Closed-loop test system and method for hardware-in-loop control air suspension

Abstract

The invention discloses a closed-loop test system for a hardware-in-loop control air suspension. The closed-loop test system comprises an air suspension ECU to be tested; the simulation module is used for correspondingly simulating various vehicle parameters based on various vehicle parameter simulation models; the hardware simulation module is used for providing a hardware simulation signal for the air suspension ECU; the control module is used for controlling the simulation module and the hardware simulation module based on a test case when a test instruction is received, and outputting a target vehicle parameter and a target hardware simulation signal; the air suspension ECU performs closed-loop testing based on the target vehicle parameters and the target hardware simulation signals, so that real-time interaction and closed-loop logic among various modules in the dynamic state of the whole vehicle can be truly simulated, the simulation precision of the working condition of the air suspension is improved, an accurate test result is provided, and the test efficiency is improved. And the problems of high cost, long period, low repeatability and safety risk under limiting working conditions caused by real vehicle testing are avoided.

Description

Technical Field

[0001] This invention relates to the field of vehicle technology, and in particular to a closed-loop testing system and method for hardware-in-the-loop control of air suspension. Background Technology

[0002] With the continuous development and upgrading of air suspension technology in vehicles, its testing functions have become increasingly important and complex. Currently, testing methods for air suspension can be mainly divided into three categories: real-vehicle road testing, bench testing, and software simulation testing.

[0003] However, all of the above tests have drawbacks. For example, real-vehicle road testing is highly dependent on real vehicles, which has problems such as high cost, long cycle and low repeatability, and there are safety risks under extreme conditions. Bench testing is mainly an open-loop method, which cannot truly reproduce the real-time interaction and closed-loop logic between various modules in the dynamics of the whole vehicle. Software simulation testing has low accuracy in simulating the dynamic characteristics of physical components, and there is a risk that the simulation may pass but the real vehicle may fail. Summary of the Invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art.

[0005] Therefore, one objective of this invention is to propose a closed-loop testing system for hardware-in-the-loop control of air suspension. This system can simulate and test the air suspension ECU by setting up a simulation module, a hardware simulation module, and a control module. This avoids the problems of high cost, long cycle, low repeatability, and safety risks under extreme conditions associated with real-vehicle testing. At the same time, the hardware simulation module can accurately simulate the dynamic characteristics of physical components, improving the simulation accuracy of the air suspension's operation and effectively reducing the risk of simulation success but real-vehicle failure. Furthermore, the air suspension ECU can perform closed-loop testing based on hardware simulation signals, realistically simulating the real-time interaction and closed-loop logic between various modules in the dynamics of the entire vehicle, to accurately simulate the working state of the air suspension during vehicle operation, thereby providing accurate test results.

[0006] Therefore, a second objective of this invention is to propose a closed-loop testing method for hardware-in-the-loop control of air suspension.

[0007] To achieve the above objectives, an embodiment of the first aspect of the present invention provides a closed-loop test system for hardware-in-the-loop control of an air suspension, characterized in that it includes: an air suspension ECU to be tested; a simulation module, which runs multiple vehicle parameter simulation models to simulate multiple vehicle parameters based on the multiple vehicle parameter simulation models; a hardware simulation module connected to the air suspension ECU and providing hardware simulation signals to the air suspension ECU, the hardware simulation signals including sensor simulation signals and actuator load simulation signals; and a control module, which, upon receiving a test command, controls the simulation module and the hardware simulation module based on test cases and outputs target vehicle parameters and target hardware simulation signals; the air suspension ECU performs closed-loop testing based on the target vehicle parameters and the target hardware simulation signals.

[0008] The hardware-in-the-loop control closed-loop testing system for air suspension according to embodiments of the present invention can simulate and test the air suspension ECU by setting up a simulation module, a hardware simulation module, and a control module. This avoids the problems of high cost, long cycle, low repeatability, and safety risks under extreme conditions associated with real-vehicle testing. Furthermore, the hardware simulation module can accurately simulate the dynamic characteristics of physical components, improving the simulation accuracy of the air suspension's operation and effectively reducing the risk of simulation success but real-vehicle failure. Simultaneously, the air suspension ECU can perform closed-loop testing based on hardware simulation signals, realistically simulating the real-time interaction and closed-loop logic between various modules in the dynamics of the entire vehicle, accurately simulating the working state of the air suspension during vehicle operation, thereby providing accurate test results.

