Air suspension HIL test system and method based on entity air storage tank
By introducing an air suspension HIL testing system that combines a physical air tank and a real-time simulator, the problem that existing air spring simulation models cannot accurately reflect air circuit actuators has been solved, achieving high-fidelity test verification and reliable test results.
Patent Information
- Application Number
- CN202511867463.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-11
- Publication Date
- 2026-04-03
AI Technical Summary
Existing hardware-in-the-loop testing methods rely on pure software models to simulate air springs, which cannot truly reflect the controller's driving performance on pneumatic actuators, resulting in insufficient test fidelity, missing verification of the execution process, and low reliability of test results.
An air suspension HIL test system based on a physical air tank is adopted, which combines the air spring model and vehicle dynamics model in a real-time simulator. Through a real air circuit execution and feedback unit, it realizes the leap from pure signal simulation to real air circuit hardware-in-the-loop test mode.
This significantly improves the physical realism of the test scenario, the verifiability of the execution process, and the reliability of the closed-loop results, ensuring comprehensive verification of the ASU assembly module and the credibility of the test results.
Smart Images
Figure CN121785284A_ABST
Abstract
Description
Technical Field
[0001] This specification relates to the field of suspension testing technology, and in particular to an air suspension HIL testing system and method based on a physical air tank. Background Technology
[0002] Hardware-in-the-loop (HIL) simulation testing is a core component of automotive electronic control system development and verification. Its key lies in building a test platform that can connect to real controller hardware and faithfully reproduce the complex operating environment of the vehicle. For electronically controlled air suspension systems, the main challenges of HIL testing lie in the accurate simulation and closed-loop interaction of key aerodynamic characteristics of the air spring. Current mainstream solutions mostly employ pure software models to simulate the dynamic characteristics of the air spring, generating spring pressure, volume, and other signals in real-time by solving the gas state equation and injecting them as virtual sensing data into the controller under test. However, this pure model method has inherent limitations: First, it completely bypasses the testing of the controller under test's ability to drive real pneumatic actuators (such as solenoid valves) and their dynamic response, making it impossible to verify the interface compatibility and performance between the controller and the real mechanism. Second, the software model struggles to accurately reproduce the nonlinear factors present in real pneumatic systems, such as the response delay and opening / closing characteristics of solenoid valves, and the pressure loss and volumetric effect of gas flowing in pipelines. This results in a fidelity gap between the simulation environment and the real vehicle environment, reducing the reliability of the test results. Third, when real gas flows rapidly within the storage tank, its temperature is affected by both adiabatic effects and environmental heat exchange, changing in real time and difficult to measure directly and accurately. Ignoring this effect or measuring it inaccurately will lead to deviations in the mass flow rate calculation based on the ideal gas equation, thereby compromising the physical accuracy of the hardware-in-the-loop test closed loop.
[0003] Therefore, there is an urgent need for an air suspension HIL testing system and method based on a physical air tank to solve the above problems. Summary of the Invention In view of this, the present invention aims to propose an air suspension HIL test system based on a physical air tank, in order to solve the problems of insufficient test fidelity, lack of verification of the execution link, and low reliability of test results caused by the existing hardware-in-the-loop test method, which relies on a pure software model to simulate the air spring and cannot truly reflect the driving performance of the controller on the air circuit actuator.
[0004] To achieve the above objectives, the present invention adopts the following technical solution: An air suspension HIL testing system based on a physical gas storage tank, the system comprising: a test control module, an ASU assembly module, and a gas supply module; The test control module includes a host computer and a real-time simulator; the host computer is communicatively connected to the real-time simulator and is used to control the real-time simulator to load a preset simulation model and configure the test scenario; The real-time simulator is communicatively connected to the ASU assembly module, and the ASU assembly module is electrically connected to the gas supply module; the real-time simulator is equipped with an air spring model and a vehicle dynamics model. The gas supply module includes an air tank, an air pump, and a distribution valve. The air pump and distribution valve control the operation of the air tank according to the gas control commands output by the ASU assembly module to simulate the inflation and deflation process of a real vehicle and provide pressure data for the air spring model. The information generated by the operation of the air spring model is output to the vehicle dynamics model to complete the closed-loop simulation test of the whole vehicle.
