Fault injection apparatus, method and test bench

Abstract

The application provides a fault injection device, method and test bench, and relates to the technical field of vehicles.The device comprises a valve mechanism, the valve mechanism comprising a valve body and a valve core, the valve body comprising a first valve cavity, a first air path and a second air path, the first air path and the second air path being divided into two parts by the first valve cavity, the first part of the first air path and the second air path being in communication with a measured component of an air suspension, the second part of the first air path being in communication with the atmosphere, the second part of the second air path being connected with a pipeline of the air suspension, the valve core being arranged in the first valve cavity, the valve core comprising a first valve rod, a first blocking part and a second blocking part, the first blocking part and the second blocking part being arranged on the first valve rod and being used for adjusting the air path opening degree of the first air path and the second air path respectively; and a driving part, the driving part being connected with the valve core and being used for driving the first valve rod to move relatively along 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] This application relates to the field of vehicle technology, and specifically to fault injection devices, methods and test benches. Background Technology

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

[0003] Air suspension systems have a limited lifespan. Aging of the valves, air springs, and air passages, along with other random factors, can lead to malfunctions such as air leaks and air passage blockages. When the air suspension system fails, it can cause vehicle imbalance, affecting driving safety. Therefore, air suspension systems are equipped with corresponding fault response functions to minimize the impact of malfunctions on vehicle operation.

[0004] Therefore, in the process of developing air suspension systems, how to conduct accurate and comprehensive fault injection tests to verify whether the air suspension system performs the corresponding fault response operations is an urgent problem to be solved. Summary of the Invention

[0005] This application provides a fault injection device, method, and test bench that can accurately and comprehensively simulate different degrees of air leakage or blockage faults in various major components of an air suspension system, so as to enable more comprehensive and accurate testing of the fault response function of the air suspension system during the development stage of the air suspension.

[0006] In a first aspect, a fault injection device is provided, comprising: a valve mechanism including a valve body and a valve core; the valve body including a first valve chamber, a first air passage, and a second air passage, wherein the first air passage and the second air passage are respectively divided into two parts by the first valve chamber; the first part of the first air passage and the first part of the second air passage are interconnected to form a main air passage, which is connected to the tested component of the air suspension; the second part of the first air passage is connected to the atmosphere; the second part of the second air passage is connected to the air suspension pipeline; the valve core is disposed in the first valve chamber, and the valve core includes a first valve stem, a first blocking part, and a second blocking part; wherein the first blocking part is disposed at a first position of the first valve stem and is used to adjust the air passage opening of the first air passage; the second blocking part is disposed at a second position of the first valve stem and is used to adjust the air passage opening of the second air passage; and a drive part connected to the valve core, which is used to drive the first valve stem to move relative to the first valve chamber.

[0007] For example, as the first valve stem moves within the first valve chamber, the first and second blocking parts disposed on the first valve stem also move synchronously, and the opening degree of their respective air passages is changed accordingly.

[0008] Therefore, it can be seen that the structure of the valve mechanism is a dual-air-path structure. The first part of the first air-path is connected to the tested component of the air suspension, and the second part of the first air-path is connected to the atmosphere. The first air-path is used to simulate the air leakage fault of the tested component. The first part of the second air-path is connected to the tested component 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 tested component. Thus, the fault injection device is inserted into the original pipeline of the air suspension. The second air-path is used to simulate the blockage fault of the tested component.

[0009] Based on the above technical solution, the device's dual-air-path structure design allows it to simulate both blockage and leakage faults in the tested component by controlling a single valve mechanism. This results in low control overhead and easy fault simulation. Furthermore, the device only needs to be directly connected to the existing air suspension piping, and is connected in series with the tested component via piping. Therefore, installing the device requires minimal modification to the existing air suspension piping, making installation simple and easy to apply.

[0010] In conjunction with the first aspect, in some implementations of the first aspect, during the process of the first blocking part reducing the opening of the first air passage from 100%, the opening of the second air passage corresponding to the second blocking part remains at 100%; during the process of the second blocking part reducing the opening of the second air passage from 100%, the opening of the first air passage corresponding to the first blocking part remains at 0%.

[0011] For example, since the first air passage corresponding to the first blocking part is connected to the atmosphere, the first blocking part is used to introduce an air leakage fault; since the second air passage corresponding to the second blocking part is connected to the air suspension piping, the second blocking part is used to introduce a blocking fault. Moreover, when the first blocking part introduces a fault, although the second blocking part will move in sync with the position change of the first blocking part, the second blocking part will not introduce a blocking fault at the same time, and vice versa, thereby decoupling the operation of introducing an air leakage fault and introducing a blocking fault.

[0012] For example, the first part and the second part of the first air passage need to be offset by a first distance in a direction perpendicular to the first valve chamber. This first distance should be less than the second distance between the first blocking part and the second blocking part on the first valve stem. Based on this, although the movement of the first blocking part and the second blocking part is synchronous, the process of the first blocking part adjusting the opening of the first air passage and the second blocking part adjusting the opening of the second air passage are asynchronous, so that the valve mechanism satisfies the above-mentioned air passage adjustment principle when it is working.

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

[0014] In conjunction with the first aspect, in some implementations of the first aspect, the positions between the first blocking part and the second blocking part are relatively fixed.

[0015] Based on the above technical solution, it is possible to introduce both air leakage faults and blockage faults into the tested component by controlling a first valve stem of the fault injection device. The control overhead is small, and the simulation of both types of faults can be achieved simply by connecting the device in series in the pipeline where the tested component is located. The modification to the air suspension pipeline is minimal and easy to implement.

[0016] In conjunction with the first aspect, in some implementations of the first aspect, the aforementioned fault injection device further includes: a first flow meter disposed in a second part of a first gas path; a second flow meter disposed in a second gas path or a main gas path; and a barometer disposed in a first part of a first gas path, or a first part of a second gas path, or a main gas path.

[0017] Based on the above technical solution, by setting up corresponding sensors at designated locations on the device, the fault injection process can be monitored in real time, enabling the device to introduce faults more accurately.

[0018] In conjunction with the first aspect, in some implementations of the first aspect, the fault injection device further includes a controller connected to the first flow meter, the second flow meter, the barometer, and the drive unit, respectively.

[0019] Based on the above technical solution, by introducing a controller into the device, the controller can obtain the corresponding parameter values ​​output by the sensor during the introduction of a fault, so as to check the severity of the current injected fault, such as minor or severe, so as to facilitate subsequent testing of whether the response state of the air suspension under minor or severe faults meets expectations, thereby completing the reasonable verification of the fault response function of the air suspension.

[0020] In conjunction with the first aspect, in some implementations of the first aspect, the shape of the first blocking part and / or the shape of the second blocking part is triangular, or the first blocking part and / or the second blocking part is a semi-circular groove.

[0021] Based on the above technical solution, the first and second blocking parts are designed with special shapes, which helps to establish a correlation between the movement of the first valve stem and the change in air flow and the linear change in current, so as to adjust the opening of the air passage corresponding to the first or second blocking part through current control.

[0022] Secondly, a fault injection method is provided, the method comprising: receiving first fault simulation information, the first fault simulation information being used to indicate that a first component of a simulated air suspension is in a first fault state, the first fault state being a component leaking air or a component being blocked, the first component being connected to a first fault injection device, the first fault injection device comprising: a valve mechanism and a drive unit, wherein the valve mechanism comprises a valve body and a valve core, the valve body comprising a first valve chamber, a first air passage and a second air passage, the first air passage and the second air passage being respectively divided into two parts by the first valve chamber, the first part of the first air passage and the first part of the second air passage being interconnected to form a main air passage, the main air passage being connected to the first component of the air suspension, and the second part of the first air passage being connected to the first component of the air suspension. The second air path is connected to the atmosphere, and its second part is connected to the air suspension piping. A valve core is located in the first valve chamber. The valve core includes a first valve stem, a first blocking part, and a second blocking part. The first blocking part is located at a first position on the first valve stem and is used to adjust the air passage opening of the first air path. The second blocking part is located at a second position on the first valve stem and is used to adjust the air passage opening of the second air path. A drive unit is connected to the valve core and is used to drive the first valve stem to move relative to the first valve chamber. Based on the aforementioned first fault simulation information, the required air flow rate is determined. This required air flow rate is used to instruct the first fault injection device to adjust the air flow rates of the first and second air paths. The required air flow rate is then sent to the first fault injection device.

[0023] For example, the first fault simulation information mentioned above can be sent by the host computer. 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 the various components of the air suspension can work normally.

[0024] For example, the different values ​​of gas flow indicated by the demand gas flow rate correspond to different faults simulated by the control drive unit of the first fault injection device, including gas leakage faults and blockage faults.

[0025] Based on the above technical solution, it is possible to realize fault simulation control of the first fault injection device, so that the first fault injection device can simulate air leakage faults and blockage faults.

[0026] In conjunction with the second aspect, in some implementations of the second aspect, the first fault injection device further includes a first barometer, a first flow meter, and a second flow meter. The first barometer is located 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 flow meter is located in the second part of the first air path, and the second flow meter is located in the second air path or the main air path. The device acquires the first 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. Based on the first fault simulation information, the first pressure value, the first air flow rate, and the second air flow rate, the device determines the required air flow rate.

