A testing method and device for a hydraulic controller in a braking system

Abstract

The embodiments of the present application provide a testing method and device for a hydraulic controller in a brake system, which relates to the field of brake testing technology. The method includes: adjusting the control parameters of a brake control module and a transfer hydraulic module in a hydraulic brake system based on a programmable device, wherein the brake control module is used to deliver brake fluid to the pipeline in the hydraulic brake system, and the transfer hydraulic module is used to control the volume flow of the brake fluid; collecting test data generated by the hydraulic controller in the brake control module under the control parameters, wherein the test data is used to characterize the operation of the hydraulic controller under the control parameters; and analyzing the test results corresponding to the test data based on preset operation data, wherein the test results are used to characterize whether the hydraulic controller meets performance requirements, wherein the preset operation data is performance standard data used to verify the performance of the hydraulic controller. The method automates the testing of the hydraulic brake system, simplifies the test operation, shortens the test cycle, and improves the test accuracy.

Description

Technical Field

[0001] The present application relates to the technical field of brake testing, and in particular to a testing method and device for a hydraulic controller in a brake system. Background Art

[0002] The electro-hydraulic brake system (EHB) uses an electronic pedal sensor to detect the driver's braking intention and transmits this signal to the electronic control unit (ECU) to control the vehicle's driving state and implement various functions. It primarily utilizes data acquisition and exchange between various sensors and buses to determine vehicle status and driver intention, and to control the vehicle through actuators. In simple terms, the EHB consists of a brake pedal assembly, a hydraulic brake controller, piping, and hydraulic calipers. The brake pedal assembly and hydraulic brake controller precisely control the flow and volume of brake fluid in the piping to control the degree to which the hydraulic calipers grip the wheels. In other words, the braking force transmitted by the EHB is the brake fluid in the hydraulic piping. Leakage or excessive air in the hydraulic brake controller's brake fluid directly affects braking efficiency and overall vehicle braking force, potentially reducing braking performance and preventing braking.

[0003] In the related art, brake fluid leakage tests for electronic hydraulic brake systems are usually conducted manually. Manual testing requires unscrewing the pipeline interface on the entire vehicle to allow air to enter the pipeline, or manually controlling the brake pipeline leakage and measuring the amount of brake fluid leakage. For example, the hydraulic brake system simulation test device and method described in CN202311401043.6 collects sensor data and data on the piston displacement state of the hydraulic brake system, and processes, evaluates, and analyzes them to determine whether the braking of the hydraulic brake system is normal. This method cannot accurately control the amount of air entering the pipeline and the amount of brake fluid leakage, and due to different vehicle models and different specifications of the electronic hydraulic brake system, the corresponding test-related parameters are likely to be different, resulting in complex test preparation, long cycles, and low accuracy.

[0004] Therefore, there is an urgent need for a testing method and device for the hydraulic controller in the brake system to automatically complete the test of the hydraulic brake system, simplify the hydraulic brake system test operation, shorten the hydraulic brake system test cycle, and improve the hydraulic brake system test accuracy. Summary of the Invention

[0005] The embodiments of the present application provide a testing method and device for a hydraulic controller in a braking system, which automatically completes the testing of the hydraulic braking system, simplifies the testing operation of the hydraulic braking system, shortens the testing cycle of the hydraulic braking system, and improves the testing accuracy of the hydraulic braking system.

[0006] In a first aspect, an embodiment of the present application provides a method for testing a hydraulic controller in a brake system, the method comprising:

[0007] Based on the program-controlled device, adjusting control parameters of a brake control module and a transfer hydraulic module in the hydraulic brake system, wherein the brake control module is used to deliver brake fluid to a pipeline in the hydraulic brake system, and the transfer hydraulic module is used to control the volume flow of the brake fluid;

[0008] collecting test data generated by a hydraulic controller in the brake control module under the control parameters, wherein the test data is used to characterize the operation of the hydraulic controller under the control parameters;

[0009] Based on the preset operating data, the test results corresponding to the test data are analyzed. The preset operating data is performance standard data for testing the performance of the hydraulic controller, and the test results are used to indicate whether the hydraulic controller meets the performance requirements.

[0010] Optionally, the control parameters include a first electric cylinder stroke and a first current value, and adjusting the control parameters of the brake control module and the transfer hydraulic module in the hydraulic brake system based on the program-controlled device includes:

[0011] Based on the program-controlled device, adjusting a first electric cylinder stroke corresponding to a program-controlled electric cylinder in the brake control module and a first current value of a corresponding solenoid valve in the transfer hydraulic module, wherein the program-controlled electric cylinder is used to provide a stroke input to the hydraulic brake system, and the hydraulic controller pushes the brake fluid in the pipeline according to the input, and the solenoid valve is used to control the volume flow of the brake fluid in the pipeline;

[0012] The collecting of the test data generated by the hydraulic controller in the brake control module under the control parameters includes: executing the following steps for each of the multiple solenoid valves included in the transfer hydraulic module:

[0013] Open the selected solenoid valve, collect the first liquid flow, first liquid volume and valve opening time in the pipeline when the selected solenoid valve is at different first current values, and record the corresponding first current value and its corresponding first liquid flow, first liquid volume and valve opening time as a set of test data.

[0014] Optionally, when the first liquid flow rate exceeds a preset flow rate threshold, the method further includes:

[0015] The first alarm data of the hydraulic controller in the brake control module is collected, and the first liquid flow exceeding the preset flow threshold and its corresponding first liquid volume, first current value, valve opening time, and the first alarm data are recorded as a set of test data.

