CN-121994515-A - Air suspension functional level simulation and fault injection test system

CN121994515ACN 121994515 ACN121994515 ACN 121994515ACN-121994515-A

Abstract

The invention relates to the technical field of suspension testing, and discloses an air suspension function level simulation and fault injection testing system which comprises an upper computer, a real-time simulation platform, a load board card set and an air suspension controller, wherein a whole vehicle model, a double-cavity air spring and an adjustable damping shock absorber function level model are arranged in the real-time simulation platform to realize suspension physical state calculation, valve state judgment and model parameter updating, the load board card set is an electric interface, a valve system load board card of the air suspension function level simulation and fault injection testing system is used for equivalently simulating a real vehicle electromagnetic valve load through an impedance-matched inductance-resistance load network, driving current of the controller can be collected and returned to the simulation platform, the simulation platform is used for judging the valve state according to actual measured current, updating suspension function level model parameters and calculating mechanical response is fed back to the whole vehicle model, and the controller receives analog sensor signals and outputs driving current, so that the technical problems that the hardware cost investment is large and the response mechanism is difficult to quantitatively analyze in the prior art are solved.

Inventors

YANG SIYU
LI SHIYING
YAN LIU
ZHAO KEYI
ZHU LIJIANG
TANG JUN
YUAN YUAN
MA YUANYUAN

Assignees

中国汽车工程研究院股份有限公司
中汽院(江苏)汽车工程研究院有限公司

Dates

Publication Date: 20260508
Application Date: 20260318

Claims (9)

1. The air suspension function level simulation and fault injection test system is characterized by comprising: The upper computer is used for configuring test working conditions, setting fault injection strategies and sampling parameters; the real-time simulation platform is internally provided with a whole vehicle model and an air suspension functional level model, wherein the air suspension functional level model comprises a double-cavity air spring functional level model and an adjustable damping shock absorber functional level model, and the real-time simulation platform is used for realizing the calculation of the physical state of the air suspension, the real-time judgment of the valve state and the dynamic update of model parameters; The load board card group is an electrical interface for connecting the real-time simulation platform and the air suspension controller and comprises a valve system load board card, a PSI5 height signal board card, an analog voltage board card and a resistance analog board card; Each independent channel of the valve system load board card is integrated with a load network formed by an inductor and a resistor element, and the electrical parameters of the load network are calibrated and matched with the impedance characteristics of a real-vehicle electromagnetic valve coil to be used for equivalently simulating the real-vehicle electromagnetic valve load; The air suspension controller is a measured controller and is used for receiving sensor signals simulated by the load board card group, generating a valve system driving instruction according to built-in control logic and outputting driving current to the valve system load board card; The real-time simulation platform judges the valve state according to the actual measured current value returned by the valve system load board card, updates the air circuit communication relation and damping force parameters of the air suspension functional level model based on the judged valve state, and re-calculates the mechanical response of the suspension and feeds back the mechanical response to the whole vehicle model.
2. The air suspension function level simulation and fault injection test system according to claim 1 is characterized in that a multichannel structure of the valve system load board card covers all actuator driving loops of an air suspension, the multichannel structure comprises an inflating pump relay, an air storage tank valve, an air exhaust valve, height valves of four suspension corner points, a rigidity valve and a continuous damping control electromagnetic valve, an equivalent load circuit of each channel is formed by connecting resistors and inductors in series, sampling resistors are connected in series at the front end of a main loop, and loop current is calculated by collecting voltage drops at the two ends of the sampling resistors.
3. The system for testing the functional level simulation and fault injection of the air suspension according to claim 2, wherein the valve system load board is integrated with a controllable short circuit branch on a specific channel, and the system is used for actively triggering the electrical fault injection of the power supply short circuit or the ground short circuit to a target channel at a specified moment according to a software instruction of an upper computer or a real-time simulation platform and verifying the fault diagnosis and fault tolerance control capability of the air suspension controller.
4. The air suspension functional level simulation and fault injection testing system according to claim 3 is characterized in that the air circuit topology of the double-cavity air spring functional level model composite reality vehicle double-cavity air spring comprises an air supply assembly and four corner double-cavity air springs, the air supply assembly comprises an air pump, an air exhaust valve, an air storage tank and an air storage tank valve, each air spring corresponds to a height valve for controlling air charging and air discharging and a rigidity valve for controlling on-off of a main cavity and a sub-cavity, and working states of all the valves are judged by the real-time simulation platform according to actual measurement currents collected by a valve system load board card and synchronous switching of air circuit states in a driving model.
5. The air suspension function level simulation and fault injection test system according to claim 4, wherein the adjustable damping shock absorber function level model is characterized in that independent shock absorber simulation models are configured for four suspension corner points of a vehicle, each model is a table lookup mapping module containing relations among current, shock absorber compression speed and damping force, and the real-time simulation platform inputs actually measured driving current of a continuous damping control electromagnetic valve collected by a valve system load board card and real-time shock absorber compression speed output by a whole vehicle model into the table lookup module together, and solves the current damping force and feeds the current damping force back to the whole vehicle model.
6. The system for functional simulation and fault injection testing of an air suspension system of claim 5 wherein said system supports physical fault injection by modifying model parameters through said real-time simulation platform, fault types including air path leakage, sensor drift/bias, valve body stuck and communication anomalies; The gas circuit leakage fault is realized by modifying the air pressure attenuation parameters of the air spring cavity, the sensor drift/bias fault is realized by modifying the analog signal parameters of the height, the air pressure and the temperature, the valve body clamping stagnation fault is realized by the opening and closing states of the valve in the fixed model, and the communication abnormal fault is realized by interrupting signal transmission.
7. The air suspension function level simulation and fault injection test system according to claim 6, wherein the PSI5 height signal board receives the air spring height values of each angular point calculated and output by the real-time simulation platform according to a whole vehicle model, generates a height simulation signal consistent with a real vehicle height sensor protocol and sends the height simulation signal to an air suspension controller, the simulation voltage board receives an air spring air pressure simulation voltage signal converted by the real-time simulation platform and outputs the air spring air pressure simulation voltage signal to the air suspension controller, and the resistance simulation board simulates signal characteristics of a real vehicle temperature sensor through resistance value change and is connected to a temperature sensor interface of the air suspension controller.
8. The system for simulating the functional level of an air suspension and injecting faults according to claim 7, wherein the real-time simulation platform judges a valve state according to a preset current threshold value or a specific current value, judges that a valve is closed when the current value is zero, judges that the valve is opened when the current value is greater than the preset threshold value, and the continuous damping control electromagnetic valve judges a continuous adjustment state according to the specific current value.
9. The system for testing the air suspension function level simulation and fault injection according to claim 8, wherein after the single channel of the valve system load board card inputs the driving current of the air suspension controller, the driving current flows through a 2000 omega sampling resistor and a load network which are connected in series, current collection nodes are connected at two ends of the sampling resistor in parallel, the collected voltage signals are amplified, filtered and analog-to-digital converted to form actual measurement current data, the actual measurement current data is output to a 485 differential communication bus and uploaded to a real-time simulation platform, the actual measurement current data is used as the only basis for judging the opening and closing states or the working gears of the corresponding valves by the real-time simulation platform, and meanwhile, an indicator lamp is connected at two ends of the load network in parallel and outputs a state indication signal according to current on-off; The inductance of the load network comprises 23mH and 12mH and the resistive elements of the load network comprise 7Ω, 16Ω and 4Ω.