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

[0028] For example, the first fault simulation information mentioned above includes fault type and fault location, wherein the fault type may include blockage fault and air leakage fault, and the fault location may be at least one component under test connected to the fault injection device.

[0029] For example, if the fault location of the 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, thereby realizing the injection of fault into the first component through the first fault injection device.

[0030] For example, 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. Accordingly, after receiving the required air flow rate, the controller will also perform the following operations: the controller sends a drive command to the drive unit and continuously monitors the air flow rates of the first flow meter and the second flow meter. This drive command is used to instruct the control of the first valve stem to make relative displacement along the direction of the first valve chamber; when the controller detects that the air flow rates of the first flow meter and the second flow meter meet the required air flow rate, the controller sends a stop command to the drive unit. This stop command is used to instruct the control of the first valve stem to stop displacement.

[0031] Based on the above technical solution, the industrial control computer obtains the readings of each sensor of the first fault injection device, combines them with the first fault simulation information, determines and sends the required air flow rate to the first fault injection device, so that the controller of the first fault injection device only needs to simulate the fault of the first component according to the air flow rate. Since the size of the required air flow rate is related to the severity of the fault simulation, this solution can accurately simulate faults of different severity.

[0032] In conjunction with the second aspect, in some implementations of the second aspect, the air spring of the air suspension is equipped with a height sensor. After sending the required air flow to the first fault injection device, in the case of a serious air leak in the first fault state, the first height value of the height sensor is continuously monitored. When the third air flow of the first flow meter is detected to be greater than 0 and the first height value continues to decrease, it is determined that the simulation of the first component being in the first fault state is complete. Alternatively, in the case of a slight air leak in the first fault state, the first height value of the height sensor is continuously monitored. When the third air flow of the first flow meter is detected to be 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 complete.

[0033] Based on the above technical solution, closed-loop control can be achieved in the process of introducing faults into the tested component through the industrial control computer, controller and various sensors of the first fault injection device, until the tested component enters the specified fault state, and can accurately introduce air leakage faults of different severity into the tested component.

[0034] In conjunction with the second aspect, in some implementations of the second aspect, after sending the required airflow to the first fault injection device, when the first fault state is severe blockage, the second air pressure value of the first barometer is acquired. When the second air pressure value is determined to be greater than or equal to the pressure relief threshold, the simulation of the first component being in the first fault state is determined to be complete. The pressure relief threshold is used to trigger the air pump of the air suspension to perform a pressure relief operation. Alternatively, when the first fault state is slight blockage, the second air pressure value of the first barometer is acquired. When the second air pressure value is determined to be less than the pressure relief threshold, the simulation of the first component being in the first fault state is determined to be complete. Based on the above technical solution, closed-loop control can be achieved during the process of introducing a fault into the tested component through the industrial control computer, controller, and various sensors of the first fault injection device, until the tested component enters the specified fault state, and it can accurately introduce blockage faults of different severity into the tested component.

[0035] In conjunction with the second aspect, in some implementations of the second aspect, the air suspension further includes a second barometer for measuring the air pressure value of the air pump and sending a first command to the first fault injection device, the first command for instructing the first fault injection device to reduce the air passage opening of the second air passage from 100%; during the process of reducing the air passage opening of the second air passage, a 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.

[0036] Based on the above technical solution, the air suspension decompression threshold can be obtained, providing a basis for the industrial control computer to judge whether the first component has reached the expected fault state based on the output result of the first barometer of the first fault injection device.

[0037] In conjunction with the second aspect, in some implementations of the second aspect, the air pump of the air suspension is connected to a second fault injection device, the structure of which is the same as that of the first fault injection device, and sends a first command to the first fault injection device, the first command being used to instruct the first fault injection device to reduce the air circuit opening of the second air circuit from 100%; during the process of reducing the air circuit opening of the second air circuit, the fourth air pressure value of the third barometer in the second fault injection device is continuously monitored, and the maximum value of the fourth air pressure value is determined as the pressure relief threshold.

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

[0039] In conjunction with the second aspect, in some implementations of the second aspect, the first fault injection device further includes a first barometer, a first flow meter, and a second flow meter. The first barometer is disposed in a first part of a first gas path, or a first part of a second gas path, or a main gas path. The first flow meter is disposed in a second part of the first gas path, and the second flow meter is disposed in the second gas path or the main gas path. When the first fault condition is component leakage, a gas flow threshold is determined. The gas flow threshold is used to determine whether the first component has a minor or serious leakage fault. A fourth gas flow rate of the first flow meter and a fifth gas flow rate of the second flow meter are obtained. Based on the gas flow threshold, the fourth gas flow rate, and the fifth gas flow rate, the required gas flow rate is determined.

[0040] For example, the above-mentioned air flow rate threshold is pre-calibrated.

[0041] Based on the above technical solution, the required gas flow rate can be directly determined by combining the output results of the first and second flow meters of the first fault injection device with the pre-calibrated gas flow rate threshold. This method has low computational overhead and high computational efficiency.

[0042] In conjunction with the second aspect, in some implementations of the second aspect, the air spring of the air suspension is equipped with a height sensor, which sends a second command to the first fault injection device. The second command is used to instruct the first fault injection device to increase the air circuit opening of the first air circuit from 0%. During the process of increasing the air circuit opening of the first air circuit, 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.

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

[0044] In conjunction with the second aspect, in some implementations of the second aspect, the aforementioned first component is an air pump, air spring, air tank, or solenoid valve of an air suspension.

[0045] Based on the above technical solution, the first fault injection device can not only simulate the fault of the air spring of the air suspension, but also the fault of other components, increasing the number of fault simulation objects. It can also realize combined fault simulation, which helps to verify the fault response function of the air suspension more reasonably and accurately in the future.

[0046] Thirdly, a test bench is provided for simulating air suspension failure. The test bench includes: N fault injection devices as described in any possible implementation of the device design in the first aspect above, wherein the N fault injection devices are connected in series with N tested components of the air suspension via pipelines, and N is a positive integer; and a simulated counterweight device disposed on the air suspension, wherein 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 solution, the test bench can not only introduce corresponding faults into the air suspension, but also further simulate the load state of the air suspension in actual operation during the fault simulation process, so as to make the fault simulation of the air suspension closer to reality and thus accurately reproduce the fault scenario of the air suspension.

[0048] Fourthly, a chip system is provided, which is applied to an electronic device; the chip system includes one or more interface circuits and one or more processors; the interface circuits and 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 processor, the signals including computer instructions stored in the memory; when the processor executes the computer instructions, the electronic device executes any possible implementation of the method design of the second aspect above.

[0049] Fifthly, a computer-readable storage medium is provided storing a computer program or instructions for implementing the method in any possible implementation of the method design of the second aspect.

[0050] In a sixth aspect, a computer program product is provided, wherein when the computer program code or instructions are executed on a computer, the computer performs the method in any possible implementation of the method design of the second aspect described above. Attached Figure Description

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

[0052] Figure 2 This is a schematic diagram of an air suspension system.

[0053] Figure 3 This is a structural schematic diagram of an air suspension system that includes a fault injection device;

[0054] Figure 4 This is a schematic diagram of the structure of a fault injection device 400 according to an embodiment of this application;

[0055] Figure 5 This is a schematic diagram of the structure of another fault injection device 400 proposed in the embodiments of this application;

[0056] Figure 6 This is a schematic diagram of the structure of a fault injection device 600 according to an embodiment of this application;

[0057] Figure 7 This is a schematic diagram of an air suspension system with multiple fault injection devices 400 installed, as proposed in an embodiment of this application.

[0058] Figure 8 This is a schematic diagram of the basic operating state of the fault injection device 400 proposed in the embodiments of this application;

[0059] Figure 9 This is a schematic diagram of the architecture of a test bench 900 according to an embodiment of this application;

[0060] Figure 10 This is a flowchart illustrating a fault injection method 1000 proposed in an embodiment of this application;

[0061] Figure 11 This is a flowchart illustrating a method 1100 for determining the required gas flow rate according to an embodiment of this application.

[0062] Figure 12 This is a flowchart illustrating a method 1200 for determining the required gas flow rate according to an embodiment of this application.

[0063] Figure 13 This is a flowchart illustrating a method 1300 for determining a gas flow threshold according to an embodiment of this application.

[0064] Figure 14 This is a schematic diagram of the architecture of a fault simulation system 1400 proposed in an embodiment of this application. Detailed Implementation

[0065] The technical solutions in the embodiments of this application will now be described with reference to the accompanying drawings.

[0066] It should be noted that, in the description of the embodiments of this application, unless otherwise stated, " / " means "or". For example, A / B can mean A or B. The "and / or" in this article is merely a description of the relationship between related objects, indicating that there can be three relationships. For example, A and / or B can mean: A exists alone, A and B exist simultaneously, and B exists alone.

[0067] In the embodiments of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. Furthermore, in the description of the embodiments of this application, "multiple" refers to two or more, and "at least one" and "one or more" refer to one, two, or more than two. The singular expressions "a," "an," "the," "the," "the," and "this" are intended to also include expressions such as "one or more," unless the context explicitly indicates otherwise.

