Fault injection device and method and test bench

Abstract

The invention provides a fault injection device and method and a test bench, and relates to the technical field of vehicles, the device comprises a valve mechanism, the valve mechanism comprises a valve body and a valve core, the valve body comprises a first valve cavity, a first gas path and a second gas path, the first gas path and the second gas path are respectively divided into two parts by the first valve cavity, the first part of the first gas path and the first part of the second gas path are communicated with a tested component of the air suspension, the second part of the first gas path is communicated with the atmosphere, the second part of the second gas path is connected with a pipeline of the air suspension, and the valve element is arranged in the first valve cavity and comprises a first valve rod, a first blocking part and a second blocking part; the first blocking part and the second blocking part are arranged on the first valve rod and used for adjusting the gas path opening degree of the first gas path and the gas path opening degree of the second gas path correspondingly. The driving part is connected with the valve element and used for driving the first valve rod to do relative movement in the direction of the first valve cavity. Based on the device, the fault response function of the air suspension system can be tested more comprehensively and accurately.

Description

Technical Field

[0001] The present application relates to the technical field of vehicles, and particularly to a fault injection device, a method, and a test bench. Background Art

[0002] With the development of the automotive industry, an electronic-controlled air suspension (ECAS) has been proposed and applied to some vehicle models.

[0003] An air suspension has a certain service life. The valves, bellows, and air circuits of the air suspension age, and other random factors can cause faults such as air leakage and air circuit blockage in the air suspension system. When a fault occurs in the air suspension system, it can lead to an imbalance in the body posture, thus affecting the driving safety of the vehicle. Therefore, the air suspension system is also equipped with corresponding fault response functions to reduce the impact of the air suspension system failure on vehicle driving.

[0004] In view of this, in the process of air suspension development, how to perform accurate and comprehensive fault injection tests on the air suspension to verify whether the air suspension system performs corresponding fault response operations is an urgent problem to be solved. Summary of the Invention

[0005] The embodiments of the present application provide a fault injection device, a method, and a test bench, which can accurately and comprehensively simulate different degrees of air leakage faults or blockage faults of each main component in the air suspension system, so that in the development stage of the air suspension, the fault response function of the air suspension system can be tested more comprehensively and accurately.

[0006] In a first aspect, a fault injection device is provided. The fault injection device includes: a valve mechanism, which includes a valve body and a valve core. The valve body includes a first valve cavity, a first air circuit, and a second air circuit. Among them, the first air circuit and the second air circuit are respectively divided into two parts by the first valve cavity. The first part of the first air circuit and the first part of the second air circuit are connected to each other and form a main air circuit, which is connected to the component under test of the air suspension. The second part of the first air circuit is connected to the atmosphere, and the second part of the second air circuit is connected to the pipeline of the air suspension. The valve core is arranged in the first valve cavity. The valve core includes a first valve rod, a first blocking part, and a second blocking part. Among them, the first blocking part is arranged at a first position of the first valve rod, and the first blocking part is used to adjust the air circuit opening degree of the first air circuit. The second blocking part is arranged at a second position of the first valve rod, and the second blocking part is used to adjust the air circuit opening degree of the second air circuit; a driving part, which is connected to the valve core, and the driving part is used to drive the first valve rod to perform relative movement along the direction of the first valve cavity.

[0007] Exemplarily, as the first valve stem moves within the first valve cavity, the first blocking portion and the second blocking portion provided on the first valve stem also move synchronously, and the first blocking portion and the second blocking portion correspondingly change the opening degrees of their respective corresponding air paths.

[0008] It can be seen from this that the structure of the above valve mechanism is a dual air path structure. The first part of the first air path is connected to the component under test of the air suspension, and the second part of the first air path is connected to the atmosphere. This first air path is used to simulate the air leakage fault of the component under test, while the first part of the second air path is connected to the component under test of the air suspension, and the second part of the second air path is connected to the pipeline that was originally directly connected to the component under test, so that the fault injection device is inserted into the original pipeline of the air suspension. This second air path is used to simulate the blocking fault of the component under test.

[0009] Based on the above technical solution, through the design of the dual air path structure of the device, the device can simulate both the blocking fault and the air leakage fault of the component under test by controlling a valve mechanism, with low control overhead and low difficulty in fault simulation. Moreover, the device only needs to be directly connected to the original pipeline of the air suspension and is connected in series with the component under test through the pipeline. Therefore, installing the device makes less modification to the original pipeline of the air suspension, with low installation difficulty and easy application.

[0010] Combined with the first aspect, in some implementation manners of the first aspect, during the process of the first blocking portion reducing the opening degree of the first air path from 100%, the opening degree of the second air path corresponding to the second blocking portion remains 100%; during the process of the second blocking portion reducing the opening degree of the second air path from 100%, the opening degree of the first air path corresponding to the first blocking portion remains 0%.

[0011] Exemplarily, since the first air path corresponding to the first blocking portion is connected to the atmosphere, the first blocking portion is used to introduce an air leakage fault; since the second air path corresponding to the second blocking portion is connected to the pipeline of the air suspension, the second blocking portion is used to introduce a blocking fault. Moreover, when the first blocking portion introduces a fault, although the second blocking portion will move synchronously with the change in the position of the first blocking portion, the second blocking portion will not introduce a blocking fault simultaneously, and vice versa, thus decoupling the operations of introducing an air leakage fault and introducing a blocking fault.

[0012] Exemplarily, the first part of the first air path and the second part of the first air path need to be offset by a first distance in a direction perpendicular to the first valve cavity. This first distance should be less than the second distance existing between the first blocking portion and the second blocking portion on the first valve stem. Based on this, although the movements of the first blocking portion and the second blocking portion are synchronous, the processes of the first blocking portion adjusting the opening degree of the first air path and the second blocking portion adjusting the opening degree of the second air path are asynchronous, so that when the valve mechanism is working, the above air path adjustment principle is satisfied.

[0013] Based on the above technical solution, the operations of introducing air leakage faults and introducing blockage faults can be decoupled, ensuring the rationality and accuracy of fault introduction.

[0014] Combined with the first aspect, in some implementation manners of the first aspect, the positions between the above-mentioned first blocking part and the above-mentioned second blocking part are relatively fixed.

[0015] Based on the above technical solution, by controlling a first valve stem of the fault injection device, it is possible to introduce both air leakage faults and blockage faults into the component under test. The control cost is low, and only by connecting the device in series in the pipeline where the component under test is located, the simulation of two types of faults can be realized, with less modification to the pipeline of the air suspension and easy to implement.

[0016] Combined with the first aspect, in some implementation manners of the first aspect, the above-mentioned fault injection device further includes: a first flowmeter, which is arranged in the second part of the first air path; a second flowmeter, which is arranged in the second air path or the main air path; a barometer, which is arranged in the first part of the first air path, or the first part of the second air path, or the main air path.

[0017] Based on the above technical solution, by arranging corresponding sensors at specified positions of the device, the process of fault injection can be monitored in real time, so that the device can introduce faults more accurately.

[0018] Combined with the first aspect, in some implementation manners of the first aspect, the above-mentioned fault injection device further includes a controller, which is respectively connected to the above-mentioned first flowmeter, the above-mentioned second flowmeter, the above-mentioned barometer and the above-mentioned driving part.

[0019] Based on the above technical solution, by introducing a controller into the device, during the process of introducing faults, the controller can obtain the corresponding parameter values output by the sensors to be used for checking the severity of the currently injected faults, such as mild or severe, so as to facilitate subsequent testing whether the response status of the air suspension under mild or severe faults meets the expectations, thereby completing a reasonable verification of the fault response function of the air suspension.

[0020] Combined with the first aspect, in some implementation manners of the first aspect, the shape of the above-mentioned first blocking part and / or the shape of the above-mentioned second blocking part is triangular, or the above-mentioned first blocking part and / or the above-mentioned second blocking part is a semi-circular groove.

[0021] Based on the above technical solution, the first blocking part and the second blocking part are designed into special shapes, which helps to establish a correlation between the movement amount of the first valve stem and the change of air flow rate and the linear change of current, so as to facilitate the adjustment of the opening degree of the air path corresponding to the first blocking part or the second blocking part through current control.

[0022] In a second aspect, a method for fault injection is provided. The method includes: receiving first fault simulation information, which is used to indicate that a first component of an air suspension is in a first fault state, where the first fault state is component air leakage or component blockage, and the first component is connected to a first fault injection device. The first fault injection device includes: a valve mechanism and a driving part. Among them, the valve mechanism includes a valve body and a valve core. The valve body includes a first valve cavity, a first air passage, and a second air passage. The first air passage and the second air passage are respectively divided into two parts by the first valve cavity. The first part of the first air passage and the first part of the second air passage are interconnected and form a main air passage, and the main air passage is connected to the first component of the air suspension. The second part of the first air passage is connected to the atmosphere, and the second part of the second air passage is connected to the pipeline of the air suspension; the valve core is arranged in the first valve cavity, and the valve core includes a first valve rod, a first blocking part, and a second blocking part. The first blocking part is arranged at a first position of the first valve rod, and the first blocking part is used to adjust the air passage opening degree of the first air passage. The second blocking part is arranged at a second position of the first valve rod, and the second blocking part is used to adjust the air passage opening degree of the second air passage. The driving part is connected to the valve core, and the driving part is used to drive the first valve rod to move relatively along the direction of the first valve cavity; according to the above first fault simulation information, determine the required air flow rate, which is used to indicate that the first fault injection device adjusts the air flow rates of the first air passage and the second air passage; send the required air flow rate to the first fault injection device.

[0023] Exemplarily, the above first fault simulation information can be sent by a host computer. Before the host computer sends the first fault simulation information to an industrial control computer, it is also necessary to power on the air suspension system so that each component of the air suspension can work normally.

[0024] Exemplarily, the air flow rates of different values indicated by the required air flow rate correspond to different faults simulated by the first fault injection device controlling the driving part, and the faults include air leakage faults and blockage faults.

[0025] Based on the above technical solution, the fault simulation control of the first fault injection device can be realized, so that the first fault injection device can simulate air leakage faults and blockage faults.

[0026] In combination with the second aspect, in some implementation manners of the second aspect, the first fault injection device further includes a first barometer, a first flowmeter, and a second flowmeter. Among them, the first barometer is arranged in the first part of the first air passage, or the first part of the second air passage, or the main air passage. The first flowmeter is arranged in the second part of the first air passage, and the second flowmeter is arranged in the second air passage or the main air passage. Obtain the first air pressure value of the first barometer, the first air flow rate of the first flowmeter, and the second air flow rate of the second flowmeter; according to the first fault simulation information, the first air pressure value, the first air flow rate, and the second air flow rate, determine the required air flow rate.

[0027] Exemplarily, the above industrial control computer is also connected to a host computer, which is used to send first fault simulation information to the industrial control computer.

[0028] Exemplarily, the above first fault simulation information includes a fault type and a fault location. The fault type may include a blockage fault and a leakage fault, and the fault location may be at least one measured component connected to the fault injection device.

[0029] Exemplarily, if the fault location of the above first fault simulation information is the first component in the above embodiment, then after the industrial control computer receives the first fault simulation information, it will send the determined required air flow rate to the controller of the first fault injection device connected to the first component, so as to realize injecting a fault into the first component through the first fault injection device.

[0030] Exemplarily, after the industrial control computer determines the required air flow rate, it can send the required air flow rate to the controller of the first fault injection device. Correspondingly, after receiving the required air flow rate, the controller will also perform the following operations: The controller sends a driving instruction to the driving part, and continuously monitors the air flow rate of the first flowmeter and the air flow rate of the second flowmeter. The driving instruction is used to indicate controlling the first valve stem to perform a relative displacement along the direction of the first valve cavity; when the controller monitors that the air flow rate of the first flowmeter and the air flow rate of the second flowmeter meet the required air flow rate, the controller sends a stop instruction to the driving part, and the stop instruction is used to indicate controlling the first valve stem to stop displacement.

