Automatic adjusting and testing system for ASU simulation air spring

Abstract

The invention discloses an automatic adjustment test system for an ASU simulation air spring, and relates to the field of automobile suspension testing, and the system comprises a simulation air spring unit which comprises a volume-adjustable cavity and an internal cavity used for simulating an air spring; the dynamic load simulation unit is used for applying programmable control simulation load force to the cavity and monitoring the load force in real time; the integrated environment simulation unit is used for providing a temperature and humidity environment which can be independently regulated and controlled; the cooperative control and acquisition unit is configured to execute a preset test sequence and control the initial volume and environmental parameters of the cavity; the air pressure in the cavity and the applied simulation load force are kept in dynamic balance through a closed-loop control algorithm; in the testing process, the cavity is inflated or deflated, dynamic balance is maintained at the same time, and various data are collected synchronously. According to the scheme, the dynamic response, the control precision, the energy consumption and the environmental adaptability of the ASU in the approximate real loading state can be accurately evaluated.

Description

Technical Field

[0001] This invention relates to the field of automotive suspension testing, and in particular to an automatic adjustment testing system for simulating air springs using an ASU (Autonomous Suspension Unit). Background Technology

[0002] As the automotive industry moves towards electrification, intelligence, and high-end development, vehicle ride comfort, handling stability, and functional safety have become core competitive indicators. Air suspension systems, due to their significant advantages such as adjustable stiffness and height, and low natural frequency, have rapidly penetrated from commercial vehicles into high-end passenger cars and mainstream electric vehicles, becoming a key assembly for improving overall vehicle dynamic performance. The core working principle of this system lies in precisely adjusting the air pressure and volume within the sealed air spring cavity through the air supply unit (ASU) to dynamically adapt to different loads and road conditions. However, the air spring itself is a complex system with strong nonlinearity, time-varying characteristics, and thermodynamic coupling. Its dynamic characteristics heavily depend on the real-time interaction of multiple physical fields, including cavity volume, internal pressure, load force, and ambient temperature. This complexity makes performance evaluation of the ASU extremely challenging. Traditional single-parameter bench tests cannot reproduce the real-world working conditions of the ASU in conjunction with the air spring-load coupling system in a real vehicle, resulting in a significant gap between test results and actual vehicle performance. This makes it difficult to accurately predict and optimize its response speed, control precision, and reliability after actual vehicle installation. Therefore, there is an urgent need for a testing method that can simulate the dynamic mechanical characteristics of real air springs and their coupling effect with the environment in a laboratory environment with high fidelity, so as to complete the comprehensive and accurate performance verification and calibration of ASU in close to real use scenarios.

[0003] Currently, testing methods for air springs (ASUs) suffer from two main limitations. First, there is a disconnect between simulation and physical testing. While high-level hardware-in-the-loop simulations can build complex vehicle dynamics models for algorithm verification, they struggle to accurately model the nonlinear physical characteristics of air springs and cannot connect to real ASU mechanical and pneumatic components for complete system-level durability and performance testing. Second, existing physical bench tests suffer from static and decoupled characteristics. Most testing systems use fixed-volume air tanks or simple cylinders to simulate air springs, enabling only basic tests such as inflation / deflation time and sealing performance. They completely fail to simulate the core coupling relationship of dynamic changes in cavity volume as the load changes in a real vehicle. More advanced solutions introduce actuators to simulate loads, but their control modes are typically simple displacement control or open-loop force control, failing to achieve dynamic balance between load force and internal air pressure under high-precision closed-loop conditions. Consequently, they cannot accurately reproduce the real-time correspondence under a specific air spring stiffness curve. Furthermore, existing testing equipment generally lacks integration and precise control of key environmental variables such as temperature and humidity, making it impossible to assess the performance degradation and operational adaptability of the ASU under extreme environments such as high and low temperatures and humid heat. These are crucial aspects of real-vehicle reliability verification. These shortcomings collectively lead to discrepancies between existing test data and the actual on-vehicle performance of the ASU, failing to effectively support the refined development and reliability assurance of next-generation intelligent suspension systems. Therefore, based on the aforementioned challenges, this invention proposes an automatic adjustment testing system for simulating air springs using an ASU. Summary of the Invention

[0004] To address the aforementioned issues, the present invention aims to provide an automatic adjustment test system for ASU simulated air springs. This system constructs a multi-physical quantity coupled test environment to comprehensively simulate the nonlinear stiffness characteristics of real air springs, actual vehicle load changes, and temperature and humidity environmental effects. This enables precise and comprehensive evaluation and verification of the dynamic response performance, control accuracy, environmental adaptability, and system matching characteristics of ASU products.