[0068] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0069] In the description of the embodiments of this application, the terms "upper," "lower," "left," "right," "inner," "outer," "vertical," and "horizontal," etc., indicate orientations or positional relationships relative to the indicated placement of components in the accompanying drawings. It should be understood that these directional terms are relative concepts, used for relative description and clarification, and not to indicate or imply a specific orientation that the device or component must have, or its construction and operation in a specific orientation. They can change accordingly depending on the orientation of the components in the accompanying drawings, and therefore should not be construed as limiting this application. Furthermore, "vertical" in this application is not strictly vertical, but within the allowable error range. "Parallel" is not strictly parallel, but within the allowable error range.

[0070] In the embodiments of this application, the same reference numerals are used to denote the same component or part. For the same part in the embodiments of this application, only one part or component may be labeled with reference numerals in the figures. It should be understood that the reference numerals also apply to other identical parts or components. In addition, the various parts in the figures are not drawn to scale, and the dimensions and sizes of the parts shown in the figures are only exemplary and should not be construed as limiting this application.

[0071] Figure 1This 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, distribution valve, air pump, air tank, air springs, height sensor, and continuous damping control (CDC) dampers. The air springs, height sensor, and CDC dampers can be adaptively adjusted for different vehicle models. Figure 1 The vehicle shown has four air springs, four height sensors, and four CDC dampers. The air springs, height sensors, and CDC dampers located at the front of the vehicle can be referred to as the front air spring, the front height sensor, and the front CDC damper, respectively. Correspondingly, the air springs, height sensors, and CDC dampers located at the rear of the vehicle can be referred to as the rear air spring, the rear height sensor, and the rear CDC damper, respectively.

[0073] The aforementioned ECAS system can achieve overall or lateral vehicle height adjustment: When the vehicle is in motion, 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 vehicle's chassis height, facilitating vehicle ferries or tunnel passage. Furthermore, the ECAS system can control the overall vehicle height based on vehicle speed. Alternatively, when the vehicle is parked, the side airbags on the doors deflate. If passengers are boarding or alighting at the front door, both front left and right airbags on that side deflate simultaneously; if passengers are boarding or alighting at the rear door, both rear left and right airbags on that side deflate simultaneously, lowering the corresponding door step height for easier passenger boarding and alighting.

[0074] More importantly, to ensure the driving safety of vehicles equipped with the ECAS system, the ECAS system also has a fault response function: it can detect whether the components are operating normally in real time, and when a component fails, it can correctly diagnose the fault, degrade the function and issue an alarm, and assist in parameter calibration, thereby avoiding vehicle posture imbalance caused by ECAS system component failure, which would affect driving safety. Especially in the event of an emergency traffic accident, if the ECAS does not have a complete fault response function, it may cause passengers to suffer more serious injuries.

[0075] Therefore, during the development phase of air suspension, it is necessary to conduct fault injection testing on the air suspension. That is, to introduce corresponding faults into the ECAS system and test whether the ECAS system will take corresponding fault response measures based on the introduced faults.

[0076] Currently, the following two methods are commonly used to simulate faults:

[0077] 1) Software-based fault simulation: This involves using software simulation to simulate faults in a vehicle model built on the air suspension function. By observing the output of the vehicle model, it can be determined whether the ECAS system has taken appropriate fault response measures.

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

[0079] 2) Fault simulation based on air suspension solenoid valves: multiple solenoid valves are installed in the air circuit of each air spring of the air suspension, and the air spring leakage or blockage is simulated by controlling the opening or closing of these solenoid valves.

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

[0081] The air suspension system includes an air pump, piping, a pressure gauge, six solenoid valves, an air tank, and four air springs. The air pump is connected via piping to the first ends of solenoid valves 1 through 6. The second end of solenoid valve 1 is connected to the atmosphere via piping; the second end of solenoid valve 2 is connected to the left front air spring (FL) via piping; the second end of solenoid valve 3 is connected to the right front air spring (FR) via piping; the second end of solenoid valve 4 is connected to the left rear air spring (RL) via piping; the second end of solenoid valve 5 is connected to the right rear air spring (RR) via piping; and the second end of solenoid valve 6 is connected to the air tank via piping.

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

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

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

[0085] When the air spring is working normally, solenoid valve 1 is open, and solenoid valves 2 and 3 are closed. In a simulated burst fault, solenoid valve 1 is open, solenoid valve 2 is fully open, and solenoid valve 3 is closed. In a simulated leak fault, solenoid valve 1 is open, solenoid valve 2 is closed, and solenoid valve 3 is open to a preset position. In a simulated blockage fault, solenoid valve 1 is fully closed, and solenoid valves 2 and 3 are also closed.

[0086] Method 2 described above has the following drawbacks:

[0087] 1) Multiple solenoid valves need to be installed in the air circuit of each air spring, and these solenoid valves need to be controlled individually. That is, air leakage faults, burst faults, and blockage faults are simulated individually through the corresponding solenoid valves. Since an air suspension usually includes 4 air springs, 12 solenoid valves need to be controlled individually to introduce faults in these 4 air springs. The control overhead is large, and the air circuit is complex. The original piping of the air suspension needs to be significantly modified. That is, 3 additional solenoid valves need to be connected to the sub-pipe corresponding to each air spring.

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

[0089] 3) The fault injection point is relatively limited. For example, the air leakage fault can be simulated by opening the solenoid valve 3. However, in the air circuit of the air spring, the air leakage may not be caused by the air spring, but by the solenoid valve 1. This causes confusion between the simulated fault and the real fault. Therefore, the fault simulated by this method is quite different from the actual air spring leakage and blockage scenario.

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

[0091] Figure 4 This is a schematic diagram of a fault injection device 400 proposed in an embodiment of this application. The device 400 is applied to an air suspension. Furthermore, the device 400 can be connected to the component that needs fault injection through the air suspension's piping, thereby enabling fault injection into the component.

[0092] refer to Figure 4 As shown, the device 400 includes:

[0093] Valve mechanism 410 includes valve body 411 and valve core 412. Valve body 411 includes a first valve chamber 4111, a first air passage 4112, and a second air passage 4113. The first air passage 4112 and the second air passage 4113 are each divided into two parts by the first valve chamber 4111. The first part 01 of the first air passage 4112 and the first part 02 of the second air passage 4113 are interconnected to form a main air passage 4114. The main air passage 4114 is connected to the tested component of the air suspension. The second part 03 of the first air passage 4112 is connected to the atmosphere. The second part 04 of the second air passage 4113 is connected to the air suspension pipeline. The valve core 412 is disposed in the first valve chamber 4111. The valve core 412 includes a first valve stem 4121, a first blocking part 4122 and a second blocking part 4123. The first blocking part 4122 is disposed at the first position of the first valve stem 4121 and is used to adjust the air passage opening of the first air passage 4112. The second blocking part 4123 is disposed at the second position of the first valve stem 4121 and is used to adjust the air passage opening of the second air passage 4113.

[0094] The drive unit 420 is connected to the valve core 412 and is used to drive the first valve stem 4121 to move relative to the first valve chamber 4111.

[0095] It should be understood that as the first valve stem 4121 moves within the first valve chamber 4111, the first blocking part 4122 and the second blocking part 4123 provided on the first valve stem 4121 will also move synchronously, and the first blocking part 4122 and the second blocking part 4123 will also change the opening degree of their respective air passages accordingly.

[0096] Compared to Figure 3 The fault injection device shown in this application embodiment 400 does not simply simulate faults by introducing multiple additional solenoid valves. Instead, it uses a valve mechanism 410 with a dual-air-path design. The first part 01 of the first air-path 4112 is connected to the tested component of the air suspension, and the second part 03 of the first air-path 4112 is connected to the atmosphere. The first air-path 4112 is used to simulate air leakage faults of the tested component. The first part 02 of the second air-path 4113 is connected to the tested component of the air suspension, and the second part 04 of the second air-path 4113 is connected to the pipeline that was originally directly connected to the tested component. Thus, the fault injection device is inserted into the original pipeline of the air suspension. The second air-path 4113 is used to simulate blockage faults of the tested component.

[0097] Therefore, a complete device 400 can simulate two types of faults for the tested component: air leakage and blockage. These two types of faults can be simulated simply by controlling the movement of the first valve stem 4121 within the first valve chamber 4111. Figure 3 The fault injection device shown requires simultaneous control of the valve opening of three solenoid valves to simulate air leakage or blockage faults, resulting in significant control overhead.

[0098] Based on the above technical solution, the dual-air-path structure design of device 400 allows it to simulate both blockage and leakage faults in the tested component by controlling a single valve mechanism 410. This results in low control overhead and easy fault simulation. Furthermore, device 400 only needs to be directly connected to the existing air suspension piping, and is connected in series with the tested component via piping. Therefore, installing device 400 requires minimal modification to the existing air suspension piping, making installation simple and easy to apply.