[0005] The beneficial effects of this solution are as follows: In existing hardware-in-the-loop testing technologies, the verification of electronically controlled air suspensions generally relies excessively on pure software simulation models, which limits the fidelity of the test environment to real vehicle operating conditions and the reliability of test conclusions. This system introduces a real air tank as a real air circuit execution and feedback unit, combined with an air spring model and vehicle dynamics model deployed in a real-time simulator, realizing a leap from pure signal simulation to a real air circuit hardware-in-the-loop testing mode, effectively improving the physical realism of the test scenario, the verifiability of the execution links, and the reliability of closed-loop results.
[0006] Furthermore, the real-time simulator is also equipped with a driver model; the driver model is used to provide driving operation signals to the vehicle dynamics model according to a preset test scenario.
[0007] Beneficial effects: This setup enables the testing process to automatically, accurately, and repeatably execute various standard or custom driving conditions, effectively replacing manual operation and ensuring the consistency of test conditions and the objective comparability of evaluation results.
[0008] Furthermore, the gas storage tank includes a vehicle-mounted gas storage tank and a fixed-volume high-pressure gas storage tank; the vehicle-mounted gas storage tank is used to provide a high-pressure gas source and exchanges gas with the fixed-volume high-pressure gas storage tank by controlling the distribution valve.
[0009] Beneficial effects: By introducing a fixed-volume high-pressure gas storage tank and a real vehicle gas storage tank, the system can transform the virtual gas flow that only exists in the model in traditional pure software simulation into measurable gas exchange that occurs in the real physical gas path and is controlled by the real ASU assembly module. This breaks through the inherent limitations of pure virtual simulation in terms of gas path fidelity and significantly improves the credibility of test results.
[0010] Furthermore, the gas exchange between the actual vehicle gas tank and the fixed-volume high-pressure gas tank includes: filling the actual vehicle gas tank with gas, releasing the actual vehicle gas tank with gas, filling the fixed-volume high-pressure gas tank with gas from the actual vehicle gas tank, and releasing the gas from the fixed-volume high-pressure gas tank to the actual vehicle gas tank.
[0011] Beneficial effects: This gas exchange mechanism fully replicates all gas path operation modes of this system, ensuring comprehensive verification of the ASU assembly module under various real working conditions.
[0012] Furthermore, the air spring model includes an LF spring, an RF spring, an LR spring, and an RR spring; the four air springs correspond to the four fixed-volume high-pressure gas storage tanks respectively through specific data interfaces.
[0013] Beneficial effects: This design enables independent, parallel and high-fidelity simulation of the air spring states of the four wheels, ensuring that the system can accurately reproduce the real suspension dynamics of the vehicle under complex postures, thereby significantly improving the verification depth and test scenario coverage of the multi-channel coordinated control capability of the ASU assembly module.
[0014] Furthermore, each fixed-volume high-pressure gas storage tank is equipped with a pressure sensor and a temperature sensor at its inlet to monitor the internal pressure of the tank in real time. and temperature Furthermore, each fixed-volume high-pressure gas storage tank is equipped with a leak-free solenoid valve at its gas inlet, which is used to seal and fix it in the non-test state to prevent gas leakage, and to precisely control the gas flow during the test state.
[0015] Beneficial effects: By equipping the inlet of each fixed-volume high-pressure gas storage tank with pressure and temperature sensors, real-time and accurate data on internal pressure and temperature can be collected, providing reliable monitoring data for the precise calculation of subsequent gas flow rate, quality, and air spring force. The installation of a leak-free solenoid valve at the gas inlet can achieve gas tank sealing and pressure maintenance during non-testing phases, effectively avoiding inaccurate test environments caused by gas leaks. It can also precisely control gas flow during testing, ensuring the timeliness and stability of gas path switching, while reducing test cost losses caused by gas leaks.
[0016] Furthermore, each fixed-volume high-pressure gas storage tank is also equipped with a patch thermocouple and a heat-insulating sleeve on the outer side of its tank wall; the patch thermocouple is used to detect the tank wall temperature of the fixed-volume high-pressure gas storage tank in real time. The heat insulation sleeve is used to reduce heat exchange between the fixed-volume high-pressure gas storage tank and the environment.
[0017] Beneficial effects: This configuration effectively isolates the interference of ambient temperature fluctuations on the testing process, and by monitoring the tank wall temperature, a key thermal boundary, it provides crucial data for accurately assessing the thermodynamic state of the gas, thereby ensuring the stability and repeatability of the system's test results under different ambient temperatures.
