Test method, device and equipment based on intelligent air suspension control system

Abstract

The invention discloses a test method, device and equipment based on an intelligent air suspension control system, and the method comprises the steps: obtaining environment information, road condition information and fault information of an intelligent air suspension based on a general control module in response to a test instruction, and transmitting the information to a working condition simulation module; environment information is simulated based on the temperature and humidity environment chamber, road condition information is simulated based on the multi-axis vibration table, and fault information is simulated based on the fault injection unit; a simulation environment signal, a simulation road condition signal and a simulation fault signal are sent to the test execution module based on the working condition simulation module so as to drive the intelligent air suspension to execute a test action; acquiring test data of the intelligent air suspension based on the data acquisition and analysis module; and the test data is analyzed based on the data acquisition and analysis module, and a data analysis result is sent to the master control module. According to the invention, the combined test of the intelligent air suspension under the multi-dimensional working condition is realized.

Description

Technical Field

[0001] This invention relates to the field of computer technology, and in particular to a testing method, apparatus, and equipment based on an intelligent air suspension control system. Background Technology

[0002] As the automotive industry transforms towards "intelligentization, high-end, and electrification," intelligent air suspension control systems have rapidly penetrated from traditional luxury gasoline vehicles to high-end new energy vehicles, becoming a core configuration for enhancing vehicle comfort, handling, and intelligent experience.

[0003] Current testing solutions for intelligent air suspension control systems are mainly divided into three categories, covering different testing scenarios: (a) Real vehicle road test plan By assembling intelligent air suspension into actual vehicles and testing it at dedicated test tracks (such as high and low temperature environmental chambers, bumpy road tracks, and high-speed ring tracks) or public roads, data such as vehicle height, suspension damping, and vibration acceleration are collected to verify the suspension's performance under real-world conditions. This solution relies on real vehicle resources and requires specialized testing equipment (such as GPS speedometers, six-axis accelerometers, and CAN bus data loggers).

[0004] (II) Component Unit Testing Plan Independent testing is conducted on individual components of the intelligent air suspension (such as air springs, ECUs, and sensors). For example, an air pressure test bench is used to test the inflation and deflation speed and sealing performance of the air springs; an electronic control unit test bench (such as the ECHIL base bench) is used to verify the communication function and fault code output of the ECU; and a sensor calibrator is used to test the signal accuracy of the height sensor. Such solutions are mostly built independently by component suppliers, focusing on verifying the performance indicators of individual components and not involving collaborative testing of multiple components.

[0005] (III) Simplified Hardware-in-the-Loop (HIL) Test Solution Some OEMs or third-party testing organizations have built basic HIL benches and connected the intelligent air suspension ECU to the simulation system. They simulate road excitation through simple dynamic models (such as single-degree-of-freedom body vibration models). However, the simulation model has low accuracy (it often ignores the mechanical characteristics of the suspension guiding mechanism), limited environmental simulation capabilities (it can only simulate normal temperature environments and cannot cover extreme temperatures of -40℃ to 85℃), and does not integrate physical testing of actuators (such as air pumps and solenoid valves), making it difficult to verify the closed-loop control performance of "ECU-sensor-actuator". Summary of the Invention

[0006] This invention provides a testing method, apparatus, and equipment based on an intelligent air suspension control system, which can realize combined testing of intelligent air suspension under multi-dimensional working conditions.

[0007] On one hand, this invention provides a testing method based on an intelligent air suspension control system. The system includes a working condition simulation module, a test execution module, a data acquisition and analysis module, and a central control module. The working condition simulation module includes a temperature and humidity environment chamber, a multi-axis vibration table, and a fault injection unit. The method includes: In response to the test command, the system acquires environmental information, road condition information, and fault information of the intelligent air suspension based on the central control module and sends them to the working condition simulation module. The environmental information is simulated based on the temperature and humidity environment chamber, the road condition information is simulated based on the multi-axis vibration table, and the fault information is simulated based on the fault injection unit. The operating condition simulation module sends simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module to drive the intelligent air suspension to perform test actions. The test data of the intelligent air suspension is collected based on the data acquisition and analysis module. The data acquisition and analysis module analyzes the test data and sends the analysis results to the central control module.

[0008] On the other hand, an intelligent air suspension control system is provided. The system is used to perform the above-mentioned test method. The system includes a working condition simulation module, a test execution module, a data acquisition and analysis module, and a central control module. The central control module is electrically connected to the working condition simulation module, the test execution module, and the data acquisition and analysis module, respectively. The operating condition simulation module includes a temperature and humidity environment chamber, a multi-axis vibration table, and a fault injection unit. The temperature and humidity environment chamber, the multi-axis vibration table, and the fault injection unit are all electrically connected to the main control module, and the fault injection unit is electrically connected to the test execution module.

[0009] On the other hand, a testing device based on an intelligent air suspension control system is provided. The system includes a working condition simulation module, a test execution module, a data acquisition and analysis module, and a central control module. The working condition simulation module includes a temperature and humidity environment chamber, a multi-axis vibration table, and a fault injection unit. The device includes: The information sending module is used to respond to test commands, acquire environmental information, road condition information and fault information of the intelligent air suspension based on the central control module, and send them to the working condition simulation module; The information simulation module is used to simulate the environmental information based on the temperature and humidity environment chamber, simulate the road condition information based on the multi-axis vibration table, and simulate the fault information based on the fault injection unit. The signal transmission module is used to send simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module based on the working condition simulation module, so as to drive the intelligent air suspension to perform test actions. A data acquisition module is used to collect test data of the intelligent air suspension based on the data acquisition and analysis module. The data analysis module is used to analyze the test data based on the data acquisition and analysis module, and send the data analysis results to the central control module.

[0010] On the other hand, a test device based on an intelligent air suspension control system is provided. The device includes a processor and a memory. The memory stores at least one instruction or at least one program. The at least one instruction or the at least one program is loaded and executed by the processor to implement the test method based on the intelligent air suspension control system as described above.

[0011] On the other hand, a computer storage medium is provided, which stores at least one instruction or at least one program, which is loaded and executed by a processor to implement the test method based on the intelligent air suspension control system as described above.

[0012] On the other hand, a computer program product or computer program is provided, which includes computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform the test method based on the intelligent air suspension control system as described above.

[0013] The testing method, apparatus, and equipment based on an intelligent air suspension control system provided by this invention have the following technical effects: The intelligent air suspension control system of the present invention includes a working condition simulation module, a test execution module, a data acquisition and analysis module, and a central control module. The working condition simulation module includes a temperature and humidity environment chamber, a multi-axis vibration table, and a fault injection unit. The test method includes: responding to a test command, acquiring environmental information, road condition information, and fault information of the intelligent air suspension based on the central control module, and sending them to the working condition simulation module; simulating the environmental information based on the temperature and humidity environment chamber, simulating the road condition information based on the multi-axis vibration table, and simulating the fault information based on the fault injection unit; sending simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module based on the working condition simulation module to drive the intelligent air suspension to perform test actions; acquiring test data of the intelligent air suspension based on the data acquisition and analysis module; analyzing the test data based on the data acquisition and analysis module, and sending the data analysis results to the central control module. This invention solves the problem that existing solutions cannot simultaneously simulate extreme environments, complex road conditions, and fault conditions. It achieves accurate reproduction and combined testing of the three-dimensional conditions of "environment-road conditions-fault conditions", thereby improving the testing accuracy of intelligent air suspension under multi-dimensional conditions. Attached Figure Description

[0014] To more clearly illustrate the technical solutions and advantages in the embodiments or prior art of this specification, the drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a flowchart illustrating a test method based on an intelligent air suspension control system provided in the embodiments of this specification. Figure 2 This is a flowchart illustrating a method provided in this specification for driving the intelligent air suspension to perform test actions by sending simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module based on the working condition simulation module. Figure 3 This is a flowchart illustrating a method provided in this specification for analyzing each feature value and the corresponding anomaly threshold based on the data acquisition and analysis module to obtain the data analysis result. Figure 4 This is a flowchart illustrating a method for sending the second correction signal to a signal interaction unit, as provided in an embodiment of this specification. Figure 5 This is a flowchart illustrating a method for constructing a vehicle dynamics module according to an embodiment of this specification. Figure 6 This is a schematic diagram of the structure of a test device based on an intelligent air suspension control system provided in the embodiments of this specification; Figure 7 This is a schematic diagram of the structure of a server provided in the embodiments of this specification. Detailed Implementation

[0016] The technical solutions in the embodiments of this specification will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or server that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or devices.

[0018] In this embodiment of the invention, the terms "module" or "unit" refer to a computer program or part of a computer program that has a predetermined function and works with other related parts to achieve a predetermined goal, and can be implemented wholly or partially using software, hardware (such as processing circuitry or memory), or a combination thereof. Similarly, a processor (or multiple processors or memory) can be used to implement one or more modules or units. Furthermore, each module or unit can be part of an overall module or unit that includes the functionality of that module or unit.

