An automatic verification device and method for the load-bearing capacity of an air pump assembly.

Abstract

This invention relates to the field of new energy bus technology, and in particular to an automatic verification device and method for the load-bearing capacity of an air pump assembly, comprising: a control unit, an air pump, an air tank, an environmental chamber, a high-voltage power supply cabinet, an oscilloscope, and four host computers; wherein, the environmental chamber is used to house the air pump and is connected to the host computer three via a CAN3 line for communication, and the host computer three can control the environmental chamber to provide the required ambient temperature for testing; this invention simulates real vehicle operating conditions in a laboratory environment, and can complete the load-bearing capacity verification without installation on the vehicle, with a latent fault detection rate of 98%, which can avoid operational accidents caused by air pump assembly failure after installation, and ensure the driving safety of new energy buses; compared with traditional real vehicle operation verification, the single test cycle of this invention is reduced from 1 minute to 20 seconds, improving efficiency several times; at the same time, it reduces the maintenance and downtime costs of faulty vehicles, and reduces the production and operation expenses of enterprises.

Description

Technical Field

[0001] This invention relates to the field of new energy bus technology, and in particular to an automatic verification device and method for the load-bearing capacity of an air pump assembly. Background Technology

[0002] The air pump assembly of new energy buses is a key component to ensure the normal operation of the vehicle's braking, suspension and other systems. It needs to frequently perform load-bearing and unloading actions according to the actual operation needs of the vehicle, and its load-bearing capacity directly affects the vehicle's operational safety.

[0003] In existing technologies, the load-bearing capacity verification of air pump assemblies can only be completed through actual vehicle operation after the assembly is installed. This verification method has obvious drawbacks: First, fault detection is delayed. If there is a hidden fault in the air pump assembly, it will only be exposed when the vehicle is in operation, which may lead to breakdowns during operation and affect driving safety. Second, the verification efficiency is low. The actual vehicle operation verification cycle is long, making it impossible to quickly test the assembly performance in batches. Third, the operating conditions are uncontrollable. The actual vehicle operating environment and load fluctuations are random, making it difficult to reproduce specific fault scenarios to analyze the causes.

[0004] Based on the above background, an automatic verification device and method for the load-bearing capacity of an air pump assembly are proposed to solve the problem. Summary of the Invention

[0005] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the description and other accompanying drawings.

[0006] The purpose of this invention is to overcome the above-mentioned shortcomings and provide an automatic verification device and method for the load-bearing capacity of an air pump assembly.

[0007] To achieve the above objectives, the technical solution of the present invention is: an automatic verification device for the load-bearing capacity of an air pump assembly, comprising: a control unit, an air pump, an air tank, an environmental chamber, a high-voltage power supply cabinet, an oscilloscope, and four host computers; wherein, The environmental chamber is used to house the air pump and is connected to the host computer via CAN3 line. The host computer can control the environmental chamber to provide the required ambient temperature for the test. The high-voltage power supply cabinet is connected to the control unit via positive and negative power lines, and communicates with the host computer via CAN2 line. The host computer can control the high-voltage power supply cabinet to output DC high voltage to the control unit. The control unit is connected to the air pump via a three-phase line and communicates with the host computer via a CAN1 line. The host computer can control the control unit to output three-phase AC power to the air pump. The air pump is connected to the air tank through an air pipe. The air tank is equipped with a pressure sensor and is connected to the host computer 4 via a CAN4 line. The pressure sensor can detect the pressure of the air tank and feed it back to the host computer 1 and the host computer 4. The host computer 4 can control the air release valve of the air tank to release air and reduce pressure according to the test requirements.

[0008] The oscilloscope is used to acquire the input and output current waveforms of the control unit and feed them back to the host computer.

[0009] In some embodiments, the device has a built-in CAN vehicle communication protocol interface, which supports data interaction and verification with the vehicle control system.

[0010] In some embodiments, the environmental chamber can simulate a variety of typical environmental parameters, with a temperature control accuracy of 0.1℃; the pressure fluctuation simulation accuracy of the gas storage tank is ±0.5kPa, and the frequency response bandwidth is extended to 200Hz.

[0011] In some embodiments, an intelligent diagnostic system is also included, which has a built-in fault feature library that can identify control unit faults and abnormal operation of the air pump.

[0012] In some embodiments, an adaptive testing module is also included, which is a test strategy optimization module based on reinforcement learning and can dynamically adjust the load curve according to historical test data.

