CN112555126B - Air source system of water-cooled air compressor for vehicle - Google Patents
Air source system of water-cooled air compressor for vehicle Download PDFInfo
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- CN112555126B CN112555126B CN202011409857.0A CN202011409857A CN112555126B CN 112555126 B CN112555126 B CN 112555126B CN 202011409857 A CN202011409857 A CN 202011409857A CN 112555126 B CN112555126 B CN 112555126B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B35/00—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for
- F04B35/04—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for the means being electric
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B25/00—Multi-stage pumps
- F04B25/005—Multi-stage pumps with two cylinders
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/0027—Pulsation and noise damping means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/0027—Pulsation and noise damping means
- F04B39/0044—Pulsation and noise damping means with vibration damping supports
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/06—Cooling; Heating; Prevention of freezing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/12—Casings; Cylinders; Cylinder heads; Fluid connections
- F04B39/122—Cylinder block
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/12—Casings; Cylinders; Cylinder heads; Fluid connections
- F04B39/125—Cylinder heads
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B39/00—Component parts, details, or accessories, of pumps or pumping systems specially adapted for elastic fluids, not otherwise provided for in, or of interest apart from, groups F04B25/00 - F04B37/00
- F04B39/12—Casings; Cylinders; Cylinder heads; Fluid connections
- F04B39/128—Crankcases
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/06—Control using electricity
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Compressor (AREA)
Abstract
The invention discloses an air source system of a water-cooling air compressor for a vehicle, which comprises a double-crank inner support transmission structure, a controller and a water-cooling system, wherein the double-crank inner support transmission structure is arranged on the double-crank inner support transmission structure; the double-crank inner support transmission structure is driven by a motor, an elastic coupling and a crank shaft, and cranks on two sides of the crank shaft drive the low-pressure cylinder piston assembly and the high-pressure cylinder piston assembly to reciprocate up and down to complete a gas compression process. The controller is fixed on the motor, a labyrinth type cooling water channel is arranged in the controller, and the controller shares the working state of the air supply system and feeds back fault information in real time; the water cooling system is supplied with water by a finished automobile water pump system, enters a crankcase water channel after passing through a labyrinth type cooling water channel in the controller, then enters a cylinder cover after passing through a water channel in a piston cylinder, returns to the piston cylinder and the crankcase after passing through a water channel in an inner cavity of the cylinder cover, and finally is discharged and converged into a finished automobile circulating water channel. The invention has the advantages of high compression efficiency, small vibration, low noise, long service life, clean air source, high efficiency, energy conservation, compact structure, small volume, convenient installation and arrangement and the like.
Description
Technical Field
The invention relates to the field of air compression equipment for automobiles, in particular to an air source system of a water-cooling air compressor for an automobile.
Background
Because the interior of the oil-free reciprocating piston type air compressor is completely free of lubricating oil, kinematic pairs at the big end and the small end of a connecting rod and at the crank position must be borne by maintenance-free bearings, the oil-free reciprocating piston type air compressor is limited by the structural characteristics of self oil-free lubrication, and the maintenance-free bearings are difficult to sleeve in the crank position, so that most of the oil-free reciprocating piston type air compressors at present adopt a single-crank cantilever structure, and the fulcrum is long, the structural strength is poor, and the operation vibration is large. The internal support double-crank transmission structure adopts a maintenance-free double-row bearing between two piston connecting rod groups, and is used for bearing and placing on a crankshaft so as to ensure that the transmission structure has reliable strength and stable operation. Meanwhile, to reduce the vibration of the transmission structure, the main consideration is to balance the crank-link mechanism and eliminate or limit unbalanced inertia force and inertia moment of the rotating mechanism or the reciprocating mechanism. At present, a few oil-free piston type air compressors adopt a non-cantilever double-crank transmission structure, only reciprocating inertia force and rotating inertia force can be balanced, reciprocating inertia moment still cannot be reduced, and rotating inertia moment is difficult to balance.
The automobile air compressor is mainly used for providing necessary air sources for an automobile braking system, an air suspension system, a door opening and closing device and an auxiliary pneumatic device. Currently, the commonly used vehicle-mounted air compressors mainly comprise sliding vane type, vortex type and piston type air compressors.