[0099] In some possible embodiments, the first valve stem 4121 includes three states: a default state, an advancing state, and a pulled-out state. In the default state, the first blocking part 4122 completely blocks the first air passage 4112, i.e., the air passage opening of the first air passage 4112 is 0%, while the second blocking part 4123 completely opens the second air passage 4113, i.e., the air passage opening of the second air passage 4113 is 100%. In the advancing state, the first valve stem 4121 is further advanced into the first valve cavity 4111 relative to the default state along the direction of the first valve cavity 4111. At this time, the first blocking part 4122 still completely blocks the first air passage 4112, i.e., the air passage opening of the first air passage 4112 is still 0%, while the second blocking part 4123 will further advance the first air passage 4111 into the first valve cavity 4111. The two air passages 4113 create a blocking effect, meaning that the opening degree of the second air passage 4113 can be adjusted between [0% and 100%) when the first valve stem 4121 is in different degrees of advance. When pulled out, the first valve stem 4121 is pulled out of the first valve chamber 4111 relative to the default state along the direction of the first valve chamber 4111. At this time, the second blocking part 4123 is fully opened, that is, the opening degree of the second air passage 4113 is 100%. The first valve stem 4121 can adjust the opening degree of the first air passage 4112 between (0% and 100%) when the first valve stem 4121 is in different degrees of pull-out state.

[0100] In summary, the valve mechanism 410 needs to meet the following air path adjustment principle: during the process of the first blocking part 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 part 4123 remains at 100%; during the process of the second blocking part 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 part 4122 remains at 0%.

[0101] Furthermore, since the volumes of the first blocking part 4122 and the second blocking part 4123 are basically the same, in order to achieve the adjustment of the air passage opening 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, reference is made to... Figure 4 As shown, the device 400 proposed in this application embodiment needs to meet the following condition: the first part 01 and the second part 03 of the first air passage 4112 need to be offset by a first distance L in the direction perpendicular to the first valve chamber 4111. This first distance L should be less than the second distance between the first blocking part and the second blocking part on the first valve stem. Based on this, although the movement of the first blocking part 4122 and the second blocking part 4123 is synchronous, the process of the first blocking part 4122 adjusting the opening of the first air passage 4112 and the process of the second blocking part 4123 adjusting the opening of the second air passage 4113 are asynchronous, so that the valve mechanism 410 satisfies the above-mentioned air passage adjustment principle when it is working.

[0102] Based on the above technical solution, the operation of introducing leakage faults and introducing blockage faults can be decoupled, ensuring the rationality and accuracy of fault introduction.

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

[0104] Based on the above technical solution, it is possible to introduce both air leakage faults and blockage faults into the tested component by controlling a first valve stem 4121 of the fault injection device 400. The control overhead is small, and the simulation of both types of faults can be achieved simply by connecting the device 400 in series in the pipeline where the tested component is located. The modification to the air suspension pipeline is small and easy to implement.

[0105] In some possible embodiments, 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.

[0106] It should be understood and referenced. Figure 4It is known that one end of the first valve stem is connected to a spring. Therefore, 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 (overcoming the spring tension) or continuously pulled out of the first valve cavity 4111 (overcoming the spring thrust), the thrust or pull force of the first valve stem 4121 needs to be gradually increased accordingly. During this process, the current in the circuit controlling the first valve stem 4121 increases linearly. Therefore, by making the shape of the first blocking part 4122 and / or the shape of the second blocking part 4123 triangular, or by making the first blocking part 4122 and / or the second blocking part 4123 a semi-circular groove, based on this special shape design, it is possible that as the first valve stem 4121 is continuously pushed into the first valve chamber 4111, or as the first valve stem 4121 is continuously pulled out of the first valve chamber 4111, the air flow rate of the air passage regulated by the second blocking part 4123 or the first blocking part 4122 also changes linearly. This allows a correlation to be established between the movement of the first valve stem and the changes in the air flow rate and current, so that the opening degree of the air passage corresponding to the first blocking part 4122 or the second blocking part 4123 can be adjusted by current control.

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

[0108] In some possible embodiments, in order to satisfy the above-mentioned air path regulation principle, the valve mechanism 410 may also have the following structure.

[0109] Figure 5 This is a schematic diagram of another fault injection device 400 proposed in the embodiments of this application.

[0110] Compared to Figure 4 The fault injection device 400 shown is... Figure 5 The valve mechanism 410 of the fault injection device 400 shown is different; see reference. Figure 5As shown, the first part 01 and the second part 03 of the first air passage 4112 of the valve mechanism 410 do not need to be offset by a first distance L in the direction perpendicular to the first valve chamber 4111. However, the geometric parameters of the first blocking part 4122 and the second blocking part 4123 differ significantly. The length of the first blocking part 4122 is greater than the length of the second blocking part 4123. Because the first blocking part 4122 is longer, during the adjustment of the air passage opening corresponding to the second blocking part 4123 between [0% and 100%), the first blocking part 4122 can always completely close the first air passage 4112. However, when the air passage opening corresponding to the second blocking part 4123 is fully closed, the first blocking part 4122 can always completely close the first air passage 4112. After full opening, if a leakage fault needs to be simulated through the first blocking part 4122, the first valve stem 4121 can be continuously pulled outward, thereby moving the first blocking part 4122 outward and gradually opening the first air passage 4112, allowing the opening degree of the first air passage 4112 to be adjusted between (0%, 100%). It can be seen that during this process, the movement of the first blocking part 4122 and the second blocking part 4123 is synchronous, but the process of the first blocking part 4122 adjusting the opening degree of the first air passage 4112 and the second blocking part 4123 adjusting the opening degree of the second air passage 4113 are asynchronous, thus ensuring that the valve mechanism 410 meets the aforementioned air passage adjustment principle during operation.

[0111] Figure 6 This is a schematic diagram of the structure of a fault injection device 600 proposed in an embodiment of this application.

[0112] Compared to Figure 4 The fault injection device 400 shown is... Figure 6 The valve mechanism 610 of the fault injection device 600 shown differs from the valve mechanism 410 of the fault injection device 400. (See reference) Figure 6As shown, the valve mechanism 610 does not have a valve chamber 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. These two sub-valves are independently controlled. Therefore, the valve core 612 and the drive part 620 of the valve mechanism 610 in this example are different. The valve core 612 of the valve mechanism 610 includes a first sub-valve 611 and a second sub-valve 612. Both the first sub-valve 611 and the second sub-valve 612 are disposed in the first valve chamber 6111. 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 drive unit 620 is connected to the valve core 612 and is used to adjust the valve opening of the first sub-valve 611 and the second sub-valve 612. Moreover, the structural extension examples of the device 400 in subsequent embodiments can also be applied to the device 600, and the structural extension of the device 600 will not be repeated in subsequent embodiments.

[0113] Therefore, it can be seen that the control logic of the first sub-valve 611 and the second sub-valve 612 is the same as described above. Figure 4 or Figure 5 The first blocking part 4122 and the second blocking part 4123 in the corresponding embodiment are different. The first sub-valve 611 and the second sub-valve 612 are not connected to each other by a valve stem; they are two independent components. The drive unit 620 needs to control the first sub-valve 611 and the second sub-valve 612 separately, therefore... Figure 6 The control overhead of the fault injection device 600 shown is relatively large.

[0114] For ease of description, the following embodiments will be described using... Figure 4 Taking the device 400 shown as an example, the technical solution proposed in this application will be further explained.

[0115] In some possible embodiments, a device 400 can be provided for each of the multiple components in an air suspension to simulate the failure of the multiple components.

[0116] Figure 7 This is a schematic diagram of an air suspension system with multiple fault injection devices 400 installed, as proposed in an embodiment of this application.

[0117] refer to Figure 7As shown, the device 400 proposed in this application embodiment can not only simulate air leakage or blockage in the air spring of the air suspension, but also simulate air leakage or blockage in other components of the air suspension, such as the air pump, air tank, and solenoid valves. The solenoid valves include solenoid valves connected to the air spring and solenoid valves connected to the air tank, typically numbering five. These five solenoid valves can also be integrated together to form a distribution valve or solenoid valve group. Correspondingly, the air suspension is equipped with a total of 11 fault injection devices 400, corresponding to... Figure 7 The fault injection devices #1 to #11 are configured to inject faults into 5 solenoid valves, 4 air springs, 1 air tank, and 1 air pump respectively.

[0118] It should be understood that Figure 7 The illustrated scheme is merely an example. The location and number of fault injection devices 400 installed can be adaptively adjusted for different or identical air suspension architectures. This application does not limit this aspect.

[0119] In some possible embodiments, based on Figure 7 The air suspension shown can be simulated by introducing faults simultaneously through multiple devices 400, thereby simulating combined faults of different components.

[0120] Based on the above technical solution, the device 400 can not only simulate the failure of the air spring of the air suspension, but also the failure of other components, increasing the number of failure simulation objects. It can also realize combined failure simulation, which helps to conduct more reasonable and accurate verification of the air suspension failure response function in the future.