[0013] An automatic verification method for the load-bearing capacity of an air pump assembly, using an automatic verification device for the load-bearing capacity of an air pump assembly, includes the following steps: S1: Host computer 3 sends a control signal to the environmental chamber via CAN3 line to adjust the temperature of the environmental chamber to the required test value; Host computer 2 sends a control signal to the high-voltage power cabinet via CAN2 line to control the high-voltage power cabinet to output DC high voltage to the control unit. S2: The host computer detects the pressure value of the air tank. When the air pressure value fed back by the pressure sensor is ≥0.78MPa, the host computer sends an enable signal to the control unit through the CAN1 line. The control unit outputs three-phase AC power to the air pump, the air pump starts and fills the air tank with air. S3: The pressure sensor monitors the pressure of the gas tank in real time. When the gas pressure value is ≥1MPa, the host computer controls the gas tank vent valve to open and release gas through the CAN4 line; when the gas pressure value is <0.78MPa, the host computer controls the vent valve to close. S4: The oscilloscope acquires the input and output current waveforms of the control unit in real time and feeds them back to the host computer. The host computer combines the pressure data and current waveforms to determine whether there is a fault. S5: Repeat steps S2-S4 for N loops, and generate a test report after the loop ends.

[0014] In some embodiments, in step S1, the temperature adjustment range of the environmental chamber covers the extremely cold to hot and humid environment of the actual operation of the new energy bus, with an adjustment accuracy of 0.1℃.

[0015] In some embodiments, in step S2, the enable signal sent by the host computer follows a preset automatic control protocol. The automatic control protocol is defined as follows: ID1=X (sender is host computer), BYTE0 / BIT1 is the enable instruction, and BYTE0 / BIT2 is the disable instruction; ID2=Y (receiver is control unit), BYTE1 / BIT2 is the operation feedback signal, BYTE1 / BIT3 is the shutdown feedback signal, and BYTE1 / BIT4 is the fault feedback signal.

[0016] In some embodiments, in step S2, after the control unit receives the enable command, the enable operation time is 10 seconds, and then it is switched to the disabled state and stopped for 10 seconds. The time parameter can be customized and adjusted according to the test requirements.

[0017] In some embodiments, in step S2, the host computer interacts with the vehicle control system via the CAN vehicle communication protocol to simulate the control logic of the real vehicle.

[0018] By employing the above-described automatic verification device and method, the beneficial effects of the present invention are: 1. Early detection of faults and reduction of operational risks: This invention simulates real vehicle operating conditions in a laboratory environment and can complete load capacity verification without loading the vehicle. The detection rate of latent faults reaches 98%, which can avoid operational accidents caused by air pump assembly failure after loading the vehicle and ensure the driving safety of new energy buses. 2. Improve verification efficiency and reduce costs: Compared with traditional real-vehicle operation verification, the single test cycle of this invention is reduced from 1 minute to 20 seconds, which is several times more efficient; at the same time, it reduces the repair and downtime costs of faulty vehicles and reduces the production and operation expenses of enterprises. 3. High testing accuracy, closely aligned with real vehicle requirements: The device achieves temperature control accuracy of 0.1℃ and pressure fluctuation accuracy of ±0.5kPa, and supports digital twin operating condition simulation, capable of reproducing various real vehicle scenarios such as extreme cold and humid heat; the reinforcement learning-based test strategy optimization module can adjust the test plan according to the characteristics of different batches of air pump assemblies, improving the verification's relevance. 4. High degree of automation and reduced manual intervention: The entire verification process is controlled by multiple host computers in a coordinated manner, eliminating the need for manual operation of pressure valves and data recording, thus avoiding human error; fault diagnosis and shutdown actions are executed automatically, further improving test reliability.

[0019] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure.

[0020] Undoubtedly, such and other objects of the present invention will become more apparent after the following detailed description of the preferred embodiments, which are illustrated in various accompanying drawings and figures.

[0021] To make the above-mentioned beneficial effects and other objects, features and advantages of the present invention more apparent and understandable, one or more preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0022] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0023] In the accompanying drawings, the same parts use the same reference numerals, and the drawings are schematic and not necessarily drawn to actual scale.

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only one or more embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on such drawings without creative effort.