1. Most of the vehicle-mounted air compressors commonly used in the market at present are air-cooled air compressors, the exhaust temperature is high, the internal high temperature is difficult to be led out to influence the service life of each part, and the requirement of continuous work cannot be met; and the higher the gas temperature is, the more difficult the gas is to be compressed, so that the compression efficiency is low and the power consumption is increased, while some water-cooled compressors have poor water channel sealing structure, serious water leakage and poor reliability.
2. The oil-free reciprocating piston type air compressor is limited by the characteristics of an oil-free transmission structure, and the transmission structure is large in size and large in operation vibration, so that the comfort of the whole vehicle is influenced.
3. The air source system of the air compressor for the vehicle consists of an air compressor and a vehicle control unit (inverter), wherein the vehicle control unit (inverter) provides a power source for a motor of the air compressor and controls the air compressor to work. The vehicle controller is usually an all-in-one controller, which is bulky and requires additional space for installation and arrangement; meanwhile, if the single function of the controller is damaged, the maintenance cost of replacing the whole controller assembly is high.
Disclosure of Invention
The invention aims to provide an air source system of a water-cooling air compressor for a vehicle, aiming at the defects of the prior art.
The purpose of the invention is realized by the following technical scheme: an air source system of a water-cooled air compressor for a vehicle comprises a double-crank inner support transmission structure, a controller and a water-cooled system;
the double-crank internal support transmission structure is driven by a motor, the crank shaft is connected with the motor through an elastic coupling, and cranks on two sides of the crank shaft drive a low-pressure cylinder piston assembly and a high-pressure cylinder piston assembly on the crank shaft to reciprocate up and down, so that the inner volumes of the two piston cylinders are periodically changed, and the gas compression process is completed.
The controller is fixed on the motor, a high-voltage power line bundle connected with the motor is arranged in the controller through an inner through bolt, a labyrinth type cooling water channel is arranged in the controller, and a whole vehicle interaction CAN communication interface is arranged on the controller and used for sharing the working state of the gas supply system in real time and monitoring and feeding back fault information through a sensor;
the water cooling system is supplied with water by a finished automobile water pump system, enters a crankcase water channel after passing through a labyrinth type cooling water channel in the controller, then enters a cylinder cover through a water passing bolt after passing through a water channel in a piston cylinder, returns to the piston cylinder and the crankcase through the water passing bolt after passing through a water channel in an inner cavity of the cylinder cover, and finally is discharged and converged into a finished automobile circulation water channel.
Further, the main shaft of the motor drives the driving end of the elastic coupling to rotate, and the driven end of the elastic coupling drives the crankshaft 7 to rotate; the driven end of the elastic coupling is provided with a counterweight structure, so that the elastic coupling can play a role of a counterweight while playing a role of power transmission, and the vibration of the whole machine is reduced.
Furthermore, a low-pressure air inlet valve plate is arranged on the low-pressure cylinder piston assembly, the valve plate has a one-way flow guiding effect, when the low-pressure piston moves downwards from an upper dead point, the interior of the cylinder is enlarged to generate negative pressure, so that natural air is sucked into a primary cylinder of the piston cylinder, a valve plate is arranged on the upper side of the piston cylinder, and a first exhaust valve assembly is arranged on the valve plate; the low-pressure piston moves upwards from the lower dead point, the volume in the cylinder is reduced, the gas is compressed, the low-pressure air inlet valve plate is closed, the first exhaust valve component opens to exhaust the gas, the gas compression of the primary cylinder is completed, the primary compressed gas enters the secondary cylinder of the piston cylinder through the cylinder cover flow channel under the action of the high-pressure air inlet valve plate, and the secondary compression is completed under the combined action of the high-pressure cylinder piston and the second exhaust valve component.
Furthermore, the low-pressure air inlet valve plate is arranged on the end face of an annular groove of the low-pressure piston, an air inlet and a limiting screw are arranged on the end face of the annular groove, the limiting screw plays a fixed-range limiting role on the low-pressure air inlet valve plate, a fixed-range bolt is adopted, and an annular wave-shaped or butterfly-shaped valve plate is arranged on the fixed-range bolt to reduce the stress concentration at the root of the valve plate and prolong the service life of the valve plate.