[0019] In related technologies, the testing efficiency, coverage, and verification accuracy of intelligent air suspension systems cannot meet the current technological development needs, specifically including: (i) The test coverage is narrow and cannot meet the verification requirements of "full operating conditions". Existing solutions either only cover a single component (such as single-unit component testing) or only simulate simple operating conditions (such as a single-degree-of-freedom model of a simplified HIL bench), failing to simultaneously cover multi-dimensional testing scenarios including "extreme environments (high and low temperatures / humidity), complex road conditions (potholes / slopes / sharp turns), and fault conditions (sensor disconnection / actuator jamming)." For example, while real-vehicle road testing can simulate real road conditions, it cannot accurately control the ambient temperature and is difficult to reproduce extreme fault scenarios such as sensor failures; although a simplified HIL bench can simulate some electronic control logic, it cannot verify the performance degradation of air springs at low temperatures, contrasting sharply with the advantages of the "integrated simulation of all operating conditions" of this invention.

[0020] (ii) Lack of multi-component collaborative testing makes it impossible to verify the "mechanical-electrical-software" coupling performance. The core value of intelligent air suspension lies in the collaborative work of "mechanical structure (air springs / shock absorbers), electronic control (ECU), and software algorithm (adaptive adjustment logic)". However, existing solutions often involve fragmented testing: single-component testing ignores the ECU's control over mechanical components, and simple HIL benches ignore the mechanical characteristics of the actuators. While real-vehicle testing can perform collaborative testing, it cannot dismantle the root cause of faults (such as vehicle height adjustment delays, making it impossible to determine whether the problem is with the ECU logic or the air pump response). This deficiency directly corresponds to the advantage of the "mechanical-electrical-software integrated testing" of this invention. By integrating the suspension assembly, ECU, sensors, and actuators, this invention can accurately verify the coupling performance of multiple components.

[0021] (iii) The testing efficiency is low and the cost is high, making it difficult to support the development cycle of mass-produced models. Real-world road testing consumes significant real-vehicle resources (costing over 100,000 RMB per vehicle) and has a long testing cycle (7-10 days for a single extreme environment test). Simple HIL benches, due to their low model accuracy, require repeated calibration and correction against real-vehicle tests, extending the testing iteration cycle (an average of 3-5 iterations). Single-unit component testing requires multiple devices, resulting in data silos (e.g., air spring test data cannot be correlated with ECU test data), necessitating manual integration and analysis, which is inefficient. These shortcomings contrast with the advantages of this invention's "highly efficient automated testing." This invention, through real-time simulation and automated data acquisition, can shorten the testing cycle by more than 50%, reducing reliance on real-vehicle testing.

[0022] (iv) Insufficient simulation accuracy and data reliability make it impossible to support accurate fault location. Existing simplified HIL (High-Intensity Leakage) test benches often use simplified dynamic models (e.g., ignoring the impact of wheel load distribution on suspension stiffness), resulting in simulation results deviating from real-vehicle data by over 15%. Real-vehicle testing is affected by external disturbances (e.g., road surface unevenness fluctuations, wind speed changes), leading to poor data repeatability and difficulty in accurately locating faults (e.g., determining whether damping adjustment deviations are due to model errors or ECU logic errors). This deficiency contrasts with the advantages of this invention: "high-precision simulation + real-time data verification." This invention employs a multi-body dynamics vehicle model (deviation rate <5%) and uses physical actuators to provide feedback and correct simulation data, thereby improving data reliability.

[0023] Based on the shortcomings of the existing technology, this invention needs to solve four core technical problems in order to achieve the testing and verification of the intelligent air suspension control system in terms of "full functionality, all operating conditions, high precision, and high efficiency": 1. How to build a "multi-condition integrated simulation system": solve the problem that existing solutions cannot simultaneously simulate extreme environments (temperatures of -40℃ to 85℃, humidity of 10% to 90%), complex road conditions (potholes / slopes / sharp turns), and fault conditions (sensor disconnection / actuator jamming), and achieve accurate reproduction and combined testing of the three dimensions of "environment-road conditions-fault".

[0024] 2. How to achieve the "mechanical-electrical-software integrated test architecture": To solve the problem of the lack of multi-component collaborative testing in existing solutions, by integrating the physical assembly of intelligent air suspension (air spring, shock absorber, guide mechanism), ECU, sensors (height / acceleration / pressure sensors) and actuators (air pump, solenoid valve), a closed-loop test system of "ECU-sensor-actuator-mechanical structure" is constructed to verify the coupling performance of multiple components.

[0025] 3. How to improve testing efficiency and data reliability: To solve the problems of long testing cycles and poor data repeatability in existing solutions, a high-precision real-time simulation platform (using a multibody dynamics vehicle model) and an automated data acquisition and analysis module are built to automate the testing process (from setting the working conditions to generating the report without human intervention). The simulation data is corrected by feedback from physical actuators, and the deviation rate between simulation and real vehicle data is controlled within 5%.

[0026] 4. How to achieve "precise fault location and source tracing": To solve the problem that existing solutions cannot dissect the root cause of faults, "module monitoring nodes" (such as ECU signal output nodes, actuator drive current nodes, and mechanical structure stress nodes) are set up in the testing system to collect data from each link in real time. When test abnormalities occur, the fault location can be quickly located (such as ECU logic errors, actuator jamming, and mechanical structure deformation), providing accurate data support for subsequent optimization.

[0027] This embodiment adopts a "central control - multi-module collaboration - closed-loop feedback" architecture. The core consists of four parts: working condition simulation module, test execution module, data acquisition and analysis module, and main control module (with simulation function). Each module realizes real-time data interaction through industrial Ethernet (Profinet) and CAN bus, forming a complete test closed loop of "command issuance - working condition simulation - data acquisition - analysis and feedback", which can cover the full-dimensional test requirements of intelligent air suspension in terms of "environmental adaptability - functional integrity - reliability - fault robustness".

[0028] This embodiment provides an intelligent air suspension control system, which includes a working condition simulation module, a test execution module, a data acquisition and analysis module, and a central control module. The central control module is electrically connected to the working condition simulation module, the test execution module, and the data acquisition and analysis module, respectively. The operating condition simulation module includes a temperature and humidity environment chamber, a multi-axis vibration table, and a fault injection unit. The temperature and humidity environment chamber, the multi-axis vibration table, and the fault injection unit are all electrically connected to the main control module, and the fault injection unit is electrically connected to the test execution module.

[0029] For example, the temperature and humidity environment chamber can be a high and low temperature humidity environment chamber with a volume of 5m³, a temperature control range of -40℃ to 85℃ (accuracy ±0.5℃), a humidity control range of 10% to 90%RH (accuracy ±3%RH), and is equipped with an air duct circulation system and a temperature compensation device. The multi-axis vibration table can be a six-axis multi-degree-of-freedom vibration table: load capacity 500kg, frequency range 5Hz~2000Hz, displacement range ±50mm (vertical) / ±25mm (horizontal), supports road surface spectrum import and custom editing; The fault injection unit includes a hardware-based signal interference module (supporting voltage / current signal offset and disconnection simulation) and a software-based ECU instruction tampering module (supporting CAN message packet loss and error frame injection).

[0030] In some embodiments, the test execution module includes the physical assembly of the intelligent air suspension, a tooling stand, a signal interaction unit, and an actuator drive unit. The tooling stand is used to fix the physical assembly. One end of the signal interaction unit is connected to the suspension ECU in the physical assembly, and the other end is connected to the main control module. The tooling stand can be a customized mechanical tooling stand, and the signal interaction unit can be an engine controller (ECU).

[0031] The data acquisition and analysis module includes a sensor group, a multi-channel data acquisition card, and a real-time data analysis tool. The sensor group is set at a preset position in the test execution module, where the preset position can be a custom key position.

[0032] The overall control module includes a central control computer, a real-time simulation platform, and a vehicle dynamics module. One end of the real-time simulation platform is connected to the central control computer, and the other end is connected to the multi-axis vibration table and the signal interaction unit.

[0033] The environmental chamber communicates with the central control module via RS485: the central control module sends out target values ​​for temperature and humidity, and the environmental chamber provides real-time temperature and humidity data. The fault injection unit is connected in series with the ECU signal interaction terminal and the sensor signal terminal of the test execution module: the central control module issues fault commands (such as "height sensor disconnection" or "ECU power supply voltage drop"), and the fault unit performs fault simulation and feeds back the status.

[0034] For example, the physical assembly includes: air springs (with air pressure sensors), adjustable damping shock absorbers, vehicle height sensors (4, corresponding to the four wheels), air pumps (with pressure valves), solenoid valve groups (4, controlling the inflation and deflation of individual wheels), and suspension ECU; Mechanical tooling stand: It adopts a steel structure frame and is equipped with a body simulation support beam (height adjustable), a wheel simulation load device (can simulate wheel load of 100kg~800kg), and a suspension attitude locking mechanism. ECU signal interaction unit: includes CAN / LIN bus interface card (supports CANFD protocol) and analog signal conditioning module (converts sensor 0~5V signals into digital signals); Actuator drive unit: includes a dedicated power supply for air pump (12V / 24V adjustable), a solenoid valve drive module (supports PWM signal control), and a current monitoring module (range 0~10A, accuracy ±0.01A).