[0031] Based on the above technical solution, the industrial control computer determines and sends the required air flow rate to the first fault injection device by obtaining the readings of each sensor of the first fault injection device and combining the first fault simulation information, so that the controller of the first fault injection device only needs to realize the fault simulation of the first component according to the air flow rate. And since the magnitude of the required air flow rate is related to the severity of the fault simulation, this solution can accurately simulate faults of different severities.

[0032] Combined with the second aspect, in some implementation manners of the second aspect, a height sensor is provided on the air spring of the air suspension. After sending the required air flow rate to the first fault injection device, when the first fault state is severe air leakage, continuously monitor the first height value of the height sensor. When it is monitored that the third air flow rate of the first flowmeter is greater than 0 and the first height value continuously decreases, it is determined that the simulation of the first component in the first fault state is completed; or, when the first fault state is slight air leakage, continuously monitor the first height value of the height sensor. When it is monitored that the third air flow rate of the first flowmeter is greater than 0 and the first height value remains unchanged, it is determined that the simulation of the first component in the first fault state is completed.

[0033] Based on the above technical solution, through the industrial control computer, the controller, and the various sensors of the first fault injection device, closed-loop control can be achieved during the process of introducing faults into the component under test until the component under test enters the specified fault state, and leak faults of different severity levels can be accurately introduced into the component under test.

[0034] Combined with the second aspect, in some implementation manners of the second aspect, after sending the required air flow rate to the first fault injection device, when the first fault state is severe blockage, obtain the second air pressure value of the first barometer, and when it is determined that the second air pressure value is greater than or equal to the pressure relief threshold, determine that the simulation of the first component in the first fault state is completed, and the pressure relief threshold is used to trigger the air pump of the air suspension to perform a pressure relief operation; or, when the first fault state is slight blockage, obtain the second air pressure value of the first barometer, and when it is determined that the second air pressure value is less than the pressure relief threshold, determine that the simulation of the first component in the first fault state is completed. Based on the above technical solution, through the industrial control computer, the controller, and the various sensors of the first fault injection device, closed-loop control can be achieved during the process of introducing faults into the component under test until the component under test enters the specified fault state, and blockage faults of different severity levels can be accurately introduced into the component under test.

[0035] Combined with the second aspect, in some implementation manners of the second aspect, the air suspension further includes a second barometer, which is used to measure the air pressure value of the air pump, send a first instruction to the first fault injection device, and this first instruction is used to instruct the first fault injection device to start reducing the air passage opening degree of the second air passage from 100%; during the process of reducing the air passage opening degree of the second air passage, continuously monitor the third air pressure value of the second barometer, and determine the maximum value of the third air pressure value as the pressure relief threshold.

[0036] Based on the above technical solution, the pressure relief threshold of the air suspension can be obtained, which provides a judgment basis for the subsequent industrial control computer to judge whether the first component reaches the expected fault state based on the output result of the first barometer of the first fault injection device.

[0037] Combined with the second aspect, in some implementation manners of the second aspect, the air pump of the air suspension is connected to the second fault injection device, and the structure of the second fault injection device is the same as that of the first fault injection device. Send a first instruction to the first fault injection device, and this first instruction is used to instruct the first fault injection device to start reducing the air passage opening degree of the second air passage from 100%; during the process of reducing the air passage opening degree of the second air passage, continuously monitor the fourth air pressure value of the third barometer in the second fault injection device, and determine the maximum value of the fourth air pressure value as the pressure relief threshold.

[0038] Based on the above technical solution, the pressure relief threshold of the air suspension can also be obtained, increasing the flexibility of obtaining the pressure relief threshold. Moreover, after obtaining the pressure relief threshold, it provides a basis for the subsequent industrial control computer to determine whether the first component reaches the desired fault state based on the output result of the first barometer of the first fault injection device.

[0039] Combined with the second aspect, in some implementation manners of the second aspect, the first fault injection device further includes a first barometer, a first flowmeter, and a second flowmeter. The first barometer is disposed in the first part of the first air path, or the first part of the second air path, or the main air path. The first flowmeter is disposed in the second part of the first air path, and the second flowmeter is disposed in the second air path or the main air path. In the case where the first fault state is component air leakage, a gas flow threshold is determined, and the gas flow threshold is used to determine whether the first component has a slight air leakage fault or a serious air leakage fault; the fourth gas flow of the first flowmeter and the fifth gas flow of the second flowmeter are obtained; and the required gas flow is determined according to the gas flow threshold, the fourth gas flow, and the fifth gas flow.

[0040] Exemplarily, the above gas flow threshold is pre-calibrated.

[0041] Based on the above technical solution, through the pre-calibrated gas flow threshold, combined with the output results of the first flowmeter and the second flowmeter of the first fault injection device, the above required gas flow can be directly determined. The calculation cost of this method is small, and the calculation efficiency is high.

[0042] Combined with the second aspect, in some implementation manners of the second aspect, a height sensor is provided on the air spring of the air suspension, and a second instruction is sent to the first fault injection device, and the second instruction is used to instruct the first fault injection device to increase the air path opening degree of the first air path from 0%. During the process of increasing the air path opening degree of the first air path, the height value of the height sensor and the gas flow of the second flowmeter are continuously monitored. When the height value of the height sensor starts to decrease, the gas flow of the second flowmeter at this time is determined as the gas flow threshold.

[0043] Based on the above technical solution, the gas flow threshold can be determined. After determining the above gas flow threshold, the gas flow threshold can be directly reused to perform repeated fault introduction tests on the first component of the air suspension. This helps to reduce the calculation cost of fault introduction.

[0044] Combined with the second aspect, in some implementation manners of the second aspect, the above first component is an air pump, an air spring, an air tank, or a solenoid valve of the air suspension.

[0045] Based on the above technical solutions, the first fault injection device can not only simulate the faults of the air springs of the air suspension, but also simulate the faults of other components, increasing the fault simulation objects, and can also achieve combined fault simulation, which helps to more reasonably and accurately verify the fault response function of the air suspension in the follow-up.

[0046] In a third aspect, a test bench is provided for simulating faults occurring in an air suspension. The test bench includes: N fault injection devices in any possible implementation manner of the device design in the first aspect above, and the N fault injection devices are respectively connected in series with N components to be tested of the air suspension through pipelines, where N is a positive integer; a simulated counterweight device, which is arranged on the air suspension, and the simulated counterweight device is configured such that its own weight can be adjusted within a first weight range.

[0047] Based on the above technical solutions, through the test bench, not only can corresponding faults be introduced into the air suspension, but also during the process of simulating the faults, the load-bearing state of the air suspension during actual operation can be further simulated, so that the fault simulation of the air suspension is closer to reality, thereby enabling the accurate reproduction of the scenario of air suspension faults.

[0048] In a fourth aspect, a chip system is provided. The chip system is applied to an electronic device; the chip system includes one or more interface circuits and one or more processors; the interface circuits and the processors are interconnected by lines; the interface circuits are used to receive signals from the memory of the electronic device and send signals to the processors, and the signals include computer instructions stored in the memory; when the processors execute the computer instructions, the electronic device executes the method in any possible implementation manner of the method design in the second aspect above.

[0049] In a fifth aspect, a computer-readable storage medium is provided, storing a computer program or instructions, and the computer program or instructions are used to implement the method in any possible implementation manner of the method design in the second aspect above.

[0050] In a sixth aspect, a computer program product is provided. When the computer program code or instructions are executed on a computer, the computer executes the method in any possible implementation manner of the method design in the second aspect above. Description of the Drawings

[0051] Figure 1 is a schematic diagram of the architecture of an ECAS system;

[0052] Figure 2 is a schematic diagram of the architecture of an air suspension;

[0053] Figure 3 is a schematic diagram of the structure of an air suspension including a fault injection device;

[0054] Figure 4 It is a schematic structural diagram of a fault injection device 400 proposed by an embodiment of the present application;

[0055] Figure 5 It is a schematic structural diagram of another fault injection device 400 proposed by an embodiment of the present application;

[0056] Figure 6 It is a schematic structural diagram of a fault injection device 600 proposed by an embodiment of the present application;

[0057] Figure 7 It is a schematic diagram of an air suspension installed with multiple fault injection devices 400 proposed by an embodiment of the present application;

[0058] Figure 8 It is a schematic diagram of the basic operating state of the fault injection device 400 proposed by an embodiment of the present application;

[0059] Figure 9 It is a schematic architecture diagram of a test bench 900 proposed by an embodiment of the present application;

[0060] Figure 10 It is a schematic flow diagram of a fault injection method 1000 proposed by an embodiment of the present application;

[0061] Figure 11 It is a schematic flow diagram of a method 1100 for determining the required air flow rate proposed by an embodiment of the present application;

[0062] Figure 12 It is a schematic flow diagram of a method 1200 for determining the required air flow rate proposed by an embodiment of the present application;

[0063] Figure 13 It is a schematic flow diagram of a method 1300 for determining the air flow rate threshold proposed by an embodiment of the present application;

[0064] Figure 14 It is a schematic architecture diagram of a fault simulation system 1400 proposed by an embodiment of the present application. Detailed implementation manners

[0065] Next, the technical solutions in the embodiments of the present application will be described with reference to the accompanying drawings.

[0066] It should be noted that in the description of the embodiments of the present application, unless otherwise specified, " / " means "or". For example, A / B may represent A or B; herein, "and / or" is merely a description of the association relationship of associated objects, indicating that there can be three relationships. For example, A and / or B may represent: A exists alone, A and B exist simultaneously, and B exists alone.

[0067] In the embodiments of the present application, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. Additionally, in the description of the embodiments of the present application, "a plurality" means two or more than two, "at least one" and "one or more" mean one, two or more than two. Singular forms such as "a", "an", "the", "above-mentioned", "said" and "this" are also intended to include expressions such as "one or more", unless the context clearly indicates otherwise.

[0068] The reference to "one embodiment" or "some embodiments" etc. described in this specification means that a specific feature, structure or characteristic described in connection with that embodiment is included in one or more embodiments of the present application. Thus, statements such as "in one embodiment", "in some embodiments", "in other some embodiments", "in still other embodiments" etc. that appear in different places in this specification do not necessarily all refer to the same embodiment, but mean "one or more but not all embodiments", unless otherwise specifically emphasized in other ways. The terms "comprise", "include", "have" and their variants all mean "include but not limited to", unless otherwise specifically emphasized in other ways.

[0069] In the description of the embodiments of the present application, the orientation or positional relationship indicated by terms such as "upper", "lower", "left", "right", "inner", "outer", "vertical", "horizontal" etc. is defined with respect to the orientation or position in which the components in the drawings are schematically placed. It should be understood that these directional terms are relative concepts, which are used for relative description and clarification, rather than indicating or implying that the indicated device or component must have a specific orientation, or be constructed and operated in a specific orientation. It can change correspondingly according to the change of the orientation in which the components in the drawings are placed, and thus cannot be construed as a limitation on the present application. In addition, the "vertical" involved in the present application is not strictly vertical, but within the allowable error range. The "parallel" is not strictly parallel, but within the allowable error range.

[0070] In the embodiments of the present application, the same reference numeral is used to represent the same component or the same part. For the same parts in the embodiments of the present application, only one of the parts or components may be marked with the reference numeral in the drawings. It should be understood that the reference numeral also applies to other same parts or components. Additionally, the components in the drawings are not drawn to scale, and the dimensions and sizes of the components shown in the drawings are only exemplary and should not be construed as a limitation on the present application.

[0071] Figure 1It is a schematic diagram of the architecture of an ECAS system.

