Air suspension performance monitoring and evaluation system and method

Abstract

The embodiment of the application relates to an air suspension performance monitoring and evaluating system, comprising: an air path monitoring unit for accessing an air suspension main air path and acquiring air path pressure data and gas flow data; a height monitoring unit for acquiring vehicle body ground clearance data; a data acquisition and processing unit connected with the air path monitoring unit and the height monitoring unit, for acquiring and processing the acquired air path parameters and vehicle body height data; a communication unit connected with the data acquisition and processing unit, for sending the data output by the data acquisition and processing unit to an upper computer; the air path monitoring unit is communicated with the air suspension main air path through a detachable air path access structure, so as to acquire the air suspension air path parameters without changing the structure of the original vehicle air suspension control system; the upper computer is used for comparing and analyzing the air path parameters and the vehicle body ground clearance data with the data output by the air suspension controller, so as to realize the evaluation of the working state and performance of the air suspension.

Description

Technical Field

[0001] This application relates to the field of vehicle suspension testing technology, and in particular to an air suspension performance monitoring and evaluation system and method. Background Technology

[0002] With the development of automotive chassis technology, air suspension systems have been increasingly applied to various vehicle types, including commercial vehicles, passenger vehicles, and special-purpose vehicles, due to their advantages such as adjustable vehicle height, improved ride comfort, and enhanced vehicle stability. Air suspension systems typically work in concert with components such as an air reservoir, air suspension valve body, solenoid valve assembly, and air springs. They adjust the internal air pressure of the air springs according to the vehicle's operating conditions, thereby achieving changes in vehicle height and controlling vehicle posture.

[0003] In the research and development and testing of air suspension systems, it is usually necessary to monitor key parameters such as air circuit pressure, air supply flow rate, and vehicle height changes to analyze the operating status of the air suspension system under different conditions. However, existing testing methods mostly use decentralized testing equipment, such as pressure gauges, flow meters, or height measuring devices, for testing. There is a lack of a unified data acquisition and management method among various testing devices, which not only makes the testing operation more complex but also makes it difficult to achieve synchronous recording and analysis of multi-parameter data.

[0004] Furthermore, some testing devices require modifications to the original air circuit structure when connected to an air suspension system, which can easily affect the normal operating condition of the air suspension system, resulting in deviations between test data and actual operating conditions. Additionally, traditional testing equipment is mostly fixed in structure, making it inconvenient to use in vehicle road testing or field testing environments, and failing to meet the needs of multi-scenario testing of air suspension systems. Summary of the Invention

[0005] One objective of this application is to provide an air suspension performance monitoring and evaluation system and method, which at least addresses the aforementioned problems.

[0006] To achieve the above objectives, some embodiments of this application provide an air suspension performance monitoring and evaluation system, including:

[0007] The air circuit monitoring unit is used to connect to the main air circuit of the air suspension and acquire air circuit pressure data and gas flow data;

[0008] The height monitoring unit is used to acquire data on the vehicle's ground clearance.

[0009] The data acquisition and processing unit is connected to the air path monitoring unit and the height monitoring unit, and is used to collect and process the collected air path parameters and vehicle height data;

[0010] A communication unit, connected to the data acquisition and processing unit, is used to send the data output by the data acquisition and processing unit to a host computer;

[0011] The air circuit monitoring unit is connected to the main air circuit of the air suspension through a detachable air circuit access structure, so as to obtain the air suspension air circuit parameters without changing the original vehicle air suspension control system structure.

[0012] The host computer is used to compare and analyze the air circuit parameters and vehicle ground clearance data with the data output by the air suspension controller in order to evaluate the working status and performance of the air suspension.

[0013] Some embodiments of this application also provide a method for monitoring and evaluating the performance of an air suspension, characterized by comprising the following steps:

[0014] The air circuit monitoring device is connected to the main air circuit of the air suspension via a detachable air circuit access structure.

[0015] Collect gas pressure and gas flow data in the air suspension air circuit;

[0016] Collect vehicle ground clearance data;

[0017] The gas pressure data, gas flow data, and vehicle ground clearance data are collected and processed.

[0018] The processed data is sent to the host computer.

[0019] The system acquires data output from the air suspension controller and compares and analyzes the gas pressure data, gas flow data, and vehicle ground clearance data with the data output from the air suspension controller to evaluate the working status and performance of the air suspension.

[0020] Compared with related technologies, the solution provided in this application embodiment can simultaneously acquire air pressure data, gas flow data, and vehicle ground clearance data of the air suspension system by setting up an air circuit monitoring unit and a height monitoring unit. These data are then uniformly collected and processed by the data acquisition and processing unit, thereby achieving synchronous monitoring between the air suspension air circuit status and vehicle attitude changes. This facilitates a more comprehensive analysis of the operating status of the air suspension system.

[0021] The air circuit monitoring unit is connected to the air suspension air circuit through a quick-release gas assembly. During the connection process, there is no need to change the internal air circuit structure of the air suspension valve body. Only the external pipeline needs to be connected to complete the system connection. Therefore, the original working state of the air suspension system will not be significantly affected during the test, which is conducive to obtaining test data that is closer to the actual working conditions.