[0035] The physical assembly is fixed by a mechanical tooling bench: the body simulates the support beam connected to the upper control arm of the suspension, and the wheel simulates the load device connected to the lower control arm of the suspension to simulate the weight distribution of the whole vehicle; One end of the ECU signal interaction unit is connected to the suspension ECU (CAN bus + analog signal), and the other end is connected to the main control module: to realize the interaction between the ECU and the main control module with commands (such as "the vehicle height is raised to 150mm") and status (such as "the current damping level is 3"). One end of the actuator drive unit is connected to the air pump and solenoid valve, and the other end is connected to the central control module: the central control module issues drive commands (such as "start the air pump, target pressure 8 bar"), and the drive unit feeds back data such as the actuator's operating current and air pressure.

[0036] Sensor group: includes laser displacement sensor (measures vehicle height, range 0~500mm, accuracy ±0.01mm), triaxial acceleration sensor (attached to the vehicle body simulation beam, range ±50g, accuracy ±0.1g), air pressure sensor (measures air spring internal pressure, range 0~10bar, accuracy ±0.02bar), and force sensor (installed at both ends of the shock absorber, range 0~50kN, accuracy ±0.1kN); Data acquisition card: 16-channel analog input (sampling rate 1kHz), 8-channel digital input / output, supporting 4~20mA signal interface with sensor group; Data analysis software: Developed based on LabVIEW, it includes real-time data display (waveform graphs / numerical tables), data storage (supporting Excel / TDMS formats), characteristic value calculation (such as height adjustment response time, damping force fluctuation range), and anomaly alarm (triggered audio and visual prompts when thresholds are exceeded). LabVIEW is a program development environment.

[0037] The sensor array is directly installed at key locations in the test execution module (e.g., a laser displacement sensor is aligned with the simulated beam of the vehicle body, and a force sensor is connected in series with the shock absorber), and outputs analog signals to the data acquisition card. The data acquisition card connects to the central control computer via a PCIe interface to transmit the acquired raw data to the data analysis software. The data analysis software and the central control module achieve two-way communication: the software receives data analysis thresholds (such as "height adjustment response time upper limit 2s") issued by the central control module and provides feedback on analysis results (such as "current response time 1.8s, qualified").

[0038] Central control computer: Industrial-grade host (CPU i7-12700K, memory 32GB), with system control software installed (developed based on C#), supporting test process editing, parameter setting, and status monitoring; Real-time simulation platform: Equipped with an FPGA chip (real-time performance ≤1ms), supports hardware-in-the-loop (HIL) testing, and can load a whole vehicle dynamics model; Vehicle dynamics modeling software: Creates a complete vehicle model including chassis, body, and tires, which can simulate the weight distribution, wheel load changes, and road excitation response of different vehicle types (such as SUVs / sedans).

[0039] The central control computer is connected to the working condition simulation module, the test execution module, and the data acquisition and analysis module via industrial Ethernet, and issues unified control commands and receives status data from each module. The real-time simulation platform is connected to the central control computer on one end (to receive vehicle parameters and road condition data), and to the six-axis vibration table and ECU signal interaction unit on the other end: it outputs the "road excitation force" calculated by the whole vehicle model to the vibration table and outputs the "virtual whole vehicle signal" (such as vehicle speed and steering angle) to the ECU. The vehicle dynamics model software is integrated with the real-time simulation platform: the model calculation results (such as the vertical displacement of the vehicle body and wheel load) are transmitted to the simulation platform in real time to correct the input signals of the vibration table and ECU.

[0040] For example, the high and low temperature humidity chamber can be replaced by a split-type environment chamber (low temperature chamber + high temperature chamber + humidity generator), which is connected to the test area through pipelines; applicable scenarios: laboratories with limited space, where temperature and humidity can be controlled independently; however, its temperature and humidity switching speed is slow (it takes 2 hours to rise from -40℃ to 85℃, while the integrated type only takes 1 hour), and the pipelines are prone to temperature loss, reducing the accuracy to ±1℃.

[0041] The six-axis vibration table is connected to the real-time simulation platform in the central control module via an EtherCAT bus: the real-time simulation platform outputs the road excitation force signal, and the vibration table feeds back the actual vibration displacement / acceleration data. For example, a six-axis multi-degree-of-freedom vibration table can be replaced with a three-axis vibration table + angle adjustment mechanism (which can achieve ±30° tilt); applicable scenarios: limited test budget and no need to simulate complex lateral road conditions (such as sharp turns); however, it cannot simulate the coupled vibration of longitudinal + lateral + vertical, and the integrity of road condition simulation decreases by 40%.

[0042] The fault injection unit can be replaced by a software simulation injection unit (simulating fault messages through CANoe software); applicable scenarios: only need to verify the ECU software fault handling logic, without testing hardware faults; however, it cannot simulate physical faults such as sensor hardware disconnection or actuator short circuit, reducing the fault coverage by 60%.

[0043] The mechanical tooling stand in the test execution module can be replaced with standardized adjustable tooling (the support height and wheel load position can be adjusted by bolts); applicable scenarios: need to test multiple suspension models (such as MacPherson strut and multi-link); however, the adaptation accuracy is low (wheel load simulation error ±5kg, customization is only ±1kg), and the tooling rigidity is insufficient, which is prone to vibration interference.

[0044] The actuator drive unit can be replaced with a general-purpose PLC drive module (such as Siemens S7-1200); applicable scenarios: the actuator control logic is simple (only switching control is required, no PWM regulation is needed); however, the current monitoring accuracy is low (±0.1A, dedicated module ±0.01A), and it cannot accurately determine the actuator jamming fault.

[0045] The sensor group in the data acquisition and analysis module can be replaced with a non-contact infrared temperature sensor (to measure the temperature of the ambient chamber) + a piezoelectric accelerometer (to measure vibration). Applicable scenarios: where physical contact between the sensor and the test piece must be avoided (e.g., the surface of the test piece is easily damaged). However, the infrared sensor is greatly affected by environmental dust, with a measurement error of ±1℃; the piezoelectric sensor has large zero drift, and the data deviation exceeds 5% during long-term testing (>24h).

[0046] The data acquisition card can be replaced with a distributed acquisition module (such as NicDAQ) to transmit data wirelessly; applicable scenarios: test areas are dispersed (such as sensors installed on moving parts of a vibration table); however, its wireless transmission latency (>10ms, compared to only 1ms with wired connections) reduces real-time performance and cannot meet the needs of dynamic testing.

[0047] The real-time simulation platform in the main control module was replaced with a high-performance industrial computer (CPU i9-13900K + real-time operating system RTX); applicable scenarios: low complexity of simulation model (such as only simplifying the vehicle dynamics model); however, its real-time performance is poor (≤5ms, dSPACE≤1ms), and under high-frequency road conditions (such as 200Hz vibration), the model calculation lag causes the test deviation to exceed 10%.

[0048] The following describes a test method based on an intelligent air suspension control system according to the present invention. Figure 1 This is a flowchart illustrating a testing method based on an intelligent air suspension control system provided in the embodiments of this specification. This specification provides the operational steps of the method described in the embodiments or flowchart, but based on conventional or non-inventive labor, more or fewer operational steps may be included. The order of steps listed in the embodiments is merely one possible execution order among many and does not represent the only possible execution order. In actual system or server product execution, the methods shown in the embodiments or drawings can be executed sequentially or in parallel (e.g., in a parallel processor or multi-threaded processing environment). Specifically, as shown in the embodiments or drawings... Figure 1 As shown, the method may include: S101: In response to the test command, the system acquires environmental information, road condition information, and fault information of the intelligent air suspension based on the central control module, and sends them to the working condition simulation module. The method of this embodiment can be applied to an intelligent air suspension control system. In this embodiment, the tester can send a test command to the control system. The control system calls the main control module to receive the test command, parses the test command, obtains the environmental information, road condition information and fault information of the intelligent air suspension, and sends them to the working condition simulation module.

[0049] S103: Simulate the environmental information based on the temperature and humidity environment chamber, simulate the road condition information based on the multi-axis vibration table, and simulate the fault information based on the fault injection unit.

[0050] In the embodiments described in this specification, the temperature and humidity environment chamber can be a high and low temperature humidity environment chamber, with a controllable temperature range of -40℃ to 85℃ (accuracy ±0.5℃) and a humidity control range of 10% to 90% RH (accuracy ±3% RH). Furthermore, the temperature and humidity environment chamber is equipped with an air circulation system and a temperature compensation device to adjust humidity and temperature data; thus, it can be used to simulate temperatures within the range of -40℃ to 85℃.

