two; 11. Low-voltage power supply; 12. High-voltage power supply. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0022] This utility model discloses an integrated pump and valve drive electronic controller powered by 48V. The electronic controller 1 has carried out differentiated power architecture design for the power needs of two loads with significantly different characteristics: high-power pump motor drive and multi-channel low-current solenoid valve drive. This achieves comprehensive optimization of drive efficiency, integration and reliability.

[0023] The entire electronic controller 1 receives a 48V DC power supply at its power input terminal. This 48V DC power supply serves as the main power supply, with one path, acting as a high-voltage power supply 12, directly connected to the power input terminal of the pump motor drive module 7. This provides the high-power pump motor load with its original high-voltage power supply without voltage reduction processing, minimizing the power supply current requirement under the same drive power output. This effectively reduces the voltage drop and conduction losses in the controller's power supply lines, significantly improving the overall efficiency of the high-power drive circuit. Simultaneously, the 48V DC power supply is also connected in parallel to two independent first-stage buck units: a first-stage DC-DC buck circuit 2 and a second-stage DC-DC buck circuit 3. These two buck circuits constitute the mid-level voltage distribution architecture of the electronic controller 1.

[0024] The first-stage DC-DC step-down circuit 2 is directly powered by a 48V DC supply. It stabilizes the output voltage within a medium-voltage range of 18V to 28V, forming a medium-voltage power supply 9. The voltage output of this medium-voltage power supply 9 is directly connected to the power input of the solenoid valve drive module 8. Setting the output voltage range of the first-stage DC-DC step-down circuit 2 to 18V to 28V is a carefully calculated and verified range, compatible with integrated solenoid valve drive chips with a withstand voltage of 36V and above commonly used in 12V systems. By using the medium-voltage power supply 9 to power it, the solenoid valve drive module 8 can eliminate the need for a large number of discrete components in the drive circuit, greatly simplifying the drive circuit design, achieving a more compact controller layout, and improving integration and long-term operational reliability. Within the limits of the selected drive chip's withstand voltage, setting the output voltage in this range at a higher value effectively reduces the drive current of each solenoid valve load, reduces conduction losses on the load lines connected to the solenoid valves, and improves system thermal performance.

[0025] The second primary DC-DC step-down circuit 3 is also directly powered by 48V DC, but its output voltage range is designed differently from that of the first primary DC-DC step-down circuit 2. Its output voltage is set in a medium-voltage range between 9V and 16V, serving as a medium-voltage power supply 10. The output of this medium-voltage power supply 10 is connected to the power input of the second secondary low-voltage power supply circuit 4. Designing the output voltage range of the second primary DC-DC step-down circuit 3 to 9V to 16V ensures full compatibility with the 18V and above withstand voltage chips and circuits commonly used in 12V systems. Setting the output voltage in this range at a lower value, above the minimum allowable operating voltage of the second secondary low-voltage power supply circuit 4, effectively reduces the linear power supply voltage drop within the second secondary low-voltage power supply circuit 4, improving the power supply efficiency and overall energy efficiency of the second-stage power supply circuit.

[0026] The secondary low-voltage power supply circuit 4 serves as the final power conversion unit in the electronic controller 1. Its power input terminal receives the medium-voltage power supply 10 provided by the primary DC-DC step-down circuit 3, which further precisely regulates the 9V to 16V medium voltage and converts it into the low-voltage power supply 11 required by the microcontroller module 6. This low-voltage power supply 11 is a standard logic level of 3.3V or 5V. Its power output terminal is directly connected to the power input terminal of the microcontroller module 6, providing a stable and low-noise power guarantee for all subsequent control logic circuits.

[0027] The communication interface module 5 serves as a bridge for internal and external information exchange in the electronic controller 1. One end of the module interacts with external communication signals, including receiving external communication signals and providing real-time feedback on the status and fault diagnosis information of the electronic controller 1. The other end is connected to the communication port of the microcontroller module 6 via a bidirectional signal connection, forwarding the received external instructions to the microcontroller module 6, and encoding and sending the status information reported by the microcontroller module 6 to the outside.

[0028] As the core control unit of the electronic controller 1, the microcontroller module 6 receives low-voltage power 11 from the secondary low-voltage power supply circuit 4 at its power input terminal to obtain a stable operating power supply. Simultaneously, it interacts with the communication interface module 5 via a bidirectional signal connection to exchange data at high speed, parsing external commands and uploading status information. The microcontroller module 6 integrates an optimized pump and valve control program, interacts with external communication signals through the communication interface module 5, and outputs control signals to the control signal input terminals of the pump motor drive module 7 and the solenoid valve drive module 8 to realize the system control function.

[0029] The pump motor drive module 7 adopts a 48V high-voltage direct drive solution. Its power input terminal is directly connected to a 48V DC power supply via a high-voltage power supply 12. The control signal input terminal receives control signals from the microcontroller module 6, and its power output terminal is connected to a compressor or other types of pump motor loads. Since the pump motor is the most powerful load in the system, its drive module uses a direct 48V power supply, avoiding power loss caused by intermediate voltage reduction stages and maximizing drive efficiency. At the same time, due to the relatively small current, it can effectively reduce voltage drop and heat generation caused by PCB wiring resistance and connector contact resistance, thereby improving the power density and reliability of the system.