[0022] This system can be used for various applications, including vehicle road testing, laboratory bench testing of air suspension systems, system debugging, quality inspection, and fault diagnosis. It can provide reliable data support for the research, development, testing, and performance evaluation of air suspension systems. Attached Figure Description

[0023] One or more embodiments are illustrated by way of example with reference numerals in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0024] Figure 1 This is a schematic diagram of the structure of the air suspension performance monitoring and evaluation system provided in this embodiment;

[0025] Figure 2 This is a structural schematic diagram of the air suspension performance monitoring and evaluation system provided in this embodiment of the present disclosure from another perspective;

[0026] Figure 3 This is a structural schematic diagram of the air suspension performance monitoring and evaluation system provided in this embodiment of the present disclosure from another perspective;

[0027] Figure 4 This is a schematic diagram of the air suspension performance monitoring and evaluation system provided in this embodiment after it is assembled with a vehicle.

[0028] Figure 5 This is a schematic diagram of the air suspension performance monitoring and evaluation system provided in this embodiment being assembled with a vehicle;

[0029] Figure 6 This is a flowchart of the air suspension performance monitoring and evaluation method provided in the embodiments of this disclosure.

[0030] Figure label:

[0031] 10: Mechanical barometer; 20: Pressure sensor; 30: Gas flow detection component; 40: Altitude sensor; 50: ADC acquisition board; 70: Power supply unit; 80: Housing; 90: Handle; 100: Gas storage device; 110: Air spring. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0033] The terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this disclosure are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this disclosure described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion.

[0034] In this disclosure, the terms "upper," "lower," "inner," "middle," "outer," "front," and "rear," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for better description of the embodiments of this disclosure and their implementations, and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to require them to be constructed and operated in a specific orientation. Furthermore, some of the aforementioned terms may be used to indicate other meanings besides orientation or positional relationship; for example, the term "upper" may in some cases indicate a dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in the embodiments of this disclosure according to the specific circumstances.

[0035] Furthermore, the terms "set up," "connect," and "fix" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of this disclosure according to the specific circumstances.

[0036] Unless otherwise stated, the term "multiple" means two or more.

[0037] In this embodiment of the disclosure, the character " / " indicates that the objects before and after it are in an "or" relationship. For example, A / B means: A or B.

[0038] The term "and / or" describes an association between objects, indicating that three relationships can exist. For example, A and / or B means: A or B, or A and B.

[0039] It should be noted that, unless otherwise specified, the embodiments and features described in the present disclosure can be combined with each other.

[0040] Combination Figures 1 to 6 As shown in the figure, an air suspension performance monitoring and evaluation system provided in this disclosure includes:

[0041] The air circuit monitoring unit is used to connect to the main air circuit of the air suspension and acquire air circuit pressure data and gas flow data;

[0042] The height monitoring unit is used to acquire data on the vehicle's ground clearance.

[0043] The data acquisition and processing unit is connected to the air path monitoring unit and the height monitoring unit, and is used to collect and process the collected air path parameters and vehicle height data;

[0044] The communication unit is connected to the data acquisition and processing unit and is used to send the data output by the data acquisition and processing unit to the host computer.

[0045] Among them, the air circuit monitoring unit is connected to the main air circuit of the air suspension through a detachable air circuit access structure, so as to obtain the air circuit parameters of the air suspension without changing the original air suspension control system structure.

[0046] The host computer is used to compare and analyze the air circuit parameters and vehicle ground clearance data with the data output by the air suspension controller in order to evaluate the working status and performance of the air suspension.

[0047] The system provided in this embodiment of the present disclosure, by setting up an air circuit monitoring unit, a height monitoring unit, a data acquisition and processing unit, and a communication unit, enables the system to simultaneously acquire multiple operating parameters such as air suspension air circuit pressure, gas flow rate, and vehicle ground clearance. These parameters are then processed through a unified data acquisition and transmission structure, thereby achieving comprehensive monitoring of the operating status of the air suspension system and improving the integrity and reliability of air suspension performance test data.

[0048] This embodiment constructs an objective evaluation benchmark independent of the original vehicle control logic. By integrating with the air circuit through non-destructive embedding, it effectively solves the performance calibration problems caused by a single data source or bus data distortion in the early stages of vehicle development. This system can acquire first-hand pressure and altitude physical data without compromising the integrity of the original vehicle hardware, and cross-compare it with the output values ​​of the ASU controller. This allows for in-depth verification of suspension response characteristics and logic accuracy, greatly improving the objectivity and safety of chassis development.

[0049] Optionally, the gas path monitoring unit includes a pressure detection component and a gas flow detection component 30. The pressure detection component is used to acquire gas path pressure data, and the gas flow detection component 30 is used to acquire gas flow data.

[0050] By setting a gas flow detection component 30 in the air path monitoring unit, the system can detect the changes in gas flow during the air supply process of the air suspension system in real time, which is beneficial for analyzing the air supply situation and its changing patterns under different working conditions of the air suspension system.

[0051] In some embodiments, the gas flow detection component 30 is disposed in the main air path between the gas storage device 100 and the air suspension valve body, and is used to detect the change in gas flow during the process of the gas storage device 100 supplying gas to the air suspension system.

[0052] By deploying the gas flow detection component 30 between the gas storage device 100 and the valve body, the dynamic flow characteristics of the system's gas supply source can be captured. This allows the system to directly quantify the efficiency of the gas storage device 100 in distributing gas to each actuator, providing physical criteria for evaluating the compressor's gas supply capacity, analyzing gas path resistance, and diagnosing system response delays.

[0053] Optionally, the pressure detection component includes a mechanical pressure gauge 10 and a pressure sensor 20, which together form a dual detection structure for the air circuit pressure.

[0054] By setting a pressure detection component in the air circuit monitoring unit, the system can detect the gas pressure of each air circuit branch of the air suspension in real time, thereby reflecting the pressure changes inside the air spring 110.