[0018] Furthermore, an air suspension HIL test method based on a physical air tank is applied to the aforementioned air suspension HIL test system based on a physical air tank, the method comprising: S1, Pressure based on a fixed-volume high-pressure gas storage tank Calculate the mass of gas in a fixed-volume high-pressure gas storage tank. The calculation logic is as follows: ; In the formula, The mass of gas in a fixed-volume high-pressure gas storage tank; The volume of a fixed-volume high-pressure gas storage tank; The molar mass of air; This is the universal gas constant; Equivalent gas temperature; The internal pressure of a fixed-volume high-pressure gas storage tank; S2. Obtain the spring compression of the air spring model from the vehicle dynamics model. Based on the spring compression amount Calculate the volume of the air spring. and the air chamber area of the air spring ; S3, based on the volume of the air spring and the air chamber area of the air spring Calculate the internal pressure of the air spring The calculation logic is as follows: ; In the formula, This refers to the internal pressure of the air spring. Let V be the volume of the air spring. The mass of gas in a fixed-volume high-pressure gas storage tank; The molar mass of air; This is the universal gas constant; The temperature inside the air spring; S4. Calculate the output force exerted by the air spring on the vehicle body. The calculation logic is as follows: ; In the formula, The air springs apply output force to the vehicle body; This refers to the internal pressure of the air spring. Atmospheric pressure; This represents the air chamber area of the air spring.
[0019] Beneficial effects: This method not only makes full use of the physical monitoring data of the physical air tank to ensure the authenticity of the parameters, but also combines the air spring model to realize the accurate simulation of mechanical characteristics, effectively improving the simulation accuracy of aerodynamic coupling characteristics in air suspension HIL test, providing reliable mechanical data support for verifying the effectiveness of ASU control strategy, while simplifying the calculation link of complex multi-physics field, and taking into account the accuracy and efficiency of the test.
[0020] Furthermore, in step S1, the equivalent gas temperature The calculation method is as follows: ; In the formula, Equivalent gas temperature; The internal temperature of a fixed-volume high-pressure gas storage tank; The temperature of the tank wall of a fixed-volume high-pressure gas storage tank; The ambient temperature; This is the heat exchange coefficient.
[0021] Beneficial effects: Due to the influence of ambient temperature and the significant adiabatic temperature change effect accompanying the rapid gas filling and discharging process, directly using a single tank internal temperature... Performing gas state calculations can introduce significant errors due to temperature measurement lag and unclear thermal boundaries. Introducing tank wall temperature can address this. With ambient temperature And construct the equivalent gas temperature based on the heat exchange weighting coefficient. This method can more comprehensively reflect the overall thermodynamic state of a gas under real heat exchange conditions. The temperature compensation method significantly improves the accuracy of the gas mass flow rate calculation model derived from the pressure change rate.
[0022] Furthermore, step S2 also includes: S210, Based on the spring compression amount Calculate the air chamber area of the air spring. The calculation logic is as follows: ; In the formula, This represents the air chamber area of the air spring; Let be the initial area of the air spring; This is the coefficient of variation of the air spring area; This represents the spring compression of the air spring model; S220, Based on the spring compression amount Calculate the volume of the air spring. The calculation logic is as follows: ; In the formula, Let V be the volume of the air spring. Let be the initial volume of the air spring; This is the coefficient of change of the air spring volume.
[0023] Beneficial effects: This method effectively captures the nonlinear relationship between the effective bearing area and internal volume of an air spring as a function of stroke. Compared to simplified models using fixed geometric parameters, this method significantly improves the accuracy of virtual spring force calculation. Attached Figure Description
[0024] This specification will be further described by way of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These embodiments are not limiting; in these embodiments, the same reference numerals denote the same structures, wherein: Figure 1 This is an exemplary overall system structure diagram of the present invention; Figure 2 This is an exemplary structural diagram of the gas storage tank of the present invention; Figure 3 This invention calculates the output force exerted by the air spring on the vehicle body. An exemplary flowchart. Detailed Implementation
[0025] To more clearly illustrate the technical solutions of the embodiments in this specification, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are merely some examples or embodiments of this specification. For those skilled in the art, these drawings can be applied to other similar scenarios without creative effort. Unless obvious from the context or otherwise specified, the same reference numerals in the drawings represent the same structures or operations.