[0009] In addition, the hardware-in-the-loop control closed-loop test system for air suspension according to embodiments of the present invention may also have the following additional technical features: In some examples, the multiple vehicle parameter simulation models include: a vehicle dynamics model, a road surface excitation model, a driver model, and an air spring physical model. The driver and road surface excitation models are used to generate road surface roughness parameters, as well as the vehicle's throttle, braking, and steering parameters. The air spring physical model is used to generate parameters of the pressure-volume-height characteristics of the air springs corresponding to the air suspension. The vehicle dynamics model is used to generate vehicle parameters based on the road surface roughness parameters, the throttle parameters, the braking parameters, the steering parameters, and the pressure-volume-height characteristics of the air springs.

[0010] In some examples, the hardware simulation module includes a sensor simulation unit and an actuator load simulation unit, wherein the sensor simulation unit is used to provide the sensor simulation signal to the air suspension ECU; and the actuator load simulation unit is used to provide the actuator load simulation signal to the air suspension ECU.

[0011] In some examples, the hardware simulation module further includes: I / O interface hardware. When the simulation module and the hardware simulation module are controlled based on test cases, the control module is configured to: control the simulation module to output target vehicle parameters corresponding to the test cases based on the test cases; determine the state of the vehicle based on the target vehicle parameters; convert the state of the vehicle into a digital signal based on the I / O interface hardware; and control the hardware simulation module to output the target hardware simulation signal based on the digital signal.

[0012] In some examples, when the air suspension ECU performs closed-loop testing based on the target vehicle parameters and the target hardware simulation signal, it is used to: generate new control commands based on the target hardware simulation signal and send them to the IO interface hardware, so that the IO interface hardware converts the new control commands into new digital signals and feeds them back to the air spring physical model, so as to adjust the pressure-volume-height characteristics parameters of the air spring corresponding to the air suspension, thereby adjusting the target vehicle parameters to determine the adjusted target vehicle parameters; and perform closed-loop testing based on the adjusted target vehicle parameters and the new target hardware simulation signal.

[0013] In some examples, the hardware simulation module further includes a fault injection module, which is used to inject fault signals into the air suspension ECU according to the test cases to test the fault diagnosis and handling capabilities of the air suspension ECU.

[0014] In some examples, the hardware simulation module further includes a bus communication unit for enabling signal interaction between the air suspension ECU, the hardware simulation module, and the simulation module.

[0015] In some examples, the control module is also used to: monitor and record in real time the data output by the simulation module, the air suspension ECU, and the hardware simulation module during the operation of the hardware-in-the-loop control air suspension closed-loop test system.

[0016] In some examples, the control module is also used to: when it is determined that the closed-loop test termination condition is met, control the hardware-in-the-loop control air suspension closed-loop test system to exit the closed-loop test; wherein, the closed-loop test termination condition includes: the closed-loop test time reaches a preset test time or the parameter corresponding to the state of the vehicle reaches a preset parameter threshold or the air suspension ECU triggers a preset fault diagnosis code.

[0017] To achieve the above objectives, a second aspect of the present invention provides a closed-loop testing method for a hardware-in-the-loop controlled air suspension, used in the closed-loop testing system for the hardware-in-the-loop controlled air suspension described in the first aspect of the present invention. The method includes: determining the air suspension ECU to be tested; running multiple vehicle parameter simulation models based on a simulation module to simulate multiple vehicle parameters corresponding to the multiple vehicle parameter simulation models; providing hardware simulation signals to the air suspension ECU, the hardware simulation signals including sensor simulation signals and actuator load simulation signals; upon receiving a test command, controlling the simulation module and the hardware simulation module based on test cases, and outputting target vehicle parameters and target hardware simulation signals; and performing a closed-loop test based on the target vehicle parameters and the target hardware simulation signals.