[0051] The temperature and humidity environment chamber can be used to simulate extreme environments in actual use of intelligent air suspension (such as cold winters in the north and hot and humid conditions in the south), the multi-axis vibration table can be used to simulate complex road conditions (such as potholes, slopes, and sharp turns), and the fault injection unit can be used to simulate different fault scenarios (such as sensor failure and actuator jamming), thus providing external conditions that are close to reality for testing; and it supports multi-condition combination simulation (such as "-30℃ low temperature + bumpy road surface + pressure sensor signal drift") to verify the functional stability of the suspension under combined conditions.

[0052] S105: Based on the operating condition simulation module, the simulated environment signal, simulated road condition signal, and simulated fault signal are sent to the test execution module to drive the intelligent air suspension to perform test actions.

[0053] In the embodiments of this specification, the test execution module serves as the core carrier of the test, realizing the physical integration of the intelligent air suspension's "mechanical structure - electronic control - actuator," thus avoiding the problem of pure simulation testing being detached from reality. It receives environmental / road condition signals from the working condition simulation module and control commands from the central control unit, driving the suspension to perform corresponding actions (such as inflating / deflating to adjust height and switching damping), providing test objects for data acquisition.

[0054] S107: Collect test data of the intelligent air suspension based on the data acquisition and analysis module.

[0055] In the embodiments of this specification, the data acquisition and analysis module can be used to collect key physical quantities (height, acceleration, pressure, force) of the suspension in real time during the testing process, providing data support for functional verification. S109: Analyze the test data based on the data acquisition and analysis module, and send the data analysis results to the central control module.

[0056] In the embodiments of this specification, the data acquisition and analysis module can also be used to automatically analyze whether the test data meets the design requirements, thereby quickly identifying suspension function abnormalities (such as "air spring air pressure leakage causing a height drop of 0.5 mm / min"), avoiding the lag and errors of manual analysis.

[0057] In the embodiments of this specification, the intelligent air suspension control system includes a working condition simulation module, a test execution module, a data acquisition and analysis module, and a central control module. The working condition simulation module includes a temperature and humidity environment chamber, a multi-axis vibration table, and a fault injection unit. The test method includes: responding to a test command, acquiring environmental information, road condition information, and fault information of the intelligent air suspension based on the central control module, and sending them to the working condition simulation module; simulating the environmental information based on the temperature and humidity environment chamber, simulating the road condition information based on the multi-axis vibration table, and simulating the fault information based on the fault injection unit; sending simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module based on the working condition simulation module to drive the intelligent air suspension to perform test actions; acquiring test data of the intelligent air suspension based on the data acquisition and analysis module; analyzing the test data based on the data acquisition and analysis module, and sending the data analysis results to the central control module. This invention solves the problem that existing solutions cannot simultaneously simulate extreme environments, complex road conditions, and fault conditions. It achieves accurate reproduction and combined testing of the three-dimensional conditions of "environment-road conditions-fault conditions", thereby improving the testing accuracy of intelligent air suspension under multi-dimensional conditions.

[0058] In some embodiments, the test execution module includes a physical assembly of the intelligent air suspension, a tooling stand, a signal interaction unit, and an actuator drive unit. The tooling stand is used to fix the physical assembly, and one end of the signal interaction unit is connected to the suspension ECU in the physical assembly, while the other end is connected to the main control module. Figure 2 As shown, the step of sending simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module based on the working condition simulation module to drive the intelligent air suspension to perform test actions includes: S1051: Based on the operating condition simulation module, send simulated environment signals, simulated road condition signals, and simulated fault signals to the central control module; S1053: The central control module is invoked to send drive commands to the actuator drive unit and control commands to the signal interaction unit based on the simulated environmental signals, simulated road condition signals and simulated fault signals. S1055: The actuator drive unit is invoked to drive the air pump and solenoid valve based on the drive command, and the signal interaction unit is invoked to control the physical assembly to perform action testing based on the control command.

[0059] In the embodiments described in this specification, the central control module can send drive commands to the actuator drive unit and control commands to the signal interaction unit based on the simulated environmental signals, simulated road condition signals, and simulated fault signals. The actuator drive unit drives the air pump and solenoid valve to operate based on the drive commands to construct external conditions that match the simulated environmental signals, simulated road condition signals, and simulated fault signals. The signal interaction unit controls the physical assembly to perform action tests under the simulated environmental signals, simulated road condition signals, and simulated fault signal conditions through the control commands, thereby obtaining comprehensive test results under different environments, different road conditions, and different fault scenarios.

[0060] In some embodiments, the data acquisition and analysis module includes a sensor group, a multi-channel data acquisition card, and a real-time data analysis tool. The sensor group is located at a preset position in the test execution module. The acquisition of test data of the intelligent air suspension based on the data acquisition and analysis module includes: During the testing of the intelligent air suspension, test data is collected based on the sensor group and sent to the multi-channel data acquisition card; The test data is sent to the real-time data analysis tool based on the multi-channel data acquisition card; The step of analyzing the test data based on the data acquisition and analysis module and sending the data analysis results to the central control module includes: Based on the data acquisition and analysis module receiving the data analysis threshold sent by the central control module; The data analysis results are obtained by analyzing the test data and the data analysis threshold based on the data acquisition and analysis module.

[0061] In the embodiments of this specification, the preset location can be a key location in the test execution module, which is a location that has a significant impact on the test results and can be determined according to the actual situation. The test data can be of various types. In this case, a target data analysis threshold matching the target data type can be queried in a preset database based on the target data type corresponding to the test data. The preset database can be a pre-built database that stores the correspondence between preset data types and preset data analysis thresholds; for example, based on the data analysis threshold (e.g., "maximum response time adjustment 2s"), the analysis result can be fed back (e.g., "current response time 1.8s, qualified").

[0062] In some embodiments, the step of analyzing the test data and the data analysis threshold based on the data acquisition and analysis module to obtain the data analysis result includes: Based on the data acquisition and analysis module, multiple characteristic values ​​of the intelligent air suspension during the testing process are obtained to obtain the test data; Based on the data acquisition and analysis module, each feature value and the corresponding abnormal threshold are analyzed to obtain the data analysis results. The method further includes: If the data analysis results indicate that any target feature value exceeds the target anomaly threshold corresponding to the target feature value, the abnormal function type of the intelligent air suspension is determined based on the target feature value, and an anomaly warning message is generated.

[0063] In the embodiments of this specification, the test data may include multiple feature values, and the data analysis threshold may also be an anomaly threshold corresponding to the feature index. The preset data analysis threshold is the critical value of the abnormal data. The preset data analysis threshold may be a data value or a data range. When the test data includes multiple target feature values, the target data analysis threshold corresponding to each target feature value can be obtained separately, and then the relationship between the test data corresponding to each target feature value and its corresponding target data analysis threshold can be determined. Specifically, the magnitude relationship between the test data and the target data analysis threshold can be compared, or it can be analyzed whether the test data exceeds the data range corresponding to the target data analysis threshold. Thus, the data analysis results are obtained, which facilitates further analysis of the abnormal function type of the intelligent air suspension. An abnormal warning message can be generated according to the abnormal function type; an audible and visual alarm can be triggered when the test data exceeds the threshold.

[0064] In the embodiments of this specification, the changes in height, acceleration, and pressure of the intelligent air suspension can be obtained; Based on the changes in the data, identify the abnormal function types of the intelligent air suspension.

[0065] In some embodiments, the height, acceleration, and pressure data of the intelligent air suspension can also be acquired. For example, during testing, by analyzing the changes in suspension height, abnormal suspension functions (such as "air spring pressure leakage causing a height drop of 0.5 mm / min") can be quickly identified, avoiding the lag and errors of manual analysis. Furthermore, after determining the type of abnormal function of the intelligent air suspension, an abnormal warning message can be generated to alert the test personnel.

[0066] In some embodiments, the plurality of characteristic values ​​include height adjustment response time and damping force fluctuation range, such as Figure 3 As shown, the data analysis module analyzes each feature value and its corresponding anomaly threshold to obtain the data analysis results, including: S301: Based on the data acquisition and analysis module, compare the height adjustment response time with the response time threshold to obtain a first analysis result; S303: Determine whether the damping force fluctuation range exceeds the preset fluctuation range, and obtain the second analysis result; S305: Determine the data analysis result based on the first analysis result and the second analysis result.

[0067] In the embodiments of this specification, multiple feature values ​​may include height adjustment response time and damping force fluctuation range. The height adjustment response time can be compared with a response time threshold by a data acquisition and analysis module to obtain a first analysis result. If the first analysis result indicates that the height adjustment response time exceeds the response time threshold, a corresponding first abnormality warning message is generated and an alarm is triggered. It can be determined whether the damping force fluctuation range exceeds a preset fluctuation range to obtain a second analysis result. If the second analysis result indicates that the damping force fluctuation range exceeds the preset fluctuation range, a corresponding second abnormality warning message is generated and an alarm is triggered. If both the first and second analysis results indicate abnormalities, a target abnormality warning message is generated based on the two abnormalities, thereby enabling rapid and accurate identification of suspension abnormalities.