[0016] Optionally, when the volume of the first liquid exceeds a preset volume threshold, the method further includes:

[0017] The second alarm data of the hydraulic controller in the brake control module is collected, and the first liquid volume exceeding the preset volume threshold and its corresponding first liquid flow, first current value, valve opening time, and the second alarm data are recorded as a set of test data.

[0018] Optionally, the control parameters include a second electric cylinder stroke and a second current value, and adjusting the control parameters of the brake control module and the transfer hydraulic module in the hydraulic brake system based on the program-controlled device includes:

[0019] Based on the program-controlled device, adjusting the second current value of each of the plurality of solenoid valves in the transfer hydraulic module and adjusting the stroke of the second electric cylinder corresponding to the program-controlled electric cylinder in the brake control module until the brake fluid in the pipeline reaches a target fluid volume, the program-controlled electric cylinder being used to provide pressure to the hydraulic brake system to push the brake fluid in the pipeline, and the solenoid valve being used to control the volume flow of the brake fluid in the pipeline;

[0020] Close the multiple solenoid valves, open the air intake solenoid valve in the transfer hydraulic module, and at the same time control the cylinder stroke of the programmable electric cylinder to return to the initial value, and close the air intake solenoid valve when the pressure environment of the hydraulic brake system meets the set pressure conditions.

[0021] Optionally, the control parameters further include a third electric cylinder stroke, and the collecting of test data generated by the hydraulic controller in the brake control module under the control parameters includes:

[0022] The target liquid volume and the corresponding brake pressure data of the hydraulic controller under different third electric cylinder strokes are collected, and the target liquid volume, the third electric cylinder stroke and its corresponding brake pressure data are recorded as a set of test data. The hydraulic controller is used to distribute the pressure in the hydraulic brake system.

[0023] Optionally, when the target liquid volume exceeds a preset volume threshold, the method further includes:

[0024] The third alarm data of the hydraulic controller is collected, and the third alarm data and its corresponding third electric cylinder stroke, brake pressure data and the target liquid volume are recorded as a set of test data.

[0025] Optionally, after completing data collection, the following is also included:

[0026] Based on the program-controlled device, multiple solenoid valves contained in the transfer hydraulic module are opened, and the electric cylinder stroke corresponding to the program-controlled electric cylinder in the brake control module is adjusted to fill and exhaust brake fluid in the hydraulic brake system.

[0027] Optionally, before adjusting the control parameters of the brake control module and the transfer hydraulic module in the hydraulic brake system based on the program-controlled device, the method further includes:

[0028] The test confirmed that the fluid consumption curve of the hydraulic brake system meets the preset curve conditions.

[0029] In a second aspect, an embodiment of the present application provides a testing device for a hydraulic controller in a brake system, wherein the testing device includes a program-controlled device and a hydraulic brake system, wherein the hydraulic brake system includes a brake control module and a transfer hydraulic module. The device includes:

[0030] The program-controlled device is electrically connected to the brake control module and the transfer hydraulic module respectively;

[0031] The brake control module is used to deliver brake fluid to the pipeline in the hydraulic brake system;

[0032] The transfer hydraulic module is used to control the flow rate and volume flow of the brake fluid;

[0033] The programmable control device is used to adjust the control parameters of the brake control module and the transfer hydraulic module, and collect test data generated by the hydraulic controller in the brake control module under the control parameters, and the test data is used to characterize the operation of the hydraulic controller under the control parameters; based on the preset operating data, the test results corresponding to the test data are analyzed, and the test results are used to characterize whether the hydraulic controller meets the performance requirements. The preset operating data is the performance standard data for testing the performance of the hydraulic controller.

[0034] The beneficial effects of this application are as follows:

[0035] In an embodiment of the present application, a method for testing a hydraulic controller in a braking system is provided. In this method, a program-controlled device is provided with simulated data of the braking device of a vehicle (or other equipment equipped with a braking device) to be tested. The program-controlled device is used to control a hydraulic braking system that simulates the actual braking device, and the control parameters of the brake control module and the transfer hydraulic module in the hydraulic braking system are adjusted to collect test data generated by the hydraulic controller under the control parameters. This eliminates the need for manual operation of the braking device in the vehicle or other equipment, simplifying the testing process and shortening the testing cycle. Furthermore, the program-controlled device can precisely control the hydraulic braking system, obtaining accurate test data of the hydraulic controller under the control parameters, and thus obtaining accurate test results. Furthermore, the program-controlled device can store or replace simulated data of the corresponding vehicle or other equipment equipped with a braking device, allowing testing of the braking device of the corresponding vehicle or equipment, thereby improving the versatility of the testing method and simplifying the testing of braking devices of different specifications while ensuring the accuracy of the test results.

[0036] These implementations or other implementations of the present application will be more concise and understandable in the description of the following embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0038] Figure 1 A schematic diagram of an electronic hydraulic brake system provided in an embodiment of the present application;

[0039] Figure 2 A schematic diagram of a testing device for a hydraulic controller in a brake system provided in an embodiment of the present application;

[0040] Figure 3 A line graph showing the relationship between different solenoid valve control currents and hydraulic leakage rates provided in an embodiment of the present application;

[0041] Figure 4 A flowchart of a method for testing a hydraulic controller in a brake system provided in an embodiment of the present application;

[0042] Figure 5 A line graph showing the relationship between the stroke of an electric cylinder and the pressure in a hydraulic controller provided in an embodiment of the present application;

[0043] Figure 6 A schematic diagram of a calibrated pressure-volume curve provided in an embodiment of the present application. DETAILED DESCRIPTION

[0044] To make the objectives, technical solutions, and advantages of this application more clear, this application will be further described in detail below with reference to the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of this application.