[0005] To achieve the above objectives, this invention provides an automatic adjustment test system for simulating air springs in an air handling unit (ASU). The simulated air spring unit utilizes a continuously adjustable physical cavity as the core controlled object of the system. A dynamic load simulation unit, through a high-precision force-controlled actuator and force sensing components, is mechanically coupled to this cavity and applies loads. An integrated environmental simulation unit provides a precisely controllable temperature and humidity field for the ASU under test and its connecting air passages. A collaborative control and acquisition unit, as the system's central hub, executes the core control logic: First, it initializes the system state according to the target test conditions. Then, through a closed-loop control algorithm, it dynamically adjusts the output force or cavity volume of the load simulation unit, ensuring that the load force applied to the cavity and its internal air pressure remain dynamically balanced, thereby accurately simulating the static stiffness and dynamic load response of a specific air spring. Finally, while maintaining this balance, it drives the ASU under test and simultaneously acquires multi-dimensional data such as pressure, volume, force, flow rate, and environmental parameters, thereby fully reproducing and quantitatively evaluating the comprehensive performance of the ASU under near-real-world vehicle conditions.

[0006] In a first aspect, the present invention provides an automatic adjustment test system for ASU simulated air springs, comprising: The simulated air spring unit includes a volume-adjustable cavity for simulating the internal cavity of an air spring; A dynamic load simulation unit is used to apply a programmable simulated load force to the cavity and monitor the load force in real time. An integrated environmental simulation unit is used to provide independently adjustable temperature and humidity environments for the simulated air spring unit and the air supply module under test. The collaborative control and acquisition unit is configured as follows: Execute a preset test sequence to control the initial volume of the cavity and environmental parameters; Based on the target load force and the real-time monitored load force, the dynamic load simulation unit is driven by a closed-loop control algorithm to keep the air pressure in the cavity and the applied simulated load force in dynamic balance. During the test, the air supply module under test is controlled to inflate or deflate the cavity while maintaining dynamic balance, and real-time data on the cavity's volume change, internal pressure change, gas flow rate, and load force are collected simultaneously.

[0007] Furthermore, the process of simulating the characteristics of a real air spring in the system is achieved through real-time, closed-loop physical coupling and calculation control between the force applied by the dynamic load simulation unit, the volume change of the simulated air spring unit, and the air pressure in the cavity, which is different from devices that only perform open-loop simulation of a single parameter.

[0008] Furthermore, the dynamic load simulation unit includes a force-controlled actuator and a high-precision force sensing component. The closed-loop control algorithm calculates and outputs displacement control commands for the force-controlled actuator in real time based on the deviation between the target load force and the measured load force. These commands also serve as driving signals for changes in the cavity volume, thereby achieving mechanical linkage and unified control between load force simulation and cavity volume adjustment, effectively improving the synchronization and control accuracy of the system's dynamic response.

[0009] Furthermore, the collaborative control and acquisition unit modifies the set value of the target load force to instruct the system to reproduce different force-displacement relationships, thereby flexibly simulating air spring curves with different stiffness characteristics and enhancing the test system's adaptability to different vehicle models and suspension configurations.

[0010] Furthermore, the integrated environment simulation unit includes independently controllable temperature and humidity zones, which can perform differentiated temperature and humidity adjustments on the air supply module body under test and its connected air circuit to simulate the complex working conditions of different microenvironments in real vehicles, thereby achieving a more comprehensive assessment of the product's environmental adaptability and reliability.

[0011] Furthermore, the collaborative control and acquisition unit is further configured as follows: Based on the synchronously acquired data, a coupling characteristic curve reflecting the dynamic correspondence between cavity volume, internal pressure, and load force is calculated and generated in real time.

[0012] Furthermore, the collaborative control and acquisition unit also includes a reconfigurable test logic module, which allows users to freely define and combine multi-dimensional test steps, including environmental parameter settings, load force change profiles, and air supply module start-stop sequence, through graphical or script-based methods, in order to construct complex comprehensive test conditions and improve the flexibility and automation level of the test system.