[0026] As indicated in this specification and claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" do not specifically refer to the singular and may also include the plural. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of expressly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.
[0027] Flowcharts are used in this specification to illustrate the operations performed by the system according to embodiments of this specification. It should be understood that the preceding or following operations are not necessarily performed in exact order. Instead, the steps can be processed in reverse order or simultaneously. Furthermore, other operations can be added to these processes, or one or more steps can be removed from them.
[0028] The following detailed explanation illustrates the specific implementation methods: Example 1: Figure 1 This is an exemplary overall system structure diagram of the present invention, such as... Figure 1 As shown, an air suspension HIL testing system based on a physical gas storage tank is disclosed. The system includes a test control module, an ASU assembly module, and a gas supply module.
[0029] The test control module is used for configuring, managing, monitoring, and analyzing data throughout the entire test process. The test control module includes a host computer and a real-time simulator; the host computer communicates with the real-time simulator to control the real-time simulator to load preset simulation models and configure test scenarios.
[0030] The preset simulation model refers to a set of models that are pre-built and compiled for high-fidelity simulation of vehicle dynamics in a real-time simulator. For example, in this embodiment, the preset simulation model may include a vehicle dynamics model, an air spring model, a driver model, etc.
[0031] Test scenarios are scenarios that can be constructed by setting different environments, vehicles, and operating parameters to create diverse virtual driving conditions, in order to systematically verify the response and performance of the tested components under different conditions. For example, test scenarios include, but are not limited to, frequency response test scenarios, transient impact test scenarios, vehicle body leveling test scenarios, steady-state driving test scenarios, and extreme condition test scenarios.
[0032] The ASU assembly module is used to make real air circuit control decisions based on received virtual vehicle status signals.
[0033] The real-time simulator is connected to the ASU assembly module. The real-time simulator sends the vehicle state signals calculated by the preset simulation model to the ASU assembly module to simulate all the sensor inputs and environmental interaction information that it needs to perceive in an actual vehicle.
[0034] In this embodiment, the signal transmission methods between the real-time simulator and the ASU assembly module include, but are not limited to, CAN bus message format, analog voltage signals, and digital switch signals.
[0035] In this embodiment, the real-time simulator is equipped with an air spring model and a vehicle dynamics model.
[0036] The air spring model is a model used to simulate the dynamic relationship between pressure, volume and output force of an air spring in real time during the inflation and deflation process, based on the gas state equation.
[0037] Vehicle dynamics models are models used to simulate the motion state and attitude changes of a vehicle under the action of forces, based on the principles of multibody dynamics.
[0038] Furthermore, the real-time simulator also deploys a driver model; this driver model is used to provide driving operation signals to the vehicle dynamics model according to preset test scenarios. For example, it provides speed following control signals, steering operation signals, and braking and accelerator pedal control signals.
[0039] In this embodiment, the setup enables vehicle simulation to automatically and repeatably execute standard or custom driving cycles and maneuvering actions, effectively replacing manual operation and ensuring the consistency and comparability of test conditions.
[0040] In this embodiment, the vehicle dynamics model and driver model can be standard commercial software models, such as CarSim, CarMaker, or SimuLink models; or custom models, driver control algorithm models, etc., developed using programming languages such as C / C++ and Python and supported for running in a real-time simulator.
[0041] The gas supply module is a module that provides a controllable high-pressure gas source to the ASU assembly module and executes its charging and discharging commands; the ASU assembly module and the gas supply module are electrically connected.
[0042] The gas supply module includes an air tank, an air pump, and a distribution valve. The air pump and distribution valve control the operation of the air tank according to the gas control commands output by the ASU assembly module to simulate the inflation and deflation process of a real vehicle and provide pressure data for the air spring model. The information generated by the operation of the air spring model is output to the vehicle dynamics model to complete the closed-loop simulation test of the whole vehicle.
[0043] Furthermore, such as Figure 2 As shown, the gas storage tank includes a vehicle-mounted gas storage tank and a fixed-volume high-pressure gas storage tank. In this embodiment, four fixed-volume high-pressure gas storage tanks are provided.
[0044] The actual vehicle air tank is used to provide a high-pressure air source and exchanges gas with the fixed-volume high-pressure air tank through a control distribution valve; the fixed-volume high-pressure air tank is used to simulate the air spring of the corresponding wheel and, based on its fixed-volume characteristics, converts the gas mass change controlled by the ASU assembly module into measurable pressure data.