[0045] The terms "first," "second," and the like in the specification and claims of this application and in the accompanying drawings are used to distinguish similar objects and are not necessarily used to describe a particular order or sequential sequence. It should be understood that the terms used in this manner are interchangeable where appropriate, such that the embodiments of the invention described herein can be practiced in sequences other than those illustrated or described herein.

[0046] The following explains some of the terms used in the embodiments of the present application to facilitate understanding by those skilled in the art:

[0047] The electronic hydraulic brake system (EHB) works by detecting the driver's braking intention through an electronic pedal sensor and transmitting the signal to the electronic control unit (ECU). After the ECU analyzes the signal, components such as the hydraulic controller and solenoid valves adjust the brake pressure, ultimately achieving precise control of the braking force at each wheel. This system not only improves braking reaction speed and response time, but also enhances the degree of freedom in brake control, thereby improving the vehicle's braking efficiency. Compared with traditional hydraulic systems, the EHB system has a more compact structure, more precise control, and better integration of auxiliary functions such as the electronic parking brake (EPB).

[0048] Hydraulic caliper: installed near the wheel. When the hydraulic brake system converts the pedal force into hydraulic energy, the hydraulic caliper converts the hydraulic energy into mechanical energy to hold the wheel tightly to achieve braking.

[0049] Calibration: Calibration is a key development process that optimizes braking performance (such as response and stability) by adjusting parameters and setting fault thresholds for sensors, pressure, etc. to ensure safe and reliable operation of the system.

[0050] Hydraulic brake system piping, consisting of rigid pipes and flexible hoses connected by connectors, transfers brake fluid from the electric cylinder to the individual wheel brakes. Pipe leaks can cause brake system failures, so brake lines are crucial components of the system and require careful inspection and maintenance.

[0051] Programmable electric cylinder: It is a modular product that integrates a servo motor and a lead screw. It converts the rotational motion of the servo motor into linear motion. At the same time, it converts the best advantages of the servo motor - precise speed control, precise rotational speed control, and precise torque control - into precise speed control, precise position control, and precise thrust control, realizing a new product series of high-precision linear motion.

[0052] Electronic level gauges operate primarily based on buoyancy and magnetic coupling. The sensor probe typically consists of a transmitter and a receiver. When the liquid level changes, the liquid affects the timing and frequency of the signal transmitted from the transmitter to the receiver. The receiver processes the signal through its internal circuitry and calculates the liquid level. Electronic level gauges measure liquid level using electronic measurement technology and typically consist of a sensor and a signal processing unit. The sensor detects the liquid level change and converts it into an electrical signal. The signal processing unit then processes and amplifies the signal, ultimately outputting a standardized electrical signal for a display.

[0053] Hydraulic flow meters measure the flow of hydraulic oil (brake fluid) through a system to ensure proper operation. They help monitor and regulate the flow rate and volume of hydraulic oil (brake fluid), thereby improving production efficiency. The data from these meters can also help identify system faults and provide accurate troubleshooting.

[0054] The following is a brief introduction to the design concept of the embodiment of this application:

[0055] In related technologies, the electronic hydraulic brake system introduces an electronic control unit and a variety of sensors, and uses the motor as the braking force source, making the brake control electrified and intelligent. Figure 1 Figure 1 shows a schematic diagram of an electronic hydraulic brake (EHB) system according to an embodiment of the present application. The electronic hydraulic brake controller 101 provides high-performance braking response, supports brake energy recovery, responds to active driving system braking requests, and can adjust braking feel, making it suitable for a wider range of new energy and traditional fuel vehicles. Furthermore, the electronic hydraulic brake controller 101 integrates the vehicle stability control (ESC) function, improving the safety of the braking system and achieving a higher level of integration. The entire electronic hydraulic brake system consists of a brake pedal unit 102, an electronic hydraulic brake controller 101, a hydraulic caliper 103, a parking actuator 104, an electronic parking switch 105, an inertial measurement unit 106, a wheel speed sensor 107 (marked 107 in the figure is the wheel speed sensor wiring harness, also referred to as sensor wiring 110), a hydraulic brake wiring 108, and a parking actuator control wiring 109.

[0056] The braking force transmission medium of a hydraulic brake system is the brake fluid in the hydraulic lines. Whether the brake fluid in the hydraulic brake controller leaks or contains excessive air directly affects the efficiency of braking force transmission. A malfunction in the hydraulic brake controller can affect the braking force of the entire vehicle, resulting in reduced braking performance and an inability to stop the vehicle. Typical failure modes of hydraulic brake systems include hydraulic line leakage and excessive air in the hydraulic lines. To address these two failure modes, the design process for hydraulic brake controllers must include calibration and testing for air detection and leak detection in hydraulic lines, tailored to the specific vehicle model.

[0057] Because hydraulic parameters in the brake system vary across vehicle models, each failure type requires measurement, calibration, and fault monitoring testing. Current testing methods typically rely on manual procedures, such as opening the brake line connector on the vehicle to allow air into the hydraulic line, or manually controlling a leak in the brake line to measure the hydraulic leakage. Actual project applications have shown that this testing and calibration approach results in complex preparation, long test cycles, and low accuracy.