Further, a balance block is additionally arranged on each crank on two sides of the crankshaft, a through hole structure is arranged on the crank on the outer side of the crankshaft, the balance blocks are arranged on the crankshaft through fastening bolts and flat key structures, balance is achieved between the balance blocks and the rotating portion of the crank connecting rod, rotating inertia force and moment generated when the piston type air compressor operates are eliminated, and vibration of oil-free piston type air compression is further reduced.
Further, the crankshaft is arranged on the crankcase by means of a maintenance-free double row support bearing.
Furthermore, the crank case and the piston cylinder adopt an inner cavity water channel structure, and the surfaces of the crank case and the piston cylinder are of closed structures; the end faces of the crank case and the piston cylinder are provided with a plurality of water through holes, double sealing is achieved through O-shaped rings or rubber composite gaskets, and the water leakage risk is reduced.
Further, a gas temperature sensor and a motor temperature sensor are arranged on the controller, and the controller judges whether the pressure of the gas system is higher than the safe pressure of the whole vehicle or not through monitoring of the gas temperature sensor and the motor temperature sensor; if the pressure of the gas system is higher than the safe pressure of the whole vehicle, the controller stops the air compressor to work, and starts the air compressor to work after the temperature is reduced or the pressure is lower than the safe pressure of the whole vehicle; if the pressure of the gas system is lower than the safe air pressure of the whole vehicle, the controller feeds back a fault signal to the whole vehicle control system, controls the water pump to accelerate the flow rate for cooling, and judges whether a fault with overlong operation time occurs or not.
Furthermore, a water temperature sensor is arranged on the controller, the controller monitors the temperature of the cooling water through the water temperature sensor, and the temperature of the cooling water is adjusted by controlling the work load rate of the air compressor.
Further, the controller monitors that the system pressure is between the safety pressure and the rated pressure of the whole vehicle, the rotating speed of the air compressor is reduced, and the load rate of the air compressor is improved. Otherwise, the rotating speed of the air compressor is increased, the load rate of the air compressor is reduced, the working temperature of the air compressor is reduced, the safety of the whole vehicle air braking system is protected, and the service life of the air compressor is prolonged.
The invention has the beneficial effects that: the invention adopts an external water-cooling carrying vertical double-cylinder two-stage compression structure, and is assisted by a double-crank inner support transmission structure: the axial distance between the connecting rod and the crankshaft support is reduced, so that the vibration in operation is reduced, and meanwhile, the balance blocks are arranged on the cranks on the two sides and balanced with the rotating mass of the crank-connecting rod mechanism, so that the rotating inertia force and moment in the operation of the piston type air compressor are eliminated, and the vibration of oil-free piston type air compression is further reduced. The invention adopts the design of an integrated controller, has compact structure, convenient installation, high efficiency and energy conservation, and has the functions of intelligent control, fault detection, whole vehicle information interaction and the like. The invention adopts an efficient and reliable water cooling structure, and reduces the internal operation temperature and the exhaust temperature of the air compressor while meeting the working environment of the controller, thereby meeting the requirement of continuous operation of the air compressor; meanwhile, the noise of the pump head is inhibited from expanding outwards, and the running noise of the air compressor is reduced.