[0013] Secondly, an automatic adjustment test method for ASU simulated air springs is also provided, the method being based on the system described in the first aspect above, comprising: Based on the test conditions, the parameters of the integrated environment simulation unit, the initial volume of the simulated air spring unit, and the target load force of the dynamic load simulation unit are set collaboratively by the collaborative control and acquisition unit. After the integrated environment simulation unit reaches the set conditions, the collaborative control and acquisition unit starts the closed-loop force control of the dynamic load simulation unit, so that the applied load force and the force generated by the initial air pressure in the cavity reach a dynamic balance. The control unit controls the operation of the air supply module to change the air pressure inside the cavity. At this time, the collaborative control and acquisition unit actively adjusts the force exerted on the cavity by the dynamic load simulation unit and / or adjusts the volume of the cavity to maintain or follow the preset force balance relationship, while simultaneously acquiring multiple physical quantity data throughout the process. Based on the collected data, a report and characteristic curves are generated to evaluate the performance of the air supply module under simulated real air spring and complex environmental coupling.

[0014] Furthermore, the collaborative control and acquisition unit simultaneously calculates load force control and cavity volume adjustment, so that the pressure-volume change relationship within the cavity approximates the curve defined by the preset air spring stiffness model in real time.

[0015] Thirdly, the present invention also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the aforementioned method.

[0016] This invention provides an automatic adjustment test system for ASU simulated air springs. The system realistically simulates the physical body of an air spring through a continuously adjustable cavity. It uses a force-controlled actuator and a closed-loop algorithm to dynamically maintain the balance between the load force applied to the cavity and the internal air pressure, so as to accurately simulate the stiffness characteristics of a specific air spring and the actual vehicle load conditions. At the same time, it combines a temperature and humidity controllable environmental unit to reproduce complex climatic conditions. Finally, through a central control unit, the above modules are coordinated and scheduled to execute a custom test sequence while simultaneously collecting multi-dimensional physical quantity data. Thus, the system can reconstruct the multi-field coupled working environment faced by the air supply module in a real vehicle with high fidelity in a laboratory environment.

[0017] This system overcomes the limitations of traditional testing methods, such as distortion in the simulation of air spring characteristics, static load conditions, and lack of environmental factors. It can accurately evaluate the dynamic response, control accuracy, energy consumption, and environmental adaptability of the ASU under near-real vehicle conditions. This significantly improves the reliability and predictive value of the test results, providing a key platform for forward product development, precise matching calibration, and reliability verification, effectively shortening the R&D cycle and reducing reliance on later real-vehicle testing.

[0018] Beneficial effects By implementing the automatic adjustment and testing system for ASU simulated air springs provided by the present invention, the following technical effects are achieved: (1) This method abandons the traditional approach of using a fixed-volume container to simulate air springs and proposes a continuously adjustable physical cavity as the core simulation unit. This mechanism directly reproduces the core physical process of the deformation of the air spring and the change of its effective area under load by precisely controlling the continuous change of the cavity volume. It fundamentally establishes the physical equivalence between the test system and the actual vehicle air spring, enabling all subsequent tests to be conducted in a manner consistent with the actual working mechanism. This lays the physical foundation for obtaining high-fidelity test data and solves the fundamental problem of low reliability of results caused by the distortion of the simulation principle in traditional tests.

[0019] (2) A closed-loop force control system integrating high-precision force sensing and feedback was designed and mechanically coupled to a variable volume cavity. This system dynamically adjusts the actuator output by calculating the deviation between the target load force and the measured force in real time, thereby actively maintaining a dynamic balance between the load force applied to the cavity and the air pressure within the cavity. It achieves accurate simulation of the static stiffness and dynamic load response of the air spring, realistically reproducing the air spring stress state of the vehicle under various attitudes. This transforms the ASU's testing environment from a simple air pressure supply to a complex mechanical interaction environment, greatly improving the accuracy and scenario coverage of performance evaluation.

[0020] (3) The wide-temperature-range, programmable temperature and humidity environment simulation chamber is integrated with the aforementioned mechanical testing system. This structure can apply independent, precise, and combinable environmental stresses to the ASU body and its connecting air passages. It realizes the multi-factor coupled testing capability of mechanical load, air pressure change, and environmental stress, and can systematically assess the performance degradation, material property changes, and system reliability of ASU products under extreme climatic conditions. It solves the problems of missing environmental variables or coarse control in traditional testing methods, significantly enhances the rigor and comprehensiveness of the test, and provides a key means for verifying the all-climate adaptability of products.