[0058] In view of this, the embodiment of the present application provides a testing device 200 for a hydraulic controller in a brake system, such as Figure 2 As shown, the test device includes a program-controlled device 201 and a hydraulic brake system 202. The hydraulic brake system includes a brake control module and a transfer hydraulic module 2022, including:

[0059] The program-controlled device 201 is electrically connected to the brake control module and the transfer hydraulic module 2022 respectively;

[0060] a brake control module for delivering brake fluid to the lines in the hydraulic brake system;

[0061] The transfer hydraulic module 2022 is used to control the volume flow of the brake fluid;

[0062] The programmable control device 201 is used to adjust the control parameters of the braking control module and the transfer hydraulic module 2022, and collect the test data generated by the hydraulic controller 2021 in the braking control module under the control parameters. The test data is used to characterize the operation of the hydraulic controller 2021 under the control parameters; based on the preset operating data, the corresponding test results of the test data are analyzed, and the test results are used to characterize whether the hydraulic controller 2021 meets the performance requirements. The preset operating data is the performance standard data for testing the performance of the hydraulic controller.

[0063] In one embodiment, the program-controlled device 201 provides an EHB virtual vehicle operating environment, including vehicle power supply, network communication, etc.

[0064] In one embodiment, the hydraulic controller may also be an electronically controlled auxiliary controller (E-Booster) and a vehicle stability controller (ESC).

[0065] In one embodiment, the above-mentioned program-controlled device 201 can use an automated program to control a hydraulic brake system (also known as a closed-loop measurement and control system) that simulates an actual brake system, support typical hydraulic pipeline air detection, hydraulic pipeline leakage detection, support parameter calibration, alarm threshold testing and consistency verification of the hydraulic controller (also known as the electronic hydraulic brake controller EHB under test).

[0066] In one embodiment, the testing device 200 may be composed of a program-controlled device 201, a program-controlled electric cylinder 2020, a hydraulic controller 2021, a transfer hydraulic module 2022 (including four solenoid valves: an intake solenoid valve 20222, a left rear solenoid valve 20224, a right front solenoid valve 20225, a left front solenoid valve 20226, and a right rear solenoid valve 20227, an air dryer 20221, and a one-way valve 20223), a hydraulic flow meter 2023, an electronic liquid level meter 2024, and four brake calipers 2025, wherein:

[0067] The lines between the program-controlled electric cylinder 2020, the hydraulic controller 2021, the air intake solenoid valve 20222, the left rear solenoid valve 20224 / the right front solenoid valve 20225 / the left front solenoid valve 20226 / the right rear solenoid valve 2022, the hydraulic flow meter 2023, the electronic liquid level meter 2024 and the program-controlled device 201 are electrical lines;

[0068] The lines connecting the four solenoid valves (left rear solenoid valve 20224, right front solenoid valve 20225, left front solenoid valve 20226, right rear solenoid valve 20227) and the hydraulic flow meter 2023 and the electronic liquid level meter 2024 are low-pressure hydraulic lines.

[0069] The line connecting the four solenoid valves, namely the left rear solenoid valve 20224 / the right front solenoid valve 20225 / the left front solenoid valve 20226 / the right rear solenoid valve 20227, and the hydraulic controller 2021 is a high-pressure hydraulic line; the line between the air dryer 20221 and the intake solenoid valve 20222 is an air line.

[0070] In one embodiment, the hydraulic controller 2021 is the device under test, and the fault monitoring logic in the algorithm of the hydraulic controller 2021 is tested, specifically the fault monitoring, the brake fluid leakage detection of the hydraulic brake system and the residual air detection in the hydraulic brake system pipeline.

[0071] In one embodiment, the programmable electric cylinder is connected to the EHB brake pedal interface and can receive instructions from the programmable device to accurately control the speed and stroke of the electric cylinder moving forward and backward, simulating the driver stepping on the brake.

[0072] In one embodiment, the transfer hydraulic module serves as a transfer pipeline for the hydraulic circuit connecting the EHB and the brake caliper, provides a hydraulic one-to-two pipeline, and can be installed with a solenoid valve to provide input and output hydraulic pipelines for the solenoid valve.

[0073] Among them, the four solenoid valves (left rear / right front / left front / right rear) can be controlled by programmable equipment to close and open the solenoid valves; different currents correspond to different solenoid valve openings; the flow of brake fluid in the brake line is controlled by the openings of different solenoid valves.

[0074] The opening of the solenoid valve is reflected in the orifice diameter. According to the hydraulic system flow formula, the hydraulic flow can be converted into:

[0075]

[0076] in, : flow coefficient, : Liquid density (unit: kg / m³), : The pressure difference before and after the throttle hole (unit: Pa), d is the throttle hole diameter of the solenoid valve opening.

[0077] For ease of understanding, the present application embodiment provides a table and a corresponding line graph of the solenoid valve current control leakage rate, as shown in Table 1 below. Under the condition of a 20 bar hydraulic pressure difference, the hydraulic leakage rate corresponding to different solenoid valve control currents is: Figure 3 It is a line chart of the corresponding data in Table 1.

[0078]

[0079] Table 1

[0080] The air dryer is used to dry air before injecting it into the brake lines. Specifically, the air intake solenoid valve is opened when air is injected into the brake lines. Because air contains moisture, the water content of the brake fluid in the brake system must be strictly controlled to avoid excessive moisture that affects braking and test performance. Therefore, when injecting air, it needs to be filtered and dried through the air dryer.

[0081] The function of the one-way valve is to allow air to enter and prevent the brake fluid from flowing back into the outside air.

[0082] The four brake calipers (hydraulic calipers) need to be adjusted according to different test items. Usually, the vehicle manufacturer provides brake calipers and brake lines consistent with mass-produced models to achieve the same brake fluid consumption as the whole vehicle, ensuring the consistency of the hydraulic brake system test method (simulated vehicle test / bench test) in this application and the whole vehicle test hydraulic brake system.

[0083] Hydraulic flow meter, used to measure the current brake fluid flow.

[0084] Electronic fluid level gauge, used to measure the total amount of brake fluid leaked during this test.