Drawings
FIG. 1 is a front view of a main structure of the present invention;
FIG. 2 is a left side cross-sectional view of the present invention;
FIG. 3 is a perspective view of the present invention;
FIG. 4 is a cross-sectional view of a cylinder head water channel of the present invention;
FIG. 5 is a top cross-sectional view of the waterway of the present invention;
FIG. 6 is a cross-sectional view of a partial waterway of a pump head of the present invention;
FIG. 7 is a crankcase construction of the invention;
FIG. 8 is a piston cylinder block diagram of the present invention;
FIG. 9 is a block diagram of the cylinder head of the present invention;
FIG. 10 is a cross-sectional view of the cylinder head of the present invention;
FIG. 11 is a block diagram of the piston valve assembly of the present invention;
FIG. 12 is a view of the driven end of the coupling of the present invention;
in the figure, 1, a rubber shock pad; 2. mounting a bracket; 3. a motor; 4. the driving end of the elastic coupling; 5. a driven end of the elastic coupling; 6. a maintenance-free double-row support bearing; 7. a crankshaft; 8. a counterbalance; 9. a crankcase; 10. an end cap; 11. a sound-deadening structure; 12. a maintenance-free grease lubricated bearing; 13. a high pressure cylinder piston link assembly; 14. a low pressure cylinder piston link assembly; 15. a piston cylinder; 16. a low pressure guide ring; 17. a low pressure piston ring; 18. a low-pressure air inlet valve plate; 19. a valve plate; 20. a cylinder cover; 21. a second exhaust valve assembly; 22. a high-pressure air inlet valve plate; 23. a high pressure seal ring; 24. a high pressure guide ring; 25. a controller; 26. a first exhaust valve assembly; 27. countersunk head screws; 28. an inner through bolt; 29. debugging an interface; 30. a high voltage power supply interface; 31. a CAN communication interface is interacted with the whole vehicle; 32. a safety valve; 33. an exhaust joint; 34. an air inlet joint; 35. a circulating water path; 36. a water discharge joint; 37. a water inlet joint; 38. connecting a water pipe; 39. a water bolt; 40. a cavity water channel in the crankcase; 41. a double-layer sealing groove of a crankcase; 42. a water through hole of the crankcase; 43. a limber hole of the piston cylinder; 44. a double-layer sealing groove of a piston cylinder; 45. a cavity water channel in the piston cylinder; 46. a low-pressure area at the inner side of the cylinder cover; 47. a water inlet and outlet channel; 48. a high-pressure area on the inner side of the cylinder cover; 49. a cavity water channel in the cylinder cover; 50. a limit screw; 51. a fixed-distance bolt; 52. an annular butterfly valve plate; 53. the end surface of the annular groove is provided with an air inlet; 54. a low pressure piston; 55. a counterweight structure.
Detailed Description
The following description will explain embodiments of the present invention in further detail with reference to the accompanying drawings.
The invention provides an air source system of a water-cooled air compressor for a vehicle, which adopts an inner support double-crank crankshaft 7, wherein a high-pressure connecting rod piston assembly 13 and a low-pressure connecting rod piston assembly 14 are respectively arranged on eccentric cranks at two sides of the crankshaft; the inner side of the elastic coupling is provided with a taper hole, a coupling driven end 5 is arranged through a fastening bolt and a key structure, a coupling driving end 4 is arranged on a main shaft of a motor 3, the elastic coupling has the function of compensating axial and radial deviation, the transmission stability and reliability of the main shaft are guaranteed, the motor 3 is arranged on the rear side of a crank case 9, and a crank shaft 7 is arranged on the crank case 9 through a maintenance-free double-row supporting bearing 6; the structure of the double-crank internal support structure ensures that the strength of the transmission structure is reliable and the operation is stable, and simultaneously, the double-crank internal support structure reduces the vibration during the operation by reducing the axial distance between the connecting rod and the crankshaft support; an end cover 10 is arranged on the front side of the crankcase 9, a silencing structure 11 is arranged in the end cover and is made of foamed aluminum, silencing cotton and the like, and a low-pressure piston ring 17, a low-pressure guide ring 16, a high-pressure sealing ring 23 and a high-pressure guide ring 24 are respectively arranged on the low-pressure cylinder piston connecting rod assembly 14 and the high-pressure cylinder piston connecting rod assembly 13 and play roles in gas sealing and motion guiding; meanwhile, the high-pressure piston and the low-pressure piston are manufactured by materials with different densities, so that the piston connecting rod assemblies of the high-pressure cylinder and the low-pressure cylinder reach the same weight. An intake connector 34 is disposed on the side of the crankcase 9, and an exhaust connector 33 and a relief valve 32 are disposed on the cylinder head 20. The whole machine is placed on the rubber shock pad 1 through the mounting bracket 2 and the crankcase 9. The crank outside the crank shaft 7 is provided with a through hole structure, a balance block 8 of the crank shaft is arranged on the crank shaft 7 through a fastening bolt and a flat key structure, and the balance block and the rotating part of the crank connecting rod mechanism achieve balance, so that the rotating inertia force and moment when the piston type air compressor operates are eliminated, and the vibration of oil-free piston type air compression is further reduced. As shown in fig. 12, the driven end 5 of the coupling is provided with a counterweight structure 55, which can play a role of a balance weight while playing a role of transmitting power, so that the volume of the transmission structure is greatly reduced while the vibration of the whole machine is reduced; so as to ensure to eliminate the rotating inertia force and moment generated when the piston type air compressor operates.