[0018] The hardware-in-the-loop control closed-loop test method for air suspension according to the present invention can simulate the test of the air suspension ECU, avoiding the problems of high cost, long cycle, low repeatability, and safety risks under extreme conditions caused by real vehicle testing. At the same time, it can accurately simulate the dynamic characteristics of physical components, improve the simulation accuracy of the air suspension's working condition, and effectively reduce the risk of simulation success but real vehicle failure. In addition, it can perform closed-loop testing based on hardware simulation signals, realistically simulating the real-time interaction and closed-loop logic between various modules in the dynamics of the whole vehicle, so as to accurately simulate the working state of the air suspension during vehicle driving, thereby providing accurate test results.

[0019] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0020] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of the structure for closed-loop testing of a hardware-in-the-loop control air suspension according to an embodiment of the present invention. Figure 2 This is a schematic diagram of the closed-loop test process for a hardware-in-the-loop control air suspension according to an embodiment of the present invention.

[0021] Figure label: Hardware-in-the-loop control closed-loop test device for air suspension - 100; air suspension ECU - 110; simulation module - 120; hardware simulation module - 130; control module - 140. Detailed Implementation

[0022] To provide a more detailed understanding of the features and technical content of the embodiments of the present invention, the implementation of the embodiments of the present invention will be described in detail below with reference to the accompanying drawings. The accompanying drawings are for illustrative purposes only and are not intended to limit the embodiments of the present invention. In the following technical description, for ease of explanation, several details are used to provide a full understanding of the disclosed embodiments. However, one or more embodiments may still be implemented without these details.

[0023] The following is for reference. Figures 1-2 A closed-loop test system 100 and method for hardware-in-the-loop control of air suspension according to embodiments of the present invention are described.

[0024] Figure 1 This is a schematic diagram of a closed-loop test system 100 for hardware-in-the-loop control of an air suspension according to an embodiment of the present invention. Figure 1 As shown, the system includes: The air suspension ECU110 to be tested.

[0025] Specifically, in the hardware-in-the-loop control air suspension closed-loop test system 100, an air suspension ECU 110 to be tested is first set up. This ECU can receive signals from various sensors and execute control algorithms to drive actuators (such as solenoid valves and air compressors) to dynamically adjust vehicle height and driving posture. It is understood that the air suspension ECU 110 to be tested is the only real structure in the hardware-in-the-loop control air suspension closed-loop test system 100. By testing the air suspension ECU 110, it can be verified whether it can correctly receive sensor signals, accurately make control decisions, and effectively control the actions of actuators, thereby ensuring that the air suspension can work normally in a real vehicle.

[0026] Simulation module 120 runs multiple vehicle parameter simulation models to simulate multiple vehicle parameters based on these models.

[0027] Specifically, the hardware-in-the-loop control closed-loop test system 100 for air suspension also includes a simulation module 120, which can run various vehicle parameter simulation models to simulate various vehicle parameters. For example, it can simulate various parameters of the vehicle under different driving speeds, different road conditions (such as bumpy roads and flat roads), and different loads, such as vehicle height, acceleration, and wheel speed, to provide conditions close to the real vehicle driving environment for testing.

[0028] The hardware simulation module 130 is connected to the air suspension ECU 110 and provides hardware simulation signals to the air suspension ECU 110. The hardware simulation signals include sensor simulation signals and actuator load simulation signals.

[0029] Specifically, the hardware-in-the-loop test system 100 for controlling the air suspension also includes a hardware simulation module 130, which is connected to the air suspension ECU 110 and can provide hardware simulation signals to the air suspension ECU 110. These hardware simulation signals include sensor simulation signals and actuator load simulation signals. It can be understood that the sensor simulation signals simulate signals collected by sensors in an actual vehicle, such as the vehicle height signal collected by the height sensor and the air spring pressure signal collected by the pressure sensor. The actuator load simulation signals simulate the electrical load signals of actuators such as solenoid valves and air pump motors, in order to construct a realistic electrical load environment.

[0030] The control module 140 is used to control the simulation module 120 and the hardware simulation module 130 based on the test cases when it receives a test command, and output the target vehicle parameters and the target hardware simulation signal.