[0085] The programmable control device integrates a programmable power supply, industrial control computer, programmable electric cylinder drive and position acquisition board, customized EHB product interface boards (including power supply, communication, digital input and output), vehicle network simulation board, wheel speed sensor simulation board, solenoid valve current regulation board, hydraulic flow meter acquisition board, and electronic hydraulic pressure gauge acquisition board. It serves as the core processing unit of the test system and provides data and display interfaces for EHB product developers. The programmable control device provides a trouble-free environment for the normal operation of the EHB product, simulating the installation of the EHB product in a complete vehicle. Furthermore, the programmable control device is required to control the programmable electric cylinder, acquire sensor position, and measure brake fluid flow and leakage according to the test scripts for EHB hydraulic system leak testing and air testing.

[0086] Based on the above Figure 2 The test device in the present application embodiment provides a test method process for the hydraulic controller in the brake system, such as Figure 4 As shown, including:

[0087] Step 401: Based on the programmable device, adjust the control parameters of the brake control module and the transfer hydraulic module in the hydraulic brake system. The brake control module is used to deliver brake fluid to the pipeline in the hydraulic brake system, and the transfer hydraulic module is used to control the liquid flow of the brake fluid.

[0088] Step 402: Collect test data generated by the hydraulic controller in the brake control module under the control parameters. The test data is used to characterize the operation of the hydraulic controller under the control parameters.

[0089] Step 403: Analyze the test results corresponding to the test data based on the preset operating data. The preset operating data is performance standard data for testing the performance of the hydraulic controller, and the test results are used to indicate whether the hydraulic controller meets the performance requirements.

[0090] In one embodiment, the programmable electric cylinder and hydraulic controller in the brake control module can convert the mechanical energy of the driver's pedal into pressure, pushing the brake fluid into the pipeline. The programmable device can control the operation of the corresponding components and parts in the brake control module, as well as parameters such as pressure.

[0091] In one embodiment, the transfer hydraulic module includes a solenoid valve. Under the control of a programmable device, different current values ​​are supplied to the solenoid valve to obtain different brake fluid flow rates.

[0092] In one embodiment, the control parameters can be set in the program-controlled device. For example, to test the hydraulic brake system of a specific vehicle, the program-controlled device can input the corresponding vehicle simulation data, along with the standard parameters of the hydraulic brake system under normal conditions, and the abnormal parameters that generate an alarm. Alternatively, the control parameters can be generated by the program-controlled device based on the received simulation data of the test item.

[0093] In one embodiment, the preset operating data can be generated when the fault monitoring logic in the hydraulic controller algorithm operates under normal circumstances. Then, under the corresponding control parameters, there are corresponding preset operating data. If the test data deviates from the preset operating data, it can be considered that there is an abnormality in the fault monitoring logic in the hydraulic controller algorithm, otherwise it is normal.

[0094] The above method eliminates the need for manual operation of the braking device in a vehicle or other equipment, simplifying testing operations and shortening test cycles. Furthermore, the program-controlled device precisely controls the hydraulic braking system, obtaining accurate test data and, consequently, accurate test results. Furthermore, the program-controlled device can store or replace simulation data of the corresponding vehicle or other equipment equipped with a braking device, allowing testing of the braking device of the corresponding vehicle or equipment, thereby increasing the versatility of the testing method and simplifying the testing of braking devices of different specifications while ensuring the accuracy of the test results.

[0095] Based on the above Figure 4 In the method flow, an embodiment of the present application provides a brake fluid leakage testing method for a hydraulic brake system, wherein the control parameters include a first electric cylinder stroke and a first current value. In step 401, based on a program-controlled device, the control parameters of a brake control module and a transfer hydraulic module in the hydraulic brake system are adjusted, including:

[0096] Based on the programmable control device, a first electric cylinder stroke corresponding to a programmable electric cylinder in the brake control module and a first current value of a corresponding solenoid valve in the transfer hydraulic module are adjusted. The programmable electric cylinder is used to provide a stroke input to the hydraulic brake system. The hydraulic controller pushes the brake fluid in the pipeline according to this input. The solenoid valve is used to control the volume flow of the brake fluid in the pipeline.

[0097] In step 402, test data generated by the hydraulic controller in the brake control module under control parameters is collected, including: for each of the multiple solenoid valves included in the transfer hydraulic module, performing the following steps:

[0098] Open the selected solenoid valve, collect the first liquid flow, first liquid volume and valve opening time in the pipeline when the selected solenoid valve is at different first current values, and record the corresponding first current value and its corresponding first liquid flow, first liquid volume and valve opening time as a set of test data.

[0099] In one embodiment, the brake fluid leak test process is as follows:

[0100] Step 501, the program-controlled device pushes the EHB brake pedal and maintains it at the set position (the brake pedal displacement can be 5mm, 10mm, 15mm, etc., and can be set as needed. There is no restriction on the specific setting of the displacement here). The EHB converts the brake pedal displacement into the hydraulic brake system pressure. The hydraulic controller feeds back the collected hydraulic brake system pressure to the program-controlled device via the communication bus with the program-controlled device (the line connecting the program-controlled device and the various components in the hydraulic brake system). The program-controlled device determines that its pressure control has reached a stable state based on the change in the pressure value. Here, the embodiment of the present application provides data on the relationship between the electric cylinder stroke and the pressure in the hydraulic controller under standard conditions, as shown in Table 2, and the corresponding line graph of Table 2 is shown in Table 2. Figure 5 :

[0101]

[0102] Table 2

[0103] Step 502: The program-controlled device controls the opening of a single left rear / right front / left front / right rear solenoid valve, and controls the solenoid valve current and adjusts the solenoid valve flow through the current control board; at the same time, data from the hydraulic flow meter and the electronic liquid level meter are collected; wherein, different currents control the brake fluid leakage rate; that is, each time a solenoid valve is adjusted, the current of the solenoid valve is used as a variable, and when the solenoid valve is at different current values, under a certain electric cylinder stroke and hydraulic controller pressure, the brake fluid flow, brake fluid leakage, valve opening time and alarm time corresponding to the solenoid valve are calculated.

