CN113324769B

CN113324769B - Suspension test bed, hardware-in-loop test system and hardware-in-loop test method

Info

Publication number: CN113324769B
Application number: CN202110591711.0A
Authority: CN
Inventors: 李以农; 吴欢; 吴行; 张志达; 张紫薇; 郑玲
Original assignee: Chongqing University
Current assignee: Chongqing University
Priority date: 2021-05-28
Filing date: 2021-05-28
Publication date: 2022-04-01
Anticipated expiration: 2041-05-28
Also published as: CN113324769A

Abstract

The invention discloses a suspension test bed, a hardware-in-the-loop test system and a test method. In the excitation test, an excitation signal generated by an excitation table simulates the excitation of a road surface, and a movable rack simulates a suspension system and generates vibration under the action of excitation; in the impact test, the lifting device lifts the movable rack to a certain height and then releases the movable rack to simulate the motion process of instantaneous impact on a suspension system when a tire leaves the ground and falls back. The signal acquisition system transmits the motion signal to the control system and generates a corresponding control signal, the execution system adjusts the damping of the suspension according to the control signal, the validity verification of various control algorithms can be carried out on the suspensions with different specifications, the actual motion condition of the suspension under two working conditions of excitation and impact can be effectively simulated, the universality is strong, the test cost can be effectively reduced, and the test accuracy is improved.

Description

Suspension test bed, hardware-in-loop test system and hardware-in-loop test method

Technical Field

The invention relates to the technical field of test science, in particular to a suspension test bed, a hardware-in-loop test system and a hardware-in-loop test method.

Background

Most of traditional suspension test systems are mainly based on pure software simulation, but various control algorithms usually have good effects in software simulation, and a series of problems occur in practical application, so that the simulation result is far from the practical result. The hardware-in-loop simulation system is a real-time closed-loop simulation system which embeds suspension system hardware objects into software simulation, can better meet the reality and has important practical significance. In addition, compared with actual experiments such as real vehicle experiments and the like, the hardware-in-loop simulation can shorten the product development period, reduce the experiment cost and realize the experiment verification in the limit environment.

In the hardware-in-loop simulation test system, the test bench is related to the error between the hardware-in-loop experimental result and the actual working condition of the suspension system, and directly determines the effectiveness of hardware-in-loop simulation. Common suspension system test bed often the structure is complicated, the dismouting difficulty, traditional bench test often only concentrates on in addition and carries out excitation test or one of them kind of impact test, lacks comprehensive consideration to the motion condition under the multiple operating mode of same suspension system for the motion analysis of same suspension system under different operating modes need be built a plurality of bench test platform and is tested, leads to test structure complicacy, experimental cost is high, development time is long.

Disclosure of Invention

Therefore, in order to solve the above problems, it is necessary to provide a suspension test bed, a hardware-in-loop test system and a hardware-in-loop test method, which can perform control test simulation on the motion conditions of a suspension system under two working conditions of shock excitation and impact.

The utility model provides a suspension test bench, includes vibration exciting table, base and portable rack, the base mounting in on the vibration exciting table, portable rack includes:

the frame body comprises an upper bracket, a lower bracket and a guide pillar, the lower bracket is arranged on the base, and two ends of the guide pillar are respectively detachably connected with the upper bracket and the lower bracket;

the sprung mass comprises an upper bearing plate and a mass block, the upper bearing plate is slidably sleeved on the guide pillar, and the mass block is arranged on the upper bearing plate;

the unsprung mass comprises a lower bearing plate, a fork arm and a tire, wherein the lower bearing plate is slidably sleeved on the guide pillar, the fork arm is connected with the lower bearing plate, and the tire is arranged on the fork arm; and

the suspension system comprises a damper and an elastic piece, wherein the damper is connected with the upper bearing plate and the lower bearing plate, and the elastic piece is sleeved outside the damper.

In one embodiment, the movable stage further includes a flange seat mounted at an end of the guide pillar, and the flange seats at two ends of the guide pillar are respectively connected with the upper bracket and the lower bracket.

In one embodiment, the movable stage further includes a connecting member through which the dampers are connected to the upper and lower load bearing plates, respectively.

In one embodiment, the movable stage further comprises a linear bearing, and the upper bearing plate and the lower bearing plate are slidably mounted on the guide post through the linear bearing.

In one embodiment, the mass block is provided with a protrusion, and the upper bearing plate is provided with a groove which is in inserted connection with the protrusion.