[0031] Specifically, the hardware-in-the-loop control closed-loop test system 100 for air suspension also includes a control module 140, which, upon receiving test commands from a host computer, can precisely control the simulation module 120 and the hardware simulation module 130 based on pre-set test cases (e.g., "driving at 60km / h in off-road mode", "static lift mode test", "simulating height sensor failure"). For example, according to the test case requirements, the simulation module 120 is controlled to simulate and generate target vehicle parameters, while the hardware simulation module 130 is controlled to output corresponding target hardware simulation signals based on the corresponding target vehicle parameters, so that the air suspension ECU can operate according to the target hardware simulation signals, thereby realizing the test of the air suspension ECU.

[0032] The air suspension ECU110 performs closed-loop testing based on target vehicle parameters and target hardware simulation signals.

[0033] Specifically, the air suspension ECU can perform closed-loop testing based on the target hardware simulation signal output by the control module 140. For example, the air suspension ECU can generate control commands according to its internal control algorithm based on the received target hardware simulation signal, and correct the target vehicle parameters according to the control commands. Based on the corrected target vehicle parameters, a new target hardware simulation signal is determined to form a closed-loop feedback system for the air suspension ECU, thereby enabling comprehensive and realistic testing of the air suspension ECU's performance and control logic under various operating conditions.

[0034] Therefore, the aforementioned hardware-in-the-loop control air suspension closed-loop test system 100 can simulate and test the air suspension ECU 110 by setting up a simulation module 120, a hardware simulation module 130, and a control module 140. This avoids the problems of high cost, long cycle, low repeatability, and safety risks under extreme conditions associated with real-vehicle testing. At the same time, the hardware simulation module 130 can accurately simulate the dynamic characteristics of physical components, improving the simulation accuracy of the air suspension's operation and effectively reducing the risk of simulation success but real-vehicle failure. Furthermore, the air suspension ECU 110 can perform closed-loop testing based on hardware simulation signals, realistically simulating the real-time interaction and closed-loop logic between various modules in the dynamics of the entire vehicle, to accurately simulate the working state of the air suspension during vehicle operation, thereby providing accurate test results.

[0035] In one embodiment of the present invention, multiple vehicle parameter simulation models are included, including: a vehicle dynamics model, a driver and road excitation model, and an air spring physical model. The driver and road excitation model is used to generate road surface roughness parameters and vehicle throttle, braking, and steering parameters. The air spring physical model is used to generate parameters of the pressure-volume-height characteristics of the air spring corresponding to the air suspension. The vehicle dynamics model is used to generate vehicle parameters based on the road surface roughness parameters, throttle parameters, braking parameters, steering parameters, and air spring pressure-volume-height characteristics parameters.

[0036] Specifically, when conducting closed-loop testing of hardware-in-the-loop control air suspension, to ensure high fidelity of the test, multiple vehicle parameter simulation models can be set up, including vehicle dynamics model, road excitation model, driver model, and air spring physical model. Among them, the driver and road model can generate throttle, brake, and steering signals corresponding to the vehicle, as well as road surface roughness parameters, according to the test cases. At the same time, the air spring physical model can generate parameters of the pressure-volume-height characteristics of the air spring corresponding to the air suspension according to the instructions of the air suspension ECU110. Furthermore, the vehicle dynamics model can receive parameter data from the driver and road excitation model and the air spring physical model, and comprehensively calculate and generate vehicle parameters, including but not limited to the vertical motion parameters, longitudinal motion parameters, and lateral motion parameters of the vehicle.

[0037] In one embodiment of the present invention, the hardware simulation module 130 includes a sensor simulation unit and an actuator load simulation unit, wherein the sensor simulation unit is used to provide sensor simulation signals to the air suspension ECU 110; and the actuator load simulation unit is used to provide actuator load simulation signals to the air suspension ECU 110.

[0038] Specifically, the hardware simulation module 130 mainly includes a sensor simulation unit and an actuator load simulation unit. The sensor simulation unit can be used to provide sensor simulation signals to the air suspension ECU 110, including but not limited to vehicle height signals collected by the height sensor and air spring pressure signals collected by the simulated pressure sensor. At the same time, the actuator load simulation unit can be used to provide actuator load simulation signals to the air suspension ECU 110, including but not limited to signals simulating the electrical load of actuators such as solenoid valves and air pump motors, in order to construct a realistic electrical load environment.

