Controller assembly applied to active suspension electro-hydraulic pump, electro-hydraulic pump assembly and automobile
Patent Information
- Application Number
- CN202521512278.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-18
- Publication Date
- 2026-10-20
- Estimated Expiration
- 2035-07-18
Smart Images
Figure CN224871416U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of automotive suspension technology, and in particular to a controller assembly, an electro-hydraulic pump assembly, and an automobile used in an active suspension electro-hydraulic pump. Background Technology
[0002] Active suspension systems, with their ability to sense road conditions and vehicle driving status in real time and adjust suspension characteristics accordingly, have become an important technical means to improve the overall performance of vehicles. They use sensors to monitor key information such as vehicle speed, vehicle acceleration, and wheel bounce in real time, transmitting this data to a controller. The controller calculates appropriate suspension parameters based on preset algorithms and sends commands to the electro-hydraulic pump. By changing the flow and pressure of hydraulic oil, it precisely adjusts the stiffness and damping of the suspension, allowing the vehicle to maintain a good driving posture under various road conditions. As a key component directly affecting vehicle driving performance, innovation in the control technology of the automotive suspension plays a decisive role in improving vehicle handling stability, ride comfort, and safety. At high speeds, active suspension can lower the vehicle height, reduce wind resistance, and improve driving stability; when driving over bumpy roads, it can promptly increase suspension damping, effectively filtering vibrations and improving ride comfort. The electro-hydraulic pump, as the power actuator of the active suspension system, directly determines the performance of the active suspension system through its operational stability and response speed.
[0003] The controller assembly for the active suspension electro-hydraulic pump, as the core hub connecting vehicle sensors, the electro-hydraulic pump, and other control systems, is responsible for accurately acquiring, processing, and transmitting various signals to achieve precise control of the electro-hydraulic pump and dynamically adjust suspension parameters. Its performance directly affects the overall operation of the active suspension system. Given the modern automotive industry's pursuit of high performance and intelligence, the research and innovation of this controller has extremely high technical value and market demand.
[0004] Despite the significant advantages of active suspension systems, current active suspension electro-hydraulic pump controllers still suffer from numerous problems. Most controllers on the market employ a separate control board and drive board design, resulting in a complex system structure. The control board primarily handles signal processing and computation, while the drive board focuses on providing drive current to the electro-hydraulic pump. Since data transmission between the two boards requires cabling or other connections, this not only increases wiring difficulty and cost but also makes signal transmission unstable due to loose connections or aging wiring, thus affecting system reliability. For example, during long-term vehicle operation, vibration and temperature changes can cause poor contact at the cabling interfaces, leading to lost or erroneous control signals, preventing the electro-hydraulic pump from functioning properly, and rendering the active suspension system ineffective. Utility Model Content
[0005] The purpose of this invention is to provide a controller assembly, an electro-hydraulic pump assembly, and an automobile for use in active suspension electro-hydraulic pumps, in order to solve the problems of difficult wiring and low reliability caused by the separate board design of the controller and the drive board in the prior art.
[0006] This utility model provides a controller assembly for an active suspension electro-hydraulic pump, comprising: A control board is provided with a signal processing unit, a control unit and a power processing unit, wherein the power processing unit is disposed on the surface of the control board opposite to the drive motor. An electronic housing is disposed on the side of the control board away from the drive motor. The surface of the electronic housing away from the control board is provided with a low-voltage power supply and signal interface and a power supply interface. The control board communicates with the upper-level control device through the low-voltage power supply and signal interface, and the power supply is fed to the control board through the power supply interface.
[0007] Preferably, the control board is configured to be divided into a low-voltage area, an isolation area, and a high-voltage area. The low-voltage area is located at the first end of the length extension direction of the control board, the high-voltage area is located at the second end of the length extension direction of the control board, and the isolation area is located between the low-voltage area and the high-voltage area. The isolation area is provided with a power isolation module and a signal isolation module for power isolation and signal isolation, respectively.