[0055] Thus, by refining the monitoring dimensions and introducing redundancy mechanisms, the system's data reliability is significantly enhanced. The gas path monitoring unit simultaneously captures pressure and flow, fully reproducing the dynamic charging and discharging process of the gas path system. In particular, the dual detection structure of the mechanical pressure gauge 10 and the electronic pressure sensor 20 not only achieves cross-calibration between analog and digital signals, but more importantly, provides a safety guarantee mechanism that is visible even in the event of a power outage. Under actual vehicle debugging or maintenance conditions, even if the power is interrupted, testers can still judge the residual pressure in the gas path through the mechanical scale, effectively avoiding high-pressure gas injuries caused by blind disassembly.

[0056] Optionally, both the mechanical air pressure gauge 10 and the pressure sensor 20 are five-channel, corresponding to the four air springs 110 air paths of the air suspension and one main air path of the valve body, respectively.

[0057] The design of five independent monitoring channels achieves comprehensive coverage of the core nodes of the air suspension. The zoned monitoring of the four air springs 110 and the main air circuit of the valve body can accurately identify the pressure response differences of each corner under different loads. This helps technicians quickly locate whether the problem is an abnormality in the airtightness of a single air chamber or a deviation in the distribution logic of the solenoid valve group, providing refined data support for attitude coordination under complex operating conditions.

[0058] Optionally, the height monitoring unit includes multiple sensors located at the four corners of the vehicle chassis to acquire ground clearance data of the vehicle body at different locations.

[0059] Optionally, the height sensor 40 is a laser rangefinder or an infrared rangefinder; wherein the detection direction of the height sensor 40 is perpendicular to the ground.

[0060] Using vertically oriented laser or infrared sensors at the four corners of the vehicle's chassis eliminates interference from longitudinal or lateral swaying during vehicle movement, obtaining the most accurate ground clearance data. This directly characterizes the dynamic adjustment speed and steady-state holding capability of the air suspension, providing the most intuitive physical criterion for evaluating vehicle leveling performance.

[0061] In some embodiments, each sensor of the height monitoring unit is mounted on the vehicle chassis structure via a fixed bracket, which is used to adjust the mounting angle and mounting height of the sensors.

[0062] The adjustable mounting bracket enhances the adaptability of the height monitoring unit to different vehicle models and chassis geometries. Technicians can flexibly adjust the sensor's installation angle and height based on the limitations of the actual vehicle testing space, ensuring the monitoring optical axis remains perpendicular to the ground, thus eliminating cosine errors caused by installation deviations.

[0063] In some embodiments, the sensors of the height monitoring unit are installed at the front left, front right, rear left, and rear right positions of the vehicle to acquire ground clearance data at the four corners of the vehicle. This design of arranging sensors at the four corners of the vehicle chassis creates a closed-loop monitoring network for the vehicle's spatial attitude. By simultaneously acquiring displacement data in four dimensions (front left, front right, rear left, and rear right), the system can fully reconstruct the vehicle's pitch, roll, and overall height changes under dynamic conditions, providing data support for evaluating the suspension system's leveling logic and dynamic balance capabilities.

[0064] This embodiment, by setting up an air path monitoring unit, a height monitoring unit, and a data acquisition and processing unit, enables the system to simultaneously acquire air path pressure data, gas flow data, and vehicle ground clearance data of the air suspension system, and record them synchronously through a unified data acquisition and processing structure. Compared with existing air suspension testing devices that only detect a single parameter, this embodiment can establish the correspondence between air path status and vehicle posture during the same testing process, thereby more comprehensively reflecting the working status of the air suspension system and facilitating a comprehensive analysis of the air suspension system's performance.

[0065] In some embodiments, the data acquisition and processing unit is an ADC acquisition board 50, which is used to convert the analog signals acquired by the gas path monitoring unit and the altitude monitoring unit into digital signals and then output them to the communication unit.

[0066] In some embodiments, the ADC acquisition board is at least a 12-bit precision acquisition board and is configured with at least 12 independent physical acquisition channels.

[0067] Digital conversion and high-precision acquisition ensured data fidelity. The use of an ADC acquisition board with a precision of 12 bits or higher, coupled with multi-channel parallel acquisition, ensured strict synchronization of various heterogeneous signals such as pressure, flow rate, and altitude across the time series. This allowed for the capture of subtle pressure pulsations and instantaneous displacement changes through high-resolution data streams, laying a solid data foundation for subsequent analysis.

[0068] In some embodiments, the data acquisition and processing unit is connected to both the gas path monitoring unit and the altitude monitoring unit to perform unified acquisition and analog-to-digital conversion processing of pressure signals, flow signals, and altitude signals.

[0069] By utilizing a unified data acquisition and processing unit to synchronously process pressure, flow, and altitude signals, strict alignment of heterogeneous signals on a time base is achieved. In this way, the integrated analog-to-digital conversion mechanism eliminates acquisition delays between different monitoring dimensions, ensuring that the causal relationship between pressure fluctuations and altitude changes can be accurately captured, laying a highly consistent data foundation for in-depth multi-parameter coupling analysis.

[0070] In some embodiments, the communication unit includes a CAN interface card that supports the CAN / CANFD communication protocol, enabling high-speed data transmission to the host computer. The communication unit supporting the CAN / CANFD protocol ensures that monitoring data can be uploaded to the host computer with high-bandwidth signals, meeting the real-time throughput requirements of massive amounts of data during dynamic road tests.