[0039] In one embodiment of the present invention, the hardware simulation module 130 further includes: IO interface hardware. When the simulation module 120 and the hardware simulation module 130 are controlled based on test cases, the control module 140 is used to: control the simulation module 120 to output target vehicle parameters corresponding to the test cases based on the test cases. Determine the vehicle's status based on the target vehicle's parameters; The vehicle's status is converted into digital signals based on I / O interface hardware. The target hardware simulation signal is output based on the digital signal control hardware simulation module 130.

[0040] Specifically, the hardware simulation module 130 also includes I / O interface hardware, which can realize signal acquisition and conversion, including but not limited to converting physical signals into digital signals.

[0041] Furthermore, when controlling the simulation module 120 and the hardware simulation module 130 based on test cases, the control module 140 can control the simulation module 120 to output target vehicle parameters corresponding to the test cases, including but not limited to generating throttle, brake, and steering signals for the vehicle based on the test cases, as well as road surface roughness parameters, and controlling the air spring physical model to generate parameters of the pressure-volume-height characteristics of the air spring corresponding to the air suspension, thereby calculating the target vehicle parameters through the vehicle dynamics model.

[0042] Furthermore, the vehicle's state can be determined based on the target vehicle parameters, that is, the real-time dynamic parameters of the vehicle can be calculated based on the target vehicle parameters, such as the absolute height of the four wheels, the vehicle's pitch angle, and the roll angle.

[0043] Furthermore, the vehicle's status can be converted into digital signals based on the IO interface hardware. That is, the calculated vehicle status (such as "left front height reduced by 2mm") can be converted into digital signals (such as binary code, CAN message) through the signal conditioning and conversion function of the IO interface hardware.

[0044] Furthermore, the hardware simulation module 130 can be controlled by digital signals to output target hardware simulation signals. Digital signals can be sent to the hardware simulation module 130 so that the hardware simulation module 130 can output the corresponding target hardware simulation signals, such as simulating a 2.5V voltage or simulating a 10Ω electrical load signal for the solenoid valve.

[0045] In one embodiment of the present invention, when the air suspension ECU110 performs closed-loop testing based on the target vehicle parameters and the target hardware analog signal, it is used to: generate new control commands based on the target hardware analog signal and send them to the IO interface hardware, so that the IO interface hardware converts the new control commands into new digital signals and feeds them back to the air spring physical model, so as to adjust the pressure-volume-height characteristics parameters of the air spring corresponding to the air suspension, thereby adjusting the target vehicle parameters to determine the adjusted target vehicle parameters; Closed-loop testing was conducted based on the adjusted target vehicle parameters and the new target hardware simulation signals.

[0046] Specifically, during the closed-loop test of the air suspension ECU110 based on the target hardware analog signal, the air suspension ECU110, upon receiving the target hardware analog signal, can first make a judgment based on its internally embedded control algorithm and logic, generate new control commands, and send them to the IO interface hardware through communication signal interaction. The IO interface hardware then converts the new control commands into new digital signals and feeds them back to the air spring physical model to adjust the pressure-volume-height characteristics parameters of the corresponding air spring (e.g., according to the "inflate" command, changes its internal state (increases gas mass) and outputs new spring stiffness and force). At this time, the air spring physical model outputs new parameters to the vehicle dynamics model, thereby adjusting the target vehicle parameters to determine the adjusted target vehicle parameters.

[0047] Furthermore, closed-loop testing can be performed based on the adjusted target vehicle parameters and the new target hardware simulation signals, that is, returning to the process of closed-loop testing of the air suspension ECU110 based on the target vehicle parameters and the target hardware simulation signals, thereby realizing the process of cyclic testing.

[0048] In one embodiment of the present invention, the hardware simulation module 130 further includes a fault injection module, which is used to inject fault signals into the air suspension ECU 110 according to test cases to test the fault diagnosis and handling capabilities of the air suspension ECU 110.

[0049] Specifically, the hardware simulation module 130 also includes a fault injection module, which can inject fault signals into the air suspension ECU 110 according to the test cases to test the fault diagnosis and processing capabilities of the air suspension ECU 110. The fault signals include, but are not limited to, sensor faults (sensor signal loss, jamming, etc.), communication bus faults (such as bus shutdown, message loss, verification error, etc.) or actuator load faults (actuator open circuit / short circuit, etc.).