[0072] Applied to Figure 1 The ECAS system of the vehicle shown includes a controller, a distribution valve, an air pump, an air storage tank, air springs, height sensors, and continuous damping control (CDC) shock absorbers. For different vehicle models, the air springs, height sensors, and CDC shock absorbers can be adjusted adaptively. For Figure 1 the vehicle model shown, there are 4 air springs, height sensors, and CDC shock absorbers respectively. The air springs, height sensors, and CDC shock absorbers located at the front of the vehicle can be called front air springs, front height sensors, and front CDC shock absorbers respectively; correspondingly, the air springs, height sensors, and CDC shock absorbers located at the rear of the vehicle can be called rear air springs, rear height sensors, and rear CDC shock absorbers respectively.

[0073] The above ECAS system can realize the overall or lateral lifting function of the vehicle: when the vehicle is driving, the ECAS system maintains the normal chassis height. Under special road conditions and driving conditions, the controller can send control signals to raise or lower the chassis height of the vehicle, facilitating vehicle ferry or passing through tunnels. In addition, the ECAS system can also control the overall vehicle height according to the driving speed. Or, when the vehicle is parked, the airbags on the door side deflate. If passengers get on or off the front door, the two front left and right airbags on that side will deflate simultaneously. If passengers get on or off the rear door, the two rear left and right airbags on that side will deflate simultaneously, so as to reduce the height of the corresponding door step and facilitate passengers to get on and off the vehicle.

[0074] More importantly, in order to ensure the driving safety of vehicles equipped with the ECAS system, the ECAS system also has a fault response function: it can detect in real time whether the components are operating normally, and when a component fails, it can perform correct fault diagnosis, function degradation, and alarm, and assist in parameter calibration, thus avoiding the imbalance of the vehicle body posture caused by the failure of the ECAS system components and affecting driving safety. Especially in the event of an emergency traffic accident, if the ECAS does not have a perfect fault response function, it may cause more serious injuries to passengers.

[0075] Therefore, in the development stage of the air suspension, it is necessary to conduct fault injection tests on the air suspension, that is, introduce corresponding faults into the ECAS system to test whether the ECAS system will take corresponding fault response measures based on the introduced faults.

[0076] At present, usually the following two methods are adopted to simulate faults:

[0077] 1) Software-based fault simulation, that is, through software simulation, fault simulation is performed on the vehicle model established based on the air suspension function, and by observing the output of the vehicle model, it is determined whether the ECAS system has taken corresponding fault response measures.

[0078] However, this method only conducts fault injection testing at a theoretical level through mathematical models and cannot accurately replicate fault scenarios such as air spring leakage in real vehicles.

[0079] 2) Fault simulation based on the solenoid valve of the air suspension, that is, multiple solenoid valves are set in the air path of each air spring of the air suspension, and the opening or closing of these solenoid valves is controlled to simulate the leakage or blockage of the air spring.

[0080] Figure 2 This is a schematic diagram of the structure of an air suspension.

[0081] The air suspension includes an air pump, a pipeline, a barometer, 6 solenoid valves, an air tank and 4 air springs. The air pump is connected to the first ends of solenoid valves 1 to 6 through pipelines, wherein the second end of solenoid valve 1 is connected to the atmosphere through a pipeline, the second end of solenoid valve 2 is connected to the left front air spring FL through a pipeline, the second end of solenoid valve 3 is connected to the right front air spring FR through a pipeline, the second end of solenoid valve 4 is connected to the left rear air spring RL through a pipeline, the second end of solenoid valve 5 is connected to the right rear air spring RR through a pipeline, and the second end of solenoid valve 6 is connected to the air tank through a pipeline.

[0082] Based on the air suspension of the above-mentioned architecture, an air suspension including a fault injection device is proposed at this stage.

[0083] Figure 3 The present invention is a schematic diagram of the structure of an air suspension including a fault injection device. The air suspension includes an air pump, a combination valve, 12 solenoid valves, and 4 air springs.

[0084] The fault injection device can simulate the following three faults of air suspension: leakage, blockage and burst. For an air spring, these three faults need to be implemented through three solenoid valves respectively, where solenoid valve 1 can reuse the solenoid valve of the air suspension, and solenoid valve 2 and solenoid valve 3 are connected to the air spring at one end and the atmosphere at the other end.

[0085] When the air spring works normally, solenoid valve 1 is in the open state, and solenoid valve 2 and solenoid valve 3 are in the closed state. When simulating a burst fault, solenoid valve 1 is in the open state, solenoid valve 2 is fully opened, and solenoid valve 3 is in the closed state; when simulating a gas leakage fault, solenoid valve 1 is in the open state, solenoid valve 2 is in the closed state, and solenoid valve 3 is opened to the preset designated position; when simulating a blockage, solenoid valve 1 is fully closed, and solenoid valve 2 and solenoid valve 3 are also in the closed state.

[0086] The above method 2 has the following disadvantages:

[0087] 1) Multiple solenoid valves need to be additionally provided on the air circuit of each air spring, and these solenoid valves need to be individually controlled. That is, the air leakage fault, burst fault, and blockage fault are all individually simulated through the corresponding solenoid valves. Usually, an air suspension includes 4 air springs. Then, for these 4 air springs to introduce faults, 12 solenoid valves need to be individually controlled, resulting in a large control overhead and a complex air circuit. A major modification to the original pipeline of the air suspension is required, that is, 3 solenoid valves need to be additionally connected to the sub-pipeline corresponding to each air spring.

[0088] 2) Moreover, based on the above method 2, although the solenoid valve 3 can be controlled to open to a specified position to simulate an air leakage fault, the degree of air leakage and blockage of the air spring cannot be accurately controlled. For example, to simulate a blockage fault that can be relieved exactly by the air suspension pressure relief function, or to simulate an air leakage fault that can be relieved exactly by the air suspension gas replenishment function.

[0089] 3) The fault injection points are relatively limited. For example, simply by opening the solenoid valve 3 to simulate an air leakage fault, but on the air circuit of this air spring, the part that may cause air leakage is not necessarily the air spring, but may also be the solenoid valve 1, resulting in confusion between the simulated fault and the actual fault. Therefore, the faults simulated by this method have a large difference from the actual air spring leakage and blockage scenarios.

[0090] In view of this, the embodiments of the present application propose a fault injection device, method, and test bench, which can accurately and comprehensively simulate the air leakage faults or blockage faults of various main components in the ECAS system to enable a more comprehensive and accurate test of the fault response function of the ECAS system during the development stage of the air suspension.

[0091] Figure 4 It is a schematic structural diagram of a fault injection device 400 proposed by the embodiments of the present application. This device 400 is applied to the air suspension. Further, this device 400 can be connected to the component that needs to perform fault injection through the pipeline of the air suspension, so as to achieve fault injection for this component.

[0092] Refer to Figure 4 As shown, this device 400 includes:

[0093] A valve mechanism 410, which includes a valve body 411 and a valve core 412. Among them, the valve body 411 includes a first valve cavity 4111, a first air passage 4112, and a second air passage 4113. The first air passage 4112 and the second air passage 4113 are respectively divided into two parts by the first valve cavity 4111. The first part 01 of the first air passage 4112 and the first part 02 of the second air passage 4113 are interconnected and form a main air passage 4114. The main air passage 4114 is connected to the component to be measured of the air suspension. The second part 03 of the first air passage 4112 is connected to the atmosphere, and the second part 04 of the second air passage 4113 is connected to the pipeline of the air suspension. The valve core 412 is arranged in the first valve cavity 4111. The valve core 412 includes a first valve rod 4121, a first blocking part 4122, and a second blocking part 4123. Among them, the first blocking part 4122 is arranged at a first position of the first valve rod 4121, and the first blocking part 4122 is used to adjust the air passage opening of the first air passage 4112. The second blocking part 4123 is arranged at a second position of the first valve rod 4121, and the second blocking part 4123 is used to adjust the air passage opening of the second air passage 4113;

[0094] A driving part 420, which is connected to the above-mentioned valve core 412, and is used to drive the above-mentioned first valve rod 4121 to move relatively along the direction of the above-mentioned first valve cavity 4111.

[0095] It should be understood that as the first valve rod 4121 moves in the first valve cavity 4111, the first blocking part 4122 and the second blocking part 4123 arranged on the first valve rod 4121 will also move synchronously, and the first blocking part 4122 and the second blocking part 4123 will correspondingly change the opening degrees of the air passages corresponding to them respectively.

[0096] Compared with Figure 3 the shown fault injection device, the above-mentioned fault injection device 400 proposed in the embodiment of the present application does not simply simulate faults by introducing multiple additional solenoid valves, but through a valve mechanism 410 with a dual-air passage design, where the first part 01 of the first air passage 4112 is connected to the component to be measured of the air suspension, and the second part 03 of the first air passage 4112 is connected to the atmosphere. The first air passage 4112 is used to simulate the air leakage fault of the component to be measured, while the first part 02 of the second air passage 4113 is connected to the component to be measured of the air suspension, and the second part 04 of the second air passage 4113 is connected to the pipeline that was originally directly connected to the component to be measured, so as to insert the fault injection device into the original pipeline of the air suspension. The second air passage 4113 is used to simulate the blockage fault of the component to be measured.

[0097] It can be seen that a complete device 400 can simulate two types of faults, namely air leakage and blockage, for the component under test, and these two types of faults can be simulated only by controlling the movement of the first valve stem 4121 within the first valve chamber 4111. And Figure 3 The shown fault injection device needs to simultaneously control the valve openings of 3 solenoid valves to simulate air leakage or blockage faults, resulting in a relatively large control overhead.

[0098] Based on the above technical solution, through the dual-airpath structure design of the device 400, the device 400 can simulate both the blockage fault and the air leakage fault of the component under test by controlling a valve mechanism 410, with a small control overhead and low difficulty in fault simulation. Moreover, the device 400 only needs to be directly connected to the original pipeline of the air suspension and is connected in series with the component under test through a pipeline. Therefore, installing the device 400 makes relatively small changes to the original pipeline of the air suspension, with low installation difficulty and easy application.

[0099] In some possible embodiments, the first valve stem 4121 includes three states: a default state, a pushed-in state, and a pulled-out state. In the default state, the first blocking portion 4122 completely blocks the first air path 4112, that is, the air path opening of the first air path 4112 is 0%, while the second blocking portion 4123 completely opens the second air path 4113, that is, the air path opening of the second air path 4113 is 100%; in the pushed-in state, the first valve stem 4121 further moves into the first valve chamber 4111 along the direction of the first valve chamber 4111 relative to the default state. At this time, the first blocking portion 4122 still completely blocks the first air path 4112, that is, the air path opening of the first air path 4112 is still 0%, while the second blocking portion 4123 causes a blocking effect on the second air path 4113. That is, in different degrees of the pushed-in state of the first valve stem 4121, the air path opening of the second air path 4113 can be adjusted between [0%, 100%); in the pulled-out state, the first valve stem 4121 moves out of the first valve chamber 4111 along the direction of the first valve chamber 4111 relative to the default state. At this time, the second blocking portion 4123 is completely open, that is, the air path opening of the second air path 4113 is 100%, and in different degrees of the pulled-out state of the first valve stem 4121, the air path opening of the first air path 4112 can be adjusted between (0%, 100%].

[0100] All in all, the valve mechanism 410 needs to meet the following air path adjustment principle. During the process of the first blocking portion 4122 reducing the opening of the first air path 4112 from 100%, the opening of the second air path 4113 corresponding to the second blocking portion 4123 remains 100%; during the process of the second blocking portion 4123 reducing the opening of the second air path 4113 from 100%, the opening of the first air path 4112 corresponding to the first blocking portion 4122 remains 0%.