[0008] Preferably, the low-pressure zone is provided with a temperature and pressure processing unit, an angle processing unit, a temperature processing unit, a power supply module, and a low-voltage power supply and signal interface. The temperature and pressure processing unit, the angle processing unit, and the temperature processing unit are connected to the control unit through the signal isolation module. The power supply module is connected to the low-voltage power supply and signal interface. The power supply module is arranged in a first width direction close to the control board, and the temperature and pressure processing unit, the angle processing unit, and the temperature processing unit are arranged in a second width direction close to the control board.
[0009] Preferably, the high-voltage zone is equipped with a temperature sampling unit, a voltage sampling unit, a current sampling unit, a control unit, a drive unit, a power supply interface, an inverter unit, and a three-phase AC interface. The temperature sampling unit, the voltage sampling unit, and the current sampling unit are electrically connected to the control unit. The control unit is electrically connected to the drive unit. The inverter unit is electrically connected to the power supply interface to receive the power voltage input from the power supply. The inverter unit is electrically connected to the motor of the active suspension electro-hydraulic pump through the three-phase AC interface. The power supply interface is located near the edge of the high-voltage zone.
[0010] Preferably, the outer surface of the electronic housing is provided with heat dissipation fins, which are wavy or interdigitated structures.
[0011] Preferably, a thermally conductive pad is provided on the inner surface of the electronic housing, and the thermally conductive pad is configured to contact the electronic components on the surface of the control board.
[0012] Preferably, thermal grease is disposed between the inner surface of the electronic housing and the thermal pad.
[0013] Preferably, the control board extends along the entire length of the drive motor assembly housing.
[0014] Preferably, the control board is provided with an FPC socket and an AC quick-connect spring on the side facing the drive motor. The control board is provided with a positioning slot to form a limiting installation with the drive motor assembly. During installation, the FPC cable of the sampling module is inserted into the FPC socket of the control board, and the AC phase wire terminal of the drive motor assembly is inserted into the AC quick-connect spring.
[0015] Based on the same concept, this utility model also provides an automotive active suspension electro-hydraulic pump assembly, including the controller assembly described in any one of the above.
[0016] Based on the same concept, this utility model also provides an automobile, including the aforementioned automobile active suspension electro-hydraulic pump assembly.
[0017] Compared with the prior art, the present invention has the following advantages: In this invention, the signal processing unit, control unit, and power processing unit are integrated onto a single control board, significantly shortening the signal transmission path. In traditional discrete designs, signal transmission from the signal processing board to the power processing board can involve long distances and numerous intermediate steps, resulting in signal delay. This integrated design reduces signal transmission time between different boards, enabling the entire controller assembly to respond more quickly to commands from higher-level control devices. This, in turn, allows the active suspension electro-hydraulic pump system to adjust its operating parameters more promptly based on vehicle driving conditions and road conditions. For example, when the vehicle travels over uneven surfaces, the output of the electro-hydraulic pump can be controlled more quickly to maintain vehicle suspension stability. Attached Figure Description
[0018] Figure 1 This is an exploded perspective view of the active suspension electro-hydraulic pump of this utility model. Figure 2 This is a single-board layout diagram of the present utility model; Figure 3 This is a three-dimensional schematic diagram and a cross-sectional view of the top surface heat dissipation structure of this utility model; Figure 4 This is a front view of the control board of this utility model; Figure 5 This is a front view of the control board of this utility model; Figure 6 A schematic diagram of the module composition for controlling the single board; Figure 7 This is a schematic diagram of the structure connecting the control board and the motor sub-assembly.
[0019] Explanation of reference numerals in the attached figures: 10-Controller assembly; 10a-Electronic housing; 11-Control board; 11'-Control unit; 11''-Power processing unit; 12-Low voltage power supply and signal interface; 13-Power supply interface; 13'-Adapter; 14-Extra interface; 15-Thermal grease; 16-Heat sink fins; 17-AC quick-connect spring; 18-FPC socket; 20-Motor; 21-Pump. Detailed Implementation
[0020] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship 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. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.