[0025] Explanation of key figure labels: Figure 1 This is a schematic diagram of the principle of an automatic verification device and method for the load-bearing capacity of an air pump assembly according to the present invention. Figure 2 This is a test flowchart of an automatic verification device and method for the load-bearing capacity of an air pump assembly according to the present invention. Detailed Implementation

[0026] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings and examples, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly. It should be noted that, as long as there is no conflict, the various embodiments and features in the various embodiments of the present invention can be combined with each other, and the resulting technical solutions are all within the protection scope of the present invention.

[0027] Furthermore, numerous specific details are set forth in the following description for illustrative purposes to provide a thorough understanding of the embodiments of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without the specific details or particular methods described herein.

[0028] Please see Figure 1-2This invention provides an automatic verification device for the load-bearing capacity of an air pump assembly, comprising: a control unit, an air pump, an air tank, an environmental chamber, a high-voltage power supply cabinet, an oscilloscope, and four host computers; wherein, The environmental chamber is used to house the air pump and is connected to the host computer via CAN3 line. The host computer can control the environmental chamber to provide the required ambient temperature for the test. The high-voltage power supply cabinet is connected to the control unit via positive and negative power lines, and communicates with the host computer via CAN2 line. The host computer can control the high-voltage power supply cabinet to output DC high voltage to the control unit. The control unit is connected to the air pump via a three-phase line and communicates with the host computer via a CAN1 line. The host computer can control the control unit to output three-phase AC power to the air pump. The air pump is connected to the air tank through an air pipe. The air tank is equipped with a pressure sensor and is connected to the host computer 4 via a CAN4 line. The pressure sensor can detect the pressure of the air tank and feed it back to the host computer 1 and the host computer 4. The host computer 4 can control the air release valve of the air tank to release air and reduce pressure according to the test requirements.

[0029] The oscilloscope is used to acquire the input and output current waveforms of the control unit and feed them back to the host computer.

[0030] During use, initialization is performed first. The host computer adjusts the environmental chamber to the test temperature, and the host computer controls the high-voltage power cabinet to output DC high voltage to the control unit. Then, air control is performed. When the air tank pressure is ≥0.78MPa, the host computer sends an enable command, and the control unit drives the air pump to inflate. The enabled operation lasts for a few seconds, and then switches to the disabled state and stops for a few seconds. When the air tank pressure is ≥1MPa, the host computer controls the vent valve to vent. When the air pressure is <0.78MPa, the vent valve is closed, forming a pressure closed-loop control. During the process, the oscilloscope collects the current waveform in real time and feeds back the data through the control unit. When a fault is reported or the host computer identifies an abnormality, it immediately stops and records the fault. This realizes a three-in-one loading verification platform for the control unit, air pump assembly, and pressure vessel, thereby simulating the actual vehicle conditions in advance to reduce the failure rate after installation and ensure normal vehicle operation.

[0031] According to some embodiments of this application, optionally, the device has a built-in CAN vehicle communication protocol interface, supporting data interaction and verification with the vehicle control system. It has connections for each CAN line, enabling data exchange with the vehicle control system and simulating real vehicle control logic.

[0032] According to some embodiments of this application, optionally, the environmental chamber can simulate various typical environmental parameters, with a temperature control accuracy of 0.1℃; the pressure fluctuation simulation accuracy of the gas storage tank reaches ±0.5kPa, and the frequency response bandwidth is extended to 200Hz. The environmental chamber can simulate typical environments such as extreme cold and humid heat, thereby reproducing various specific fault scenarios.

[0033] According to some embodiments of this application, optionally, the device further includes an intelligent diagnostic system, which has a built-in fault feature database. This system has the function of identifying control unit faults and abnormal operation of the air pump.

[0034] According to some embodiments of this application, optionally, the device further includes an adaptive testing module, which is based on a reinforcement learning-based test strategy optimization module. This module dynamically adjusts the load curve based on historical test data.

[0035] An automatic verification method for the load-bearing capacity of an air pump assembly, using an automatic verification device for the load-bearing capacity of an air pump assembly, includes the following steps: S1: The third host computer sends a control signal to the environmental chamber via CAN3 line to adjust the temperature of the environmental chamber to the required test value; the second host computer sends a control signal to the high-voltage power supply cabinet via CAN2 line to control the high-voltage power supply cabinet to output DC high voltage to the control unit.

[0036] In step S1, the environmental chamber is adjusted to the target temperature (such as -30℃ extreme cold environment or 45℃ humid heat environment) according to the test requirements; the host computer controls the high-voltage power cabinet to output DC high voltage to the control unit to simulate the power supply status of the actual vehicle.