[0101] In addition, since the volumes of the first blocking portion 4122 and the second blocking portion 4123 are substantially the same, in order to adjust the opening degrees of the first air passage 4112 and the second air passage 4113 by means of a first valve stem 4121 while meeting the above requirements, with reference to Figure 4 As shown, the device 400 proposed in the embodiment of the present application needs to meet the following conditions, that is, a first part 01 of the first air passage 4112 and a second part 03 of the first air passage 4112 need to be offset by a first distance L in a direction perpendicular to the first valve cavity 4111, and the first distance L should be less than a second distance existing on the first valve stem between the first blocking portion and the second blocking portion. Based on this, although the movements of the first blocking portion 4122 and the second blocking portion 4123 are synchronous, the processes of adjusting the opening degree of the first air passage 4112 by the first blocking portion 4122 and adjusting the opening degree of the second air passage 4113 by the second blocking portion 4123 are asynchronous, so that when the valve mechanism 410 works, the above air passage adjustment principle is satisfied.

[0102] Based on the above technical solution, it is possible to decouple the operations of introducing air leakage faults and introducing blocking faults, and ensure the rationality and accuracy of fault introduction.

[0103] In some possible embodiments, the positions of the first blocking portion and the second blocking portion are relatively fixed.

[0104] Based on the above technical solution, it is possible to introduce both an air leakage fault and a blocking fault into the component under test by controlling a first valve stem 4121 of the fault injection device 400. The control cost is low, and only by connecting the device 400 in series in the pipeline where the component under test is located, the simulation of two types of faults can be realized, and the modification of the pipeline of the air suspension is small and easy to implement.

[0105] In some possible embodiments, the shape of the above first blocking portion 4122 and / or the shape of the above second blocking portion 4123 is triangular, or the above first blocking portion 4122 and / or the above second blocking portion 4123 is a semi-circular groove.

[0106] It should be understood that with reference to Figure 4It can be known that one end of the first valve stem is connected to a spring. Then, when the first valve stem 4121 is in a non-default state, whether the first valve stem 4121 is continuously pushed into the first valve cavity 4111 (against the pulling force of the spring) or continuously pulled out of the first valve cavity 4111 (against the pushing force of the spring), it is necessary to gradually increase the pushing force or pulling force of the first valve stem 4121 correspondingly. Then, during this process, the current in the circuit controlling the first valve stem 4121 increases linearly. Then, the shape of the first blocking portion 4122 and / or the shape of the second blocking portion 4123 is triangular, or the first blocking portion 4122 and / or the second blocking portion 4123 is a semi-circular groove. Based on this special shape design, it can be made such that as the first valve stem 4121 is continuously pushed into the first valve cavity 4111, or as the first valve stem 4121 is continuously pulled out of the first valve cavity 4111, the air flow rate of the air passage adjusted based on the second blocking portion 4123 or the first blocking portion 4122 also changes linearly. Thus, a correlation can be established between the movement amount of the first valve stem, the change in the air flow rate of the air passage, and the change in the current, so as to facilitate the adjustment of the opening degree of the air passage corresponding to the first blocking portion 4122 or the second blocking portion 4123 through current control.

[0107] Based on the above technical solution, the first blocking portion 4122 and the second blocking portion 4123 are designed with special shapes, which helps to establish a correlation between the movement amount of the first valve stem 4121, the change in the air flow rate, and the linear change in the current, so as to facilitate the adjustment of the opening degree of the air passage corresponding to the first blocking portion 4122 or the second blocking portion 4123 through current control.

[0108] In some possible embodiments, in order to meet the above air passage adjustment principle, the valve mechanism 410 can also be the following structure.

[0109] Figure 5 It is a schematic structural diagram of another fault injection device 400 proposed in the embodiment of the present application.

[0110] Compared with Figure 4 the fault injection device 400 shown, Figure 5 the valve mechanism 410 of the fault injection device 400 shown in Figure 5As shown, the first part 01 of the first gas path 4112 of the valve mechanism 410 and the second part 03 of the first gas path 4112 do not need to be staggered by a first distance L in the direction perpendicular to the first valve cavity 4111. However, the geometric parameters of the first blocking portion 4122 and the second blocking portion 4123 are quite different. The length of the first blocking portion 4122 is greater than the length of the second blocking portion 4123. Due to the relatively long first blocking portion 4122, during the process of adjusting the opening degree of the gas path corresponding to the second blocking portion 4123 within the range of [0%, 100%), the first blocking portion 4122 can always completely close the first gas path 4112. And when the gas path corresponding to the second blocking portion 4123 is completely opened, if it is necessary to simulate a leakage fault through the first blocking portion 4122, the first valve stem 4121 can be continuously pulled outwards, so that the first blocking portion 4122 moves outwards and gradually opens the first gas path 4112, enabling the opening degree of the first gas path 4112 to be adjusted within the range of (0%, 100%]. It can be seen that during this process, the movements of the first blocking portion 4122 and the second blocking portion 4123 are synchronous, but the processes of adjusting the opening degree of the first gas path 4112 by the first blocking portion 4122 and adjusting the opening degree of the second gas path 4113 by the second blocking portion 4123 are asynchronous, so that when the valve mechanism 410 is working, the above gas path adjustment principle is satisfied.

[0111] Figure 6 It is a schematic structural diagram of a fault injection device 600 proposed in an embodiment of the present application.

[0112] Compared with Figure 4 the fault injection device 400 shown, Figure 6 the valve mechanism 610 of the fault injection device 600 shown is different from the valve mechanism 410 of the fault injection device 400. Refer to Figure 6As shown, the valve mechanism 610 does not have a valve cavity for pushing the valve stem and communicating with the first air passage 6112 and the second air passage 6113 of the valve mechanism 610 respectively. Therefore, the first air passage 6112 and the second air passage 6113 of the valve mechanism 610 are not divided into two parts. However, corresponding sub-valves need to be assigned to the first air passage 6112 and the second air passage 6113 of the valve mechanism 610 respectively, and these two sub-valves are independently controlled. Therefore, the valve core 612 and the driving part 620 of the valve mechanism 610 in this example are different. Among them, the valve core 612 of the valve mechanism 610 includes a first sub-valve 611 and a second sub-valve 612. The first sub-valve 611 and the second sub-valve 612 are both arranged in the first valve cavity 6111, and the first sub-valve 611 is used to adjust the air passage opening of the first air passage 6112, and the second sub-valve 612 is used to adjust the air passage opening of the second air passage 6113; correspondingly, the driving part 620 is connected to the above-mentioned valve core 612, and the driving part 620 is used to adjust the valve openings of the above-mentioned first sub-valve 611 and the above-mentioned second sub-valve 612. Moreover, in the subsequent embodiments, the structural expansion examples of the device 400 can also be applied to the device 600, and the structural expansion of the device 600 will not be repeated in the subsequent embodiments.

[0113] It can be seen from this that the control logics of the first sub-valve 611 and the second sub-valve 612 are different from those of the first blocking part 4122 and the second blocking part 4123 in the corresponding embodiments described above. The first sub-valve 611 and the second sub-valve 612 are not connected to each other through a valve stem and are two independent components. And the driving part 620 needs to control the first sub-valve 611 and the second sub-valve 612 respectively. Therefore, Figure 4 or Figure 5 the control overhead of the fault injection device 600 shown is relatively large. Figure 6 The control overhead of the fault injection device 600 shown is relatively large.

[0114] For the convenience of description, the following embodiments will take the Figure 4 device 400 shown as an example to further illustrate the technical solutions proposed in this application.

[0115] In some possible embodiments, a device 400 can be equipped for multiple components in an air suspension respectively to implement fault simulation for multiple components.

[0116] Figure 7 is a schematic diagram of an air suspension with multiple fault injection devices 400 installed proposed in the embodiments of this application.

[0117] Refer to Figure 7As shown, the device 400 proposed in the embodiment of the present application can not only simulate air leakage or blockage of the air spring of the air suspension, but also simulate air leakage or blockage of other components of the air suspension, such as air pumps, air tanks, solenoid valves, etc. Among them, the solenoid valves include solenoid valves connected to the air spring and solenoid valves connected to the air tank, usually 5 in number. In addition, these 5 solenoid valves can also be integrated together to form a distribution valve or a solenoid valve group. Correspondingly, a total of 11 fault injection devices 400 are installed in the air suspension, corresponding to Figure 7 the fault injection device #1 to the fault injection device #11 in

[0118] It should be understood that Figure 7 the scheme shown is only an example. For air suspensions with different architectures or the same architecture, the installation location and the installation quantity of the fault injection device 400 can be adjusted adaptively. The embodiment of the present application does not limit this.

[0119] In some possible embodiments, based on Figure 7 the air suspension shown, faults can be introduced simultaneously through multiple devices 400, so as to realize the combined fault simulation of different components.

[0120] Based on the above technical solution, the device 400 can not only simulate the faults of the air spring of the air suspension, but also simulate the faults of other components, increasing the fault simulation objects, and can also realize the combined fault simulation, which is helpful for more reasonable and accurate verification of the air suspension fault response function in the follow-up.

[0121] In some possible embodiments, in order to further improve the accuracy and precision of fault injection, while introducing faults through the device 400, relevant parameters of the air circuit also need to be monitored, such as the air flow rate of the first air circuit 4112, the air flow rate of the second air circuit 4113, and the air pressure of the first part 01 of the first air circuit 4112 or the first part 02 of the second air circuit 4113. In view of this, the above device 400 further includes: a first flowmeter 430, arranged in the second part 03 of the first air circuit 4112; a second flowmeter 440, arranged in the second air circuit 4113 or the main air circuit 4114; a barometer 450, arranged in the first part 01 of the first air circuit 4112, or the first part 02 of the second air circuit 4113, or the main air circuit 4114.

[0122] In some possible embodiments, the above device 400 may further include a controller 460, and the controller 460 is respectively connected to the above first flowmeter 430, the above second flowmeter 440, the above barometer 450 and the above driving part 420.

[0123] Exemplarily, based on the connection relationship between the above-mentioned controller 460 and other components, it can be known that the above-mentioned controller 460 can obtain the output results of the first flowmeter 430, the second flowmeter 440, and the barometer 450 in real time, and can also control the driving unit 420 to drive the first valve stem 4121 to move relatively along the direction of the first valve cavity 4111 to adjust the gas path opening degree of the first gas path 4112 or the second gas path 4113.

[0124] In some possible embodiments, through the above three sensors, during the process of injecting a fault into the device 400, the gas flow rate of each gas path and the air pressure of the first part of the first gas path 4112 or the first part 02 of the second gas path 4113 can be monitored in real time, so that the severity of the simulated fault can be quantified through these parameters, and the fault can be further divided into minor air leakage, severe air leakage, minor blockage, and severe blockage. Among them, when the gas flow rate output by the first flowmeter 430 is greater than the pre-calibrated gas flow rate threshold Q1, this fault can be set as a severe air leakage fault; when the gas flow rate output by the first flowmeter 430 is less than the pre-calibrated gas flow rate threshold Q1, this fault can be set as a minor air leakage fault; when the pressure value output by the barometer 450 is greater than the pre-calibrated pressure threshold P1, this fault can be set as a severe blockage fault; when the pressure value output by the barometer 450 is less than the pre-calibrated pressure threshold P1, this fault can be set as a minor blockage fault.

[0125] In addition, if multiple above-mentioned devices 400 are respectively connected in series with multiple measured components in the air suspension through pipelines, the faults existing in the current air suspension can be identified through the output of the corresponding sensors in the multiple devices 400, whether they are introduced by the device 400, or the faults existing in the measured components of the air suspension itself, or a mixture of the two faults.