[0021] It should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal connection between 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.
[0022] Furthermore, in the description of this application, "proximal" and "distal" are commonly used terms in the medical field. Specifically, "proximal" refers to the end closer to the operator, "proximal face" refers to the end face closer to the operator, "distal" refers to the end farther from the operator, and "distal face" refers to the end face farther from the operator.
[0023] First Embodiment See Figure 1 and Figure 6 This embodiment provides a controller assembly 10 for an active suspension electro-hydraulic pump, comprising: A control board 11 is provided with a signal processing unit, a control unit 11' and a power processing unit 11'', wherein the power processing unit 11'' is disposed on the surface of the control board 11 facing away from the drive motor; An electronic housing 10a is disposed on the side of the control board 11 away from the drive motor. The surface of the electronic housing 10a away from the control board 11 is provided with a low-voltage power supply and signal interface 12 and a power supply interface 13. The control board 11 communicates with the upper-level control device through the low-voltage power supply and signal interface 12, and the power supply is fed to the control board 11 through the power supply interface 13.
[0024] In this invention, the signal processing unit, control unit 11', and power processing unit 11'' are integrated onto a single control board 11, significantly shortening the signal transmission path. In traditional discrete designs, signal transmission from the signal processing board to the power processing board may involve a long transmission distance and numerous intermediate steps, resulting in signal delay. The integrated design of this invention reduces the transmission time between different boards, enabling the entire controller assembly 10 to respond more quickly to commands from the higher-level control device. This allows the active suspension electro-hydraulic pump system to adjust its operating parameters more promptly based on vehicle driving conditions and road conditions. For example, when the vehicle travels on uneven surfaces, it can more quickly control the output of the electro-hydraulic pump to maintain the stability of the vehicle suspension. Furthermore, the integrated design reduces interference during signal transmission. In discrete designs, signal transmission between different boards may be affected by interference from the surrounding electromagnetic environment, leading to signal distortion. The single-board integrated design allows signal processing and power processing to work closely together on the same board, resulting in more stable signal transmission and improved control accuracy. This allows the active suspension electro-hydraulic pump system to more precisely control parameters such as the speed and pressure of the electro-hydraulic pump, thereby more accurately adjusting the stiffness and damping of the vehicle suspension and improving the vehicle's driving comfort and handling stability.
[0025] By integrating the functions of two control boards onto a single board, the integration level is increased by more than 30% compared to the traditional separate board design. This completely eliminates the traditional separate control board and drive board model, significantly reducing the volume and size of the controller assembly 10, making the entire system more compact. This provides greater flexibility for the layout and installation of the automotive active suspension electro-hydraulic pump assembly within the limited space of a vehicle, which is beneficial for optimizing the vehicle's internal space structure, improving space utilization, and facilitating installation and maintenance. Especially now that many consumers prefer convenient microcars, this miniaturized design makes it easier to install the electro-hydraulic pump assembly in the vehicle chassis or other limited spaces without affecting the layout and function of other components. The integrated design reduces the number of control boards and the use of related electrical connection components, thereby reducing manufacturing costs. At the same time, the single-board integrated controller assembly 10 is simpler and faster to assemble, reducing assembly steps and time, and improving production efficiency. In addition, due to the reduced system complexity, subsequent maintenance and repair are also more convenient and faster, reducing maintenance costs and repair time, and improving the overall system's economy and practicality.
[0026] Figure 1 An exploded perspective view of the active suspension electro-hydraulic pump is shown, with the motor pump housing housing the motor 20 and the pump 21, which are fixedly connected via a rotatable motor shaft (not shown).
[0027] See Figure 2 and Figure 6 Preferably, the control board 11 is configured to be divided into a low-voltage area, an isolation area, and a high-voltage area. The low-voltage area is located at the first end of the length extension direction of the control board 11, the high-voltage area is located at the second end of the length extension direction of the control board 11, and the isolation area is located between the low-voltage area and the high-voltage area. The isolation area is provided with a power isolation module and a signal isolation module to perform power isolation and signal isolation, respectively.