[0104] Step 503, the program-controlled device collects the EHB leakage monitoring status in real time; when the EHB triggers a leakage fault, the solenoid valve current, hydraulic flow meter flow, total brake fluid leakage, and valve opening time are recorded as a set of test data.

[0105] Step 504: Adjust the solenoid valve control current, repeat steps 501 to 503, record the measurement data, and draw a curve. Table 3 below shows a test result data provided by the embodiment of the present application:

[0106]

[0107] Table 3

[0108] Step 505: Control different brake pedal displacement positions, repeat steps 501 to 504, record measurement data, and draw a curve.

[0109] Step 506: Select the left rear / right front / left front / right rear solenoid valves and test them in sequence, and repeat steps 501 to 505.

[0110] Based on the testing method of the hydraulic brake system of the present application, the entire testing process can be automated through programming.

[0111] Based on the above-mentioned brake fluid leakage testing method for a hydraulic brake system, an embodiment of the present application provides a brake fluid leakage testing method when a first fluid flow rate exceeds a preset flow rate threshold, further comprising:

[0112] Collect the first alarm data of the hydraulic controller in the brake control module, record the first liquid flow exceeding the preset flow threshold and its corresponding first liquid volume, first current value, valve opening time, and the first alarm data as a set of test data.

[0113] In one embodiment, the condition for determining a rapid brake fluid leak is that the hydraulic controller should issue a brake fluid leak alarm when the brake fluid leakage rate reaches 0.5 ml / s and the leakage duration is 500 ms. For example, the data in Table 2 above can be compared with the leakage calibration parameters.

[0114] Based on the above-mentioned brake fluid leakage testing method for a hydraulic brake system, an embodiment of the present application provides a brake fluid leakage testing method when a first liquid volume exceeds a preset volume threshold, further comprising:

[0115] Collect the second alarm data of the hydraulic controller in the brake control module, record the first liquid volume exceeding the preset volume threshold and its corresponding first liquid flow, first current value, valve opening time, and the second alarm data as a set of test data.

[0116] In one embodiment, the brake fluid slow leakage determination condition is: after the total amount of brake fluid leakage detected exceeds 1 ml, the hydraulic controller should issue a brake fluid leakage alarm. For example, the data in Table 2 above can be compared with the leakage calibration parameters.

[0117] Based on the above Figure 4 In the method flow, an embodiment of the present application provides a residual air testing method for a hydraulic brake system, wherein the control parameters include a second electric cylinder stroke and a second current value. In step 401, based on a program-controlled device, the control parameters of a brake control module and a transfer hydraulic module in the hydraulic brake system are adjusted, including:

[0118] Based on the programmable control device, a second current value of each of the plurality of solenoid valves in the transfer hydraulic module is adjusted, and a second electric cylinder stroke corresponding to the programmable electric cylinder in the brake control module is adjusted until the brake fluid in the pipeline reaches a target liquid volume. The programmable electric cylinder is used to provide pressure to the hydraulic brake system to push the brake fluid in the pipeline, and the solenoid valve is used to control the volume flow of the brake fluid in the pipeline;

[0119] Close multiple solenoid valves, open the air intake solenoid valve in the transfer hydraulic module, and at the same time control the electric cylinder stroke of the programmable electric cylinder to return to the initial value, and close the air intake solenoid valve when the pressure environment of the hydraulic brake system meets the set pressure conditions.

[0120] Based on the above-mentioned residual air test method for the hydraulic brake system, the control parameters also include the third electric cylinder stroke. In step 402, test data generated by the hydraulic controller in the brake control module under the control parameters is collected, including:

[0121] The target liquid volume and the corresponding brake pressure data of the hydraulic controller under different third electric cylinder strokes are collected, and the target liquid volume, the third electric cylinder stroke and its corresponding brake pressure data are recorded as a set of test data. The hydraulic controller is used to distribute the pressure in the hydraulic brake system.

[0122] In one embodiment, the residual air test of the hydraulic brake system is performed as follows:

[0123] Step 601: The program-controlled device controls the left rear / right front / left front / right rear solenoid valves to open, and adjusts the solenoid valve current and controls the solenoid valve flow through the current control board; at the same time, the program-controlled device collects data from the electronic liquid level meter.

[0124] Step 602: The program-controlled device controls the electric cylinder to push the EHB brake pedal and maintain it at the set position (5 mm). At the same time, the program-controlled device collects the total amount of brake fluid from the electronic liquid level gauge. When the target brake fluid volume (for example, 2 ml) is reached, the left rear / right front / left front / right rear solenoid valves are closed.

[0125] Step 603: The program-controlled device controls the air solenoid valve to open and simultaneously controls the electric cylinder to return to the EHB brake pedal un-pressed position (0 mm). As the electric cylinder returns, the hydraulic controller also draws back brake fluid. Because the air solenoid valve is open, a fixed amount of air is drawn in. After the brake system hydraulic pressure stabilizes at 0 bar for 1 second, the air solenoid valve closes.

[0126] Step 604: The program-controlled device pushes the EHB brake pedal and maintains it at a set position (5mm, 10mm, 15mm). The brake pressure fed back by the hydraulic controller determines that the control pressure has reached a stable state.