[0126] Exemplarily, taking Figure 2 the shown air suspension as an example, assume that a Figure 3 fault injection device shown is installed on the pipeline where the left front air spring is located, and a leakage fault is simulated through this fault injection device. After injecting the fault, although the phenomenon of air leakage in the left front air spring can be reproduced, the air leakage in the left front air spring may be because the leakage valve of the fault injection device is opened, or the solenoid valve 2 leaks, or even the internal components of the fault injection device leak, so there is confusion between the simulated fault and the possible real faults of the components, and the fault simulation accuracy is poor.

[0127] However, based on the foregoing embodiments, it can be known that in an air suspension, a device 400 can be connected in series for multiple components at the same time, and the device 400 is also equipped with corresponding sensors, so as to effectively improve the accuracy of fault simulation and avoid confusion between the simulated fault and the real fault of the component. TakingFigure 2 Taking the air suspension shown as an example, assume that a Figure 4 fault injection device #7 shown is installed on the pipeline where the left front air spring is located, and a Figure 4 fault injection device #2 shown is also installed on the pipeline where the solenoid valve 2 is located. By simulating an air leakage fault in the left front air spring through device #7 and not introducing a fault in device #2. After injecting the fault, the phenomenon of air leakage in the left front air spring is reproduced. It can be monitored that the air flow rates detected by the first flowmeter 430 and the second flowmeter 440 of device #7 increase significantly. At the same time, it can be monitored that the air flow rate detected by the second flowmeter 440 of device #2 remains basically unchanged, or increases slightly, but the increase amount is much smaller than the increase amount of the second flowmeter 440 of device #7. Thus, it can be determined that this fault is caused by the air leakage in the left front air spring simulated by device #7. Because device #2 does not introduce a fault and the second flowmeter 440 of device #2 remains basically unchanged, the solenoid valve 2 does not have an air leakage. Generally speaking, this air leakage fault is introduced through fault simulation, thus avoiding confusion between simulated faults and real faults.

[0128] In the above example scenario, if the air flow rate detected by the second flowmeter 440 of device #2 also increases significantly, it can be determined that the solenoid valve 2 itself has an air leakage fault. At this time, the air suspension is in a fault state where simulated faults and real faults coexist.

[0129] It should be understood that for injecting a blocking fault, the method of distinguishing between the simulated blocking fault and the actual blocking fault existing in the component is similar to the principle of the above method for distinguishing between the simulated air leakage fault and the actual air leakage fault in the component, and will not be repeated here.

[0130] Based on the above technical solution, by introducing a controller 460 and corresponding sensors into device 400, when device 400 introduces a fault, the controller 460 can obtain the corresponding parameter values output by the sensors to be used to check the severity of the currently injected fault, such as mild or severe, so as to facilitate subsequent testing whether the response state of the air suspension under mild or severe faults meets the expectations, thereby completing a reasonable verification of the air suspension fault response function. In addition, since device 400 can simulate faults for all components in the entire air suspension that may have air leakage or blockage, the fault simulation accuracy is increased. By the output values of the sensors of the fault injection devices connected to each component of the air suspension, it is inferred whether the current fault existing in the air suspension is a simulated fault, a real fault, or a coexistence of simulated faults and real faults, thus avoiding confusion between simulated faults and real faults.

[0131] For the convenience of understanding, the following is based on Figure 4Taking the fault injection device 400 with the shown structure as an example, the five basic operating states of the device 400 will be described in detail.

[0132] Figure 8 It is a schematic diagram of the basic operating state of the fault injection device 400 proposed in the embodiment of the present application.

[0133] Figure 8 In (a), it is a schematic diagram when the device 400 is in the default state. In this state, the position of the first valve stem 4121 exactly makes the first blocking portion 4122 completely close the first air path 4112, and makes the second blocking portion 4123 completely open the second air path 4113. Correspondingly, the output result of the first flowmeter 430 is 0; the output result of the second flowmeter 440 is equal to the air flow rate a when the air suspension operates normally, and this air flow rate a can be obtained in advance through a calibration experiment for the air suspension; the output result of the barometer 450 is equal to the pressure value a in the pipeline or air path when the air suspension operates normally, and this pressure value a can also be obtained in advance through a calibration experiment for the air suspension.

[0134] It should be understood that the above-mentioned calibration experiment for the air suspension refers to the working parameters such as the air flow rate a in the pipeline and the pressure value a in the pipeline obtained by the built-in sensor when the air suspension is in the normal operating state.

[0135] Figure 8 In (b), it is a schematic diagram when the device 400 is in the severe block state. In this state, the position of the first valve stem 4121 makes the first blocking portion 4122 completely close the first air path 4112, and makes the second blocking portion 4123 block part or all of the second air path 4113. Correspondingly, the output result of the first flowmeter 430 is 0; the output result of the second flowmeter 440 is less than the air flow rate a when the air suspension operates normally; the output result of the barometer 450 is greater than or equal to the pressure relief threshold P of the air suspension. This pressure relief threshold P is used to indicate the pressure value of the pipeline where the air suspension air pump is located when the air suspension detects a block inside the suspension and triggers a pressure relief operation, and this pressure relief threshold can be obtained in advance through a calibration experiment for the air suspension.

[0136] Exemplarily, in the case where the second blocking portion 4123 completely blocks the second air path 4113, this fault can also be defined as a complete block fault, which is the most serious block fault. At this time, the output result of the first flowmeter 430 is 0; the output result of the second flowmeter 440 is also 0; the output result of the barometer 450 is greater than or equal to the pressure relief threshold P of the air suspension.

[0137] Figure 8In (c), it is a schematic diagram of the device 400 in a slightly blocked state. In this state, the position of the first valve stem 4121 is such that the first blocking portion 4122 completely closes the first air passage 4112, and the second blocking portion 4123 blocks a part of the second air passage 4113. Accordingly, the output result of the first flowmeter 430 is 0; the output result of the second flowmeter 440 is less than the air flow rate a during the normal operation of the air suspension; the output result of the barometer 450 is less than the pressure relief threshold P of the air suspension.

[0138] It should be understood that for air suspensions with different hardware parameters, there are different pressure relief thresholds P.

[0139] Figure 8 In (d), it is a schematic diagram of the device 400 in a severe leakage state. In this state, the position of the first valve stem 4121 is such that the first blocking portion 4122 opens part or the entire first air passage 4112, and the second blocking portion 4123 opens the entire second air passage 4113. Accordingly, the output result of the first flowmeter 430 is greater than 0; the second flowmeter 440 is greater than the air flow rate a during the normal operation of the air suspension; the output result of the barometer 450 is less than the pressure relief threshold P of the air suspension.

[0140] Exemplarily, in the case where the first blocking portion 4122 completely opens the first air passage 4112, this failure can also be defined as a maximum air leakage failure, which is the most serious air leakage failure. At this time, the output result of the first flowmeter 430 is greater than 0, usually much greater than 0; the second flowmeter 440 is greater than the air flow rate a during the normal operation of the air suspension; the output result of the barometer 450 is less than the pressure relief threshold P of the air suspension.

[0141] Figure 8 In (e), it is a schematic diagram of the device 400 in a slightly leaked state. In this state, the position of the first valve stem 4121 is such that the first blocking portion 4122 opens part or the entire first air passage 4112, and the second blocking portion 4123 opens the entire second air passage 4113. Accordingly, the output result of the first flowmeter 430 is greater than 0; the second flowmeter 440 is greater than the air flow rate a during the normal operation of the air suspension; the output result of the barometer 450 is less than the pressure relief threshold P of the air suspension.

[0142] In some possible embodiments, in order to further increase the accuracy of fault simulation, the above-mentioned device 400 further includes: a height sensor 470, and this height sensor 470 is arranged on the air spring of the air suspension.

[0143] In some possible embodiments, the height sensor 470 of the device 400 can reuse the height sensor 470 originally installed in the air spring of the air suspension.

[0144] It should be understood that, based on the output results of the height sensor 470 and the output results of the first flowmeter 430, the critical points for determining mild air leakage and severe air leakage can be accurately determined.

[0145] Exemplarily, for a normally functioning air suspension, when an air leakage fault is introduced into the air spring through the device 400, the air suspension will trigger a fault response measure, that is, through the air pump and air tank in the air suspension, air is pumped into the airbag of the air spring, so as to maintain the height of the air suspension unchanged as much as possible. If the output result of the height sensor 470 of the device 400 remains unchanged when air is pumped into the airbag of the air spring through the air pump and air tank in the air suspension, it can be judged through this phenomenon that the device 400 has completed the simulation of the mild air leakage fault; on the contrary, if the output result of the height sensor 470 of the device 400 continues to decrease when air is pumped into the airbag of the air spring through the air pump and air tank in the air suspension, it can be judged through this phenomenon that the device 400 has completed the simulation of the severe air leakage fault.

[0146] Exemplarily, based on the above method for judging mild air leakage fault and severe air leakage fault, the critical points for determining mild blockage and severe blockage of the air suspension can be determined in advance through a calibration experiment: through the controller 460 of the device 400, the driving part 420 is controlled to drive the first valve stem 4121 to continuously pull out from the default state to the outside of the first valve cavity 4111. At the same time, the controller 460 continuously obtains the output results of the first flowmeter 430 and the height sensor 470. During the process of the first valve stem 4121 continuously pulling out to the outside of the first valve cavity 4111, if it is monitored that the output result of the height sensor 470 starts to decrease and the output result of the first flowmeter 430 is greater than 0, the position of the current first valve stem 4121 is the fault critical point of mild air leakage and severe air leakage, and the displacement of the first valve stem 4121 during this process is the critical displacement. Then, if a mild air leakage fault is to be introduced subsequently, the displacement of the first valve stem 4121 should be less than or equal to the critical displacement; if a severe air leakage fault is to be introduced subsequently, the displacement of the first valve stem 4121 should be greater than the critical displacement.

[0147] Based on the above technical solution, by introducing the height sensor 470 into the device 400, the accuracy of air leakage fault simulation can be further increased, the critical points for determining mild air leakage and severe air leakage can be accurately determined, and the device 400 can perform air leakage fault simulation more reasonably and accurately.

[0148] In some possible embodiments, refer to Figure 4 Or Figure 5The device 400 shown, the driving part 420 of the device 400 includes: a first box body 421; a slider 422 is arranged in the first box body 421, and the slider 422 is fixed to the first valve stem 4121; a force applying part 423, the force applying mechanism 423 is arranged on the outer surface of the first box body 421, and the force applying part 423 is configured to drive the slider 422 to slide in the first box body 421.

[0149] In some possible embodiments, the force applying part 423 is a proportional electromagnet. Correspondingly, the slider includes any one of the following substances: iron, cobalt, nickel.

[0150] In some possible embodiments, a spring 424 is arranged on the first side surface α of the first box body 421, and the spring 424 is connected to the slider 422. When the force applying part 423 does not apply a force to the slider 422, the spring 424 can push the slider 422 to a preset position. In this preset position, the first blocking part 4122 and the second blocking part 4123 of the first valve stem 4121 connected to the slider 422 completely block the first air passage 4112 and the second air passage 4113 respectively.

[0151] Exemplarily, when the force applying part 423 is a proportional electromagnet, the controller 460 can input a current with a corresponding value into the circuit where the force applying part 423 of the driving part 420 is located, so that the force applying part 423 has a magnetic force and magnetism with a corresponding value, thereby driving the slider 422 to push outward or pull inward along the direction of the first box body 421. Since the slider 422 is fixed to the first valve stem 4121, the first valve stem 4121 will also move in the first valve cavity 4111 along with the movement of the slider 422, so that the first blocking part 4122 on the first valve stem 4121 adjusts the opening degree of the first air passage 4112, or the second blocking part 4123 on the first valve stem 4121 adjusts the opening degree of the second air passage 4113.

[0152] Based on the above technical solution, through the driving part 420 with the above structure, it is possible to drive the first valve stem 4121 based on the current control of the controller 460, and further adjust the air passage opening degree of the first air passage 4112 or the second air passage 4113.