[0021] (4) A user-defined, modular collaborative control and data acquisition software architecture was constructed. This architecture allows users to freely define and combine test steps, environmental parameter profiles, load force variation curves, etc., and the central controller uniformly schedules hardware resources for collaborative execution. It endows the test system with a high degree of flexibility and automation, enabling it to quickly adapt to the air spring stiffness curves of different vehicle models, complex road condition simulations, and diverse durability test specifications. It realizes a leap from single fixed testing to customizable, complex comprehensive testing, greatly improving testing efficiency and system versatility, and meeting the needs of rapid product iteration development. Attached Figure Description

[0022] To make the above-described automatic adjustment test system for ASU simulated air springs of the present invention more apparent and understandable, the accompanying drawings used in the specific embodiments of the present invention 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 from these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the test system structure of this application; Figure 2 This is a schematic diagram of the test system principle of this application; Figure 3 A schematic diagram showing the real-time relationship between cavity volume change and air pressure / load under normal temperature and load conditions with a load of 1000kg; Figure 4 A schematic diagram showing the real-time relationship between cavity volume change and air pressure / load under low-temperature conditions (-20℃) and a load mass of 6000kg; Figure 5 A schematic diagram showing the real-time relationship between cavity volume change and air pressure / load under high-temperature (60℃) and 6000kg load conditions; Figure 6 This represents the stiffness curve of the air spring. Detailed Implementation

[0024] Example 1: This embodiment provides a specific implementation of an ASU simulated air spring automatic adjustment test system. The system aims to reproduce, in a laboratory environment, the coupled working condition of the air supply module and the air spring working together in a real vehicle.

[0025] The system structure is as follows: Figure 1As shown, the core components include four functional units: a simulated air spring unit, a dynamic load simulation unit, an integrated environmental simulation unit, and a collaborative control and acquisition unit. Through hardware and software collaboration, a physical mapping of real-world operating conditions is achieved. The core of the simulated air spring unit is a continuously adjustable physical cavity. This cavity uses a piston mechanism driven by a high-precision servo motor to achieve linear or non-linear volume adjustment, thus directly simulating the deformation and effective area change of a real air spring capsule under stress at the physical level. This is a fundamental difference from traditional testing systems using fixed-volume air tanks. The dynamic load simulation unit is rigidly mechanically coupled to this cavity and includes a high-precision force-controlled electric cylinder and a force sensor integrated into the force application end. It can apply programmable controlled simulated load forces to the cavity and monitor feedback in real time. The integrated environmental simulation unit provides an independent and controllable temperature and humidity environment for the ASU under test and its connected air circuits. This is typically achieved using a programmable temperature and humidity chamber, capable of simulating a temperature range of -40℃ to 120℃ and a relative humidity of 10% to 98%, ensuring accurate reproduction of environmental stress. The collaborative control and acquisition unit, as the control center of the system, adopts an industrial computer and real-time control software architecture, and is responsible for executing test sequences, realizing closed-loop control, and synchronously acquiring multiple data.

[0026] The system principle is as follows: Figure 2 As shown, the details are as follows.

[0027] The system's testing process begins with the user defining test conditions through a graphical interface, such as selecting the stiffness curve of the target air spring, setting the load mass, and ambient temperature and humidity parameters. The control unit first initializes the system state: based on the volume corresponding to the initial height of the target air spring, it instructs the servo motor to adjust the cavity to the initial volume; simultaneously, it controls the ambient temperature and humidity chamber to adjust towards the set temperature and humidity point and waits for it to stabilize. Afterward, the system enters the initial force balance establishment phase: the control unit shuts off the external air source, and based on the gas state equation and the target load force, it calculates and sets the initial target air pressure within the cavity; subsequently, it activates the closed-loop control mode of the force-controlled electric cylinder. The force sensor provides real-time feedback of the measured load force, and the control algorithm calculates the control quantity in real-time based on the deviation, dynamically adjusting the electric cylinder output to achieve a dynamic balance between the mechanical load force applied to the cavity and the aerodynamic force generated by the initial air pressure within the cavity, simulating the balance between the vehicle's weight and the air spring's support force when the vehicle is stationary.