[0068] In some embodiments, the central control module includes a central control computer, a real-time simulation platform, and a vehicle dynamics module. One end of the real-time simulation platform is connected to the central control computer, and the other end is connected to the multi-axis vibration table and the signal interaction unit. Figure 4 As shown, the method further includes: S401: Based on the central control computer, obtain the vehicle parameters and road condition data of the intelligent air suspension and send them to the real-time simulation platform; S403: Calculate the road excitation force corresponding to the intelligent air suspension based on the vehicle dynamics module, obtain the virtual vehicle signal, and send the road excitation force and the virtual vehicle signal to the real-time simulation platform; S405: Based on the real-time simulation platform, the vehicle parameters, road condition data, road surface excitation force and virtual vehicle signal are analyzed to obtain the first correction signal of the multi-axis vibration table and the second correction signal of the signal interaction unit; S407: Based on the real-time simulation platform, send the first correction signal to the multi-axis vibration table and send the second correction signal to the signal interaction unit.

[0069] The simulation of road condition information based on the multi-axis vibration table includes: The multi-axis vibration table is invoked to simulate the road condition information based on the first correction signal; The invocation of the signal interaction unit to control the physical assembly to perform action testing based on the control command includes: The signal interaction unit is invoked to control the physical assembly to perform an action test according to the second correction signal.

[0070] In the embodiments described in this specification, the central control module serves as the core component of the system, enabling coordinated control of all modules and supporting automated testing processes (such as one-click execution of "environmental chamber temperature rise to 60℃ → vibration table loading of Class B road spectrum → ECU execution of height adjustment → data acquisition and analysis"). Through the vehicle dynamics model and HIL technology, it simulates adaptation scenarios for different vehicle models, avoiding the limitation of the testing system only adapting to a single vehicle model and improving the versatility of the solution.

[0071] The overall control module includes a central control computer, a real-time simulation platform, and a vehicle dynamics module. The central control computer is an industrial-grade host (CPU i7-12700K, 32GB memory), equipped with system control software, supporting test process editing, parameter setting, and status monitoring. The real-time simulation platform is equipped with an FPGA chip (real-time performance ≤1ms), supports hardware-in-the-loop (HIL) testing, and can load a vehicle dynamics model. The real-time simulation platform analyzes the vehicle parameters, road condition data, road surface excitation force, and virtual vehicle signals to obtain a first correction signal from the multi-axis vibration table and a second correction signal from the signal interaction unit. It then calls the multi-axis vibration table to simulate the road condition information based on the first correction signal and can call the signal interaction unit to control the physical assembly to perform action tests based on the second correction signal.

[0072] In some embodiments, the vehicle dynamics module loads a vehicle dynamics model, such as... Figure 5 As shown, the method for constructing the vehicle dynamics module includes: S501: Create an initial complete vehicle model including the chassis, body, and tires; S503: Based on the vehicle model parameters, determine the vehicle's weight distribution data, wheel load variation data, and road excitation response data; S505: Construct the vehicle dynamics model based on the initial vehicle model, the weight distribution data, the wheel load change data, and the road excitation response data.

[0073] In the embodiments of this specification, the vehicle dynamics module can be vehicle dynamics modeling software: It establishes a vehicle model including the chassis, body, and tires, capable of simulating the weight distribution, wheel load changes, and road excitation response of different vehicle types (such as SUVs / sedans); first, an initial vehicle model including the chassis, body, and tires is established; then, based on the vehicle type parameters, the vehicle's weight distribution data, wheel load change data, and road excitation response data are determined; subsequently, based on the initial vehicle model, the weight distribution data, wheel load change data, and road excitation response data, a vehicle dynamics model is constructed; thereby, it can simulate adaptation scenarios for different vehicle types, avoiding the limitation of a test system only adapting to a single vehicle type.

[0074] The central control computer is connected to the operating condition simulation module, test execution module, and data acquisition and analysis module via industrial Ethernet, issuing unified control commands and receiving status data from each module. The real-time simulation platform is connected to the central control computer on one end (receiving vehicle parameters and road condition data) and to the six-axis vibration table and ECU signal interaction unit on the other end: it outputs the "road excitation force" calculated by the whole vehicle model to the vibration table and outputs the "virtual whole vehicle signals" (such as vehicle speed and steering angle) to the ECU. The whole vehicle dynamics model software is integrated with the real-time simulation platform: the model calculation results (such as vehicle vertical displacement and wheel load) are transmitted to the simulation platform in real time to correct the input signals of the vibration table and ECU.

[0075] (i) This solution adopts a multi-condition three-dimensional integrated simulation (to solve the defect of "incomplete coverage of operating conditions" in existing technologies). 1. Environment-Road Condition-Fault Co-simulation Architecture Breaking through the limitations of traditional testing solutions that rely on independent simulation of single operating conditions, this innovative architecture pioneers a deep collaborative system combining a high-low temperature and humidity environment chamber, a six-axis vibration table, and a fault injection unit. Data synchronization among these three components is achieved via industrial Ethernet (time error <1ms), enabling precise reproduction of complex operating conditions such as -30℃ low temperature + bumpy road surface + pressure sensor signal drift and 85℃ high temperature + sharp turn + ECU power supply drop. Compared to existing solutions that can only simulate a single environment or road condition, this architecture expands the operating condition coverage from "1D" to "3D," increasing the ability to simulate complex operating conditions by 200%, and fully validating the functional stability of intelligent air suspension in extremely complex scenarios.

[0076] 2. Dynamic operating condition parameter adaptive adjustment technology A "vehicle dynamics model feedback" mechanism is integrated into the control logic of the six-axis vibration table: the real-time simulation platform dynamically corrects the road excitation parameters of the vibration table (such as adjusting the amplitude and frequency of bumpy road surfaces) based on the action commands of the suspension ECU (such as "raising the vehicle height by 50mm"), simulating the coupling relationship between "suspension action and road condition response" in real driving. Existing solutions mostly use fixed road condition parameters for testing, which cannot reflect dynamic interactive characteristics. This technology improves the "realism matching degree" of road condition simulation from 60% to 95%, making it more in line with actual use scenarios.

[0077] (II) Innovation of Mechatronics-Software Integrated Closed-Loop Testing Architecture (Addressing the Deficiency of "Lack of Multi-Component Collaboration" in Existing Technologies) 1. Deep integration of physical assembly and virtual simulation design Breaking away from the disconnect between "pure physical testing" and "pure simulation testing," this architecture constructs a closed loop of "intelligent air suspension physical assembly + vehicle dynamics virtual model": sensor data from the physical assembly (such as vehicle height and shock absorber force) is fed back to the ADAMS / Car model in real time. After calculation, the model outputs "virtual vehicle signals" (such as vehicle speed and wheel load) to the suspension ECU, forming a closed-loop control of "physical action - virtual feedback - ECU decision - physical execution." Compared to existing simplified HIL solutions that only integrate ECU simulation, this architecture incorporates "mechanical structure - electronic control - software algorithm" into the same testing system, increasing the multi-component coupling performance verification coverage from 40% to 100%, and accurately identifying hidden problems such as "ECU logic is correct but mechanical response is delayed."

[0078] 2. Modular monitoring and fault tracing technology The test execution module is equipped with a three-level monitoring system: ECU signal, actuator current, and mechanical stress. Control commands are collected via the ECU signal interaction unit, operating current is monitored by the actuator drive unit, and mechanical stress data is collected by the force sensor. These three data points are linked and stored in real time. When an anomaly occurs during testing (such as vehicle height adjustment timeout), the system can automatically trace back to whether the ECU issued the correct command, whether the actuator responded normally, and whether there was any jamming in the mechanical structure. This reduces the time to locate the fault from 2 hours in the existing solution to 5 minutes, and improves the accuracy of fault tracing from the "module level" to the "component level."

[0079] (III) Collaborative optimization and innovation of high precision and high efficiency (solving the defects of "low precision and poor efficiency" in existing technologies) 1. Multi-dimensional data calibration and accuracy assurance mechanism Establish a dual precision assurance system of "sensor hardware calibration + model software correction": At the hardware level: key equipment such as laser displacement sensors and force sensors are regularly calibrated through national metrological standard parts (accuracy traceable to ±0.001mm). On the software level: The real-time simulation platform dynamically corrects the parameters of the vehicle dynamics model based on physical test data (such as the inflation and deflation speed of air springs), reducing the deviation rate between simulation and physical data from 15% in the existing scheme to less than 5%.

[0080] Compared to existing solutions that rely solely on the precision of a single hardware or software component, this mechanism increases the reliability of test data by 180%, providing precise data support for suspension performance optimization.

[0081] 2. Full-process automation and flexible adaptation design Develop a system that allows for "visual editing of the test process and quick switching of parameters across multiple vehicle models": In terms of automation: It supports editing the test process through a drag-and-drop interface (such as "environmental chamber preheating → vibration table loading → ECU testing → data report generation"), without the need for manual intervention. The test time for a single batch is reduced from 8 hours to 3 hours. In terms of flexible adaptation: Through parameterized settings of the whole vehicle dynamics model (such as modifying the vehicle weight and wheelbase), it can quickly adapt to the intelligent air suspension test of different models such as SUVs, sedans, and MPVs without changing mechanical tooling, and the model adaptation cycle is shortened from 7 days to 2 hours.