[0071] In some embodiments, the communication unit connects to a host computer via a DB9 interface for displaying and storing test data. Using the industry-standard DB9 interface enhances the robustness of the physical connection and the anti-interference capability of data transmission. This ensures that high-speed acquired test data can be stably and in real-time transmitted to the host computer for display and storage, meeting the stringent requirements for equipment connection reliability under road test conditions.

[0072] This embodiment uses a data acquisition and processing unit and a communication unit to uniformly acquire pressure, flow, and altitude signals, transmit the data via the controller's local area network, and connect to a host computer via a DB9 interface. This structure enables the acquired test data to be processed uniformly and transmitted to the host computer in real time. The host computer then parses and stores the data using a database file, thereby achieving real-time recording and subsequent analysis of the air suspension test data.

[0073] In some embodiments, the host computer parses the air pressure data, gas flow data, and vehicle ground clearance data through a custom database file, and converts them into controller area network signals for display and storage.

[0074] By utilizing a custom database file to parse and convert data according to protocols, seamless integration between underlying measurement data and standard vehicle network communication protocols is achieved. By converting pressure, flow, and altitude data into universal signals for storage, researchers can directly call mainstream bus analysis tools for real-time visualization monitoring and data post-processing, significantly reducing the complexity of heterogeneous data analysis.

[0075] Optionally, the gas path access structure includes a quick-release gas connector for connecting the gas path monitoring unit in series with the air suspension gas storage device 100 and the solenoid valve assembly. This series connection using the quick-release connector significantly shortens the test preparation cycle and enables rapid reuse and efficient switching of the equipment in different test sample workshops.

[0076] In some embodiments, the air path monitoring unit may also be connected to the air suspension air path via a metal connection assembly, which includes a threaded joint or a sealing joint for achieving a sealed connection between the pressure sensor 20 and the air path pipeline.

[0077] By employing metal connection assemblies consisting of threaded or sealed joints, the mechanical strength and static sealing reliability of the pressure sensor 20 when connected to the high-pressure air circuit are ensured. This effectively resists air pressure pulsations generated during frequent charging and discharging of the air suspension, preventing air leakage at the interface due to vibration or high-pressure impact, thereby guaranteeing the measurement accuracy and safety of the air circuit monitoring unit during long-term testing.

[0078] In this embodiment, the gas path monitoring unit is connected to the air suspension gas path system via a quick-release gas connector and a metal connection assembly. This allows the gas flow detection component 30 to be positioned in the main gas path between the air storage device 100 and the air suspension valve body, while simultaneously enabling the pressure detection component to be connected to the air spring 110 branch. Through this connection method, the internal gas path structure of the air suspension valve body does not need to be altered during testing; the test system can be accessed solely through an external connection. Therefore, it does not significantly affect the original operating state of the air suspension system, thus facilitating the acquisition of test data that more closely approximates actual operating conditions.

[0079] Optionally, the system also includes a power supply unit 70, which is electrically connected to the air path monitoring unit, altitude monitoring unit, data acquisition and processing unit, and communication unit to provide operating power. This further enhances the system's robustness in complex testing environments. The independent power supply unit 70 eliminates the impact of vehicle voltage fluctuations on sampling accuracy, ensuring the consistency of measurement results.

[0080] Optionally, it also includes a housing 80, in which the gas path monitoring unit, data acquisition and processing unit, and communication unit are integrated; wherein, the housing 80 is a metal shielding structure to isolate electromagnetic interference.

[0081] The enclosure 80 with a metal shielding structure not only achieves integrated protection and portability of the hardware system, but more importantly, it effectively blocks high-frequency electromagnetic interference in the vehicle environment through electromagnetic shielding, ensuring that high-quality, low-noise test signals can still be output under harsh working conditions.

[0082] In some embodiments, the housing 80 is provided with a sheet metal bracket or slide rail structure for installing and fixing the gas path monitoring unit, data acquisition and processing unit, and communication unit.

[0083] The introduction of sheet metal brackets or sliding rail structures within the enclosure 80 provides a stable physical support for precision electronic components and pneumatic monitoring assemblies. This structured internal layout not only optimizes cable and pipe routing and reduces internal interference, but also enhances the system's shock resistance under bumpy road test conditions and facilitates rapid hardware disassembly and maintenance.

[0084] In some embodiments, the bottom of the housing 80 is equipped with casters, and the side of the housing 80 is equipped with a handle 90 to facilitate the movement and deployment of the system at the vehicle testing site. The integrated design of the casters and handle 90 optimizes the deployment flexibility of the system at the testing site. This portable physical structure allows the equipment to be quickly moved between different prototype vehicles or experimental workstations by a single person, greatly shortening the test preparation cycle and improving the overall efficiency of real-vehicle calibration work.

[0085] Specifically, the communication unit, power supply unit 70, air path monitoring unit, altitude monitoring unit, and data acquisition and processing unit are modularly designed and integrated into the system housing 80. The housing 80 contains mounting brackets or sliding rails to secure the modules, and casters are installed at the bottom of the housing 80, with a handle 90 on the side. This structure makes the overall system more compact, ensures stable installation of each functional module, and allows for rapid movement and deployment at the test site, thereby improving the ease of use of the air suspension testing system.

[0086] This disclosure also provides a method for monitoring and evaluating the performance of an air suspension system, including the following steps:

[0087] The air circuit monitoring device is connected to the main air circuit of the air suspension via a detachable air circuit access structure.

[0088] Collect gas pressure and gas flow data in the air suspension air circuit;

[0089] Collect vehicle ground clearance data;

[0090] Data collection and processing are performed on gas pressure data, gas flow data, and vehicle ground clearance data.

[0091] The processed data is sent to the host computer.