[0028] After force balance is established, the system enters the performance testing phase. The control unit instructs the ASU under test to start, for example, by opening its inflation valve to fill the chamber with gas. As the gas pressure inside the chamber increases, the original force balance is broken, generating additional aerodynamic force. At this time, the closed-loop force control system responds immediately. The force sensor detects the force deviation, the control algorithm quickly calculates and drives the force-controlled electric cylinder to move, so that its output force tracks and counteracts the gas pressure change in real time, thereby maintaining a dynamic balance relationship throughout the entire operation of the ASU. It is worth noting that the displacement of the electric cylinder is not only used to adjust the output force, but also directly drives the piston to change the chamber volume. This coupling process realistically reproduces the expansion and contraction of the air spring during the lifting and lowering of a real vehicle. According to the gas state equation, the change in volume will in turn affect the gas pressure, thus constructing a physical closed loop in the system. The cooperative control unit embeds this physical model in the algorithm design as a feedforward or state observer, so that each step of control simultaneously aims at two goals: restoring force balance and moving the current state point along the target stiffness curve, thereby accurately simulating the nonlinear stiffness characteristics of a specific air spring. Throughout the test, the system synchronously acquired data on cavity pressure, cavity volume, load force, ASU operating current, voltage, gas flow rate, and ambient temperature and humidity at a frequency of no less than 1 kHz. All data were time-stamped and strictly aligned. Based on this data, the system can plot and display data in real time, such as... Figure 3 , 4 The curves showing the real-time correlation between cavity volume change and air pressure / load, as shown in Figure 5, provide a visual verification of the simulation's fidelity and can be used to export test reports for evaluating key performance aspects of the ASU, such as dynamic response time, control accuracy, and energy efficiency.

[0029] Example 2: Based on the aforementioned embodiments, the deep collaborative control mechanism for simulating the stiffness characteristics of a high-precision vacuum spring in the test system is described. The core of this mechanism is to integrate load force control and volume adjustment from two independent processes into a unified control target with clear physical meaning, namely, to accurately reproduce the force-displacement characteristic curve of the target air spring.

[0030] The key difference between this system and any scheme employing fixed-volume simulation or open-loop control is that its control logic begins with the stiffness characteristic curve of the target air spring, such as... Figure 6 As shown, this curve defines the nonlinear functional relationship between the air spring support force and its compression displacement under a specific design. Users can input or select preset curves through the interface, and the collaborative control and acquisition unit will convert them into two intrinsically related set trajectories that the system can execute: one is the profile of the load force setpoint as a direct control target changing with time and / or displacement; the other is the expected pressure-volume relationship curve obtained by back-calculation through force balance relationships and gas laws.

[0031] Taking the inflation process of a simulated air spring as an example, the specific collaborative working mechanism is as follows: After test initialization, the system is in an initial force balance state. When the control unit instructs the ASU to inflate, the air pressure inside the cavity begins to rise, instantaneously causing the aerodynamic force to exceed the current target load force. The force control system immediately detects the positive force deviation, its closed-loop algorithm quickly solves the problem, and instructs the force-controlled electric cylinder to move in the direction of reducing the output force. This electric cylinder movement has a dual synchronous effect: the primary effect is that its output force changes to counteract and gradually offset the additional force brought about by the air pressure change, thereby maintaining the dynamic force balance of the system; the core second effect is that the displacement of the electric cylinder is directly and linearly converted into the increase in cavity volume. According to the gas state equation, when the gas mass or flow rate input is constant, the increase in volume will buffer the rate of increase in air pressure. The ingenuity of the collaborative control unit lies in the fact that its algorithm solves the force balance equation and the gas state equation simultaneously in real time, forming an observation and prediction of the system state. Therefore, the control command is not simply a response to the force deviation, but guides the system state to evolve along the preset target stiffness curve.