[0082] Compared to the existing solution of "single-model customized testing", this design improves the system's versatility by 300%, adapting to the diverse and rapid iteration needs of mass-production vehicle development.

[0083] (iv) Scenario-based innovation of fault injection technology (solving the defect of "incomplete fault coverage" in existing technologies) 1. Hardware and software fault co-injection system Overcoming the limitations of existing solutions that can only inject software faults or only inject hardware faults, a collaborative injection system combining hardware signal interference and software message tampering is constructed: Hardware failure: The signal interference module of the fault injection unit simulates sensor disconnection and voltage drift (such as the height sensor signal dropping from 5V to 0V). Software fault: The CAN message editing module simulates ECU communication packet loss and erroneous frames (such as tampering with vehicle speed signals).

[0084] The two can be injected in combination (such as "sensor hardware disconnection + ECU software message error"), expanding the fault coverage scenarios from 30 in the existing solution to 120, and fully verifying the effectiveness of the suspension ECU's fault self-diagnosis and degradation strategy.

[0085] 2. Fault level matching design with actual scenario Based on the actual failure rate of the intelligent air suspension, failures are categorized into three levels: "high-frequency minor failures (such as sensor signal drift), mid-frequency general failures (such as solenoid valve sticking), and low-frequency severe failures (such as ECU power failure)." During testing, the failure injection probability can be allocated according to the actual proportion to simulate the failure distribution scenarios in real use. Compared with the existing solution of "randomly injecting failures," this design improves the consistency between failure test results and actual usage by 80%, providing a more valuable reference for suspension reliability design.

[0086] As can be seen from the technical solutions provided in the embodiments of this specification above, the embodiments of this specification have the following technical effects: (i) The testing coverage has been significantly expanded, and the verification capability in extremely complex scenarios has been greatly improved. 1. Composite operating condition verification meets the needs of all scenarios. Based on the "environment-road condition-fault collaborative simulation architecture," this solution can reproduce composite scenarios of "extreme environment + complex road conditions + multiple types of faults." Compared to existing solutions that can only verify single-dimensional operating conditions (such as only high-temperature environment or only flat road surface), the coverage of test scenarios is increased by more than 3 times. For example, for users in the frigid winter regions of northern China, it can simulate the scenario of "-40℃ low temperature + bumpy icy and snowy road surface + altitude sensor signal drift," which can detect problems such as suspension inflation and deflation delays and false alarms in fault diagnosis at low temperatures in advance, avoiding the risk of functional failure after actual vehicle delivery. This increases the pass rate of full-scenario adaptability verification of intelligent air suspension from 60% of the existing solutions to 98%.

[0087] 2. The dynamic interactive scenes closely resemble real-world usage. Through "dynamic operating condition parameter adaptive adjustment technology," the vibration table can dynamically adjust road condition parameters according to the real-time actions of the suspension ECU. For example, when the ECU executes the "high-speed vehicle body lowering" command, the vibration table simultaneously reduces the amplitude of road bumps to simulate real high-speed road conditions, increasing the realism of the road condition simulation from 60% to 95%. This effect can avoid the problem of "passing laboratory tests but malfunctioning in real-world use" caused by fixed road condition testing. For example, the problem of "suspension noise during high-speed vehicle body adjustment" that was not found using traditional testing methods can be accurately reproduced and resolved through this solution, reducing the failure detection rate in real-world road tests by 70%.

[0088] (II) Improved accuracy of multi-component collaborative verification and enhanced ability to identify hidden problems. 1. Mechatronics-soft coupling performance verification without blind spots The "deep integration design of physical assemblies and virtual simulation" breaks through the limitations of purely physical or purely simulation testing, incorporating "mechanical structure, electronic control, and software algorithms" into the same closed-loop testing system. This increases the coverage of multi-component coupling performance verification from 40% to 100%. For example, it can accurately identify hidden problems such as "correct ECU logic but insufficient air spring tightness leading to height adjustment timeout" and "mismatch between shock absorber damping algorithm and mechanical stiffness causing excessive body vibration." These problems are difficult to detect in existing split testing schemes, but this solution can improve the identification rate of hidden problems by 200%, providing precise direction for the design optimization of intelligent air suspension and shortening the product iteration cycle by 15% to 20%.

[0089] 2. Dual optimization of efficiency and accuracy in fault tracing Leveraging "modular monitoring and fault tracing technology," the system can pinpoint abnormalities within 5 minutes (compared to 2 hours for existing solutions), improving fault tracing accuracy from the "module level" to the "component level." For example, when "vehicle height adjustment fails," it can quickly determine whether the issue is due to "ECU not issuing commands," "abnormal solenoid valve drive current," or "insufficient air pump pressure," avoiding the inefficient process of "checking components one by one" in traditional testing. This reduces single-fault troubleshooting time by 96%, significantly reducing the workload of testing personnel and minimizing test cycle delays caused by fault troubleshooting, thereby increasing the test plan completion rate by 30%.

[0090] (III) Testing efficiency is significantly improved, while R&D costs and cycle time are reduced. 1. Full-process automation shortens the testing cycle. The "fully automated design" supports one-click editing and execution of the testing process, eliminating the need for manual intervention in temperature and humidity adjustment, road condition loading, data recording, and other aspects. The testing time for a single batch is reduced from 8 hours to 3 hours, improving testing efficiency by 62.5%. Taking a car manufacturer's intelligent air suspension R&D project as an example, the traditional solution required 30 days to complete "10 operating conditions × 5 batches" of testing, but with this solution, it can be completed in just 12 days, directly shortening the R&D cycle by 60%.

[0091] 2. Flexible adaptation reduces testing costs for multiple vehicle models. The "rapid switching of parameters across multiple vehicle models" design allows for adaptation to different vehicle models such as SUVs, sedans, and MPVs by modifying vehicle dynamics model parameters (such as vehicle weight and wheelbase). This eliminates the need to change mechanical tooling, reducing the vehicle adaptation cycle from 7 days to 2 hours and lowering adaptation costs by 99%. For automakers developing multiple models simultaneously, this avoids the need to build separate test benches for each model, reducing annual testing equipment investment costs by over 5 million yuan per company. It also reduces tooling storage space requirements and increases laboratory utilization by 40%.

[0092] 3. High-precision data reduces reliance on real-vehicle road tests The "multi-dimensional data calibration and accuracy assurance mechanism" reduces the deviation rate between simulation and physical data from 15% to less than 5%, and improves the reliability of test data by 180%. Based on high-precision data, automakers can reduce the number of real-vehicle road tests. For example, a certain model that traditionally requires 10 real-vehicle road tests can be completed in only 3 tests with this solution, significantly saving road test costs and reducing safety risks in real-vehicle testing (such as vehicle failures in extreme environments).

[0093] (iv) Enhanced reliability verification capabilities lead to improved product quality and market competitiveness. 1. Verify the robustness of the system by verifying all types of faults. The "Hardware and Software Fault Collaborative Injection System" expands the fault coverage scenarios from 30 to 120, enabling comprehensive verification of the ECU's fault self-diagnosis and degradation strategies. For example, it can simulate a combined fault of "sensor disconnection + ECU communication packet loss" to verify whether the suspension can switch to "emergency damping mode" to ensure basic vehicle handling. Such combined faults cannot be verified in existing solutions, but this solution can increase the ECU fault handling capability verification coverage from 50% to 95%, significantly reducing the fault risk of intelligent air suspension in real-vehicle use and improving product reliability by 120%.

[0094] 2. Scenario-based fault testing aligns with actual user needs. The "fault level matching design" allocates injection probabilities based on the actual fault occurrence rate, improving the consistency between fault test results and user experience by 80%. For example, increasing the testing frequency for "sensor signal drift" (high-frequency fault) and optimizing the ECU's signal filtering algorithm in advance reduces the "vehicle height misadjustment" problem encountered by users in daily use; for "ECU power failure" (low-frequency fault), the focus is on verifying the emergency mode to ensure driving safety in extreme situations. This effect can reduce the user complaint rate of intelligent air suspension by 60%.

[0095] This solution is based on the PXI bus, featuring powerful multi-core parallel computing; rich IO (Input / Output) interface hardware; supports operation on numerous modeling software platforms; provides unified management and configuration of the system, model, and hardware; maps model variables to controller and message variables; enables model download and online debugging; implements virtual instruments and virtual controls; allows for customizable interface layouts; enables real-time IO board resource allocation and mapping; allows for reference terminal selection and configuration; provides signal conditioning, driving, amplification, filtering, and protection; handles special signal processing, such as current-type signal output conditioning; manages test projects; provides graphical descriptions of test programs; supports multiple operating platforms; and allows one-click generation of test reports (PDF or HTML formats).