[0045] In this embodiment, by introducing a fixed-volume high-pressure gas storage tank and a real vehicle gas storage tank, the system can transform the virtual gas flow that only exists in the model in traditional pure software simulation into measurable gas exchange that occurs in the real physical gas path and is controlled by the real ASU assembly module, thus breaking through the inherent limitations of pure virtual simulation in terms of gas path fidelity.
[0046] Furthermore, the gas exchange between the actual vehicle gas tank and the fixed-volume high-pressure gas tank includes: filling the actual vehicle gas tank with gas, releasing the actual vehicle gas tank with gas, filling the fixed-volume high-pressure gas tank with gas from the actual vehicle gas tank, and releasing the gas from the fixed-volume high-pressure gas tank to the actual vehicle gas tank.
[0047] In this embodiment, the gas exchange mechanism fully replicates all gas path operation modes of the system, ensuring comprehensive verification of the ASU assembly module under various real working conditions.
[0048] Furthermore, the air spring model includes LF spring, RF spring, LR spring and RR spring; the four air springs correspond to the four fixed-volume high-pressure air tanks through specific data interfaces, and further correspond one-to-one with the left front, right front, left rear and right rear wheel positions of the test vehicle.
[0049] Among them, the specific data interface can be a configuration interface that binds the I / O channel address of the fixed-volume high-pressure gas storage tank to the air spring model instance in a real-time simulator.
[0050] Furthermore, each fixed-volume high-pressure gas storage tank is equipped with a pressure sensor and a temperature sensor at its inlet to monitor the internal pressure of the tank in real time. and temperature Furthermore, each fixed-volume high-pressure gas storage tank is equipped with a leak-free solenoid valve at its gas inlet, which is used to seal and fix it in the non-test state to prevent gas leakage, and to precisely control the gas flow during the test state.
[0051] In this embodiment, pressure and temperature sensors are installed at the inlet of each fixed-volume high-pressure gas storage tank. These sensors can collect real-time and accurate data on the pressure and temperature inside the tank, providing reliable monitoring data for the subsequent accurate calculation of gas flow rate, quality, and air spring force. The installation of a leak-free solenoid valve at the gas inlet not only ensures the sealing and pressure maintenance of the gas tank during non-testing phases, effectively preventing inaccuracies in the test environment caused by gas leakage, but also allows for precise control of gas flow during testing, ensuring the timeliness and stability of gas path switching, while reducing test cost losses caused by gas leakage.
[0052] Furthermore, each fixed-volume high-pressure gas storage tank is equipped with a patch thermocouple and a thermal insulation sleeve on the outer side of its tank wall; the patch thermocouple is used to monitor the tank wall temperature of the fixed-volume high-pressure gas storage tank in real time. The heat insulation sleeve is used to reduce heat exchange between the fixed-volume high-pressure gas storage tank and the environment.
[0053] In this embodiment, by accurately collecting the tank wall temperature in real time and combining it with the tank interior temperature, the thermal state of the gas inside the tank can be more comprehensively understood, providing more complete temperature parameter support for the accurate solution of the gas state equation, effectively making up for the limitations of only monitoring the temperature at a single point inside the tank; the setting of the heat insulation sleeve can significantly reduce the heat exchange between the gas tank and the external environment, and reduce the interference of ambient temperature fluctuations on the gas temperature inside the tank.
[0054] Example 2: Furthermore, such as Figure 3 As shown, the present invention also provides a method for HIL testing of air suspension based on a physical air tank. The method is performed by an air suspension HIL testing system based on a physical air tank, and the method includes: Step S1, based on the pressure of the fixed-volume high-pressure gas storage tank Calculate the mass of gas in a fixed-volume high-pressure gas storage tank. The calculation logic is as follows: ; In the formula, The mass of gas in a fixed-volume high-pressure gas storage tank; The volume of a fixed-volume high-pressure gas storage tank; The molar mass of air; This is the universal gas constant; Equivalent gas temperature; The pressure inside a fixed-volume high-pressure gas storage tank.
[0055] In this embodiment, the volume of the fixed-volume high-pressure gas storage tank It can be obtained in various ways. For example, it can be obtained through standard volume measuring equipment before the system is integrated; or it can be obtained directly from the nominal volume value provided by the gas tank manufacturer and marked on the product nameplate.