[0028] By dividing the control board 11 into a low-voltage zone, an isolation zone, and a high-voltage zone, the high-voltage and low-voltage circuits are strictly separated. The high-voltage zone mainly handles power supply-related circuits, while the low-voltage zone involves low-voltage circuits such as control signals. This partitioning design effectively prevents interference and damage from high-voltage circuits to low-voltage circuits. The high-voltage and low-voltage zones are isolated by an isolation zone, where power isolation modules and signal isolation modules effectively suppress the impact of electromagnetic interference generated in the high-voltage zone on the signal processing unit in the low-voltage zone. In the high-voltage zone, high-current power processing may generate strong electromagnetic fields. If these electromagnetic fields directly act on the low-voltage zone, they may cause signal distortion, false triggering, and other problems. The existence of the isolation zone acts like an "electromagnetic barrier" between the high-voltage and low-voltage zones, allowing signal processing in the low-voltage zone to take place in a relatively stable electromagnetic environment, thereby ensuring signal integrity and accuracy and improving the electromagnetic compatibility of the entire controller assembly 10.
[0029] See Figure 2 The signal processing unit, control unit 11', and power processing unit 11'' are arranged on the side facing the electronic housing 10a and away from the motor 20. The electronic housing 10a includes a low-voltage power supply and signal interface 12, a power supply interface 13, and an additional interface 14. The low-voltage power supply and signal interface 12 is used to communicate with the upper-level chassis control device, while the high-voltage power supply of the control board 11 is fed through the power supply interface 13. The additional interface 14 is provided for regulating or operating external devices.
[0030] Preferably, the low-pressure zone is provided with a temperature and pressure processing unit, an angle processing unit, a temperature processing unit, a power supply module, and a low-voltage power supply and signal interface 12. The temperature and pressure processing unit, the angle processing unit, and the temperature processing unit are connected to the control unit 11' through the signal isolation module. The power supply module is connected to the low-voltage power supply and signal interface 12. The power supply module is arranged in a first width direction close to the control board 11, and the temperature and pressure processing unit, the angle processing unit, and the temperature processing unit are arranged in a second width direction close to the control board 11.
[0031] In this embodiment, the temperature and pressure processing unit, the angle processing unit, and the temperature processing unit are arranged in the second width direction close to the control board 11. This layout allows each processing unit to operate independently and reduces mutual interference. See also Figure 6 For example, W1 represents the first width direction, and W2 represents the second width direction. The temperature and pressure processing unit includes a sampling module and a filtering module, arranged sequentially along the second direction. The angle processing unit includes a sampling module and a filtering module, arranged sequentially along the second direction. The temperature sampling unit includes a sampling module, a filtering module, and a comparison module, arranged sequentially along the second direction.
[0032] Preferably, the high-voltage zone is equipped with a temperature sampling unit, a voltage sampling unit, a current sampling unit, a control unit 11', a drive unit, a power supply interface 13, an inverter unit, and a three-phase AC interface. The temperature sampling unit, the voltage sampling unit, and the current sampling unit are electrically connected to the control unit 11', the control unit 11' is electrically connected to the drive unit, the inverter unit is electrically connected to the power supply interface 13 to receive the power voltage input from the power supply, and the inverter unit is electrically connected to the motor of the active suspension electro-hydraulic pump through the three-phase AC interface. The power supply interface 13 is located near the edge of the high-voltage zone.
[0033] This embodiment, through the rational arrangement of various functional units, disperses heat sources, avoiding localized overheating, and also prevents electromagnetic interference between different units. For example, the inverter unit generates a certain amount of heat during operation; placing it in a suitable location in the high-voltage area, maintaining a certain distance from other units, reduces the impact of heat on other units.