The compression working process of the invention is as follows: as shown in fig. 1-2, a main shaft of a motor 3 drives a driving end 4 of an elastic coupling to rotate, and a driven end 5 of the elastic coupling drives a crankshaft 7 to rotate. The cranks at two sides of the crankshaft are provided with maintenance-free grease lubrication bearings 12 which drive a low-pressure cylinder piston connecting rod assembly 14 and a high-pressure cylinder piston connecting rod assembly 13 on the cranks to reciprocate up and down, so that the volumes in the two cylinders change periodically, wherein the low-pressure cylinder piston is provided with a low-pressure air inlet valve plate 18, the unidirectional flow guide effect of the valve plate is realized, when the low-pressure piston moves downwards from an upper dead point, the cylinder is enlarged to generate negative pressure, and natural air is sucked into a primary cylinder of a piston cylinder 15. A valve plate 19 is arranged on the upper side of the piston cylinder, and a first exhaust valve component 26 is arranged on the valve plate; the low-pressure piston moves upwards from the bottom dead center, the gas in the cylinder is compressed, the low-pressure air inlet valve plate 18 is closed at the moment, the first exhaust valve assembly 26 opens the exhaust gas, and the gas compression of the first-stage cylinder is completed at the moment. And then the primary compressed gas enters the secondary cylinder of the piston cylinder through a flow passage of the cylinder cover 20 under the action of a high-pressure inlet valve plate 22, and secondary compression is completed under the combined action of the piston of the high-pressure cylinder and the second exhaust valve component 21.
As shown in fig. 11, the low-pressure intake valve plate 18 is disposed on the annular groove end face of the low-pressure piston 54, the limit screw 50 is disposed on the annular groove end face while the air inlet 53 is disposed on the annular groove end face, and at the position of the highest upward-lift point of the valve plate, the limit screw 50 plays a fixed-distance limiting role in the low-pressure intake valve plate, so that the problem that the root of the valve plate is easy to break due to the fact that the upward-lift opening angle of the valve plate is too high is avoided, timely closing of the valve plate during a compression stroke is guaranteed, and compression efficiency is improved. The fixed-stroke bolt 51 is provided with the annular butterfly valve plate 52 or the annular waveform valve plate, so that the pressing force of the valve plate and the free stroke of the root part of the valve plate are controlled, the problem of stress concentration of the root part of the valve plate is greatly reduced, and the service life of the valve plate is greatly prolonged. The annular butterfly valve plate or the annular wave valve plate structure is matched with an annular groove design on the end face of the piston, the valve plate is completely avoided in the groove of the piston when the top dead center is compressed, so that dry impact on the valve plate when the top dead center of the piston is avoided, a fixed-stroke bolt and a limit bolt head are completely avoided in an exhaust hole of the valve plate, the clearance volume is minimized, and the compression efficiency is greatly improved. The screw head is arranged in the inner hole of the valve plate and carries the design of a piston ring groove, the structure greatly reduces the clearance volume when the piston operates at the top dead center, and the compression efficiency of the whole machine is improved. The air inlet piston design of the invention has the advantages of small volume, light weight, high compression efficiency, long service life and the like.
The invention adopts the water cooling system, so that the internal operating temperature of the controller and the compressor pump head is greatly reduced by high-efficiency cooling, and the requirement of continuous work of the gas supply system is met. Particularly, the air compressor can work in a controllable compression temperature range, so that the compressor is more efficient and energy-saving; meanwhile, the exhaust temperature of the air compressor is greatly reduced, and the design of a pump head water channel can effectively inhibit the outward expansion of noise, so that the running noise of the whole machine is reduced.