[0121] In some possible embodiments, to further improve the accuracy and precision of fault injection, while introducing a fault through device 400, it is also necessary to monitor relevant parameters of the gas path, such as the air flow rate of the first gas path 4112, the air flow rate of the second gas path 4113, and the air pressure of the first portion 01 of the first gas path 4112 or the first portion 02 of the second gas path 4113. Therefore, the device 400 further includes: a first flow meter 430 disposed in the second portion 03 of the first gas path 4112; a second flow meter 440 disposed in the second gas path 4113 or the main gas path 4114; and a barometer 450 disposed in the first portion 01 of the first gas path 4112, the first portion 02 of the second gas path 4113, or the main gas path 4114.

[0122] In some possible embodiments, the device 400 may further include a controller 460, which is connected to the first flow meter 430, the second flow meter 440, the barometer 450 and the drive unit 420 respectively.

[0123] For example, based on the connection relationship between the controller 460 and other components, it can be seen that the controller 460 can obtain the output results of the first flow meter 430, the second flow meter 440 and the barometer 450 in real time, and can also control the drive unit 420 to drive the first valve stem 4121 to move relative to the first valve chamber 4111 in order to adjust the opening of the first air passage 4112 or the second air passage 4113.

[0124] In some possible embodiments, the three sensors described above can monitor the air flow rate of each air path and the air pressure of the first part of the first air path 4112 or the first part 02 of the second air path 4113 in real time during the injection of a fault into the device 400. This allows the severity of the simulated fault to be quantified using these parameters, further classifying the fault into minor leaks, major leaks, minor blockages, and major blockages. Specifically, when the air flow rate output by the first flow meter 430 is greater than a pre-calibrated air flow rate threshold Q1, the fault can be set as a major leak; when the air flow rate output by the first flow meter 430 is less than the pre-calibrated air flow rate threshold Q1, the fault can be set as a minor leak; when the pressure value output by the barometer 450 is greater than a pre-calibrated pressure threshold P1, the fault can be set as a major blockage; and when the pressure value output by the barometer 450 is less than the pre-calibrated pressure threshold P1, the fault can be set as a minor blockage.

[0125] Furthermore, if multiple devices 400 are connected in series with multiple tested components in the air suspension through pipelines, the corresponding sensor outputs in the multiple devices 400 can be used to identify whether the current fault in the air suspension is introduced by the device 400, or a fault existing in the tested component of the air suspension itself, or a combination of both faults.

[0126] For example, with Figure 2 Taking the air suspension shown as an example, assuming that the air spring is installed on the pipe where the left front air spring is located... Figure 3 The fault injection device shown is used to simulate an air leak. 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 due to the fault injection device opening the leakage valve, or it may be due to air leakage in solenoid valve 2, or even air leakage in the internal components of the fault injection device. Therefore, the simulated fault is confused with the possible real component faults, resulting in poor fault simulation accuracy.

[0127] However, as can be seen from the foregoing embodiments, in an air suspension system, multiple components can be connected in series with a single device 400, and the device 400 is also equipped with corresponding sensors, thereby effectively increasing the accuracy of fault simulation and avoiding confusion between simulated faults and actual component faults. Figure 2 Taking the air suspension shown as an example, assuming that the air spring is installed on the pipe where the left front air spring is located... Figure 4 The fault injection device #7 shown is also installed on the pipeline where solenoid valve 2 is located. Figure 4 The fault injection device #2 is shown, and a leakage fault in the left front air spring is simulated through device #7. Device #2 does not introduce the fault. After the fault is injected, the phenomenon of leakage in the left front air spring is reproduced. It can be observed that the air flow detected by the first flowmeter 430 and the second flowmeter 440 of device #7 increases significantly. At the same time, it can be observed that the air flow detected by the second flowmeter 440 of device #2 remains basically unchanged or increases slightly, but the increase is much smaller than the increase in air flow detected by the second flowmeter 440 of device #7. Therefore, it can be clearly seen that the fault is caused by the leakage of the left front air spring simulated by device #7. Since device #2 does not introduce the fault and the second flowmeter 440 of device #2 remains basically unchanged, the solenoid valve 2 does not leak. In summary, the leakage fault is introduced through fault simulation, thereby avoiding confusion between simulated fault and real fault.

[0128] In the above example scenario, if the air flow detected by the second flow meter 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 both simulated fault and real fault coexist.

[0129] It should be understood that the method for distinguishing between simulated blockage faults and actual blockage faults in components is similar in principle to the method for distinguishing between simulated leakage faults and actual leakage faults in components, and will not be repeated here.

[0130] Based on the above technical solution, by introducing a controller 460 and corresponding sensors into the device 400, the controller 460 can acquire the corresponding parameter values ​​output by the sensors during the introduction of a fault. This allows the controller 460 to verify the severity of the injected fault, such as minor or severe, so that subsequent testing can be conducted to determine whether the air suspension's response to minor or severe faults meets expectations, thereby completing a reasonable verification of the air suspension's fault response function. Furthermore, since the device 400 can simulate faults in all components of the entire air suspension that may experience leaks or blockages, the accuracy of the fault simulation is increased. By using the sensor output values ​​from the fault injection devices connected to various air suspension components, it can be inferred whether the current fault in the air suspension is a simulated fault, a real fault, or a coexistence of simulated and real faults, thus avoiding confusion between simulated and real faults.

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

[0132] Figure 8 This is a schematic diagram of the basic operating state of the fault injection device 400 proposed in the embodiments of this application.

[0133] Figure 8 (a) in the diagram is a schematic diagram of device 400 in its default state. In this state, the position of the first valve stem 4121 is such that the first blocking part 4122 completely closes the first air passage 4112, and the second blocking part 4123 completely opens the second air passage 4113. Accordingly, the output of the first flow meter 430 is 0; the output of the second flow meter 440 is equal to the air flow rate a when the air suspension is operating normally, which can be obtained in advance through calibration experiments for the air suspension; the output of the barometer 450 is equal to the pressure value a in the pipeline or air passage when the air suspension is operating normally, which can also be obtained in advance through calibration experiments for the air suspension.

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

[0135] Figure 8 (b) is a schematic diagram of device 400 in a severely blocked state. In this state, the position of the first valve stem 4121 causes the first blocking part 4122 to completely close the first air passage 4112, and causes the second blocking part 4123 to block part or all of the second air passage 4113. Accordingly, the output of the first flow meter 430 is 0; the output of the second flow meter 440 is less than the air flow rate a during normal operation of the air suspension; the output of the barometer 450 is greater than or equal to the air suspension's pressure relief threshold P. This pressure relief threshold P is used to indicate the pressure value in the pipeline where the air suspension pump is located when the air suspension detects a blockage inside the suspension and triggers a pressure relief operation. This pressure relief threshold can be obtained in advance through calibration experiments for the air suspension.

[0136] For example, if the second blockage part 4123 completely blocks the second air passage 4113, the fault can also be defined as a complete blockage fault, which is the most serious blockage fault. At this time, the output of the first flow meter 430 is 0; the output of the second flow meter 440 is also 0; and the output of the barometer 450 is greater than or equal to the air suspension pressure relief threshold P.

[0137] Figure 8(c) is a schematic diagram of device 400 in a slightly blocked state. In this state, the position of the first valve stem 4121 causes the first blocking part 4122 to completely close the first air passage 4112, and causes the second blocking part 4123 to partially block the second air passage 4113. Accordingly, the output of the first flow meter 430 is 0; the output of the second flow meter 440 is less than the air flow rate a during normal operation of the air suspension; and the output of the barometer 450 is less than the air suspension's pressure relief threshold P.

[0138] It should be understood that air suspensions with different hardware parameters have different pressure relief thresholds P.

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

[0140] For example, when the first blockage part 4122 is fully open to the first air passage 4112, the fault can also be defined as the maximum leakage fault, which is the most serious leakage fault. At this time, the output of the first flow meter 430 is greater than 0, usually much greater than 0; the second flow meter 440 is greater than the air flow a when the air suspension is running normally; and the output of the barometer 450 is less than the air suspension pressure relief threshold P.

[0141] Figure 8 (e) is a schematic diagram of device 400 in a slight leakage state. In this state, the position of the first valve stem 4121 causes the first blocking part 4122 to open part or the entire first air passage 4112, and causes the second blocking part 4123 to open the entire second air passage 4113. Accordingly, the output of the first flow meter 430 is greater than 0; the second flow meter 440 is greater than the air flow rate a during normal operation of the air suspension; and the output of the pressure gauge 450 is less than the air suspension's pressure relief threshold P.

[0142] In some possible embodiments, to further increase the accuracy of fault simulation, the device 400 further includes a height sensor 470 disposed on the air spring of the air suspension.

[0143] In some possible embodiments, the height sensor 470 of the device 400 may reuse the height sensor 470 that is already installed in the air spring of the air suspension.

[0144] It should be understood that the critical points for determining minor and serious air leaks can be accurately determined based on the output results of the height sensor 470 and the first flow meter 430.

[0145] For example, for a properly functioning air suspension, if a leak fault is introduced into the air spring via device 400, the air suspension will trigger a fault response measure. This involves inflating the air spring's air bladder using the air pump and air tank within the air suspension to maintain the air suspension height as much as possible. If the output of the height sensor 470 of device 400 remains unchanged after inflating the air spring's air bladder via the air pump and air tank, it can be determined that device 400 has successfully simulated a minor leak fault. Conversely, if the output of the height sensor 470 of device 400 continuously decreases after inflating the air spring's air bladder via the air pump and air tank, it can be determined that device 400 has successfully simulated a severe leak fault.