[0034] In the circuit design process, this invention fully considers the signal flow and electromagnetic compatibility between various functional modules, employs multi-layer circuit board technology, and rationally allocates power and signal layers to reduce signal interference. Simultaneously, based on surface mount technology (SMT) and chip-level packaging technology, a large number of electronic components are tightly arranged on the circuit board, significantly reducing its size. This integrated design not only reduces the number of interconnecting lines between circuit boards, lowering signal transmission loss and failure risk, but also improves the system's integration and stability. For example, by integrating control signal processing and drive signal generation into the same chip, i.e., the control unit 11', delays in signal transmission are reduced, enabling the controller to respond to sensor signals more quickly and accurately, controlling the operation of the electro-hydraulic pump.
[0035] In some embodiments, the high-voltage region includes a current sampling unit, a voltage sampling unit, and a temperature sampling unit. The current sampling unit is located on both sides of the drive unit and includes a sampling module, a filtering module, and a comparison module, arranged sequentially along a second direction. The voltage sampling unit includes a sampling module, a filtering module, and a comparison module, arranged sequentially along the second direction. The temperature sampling unit includes a sampling module, a filtering module, and a comparison module, arranged sequentially along the second direction.
[0036] In existing technologies, when an active suspension system is operating, the electronic components in the controller continuously generate heat, especially under high-load conditions, such as continuous high-speed driving or frequent travel over bumpy roads, where the heat generation of the controller increases dramatically. The heat dissipation structure design of existing controllers is often inadequate, relying mostly on simple natural cooling or small heat sinks, which cannot meet the requirements for rapid heat dissipation. Prolonged exposure to high temperatures can degrade the performance of electronic components or even damage them, severely impacting the lifespan and stability of the controller. For example, the on-resistance of power transistors increases at high temperatures, leading to increased power loss, further exacerbating heat generation, creating a vicious cycle, and ultimately potentially causing controller failure.
[0037] See Figure 3 Preferably, the outer surface of the electronic housing 10a is provided with heat dissipation fins 16, which are wavy or interdigitated structures.
[0038] This embodiment is based on the basic concept of using a single control board 11, and features an optimized heat dissipation structure design. Large-area heat dissipation fins 16 are provided on the outer surface of the electronic housing 10a. The heat dissipation fins 16 are made of aluminum alloy, which has excellent thermal conductivity and heat dissipation effect. The shape of the fins is carefully designed, employing a wave-shaped or interdigitated structure, effectively increasing the heat dissipation area. Under the same operating conditions, compared with traditional heat dissipation designs, the controller's operating temperature can be reduced by more than 10℃, effectively extending the service life of electronic components and ensuring stable operation of the controller under various harsh conditions. This not only improves the reliability of the active suspension system but also reduces the possibility of performance degradation and malfunctions caused by controller overheating.
[0039] See also Figure 3 Preferably, a thermally conductive pad is provided on the inner surface of the electronic housing 10a, and the thermally conductive pad is configured to contact the electronic components on the surface of the control board 11.
[0040] In this embodiment, thermal pads are also provided on the inner surface of the electronic housing 10a and on the top of the electronic components on the circuit board to further enhance the heat conduction effect.
[0041] See also Figure 3 Preferably, thermal grease is disposed between the inner surface of the electronic housing 10a and the thermal pad.
[0042] In this embodiment, a high thermal conductivity thermal grease is applied between the metal casing and the thermal pad to ensure that heat can be quickly and efficiently conducted from the thermal pad to the metal casing. When the controller is working, the heat generated by the electronic components is first conducted through the thermal pad to the thermal grease, then transferred through the thermal grease to the metal casing, and finally dissipated into the surrounding air by the heat sink 16.
[0043] Figure 3 The locations of components such as the heat sink, thermal grease 15, and power processing unit 11'' are clearly marked. On the control board 11, the power processing unit 11'' is arranged on the side of the control board 11 facing the electronic housing 10a, and is in contact with the electronic housing 10a via the thermal grease 15 and the heat sink.