[0092] The system acquires data output from the air suspension controller and compares and analyzes the gas pressure data, gas flow data, and vehicle ground clearance data with the data output from the air suspension controller to evaluate the working status and performance of the air suspension.

[0093] The monitoring and evaluation method provided in this disclosure achieves dynamic quantitative evaluation of air suspension performance by establishing a detection logic that is parallel to and physically isolated from the original vehicle's electronic control unit. Firstly, a detachable structure is used to connect to the main air circuit, ensuring that firsthand pressure and flow physical data are obtained without altering the original aerodynamic characteristics of the prototype vehicle, effectively avoiding systematic errors caused by hardware modifications. This quasi-static or dynamic access method not only ensures the safety of the testing process but also provides physical support for the authenticity of subsequent data.

[0094] Secondly, this method achieves cross-dimensional signal fusion analysis. By forcibly aligning the microscopic pressure changes within the air circuit, the macroscopic gas flow characteristics, and the instantaneous displacement data of the vehicle chassis on a time reference, a complete transmission chain is formed for the air suspension from command issuance to air circuit execution and then to vehicle body response. This end-to-end data acquisition and processing flow eliminates the limitations of single sensor signals, providing multi-dimensional criteria for analyzing system lag time, overcharge phenomena, or dynamic stiffness changes.

[0095] Finally, this method also establishes a closed-loop comparison mechanism. By cross-verifying independently collected raw data with the logical data output by the air suspension controller, the accuracy of the control algorithm under complex real-world vehicle conditions can be intuitively revealed. This comparative analysis method can not only be used to quickly identify logical defects in the control strategy, but also serve as an objective basis for chassis tuning and performance optimization, improving the verification efficiency of air suspension from R&D calibration to quality evaluation.

[0096] This embodiment provides an air suspension performance monitoring and evaluation system for real-time monitoring and data recording of air circuit pressure, gas flow rate, and vehicle height changes during vehicle air suspension system operation, thereby achieving objective testing and evaluation of air suspension performance. The system adopts a modular design, with all functional modules integrated within the same system housing 80, allowing for vehicle connection and testing without altering the original air circuit structure of the air suspension system under test.

[0097] The air suspension performance monitoring and evaluation system of this embodiment mainly includes a communication unit, a power supply unit 70, an air circuit monitoring unit, a height monitoring unit, a data acquisition and processing unit, and a housing 80. The communication unit is used to enable communication between the test data and the host computer; the power supply unit 70 provides a stable power supply to the various modules within the system; the air circuit monitoring unit acquires pressure and flow parameters in the air suspension air circuit; the height monitoring unit detects changes in the vehicle's ground clearance; the data acquisition and processing unit acquires, converts, and processes various detection signals; and the housing 80 houses and secures all the aforementioned modules.

[0098] In this embodiment, the communication unit includes a CAN interface card, a controller base, an ADC acquisition board, a DB9 interface, and a power supply interface. The CAN interface card is electrically connected to the data acquisition and processing unit and is used to transmit the acquired pressure, flow, and height signals through the controller's local area network. The DB9 interface is used to establish a physical connection between the system and a host computer device, which displays, records, and analyzes the data using appropriate software.

[0099] The power supply unit 70 includes a power supply module, a transformer module, a protection switch module, an AC / DC converter module, and a wiring harness assembly. The power supply module connects to an external power source, performs voltage conversion via the transformer module, and outputs the DC power required by the system through the AC / DC converter module. The protection switch module is used to cut off the power supply in case of abnormal current to ensure safe system operation. The wiring harness assembly is used to transmit the electrical energy output from the power supply unit 70 to the communication unit, data acquisition and processing unit, and various monitoring units.

[0100] The air path monitoring unit is used to detect the gas flow rate and pressure of each branch in the air suspension air path. This unit includes a gas flow rate detection component 30, a pressure detection component, and a metal connection component. The gas flow rate detection component 30 is located in the main air path between the air storage device 100 and the air suspension valve body, and is used to detect changes in gas flow rate during the air supply process from the air storage device 100 to the air suspension system. The pressure detection component includes a mechanical pressure gauge 10 and a pressure sensor 20. The pressure sensor 20 is connected to the air suspension air path via the metal connection component and is used to detect the gas pressure in each airbag branch of the air suspension. The mechanical pressure gauge 10 is used to visually display the detected pressure for on-site observation during testing.

[0101] Regarding the air circuit connection structure, this embodiment connects to the air suspension system under test via a quick-release gas assembly, thereby enabling rapid connection and disconnection between the test system and the existing air circuit system. During the connection process, the system only performs external series connection of the air circuit, without altering the internal air circuit structure of the air suspension valve body, and therefore will not significantly affect the normal operating status of the air suspension system.

[0102] The height monitoring unit is used to detect changes in the vehicle's ground clearance. In this embodiment, the height monitoring unit includes multiple laser rangefinders and corresponding mounting brackets. Each laser rangefinder is installed at a corresponding position on the vehicle chassis. The mounting angle and height of the sensors are adjusted using the mounting brackets to ensure measurement accuracy. Preferably, the laser rangefinders are positioned at four locations: the front left, front right, rear left, and rear right of the vehicle, to detect the ground clearance at the four corners of the vehicle, thereby reflecting the height changes of the air suspension under different operating conditions.

[0103] The data acquisition and processing unit is connected to the gas path monitoring unit and the altitude monitoring unit, respectively, and is used to receive signals from the pressure sensor 20, the flow detection component, and the laser rangefinder. The data acquisition and processing unit is equipped with an ADC acquisition board, which is used to perform analog-to-digital conversion on the pressure signal, flow signal, and altitude signal, and send the processed data to the communication unit.