[0096] This specification also provides an intelligent air suspension control system, which is used to perform the above-described test method. The system includes a working condition simulation module, a test execution module, a data acquisition and analysis module, and a central control module. The central control module is electrically connected to the working condition simulation module, the test execution module, and the data acquisition and analysis module, respectively. The operating condition simulation module includes a temperature and humidity environment chamber, a multi-axis vibration table, and a fault injection unit. The temperature and humidity environment chamber, the multi-axis vibration table, and the fault injection unit are all electrically connected to the main control module, and the fault injection unit is electrically connected to the test execution module.

[0097] This specification also provides a testing device based on an intelligent air suspension control system. The system includes a working condition simulation module, a test execution module, a data acquisition and analysis module, and a central control module. The working condition simulation module includes a temperature and humidity environment chamber, a multi-axis vibration table, and a fault injection unit. Figure 6 As shown, the device includes: The information sending module 610 is used to respond to the test command, acquire the environmental information, road condition information and fault information of the intelligent air suspension based on the central control module, and send them to the working condition simulation module; The information simulation module 620 is used to simulate the environmental information based on the temperature and humidity environment chamber, simulate the road condition information based on the multi-axis vibration table, and simulate the fault information based on the fault injection unit. The signal transmission module 630 is used to send simulated environment signals, simulated road condition signals and simulated fault signals to the test execution module based on the working condition simulation module, so as to drive the intelligent air suspension to perform test actions. The data acquisition module 640 is used to acquire test data of the intelligent air suspension based on the data acquisition and analysis module; The data analysis module 650 is used to analyze the test data based on the data acquisition and analysis module, and send the data analysis results to the central control module.

[0098] In some embodiments, the test execution module includes a physical assembly of the intelligent air suspension, a tooling stand, a signal interaction unit, and an actuator drive unit. The tooling stand is used to fix the physical assembly. One end of the signal interaction unit is connected to the suspension ECU in the physical assembly, and the other end is connected to the main control module. The signal transmission module includes: The signal transmitting unit is used to send simulated environmental signals, simulated road condition signals, and simulated fault signals to the central control module based on the operating condition simulation module. The instruction sending unit is used to call the central control module to send drive instructions to the actuator drive unit and control instructions to the signal interaction unit based on the simulated environmental signals, simulated road condition signals and simulated fault signals. The test execution unit is used to call the actuator drive unit to drive the air pump and solenoid valve to work based on the drive command, and to call the signal interaction unit to control the physical assembly to perform action tests based on the control command.

[0099] In some embodiments, the data acquisition and analysis module includes a sensor group, a multi-channel data acquisition card, and a real-time data analysis tool. The sensor group is located at a preset position in the test execution module. The data acquisition module includes: The first data transmission unit is used to collect test data based on the sensor group and send it to the multi-channel data acquisition card during the testing process of the intelligent air suspension. The second data transmission unit is used to send the test data to the real-time data analysis tool based on the multi-channel data acquisition card. The data analysis module includes: A threshold receiving unit is used to receive data analysis thresholds sent by the central control module based on the data acquisition and analysis module. The result determination unit is used to analyze the test data and the data analysis threshold based on the data acquisition and analysis module to obtain the data analysis result.

[0100] In some embodiments, the result determination unit is further configured to obtain multiple feature values ​​of the intelligent air suspension during the testing process based on the data acquisition and analysis module, thereby obtaining the test data; and to analyze each feature value and the corresponding abnormal threshold based on the data acquisition and analysis module, thereby obtaining the data analysis result. The device further includes: The early warning module is used to determine the abnormal function type of the intelligent air suspension and generate abnormal early warning information based on the target feature value if the data analysis result indicates that any target feature value exceeds the target abnormal threshold corresponding to the target feature value.

[0101] In some embodiments, the plurality of characteristic values ​​include height adjustment response time and damping force fluctuation range, and the result determination unit includes: The first analysis subunit is used to compare the height adjustment response time with the response time threshold based on the data acquisition and analysis module to obtain a first analysis result. The second analysis subunit is used to determine whether the damping force fluctuation range exceeds the preset fluctuation range and obtain the second analysis result. The result determination subunit is used to determine the data analysis result based on the first analysis result and the second analysis result.

[0102] In some embodiments, the central control module includes a central control computer, a real-time simulation platform, and a vehicle dynamics module. One end of the real-time simulation platform is connected to the central control computer, and the other end is connected to the multi-axis vibration table and the signal interaction unit. The device further includes: The road condition data transmission module is used to acquire vehicle parameters and road condition data of the intelligent air suspension based on the central control computer, and send them to the real-time simulation platform; The vehicle signal transmission module is used to calculate the road excitation force corresponding to the intelligent air suspension based on the vehicle dynamics module, obtain the virtual vehicle signal, and send the road excitation force and the virtual vehicle signal to the real-time simulation platform; The correction signal determination module is used to analyze the vehicle parameters, road condition data, road surface excitation force and virtual vehicle signals based on the real-time simulation platform to obtain the first correction signal of the multi-axis vibration table and the second correction signal of the signal interaction unit. The correction signal sending module is used to send the first correction signal to the multi-axis vibration table based on the real-time simulation platform, and to send the second correction signal to the signal interaction unit; The information simulation module is also used to call the multi-axis vibration table to simulate the road condition information based on the first correction signal; The test execution unit is also used to call the signal interaction unit to control the physical assembly to perform action tests according to the second correction signal.

[0103] In some embodiments, the vehicle dynamics module loads a vehicle dynamics model, and the device further includes: The initial model building module is used to create an initial complete vehicle model that includes the chassis, body, and tires. The data determination module is used to determine the vehicle's weight distribution data, wheel load change data, and road excitation response data based on the vehicle model parameters. The vehicle model construction module is used to construct the vehicle dynamics model based on the initial vehicle model, the weight distribution data, the wheel load change data, and the road excitation response data.

[0104] The apparatus and method embodiments described herein are based on the same inventive concept.

[0105] This specification provides a test device based on an intelligent air suspension control system. The device includes a processor and a memory. The memory stores at least one instruction or at least one program. The processor loads and executes the at least one instruction or at least one program to implement the test method based on the intelligent air suspension control system provided in the above method embodiments.

[0106] Embodiments of the present invention also provide a computer storage medium, which can be disposed in a terminal to store at least one instruction or at least one program related to implementing a test method based on an intelligent air suspension control system in the method embodiments. The at least one instruction or at least one program is loaded and executed by the processor to implement the test method based on an intelligent air suspension control system provided in the above method embodiments.

[0107] Embodiments of the present invention also provide a computer program product or computer program, which includes computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium and executes the computer instructions, causing the computer device to perform the test method based on the intelligent air suspension control system provided in the above-described method embodiments.

[0108] Optionally, in the embodiments of this specification, the storage medium may be located at at least one of the multiple network servers in a computer network. Optionally, in this embodiment, the storage medium may include, but is not limited to, various media capable of storing program code, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.

[0109] The memory described in the embodiments of this specification can be used to store software programs and modules. The processor executes various functional applications and data processing by running the software programs and modules stored in the memory. The memory may mainly include a program storage area and a data storage area. The program storage area may store the operating system, application programs required for the functions, etc.; the data storage area may store data created according to the use of the device, etc. In addition, the memory may include high-speed random access memory, and may also include non-volatile memory, such as at least one disk storage device, flash memory device, or other volatile solid-state storage device. Accordingly, the memory may also include a memory controller to provide the processor with access to the memory.

[0110] The test method embodiments based on the intelligent air suspension control system provided in this specification can be executed on a mobile terminal, computer terminal, server, or similar computing device. Taking running on a server as an example, Figure 7 This is a hardware structure block diagram of a server for a testing method based on an intelligent air suspension control system, as provided in the embodiments of this specification. Figure 7 As shown, the server 700 can vary significantly due to different configurations or performance. It may include one or more Central Processing Units (CPUs) 710 (CPUs 710 may include, but are not limited to, microprocessors (MCUs) or programmable logic devices (FPGAs), a memory 730 for storing data, and one or more storage media 720 (e.g., one or more mass storage devices) for storing application programs 723 or data 722. The memory 730 and storage media 720 may be temporary or persistent storage. The program stored in the storage media 720 may include one or more modules, each module may include a series of instruction operations on the server. Furthermore, the CPU 710 may be configured to communicate with the storage media 720 and execute the series of instruction operations stored in the storage media 720 on the server 700. Server 700 may also include one or more power supplies 760, one or more wired or wireless network interfaces 750, one or more input / output interfaces 740, and / or one or more operating systems 721, such as Windows Server™, Mac OS X™, Unix™, Linux™, FreeBSD™, etc.

[0111] The input / output interface 740 can be used to receive or send data via a network. Specific examples of the network described above may include a wireless network provided by the communication provider of server 700. In one example, the input / output interface 740 includes a network interface controller (NIC), which can connect to other network devices via a base station to communicate with the Internet. In another example, the input / output interface 740 may be a radio frequency (RF) module used for wireless communication with the Internet.

[0112] Those skilled in the art will understand that Figure 7 The structure shown is for illustrative purposes only and does not limit the structure of the aforementioned electronic device. For example, server 700 may also include... Figure 7 The more or fewer components shown, or having the same Figure 7 The different configurations shown.