[0127] Step 605: Repeat step 4) to adjust different brake pedal positions and record measurement data.

[0128] Step 606: The program controls the four solenoid valves (left rear / right front / left front / right rear) to open in sequence, and at the same time controls the electric cylinder to push the brake pedal push rod of the EHB, so that the brake fluid flows from the oil tank of the hydraulic controller through the four solenoid valves, through the hydraulic flow meter, and into the electronic liquid level meter, completing the filling and exhaust of the brake fluid in the measuring circuit.

[0129] Step 607: Repeat steps 1) to 6) to adjust the brake fluid discharge amount until the brake system residual air test threshold is detected. Record the measurement data.

[0130] This embodiment of the present application provides an example of test results, as shown in Table 4 below:

[0131]

[0132] Table 4

[0133] Based on the above-mentioned residual air testing method for a hydraulic brake system, an embodiment of the present application provides a residual air testing method when a target liquid volume exceeds a preset volume threshold, further comprising:

[0134] The third alarm data of the hydraulic controller is collected, and the third alarm data and its corresponding third electric cylinder stroke, brake pressure data and target liquid volume are recorded as a set of test data.

[0135] In one embodiment, the residual air alarm condition is: if the residual air in the brake line exceeds 4 ml, the EHB will issue a residual air alarm signal within 500 ms. For example, the data in Table 3 above can be compared with the residual air calibration parameters.

[0136] In each of the above-mentioned residual air testing methods, after completing data collection, it also includes: based on the programmable device, opening the multiple solenoid valves contained in the transfer hydraulic module, and adjusting the cylinder stroke corresponding to the programmable electric cylinder in the brake control module, and filling and exhausting the hydraulic brake system with brake fluid.

[0137] Based on the above architecture and the corresponding test method processes, an embodiment of the present application provides a pre-test preparation method. Before adjusting the control parameters of the brake control module and the transfer hydraulic module in the hydraulic brake system based on the programmable device in step 401, it also includes: testing to confirm that the fluid consumption curve of the hydraulic brake system meets the preset curve conditions.

[0138] In one embodiment, the test preparation:

[0139] 1) Replace the brake caliper and brake line. Use the original brake caliper and brake line of the target vehicle. Exhaust the entire brake line and add brake fluid. Confirm that the hydraulic system fluid consumption curve in the test bench is consistent with that of the vehicle. This can be determined by measuring the pressure-volume curve. Check the hydraulic brake system fluid consumption. The recommended error is ±10%. Figure 6 As shown in FIG. 1 , a schematic diagram of a calibrated pressure-volume curve provided in an embodiment of the present application (the vertical axis is the brake fluid leakage volume (ml) - volume [ml], the horizontal axis is the pressure (bar) - pressure [bar], wherein, Figure 6 (a) is the pressure-volume curve of the hydraulic line leakage test of the front wheel brake system (Front Brake (incl bose+pipo)). Figure 6 (b) is the pressure-volume curve of the hydraulic line leakage test of the rear wheel brake system (rear brake (incl bose + pipo)).

[0140] 2) Control the four solenoid valves (left rear / right front / left front / right rear) to open in sequence, and at the same time control the programmable electric cylinder to push the brake pedal push rod of the EHB, so that the brake fluid flows from the oil tank of the hydraulic controller through the four solenoid valves, through the hydraulic flow meter, and into the electronic liquid level meter, completing the brake fluid filling and exhaust of the measuring circuit.

[0141] The entire testing process, including test preparation, brake fluid leakage testing, and brake system residual air testing, can be automated through programming within the programmable control equipment. This maximizes the verification of leakage parameters, enabling rapid closed-loop testing. This improves the accuracy and coverage of brake control system fault diagnosis, effectively shortens fault testing time, and ensures vehicle operational safety. It enables multi-dimensional fault diagnosis of system components, offering strong versatility and scalability. This provides strong support for system maintenance and management, reducing maintenance costs.

[0142] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may take the form of an entirely hardware embodiment, an entirely software embodiment, or an embodiment combining software and hardware. Furthermore, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to magnetic disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0143] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the present application. It should be understood that each process and / or block in the flowchart and / or block diagram, as well as the combination of processes and / or blocks in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0144] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0145] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operational steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0146] Obviously, those skilled in the art may make various changes and modifications to this application without departing from the spirit and scope of this application. Thus, if these modifications and variations of this application fall within the scope of the claims of this application and their equivalents, this application is intended to include these modifications and variations.

Claims

1. A method for testing a hydraulic controller in a brake system, characterized in that: Applicable to a test device, the test device includes a program-controlled device and a hydraulic brake system, the hydraulic brake system includes a brake control module, a transfer hydraulic module and multiple brake calipers, the brake control module includes a hydraulic controller for the test piece, the hydraulic controller and the multiple brake calipers correspond to the same vehicle model, the method includes: Based on the program-controlled device, adjusting control parameters of the brake control module and the transfer hydraulic module, the brake control module being used to deliver brake fluid to the pipeline in the hydraulic brake system, and the transfer hydraulic module being used to control the volume flow of the brake fluid; collecting test data generated by the hydraulic controller under the control parameters, wherein the test data is used to characterize the operation of the hydraulic controller under the control parameters; Analyzing test results corresponding to the test data based on preset operating data, wherein the preset operating data is performance standard data for verifying the performance of the hydraulic controller, and the test results are used to indicate whether the hydraulic controller meets performance requirements; The control parameters include a first electric cylinder stroke and a first current value. The control parameters of the brake control module and the transfer hydraulic module are adjusted based on the program-controlled device, including: Based on the program-controlled device, adjusting a first electric cylinder stroke corresponding to a program-controlled electric cylinder in the brake control module and a first current value of a corresponding solenoid valve in the transfer hydraulic module, wherein the program-controlled electric cylinder is used to provide a stroke input to the hydraulic brake system, and the hydraulic controller pushes the brake fluid in the pipeline according to the input, and the solenoid valve is used to control the volume flow of the brake fluid in the pipeline; The collecting of the test data generated by the hydraulic controller under the control parameters includes: executing the following steps for each of the plurality of solenoid valves included in the transfer hydraulic module: Open the selected solenoid valve, collect the first liquid flow, first liquid volume and valve opening time in the pipeline when the selected solenoid valve is at different first current values, and record the corresponding first current value and its corresponding first liquid flow, first liquid volume and valve opening time as a set of test data.