[0032] For example, for an air spring with a soft initial stiffness, during the initial inflation phase, the target curve requires a significant increase in volume when the supporting force increases only slightly. The system achieves this process as follows: The ASU starts inflating, the air pressure increases slightly, the force control system detects a small positive deviation, and instructs the electric cylinder to slow down at a specific rate. The cavity volume increases rapidly, absorbing some of the pressure increase, resulting in a smoother actual pressure rise. Finally, the system stabilizes at a new equilibrium point, and the recorded trajectory points perfectly match the corresponding segment of the target stiffness curve. The entire dynamic process is continuous, adaptive, and highly synchronized. Through this mechanism, the system not only simulates the static equilibrium point but also accurately reproduces the nonlinear stiffness and hysteresis characteristics exhibited by the air spring during dynamic operation. This collaborative working mechanism ensures that the ASU faces a real load with correct dynamic mechanical characteristics during testing, giving the test results of its operating state, power consumption, response time, and other performance data extremely high real-vehicle correlation value and engineering reference significance.

[0033] Example 3: Based on the aforementioned embodiments, this paper demonstrates the specific application of the test system after integrating an environmental stress field to perform and evaluate the performance of the ASU under extreme and complex operating conditions, highlighting its ability to solve the problem of missing environmental factors in traditional testing.

[0034] This system deeply integrates a high-precision temperature and humidity environment simulation unit with the aforementioned force-volume coupling test platform, enabling multi-physics field and programmable stress superposition testing of mechanical load, air pressure cycle and climate environment. It can systematically assess the thermal management challenges, material performance degradation and long-term reliability that ASU products may face after actual vehicle installation.

[0035] The testing begins with the definition of multi-dimensional composite operating conditions. Users can program complex test sequences using collaborative control software, such as: "Phase 1: Ambient temperature stabilizes at -30℃ and 10%RH for 4 hours; Phase 2: Temperature increases to 70℃ at a rate of 10℃ / minute; Phase 3: Steady-state maintenance at 70℃ and 50%RH for 2 hours; Phase 4: Perform 5 cycles of inflation and deflation tests, with each cycle's load force varying sinusoidally between 5000N and 7000N." The control unit coordinates the entire process. In the initial phase, it first instructs the environmental simulation unit to rapidly and accurately approach the target low temperature point (-30℃), and monitors the thermal equilibrium process using multiple temperature sensors located inside the ASU housing, at key gas path points, and near the cavity, ensuring that the motors, solenoid valves, sealing materials, and gas in the pipelines of the ASU under test all reach the set temperature. In the low-temperature stabilization phase, the system can perform a cold start performance test: after initializing the system to a force balance state simulating a 6000kg load mass, the ASU is instructed to perform a standard inflation operation. Due to the increased hardness of rubber seals, increased viscosity of grease, and changes in the performance of motor magnets and winding resistance at low temperatures, parameters such as the ASU's starting peak current, time required to reach rated flow, working stability under heavy load, and minimum starting voltage can all be completely recorded by the system and compared with the benchmark data at 25℃, thereby quantifying its low-temperature performance degradation coefficient.

[0036] Even more stringent is the combined stress test of dynamic temperature change and mechanical fatigue. During the programmed temperature rise from -30℃ to 70℃, the control unit can periodically and automatically insert a standard performance test sub-sequence: pause the temperature rise, wait for the temperature plateau to stabilize, execute a complete test cycle, and collect key parameters such as the ASU inflation time curve, steady-state operating current, and system leakage rate at that temperature point. By analyzing the changing trends of these performance parameters throughout the temperature change process, the effective operating temperature window of the ASU can be accurately assessed, and the existence of performance inflection points or failure risks due to the mismatch of thermal expansion coefficients of different materials can be identified. Figure 4 and Figure 5 The provided real-time correlation curves of cavity volume-gas pressure-load force under low-temperature (-20℃) and high-temperature (60℃) conditions with a load mass of 6000kg are direct results of this type of test. The curves show that the test system itself can still maintain a good force-volume-pressure coupling relationship under different extreme temperatures, proving its environmental robustness. However, comparing the curve shape and data details reveals that the inflation time required for the ASU to reach the same pressure change may be shorter at high temperatures, while it may be longer at low temperatures. At the same time, the shape of its operating current curve will also be different. These subtle differences are the key information that the system needs to accurately capture and quantify, which cannot be obtained by traditional room-temperature bench tests.