[0104] The enclosure 80 serves to house and protect the aforementioned functional modules. Inside the enclosure 80, sheet metal brackets or sliding rails are provided for mounting and securing the gas path monitoring unit, data acquisition and processing unit, and communication unit, thus making the internal structure of the system more compact. A cover is provided on the top of the enclosure 80, with a mechanical pressure gauge 10 mounted on it for easy viewing during on-site testing. Handles 90 are provided on both sides of the enclosure 80, and casters are provided at the bottom, enabling easy movement and deployment of the entire system at the testing site.

[0105] During actual testing, after the system is powered on, the power supply unit 70 provides operating power to each functional module, and the data acquisition and processing unit begins to collect signals output by the air path monitoring unit and the height monitoring unit. Before entering the air suspension valve body, the compressed air in the air storage device 100 first passes through the gas flow detection component 30, thereby obtaining the air supply flow data. Subsequently, the gas enters the valve body air path via the air drying module, and under the control of the electronic control module, it supplies or exhausts air to each air spring 110 through the solenoid valve group. During this process, the gas pressure of each air spring 110 branch is detected by the pressure sensor 20, and the mechanical pressure gauge 10 provides a direct display of the pressure status.

[0106] When the air suspension system adjusts its height, changes in the air pressure inside each air spring 110 cause changes in the vehicle's height. The laser rangefinder in the height monitoring unit can measure the change in distance from the bottom of the vehicle to the ground in real time, thus indirectly reflecting the change in the height of the air springs 110. The aforementioned pressure data, flow data, and height data are collected and converted into digital signals by the data acquisition and processing unit, and then transmitted to the host computer for storage via the CAN interface of the communication unit.

[0107] In terms of data processing, the host computer can parse the received CAN signals through a custom database file, convert pressure data, flow data, and height data into corresponding monitoring parameters, and display and record them, thereby forming complete test data of the air suspension system's operating status, providing a basis for air suspension performance evaluation and system debugging.

[0108] With the above structure, the air suspension performance monitoring and evaluation system of this embodiment can simultaneously monitor the air suspension air circuit pressure, air supply flow and vehicle height changes without changing the original working state of the air suspension. It has the advantages of high structural integration, convenient installation, fast response speed and high testing efficiency, and is suitable for the research and development testing and performance evaluation of vehicle air suspension systems.

[0109] For example, in a vehicle road test scenario, the air suspension performance monitoring and evaluation system is used to test the air suspension performance of the vehicle under road driving conditions. Before the test, the air circuit monitoring unit is connected to the main air circuit of the vehicle's air suspension system via a quick-release gas assembly. Specifically, the gas flow detection assembly 30 is installed in the air supply pipeline between the air storage device 100 and the air suspension valve body to detect the flow rate change of compressed air entering the air suspension system in real time. At the same time, the pressure detection assembly is connected to the branch pipelines of each air spring 110 via metal connection assemblies to obtain the pressure data of the left front, right front, left rear, and right rear air spring 110 branches of the vehicle.

[0110] The laser rangefinders in the height monitoring unit are installed at corresponding positions on the vehicle chassis. The sensors are fixed to the vehicle body structure using mounting brackets, and the installation angles are adjusted appropriately to ensure that the sensor's measurement direction is essentially perpendicular to the ground. While the vehicle is traveling on the road, as the air suspension automatically adjusts according to the control strategy, each laser rangefinder can measure the changes in the vehicle's ground clearance in real time.

[0111] During testing, pressure and gas flow data collected by the air path monitoring unit and vehicle height data collected by the height monitoring unit are simultaneously transmitted to the data acquisition and processing unit for analog-to-digital conversion. The processed data is then sent to the host computer via the CAN interface through the communication unit. The host computer parses and stores the received data using a custom database file, thus creating a record of the vehicle's air suspension operating status under real-world road conditions, providing data support for the overall vehicle suspension performance evaluation.

[0112] For example, in a laboratory bench test scenario, an air suspension performance monitoring and evaluation system is applied to the laboratory bench test of an air suspension system. The air suspension valve body, air spring 110, and air storage device 100 are mounted on the test bench, and the air suspension system is functionally tested using simulated control signals.

[0113] The gas path monitoring unit of the test system is connected to the gas path of the test bench via a connector. The gas flow detection component 30 is installed between the output end of the gas storage device 100 and the air suspension valve body to detect changes in gas flow during the gas supply process. The pressure detection components are connected to the pipelines between the air suspension valve body and each air spring 110 to monitor the gas pressure of different branches in real time.

[0114] In this embodiment, the laser rangefinder of the height monitoring unit is mounted on a test bench structure, with the sensor's measurement direction aligned with the upper mounting plate of the air spring 110 or a simulated vehicle body structure. When the air spring 110 expands or contracts during inflation or deflation, the laser rangefinder can measure its height change.

[0115] During testing, the bench control system drives the solenoid valve assembly in the air suspension valve body to perform different air supply or exhaust actions according to a preset control program. Pressure, flow, and height signals collected by the air path monitoring unit and height monitoring unit are processed by the data acquisition and processing unit and transmitted to the host computer via the communication unit. The host computer records the test data under different control conditions to analyze the response characteristics of the air suspension system in different operating modes.

[0116] For example, in an air suspension system commissioning scenario, the air suspension performance monitoring and evaluation system is used for software calibration and commissioning of the vehicle's air suspension system. The testing system connects to the vehicle's air suspension air circuit via a connector and establishes data communication with the vehicle control system via a communication unit.