[0037] S2: The host computer detects the pressure value of the air tank. When the air pressure value fed back by the pressure sensor is ≥0.78MPa, the host computer sends an enable signal to the control unit through the CAN1 line. The control unit outputs three-phase AC power to the air pump, which starts and fills the air tank with air.

[0038] In step S2, the host computer obtains the pressure of the air tank through the pressure sensor. If the pressure is ≥0.78MPa and there is no fault signal, it sends an enable signal to the control unit through the CAN1 line. After receiving the signal, the control unit outputs three-phase AC power to drive the air pump assembly to work and pump air into the air tank.

[0039] S3: The pressure sensor monitors the pressure of the gas tank in real time. When the gas pressure value is ≥1MPa, the host computer controls the gas tank vent valve to open and release gas through the CAN4 line; when the gas pressure value is <0.78MPa, the host computer controls the vent valve to close.

[0040] In step S3, the pressure sensor provides real-time feedback on the air tank pressure: when the pressure is ≥1MPa, the host computer controls the vent valve to open and release air, simulating the unloading process of the actual vehicle; when the pressure is <0.78MPa, the host computer controls the vent valve to close, and the air pump assembly continues to pump air under load, forming a pressure closed-loop control.

[0041] S4: The oscilloscope acquires the input and output current waveforms of the control unit in real time and feeds them back to the host computer. The host computer combines the pressure data and current waveforms to determine whether there is a fault.

[0042] In step S4, the oscilloscope acquires the current waveform of the control unit and feeds it back to the host computer. The intelligent diagnostic system compares the waveform data with the fault feature database to determine whether there is a hidden fault (such as abnormal current fluctuation). If a fault is found, the control unit immediately reports a fault code and requests the host computer to perform a shutdown action to prevent the fault from escalating.

[0043] S5: Repeat steps S2-S4 for N times (N is the preset number of test requirements), and generate a test report after the loop ends.

[0044] In step S5, steps S2-S4 are repeated N times according to the test requirements. Each time, the system is enabled for 10 seconds and disabled for 10 seconds (the time can be adjusted as needed). The test strategy optimization module dynamically adjusts the load parameters for the next cycle based on the pressure and current data of each cycle. After the cycle is completed, the system automatically generates a verification report, indicating whether the load capacity meets the standard and the fault record.

[0045] According to some embodiments of this application, optionally, in step S1, the temperature adjustment range of the environmental chamber covers the extremely cold to humid and hot environment of the actual operation of the new energy bus, and the adjustment accuracy is 0.1℃.

[0046] According to some embodiments of this application, optionally, in step S2, the enable signal sent by the host computer follows a preset automatic control protocol. The automatic control protocol is defined as follows: ID1=X (sender is host computer), BYTE0 / BIT1 is the enable instruction, and BYTE0 / BIT2 is the disable instruction; ID2=Y (receiver is control unit), BYTE1 / BIT2 is the operation feedback signal, BYTE1 / BIT3 is the shutdown feedback signal, and BYTE1 / BIT4 is the fault feedback signal. This automatic control protocol ensures the coordination of all modules. When the gas pressure in the storage tank is ≥0.78MPa, the host computer sends an enable command (ID1=X, BYTE0 / BIT1), and the control unit drives the air pump to inflate the tank. After enabling for 10 seconds, the system switches to the disabled state and stops for 10 seconds (the time can be customized). During fault monitoring, the oscilloscope collects the current waveform in real time, and the intelligent diagnostic system compares the data. If the control unit reports a fault (ID2=Y, BYTE1 / BIT4) or the host computer identifies an abnormality, the system immediately stops and records the fault to prevent equipment damage.

[0047] According to some embodiments of this application, optionally, in step S2, after the control unit receives the enable command, the enable operation time is 10 seconds, followed by a 10-second shutdown in a deactivated state. The time parameter can be customized and adjusted according to test requirements. Each enable operation lasts 10 seconds, and the deactivated shutdown lasts 10 seconds (the time can be adjusted as needed).

[0048] According to some embodiments of this application, optionally, in step S2, the host computer interacts with the vehicle control system through the CAN vehicle communication protocol to simulate the control logic of the real vehicle.

[0049] It should be understood that the embodiments disclosed herein are not limited to the specific processing steps or materials disclosed herein, but should be extended to equivalent substitutions of such features as understood by those skilled in the art. It should also be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0050] The term "embodiment" in this specification refers to a specific feature or characteristic described in connection with an embodiment that is included in at least one embodiment of the invention. Therefore, phrases or "embodiments" appearing in various places throughout the specification do not necessarily refer to the same embodiment.