As shown in fig. 3 to 5, the cooling water in the circulation water path 35 is supplied by the vehicle water pump system, enters from the water inlet joint 37, passes through a labyrinth-shaped cooling water path provided in the controller 25, enters into the water tank of the crankcase 9 through the connection water pipe 38, passes through the water tank in the piston cylinder 15, enters into the cylinder cover 20 through the water bolts 39 arranged on the cylinder cover 20, passes through the water channel in the cylinder cover, returns to the piston cylinder 15 and the crankcase 9 through the water bolts, and is finally discharged through the water discharge joint 36 to be collected in the vehicle circulation water path.
The water channel circulation process is connected with the controller and the cylinder head area of the air compressor, and efficient circulating cooling of the controller 25 and the cylinder head area crank case 9, the piston cylinder 15 and the cylinder cover 20 of the air compressor is achieved.
As shown in fig. 7-8, the crankcase 9 and the piston cylinder 15 can adopt a crankcase internal cavity water channel 40 and a piston cylinder internal cavity water channel 45, the reliability of the structure is higher, the crankcase 9 and the piston cylinder 15 are cast and formed by sand core molds, the surfaces of parts are closed structures, and the inner cavities of the parts are formed by sand molds; the end face of the crankcase 9 is provided with a plurality of crankcase limber holes 42, the end face of the piston cylinder 15 is provided with a plurality of piston cylinder limber holes 43, and the limber holes also play a role of fabrication holes to realize the positioning and the supporting of the sand core. And the double-layer sealing groove 41 designed on the end face of the crankcase 9 and the double-layer sealing groove 44 designed on the end face of the piston cylinder 15 are used as auxiliary materials, so that double sealing can be realized through an O-shaped ring or a rubber composite gasket, and the water leakage risk is greatly reduced.
As shown in fig. 9-10, the cylinder head is provided with a low pressure region 46 and a high pressure region 48 inside, and the surface of the cylinder head is designed with grid reinforcing ribs which can play a role in exhaust and noise reduction. The water inlet and outlet channel 47 is connected with the cavity water channel 49 in the cylinder cover, and the structure has high reliability, large heat dissipation area and high cooling efficiency.
The water cooling system of the invention has the following advantages:
1. the circulating water channel design of high reliability, little volume lightweight structural layout, high-efficient cooling: the controller, the crankcase, the piston cylinder and the cylinder cover, and the flow channel covers the heating source, so that the exhaust temperature is reduced, and the compression efficiency is improved.
2. The structural design of the cavity in the main body part achieves high-efficiency cooling and greatly reduces the water channel leakage surface at the joint of each part at the same time by casting the water-through cavity structure,
3. the design of annular grooves on sealing surfaces of a crankcase and a piston cylinder is assisted to form multi-protection, so that the water leakage risk is greatly reduced
4. The cylinder cap, the design of leading to water bolt in the piston cylinder connection adoption, this bolt both plays the runner effect, plays the connection fastening effect again to this structural design advantage lies in that bolt installation terminal surface, valve plate both sides jar pad, screw thread department homoenergetic play water-proof effects, thereby form the multichannel protection, promoted the reliability greatly.
The controller 25 adopts a lightweight design, is directly installed and fixed on the motor 3 of the air compressor, and is internally provided with a high-voltage power cord bundle connected with the motor 3, so that the structure is compact and the installation is convenient; a cooling water channel is designed inside, so that the efficiency and the energy are high; and has the functions of intelligent control, fault detection, whole vehicle information interaction and the like.
As shown in fig. 6: the controller 25 is fixed on the motor 3 through a countersunk head screw 27, and a high-voltage power wire bundle connected with the motor 3 is arranged in the controller through an inner through bolt 28; the structure is compact, safe and reliable. The controller is provided with a whole vehicle interaction CAN communication interface 31 for sharing the working state of the gas supply system, feeding back fault information and the like in real time, and a high-voltage power supply interface 30 and a debugging interface 29.
The intelligent control process of the controller 25 is as follows: the intelligent starting and stopping of the whole vehicle air brake system are realized between the preset safe air pressure and the highest rated air pressure, the air compressor is enabled to work under the best performance load factor by controlling the working rotating speed of the motor of the air compressor, the service life of the air compressor is further guaranteed, the air compressor is enabled to be more efficient and energy-saving, and the safety performance of the whole vehicle is improved.