[0056] In this embodiment, the pressure inside the fixed-volume high-pressure gas storage tank is... The pressure is measured by a pressure sensor installed at the inlet of a fixed-volume high-pressure gas storage tank.
[0057] In this embodiment, the equivalent gas temperature Based on the internal temperature of a fixed-volume high-pressure gas storage tank Tank wall temperature and ambient temperature Obtained through calculation.
[0058] Among them, the internal temperature of the fixed-volume high-pressure gas storage tank Temperature is measured and obtained using a temperature sensor installed at the inlet of a fixed-volume high-pressure gas storage tank; tank wall temperature. Measurements are obtained using patch thermocouples mounted on the outer side of the wall of a fixed-volume high-pressure gas storage tank.
[0059] Ambient temperature Data can be obtained in various ways. For example, it can be obtained by installing environmental temperature and humidity sensors on the gas storage tank; or it can be obtained by reading real-time data from laboratory environmental monitoring through a host computer.
[0060] Specifically, the equivalent gas temperature in step S1 The calculation method is as follows: ; In the formula, Equivalent gas temperature; The internal temperature of a fixed-volume high-pressure gas storage tank; The temperature of the tank wall of a fixed-volume high-pressure gas storage tank; The ambient temperature; This is the heat exchange coefficient.
[0061] In this embodiment, the heat exchange coefficient The weighting coefficient is determined based on the thermal resistance relationship between the gas and the tank wall, the tank interior, and the environment. It can be obtained through experimental calibration or theoretical estimation.
[0062] In this embodiment, due to the influence of ambient temperature and the significant adiabatic temperature change effect accompanying the rapid gas filling and discharging process, directly using a single tank temperature would be insufficient. Performing gas state calculations can introduce significant errors due to temperature measurement lag and unclear thermal boundaries. Introducing tank wall temperature can address this. With ambient temperature And construct the equivalent gas temperature based on the heat exchange weighting coefficient. This method can more comprehensively reflect the overall thermodynamic state of a gas under real heat exchange conditions. The temperature compensation method significantly improves the accuracy of the gas mass flow rate calculation model derived from the pressure change rate.
[0063] Step S2: Obtain the spring compression of the air spring model from the vehicle dynamics model. Based on spring compression Calculate the volume of the air spring. and the air chamber area of the air spring .
[0064] Furthermore, step S2 also includes: S210, based on spring compression Calculate the air chamber area of the air spring. The calculation logic is as follows: ; In the formula, This represents the air chamber area of the air spring; Let be the initial area of the air spring; This is the coefficient of variation of the air spring area; This represents the spring compression of the air spring model.
[0065] In this embodiment, the initial area of the air spring The effective bearing area can be obtained directly from the design drawings or specifications of air spring products; the spring compression of the air spring model. It can be obtained directly from the vehicle dynamics model.
[0066] S220, Based on the spring compression amount Calculate the volume of the air spring. The calculation logic is as follows: ; In the formula, Let V be the volume of the air spring. Let be the initial volume of the air spring; This is the coefficient of change of the air spring volume.
[0067] In this embodiment, the initial volume of the air spring The internal volume can be obtained directly from the design drawings or specifications of products using air springs.
[0068] Step S3, based on the volume of the air spring and the air chamber area of the air spring Calculate the internal pressure of the air spring The calculation logic is as follows: ; In the formula, This refers to the internal pressure of the air spring. Let V be the volume of the air spring. The mass of gas in a fixed-volume high-pressure gas storage tank; The molar mass of air; This is the universal gas constant; This refers to the temperature inside the air spring.
[0069] In this embodiment, the temperature inside the air spring The equivalent gas temperature of the fixed-volume high-pressure gas storage tank is directly used. The value is sufficient.
[0070] S4. Calculate the output force exerted by the air spring on the vehicle body. The calculation logic is as follows: ; In the formula, The air springs apply output force to the vehicle body; This refers to the internal pressure of the air spring. Atmospheric pressure; This represents the air chamber area of the air spring.
[0071] In this embodiment, the method not only makes full use of the physical monitoring data of the physical air tank to ensure the authenticity of the parameters, but also combines the air spring model to realize the accurate simulation of mechanical characteristics, effectively improving the simulation accuracy of aerodynamic coupling characteristics in the HIL test of air suspension, providing reliable mechanical data support for verifying the effectiveness of the ASU control strategy, while simplifying the calculation link of complex multi-physics field, and taking into account both the accuracy and efficiency of the test.