[0051] Furthermore, the described features or characteristics can be incorporated into one or more embodiments in any other suitable manner. In the above description, specific details, such as thickness, quantity, etc., are provided to provide a comprehensive understanding of embodiments of the invention. However, those skilled in the art will understand that the invention can be implemented without the aforementioned specific details or may be implemented using other methods, components, materials, etc.

Claims

1. An apparatus for automatically verifying the load capacity of a pump assembly, comprising: include: Control unit, air pump, air tank, environmental chamber, high-voltage power supply cabinet, oscilloscope, and host computer (units one through four); among which, The environmental chamber is used to house the air pump and is connected to the host computer via CAN3 line. The host computer can control the environmental chamber to provide the required ambient temperature for the test. The high-voltage power supply cabinet is connected to the control unit via positive and negative power lines, and communicates with the host computer via CAN2 line. The host computer can control the high-voltage power supply cabinet to output DC high voltage to the control unit. The control unit is connected to the air pump via a three-phase line and communicates with the host computer via a CAN1 line. The host computer can control the control unit to output three-phase AC power to the air pump. The air pump is connected to the air tank through an air pipe. The air tank is equipped with a pressure sensor and is connected to the host computer 4 via a CAN4 line. The pressure sensor can detect the pressure of the air tank and feed it back to the host computer 1 and the host computer 4. The host computer 4 can control the air release valve of the air tank to release air and reduce pressure according to the test requirements. The oscilloscope is used to acquire the input and output current waveforms of the control unit and feed them back to the host computer. The device has a built-in CAN vehicle communication protocol interface, which supports data interaction and verification with the vehicle control system. It also includes an intelligent diagnostic system, which has a built-in fault feature database that can identify control unit faults and abnormal operation of the air pump. It also includes an adaptive testing module, which is a test strategy optimization module based on reinforcement learning, and can dynamically adjust the load curve according to historical test data.

2. An automatic verification device for the load capacity of a pump assembly according to claim 1, characterized in that The environmental chamber can simulate a variety of typical environmental parameters, with a temperature control accuracy of 0.1℃; the pressure fluctuation simulation accuracy of the gas storage tank is ±0.5kPa, and the frequency response bandwidth is extended to 200Hz.

3. The method for automatically verifying the load carrying capacity of a pump assembly, using the device for automatically verifying the load carrying capacity of a pump assembly according to any one of claims 1-2, characterized in that, Includes the following steps: S1: Host computer 3 sends a control signal to the environmental chamber via CAN3 line to adjust the temperature of the environmental chamber to the required test value; Host computer 2 sends a control signal to the high-voltage power cabinet via CAN2 line to control the high-voltage power cabinet to output DC high voltage to the control unit. S2: The host computer detects the pressure value of the air tank. When the air pressure value fed back by the pressure sensor is ≥0.78MPa, the host computer sends an enable signal to the control unit through the CAN1 line. The control unit outputs three-phase AC power to the air pump, the air pump starts and fills the air tank with air. S3: The pressure sensor monitors the pressure of the gas tank in real time. When the gas pressure value is ≥1MPa, the host computer controls the gas tank vent valve to open and release gas through the CAN4 line; when the gas pressure value is <0.78MPa, the host computer controls the vent valve to close. S4: The oscilloscope acquires the input and output current waveforms of the control unit in real time and feeds them back to the host computer. The host computer combines the pressure data and current waveforms to determine whether there is a fault. S5: Repeat steps S2-S4 for N loops, and generate a test report after the loop ends.

4. The automatic verification method for the load-bearing capacity of an air pump assembly according to claim 3, characterized in that, In step S1, the temperature adjustment range of the environmental chamber covers the extremely cold to hot and humid environment of the actual operation of the new energy bus, with an adjustment accuracy of 0.1℃.

5. The automatic verification method for the load-bearing capacity of an air pump assembly according to claim 3, characterized in that, In step S2, after the control unit receives the enable command, the enable operation time is 10 seconds, and then it switches to the disabled state and stops for 10 seconds. The time parameter can be customized and adjusted according to the test requirements.

6. The automatic verification method for the load-bearing capacity of an air pump assembly according to claim 3, characterized in that, In step S2, the host computer interacts with the vehicle control system via the CAN vehicle communication protocol to simulate the control logic of the real vehicle.

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