[0146] For example, based on the above method for judging minor and serious air leakage faults, the critical point for judging minor and serious air leakage faults of the air suspension can be determined in advance through calibration experiments: the controller 460 of the device 400 controls the drive unit 420 to drive the first valve stem 4121 from the default state to continuously pull it out of the first valve chamber 4111. At the same time, the controller 460 continuously acquires the output results of the first flow meter 430 and the height sensor 470. During the process of the first valve stem 4121 being continuously pulled out of the first valve chamber 4111, if the output result of the height sensor 470 is detected to begin to decrease and the output result of the first flow meter 430 is greater than 0, then the current position of the first valve stem 4121 is the fault critical point for minor and serious air leakage, and the displacement of the first valve stem 4121 during this process is the critical displacement. Therefore, if a minor air leakage fault is to be introduced, the displacement of the first valve stem 4121 should be less than or equal to the critical displacement; if a serious air leakage fault is to be introduced, the displacement of the first valve stem 4121 should be greater than the critical displacement.

[0147] Based on the above technical solution, by introducing a height sensor 470 into the device 400, the accuracy of air leakage fault simulation can be further increased, and the critical point for judging minor air leakage and serious air leakage can be accurately determined, so that the device 400 can perform air leakage fault simulation more reasonably and accurately.

[0148] In some possible embodiments, reference Figure 4 or Figure 5The device 400 shown includes a drive unit 420 comprising: a first housing 421; a slider 422 disposed within the first housing 421 and fixed to a first valve stem 4121; and a force-applying unit 423 disposed on the outer surface of the first housing 421, the force-applying unit 423 being configured to drive the slider 422 to slide within the first housing 421.

[0149] In some possible embodiments, the force-applying part 423 is a proportional electromagnet, and correspondingly, the slider includes any of the following materials: iron, cobalt, and nickel.

[0150] In some possible embodiments, a spring 424 is provided on the first side α of the first housing 421, and the spring 424 is connected to the slider 422. When the force-applying part 423 does not apply 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] For example, when the force-applying part 423 is a proportional electromagnet, the controller 460 can input a current of a corresponding value into the circuit where the force-applying part 423 of the drive part 420 is located, so that the force-applying part 423 has a corresponding value of magnetic force and magnetism, thereby driving the slider 422 to push outward or pull inward along the direction of the first housing 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 chamber 4111 as the slider 422 moves, so that the first blocking part 4122 on the first valve stem 4121 adjusts the opening of the first air passage 4112, or the second blocking part 4123 on the first valve stem 4121 adjusts the opening of the second air passage 4113.

[0152] Based on the above technical solution, the drive unit 420 of the above structure can drive the first valve stem 4121 based on the current control of the controller 460, thereby adjusting the air passage opening of the first air passage 4112 or the second air passage 4113.

[0153] In some possible embodiments, in order to make the simulated air suspension failure scenario more realistic, the air suspension can be set on a test bench to simulate the air suspension failure in real-world scenarios.

[0154] Figure 9 This is a schematic diagram of the architecture of a test bench 900 proposed in an embodiment of this application.

[0155] The test bench 900 consists of two parts: one part is the air suspension air circuit structure, which can be referred to the aforementioned... Figure 7 The air suspension system shown has multiple fault injection devices installed. Specifically, the test bench includes N fault injection devices 400 as described in the preceding embodiments, and each of these N devices 400 is connected in series with N components under test in the air suspension via piping. It should be understood that the N components under test can be all components in the air suspension, for example... Figure 7 The diagram shows the air tank, air pump, air spring, and solenoid valve; the N tested components can also be parts of the air suspension, such as only the air spring. (Reference) Figure 9 As shown, FR, FL, and RR are used to indicate the position of the air spring in the entire air suspension. 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] Furthermore, considering that in real-world applications, air suspension needs to support the vehicle body and axles, it typically operates under load. Therefore, another part of the test bench is a simulated counterweight device, which is mounted on the air suspension and configured 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 used to simulate the total weight of the chassis, axles, etc.

[0158] Based on the above technical solution, the test bench 900 can not only introduce corresponding faults into the air suspension, but also further simulate the load state of the air suspension in actual operation during the fault simulation process, so as to make the fault simulation of the air suspension closer to reality and thus accurately reproduce the fault scenario of the air suspension.

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

[0160] Figure 10 This is a flowchart illustrating a fault injection method 1000 proposed in an embodiment of this application.

[0161] S1010: Receive first fault simulation information, which is used to indicate that the first component of the simulated air suspension is in a first fault state, which is a component leaking air or a component being blocked.

[0162] The first component is connected to a first fault injection device, which includes at least a valve mechanism, a first flow meter, a second flow meter, and a controller. The structure and connection relationships of the components in the first fault injection device are the same as those of the fault injection device 400 proposed in the corresponding embodiment above. The controller can be part of the first fault injection device or operate independently of it. The controller is connected to and controls the components of the first fault injection device.

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

[0164] S1020: Based on the above-mentioned first fault simulation information, determine the required gas flow rate, which is used to instruct the first fault injection device to adjust the gas flow rate 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 flow meter, and a second flow meter. The first barometer is disposed in a first part of a first air path, or a first part of a second air path, or a main air path. The first flow meter is disposed in a second part of the first air path, and the second flow meter is disposed in a second air path or a main air path. Moreover, the first barometer, the first flow meter, and the second flow meter have the same structure and placement as the barometer 450, the first flow meter 430, and the second flow meter 440 of the device 400 in the aforementioned embodiments.

[0167] In some possible embodiments, in S1030 above, the required air flow rate can be sent to the controller of the first fault injection device. Accordingly, after receiving the required air flow rate, the controller will also perform the following operations: the controller sends a drive command to the drive unit and continuously monitors the air flow rate of the first flow meter and the air flow rate of the second flow meter. The drive command is used to instruct the control of the first valve stem to make relative displacement along the direction of the first valve chamber; when the controller detects that the air flow rate of the first flow meter and the air flow rate of the second flow meter meet the required air flow rate, the controller sends a stop command to the drive unit. The stop command is used to instruct the control of the first valve stem to stop displacement.

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

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

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

[0171] Furthermore, embodiments of this application propose a method for determining the aforementioned required gas flow rate.

[0172] It should be understood that before the required airflow is determined, 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, the air suspension system needs to be powered on so that the various components of the air suspension can work normally.

[0173] Figure 11 This is a flowchart illustrating a method 1100 for determining the required gas flow rate according to an embodiment of this 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 based on 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 first fault simulation information mentioned above includes fault type and fault location, wherein the fault type may include blockage fault and air leakage fault, and the fault location may be at least one component under test connected to the fault injection device.

[0177] For example, if the fault location of the 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, thereby realizing the injection of 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 single main controller, which is used to control the multiple fault injection devices individually. In this case, the industrial control computer needs to be connected to this main controller, and after determining the required airflow, it also needs to carry the fault location from the first fault simulation information to inform the main controller of the fault injection device requiring airflow control.

[0179] In some possible embodiments, the operating principle of the above-mentioned S1130 may be as follows: during the process of introducing a leakage fault or a blockage fault into the first component, the first barometer of the fault injection device corresponds to different target pressure values. Moreover, different severity faults also correspond to different target pressure values. There is a physical conversion relationship between the pressure value and the air flow rate. Based on this physical conversion relationship, the target total air flow rate corresponding to the first barometer reaching the target pressure value can be determined. The required air flow rate can be determined by performing mathematical calculations between this target total air flow rate and the first air flow rate of the first flow meter and the second air flow rate of the second flow meter before the fault is introduced.

[0180] Based on the above technical solution, the industrial control computer obtains the readings of each sensor of the first fault injection device, combines them with the first fault simulation information, determines and sends the required air flow rate to the first fault injection device, so that the controller of the first fault injection device only needs to simulate the fault of the first component according to the air flow rate. Since the size of the required air flow rate is related to the severity of the fault simulation, this solution can accurately simulate faults of different severity.

[0181] Considering the need 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 brought the first component into the desired fault state. Moreover, in order to achieve accurate simulation of the fault of the first component, the aforementioned first fault state can be a slight air leak, a severe air leak, a slight blockage, or a severe blockage.

[0182] In some possible embodiments, the air spring of the air suspension is equipped with a height sensor, which may be part of the first fault injection device. Based on the height sensor and the first flow meter of the first fault injection device, it can be determined whether the first component has entered the desired air leakage fault state. The air leakage fault state includes minor air leakage and severe air leakage. The determination method is as follows:

[0183] In the first fault condition of severe air leakage, the industrial control computer continuously monitors the first height value of the height sensor. When the industrial control computer detects that the third air flow rate of the first flow meter is greater than 0 and the first height value continues to decrease, it determines that the simulation of the first component being in the first fault condition is complete; or...

[0184] In the case of a slight air leak in the first fault state, the industrial control computer continuously monitors the first height value of the height sensor. When the industrial control computer detects that the third air flow of the first flow meter is greater than 0 and the first height value remains unchanged, it determines that the simulation of the first component being in the first fault state is complete.