A hardware-in-the-loop testing system comprising:

the suspension test stand of any one of the above;

the lifting device is used for lifting and releasing the movable rack in the impact test so as to enable the movable rack to fall freely;

the signal acquisition system is used for acquiring a motion signal of the movable rack;

the control system is used for receiving the motion signal output by the signal acquisition system, executing corresponding control algorithm calculation according to the motion signal and outputting a control signal; and

and the execution system is used for receiving the control signal output by the control system and finishing the control of the suspension system according to the control signal.

In one embodiment, the lifting device comprises a crane, a rope and a detacher, the detacher is connected with the crane through the rope, and the detacher can hook or release the movable rack.

In one embodiment, the signal acquisition system comprises an acceleration sensor, a displacement sensor, a charge amplifier and a data acquisition unit;

the acceleration sensor is used for acquiring acceleration signals of the sprung mass and the unsprung mass, the displacement sensor is used for acquiring displacement signals of the sprung mass and the unsprung mass, the charge amplifier is used for amplifying the acceleration signals and the displacement signals and integrating the acceleration signals to obtain speed signals, and the data acquisition unit is used for performing signal conversion on the acceleration signals, the displacement signals and the speed signals and filtering the signals;

the control system comprises a PC (personal computer) and a lower computer, wherein the PC is used for displaying the motion signal and writing the control algorithm into the lower computer, and the lower computer is used for calculating the control algorithm and outputting a control signal;

the executing system comprises a voltage-stabilized power supply, a driving circuit board and a potentiometer, wherein the voltage-stabilized power supply is used for providing power for the driving circuit board, the driving circuit board is used for outputting driving current according to an output control signal, and the potentiometer is used for adjusting the driving current so that the current is in the working range of current required by damping adjustment of the suspension system.

A hardware-in-loop test method adopts any one of the hardware-in-loop test systems, and comprises the following steps:

when an excitation test is carried out, the base is connected with the excitation table and the movable rack, the excitation table applies excitation force to the tire, and the motion process of the suspension system under the action of road excitation is simulated;

when an impact test is carried out, guide columns with different lengths are replaced, the movable rack is lifted and released by the lifting device, and the motion process of the suspension system under the condition that the tire is subjected to instantaneous impact when the tire leaves the ground and falls back is simulated;

in the test process, the signal acquisition system acquires a motion signal of the movable rack and transmits the motion signal to the control system, the control system executes corresponding control algorithm calculation according to the input motion signal and outputs a control signal to the execution system, and the execution system completes control on the suspension system according to the control signal.

In one embodiment, the step of acquiring the motion signal of the movable stage by the signal acquisition system and transmitting the motion signal to the control system is specifically as follows: the method comprises the following steps that an acceleration sensor collects acceleration signals of a sprung mass and an unsprung mass, a displacement sensor collects displacement signals of the sprung mass and the unsprung mass, the acceleration signals and the displacement signals are amplified through a charge amplifier, the acceleration signals are integrated to obtain speed signals, and then the acceleration signals, the displacement signals and the speed signals are subjected to signal conversion and signal filtering through a data collector;

the steps of the control system executing corresponding control algorithm calculation according to the input motion signal and outputting a control signal to the execution system are specifically as follows: the PC displays the motion signal, writes a control algorithm into the lower computer through the PC, and performs calculation on the control algorithm and outputs a control signal;

the step of the executing system for controlling the suspension system according to the control signal is specifically as follows: the voltage-stabilized power supply provides power for the driving circuit board, the driving circuit board outputs driving current according to the output control signal, and the current is adjusted through the potentiometer driving circuit, so that the current is in the working range of the current required by damping adjustment of the suspension system.

The suspension test bench, the hardware-in-loop test system and the hardware-in-loop test method can be applied to a suspension system shock excitation test and an impact test, and can perform control test simulation on the motion conditions of the suspension system under two working conditions of shock excitation and impact through the hardware-in-loop test method. In the excitation test, the base is added in excitation platform and the portable rack and can increase the stability of rack, and portable rack collocation not unidimensional base can be connected with the excitation platform of different models, has improved the scalability of portable rack. The length of the guide rod of the movable rack is changed, so that the movable rack can be applied to an impact test, the movable rack has universality, the test cost is effectively reduced, and the development period of a suspension system is shortened. The effectiveness verification of various control algorithms can be carried out on the vibration absorbers of different models through a hardware-in-the-loop test, and the application range is wide.