[0117] During the commissioning process, the vehicle controller controls the solenoid valve group in the air suspension valve body to adjust the inflation or deflation of the air spring 110 according to the calibration parameters. The pressure detection component in the air circuit monitoring unit detects the gas pressure changes of each air spring 110 branch in real time, and the gas flow detection component 30 is used to record the changes in air supply flow.

[0118] Meanwhile, the laser rangefinder of the height monitoring unit measures the vehicle's ground clearance in real time. When the air suspension system executes control commands to raise or lower the vehicle, the system can simultaneously acquire the correlation between changes in internal pressure of the air spring 110 and changes in vehicle height.

[0119] After collecting and processing the aforementioned monitoring data, the data acquisition and processing unit sends it to the host computer via the communication unit. Engineers can then use the host computer software to analyze the pressure, flow rate, and height change curves under different calibration parameters, thereby optimizing the air suspension control strategy and improving system adjustment accuracy and response speed.

[0120] For example, in a vehicle quality inspection scenario, this air suspension performance monitoring and evaluation system is used for quality inspection during the vehicle production process. After the vehicle is assembled, the working status of the air suspension system needs to be tested to confirm whether the system meets the design requirements.

[0121] During the testing process, the air circuit monitoring unit is connected to the vehicle's air suspension system, and the laser rangefinder of the height monitoring unit is positioned at the corresponding location on the vehicle chassis. After the testing system is powered on, it supplies operating power to each module through the power supply unit 70.

[0122] The testing personnel can control the vehicle's air suspension system to raise and lower it. During this process, the air circuit monitoring unit records changes in the pressure and air flow of the air spring branch 110, while the height monitoring unit records changes in the vehicle's height. All data is processed by the data acquisition and processing unit and then transmitted to the host computer for recording via the communication unit.

[0123] The host computer compares the test data according to the preset test standards. When the test data is within the allowable range, it indicates that the air suspension system is working normally. If abnormal data occurs, the specific fault location can be determined by the changes in pressure and flow, thereby improving the efficiency of vehicle testing.

[0124] For example, in extreme operating condition testing scenarios, the air suspension performance monitoring and evaluation system is used to test the air suspension performance of vehicles under extreme road conditions, such as continuous speed bumps, potholes, or high-speed lane changes. Before testing, the air circuit monitoring unit is connected to the air supply line of the vehicle's air suspension system and the branches of each air spring 110 via connectors and quick-release gas components. The gas flow detection component 30 is positioned in the main air circuit between the air storage device 100 and the air suspension valve body, while the pressure detection components are connected to the corresponding air circuit branches of each air spring 110.

[0125] The laser rangefinder in the altitude monitoring unit is installed on the vehicle chassis structure, and the installation angle of the sensor is adjusted by a fixed bracket so that its measurement direction is basically perpendicular to the ground. When the vehicle travels on continuously undulating or uneven roads, the air suspension system will quickly adjust according to the changes in vehicle posture, and the air pressure inside each air spring 110 will change relatively frequently.

[0126] During testing, the air circuit monitoring unit records real-time changes in air circuit pressure and air supply flow of the air suspension system, while the height monitoring unit simultaneously records changes in the vehicle's ground clearance at all four corners. The data acquisition and processing unit synchronously acquires various monitoring signals and performs analog-to-digital conversion processing, then transmits them to the host computer via the CAN network through the communication unit for recording. By analyzing the pressure, flow, and vehicle height change curves under extreme conditions, the response speed and stability of the air suspension system in complex road environments can be evaluated.

[0127] For example, in a remote monitoring test scenario, the air suspension performance monitoring and evaluation system is used for remote monitoring tests of vehicles operating for extended periods. The test system is installed inside the vehicle or in the test equipment housing 80, and is connected to the vehicle's air suspension air circuit system via connectors and quick-release gas components.

[0128] When the vehicle is in actual operation, the air circuit monitoring unit continuously collects data on changes in air circuit pressure and air supply flow of the air suspension system, while the height monitoring unit continuously collects data on the vehicle's ground clearance. The data acquisition and processing unit performs analog-to-digital conversion on the collected signals and converts them into CAN data frames via the communication unit before sending them to the host computer.

[0129] The host computer parses and stores the received data. When the monitored data reaches preset conditions or undergoes abnormal changes, it can be sent to a remote monitoring terminal via a remote network. Technicians can analyze the operating status of the air suspension system based on the pressure changes, flow rate changes, and vehicle height changes displayed on the remote monitoring terminal, thereby achieving long-term operational monitoring of the vehicle's air suspension system.

[0130] For example, in the scenario of air suspension system fault diagnosis, the air suspension performance monitoring and evaluation system is used for fault diagnosis testing of the vehicle air suspension system. When the vehicle air suspension system experiences problems such as abnormal vehicle height or slow lifting response during operation, this system can be used to detect the status of the air suspension air circuit.

[0131] In practice, the air circuit monitoring unit is connected to the air circuit of the vehicle's air suspension system via connectors and quick-release gas components. The gas flow detection component 30 is installed in the main air circuit between the air storage device 100 and the air suspension valve body to detect changes in the air supply flow of the air suspension system. The pressure detection component is connected to the branch lines of each air spring 110 via metal connection components to monitor the gas pressure of the air spring 110 branch lines in real time.

[0132] When the vehicle is being raised or lowered, the laser rangefinder in the height monitoring unit simultaneously measures the ground clearance of the vehicle at each corner. When there are issues such as air leakage in the air suspension system, abnormal valve control, or damage to the air spring 110, an abnormal correlation will appear between changes in air pressure, changes in air flow, and changes in vehicle height.