[0153] In some possible embodiments, in order to make the scenario of air suspension fault simulation closer to reality, the air suspension can be arranged on a test bench, and the test bench is used to simulate the situation where the air suspension fails in a real scenario.

[0154] Figure 9 It is a schematic structural diagram of a test bench 900 proposed by an embodiment of the present application.

[0155] The test bench 900 includes two parts. One part is the air suspension air circuit structure, and the air suspension air circuit structure can refer to the air circuit structure of the air suspension equipped with multiple fault injection devices described above. Figure 7 That is, the test bench includes N fault injection devices 400 proposed in the foregoing embodiments, and the N devices 400 are respectively connected in series with N components to be tested in the air suspension through pipelines. It should be understood that the N components to be tested can be all components in the air suspension, such as Figure 7 the air tank, air pump, air spring, and solenoid valve shown; the N components to be tested can also be part of the components in the air suspension, such as only the air spring, etc. Refer to Figure 9 As shown, FR, FL, and RR are used to represent the positions of the air springs in the entire air suspension. Among them, FR refers to the right front air spring in the air suspension, FL refers to the left front air spring in the air suspension, and RR refers to the right rear air spring in the air suspension.

[0156] In addition, considering that in the actual application scenario of the air suspension, the air suspension needs to carry devices such as the vehicle body and axle, so the air suspension usually operates under a load. Therefore, the other part of the test bench is a simulated counterweight device, which is arranged on the air suspension, and the simulated counterweight device is configured to be able to adjust its own weight within a first weight range.

[0157] It should be understood that the first weight range is a pre-calibrated reasonable range for simulating the total weight of the vehicle frame and axle, etc.

[0158] Based on the above technical solution, through the test bench 900, not only can corresponding faults be introduced into the air suspension, but also during the process of simulating faults, the load state of the air suspension during actual operation can be further simulated, so that the fault simulation of the air suspension is closer to reality, and thus the scenario of the air suspension fault can be accurately reproduced.

[0159] Based on any one of the fault injection devices 400 proposed in the foregoing embodiments, the embodiment of the present application also proposes a fault injection method, and this method can be executed by an industrial control computer.

[0160] Figure 10 It is a schematic flowchart of a fault injection method 1000 proposed by the embodiment of the present application.

[0161] S1010: Receive first fault simulation information, where the first fault simulation information is used to indicate that the first component of the simulated air suspension is in a first fault state, and the first fault state is component air leakage or component blockage.

[0162] Among them, the first component is connected to the first fault injection device, and the first fault injection device at least includes: a valve mechanism, a first flowmeter, a second flowmeter, and a controller. The structures and connection relationships of the various components in the first fault injection device are the same as those of the fault injection device 400 proposed in the corresponding foregoing embodiments. Among them, the controller can either belong to the first fault injection device or be a separate controller independent of the first fault injection device. The controller is connected to the various components of the first fault injection device and controls the various components of the first fault injection device.

[0163] In some possible embodiments, the above industrial control computer is also connected to a host computer, and the host computer is used to send first fault simulation information to the industrial control computer.

[0164] S1020: Determine the required gas flow rate according to the above first fault simulation information, and the required gas flow rate is used to instruct the first fault injection device to adjust the gas flow rates of the first gas path and the second gas path.

[0165] S1030: Send the required gas flow rate to the first fault injection device.

[0166] In some possible embodiments, the first fault injection device further includes a first barometer, a first flowmeter, and a second flowmeter. Among them, the first barometer is disposed in the first part of the first gas path, or the first part of the second gas path, or the main gas path, the first flowmeter is disposed in the second part of the first gas path, and the second flowmeter is disposed in the second gas path or the main gas path. Moreover, the structures and installation positions of the first barometer, the first flowmeter, and the second flowmeter are the same as those of the barometer 450, the first flowmeter 430, and the second flowmeter 440 of the device 400 in the foregoing embodiments respectively.

[0167] In some possible embodiments, in the above S1030, the required gas flow rate can be sent to the controller of the first fault injection device. Correspondingly, after receiving the required gas flow rate, the controller will also perform the following operations: The controller sends a driving instruction to the driving part and continuously monitors the gas flow rates of the first flowmeter and the second flowmeter. The driving instruction is used to instruct to control the first valve stem to perform a relative displacement along the direction of the first valve cavity; when the controller monitors that the gas flow rates of the first flowmeter and the second flowmeter meet the required gas flow rate, the controller sends a stop instruction to the driving part, and the stop instruction is used to instruct to control the first valve stem to stop displacement.

[0168] In some possible embodiments, the gas flow rates of different values indicated by the required gas flow rate correspond to different faults simulated by the industrial control computer controlling the first fault injection device, and the faults include a leakage fault and a blockage fault.

[0169] In some possible embodiments, the first component connected to the first fault injection device may be an air pump, an air tank, or a solenoid valve in an air suspension.

[0170] Based on the above technical solution, the control of the fault simulation of the first fault injection device can be realized, so that the first fault injection device can simulate air leakage faults and blockage faults.

[0171] In addition, the embodiments of the present application propose a method for determining the above-mentioned required air flow rate.

[0172] It should be understood that before determining the above-mentioned required air flow rate, the air suspension is in a fault-free state, that is, before the host computer sends the first fault simulation information to the industrial control computer, it is also necessary to power on the air suspension system so that each component of the air suspension can work properly.

[0173] Figure 11 It is a schematic flow chart of a method 1100 for determining the required air flow rate proposed by the embodiments of the present application.

[0174] S1110: Obtain the first air pressure value of the first barometer, the first air flow rate of the first flow meter, and the second air flow rate of the second flow meter.

[0175] S1120: Determine the required air flow rate according to the first fault simulation information, the first air pressure value, the first air flow rate, and the second air flow rate.

[0176] In some possible embodiments, the above-mentioned first fault simulation information includes a fault type and a fault location, where the fault type may include a blockage fault and an air leakage fault, and the fault location may be at least one measured component connected to the fault injection device.

[0177] Exemplarily, if the fault location of the above-mentioned first fault simulation information is the first component in the above embodiment, then after the industrial control computer receives the first fault simulation information, the determined required air flow rate will be sent to the controller of the first fault injection device connected to the first component, so as to realize injecting a fault into the first component through the first fault injection device.

[0178] In some possible embodiments, when the air suspension is connected to multiple fault injection devices (with the same structure as device 400), the controllers of each fault injection device can be integrated into a total controller, and the total controller is used to control each of the multiple fault injection devices separately. Then, the above-mentioned industrial control computer needs to be connected to the total controller, and after determining the required air flow rate, it is also necessary to carry the fault location in the above-mentioned first fault simulation information to inform the total controller of the fault injection device that needs to perform air flow rate control.

[0179] In some possible embodiments, the operating principle of S1130 above may be as follows: during the process of introducing a leakage fault or a blockage fault into the first component, different target air pressure values correspond to the first barometer of the fault injection device. Moreover, different severities of faults also correspond to different target air pressure values. Since there is a physical conversion relationship between the air pressure value and the air flow rate, based on this physical conversion relationship, the target total air flow rate corresponding to when the first barometer reaches the target air pressure value can be determined. By performing a mathematical operation between this target total air flow rate and the first air flow rate of the first flowmeter and the second air flow rate of the second flowmeter before the fault is introduced, the required air flow rate can be determined.

[0180] Based on the above technical solution, the industrial control computer determines and sends the required air flow rate to the first fault injection device by obtaining the readings of each sensor of the first fault injection device and combining the first fault simulation information, so that the controller of the first fault injection device only needs to achieve fault simulation of the first component according to the air flow rate. And since the magnitude of the required air flow rate is related to the severity of the fault simulation, this solution can accurately simulate faults of different severities.

[0181] Considering that it is necessary to verify the fault response function of the air suspension, after introducing a fault into the first component through the first fault injection device, it is necessary to determine whether the first fault injection device has made the first component enter the desired fault state. Moreover, in order to achieve accurate simulation of the first component's fault, the above first fault state can be slight leakage, severe leakage, slight blockage or severe blockage.

[0182] In some possible embodiments, a height sensor is provided on the air spring of the air suspension. This height sensor may belong to the first fault injection device. Then, based on the height sensor and the first flowmeter of the first fault injection device, it can be determined whether the first component has entered the desired leakage fault state, and this leakage fault state includes slight leakage and severe leakage. The judgment method is as follows:

[0183] In the case where the first fault state is severe leakage, the industrial control computer continuously monitors the first height value of the height sensor. When the industrial control computer monitors that the third air flow rate of the first flowmeter is greater than 0 and the first height value continuously decreases, it is determined that the simulation of the first component in the first fault state is completed; or,

[0184] In the case where the first fault state is slight leakage, the industrial control computer continuously monitors the first height value of the height sensor. When the industrial control computer monitors that the third air flow rate of the first flowmeter is greater than 0 and the first height value remains unchanged, it is determined that the simulation of the first component in the first fault state is completed.

[0185] In some possible embodiments, generally, one height sensor is installed for each of the four air springs of the air suspension. Therefore, the industrial control computer can also continuously monitor the height values output by the height sensors corresponding to the four air springs respectively. If these four height values decrease simultaneously and the deviation between the four height values is within the preset height deviation range, then this fault is considered a serious air leakage fault; if these four height values decrease simultaneously and the deviation between the four height values exceeds the preset height deviation range, then this fault is considered a dangerous serious air leakage fault, because the deviation between the four height values exceeds the preset height deviation range, that is, the air suspension has a large tilt, which is likely to cause the imbalance of the moving vehicle and is a fault with relatively high risk. It should be understood that when the architecture of the air suspension changes, such as the number of air springs increases or decreases, the number of the above-mentioned height sensors will also increase or decrease accordingly.

[0186] In some possible embodiments, based on this first barometer, it can also be determined whether the first component enters the desired blocked fault state, and the blocked fault state includes slight blockage and serious blockage. Before the determination, the industrial control computer determines the pressure relief threshold of the air pump of the air suspension, and this pressure relief threshold is used to trigger the air pump to perform a pressure relief operation. For example, when the air pressure of the air pump is greater than or equal to the pressure relief threshold, the air pump triggers a pressure relief operation. The determination method is as follows:

[0187] In the case where the first fault state is serious blockage, the industrial control computer obtains the second air pressure value of the first barometer. When the industrial control computer determines that the second air pressure value is greater than or equal to the pressure relief threshold, it is determined that the simulation of the first component in the first fault state is completed, and the pressure relief threshold is used to trigger the air pump to perform a pressure relief operation; or,

[0188] In the case where the first fault state is slight blockage, the industrial control computer obtains the second air pressure value of the first barometer. When the industrial control computer determines that the second air pressure value is less than the pressure relief threshold, it is determined that the simulation of the first component in the first fault state is completed.

[0189] It should be understood that in the case where the first fault state is component blockage, during the above determination process, the output of the first flowmeter is always 0.

[0190] In some possible embodiments, the above-mentioned pressure relief threshold can be sent from the upper computer to the industrial control computer.

[0191] In some possible embodiments, when the industrial control computer cannot directly obtain the above-mentioned pressure relief threshold, the pressure relief threshold can also be obtained through the following method. The prerequisite for applying this method is that the above-mentioned air suspension further includes a second barometer, which is used to measure the air pressure value of the air pump. The method is as follows: The industrial control computer sends a first instruction to the first fault injection device (which can be the controller of the first fault injection device), and this first instruction is used to instruct the first fault injection device to lower the air passage opening of the second air passage from 100%. During the process of the air passage opening of the second air passage in the first fault injection device decreasing, the industrial control computer continuously monitors the third air pressure value of the second barometer, and determines the maximum value of the third air pressure value as the pressure relief threshold.