Drawings

In order to more clearly illustrate the embodiments of the present invention, the drawings, which are required to be used in the embodiments, will be briefly described below. In all the drawings, the elements or parts are not necessarily drawn to actual scale.

FIG. 1 is a schematic diagram of a suspension test stand according to one embodiment;

FIG. 2 is a front view of the suspension test stand of FIG. 1;

FIG. 3 is a schematic structural view of the movable stage of FIG. 1;

FIG. 4 is a schematic structural diagram of a movable gantry lifted by a lifting device according to an embodiment;

FIG. 5 is a diagram illustrating a hardware-in-the-loop test system performing a shock excitation test in one embodiment;

FIG. 6 is a schematic diagram of a hardware-in-the-loop test system for impact testing in one embodiment;

FIG. 7 is a flow diagram of a hardware-in-the-loop testing method in one embodiment.

Reference numerals:

10-excitation stage, 20-base, 30-movable stage, 32-frame, 322-upper support, 324-lower support, 326-guide column, 328-flange seat, 34-sprung mass, 342-upper bearing plate, 344-mass, 346-linear bearing, 348-lifting ring, 36-unsprung mass, 362-lower bearing plate, 364-yoke, 366-tire, 38-suspension system, 382-damper, 384-elastic element, 386-connecting element, 40-lifting device, 42-rope, 44-unhooking device, 442-safety catch, 50-signal acquisition system, 52-acceleration sensor, 54-displacement sensor, 56-charge amplifier, 58-data collector, 60-control system, 62-PC machine, 64-lower computer, 70-execution system, 72-stabilized voltage supply, 74-drive circuit board and 76-potentiometer.

Detailed Description

In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein, but rather should be construed as broadly as the present invention is capable of modification in various respects, all without departing from the spirit and scope of the present invention.

It will be understood that when an element is referred to as being "secured to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for illustrative purposes only and do not represent the only embodiments.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

Referring to fig. 1, a suspension test stand according to an embodiment includes an excitation stage 10, a base 20, and a movable stage 30, wherein the base 20 is mounted on the excitation stage 10, and the movable stage 30 is mounted on the base 20. The size of the base 20 can be adjusted according to different vibration exciting tables 10, so that the movable table 30 can be connected with different vibration exciting tables 10 through the bases 20 with different sizes, and the expandability of the movable table 30 is improved.

Referring to fig. 2 and 3 together, the movable stage 30 includes a frame 32, a sprung mass 34, an unsprung mass 36, and a suspension system 38. Specifically, the frame 32 includes an upper frame 322, a lower frame 324 and a guide pillar 326, the lower frame 324 is mounted on the base 20, and two ends of the guide pillar 326 are detachably connected to the upper frame 322 and the lower frame 324, respectively. The guide posts 326 may be replaced, and by replacing different lengths of the guide posts 326, the movable stage 30 may be used for shock excitation testing and impact testing, respectively.

In one embodiment, the lower bracket 324 is mounted to the base 20 by bolts, and the lower bracket 324 is detachable with respect to the base 20, so that the movable bracket is detachable from the base 20. The movable stage 30 further includes a flange seat 328, the flange seat 328 is mounted on the end of the guide pillar 326, and the flange seats 328 on both ends of the guide pillar 326 are respectively connected to the lower bracket 324 and the upper bracket 322. The number of the guide posts 326 is four, and the four guide posts 326 are uniformly distributed at four corners of the upper bracket 322 and the lower bracket 324, so as to ensure the stability of the frame body 32.

The sprung mass 34 includes an upper bearing plate 342 and a mass 344, the upper bearing plate 342 is slidably sleeved on the guide post 326, the mass 344 is mounted on the upper bearing plate 342, and the mass 344 is located on a side of the upper bearing plate 342 away from the lower bearing plate 362. In one embodiment, the moveable stage 30 further includes a linear bearing 346, and the upper bearing plate 342 is slidably mounted to the guide post 326 via the linear bearing 346 to simulate vertical movement of the sprung mass 34.