Description

Air suspension functional level simulation and fault injection test system Technical Field The invention relates to the technical field of suspension testing, in particular to an air suspension functional level simulation and fault injection testing system. Background The air suspension system is used as the core component of the intelligent automobile chassis and consists of an air spring, an air supply unit, a sensor assembly, a suspension controller (ECU) and the like, and can realize the adjustment of the height of the automobile, the stable posture and the rigidity matching of the suspension according to the running state of the automobile, and the rationality of a control strategy directly influences the comfort, the stability and the dynamic safety of the automobile. With the improvement of the intelligent degree of the whole vehicle, the air suspension control logic is more and more complex, and the functional verification of the air suspension control logic under different working conditions and abnormal conditions becomes a research and development core link. The prior air suspension verification method has the following defects: The existing air suspension test mostly adopts a physical bench mode, and a complex test environment containing a large number of dynamic components and pneumatic components is required to be built, so that hardware investment is large, a test preparation period is long, the test environment is difficult to quickly multiplex, meanwhile, the repeatability and the controllability of a test result of the physical bench test are poor and extreme fault scenes cannot be simulated due to the limitation of conditions such as environment, road conditions and the like, and safety risks exist. In the existing air suspension simulation test technology, high-precision multi-physical-field simulation is mostly pursued, modeling, parameter calibration and real-time operation costs are high, normal working condition verification is only concerned, simulation capability on actual faults such as valve body clamping stagnation, leakage and signal bias is limited, the coupling degree of a signal simulation unit and a simulation model is high, a closed-loop control environment cannot be built, and response mechanisms of a controller on different signal sources, load conditions and fault types are difficult to quantitatively analyze. Disclosure of Invention The invention aims to provide an air suspension function level simulation and fault injection test system so as to solve the technical problems that hardware cost investment is large and a response mechanism is difficult to quantitatively analyze in the prior art. In order to achieve the purpose, the invention adopts the following technical scheme that the air suspension function level simulation and fault injection test system comprises: The upper computer is used for configuring test working conditions, setting fault injection strategies and sampling parameters; the real-time simulation platform is internally provided with a whole vehicle model and an air suspension functional level model, wherein the air suspension functional level model comprises a double-cavity air spring functional level model and an adjustable damping shock absorber functional level model, and the real-time simulation platform is used for realizing the calculation of the physical state of the air suspension, the real-time judgment of the valve state and the dynamic update of model parameters; The load board card group is an electrical interface for connecting the real-time simulation platform and the air suspension controller and comprises a valve system load board card, a PSI5 height signal board card, an analog voltage board card and a resistance analog board card; Each independent channel of the valve system load board card is integrated with a load network formed by an inductor and a resistor element, and the electrical parameters of the load network are calibrated and matched with the impedance characteristics of a real-vehicle electromagnetic valve coil to be used for equivalently simulating the real-vehicle electromagnetic valve load; The air suspension controller is a measured controller and is used for receiving sensor signals simulated by the load board card group, generating a valve system driving instruction according to built-in control logic and outputting driving current to the valve system load board card; The real-time simulation platform judges the valve state according to the actual measured current value returned by the valve system load board card, updates the air circuit communication relation and damping force parameters of the air suspension functional level model based on the judged valve state, and re-calculates the mechanical response of the suspension and feeds back the mechanical response to the whole vehicle model. The principle and the advantages of the scheme are that in practical application, an upper computer firstly configures test