[0192] It should be understood that after the industrial control computer sends the required air flow rate to the controller, it will trigger the controller to control the first fault injection device to introduce a blocking fault into the first component. At this time, the controller controls the driving part to drive the first valve stem to push into the interior of the first valve cavity, thereby causing the blockage of the second air passage. During this process, the air suspension will trigger the fault response function, that is, when the air pressure value of the second barometer is greater than a certain value, the air pump of the air suspension will trigger the pressure relief operation. Then, after the air pump triggers the pressure relief operation, the air pressure value of the second barometer will drop rapidly. Therefore, there is a maximum value in the output result of the second barometer during this process. Because when the air pressure monitored by the second barometer reaches the maximum value, the pressure relief operation of the air pump is triggered, so this maximum value can be used as the above-mentioned pressure relief threshold.

[0193] The above-mentioned pressure relief threshold is determined by the output result of the second barometer. In addition, the above-mentioned pressure relief threshold can also be determined by the output result of the third barometer of the second fault injection device connected to the air pump. The structure of the second fault injection device is the same as that of the first fault injection device. The method is as follows: The industrial control computer sends a first instruction to the first fault injection device (which can be the controller of the first fault injection device), and this first instruction is used to instruct the first fault injection device to lower the air passage opening of the second air passage from 100%. During the process of the air passage opening of the second air passage decreasing, the industrial control computer continuously monitors the fourth air pressure value of the third barometer in the second fault injection device, and determines the maximum value of the fourth air pressure value as the pressure relief threshold.

[0194] In some possible embodiments, if it is found based on the above-mentioned fault state judgment that the current first component has not entered the first fault state indicated by the first fault simulation information, the industrial control computer re-determines the required air flow rate based on the data collected by each sensor of the current first fault injection device until the first component enters the first fault state indicated by the first fault simulation information, so as to realize the closed-loop control of fault simulation.

[0195] Based on the above technical solution, through the industrial control computer, the controller, and the various sensors of the first fault injection device, closed-loop control can be achieved during the process of introducing faults into the component to be tested until the component to be tested enters the specified fault state, and faults of different severities can be accurately introduced into the component to be tested.

[0196] Similarly, for the simulation of slight air leakage and severe air leakage, that is, when the first fault state in the above first fault simulation information is component air leakage, the required air flow rate can be directly determined based on an air flow rate threshold. Based on the foregoing embodiments, it is known that the above first fault injection device is connected to the industrial control computer. Then, the required air flow rate can also be determined by the following method.

[0197] Figure 12 FIG. 1200 is a schematic flow chart of a method for determining the required air flow rate proposed by an embodiment of the present application. This method can be executed by the above industrial control computer.

[0198] S1210: Determine an air flow rate threshold, which is used to determine whether the first component has a slight air leakage fault or a severe air leakage fault;

[0199] Exemplarily, when the air flow rate threshold refers to the air flow rate threshold of the second air path of the first fault injection device, if the air flow rate of the second air path is greater than or equal to this air flow rate threshold, the fault introduced by the first fault injection device is a severe air leakage fault, and if the air flow rate of the second air path is less than this air flow rate threshold, the fault introduced by the first fault injection device is a slight air leakage fault.

[0200] S1220: Obtain the fourth air flow rate of the first flowmeter and the fifth air flow rate of the second flowmeter.

[0201] S1230: Determine the required air flow rate according to the air flow rate threshold, the fourth air flow rate, and the fifth air flow rate.

[0202] In some possible embodiments, the required air flow rate includes that the air flow rate that the first flowmeter needs to reach is the difference between the air flow rate threshold and the fourth air flow rate. Further, the required air flow rate may further include that the air flow rate that the second flowmeter needs to reach is the fifth air flow rate.

[0203] In some possible embodiments, the above air flow rate threshold can be obtained in advance by the following method.

[0204] Figure 13 FIG. 1300 is a schematic flow chart of a method for determining the air flow rate threshold proposed by an embodiment of the present application. This method can be executed by the above industrial control computer.

[0205] S1310: Send a second instruction to the first fault injection device, where the second instruction is used to instruct the first fault injection device to gradually increase the opening degree of the first air path from 0%.

[0206] Exemplarily, the industrial control computer may send the above second instruction to the controller of the first fault injection device.

[0207] S1320: During the process of increasing the air passage opening degree of the first air passage, continuously monitor the height value of the height sensor and the air flow rate of the second flowmeter. When the height value of the height sensor starts to decrease, determine the air flow rate of the second flowmeter at this time as the air flow rate threshold.

[0208] Exemplarily, the above height sensor may reuse the height sensor provided in the air suspension.

[0209] It should be understood that after determining the above air flow rate threshold, the air flow rate threshold can be directly reused to perform a repeated fault introduction test on the first component of the air suspension.

[0210] Based on the above technical solution, the air flow rate threshold can be determined, and the air flow rate threshold can be reused to perform a repeated fault introduction test on the first component of the air suspension. Compared with the method of determining the required air flow rate according to the air pressure value and air flow rate of the first air passage and the air flow rate of the second air passage of the first fault injection device, the calculation overhead is smaller and the calculation efficiency is higher.

[0211] It should be understood that the above method 1000 to method 1300 and the corresponding extended embodiments may also be applicable to other fault injection devices 400 installed in the air suspension.

[0212] In addition, on the basis of the foregoing embodiments, an embodiment of the present application further proposes a fault simulation system.

[0213] Figure 14 It is a schematic structural diagram of a fault simulation system 1400 proposed by an embodiment of the present application.

[0214] The system 1400 includes: a host computer, an industrial control computer, and a test bench.

[0215] Among them, the host computer is connected to the industrial control computer. The host computer is used to receive the fault simulation instruction of the tester to determine the first fault simulation information, and send the first fault simulation information to the industrial control computer to indicate the fault type and fault location that the industrial control computer needs to simulate.

[0216] The industrial control computer is further connected to the test bench. Further, the industrial control computer is also connected to the suspension controller of the air suspension system and the controller of the fault injection device in the test bench.

[0217] Among them, the suspension controller is respectively connected to the air pump, the solenoid valve group, the air spring, the height sensor and the barometer in the air suspension system. The height sensor can be arranged in the air spring to detect the support height of the air spring. The barometer can be connected in series with the air pump through a pipeline to detect the air pressure in the external pipeline of the air pump, so that the suspension controller can judge whether to trigger the pressure relief or inflation operation. In addition, the air suspension system further includes an air tank for cooperating with the air pump to perform pressure relief or inflation operations.

[0218] The controller of the fault injection device is respectively connected to the first flowmeter, the second flowmeter, the barometer and the driving part. The deployment positions and functions of each component are as described in the foregoing embodiments and will not be repeated here.

[0219] For the convenience of understanding, the following will take Figure 7 the air suspension installed with fault injection devices #1 to #11 shown as an example to elaborate in detail on the scenario of simulating a single component fault.

[0220] Fault simulation scenario 1: Simulate a serious air leakage fault of the left front air spring. Based on the foregoing embodiments, the fault simulation process is as follows:

[0221] Power on the air suspension system to make all components in the air suspension system work normally.

[0222] The tester inputs a fault simulation instruction to the host computer. For example, the fault simulation instruction can be a fault information code, such as 0010, 0101, etc. The fault information code has a mapping relationship with the fault type and fault location, and this mapping relationship can be pre-calibrated through experiments.

[0223] The host computer analyzes the fault simulation instruction. For example, according to the mapping relationship, it determines the fault type and fault location to be simulated, that is, fault type: serious air leakage, fault location: left front air spring (or directly indicate the fault injection device #7 corresponding to the left front air spring), to determine the first fault simulation information. Then it sends the first fault simulation information to the industrial control computer.

[0224] The industrial control computer determines that a serious air leakage fault needs to be injected through the fault injection device #7 according to the first fault simulation information. Then, based on the method 1100 or method 1200 proposed in the foregoing embodiments, it determines the required air flow rate, and then sends the required air flow rate to the controller of the fault injection device #7, which is simply referred to as controller #7 here.

[0225] The controller #7 controls the spool valve of the fault injection device #7 based on the method 1000 proposed in the foregoing embodiment. By moving the first valve stem of the spool valve, the opening degree of the first air passage of the spool valve is adjusted. During the adjustment process, the opening degree of the second air passage remains 100%. The opening degree of the first air passage gradually increases from 0% until the output result of the first barometer in the first air passage meets the required air flow rate. At this time, the first valve stem of the spool valve reaches the specified position and stops moving. At the same time, according to the output result of the height sensor set at the position of the air spring of the air suspension and the output result of the first flow meter, it is judged whether the fault simulation scenario 1 is reproduced: when the output result of the first flow meter is greater than 0 and the output result of the height sensor continuously decreases, it is judged that the fault simulation scenario 1 has been successfully reproduced.

[0226] In some possible embodiments, the operation of the above controller to adjust the opening degree of the first air passage and the operation of judging whether the fault simulation scenario 1 is reproduced can be carried out simultaneously. During this process, if the controller detects that the output result of the first flow meter is greater than 0 and the output result of the height sensor continuously decreases, the controller can directly stop moving the first valve stem of the spool valve, thereby stopping the adjustment of the opening degree of the first air passage. This method does not require obtaining the required air flow rate in advance and then controlling the first valve stem based on the required air flow rate. Instead, it continuously judges whether the fault simulation scenario is reproduced and stops moving the first valve stem when it is reproduced.

[0227] Fault simulation scenario 2: Simulate a slight blockage fault of the air pump. Based on the foregoing embodiment, the fault simulation process is as follows:

[0228] Power on the air suspension system so that all components in the air suspension system work normally.

[0229] The tester inputs a fault simulation instruction to the host computer.

[0230] The host computer analyzes the fault simulation instruction. For example, according to the pre-calibrated mapping relationship, it determines the fault type and fault location to be simulated, that is, the fault type: slight blockage, the fault location: the air pump (or directly indicate the fault injection device #1 corresponding to the air pump), to determine the first fault simulation information. Then it sends the first fault simulation information to the industrial control computer.

[0231] The industrial control computer determines that a slight blockage fault needs to be injected through the fault injection device #1 according to the first fault simulation information. Then, based on the method 1100 proposed in the foregoing embodiment, it determines the required air flow rate and then sends the required air flow rate to the controller of the fault injection device #1, which is simply referred to as controller #1 here.

[0232] Controller #1 controls the spool valve of the fault injection device #1 based on the method 1000 proposed in the foregoing embodiment. By moving the first valve stem of the spool valve, the opening degree of the second air passage of the spool valve is adjusted. During the adjustment process, the opening degree of the first air passage remains at 0%, and the opening degree of the first air passage gradually decreases from 100% until the output result of the second barometer corresponding to the second air passage meets the required air flow rate. At this time, the first valve stem of the spool valve reaches the specified position and stops moving. At the same time, based on the output result of the barometer of the fault injection device #1, it can be judged whether the fault simulation scenario 2 is reproduced: when the output result of the barometer of the fault injection device #1 is greater than the pressure relief threshold of the air pump, it is judged that the fault simulation scenario 1 has been successfully reproduced.

[0233] In some possible embodiments, the operation of the above controller to adjust the opening degree of the second air passage and the operation of judging whether the fault simulation scenario 2 is reproduced can be carried out simultaneously. During this process, if the output result of the barometer of the fault injection device #1 is greater than the pressure relief threshold of the air pump, the controller can directly stop moving the first valve stem of the spool valve, thereby stopping the adjustment of the opening degree of the second air passage. This method does not require pre-obtaining the required air flow rate and then controlling the first valve stem based on the required air flow rate, but continuously judges whether the fault simulation scenario is reproduced and stops moving the first valve stem when it is reproduced.