[0072] The basic concepts have been described above. Obviously, for those skilled in the art, the detailed disclosure above is merely illustrative and does not constitute a limitation of this specification. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and corrections to this specification. Such modifications, improvements, and corrections are suggested in this specification and therefore remain within the spirit and scope of the exemplary embodiments described herein.
[0073] Furthermore, unless expressly stated in the claims, the order of processing elements and sequences, the use of numbers and letters, or other names described in this specification are not intended to limit the order of the processes and methods described herein. Although various examples have been discussed in the foregoing disclosure of some embodiments of the invention that are currently considered useful, it should be understood that such details are for illustrative purposes only, and the appended claims are not limited to the disclosed embodiments; rather, the claims are intended to cover all modifications and equivalent combinations that conform to the spirit and scope of the embodiments described herein. For example, while the system components described above can be implemented using hardware devices, they can also be implemented solely using software solutions, such as installing the described system on existing servers or mobile devices.
[0074] Similarly, it should be noted that, in order to simplify the description disclosed herein and thus aid in the understanding of one or more embodiments of the invention, the foregoing description of embodiments in this specification may sometimes combine multiple features into a single embodiment, drawing, or description thereof. However, this method of disclosure does not imply that the subject matter of this specification requires more features than those mentioned in the claims. In fact, the embodiments contain fewer features than all the features of a single embodiment disclosed above.
[0075] In some embodiments, numbers describing the quantity of components and attributes are used. It should be understood that such numbers used in the description of embodiments are modified in some examples with the terms "approximately," "approximately," or "generally." Unless otherwise stated, "approximately," "approximately," or "generally" indicates that the numbers are allowed to vary by ±20%. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximate values, which may be changed depending on the characteristics required by individual embodiments. In some embodiments, numerical parameters should take into account specified significant digits and employ a general method of digit reservation. Although the numerical ranges and parameters used to confirm their breadth of range in some embodiments of this specification are approximate values, in specific embodiments, such values are set as precisely as feasible.
[0076] For each patent, patent application, patent application publication, and other material such as articles, books, specifications, publications, and documents referenced in this specification, the entire contents of which are incorporated herein by reference. This excludes historical application documents that are inconsistent with or conflict with the content of this specification, as well as documents that limit the broadest scope of the claims in this specification (currently or subsequently appended to this specification). It should be noted that in the event of any inconsistency or conflict between the descriptions, definitions, and / or terminology used in the supplementary materials to this specification and the content of this specification, the descriptions, definitions, and / or terminology used in this specification shall prevail.
[0077] Finally, it should be understood that the embodiments described in this specification are merely illustrative of the principles of the embodiments described herein. Other variations may also fall within the scope of this specification. Therefore, alternative configurations of the embodiments described herein are intended to be illustrative rather than limiting, and should be considered consistent with the teachings of this specification. Accordingly, the embodiments described herein are not limited to those explicitly introduced and described herein.
Claims
1. An air suspension HIL testing system based on a physical air tank, characterized in that, The system includes: a test control module, an ASU assembly module, and a gas supply module; The test control module includes a host computer and a real-time simulator; the host computer is communicatively connected to the real-time simulator and is used to control the real-time simulator to load a preset simulation model and configure the test scenario; The real-time simulator is communicatively connected to the ASU assembly module, and the ASU assembly module is electrically connected to the gas supply module; the real-time simulator is equipped with an air spring model and a vehicle dynamics model. The gas supply module includes an air tank, an air pump, and a distribution valve. The air pump and distribution valve control the operation of the air tank according to the gas control commands output by the ASU assembly module to simulate the inflation and deflation process of a real vehicle and provide pressure data for the air spring model. The information generated by the operation of the air spring model is output to the vehicle dynamics model to complete the closed-loop simulation test of the whole vehicle.
2. The air suspension HIL testing system based on a physical air tank according to claim 1, characterized in that, The real-time simulator is also equipped with a driver model; the driver model is used to provide driving operation signals to the vehicle dynamics model according to a preset test scenario.