[0050] In one embodiment of the present invention, the hardware simulation module 130 further includes a bus communication unit, which is used to realize signal interaction between the air suspension ECU 110, the hardware simulation module 130, the control module 140 and the simulation module 120.

[0051] Specifically, the hardware simulation module 130 also includes a bus communication unit, which can be used to realize signal interaction between the air suspension ECU 110, the hardware simulation module 130, the control module 140, and the simulation module 120. For example, the air suspension ECU can generate control commands based on its internal control algorithm and the received hardware simulation signals, while the control module 140 can control the simulation module 120 and the hardware simulation module 130 through signal interaction. At the same time, the air suspension ECU 110 can also receive target vehicle parameters and target hardware simulation signals through signal interaction to perform closed-loop testing.

[0052] In one embodiment of the present invention, the control module 140 is further configured to: monitor and record in real time the data output by the simulation module 120, the air suspension ECU 110 and the hardware simulation module 130 during the operation of the hardware-in-the-loop control air suspension closed-loop test system 100.

[0053] Specifically, during the operation of the hardware-in-the-loop control air suspension closed-loop test system 100, the control module 140 can also monitor and record the data output by the simulation module 120, the air suspension ECU 110, and the hardware simulation module 130 in real time, so as to promptly detect data anomalies that occur during the operation of the hardware-in-the-loop control air suspension closed-loop test system 100, such as data exceeding the normal range or data mutations, thereby ensuring that the entire hardware-in-the-loop control air suspension closed-loop test system 100 operates in a stable and reliable state.

[0054] In specific embodiments, the monitored and recorded data includes, but is not limited to, vehicle dynamic parameters such as vehicle acceleration and vehicle height change rate, environmental parameters such as road surface unevenness, as well as information exchange data such as vehicle height sensor signals, air spring pressure sensor signals, and feedback signals from closed-loop tests of hardware-in-the-loop controlled air suspension.

[0055] In one embodiment of the present invention, the control module 140 is further configured to: when it is determined that the closed-loop test end conditions are met, control the hardware-in-the-loop control of the closed-loop test system 100 of the air suspension to exit the closed-loop test; wherein, the closed-loop test end conditions include: the closed-loop test time reaches a preset test time or the parameters corresponding to the vehicle state reach a preset parameter threshold or the air suspension ECU 110 triggers a preset fault diagnosis code.

[0056] Specifically, during the closed-loop test of the air suspension ECU 110 based on the target hardware simulation signal, the control module 140 can also determine whether the closed-loop test termination condition is met. If so, the closed-loop test system 100 controlling the hardware-in-the-loop control of the air suspension exits the closed-loop test, that is, the closed-loop interaction is terminated, the control simulation module 120, the hardware simulation module 130, and the air suspension ECU 110 stop working, and the closed-loop test termination status is recorded. The closed-loop test termination conditions include: the closed-loop test time reaches the preset test time (i.e., the closed-loop test time reaches the upper limit of the test run time), or the parameters corresponding to the vehicle's state (such as vehicle height, spring pressure, pitch angle, etc.) reach the preset parameter threshold, or the air suspension ECU 110 triggers a preset fault diagnosis code (such as the fault diagnosis code generated by the fault injection module injecting fault signals into the air suspension ECU 110 according to the test case, etc.).

[0057] In summary, the hardware-in-the-loop control air suspension closed-loop test system 100 according to the embodiments of the present invention can simulate and test the air suspension ECU 110 by setting up a simulation module 120, a hardware simulation module 130, and a control module 140. This avoids the problems of high cost, long cycle, low repeatability, and safety risks under extreme conditions caused by real vehicle testing. At the same time, the hardware simulation module 130 can accurately simulate the dynamic characteristics of physical components, improve the simulation accuracy of the air suspension's working condition, and effectively reduce the risk of simulation success but failure in the real vehicle. Furthermore, the air suspension ECU 110 can perform closed-loop testing based on hardware simulation signals, realistically simulating the real-time interaction and closed-loop logic between various modules in the dynamics of the whole vehicle, so as to accurately simulate the working state of the air suspension during vehicle driving, thereby providing accurate test results.