[0234] It should be understood that Figure 7 The air suspension equipped with the fault injection device #1 to the fault injection device #11 can simulate fault positions including: left front air spring, right front air spring, left rear air spring, right rear air spring, air pump, air tank, solenoid valve, and at each fault position, it can simulate slight blockage fault, severe blockage fault, slight air leakage fault and severe air leakage fault. It can be seen that through the fault injection device #1 to the fault injection device #11, a total of 44 single-type faults can be simulated. If combined faults of different components are considered, the number of fault types that can be simulated will be even more. The principle of fault simulation is the same as that of the foregoing embodiment and will not be repeated here.

[0235] In addition, the fault simulation device 400 in the embodiment of the present application is modularized. As long as the device 400 is connected in series with the components that need to be tested for fault simulation through pipelines, the device 400 can be applied to different air suspension systems.

[0236] Those of ordinary skill in the art can realize that the units and algorithm steps of each example described in combination with the embodiments disclosed herein can be implemented by electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are executed in a hardware or software manner depends on the specific application and design constraints of the technical solution. Professional technicians can use different methods to implement the described functions for each specific application, but such implementation should not be considered to exceed the scope of this application.

[0237] Those skilled in the art can clearly understand that for the convenience and simplicity of description, the specific working processes of the systems, devices, and units described above can refer to the corresponding processes in the foregoing method embodiments and will not be elaborated herein.

[0238] In several embodiments provided in this application, it should be understood that the disclosed systems, devices, and methods can be implemented in other ways. For example, the device embodiments described above are merely illustrative. For example, the division of the units is only a logical function division. In actual implementation, there may be other division methods. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the displayed or discussed coupling or direct coupling or communication connection to each other can be through some interfaces. The indirect coupling or communication connection of the devices or units can be in an electrical, mechanical, or other form.

[0239] The units described as separate components may or may not be physically separated. The components displayed as units may or may not be physical units, that is, they can be located in one place or distributed to multiple network units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of this embodiment.

[0240] In addition, the functional units in each embodiment of this application can be integrated into one processing unit, or each unit can exist physically alone, or two or more units can be integrated into one unit.

[0241] If the described functions are implemented in the form of software function units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a part of this technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in each embodiment of this application.

[0242] As described above, it is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present application can easily think of changes or substitutions, which should all be covered within the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims described above.

Claims

1. A fault injection device (400), characterized in that: The fault injection device (400) comprises: A valve mechanism (410), the valve mechanism (410) comprising a valve body (411) and a valve core (412), the valve body (411) comprising a first valve chamber (4111), a first air path (4112) and a second air path (4113), the first air path (4112) and the second air path (4113) being respectively divided into two parts by the first valve chamber (4111), the first part (01) of the first air path (4112) and the first part (02) of the second air path (4113) being connected to each other to form a main air path (4114), the main air path (4114) being connected to a tested component of an air suspension, the second part (03) of the first air path (4112) being connected to the atmosphere, The second part (04) of the second air path (4113) is connected to the pipeline of the air suspension, the valve core (412) is arranged in the first valve chamber (4111), the valve core (412) comprises a first valve stem (4121), a first blocking portion (4122) and a second blocking portion (4123), the first blocking portion (4122) is arranged at a first position of the first valve stem (4121), the first blocking portion (4122) is used to adjust the air path opening of the first air path (4112), the second blocking portion (4123) is arranged at a second position of the first valve stem (4121), the second blocking portion (4123) is used to adjust the air path opening of the second air path (4113); A driving part (420), wherein the driving part (420) is connected to the valve core (412), and the driving part (420) is used to drive the first valve stem (4121) to perform relative movement along the direction of the first valve cavity (4111).

2. The fault injection device (400) according to claim 1, characterized in that: During the process of the first blocking portion (4122) reducing the opening of the first gas path (4112) from 100%, the opening of the second gas path (4113) corresponding to the second blocking portion (4123) is maintained at 100%; during the process of the second blocking portion (4123) reducing the opening of the second gas path (4113) from 100%, the opening of the first gas path (4112) corresponding to the first blocking portion (4122) is maintained at 0%.

3. The fault injection device (400) according to claim 1 or 2, characterized in that: The position between the first blocking portion (4122) and the second blocking portion (4123) is relatively fixed.

4. The fault injection device (400) according to any one of claims 1 to 3, characterized in that: The fault injection device (400) further comprises: a first flow meter (430), the first flow meter (430) being disposed in the second portion (03) of the first gas path (4112); a second flow meter (440), wherein the second flow meter (440) is disposed in the second gas path (4113) or the main gas path (4114); A barometer (450), wherein the barometer (450) is disposed in the first portion (01) of the first gas path (4112), or the first portion (02) of the second gas path (4113), or the main gas path (4114).

5. The fault injection device (400) according to claim 4, characterized in that: The device further comprises a controller (460), and the controller (460) is respectively connected to the first flow meter (430), the second flow meter (440), the barometer (450) and the driving unit (420).

6. The fault injection device (400) according to any one of claims 1 to 5, characterized in that: The shape of the first blocking portion (4122) and / or the shape of the second blocking portion (4123) is a triangle, or the first blocking portion (4122) and / or the second blocking portion (4123) is a semicircular groove.

7. A fault injection method, characterized in that: The method comprises: Receive first fault simulation information, the first fault simulation information is used to indicate that a first component of the simulated air suspension is in a first fault state, the first fault state is component leakage or component blockage, the first component is connected to a first fault injection device, the first fault injection device includes: a valve mechanism and a drive unit, the valve mechanism includes a valve body and a valve core, the valve body includes a first valve cavity, a first air path and a second air path, the first air path and the second air path are respectively divided into two parts by the first valve cavity, the first part of the first air path and the first part of the second air path are connected to each other to form a main air path, the main air path is connected to the first part of the air suspension The first air path is connected to the air chamber, the second part of the first air path is connected to the atmosphere, and the second part of the second air path is connected to the pipeline of the air suspension; the valve core is arranged in the first valve cavity, the valve core comprises a first valve stem, a first blocking part and a second blocking part, the first blocking part is arranged at a first position of the first valve stem, the first blocking part is used to adjust the air path opening of the first air path, the second blocking part is arranged at a second position of the first valve stem, the second blocking part is used to adjust the air path opening of the second air path, the driving part is connected to the valve core, and the driving part is used to drive the first valve stem to perform relative movement along the direction of the first valve cavity; determining a required gas flow rate according to the first fault simulation information, wherein the required gas flow rate is used to instruct the first fault injection device to adjust the gas flow rates of the first gas path and the second gas path; The required gas flow rate is sent to the first fault injection device.

8. The method according to claim 7, characterized in that The first fault injection device further includes a first pressure meter, a first flow meter, and a second flow meter. The first pressure meter is arranged at a first part of the first gas path, or a first part of the second gas path, or the main gas path. The first flow meter is arranged at a second part of the first gas path, and the second flow meter is arranged at the second gas path or the main gas path. The first fault simulation information determines the required gas flow rate, including: Acquire a first air pressure value of the first air pressure meter, a first air flow rate of the first flow meter, and a second air flow rate of the second flow meter; The required air flow is determined according to the first fault simulation information, the first air pressure value, the first air flow rate, and the second air flow rate.

9. The method according to claim 8, characterized in that The air spring of the air suspension is provided with a height sensor. After sending the required air flow rate to the first fault injection device, the method further includes: When the first fault state is severe air leakage, continuously monitoring the first height value of the height sensor, and when monitoring that the third air flow rate of the first flow meter is greater than 0 and the first height value continues to decrease, determining that the simulation of the first component being in the first fault state is completed; or, When the first fault state is a slight air leakage, the first height value of the height sensor is continuously monitored, and when it is monitored that the third air flow rate of the first flow meter is greater than 0 and the first height value remains unchanged, it is determined that the simulation of the first component being in the first fault state is completed.

10. The method according to claim 9, characterized in that After sending the required gas flow to the first fault injection device, the method further includes: In the case where the first fault state is severe obstruction, obtaining a second air pressure value of the first barometer, and when it is determined that the second air pressure value is greater than or equal to a pressure relief threshold, determining that the simulation of the first component being in the first fault state is completed, the pressure relief threshold is used to trigger the air pump of the air suspension to perform a pressure relief operation; or, In the case where the first fault state is slight obstruction, a second air pressure value of the first barometer is obtained, and when it is determined that the second air pressure value is less than the pressure relief threshold, it is determined that the simulation of the first component being in the first fault state is completed.

11. The method according to claim 10, characterized in that The air suspension further includes a second barometer, and the second barometer is used to measure the air pressure value of the air pump. The method further includes: Sending a first instruction to the first fault injection device, wherein the first instruction is used to instruct the first fault injection device to reduce the gas path opening of the second gas path from 100%; During the process of decreasing the air path opening of the second air path, the third air pressure value of the second barometer is continuously monitored, and the maximum value of the third air pressure value is determined as the pressure relief threshold.

12. The method according to claim 10, characterized in that The air pump of the air suspension is connected to a second fault injection device, the structure of the second fault injection device is the same as that of the first fault injection device, and the method further includes: Sending a first instruction to the first fault injection device, wherein the first instruction is used to instruct the first fault injection device to reduce the gas path opening of the second gas path from 100%; During the process of decreasing the gas path opening of the second gas path, the fourth gas pressure value of the third barometer in the second fault injection device is continuously monitored, and the maximum value of the fourth gas pressure value is determined as the pressure relief threshold.

13. The method according to claim 7, characterized in that The first fault injection device further includes a first pressure gauge, a first flow meter, and a second flow meter. The first pressure gauge is arranged at a first part of the first gas path, or a first part of the second gas path, or the main gas path. The first flow meter is arranged at a second part of the first gas path. The second flow meter is arranged at the second gas path or the main gas path. When the first fault state is a component leak, determining the required gas flow includes: Determine an air flow threshold value, where the air flow threshold value is used to determine whether the first component has a slight air leakage fault or a severe air leakage fault; obtaining a fourth gas flow rate of the first flow meter and a fifth gas flow rate of the second flow meter; The required air flow rate is determined according to the air flow rate threshold, the fourth air flow rate, and the fifth air flow rate.

14. The method according to claim 13, characterized in that The air spring of the air suspension is provided with a height sensor, and the determining of the air flow threshold comprises: Sending a second instruction to the first fault injection device, wherein the second instruction is used to instruct the first fault injection device to increase the gas path opening of the first gas path from 0%; During the process of increasing the air path opening of the first air path, the height value of the height sensor and the air flow of the second flow meter are continuously monitored. When the height value of the height sensor begins to decrease, the air flow of the second flow meter at this time is determined as the air flow threshold.

15. The method according to any one of claims 7 to 14, characterized in that The first component is an air pump, an air spring, an air tank or a solenoid valve of an air suspension.

16. A test bench, characterized in that: Used to simulate the failure of air suspension, the test bench includes: N fault injection devices according to any one of claims 1 to 6, wherein the N fault injection devices are respectively connected in series with the N tested components of the air suspension through pipelines, and N is a positive integer; A simulated counterweight device is provided on the air suspension, and the simulated counterweight device is configured so that its own weight can be adjusted within a first weight range.

17. A chip system, characterized in that: The chip system is applied to an electronic device; the chip system includes one or more interface circuits and one or more processors; the interface circuit and the processor are interconnected through lines; the interface circuit is used to receive a signal from a memory of the electronic device and send the signal to the processor, the signal including a computer instruction stored in the memory; when the processor executes the computer instruction, the electronic device executes the method as described in any one of claims 7 to 15.

18. A computer-readable storage medium, characterized in that: The computer-readable storage medium stores a computer program, and the computer program is executed by a processor to implement the method according to any one of claims 7 to 15.

19. A computer program product, characterized in that When the codes or instructions of the computer program are executed on a computer, the computer is caused to perform the method according to any one of claims 7 to 15.

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