3. The air suspension HIL testing system based on a physical air tank according to claim 1, characterized in that, The gas storage tank includes a vehicle-mounted gas storage tank and a fixed-volume high-pressure gas storage tank; the vehicle-mounted gas storage tank is used to provide a high-pressure gas source and exchanges gas with the fixed-volume high-pressure gas storage tank by controlling the distribution valve.
4. The air suspension HIL testing system based on a physical air tank according to claim 3, characterized in that, The gas exchange between the actual vehicle gas tank and the fixed-volume high-pressure gas tank includes: filling the actual vehicle gas tank with gas, releasing the actual vehicle gas tank with gas, filling the fixed-volume high-pressure gas tank with gas from the actual vehicle gas tank, and releasing the gas from the fixed-volume high-pressure gas tank to the actual vehicle gas tank.
5. The air suspension HIL testing system based on a physical air tank according to claim 4, characterized in that, The air spring model includes an LF spring, an RF spring, an LR spring, and an RR spring; the four air springs correspond to the four fixed-volume high-pressure gas storage tanks respectively through specific data interfaces.
6. The air suspension HIL testing system based on a physical air tank according to claim 5, characterized in that, Each fixed-volume high-pressure gas storage tank is equipped with a pressure sensor and a temperature sensor at its inlet to monitor the internal pressure of the tank in real time. and the temperature inside the tank Furthermore, each fixed-volume high-pressure gas storage tank is equipped with a leak-free solenoid valve at its gas inlet, which is used to seal and fix it in the non-test state to prevent gas leakage, and to precisely control the gas flow during the test state.
7. The air suspension HIL testing system based on a physical air tank according to claim 6, characterized in that, Each fixed-volume high-pressure gas storage tank is also equipped with a patch thermocouple and a heat insulation sleeve on the outer side of its tank wall; the patch thermocouple is used to detect the tank wall temperature of the fixed-volume high-pressure gas storage tank in real time. The heat insulation sleeve is used to reduce heat exchange between the fixed-volume high-pressure gas storage tank and the environment.
8. A method for testing the High Intake Level (HIL) of an air suspension system based on a solid air tank, applied to the HIL testing system for an air suspension system based on a solid air tank as described in claim 7, the method comprising: S1, Pressure based on a fixed-volume high-pressure gas storage tank Calculate the mass of gas in a fixed-volume high-pressure gas storage tank. The calculation logic is as follows: ； In the formula, The mass of gas in a fixed-volume high-pressure gas storage tank; The volume of a fixed-volume high-pressure gas storage tank; The molar mass of air; This is the universal gas constant; Equivalent gas temperature; The internal pressure of a fixed-volume high-pressure gas storage tank; S2. Obtain the spring compression of the air spring model from the vehicle dynamics model. Based on the spring compression amount Calculate the volume of the air spring. and the air chamber area of the air spring ; S3, based on the volume of the air spring and the air chamber area of the air spring Calculate the internal pressure of the air spring The calculation logic is as follows: ； In the formula, This refers to the internal pressure of the air spring. Let V be the volume of the air spring. The mass of gas in a fixed-volume high-pressure gas storage tank; The molar mass of air; This is the universal gas constant; The temperature inside the air spring; S4. Calculate the output force exerted by the air spring on the vehicle body. The calculation logic is as follows: ； In the formula, The air springs apply output force to the vehicle body; This refers to the internal pressure of the air spring. Atmospheric pressure; This represents the air chamber area of the air spring.
9. The air suspension HIL test method based on a physical air tank according to claim 8, characterized in that, The equivalent gas temperature in step S1 The calculation method is as follows: ； In the formula, Equivalent gas temperature; The internal temperature of a fixed-volume high-pressure gas storage tank; The temperature of the tank wall of a fixed-volume high-pressure gas storage tank; The ambient temperature; This is the heat exchange coefficient.
10. The air suspension HIL test method based on a solid air tank according to claim 8, characterized in that, Step S2 further includes: S210, Based on the spring compression amount Calculate the air chamber area of the air spring. The calculation logic is as follows: ； In the formula, This represents the air chamber area of the air spring; Let be the initial area of the air spring; The coefficient of variation of the air spring area; This represents the spring compression of the air spring model; S220, Based on the spring compression amount Calculate the volume of the air spring. The calculation logic is as follows: ； In the formula, Let V be the volume of the air spring. Let be the initial volume of the air spring; This is the coefficient of change of the air spring volume.