[0044] In some embodiments, to further improve heat dissipation efficiency, a small cooling fan can be installed around the heat dissipation fins 16 to accelerate airflow and remove more heat through forced air cooling. This top-mounted heat dissipation structure design ensures that the controller's temperature remains within a reasonable range under long-term, high-load operation, guaranteeing the normal operation of electronic components and extending the controller's lifespan.
[0045] Preferably, the control board 11 extends along the entire length of the drive motor assembly housing.
[0046] In the example embodiment, the control board 11 is arranged laterally on the housing of the motor 20 and extends substantially over the entire housing of the motor 20, which allows for a shorter path between the control board 11 and all the components to be controlled (motor 20, sampling module, pressure sensor, etc.).
[0047] Furthermore, the design of high- and low-voltage connectors in existing controllers for connecting to external wiring has shortcomings. On one hand, the connector connection method is not robust enough; during vehicle operation, vibrations and bumps can easily loosen the connectors, leading to poor contact and affecting power transmission and signal transmission. On the other hand, the specifications and interface standards of the connectors are inconsistent. In actual assembly and maintenance, various types of cables and connectors are required, increasing operational difficulty and cost, while also reducing connection reliability. Moreover, when assembling the controller and motor sub-assemblies, the existing design lacks convenient and reliable connection methods. The assembly process often requires complex positioning and tightening operations, consuming significant time and manpower. Furthermore, during vehicle operation, vibrations and mechanical stress can easily loosen the connections, affecting the coordinated operation between the electro-hydraulic pump and the controller, and reducing the response speed and control accuracy of the active suspension system.
[0048] Preferably, the control board 11 is provided with an FPC socket 18 and an AC quick-connect spring 17 on the side facing the drive motor. The control board 11 is provided with a positioning slot to form a limiting installation with the drive motor assembly. During installation, the FPC cable of the sampling module is inserted into the FPC socket 18 of the control board 11, and the AC phase wire terminal of the drive motor assembly is inserted into the AC quick-connect spring 17.
[0049] This embodiment of the connector adopts a modular design, divided into high-voltage and low-voltage connectors, used for connecting power and signal lines respectively. The connector shell is made of high-strength engineering plastic, possessing excellent insulation performance and mechanical strength. Internally, it employs elastic contact pieces and a locking connection structure. When the plug is inserted into the socket, the elastic contact pieces tightly conform to the cable conductor, ensuring a good electrical connection; simultaneously, the locking structure securely locks the plug and socket together, preventing loosening due to vibration. It should be noted that the connector interface adopts a standardized design conforming to common electrical connection standards in the automotive industry, facilitating rapid assembly with various cable specifications. The connector layout fully considers practical usage needs, placing the high-voltage and low-voltage connectors on the same side of the controller for easy operation and maintenance. This integrated high- and low-voltage connector design not only improves connection reliability and stability but also simplifies the assembly process and reduces costs. The locking connection structure and standardized interface design of the connector ensure the stability of power transmission and signal transmission, reducing malfunctions caused by loose connections. The quick-assembly design of the sub-assembly with the motor significantly reduces assembly time, improves production efficiency, and facilitates later maintenance and replacement. This convenient and reliable connection method provides a strong guarantee for the efficient operation of the active suspension system.