[0133] The data acquisition and processing unit collects and processes the aforementioned monitoring data and sends it to the host computer via the communication unit. Technicians use the host computer software to comprehensively analyze the pressure change curves, flow rate change curves, and vehicle height change curves. This allows them to determine potential fault locations in the air suspension system, such as abnormal air supply, air circuit leaks, or valve control malfunctions, thus enabling fault diagnosis of the air suspension system.

[0134] For example, in the scenario of air suspension performance evaluation, the air suspension performance monitoring and evaluation system is used to objectively evaluate the performance of the air suspension system. During the research and development or testing phase of the vehicle air suspension system, this system collects operating data of the air suspension under different working conditions and performs comprehensive analysis of the system performance.

[0135] During the test, the air circuit monitoring unit continuously collected air circuit pressure data and air supply flow data of the air suspension system, while the height monitoring unit measured changes in the vehicle's ground clearance in real time. When the air suspension system performs control actions such as raising, lowering, or maintaining the vehicle's height, the system can simultaneously record changes in the internal pressure of the air spring 110 and the changes in vehicle height.

[0136] The collected pressure, flow, and height data are processed by the data acquisition and processing unit and then transmitted to the host computer via the communication unit. The host computer stores the monitoring data and generates corresponding test curves, such as the air spring 110 pressure change curve, air supply flow change curve, and vehicle height change curve.

[0137] By analyzing the above data, performance indicators such as response time, adjustment speed, and height control stability of the air suspension system under different control conditions can be obtained. Technicians can then optimize the air suspension control strategy based on the test results, thereby improving the overall performance of the air suspension system.

[0138] The foregoing description and accompanying drawings fully illustrate embodiments of the present disclosure to enable those skilled in the art to practice them. Other embodiments may include structural and other changes. The embodiments represent only possible variations. Individual components and functions are optional unless explicitly required, and the order of operation may vary. Parts and features of some embodiments may be included or substituted for parts and features of other embodiments. Embodiments of the present disclosure are not limited to the structures described above and shown in the accompanying drawings, and various modifications and changes may be made without departing from its scope. The scope of the present disclosure is limited only by the appended claims, and the foregoing embodiments should be considered exemplary and non-limiting.

Claims

1. An air suspension performance monitoring and evaluation system, characterized in that, include: The air circuit monitoring unit is used to connect to the main air circuit of the air suspension and acquire air circuit pressure data and gas flow data; The height monitoring unit is used to acquire data on the vehicle's ground clearance. The data acquisition and processing unit is connected to the air path monitoring unit and the height monitoring unit, and is used to collect and process the collected air path parameters and vehicle height data; A communication unit, connected to the data acquisition and processing unit, is used to send the data output by the data acquisition and processing unit to a host computer; The air circuit monitoring unit is connected to the main air circuit of the air suspension through a detachable air circuit access structure, so as to obtain the air suspension air circuit parameters without changing the original vehicle air suspension control system structure. The host computer is used to compare and analyze the air circuit parameters and vehicle ground clearance data with the data output by the air suspension controller in order to evaluate the working status and performance of the air suspension.

2. The air suspension performance monitoring and evaluation system according to claim 1, characterized in that: The gas path monitoring unit includes a pressure detection component and a gas flow detection component. The pressure detection component is used to acquire the gas path pressure data, and the gas flow detection component is used to acquire the gas flow data.

3. The air suspension performance monitoring and evaluation system according to claim 2, characterized in that: The pressure detection component includes a mechanical barometer and a pressure sensor, which together form a dual detection structure for the air pressure.

4. The air suspension performance monitoring and evaluation system according to claim 3, characterized in that, The mechanical air pressure gauge and pressure sensor are both five-channel, corresponding to the four air spring air paths and one main air path of the valve body of the air suspension.

5. The air suspension performance monitoring and evaluation system according to claim 1, characterized in that, The height monitoring unit includes multiple sensors located at the four corners of the vehicle chassis, used to acquire ground clearance data of the vehicle body at different positions.

6. The air suspension performance monitoring and evaluation system according to claim 5, characterized in that, The height sensor is a laser rangefinder or an infrared rangefinder; The height sensor's detection direction is perpendicular to the ground.

7. The air suspension performance monitoring and evaluation system according to claim 1, characterized in that, The gas path access structure includes a quick-release gas connector for connecting the gas path monitoring unit in series with the gas path between the air suspension gas storage device and the solenoid valve assembly.

8. The air suspension performance monitoring and evaluation system according to claim 1, characterized in that, It also includes a power supply unit, which is electrically connected to the air path monitoring unit, altitude monitoring unit, data acquisition and processing unit and communication unit respectively, to provide working power.

9. The air suspension performance monitoring and evaluation system according to claim 1, characterized in that, It also includes a housing, in which the gas path monitoring unit, data acquisition and processing unit and communication unit are integrated; The enclosure is a metal shielding structure that isolates electromagnetic interference.

10. A method for monitoring and evaluating the performance of an air suspension system, characterized in that, Includes the following steps: The air circuit monitoring device is connected to the main air circuit of the air suspension via a detachable air circuit access structure. Collect gas pressure and gas flow data in the air suspension air circuit; Collect vehicle ground clearance data; The gas pressure data, gas flow data, and vehicle ground clearance data are collected and processed. The processed data is sent to the host computer. The system acquires data output from the air suspension controller and compares and analyzes the gas pressure data, gas flow data, and vehicle ground clearance data with the data output from the air suspension controller to evaluate the working status and performance of the air suspension.

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