The controller 25 has the following functions:
function 1: when the gas temperature sensor and the motor temperature sensor on the controller 25 monitor that the temperature is too high, the controller system judges whether the pressure of the gas system is higher than the safe pressure of the whole vehicle; if the pressure of the gas system is higher than the safe pressure of the whole vehicle, the controller stops the air compressor to work, and the air compressor is started to work after the temperature is reduced or the pressure is lower than the safe pressure of the whole vehicle; if the pressure of the gas system is lower than the safe air pressure of the whole vehicle, the controller feeds back a fault signal to the whole vehicle control system, detects whether the air compression is started to operate or not, controls the water pump to accelerate the flow speed to cool if the air compression is detected to operate, prevents the compressor from continuously operating at an overhigh temperature, and judges whether a fault with overlong operation time occurs or not.
Function 2: the controller 25 controls the work load rate of the air compressor by monitoring the work state of the air compressor, so that the air compressor can run more efficiently and energy-saving. When the controller system detects that the long-time shutdown load rate of the air compressor is low during driving, and the system pressure is between the safety pressure and the rated pressure of the whole vehicle, the controller properly reduces the rotating speed of the air compressor and properly improves the load rate of the air compressor. Otherwise, when the controller system detects that the load rate of the air compressor is high after long-time shutdown, the controller properly increases the rotating speed of the air compressor, properly reduces the load rate of the air compressor, lowers the working temperature, protects the safety of the whole air brake system and prolongs the service life of the air compressor.
Function 3: when the water temperature sensor on the controller 25 monitors that the temperature of cooling water is too low, the cooling water is fed back to the whole vehicle controller and is communicated and interacted with a whole vehicle control system, and when the whole vehicle controller judges that the temperature of the cooling water is too low and the performance service life of components such as a battery is influenced, the air compressor controller controls the work load rate of the air compressor to be increased, and the temperature of the cooling water is increased.
The controller adopts the design of an integrated compressor, shares a water channel and a shell structure, has compact structure and small volume, and can more efficiently control the compressor to work.
The above-described embodiments are intended to illustrate rather than to limit the invention, and any modifications and variations of the present invention are within the spirit of the invention and the scope of the appended claims.
Claims (8)
1. An air source system of a water-cooled air compressor for a vehicle is characterized by comprising a double-crank inner support transmission structure, a controller and a water-cooled system;
the double-crank internal support transmission structure is driven by a motor, the crank shaft is connected with the motor through an elastic coupling, cranks on two sides of the crank shaft drive a low-pressure cylinder piston assembly and a high-pressure cylinder piston assembly on the crank shaft to reciprocate up and down, so that the inner volumes of the two piston cylinders are periodically changed to complete the gas compression process,
the controller is fixed on the motor, a high-voltage power cord bundle connected with the motor is arranged in the controller through an inner through bolt, a labyrinth type cooling water channel is arranged in the controller, and a whole vehicle interaction CAN communication interface is arranged on the controller and used for sharing the working state of the gas supply system in real time and monitoring and feeding back fault information through a sensor;
the water cooling system is supplied with water by a finished automobile water pump system, the water enters a crankcase water channel after passing through a labyrinth type cooling water channel in the controller, a crankshaft is arranged on a crankcase through a maintenance-free double-row support bearing, then enters a cylinder cover through a water passing bolt after passing through the water channel in the piston cylinder, returns to the piston cylinder and the crankcase through the water passing bolt after passing through a water channel in an inner cavity of the cylinder cover, and finally is discharged and collected into a finished automobile circulating water channel, the water channel circulating process is connected with the controller and a cylinder head area of an air compressor, and the efficient circulating cooling of the crankcase, the piston cylinder and the cylinder cover in the cylinder head area of the controller and the air compressor is completed; the crankcase and the piston cylinder adopt an inner cavity water channel structure, and the surfaces of the crankcase and the piston cylinder are of closed structures; the crankcase and the piston cylinder end face are provided with a plurality of limber holes, double-channel sealing is realized through an O-shaped ring or a rubber composite gasket, and the water leakage risk is reduced.