[0050] Figure 4 This diagram illustrates the structure and assembly of integrated high- and low-voltage connectors, showcasing their internal structure and connection method. The low-voltage power supply and signal interface 12 is used for communication between the control board 11 and the upper-level chassis control device, while the high-voltage power supply voltage for the control board 11 is fed via the power supply interface 13. For example, in this invention, an integrally bent high-voltage power supply interface is used to connect to the control board 11. Figure 5 Alternatively, the power interface 13 can be a straight type and connected to the control board 11 via an adapter 13'. The connection between the power interface 13 and the adapter 13' can be a hard connection or a soft connection, which is not limited here. Figure 7This diagram illustrates the structural connection between the control board 11 and the motor sub-assembly, showcasing key structures such as the positioning slot and fastening bolt holes, as well as the assembly steps. During assembly, firstly, the FPC cable of the sampling module in the motor sub-assembly is inserted into the FPC socket 18 of the control board 11. The FPC socket 18, located at the bottom of the control board 11, uses an automotive-grade quick-release connector for rapid assembly. Next, the positioning slot of the control board 11 is aligned with the positioning protrusion on the motor sub-assembly and gently pushed in to complete the initial positioning. This ensures that the AC phase wire terminals on the motor sub-assembly are accurately inserted into the AC quick-connect spring 17 of the controller unit. Finally, the fastening bolts are passed through the bolt holes to secure the connection. To further enhance the stability of the connection, rubber buffer pads are used at the connection points of the positioning slot and fastening bolts to reduce stress damage to the connecting components caused by vibration.
[0051] Furthermore, to achieve convenient, reliable, and rapid assembly and connection with the motor sub-assembly, a dedicated positioning slot and fastening bolt holes are designed on the side of the controller. The positioning slot adopts a dovetail or T-slot structure, precisely matching the positioning protrusion on the motor sub-assembly, enabling rapid initial positioning of the controller and motor sub-assembly. The position and size of the fastening bolt holes are precisely calculated to ensure that a uniform tightening force is applied when using the fastening bolts, ensuring a tight connection between the controller and the motor sub-assembly. During assembly, firstly, the sampling module FPC cable from the motor sub-assembly is inserted into the FPC socket 18 of the controller unit. The FPC socket 18 is located at the bottom of the circuit board and uses an automotive-grade quick-release connector for convenient and rapid assembly. Then, the positioning slot of the controller is aligned with the positioning protrusion on the motor sub-assembly and gently pushed in to complete the initial positioning. This ensures that the AC phase wire terminals on the motor sub-assembly are accurately inserted into the AC quick-connect spring 17 of the controller unit. Finally, the fastening bolts are passed through the bolt holes to secure the two tightly.
[0052] In some embodiments, to further enhance the stability of the connection, rubber buffer pads are used at the positioning slots and fastening bolt connections to reduce damage to the connecting components caused by vibration stress. This design not only ensures the accuracy and convenience of assembly, but also ensures that the controller and motor sub-assembly maintain a stable connection during vehicle operation, avoiding the impact of vibration or displacement on the normal operation of the system.
[0053] This innovative single-board design reduces the number of circuit boards and connecting lines, lowering hardware costs. Combined with an optimized heat dissipation structure, it eliminates the need for a complex water-cooling system, reducing equipment purchase and maintenance costs. Integrated connectors and a rapid assembly design improve production efficiency, reducing labor and time costs. Overall, this invention effectively controls costs while improving product performance, bringing significant economic benefits to both automakers and users.
[0054] Based on the same concept, this utility model also provides an automotive active suspension electro-hydraulic pump assembly, including the controller assembly 10 described in any one of the above.
[0055] Based on the same concept, this utility model also provides an automobile, including the aforementioned automobile active suspension electro-hydraulic pump assembly.
[0056] This invention integrates signal processing and power processing onto a single control board, achieving a high degree of integration. This integrated design significantly reduces electrical connections between control boards, lowers system complexity and failure risk, and improves system reliability and stability. Simultaneously, the integrated design makes signal transmission more direct and faster, reducing signal transmission delay and interference, thereby improving system response speed and control accuracy, and better meeting the requirements of automotive active suspension electro-hydraulic pump assemblies for rapid and precise control.
[0057] This utility model aims to comprehensively solve the problems existing in current active suspension electro-hydraulic pump controllers. Through innovative design concepts and advanced technical means, it develops a highly integrated, heat-dissipating, reliable, and easy-to-assemble controller assembly 10. It achieves high integration of controller hardware, simplifying the system structure; optimizes heat dissipation design to ensure stable operation of the controller under various working conditions; and improves connector and assembly connection design to enhance reliability and convenience. This significantly improves the overall performance and reliability of the active suspension system, providing the automotive industry with a more advanced and practical active suspension control solution.