[0113] As can be seen from the embodiments of the test method, apparatus, equipment, or storage medium based on the intelligent air suspension control system provided by the present invention, the intelligent air suspension control system of the present invention includes a working condition simulation module, a test execution module, a data acquisition and analysis module, and a central control module. The working condition simulation module includes a temperature and humidity environment chamber, a multi-axis vibration table, and a fault injection unit. The test method includes: responding to a test command, acquiring environmental information, road condition information, and fault information of the intelligent air suspension based on the central control module, and sending them to the working condition simulation module; simulating the environmental information based on the temperature and humidity environment chamber, simulating the road condition information based on the multi-axis vibration table, and simulating the fault information based on the fault injection unit; sending simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module based on the working condition simulation module to drive the intelligent air suspension to perform test actions; acquiring test data of the intelligent air suspension based on the data acquisition and analysis module; analyzing the test data based on the data acquisition and analysis module, and sending the data analysis results to the central control module. This invention solves the problem that existing solutions cannot simultaneously simulate extreme environments, complex road conditions, and fault conditions. It achieves accurate reproduction and combined testing of the three-dimensional conditions of "environment-road conditions-fault conditions", thereby improving the testing accuracy of intelligent air suspension under multi-dimensional conditions.

[0114] It should be noted that the order of the embodiments described above is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. Furthermore, specific embodiments of this specification have been described above. Other embodiments are within the scope of the appended claims. In some cases, the actions or steps recorded in the claims can be performed in a different order than that shown in the embodiments and still achieve the desired result. Additionally, the processes depicted in the drawings do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0115] The various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to mutually. Each embodiment focuses on describing the differences from other embodiments. In particular, the embodiments of apparatus, devices, and storage media are basically similar to the method embodiments, so the descriptions are relatively simple; relevant parts can be referred to the descriptions of the method embodiments.

[0116] Those skilled in the art will understand that all or part of the steps of the above embodiments can be implemented by hardware or by a program instructing related hardware. The program can be stored in a computer storage medium, such as a read-only memory, a disk, or an optical disk.

[0117] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A test method based on an intelligent air suspension control system, characterized by, The system comprises a working condition simulation module, a test execution module, a data acquisition and analysis module, and a general control module, the working condition simulation module comprises a temperature and humidity environment cabin, a multi-axis vibration table, and a fault injection unit, and the method comprises: In response to a test instruction, the general control module acquires environmental information, road condition information, and fault information of the intelligent air suspension, and sends them to the working condition simulation module; The temperature and humidity environment cabin simulates the environmental information, the multi-axis vibration table simulates the road condition information, and the fault injection unit simulates the fault information; The working condition simulation module sends simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module to drive the intelligent air suspension to perform a test action; The data acquisition and analysis module acquires test data of the intelligent air suspension; The data acquisition and analysis module analyzes the test data and sends a data analysis result to the general control module.

2. The method of claim 1, wherein, The test execution module comprises a physical assembly of the intelligent air suspension, a tooling bench, a signal interaction unit, and an actuator driving unit, the tooling bench is used to fix the physical assembly, one end of the signal interaction unit is connected with a suspension ECU in the physical assembly, and the other end is connected with the general control module; the working condition simulation module sends simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module to drive the intelligent air suspension to perform a test action, which comprises: The working condition simulation module sends simulated environmental signals, simulated road condition signals, and simulated fault signals to the general control module; The general control module sends driving instructions to the actuator driving unit and control instructions to the signal interaction unit based on the simulated environmental signals, simulated road condition signals, and simulated fault signals; The actuator driving unit drives an air pump and an electromagnetic valve to work based on the driving instructions, and the signal interaction unit controls the physical assembly to perform an action test based on the control instructions.

3. The method of claim 2, wherein, The data acquisition and analysis module comprises a sensor group, a multi-channel data acquisition card, and a real-time data analysis tool, the sensor group is arranged at a preset position of the test execution module, and the data acquisition and analysis module acquires test data of the intelligent air suspension, which comprises: During the test of the intelligent air suspension, the sensor group acquires test data and sends it to the multi-channel data acquisition card; The multi-channel data acquisition card sends the test data to the real-time data analysis tool; The data acquisition and analysis module analyzes the test data and sends a data analysis result to the general control module, which comprises: The data acquisition and analysis module receives a data analysis threshold value sent by the general control module; The data acquisition and analysis module analyzes the test data and the data analysis threshold value to obtain the data analysis result.

4. The method of claim 2, wherein, The data acquisition and analysis module analyzes the test data and the data analysis threshold value to obtain the data analysis result, which comprises: Obtaining a plurality of characteristic values of the intelligent air suspension during a test process based on the data acquisition and analysis module to obtain the test data; Analyzing each characteristic value and the abnormal threshold corresponding to each characteristic value based on the data acquisition and analysis module to obtain the data analysis result; The method further comprises: If the data analysis result indicates that any target characteristic value exceeds the target abnormal threshold corresponding to the target characteristic value, determining the abnormal function type of the intelligent air suspension based on the target characteristic value and generating an abnormal warning information.

5. The method of claim 4, wherein, The plurality of characteristic values include a height adjustment response time and a damping force fluctuation range, and the analysis of each characteristic value and the abnormal threshold corresponding to each characteristic value based on the data acquisition and analysis module to obtain the data analysis result comprises: Comparing the height adjustment response time and the response time threshold based on the data acquisition and analysis module to obtain a first analysis result; Determining whether the damping force fluctuation range exceeds a preset fluctuation range to obtain a second analysis result; According to the first analysis result and the second analysis result, the data analysis result is determined.

6. The method of claim 2, wherein, The total control module comprises a total control computer, a real-time simulation platform and a vehicle dynamics module, one end of the real-time simulation platform is connected with the total control computer, the other end is connected with the multi-axis vibration table and the signal interaction unit, and the method further comprises: Obtaining the vehicle type parameters and road condition data of the intelligent air suspension based on the total control computer and sending them to the real-time simulation platform; Calculating the road excitation force corresponding to the intelligent air suspension based on the vehicle dynamics module, obtaining a virtual vehicle signal, and sending the road excitation force and the virtual vehicle signal to the real-time simulation platform; Analyzing the vehicle type parameters, road condition data, road excitation force and virtual vehicle signal based on the real-time simulation platform to obtain a first correction signal of the multi-axis vibration table and a second correction signal of the signal interaction unit; Sending the first correction signal to the multi-axis vibration table and the second correction signal to the signal interaction unit based on the real-time simulation platform; The simulation of the road condition information based on the multi-axis vibration table comprises: Calling the multi-axis vibration table to simulate the road condition information according to the first correction signal; The calling of the signal interaction unit to control the physical assembly to perform action test based on the control instruction comprises: calling the signal interaction unit to control the physical assembly to perform action test according to the second correction signal.

7. The method of claim 6, wherein, The vehicle dynamics module loads a vehicle dynamics model, and the construction method of the vehicle dynamics module comprises: Establishing an initial vehicle model including chassis, vehicle body and tires; According to the vehicle type parameters, determining the weight distribution data, wheel load change data and road excitation response data of the vehicle; According to the initial vehicle model, the weight distribution data, wheel load change data and road excitation response data, the vehicle dynamics model is constructed.

8. An intelligent air suspension control system characterized by, The system is used for executing the test method of any one of claims 1-7, and the system comprises a working condition simulation module, a test execution module, a data acquisition and analysis module, and a general control module, the general control module is electrically connected with the working condition simulation module, the test execution module, and the data acquisition and analysis module respectively; The working condition simulation module comprises a temperature and humidity environment cabin, a multi-axis vibration table, and a fault injection unit, the temperature and humidity environment cabin, the multi-axis vibration table, and the fault injection unit are electrically connected with the general control module, and the fault injection unit is electrically connected with the test execution module.

9. A test device for an intelligent air suspension control system, characterized by The system comprises a working condition simulation module, a test execution module, a data acquisition and analysis module, and a general control module, the working condition simulation module comprises a temperature and humidity environment cabin, a multi-axis vibration table, and a fault injection unit, and the device comprises: An information sending module is configured to, in response to a test instruction, acquire environmental information, road condition information, and fault information of the intelligent air suspension based on the general control module, and send the information to the working condition simulation module; An information simulation module is configured to simulate the environmental information based on the temperature and humidity environment cabin, simulate the road condition information based on the multi-axis vibration table, and simulate the fault information based on the fault injection unit; A signal sending module is configured to send simulated environmental signals, simulated road condition signals, and simulated fault signals to the test execution module based on the working condition simulation module, so as to drive the intelligent air suspension to perform a test action; A data acquisition module is configured to acquire test data of the intelligent air suspension based on the data acquisition and analysis module; A data analysis module is configured to analyze the test data based on the data acquisition and analysis module, and send a data analysis result to the general control module.

10. A computer storage medium, characterized in that, The computer storage medium stores at least one instruction or at least one program, the at least one instruction or at least one program is loaded and executed by the processor to realize the test method based on the intelligent air suspension control system according to any one of claims 1-7.

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