[0037] Furthermore, the system can perform long-term durability and sealing reliability tests under high temperature and humidity environments. For example, in a high temperature and humidity environment of 70℃ and 85%RH, the system maintains a force balance state simulating a certain load for an extended period, while applying small-amplitude, high-frequency pressure cycles to the ASU. During this process, the system continuously monitors the insulation resistance of the ASU, the leakage current to ground, and the gas leakage rate of the entire test circuit. This multi-stress accelerated aging test can expose corrosion defects in the internal PCB board of the ASU, insufficient moisture resistance of connectors, and the risk of failure of gas interface seals after thermal aging. In summary, this system can significantly shorten the product development and verification cycle, reduce the cost and uncertainty of relying on real-vehicle road testing, and provide an indispensable engineering development and verification platform for improving the overall quality, reliability, and environmental adaptability of ASU products.

Claims

1. An automatic adjustment test system for ASU simulated air springs, characterized in that, include: The simulated air spring unit includes a volume-adjustable cavity for simulating the internal cavity of an air spring; A dynamic load simulation unit is used to apply a programmable simulated load force to the cavity and monitor the load force in real time. An integrated environmental simulation unit is used to provide independently adjustable temperature and humidity environments for the simulated air spring unit and the air supply module under test. The collaborative control and acquisition unit is configured as follows: Execute a preset test sequence to control the initial volume of the cavity and environmental parameters; Based on the target load force and the real-time monitored load force, the dynamic load simulation unit is driven by a closed-loop control algorithm to keep the air pressure in the cavity and the applied simulated load force in dynamic balance. During the test, the air supply module under test is controlled to inflate or deflate the cavity while maintaining dynamic balance, and real-time data on the cavity's volume change, internal pressure change, gas flow rate, and load force are collected simultaneously.

2. The system according to claim 1, characterized in that: The process of simulating the characteristics of a real air spring in the system is achieved through real-time, closed-loop physical coupling and calculation control between the force applied by the dynamic load simulation unit, the volume change of the simulated air spring unit, and the air pressure inside the cavity.

3. The system according to claim 1, characterized in that: The dynamic load simulation unit includes a force control actuator and a high-precision force sensing component. The closed-loop control algorithm calculates and outputs displacement control commands for the force control actuator in real time based on the deviation between the target load force and the measured load force. These commands also serve as driving signals for changes in the cavity volume.

4. The system according to claim 3, characterized in that: The collaborative control and acquisition unit instructs the system to reproduce different force-displacement relationships by modifying the set value of the target load force.

5. The system according to claim 1, characterized in that: The integrated environment simulation unit includes independently controllable temperature and humidity zones, which can perform differentiated temperature and humidity adjustments on the air supply module body and its connected air path.

6. The system according to claim 1, characterized in that, The collaborative control and acquisition unit is further configured as follows: Based on the synchronously acquired data, a coupling characteristic curve reflecting the dynamic correspondence between cavity volume, internal pressure, and load force is calculated and generated in real time.

7. The system according to claim 6, characterized in that: The collaborative control and acquisition unit also includes a reconfigurable test logic module, which allows users to freely define and combine multi-dimensional test steps, including environmental parameter settings, load force change profiles, and air supply module start-stop timing, through graphical or script-based methods.

8. An automatic adjustment test method for ASU simulated air springs, characterized in that: The method is implemented based on the system described in any one of claims 1-7: The method includes: Based on the test conditions, the parameters of the integrated environment simulation unit, the initial volume of the simulated air spring unit, and the target load force of the dynamic load simulation unit are set collaboratively by the collaborative control and acquisition unit. After the integrated environment simulation unit reaches the set conditions, the collaborative control and acquisition unit starts the closed-loop force control of the dynamic load simulation unit, so that the applied load force and the force generated by the initial air pressure in the cavity reach a dynamic balance. The control unit controls the operation of the air supply module to change the air pressure inside the cavity. At this time, the collaborative control and acquisition unit actively adjusts the force exerted on the cavity by the dynamic load simulation unit and / or adjusts the volume of the cavity to maintain or follow the preset force balance relationship, while simultaneously acquiring multiple physical quantity data throughout the process. Based on the collected data, a report and characteristic curves are generated to evaluate the performance of the air supply module under simulated real air spring and complex environmental coupling.

9. The method according to claim 8, characterized in that: The collaborative control and acquisition unit simultaneously calculates load force control and cavity volume adjustment, so that the pressure-volume change relationship in the cavity approximates the curve defined by the preset air spring stiffness model in real time.

10. A computer-readable storage medium storing a computer program, characterized in that: When the computer program is executed by a processor, it implements the method of claim 8 or 9.

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