[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 controller assembly for an active suspension electro-hydraulic pump, characterized in that, include: A control board is provided with a signal processing unit, a control unit and a power processing unit, wherein the power processing unit is disposed on the surface of the control board opposite to the drive motor. An electronic housing is disposed on the side of the control board away from the drive motor. The surface of the electronic housing away from the control board is provided with a low-voltage power supply and signal interface and a power supply interface. The control board communicates with the upper-level control device through the low-voltage power supply and signal interface, and the power supply is fed to the control board through the power supply interface.
2. The controller assembly for an active suspension electro-hydraulic pump as described in claim 1, characterized in that, The control board is configured to be divided into a low-voltage zone, an isolation zone, and a high-voltage zone. The low-voltage zone is located at the first end of the length extension direction of the control board, the high-voltage zone is located at the second end of the length extension direction of the control board, and the isolation zone is located between the low-voltage zone and the high-voltage zone. The isolation zone is equipped with a power isolation module and a signal isolation module to perform power isolation and signal isolation, respectively.
3. The controller assembly for an active suspension electro-hydraulic pump as described in claim 2, characterized in that, The low-pressure zone is equipped with a temperature and pressure processing unit, an angle processing unit, a temperature processing unit, a power supply module, and a low-voltage power supply and signal interface. The temperature and pressure processing unit, the angle processing unit, and the temperature processing unit are connected to the control unit through the signal isolation module. The power supply module is connected to the low-voltage power supply and signal interface. The power supply module is arranged in a first width direction close to the control board. The temperature and pressure processing unit, the angle processing unit, and the temperature processing unit are arranged in a second width direction close to the control board.
4. The controller assembly for an active suspension electro-hydraulic pump as described in claim 2, characterized in that, The high-voltage zone is equipped with a temperature sampling unit, a voltage sampling unit, a current sampling unit, a control unit, a drive unit, a power supply interface, an inverter unit, and a three-phase AC interface. The temperature sampling unit, the voltage sampling unit, and the current sampling unit are electrically connected to the control unit. The control unit is electrically connected to the drive unit. The inverter unit is electrically connected to the power supply interface to receive the power voltage input from the power supply. The inverter unit is electrically connected to the motor of the active suspension electro-hydraulic pump through the three-phase AC interface. The power supply interface is located near the edge of the high-voltage zone.
5. The controller assembly for an active suspension electro-hydraulic pump as described in claim 1, characterized in that, The outer surface of the electronic housing is provided with heat dissipation fins, which are wavy or interdigitated structures.
6. The controller assembly for an active suspension electro-hydraulic pump as described in claim 5, characterized in that, A thermally conductive pad is provided on the inner surface of the electronic housing, and the thermally conductive pad is configured to contact the electronic components on the surface of the control board.
7. The controller assembly for an active suspension electro-hydraulic pump as described in claim 6, characterized in that, Thermal grease is applied between the inner surface of the electronic housing and the thermal pad.
8. The controller assembly for an active suspension electro-hydraulic pump as described in claim 1, characterized in that, The control board extends along the entire length of the drive motor assembly housing.
9. The controller assembly for an active suspension electro-hydraulic pump as described in claim 1 or 8, characterized in that, The control board is equipped with an FPC socket and an AC quick-connect spring on the side facing the drive motor. The control board is also equipped with a positioning slot to limit the installation with the drive motor assembly. During installation, the FPC cable of the sampling module is inserted into the FPC socket of the control board, and the AC phase wire terminal of the drive motor assembly is inserted into the AC quick-connect spring.
10. An electro-hydraulic pump assembly, characterized in that, Includes the controller assembly as described in any one of claims 1-9.
11. A car, characterized in that, Includes the electro-hydraulic pump assembly as described in claim 10.