2. The air source system of the water-cooled air compressor for the vehicle as claimed in claim 1, wherein the motor spindle drives the driving end of the elastic coupling to rotate, and the driven end of the elastic coupling drives the crankshaft 7 to rotate; the driven end of the elastic coupling is provided with a counterweight structure, so that the elastic coupling can play a role of a balance block while playing a role of power transmission, and the vibration of the whole machine is reduced.
3. The air source system of the water-cooled air compressor for the vehicle as claimed in claim 1, wherein the low pressure cylinder piston assembly is provided with a low pressure air inlet valve plate, the valve plate has a one-way flow guiding effect, when the low pressure piston moves downwards from the upper dead point, the cylinder becomes large to generate negative pressure, so that natural air is sucked into the primary cylinder of the piston cylinder, the upper side of the piston cylinder is provided with a valve plate, and the valve plate is provided with a first exhaust valve assembly; the low-pressure piston moves upwards from the lower dead point, the volume in the cylinder is reduced, the gas is compressed, the low-pressure air inlet valve plate is closed, the first exhaust valve component opens to exhaust the gas, the gas compression of the primary cylinder is completed, the primary compressed gas enters the secondary cylinder of the piston cylinder through the cylinder cover flow channel under the action of the high-pressure air inlet valve plate, and the secondary compression is completed under the combined action of the high-pressure cylinder piston and the second exhaust valve component.
4. The air source system of claim 3, wherein the low pressure air intake valve plate is disposed on an end surface of an annular groove of the low pressure piston, the end surface of the annular groove is provided with the air inlet and a limit screw, the limit screw performs a fixed distance limiting function on the low pressure air intake valve plate, and a fixed distance bolt is adopted, and an annular wave-shaped or butterfly-shaped valve plate is disposed on the fixed distance bolt to reduce stress concentration at the root of the valve plate and prolong the service life of the valve plate.
5. The air source system of the vehicular water-cooled air compressor as claimed in claim 1, wherein a balance block is additionally arranged on each crank at two sides of the crankshaft, a through hole structure is arranged on the crank at the outer side of the crankshaft, the balance blocks are arranged on the crankshaft through fastening bolts and a flat key structure, the balance blocks and the rotating part of the crank connecting rod achieve balance, rotational inertia force and moment when the piston type air compressor operates are eliminated, and vibration of oil-free piston type air compression is further reduced.
6. The air source system of the water-cooled air compressor for the vehicle as claimed in claim 1, wherein the controller is provided with a gas temperature sensor and a motor temperature sensor, and the controller judges whether the pressure of the gas system is higher than the safe pressure of the whole vehicle or not through the monitoring of the gas temperature sensor and the motor temperature sensor; if the pressure of the gas system is higher than the safe pressure of the whole vehicle, the controller stops the air compressor to work, and starts the air compressor to work after the temperature is reduced or the pressure is lower than the safe pressure of the whole vehicle; if the pressure of the gas system is lower than the safe air pressure of the whole vehicle, the controller feeds back a fault signal to the control system of the whole vehicle, detects whether the air compression is started to operate or not, controls the water pump to accelerate the flow rate to cool and protect the compressor if the air compressor is detected to operate, and simultaneously feeds back and judges whether a fault with overlong operation time occurs or not.
7. The air source system of claim 1, wherein the controller is provided with a water temperature sensor, and the controller monitors the temperature of the cooling water through the water temperature sensor and adjusts the temperature of the cooling water by controlling the duty ratio of the air compressor.
8. The air source system of the water-cooled air compressor for the vehicle as claimed in claim 1, wherein the controller monitors the system pressure between the safety pressure and the rated pressure of the vehicle, and then adjusts the rotation speed of the air compressor to lower the load rate of the air compressor, and otherwise, adjusts the rotation speed of the air compressor to increase the load rate of the air compressor, so that the working temperature of the air compressor is reduced, the safety of the air brake system of the vehicle is protected, and the service life of the air compressor is prolonged.
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| CN113309687B (en) * | 2021-05-24 | 2023-01-24 | 瑞立集团瑞安汽车零部件有限公司 | Inside cooling water course structure of air compressor machine and air compressor machine |
| CN117547875B (en) * | 2024-01-11 | 2024-03-26 | 太原市佳帝涂料有限公司 | Coating production filtration equipment |
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