2. The method according to claim 1, wherein When the first liquid flow rate exceeds a preset flow rate threshold, the method further includes: The first alarm data of the hydraulic controller is collected, and the first liquid flow exceeding the preset flow threshold and its corresponding first liquid volume, first current value, valve opening time, and the first alarm data are recorded as a set of test data.

3. The method according to claim 1, wherein When the volume of the first liquid exceeds a preset volume threshold, the method further includes: The second alarm data of the hydraulic controller is collected, and the first liquid volume exceeding the preset volume threshold and its corresponding first liquid flow, first current value, valve opening time, and the second alarm data are recorded as a set of test data.

4. The method according to claim 1, wherein The control parameters include the second electric cylinder stroke and the second current value. The control parameters of the brake control module and the transfer hydraulic module are adjusted based on the program-controlled device, including: Based on the program-controlled device, adjusting the second current value of each of the plurality of solenoid valves in the transfer hydraulic module and adjusting the stroke of the second electric cylinder corresponding to the program-controlled electric cylinder in the brake control module until the brake fluid in the pipeline reaches a target fluid volume, the program-controlled electric cylinder being used to provide pressure to the hydraulic brake system to push the brake fluid in the pipeline, and the solenoid valve being used to control the volume flow of the brake fluid in the pipeline; Close the multiple solenoid valves, open the air intake solenoid valve in the transfer hydraulic module, and at the same time control the cylinder stroke of the programmable electric cylinder to return to the initial value, and close the air intake solenoid valve when the pressure environment of the hydraulic brake system meets the set pressure conditions.

5. The method according to claim 4, wherein The control parameters also include a third electric cylinder stroke, and the collecting of test data generated by the hydraulic controller under the control parameters includes: The target liquid volume and the corresponding brake pressure data of the hydraulic controller under different third electric cylinder strokes are collected, and the target liquid volume, the third electric cylinder stroke and its corresponding brake pressure data are recorded as a set of test data. The hydraulic controller is used to distribute the pressure in the hydraulic brake system.

6. The method according to claim 5, wherein In the case where the target liquid volume exceeds a preset volume threshold, the method further includes: The third alarm data of the hydraulic controller is collected, and the third alarm data and its corresponding third electric cylinder stroke, brake pressure data and the target liquid volume are recorded as a set of test data.

7. The method according to any one of claims 4 to 6, wherein: After completing data collection, it also includes: Based on the program-controlled device, multiple solenoid valves contained in the transfer hydraulic module are opened, and the electric cylinder stroke corresponding to the program-controlled electric cylinder in the brake control module is adjusted to fill and exhaust brake fluid in the hydraulic brake system.

8. The method according to any one of claims 1 to 6, wherein: Before adjusting the control parameters of the brake control module and the transfer hydraulic module based on the program-controlled device, the method further includes: The test confirmed that the fluid consumption curve of the hydraulic brake system meets the preset curve conditions.

9. A testing device for a hydraulic controller in a brake system, characterized in that: The test device includes a program-controlled device and a hydraulic brake system. The hydraulic brake system includes a brake control module, a transfer hydraulic module, and multiple brake calipers. The brake control module includes a hydraulic controller for the test piece. The hydraulic controller and the multiple brake calipers correspond to the same vehicle model, including: The program-controlled device is electrically connected to the brake control module and the transfer hydraulic module respectively; The brake control module is used to deliver brake fluid to the pipeline in the hydraulic brake system; The transfer hydraulic module is used to control the volume flow of the brake fluid; The program-controlled device is used to adjust the control parameters of the brake control module and the transfer hydraulic module, and collect test data generated by the hydraulic controller under the control parameters, the test data being used to characterize the operation of the hydraulic controller under the control parameters; based on preset operation data, the test results corresponding to the test data are analyzed, the test results being used to characterize whether the hydraulic controller meets the performance requirements, and the preset operation data are performance standard data for testing the performance of the hydraulic controller; the program-controlled device is specifically used to, wherein the control parameters include a first electric cylinder stroke and a first current value, adjust the first electric cylinder stroke corresponding to the program-controlled electric cylinder in the brake control module and the first current value of the corresponding solenoid valve in the transfer hydraulic module, the program-controlled electric cylinder being used to provide a stroke input to the hydraulic brake system, the hydraulic controller pushing the brake fluid in the pipeline according to this input, and the solenoid valve being used to control the volume flow of the brake fluid in the pipeline; For each of the multiple solenoid valves included in the transfer hydraulic module, perform the following steps: Open the selected solenoid valve, collect the first liquid flow, first liquid volume and valve opening time in the pipeline when the selected solenoid valve is at different first current values, and record the corresponding first current value and its corresponding first liquid flow, first liquid volume and valve opening time as a set of test data.

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