[0030] The solenoid valve drive module 8 adopts a medium-voltage drive scheme. Its power input terminal receives the medium-voltage power supply 9 from the output of the first-stage DC-DC step-down circuit 2, and its control signal input terminal receives the control signal from the microcontroller module 6. Its load output terminal is connected to the loads of solenoid valves 1 to 28V (a total of n) solenoid valves. This module can drive multiple solenoid valves. Powered by a medium-voltage supply of 18V to 28V, it satisfies the high drive voltage required for the rapid response of the solenoid valves while optimizing line losses by reducing drive current, thus lowering costs and improving design reliability.

[0031] Electronic controller 1 achieves optimized control through the coordinated operation of the aforementioned modules. After power-on initialization, the 48V DC power supply immediately provides the main power to the pump motor drive module 7. Simultaneously, the two-stage buck circuit starts working to establish medium-voltage power supply 9 and medium-voltage power supply 10. The secondary low-voltage power supply circuit 4 then outputs a stable low-voltage power supply 11 to enable the microcontroller module 6 to start operating. Throughout the entire operation, the first-stage DC-DC buck circuit 2 continuously provides a stable medium voltage of 18V to 28V to the solenoid valve drive module 8, and the first-stage DC-DC buck circuit 3 continuously provides an optimized medium voltage of 9V to 16V to the secondary low-voltage power supply circuit 4, ensuring that each load operates within the optimal voltage window.

[0032] Based on the load power requirements, this utility model retains the high-voltage and high-efficiency drive for high-power pump motor loads. For the power supply of low-power solenoid valve drive and control circuits, a single-stage DC-DC step-down circuit is adopted. Different medium-voltage power supply output voltage ranges are set to optimize and improve the load drive efficiency and low-voltage power supply efficiency. Within the set medium-voltage power supply range, the complexity of the drive circuit design can be reduced by selecting commonly used integrated chips in 12V systems, thereby improving the integration and reliability of the product.

[0033] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An electronic controller for an integrated pump valve driven by a 48V power supply, characterized in that, The electronic controller (1) is provided with a 48V DC main power input terminal, and the electronic controller (1) includes: The pump motor drive module (7) has its power input terminal connected to the 48V DC total power input terminal to receive high-voltage power supply (12) without step-down processing. The first-stage DC-DC step-down circuit (2) has its input terminal connected to the input terminal of the 48V DC main power supply and its output terminal outputting medium-voltage power supply (9). The solenoid valve drive module (8) has its power input terminal connected to the medium-voltage power supply (9). The first-level DC-DC step-down circuit (3) is connected to the input terminal of the 48V DC main power supply and outputs medium-voltage power supply (10). The secondary low-voltage power supply circuit (4) has its input terminal connected to the medium-voltage power supply (10) and its output terminal outputting low-voltage power supply (11). The microcontroller module (6) has its power input terminal connected to the low-voltage power supply (11) and is connected to the pump motor drive module (7) and the solenoid valve drive module (8) via control signals. The communication interface module (5) is bidirectionally connected to the microcontroller module (6); The electronic controller (1) adopts a differentiated power architecture to optimize drive efficiency, integration and reliability.

2. The electronic controller for an integrated pump valve driven by a 48V power supply according to claim 1, characterized in that, The power supply paths of the pump motor drive module (7) and the solenoid valve drive module (8) are independent of each other, and are provided by the high voltage power supply (12) and the medium voltage power supply (9) respectively, thereby reducing line conduction losses and increasing system power density.

3. The electronic controller for an integrated pump valve driven by a 48V power supply according to claim 2, characterized in that, The pump motor drive module (7) adopts 48V high voltage direct drive to directly drive the compressor or pump motor load, avoiding power loss in the intermediate voltage reduction stage.

4. The electronic controller for an integrated pump valve driven by a 48V power supply according to claim 3, characterized in that, The solenoid valve drive module (8) receives medium-voltage power from the first-stage DC-DC step-down circuit (2) and drives the multi-channel solenoid valve load.

5. An electronic controller for an integrated pump valve driven by a 48V power supply according to claim 4, characterized in that, The solenoid valve drive module (8) uses an integrated solenoid valve drive chip.

6. The electronic controller for an integrated pump valve driven by a 48V power supply according to claim 2, characterized in that, The first-stage DC-DC step-down circuit (2) and the second-stage DC-DC step-down circuit (3) are connected in parallel to the input terminal of the 48V DC main power supply to form a mid-level voltage distribution architecture.

7. An electronic controller for an integrated pump valve driven by a 48V power supply according to claim 6, characterized in that, The output voltage range of the first-stage DC-DC step-down circuit (2) is 18V to 28V.

8. An electronic controller for an integrated pump valve driven by a 48V power supply according to claim 7, characterized in that, The output voltage range of the first-stage DC-DC step-down circuit 2 (3) is 9V to 16V.

9. An electronic controller for an integrated pump valve driven by a 48V power supply according to claim 8, characterized in that, The secondary low-voltage power supply circuit (4) converts the 9V to 16V medium-voltage precision regulation to a 3.3V or 5V standard logic level, providing a stable and low-noise power supply for the microcontroller module (6).

10. An electronic controller for an integrated pump valve driven by a 48V power supply according to any one of claims 1-9, characterized in that, The microcontroller module (6) interacts with external communication signals through the communication interface module (5), receives external instructions, and uploads status and fault diagnosis information.

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