[0185] In some possible embodiments, typically, each of the four air springs in an air suspension system is equipped with a height sensor. Therefore, the industrial control computer can continuously monitor the height values ​​output by the height sensors corresponding to each of the four air springs. If all four height values ​​decrease simultaneously, and the deviation between them is within a preset height deviation range, the fault is considered a serious air leak. If all four height values ​​decrease simultaneously, and the deviation between them exceeds the preset height deviation range, the fault is considered a dangerous serious air leak. This is because a deviation exceeding the preset height deviation range indicates significant tilting of the air suspension, which can easily cause the vehicle to become unbalanced, making it a highly dangerous fault. It should be understood that if the air suspension structure changes, such as increasing or decreasing the number of air springs, the number of height sensors will also increase or decrease accordingly.

[0186] In some possible embodiments, based on the first barometer, it can also be determined whether the first component has entered a desired blockage fault state, including minor blockage and severe blockage. Before the determination, the industrial control computer determines the pressure relief threshold of the air suspension's air pump, which is used to trigger the air pump to perform a pressure relief operation. For example, when the air pump's pressure 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 of severe blockage in the first fault state, the industrial control computer acquires the second pressure value of the first barometer. When the industrial control computer determines that the second pressure value is greater than or equal to the pressure relief threshold, it confirms that the simulation of the first component being in the first fault state is complete. The pressure relief threshold is used to trigger the air pump to perform a pressure relief operation; or...

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

[0189] It should be understood that, in the case of component blockage in the first fault state, the output of the first flow meter will always be 0 during the above judgment process.

[0190] In some possible embodiments, the aforementioned pressure relief threshold can be sent from the host computer to the industrial control computer.

[0191] In some possible embodiments, when the industrial control computer cannot directly obtain the aforementioned pressure relief threshold, the pressure relief threshold can also be obtained through the following method. The prerequisite for applying this method is that the air suspension also 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 may be the controller of the first fault injection device), the first instruction instructing the first fault injection device to reduce the air passage opening of the second air passage from 100%; during the process of reducing the air passage opening of the second air passage of the first fault injection device, 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 to the controller, it will trigger the controller to control the first fault injection device to introduce a blockage fault into the first component. At this time, the controller controls the drive unit to drive the first valve stem into the first valve chamber, thereby causing the second air passage to be blocked. During this process, the air suspension will trigger the fault response function. That is, after 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. After the air pump triggers the pressure relief operation, the air pressure value of the second barometer will drop rapidly. Therefore, the output result of the second barometer has a maximum value during this process. Since the air pressure monitored by the second barometer reaches the maximum value, the pressure relief operation of the air pump is triggered. Therefore, this maximum value can be used as the aforementioned pressure relief threshold.

[0193] The aforementioned pressure relief threshold is determined by the output of the second barometer. Furthermore, the pressure relief threshold can also be determined by the output 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 command to the first fault injection device (which may be the controller of the first fault injection device), instructing the first fault injection device to reduce the opening of the second air path from 100%. During the reduction of the opening of the second air path, the industrial control computer continuously monitors the fourth pressure value of the third barometer in the second fault injection device, and determines the maximum value of the fourth pressure value as the pressure relief threshold.

[0194] In some possible embodiments, if the first component is found not to have entered the first fault state indicated by the first fault simulation information based on the above fault state judgment, the industrial control computer will redetermine the required air flow rate based on the data collected by each sensor of the first fault injection device until the first component enters the first fault state indicated by the first fault simulation information, thereby realizing closed-loop control of fault simulation.

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

[0196] Similarly, for simulations of minor and severe air leaks, i.e., the first fault state in the aforementioned first fault simulation information is component leakage, the required air flow rate can be directly determined based on an air flow rate threshold. As described in the foregoing embodiments, the aforementioned first fault injection device is connected to an industrial control computer. Therefore, the required air flow rate can also be determined using the following method.

[0197] Figure 12 This is a flowchart illustrating a method 1200 for determining the required gas flow rate according to an embodiment of this application. This method can be executed by the aforementioned industrial control computer.

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

[0199] For example, when the air flow threshold refers to the air flow threshold of the second air path of the first fault injection device, if the air flow of the second air path is greater than or equal to the air flow threshold, the fault introduced by the first fault injection device is a serious air leakage fault; if the air flow of the second air path is less than the air flow threshold, the fault introduced by the first fault injection device is a minor air leakage fault.

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

[0201] S1230: Determine the required gas flow rate based on the gas flow rate threshold, the fourth gas flow rate, and the fifth gas flow rate.

[0202] In some possible embodiments, the required gas flow rate includes the difference between the gas flow rate threshold to be reached by the first flow meter and the fourth gas flow rate. Further, the required gas flow rate may also include the gas flow rate to be reached by the second flow meter as the fifth gas flow rate.

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

[0204] Figure 13 This is a flowchart illustrating a method 1300 for determining a gas flow threshold according to an embodiment of this application. This method can be executed by the aforementioned industrial control computer.

[0205] S1310: Send a second instruction to the first fault injection device, the second instruction being used to instruct the first fault injection device to increase the gas path opening of the first gas path from 0%.

[0206] For example, the industrial control computer can send the aforementioned second instruction to the controller of the first fault injection device.

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

[0208] For example, the height sensor described above can reuse the height sensor installed in the air suspension.

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

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

[0211] It should be understood that the methods 1000 to 1300 described above, as well as the corresponding extended embodiments, can also be applied to other fault injection devices 400 installed in air suspensions.

[0212] Furthermore, based on the foregoing embodiments, this application also proposes a fault simulation system.

[0213] Figure 14 This is a schematic diagram of the architecture of a fault simulation system 1400 proposed in an embodiment of this application.

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

[0215] The host computer is connected to the industrial control computer. The host computer is used to receive fault simulation instructions from the testers to determine the first fault simulation information, and to 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 computer is also connected to the test bench, and further, it is also connected to the suspension controller and fault injection device controller of the air suspension system in the test bench.

[0217] The suspension controller is connected to the air pump, solenoid valve assembly, air spring, height sensor, and pressure gauge in the air suspension system. The height sensor can be installed in the air spring to detect its support height. The pressure gauge can be connected in series with the air pump via piping to detect the air pressure in the external piping, allowing the suspension controller to determine whether to trigger a depressurization or inflation operation. Additionally, the air suspension system includes an air tank for use with the air pump for depressurization or inflation.

[0218] The controller of the fault injection device is connected to the first flow meter, the second flow meter, the barometer and the drive unit respectively. The deployment location and function of each component are detailed in the foregoing embodiments and will not be repeated here.

[0219] For ease of understanding, the following will be based on Figure 7 Taking the air suspension equipped with fault injection devices #1 to #11 as an example, a detailed explanation of the scenario simulating a single component failure is provided.

[0220] Fault Simulation Scenario 1: Simulating a severe air leak in the left front air spring. Based on the aforementioned examples, the fault simulation process is as follows:

[0221] Power on the air suspension system to enable all components in the air suspension system to function normally.

[0222] The tester inputs a fault simulation command to the host computer. For example, the fault simulation command 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 command, for example, based on the mapping relationship, it determines the type and location of the fault to be simulated, i.e., fault type: severe air leakage, fault location: left front air spring (or directly indicates 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, based on the first fault simulation information, that a severe gas leak fault needs to be injected through the fault injection device #7. Then, based on the method 1100 or method 1200 proposed in the aforementioned embodiments, it determines the required gas flow rate and then sends the required gas flow rate to the controller of the fault injection device #7, which is referred to here as controller #7.

[0225] Based on the method 1000 proposed in the aforementioned embodiment, controller #7 controls the valve core of fault injection device #7. By moving the first valve stem of the valve core, the air passage opening of the first air passage of the valve core is adjusted. During the adjustment process, the air passage opening of the second air passage remains at 100%, and the air passage opening of the first air passage gradually increases from 0% until the output result of the first air pressure gauge of the first air passage meets the required air flow rate. At this time, the first valve stem of the valve core reaches the designated position and stops moving. At the same time, based on the output results of the height sensor and the first flow meter located at the air spring position of the air suspension, it is determined whether fault simulation scenario 1 has been reproduced: when the output result of the first flow meter is greater than 0 and the output result of the height sensor continues to decrease, it is determined that fault simulation scenario 1 has been successfully reproduced.

[0226] In some possible embodiments, the operation of the controller adjusting the opening of the first air path and the operation of determining whether the fault simulation scenario 1 is reproduced can be performed simultaneously. During this process, if the controller detects that the output of the first flow meter is greater than 0 and the output of the height sensor continues to decrease, the controller can directly stop moving the first valve stem of the valve core, thereby stopping the adjustment of the air path opening of the first air path. This method does not require prior acquisition of the required air flow rate and then control of the first valve stem based on the required air flow rate. Instead, it continuously determines whether the fault simulation scenario is reproduced, and stops moving the first valve stem when it is reproduced.