[0058] A further embodiment of the present invention proposes a closed-loop testing method for hardware-in-the-loop control of air suspension, such as... Figure 2 As shown, the closed-loop test method for hardware-in-the-loop control of air suspension includes the following steps: determining the air suspension ECU to be tested; running multiple vehicle parameter simulation models based on the simulation module to simulate multiple vehicle parameters corresponding to the simulation models; providing hardware simulation signals to the air suspension ECU, including sensor simulation signals and actuator load simulation signals; upon receiving a test command, controlling the simulation module and hardware simulation module based on the test cases, and outputting target vehicle parameters and target hardware simulation signals; and performing closed-loop testing based on the target vehicle parameters and target hardware simulation signals.

[0059] In some embodiments, controlling the simulation module and the hardware simulation module based on test cases includes: controlling the simulation module to output target vehicle parameters corresponding to the test cases; determining the vehicle state based on the target vehicle parameters; converting the vehicle state into a digital signal based on the IO interface hardware; and controlling the hardware simulation module to output a target hardware simulation signal based on the digital signal.

[0060] In some embodiments, the air suspension ECU performs closed-loop testing based on target vehicle parameters and target hardware analog signals, including: generating new control commands based on the target hardware analog signals and sending them to the IO interface hardware, so that the IO interface hardware converts the new control commands into new digital signals and feeds them back to the air spring physical model to adjust the pressure-volume-height characteristics parameters of the air spring corresponding to the air suspension, thereby adjusting the target vehicle parameters to determine the adjusted target vehicle parameters; and performing closed-loop testing based on the adjusted target vehicle parameters and the new target hardware analog signals.

[0061] In some embodiments, the closed-loop test method for hardware-in-the-loop control of air suspension further includes: injecting fault signals into the air suspension ECU according to test cases to test the fault diagnosis and handling capabilities of the air suspension ECU.

[0062] In some embodiments, the closed-loop test method for hardware-in-the-loop control of air suspension further includes: during the operation of the closed-loop test system for hardware-in-the-loop control of air suspension, real-time monitoring and recording of the data output by the simulation module, air suspension ECU, control module, and hardware simulation module.

[0063] In some embodiments, the closed-loop test method for hardware-in-the-loop control of air suspension further includes: when it is determined that the closed-loop test termination condition is met, controlling the closed-loop test system for hardware-in-the-loop control of air suspension to exit the closed-loop test; wherein the closed-loop test termination condition includes: the closed-loop test time reaches a preset test time or the parameter corresponding to the vehicle state reaches a preset parameter threshold or the air suspension ECU triggers a preset fault diagnosis code.

[0064] The hardware-in-the-loop control closed-loop testing method for air suspension according to the present invention can simulate testing of the air suspension ECU, avoiding the problems of high cost, long cycle, low repeatability, and safety risks under extreme conditions caused by real vehicle testing. At the same time, it can accurately simulate the dynamic characteristics of physical components, improve the simulation accuracy of the air suspension's working condition, and effectively reduce the risk of simulation success but real vehicle failure. Furthermore, it can perform closed-loop testing based on hardware simulation signals, realistically simulating the real-time interaction and closed-loop logic between various modules in the dynamics of the whole vehicle, so as to accurately simulate the working state of the air suspension during vehicle driving, thereby providing accurate test results.

[0065] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example.

[0066] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A closed-loop test system for hardware-in-the-loop control of an air suspension, characterized in that, include: The air suspension ECU to be tested; The simulation module runs multiple vehicle parameter simulation models to simulate multiple vehicle parameters based on the corresponding vehicle parameter simulation models. A hardware simulation module is connected to the air suspension ECU and provides hardware simulation signals to the air suspension ECU, the hardware simulation signals including sensor simulation signals and actuator load simulation signals; The control module is used to control the simulation module and the hardware simulation module based on the test cases when a test command is received, and to output the target vehicle parameters and the target hardware simulation signal. The air suspension ECU performs closed-loop testing based on the target vehicle parameters and the target hardware simulation signals.