[0227] Fault Simulation Scenario 2: Simulating a minor blockage in the air pump. Based on the aforementioned embodiments, the fault simulation process is as follows:

[0228] Power on the air suspension system to enable all components in the air suspension system to function normally.

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

[0230] The host computer analyzes the fault simulation command, for example, based on the pre-defined mapping relationship, to determine the fault type and fault location to be simulated, i.e., fault type: minor blockage, fault location: air pump (or directly indicating 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, based on the first fault simulation information, that a minor blockage fault needs to be injected through the fault injection device #1. Then, based on the method 1100 proposed in the aforementioned embodiment, it determines the required gas flow rate and then sends the required gas flow rate to the controller of the fault injection device #1, which is referred to here as controller #1.

[0232] Based on the method 1000 proposed in the aforementioned embodiment, controller #1 controls the valve core of fault injection device #1. By moving the first valve stem of the valve core, the air passage opening of the second air passage of the valve core is adjusted. During the adjustment process, the air passage opening of the first air passage remains at 0%, and the air passage opening 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. At this time, the first valve stem of the valve core reaches the designated position and stops moving. At the same time, based on the output result of the barometer of fault injection device #1, it can be determined whether fault simulation scenario 2 has been reproduced: when the output result of the barometer of fault injection device #1 is greater than the pressure relief threshold of the air pump, it is determined that fault simulation scenario 1 has been successfully reproduced.

[0233] In some possible embodiments, the operation of the controller adjusting the opening of the second air path and the operation of determining whether the fault simulation scenario 2 is reproduced can be performed 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 valve core, thereby stopping the adjustment of the air path opening of the second air path. This method does not require prior acquisition of the required air flow rate and then control of the first valve stem based on the required air flow rate. Instead, it continuously determines 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 shown, equipped with fault injection devices #1 to #11, can simulate fault locations including: left front air spring, right front air spring, left rear air spring, right rear air spring, air pump, air tank, and solenoid valve. Furthermore, it can simulate minor blockage, severe blockage, minor air leakage, and severe air leakage at each fault location. Therefore, fault injection devices #1 to #11 can simulate a total of 44 single-type faults. If combined faults of different components are considered, the number of fault types that can be simulated will be even greater. The principle of fault simulation is the same as in the aforementioned embodiments and will not be repeated here.

[0235] Furthermore, the fault simulation device 400 in this application embodiment is modularized. It can be connected in series with the component that needs to be tested for fault simulation through a pipeline. Therefore, the device 400 can be applied to different air suspension systems.

[0236] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0237] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0238] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

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

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

[0241] If the aforementioned functions are implemented as software functional 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 part of the 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 to cause a computer device (which may be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application.

[0242] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A fault injection device (400), characterized in that, The fault injection device (400) includes: The valve mechanism (410) includes a valve body (411) and a valve core (412). The valve body (411) includes a first valve chamber (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 chamber (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 tested component of the air suspension. The second part (03) of the first air passage (4112) is connected to the atmosphere. The second part (04) of the second air passage (4113) is connected to the air suspension pipe. The valve core (412) is disposed in the first valve chamber (4111). The valve core (412) includes a first valve stem (4121), a first blocking part (4122) and a second blocking part (4123). The first blocking part (4122) is disposed at a first position of the first valve stem (4121). 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 disposed at a second position of the first valve stem (4121). The second blocking part (4123) is used to adjust the air passage opening of the second air passage (4113). A drive unit (420) is connected to the valve core (412), and the drive unit (420) is used to drive the first valve stem (4121) to move relative to the first valve cavity (4111) in the direction of the first valve cavity (4111); The first flow meter (430) is located in the second part (03) of the first gas passage (4112); The second flow meter (440) is disposed in the second gas passage (4113) or the main gas passage (4114). The first barometer (450) is disposed in the first part (01) of the first air passage (4112), or the first part (02) of the second air passage (4113), or the main air passage (4114). During the process of the first blocking part (4122) reducing the opening of the first air passage (4112) from 100%, the opening of the second air passage (4113) corresponding to the second blocking part (4123) remains at 100%; during the process of the second blocking part (4123) reducing the opening of the second air passage (4113) from 100%, the opening of the first air passage (4112) corresponding to the first blocking part (4122) remains at 0%.

2. The fault injection device (400) according to claim 1, characterized in that, The positions between the first blocking part (4122) and the second blocking part (4123) are relatively fixed.

3. The fault injection device (400) according to claim 1 or 2, characterized in that, The device also includes a controller (460) which is connected to the first flow meter (430), the second flow meter (440), the first barometer (450) and the drive unit (420).

4. The fault injection device (400) according to claim 1 or 2, characterized in that, The shape of the first blocking part (4122) and / or the shape of the second blocking part (4123) is triangular, or the first blocking part (4122) and / or the second blocking part (4123) is a semi-circular groove.

5. A method for fault injection, characterized in that, The method includes: Receive first fault simulation information, the first fault simulation information is used to indicate that the first component of the simulated air suspension is in a first fault state, the first fault state is that the component is leaking air or the component is blocked, the first component is connected to a first fault injection device, the first fault injection device is a fault injection device as described in any one of claims 1 to 4. Based on the first fault simulation information, the required gas flow rate is determined, and the required gas flow rate is used to instruct the first fault injection device to adjust the gas flow rate of the first gas path and the second gas path. The required gas flow rate is sent to the first fault injection device.

6. The method according to claim 5, characterized in that, The first fault simulation information determines the required gas flow rate, including: 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; The required air flow rate is determined based on the first fault simulation information, the first air pressure value, the first air flow rate, and the second air flow rate.

7. The method according to claim 6, characterized in that, The air springs of the air suspension are equipped with height sensors. After sending the required air flow rate to the first fault injection device, the method further includes: In the case of severe air leakage in the first fault state, the first height value of the height sensor is continuously monitored. If the third air flow rate of the first flow meter is detected to be greater than 0 and the first height value continues to decrease, it is determined that the simulation of the first component being in the first fault state is complete; or, When the first fault condition is a slight air leak, the first height value of the height sensor is continuously monitored. When the third air flow rate of the first flow meter is detected to be 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 condition is complete.

8. The method according to claim 7, characterized in that, After sending the required gas flow rate to the first fault injection device, the method further includes: When the first fault state is severe blockage, the second pressure value of the first barometer is acquired. If the second pressure value is determined to be greater than or equal to a pressure relief threshold, the simulation of the first component being in the first fault state is considered complete. The pressure relief threshold is used to trigger the air suspension's air pump to perform a pressure relief operation; or... When the first fault state is a slight blockage, the second pressure value of the first barometer is obtained. When it is determined that the second pressure value is less than the pressure relief threshold, the simulation of the first component being in the first fault state is completed.

9. The method according to claim 8, characterized in that, The air suspension also includes a second barometer for measuring the air pressure value of the air pump, and the method further includes: Send a first instruction to the first fault injection device, the first instruction being used to instruct the first fault injection device to reduce the gas path opening of the second gas path from 100%; As the opening of the second air path decreases, 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.

10. The method according to claim 8, characterized in that, The air pump of the air suspension is connected to a second fault injection device, the second fault injection device having the same structure as the first fault injection device. The method further includes: Send a first instruction to the first fault injection device, the first instruction being 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 reducing the opening of the second air path, the fourth air pressure value of the third barometer in the second fault injection device is continuously monitored, and the maximum value of the fourth air pressure value is determined as the pressure relief threshold.

11. The method according to claim 5, characterized in that, When the first fault condition is component leakage, determining the required air flow rate includes: Determine an air flow threshold, which is used to determine whether the first component has a minor air leakage fault or a serious air leakage fault; Obtain the fourth gas flow rate of the first flow meter and the fifth gas flow rate of the second flow meter; The required gas flow rate is determined based on the gas flow rate threshold, the fourth gas flow rate, and the fifth gas flow rate.

12. The method according to claim 11, characterized in that, The air spring of the air suspension is equipped with a height sensor, and the determination of the air flow threshold includes: Send a second instruction to the first fault injection device, the second instruction being used to instruct the first fault injection device to increase the gas path opening of the first gas path from 0%; As the opening of the first air path increases, the height value of the height sensor and the air flow rate of the second flow meter are continuously monitored. When the height value of the height sensor begins to decrease, the air flow rate of the second flow meter at this time is determined as the air flow rate threshold.

13. The method according to any one of claims 5 to 12, characterized in that, The first component is an air pump, air spring, air tank, or solenoid valve of an air suspension.

14. A test bench, characterized in that, The test bench is used to simulate air suspension failure and includes: N fault injection devices as described in any one of claims 1 to 4, wherein the N fault injection devices are 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 mounted on the air suspension and is configured such that its own weight can be adjusted within a first weight range.

15. 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 circuits and the processors are interconnected via lines; the interface circuits are used to receive signals from the memory of the electronic device and send the signals to the processors, the signals including computer instructions stored in the memory; when the processor executes the computer instructions, the electronic device performs the method as described in any one of claims 5 to 13.

16. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program that is executed by a processor to implement the method as described in any one of claims 5 to 13.

17. A computer program product, characterized in that, When the code or instructions of the computer program are executed on a computer, the computer performs the method as described in any one of claims 5 to 13.

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