2. The closed-loop test system for hardware-in-the-loop control of air suspension according to claim 1, characterized in that, The various vehicle parameter simulation models include: a vehicle dynamics model, a road surface excitation model, a driver model, and an air spring physical model, wherein: The driver and road excitation model is used to generate road roughness parameters as well as the vehicle's throttle, braking and steering parameters. The physical model of the air spring is used to generate parameters of the pressure-volume-height characteristics of the air spring corresponding to the air suspension. The vehicle dynamics model is used to generate vehicle parameters based on the road surface roughness parameters, the throttle parameters, the braking parameters, the steering parameters, and the pressure-volume-height characteristics of the air spring.

3. The closed-loop test system for hardware-in-the-loop control of air suspension according to claim 1, characterized in that, The hardware simulation module includes: a sensor simulation unit and an actuator load simulation unit, wherein... The sensor simulation unit is used to provide the sensor simulation signal to the air suspension ECU; The actuator load simulation unit is used to provide the actuator load simulation signal to the air suspension ECU.

4. The closed-loop test system for hardware-in-the-loop control of air suspension according to claim 2, characterized in that, The hardware simulation module further includes: I / O interface hardware. When controlling the simulation module and the hardware simulation module based on test cases, the control module is used for: Based on the test cases, the simulation module is controlled to output target vehicle parameters corresponding to the test cases; The state of the vehicle is determined based on the target vehicle parameters; The vehicle's state is converted into a digital signal based on the IO interface hardware. The target hardware simulation signal is output by controlling the hardware simulation module based on the digital signal.

5. The closed-loop test system for hardware-in-the-loop control of air suspension according to claim 4, characterized in that, When the air suspension ECU performs closed-loop testing based on the target vehicle parameters and the target hardware simulation signals, it is used for: New control commands are generated based on the target hardware analog signals and sent to the IO interface hardware, so that the IO interface hardware converts the new control commands into new digital signals and feeds them back to the air spring physical model to adjust the pressure-volume-height characteristics parameters of the air spring corresponding to the air suspension, thereby adjusting the target vehicle parameters to determine the adjusted target vehicle parameters. A closed-loop test is performed based on the adjusted target vehicle parameters and the new target hardware simulation signal.

6. The closed-loop test system for hardware-in-the-loop control of air suspension according to claim 1, characterized in that, The hardware simulation module further includes a fault injection module, which is used to inject fault signals into the air suspension ECU according to the test cases in order to test the fault diagnosis and handling capabilities of the air suspension ECU.

7. The closed-loop test system for hardware-in-the-loop control of air suspension according to claim 1, characterized in that, The hardware simulation module further includes a bus communication unit, which is used to realize signal interaction between the air suspension ECU, the hardware simulation module, and the simulation module.

8. The closed-loop test system for hardware-in-the-loop control of air suspension according to claim 1, characterized in that, The control module is also used for: During the operation of the closed-loop test system for hardware-in-the-loop control of the air suspension, the data output by the simulation module, the air suspension ECU, and the hardware simulation module are monitored and recorded in real time.

9. The closed-loop test system for hardware-in-the-loop control of air suspension according to claim 1, characterized in that, The control module is further configured to: when it is determined that the closed-loop test termination condition is met, control the hardware-in-the-loop control air suspension closed-loop test system to exit the closed-loop test; wherein, the closed-loop test termination condition includes: the closed-loop test time reaches a preset test time or the parameter corresponding to the vehicle's state reaches a preset parameter threshold or the air suspension ECU triggers a preset fault diagnosis code.

10. A closed-loop test method for hardware-in-the-loop control of an air suspension, characterized in that, A closed-loop test system for a hardware-in-the-loop controlled air suspension as described in any one of claims 1-9, the method comprising: Identify the air suspension ECU to be tested; The simulation module runs multiple vehicle parameter simulation models to simulate multiple vehicle parameters based on the various vehicle parameter simulation models. The air suspension ECU is provided with hardware analog signals, which include sensor analog signals and actuator load analog signals. Upon receiving a test instruction, the simulation module and the hardware simulation module are controlled based on the test cases, and the target vehicle parameters and target hardware simulation signals are output. Closed-loop testing is performed based on the target vehicle parameters and the target hardware simulation signals.

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