Furthermore, the mass block 344 is provided with a protrusion, and the upper bearing plate 342 is provided with a groove which is in insertion fit with the protrusion, so that the mass center of the sprung mass 34 can be ensured to be positioned at the geometric center of the upper bearing plate 342. The bolts securing the plurality of masses 344 to the upper bearing plate 342 ensure that the sprung mass 34 is aligned with the suspension system 38 in a vertical axis. The topmost mass 344 is provided with a lifting ring 348, and the lifting ring 348 can facilitate lifting of the movable gantry 30.

The unsprung mass 36 includes a lower load plate 362, a yoke 364 and a tire 366. The lower bearing plate 362 is slidably sleeved on the guide post 326, the fork arm 364 is located on a side of the lower bearing plate 362 away from the upper bearing plate 342, the fork arm 364 is connected with the lower bearing plate 362, and the tire 366 is mounted on the fork arm 364. In one embodiment, the lower bearing plate 362 is also slidably mounted to the guide post 326 via a linear bearing 346 to simulate vertical motion of the unsprung mass 36.

Suspension system 38 includes a damper 382 and a spring 384, damper 382 being positioned between upper load plate 342 and lower load plate 362, damper 382 connecting upper load plate 342 and lower load plate 362. The elastic member 384 is sleeved outside the damper 382, and the elastic member 384 cooperates with the damper 382 to form the suspension system 38.

In one embodiment, the movable stage 30 further includes a connecting member 386, the upper bearing plate 342 and the lower bearing plate 362 are respectively provided with the connecting member 386, and two ends of the damper 382 are respectively connected to the connecting member 386 on the upper bearing plate 342 and the connecting member 386 on the lower bearing plate 362. The elastic member 384 is a coil spring.

Referring to fig. 4 to 6, the present invention further provides a hardware-in-the-loop testing system, which includes the suspension testing stand, the hoisting device 40, the signal acquisition system 50, the control system 60, and the execution system 70.

The lifting device 40 is used for lifting and releasing the movable platform frame 30 in an impact test, so that the movable platform frame 30 can freely fall down, and the impact motion process that the tire 366 leaves the ground and then falls back to the ground when the vehicle crosses an obstacle is simulated. In one embodiment, the lifting device 40 includes a crane (not shown), a rope 42, and a detacher 44.

The detacher 44 is connected to the crane by a rope 42, and the detacher 44 can catch or release the movable stage 30. Specifically, the cord 42 connects the bail 348 to the detacher 44, and the safety catch 442 on the detacher 44 prevents the cord 42 from separating from the detacher 44. When it is desired to release the moveable carriage 30, the safety catch 442 is rotated open and the cord 42 is disengaged from the detacher 44 to effect release of the moveable carriage 30. Wherein, a rope 42 can be connected to the safety buckle 442 to facilitate the ground operator to drive the safety buckle 442 to rotate through the rope 42.

In one embodiment, when the shock excitation test and the impact test are performed, the movable gantry 30 may be suspended from the crane by the rope 42, and the rope 42 is in a slack state during the normal test, and the test result is not affected. When the movable stand 30 is collapsed or the like, the rope 42 can be tensioned to pull the movable stand 30 to ensure the safety of the test.

The signal acquisition system 50 is used to acquire a motion signal of the movable stage 30. In one embodiment, the signal acquisition system 50 includes an acceleration sensor 52, a displacement sensor 54, a charge amplifier 56, and a data collector 58. An acceleration sensor 52 is used to acquire acceleration signals of the sprung and

unsprung masses

34, 36 and a displacement sensor 54 is used to acquire displacement signals of the sprung and

unsprung masses

34, 36. The charge amplifier 56 is used for amplifying the acceleration signal and the displacement signal, the charge amplifier 56 has a hardware integration function, and can integrate the acceleration signal to obtain a speed signal, and the acceleration signal, the displacement signal and the speed signal form a motion signal of the movable stage 30. The data collector 58 is used for converting the acceleration signal, the displacement signal and the speed signal and filtering the signals. Specifically, the data collector 58 performs I/O signal conversion.

The control system 60 is configured to receive the motion signal output by the signal acquisition system 50, perform corresponding control algorithm calculation according to the motion signal, and output a control signal. Specifically, the control system 60 includes a PC 62 and a lower computer 64, the PC 62 can display the motion signal, and the PC 62 writes the control algorithm into the lower computer 64, and the lower computer 64 is configured to perform calculation on the control algorithm and output the control signal.

Actuator system 70 is configured to receive control signals from control system 60 and to effectuate control of suspension system 38 in response to the control signals. In one embodiment, the execution system 70 includes a regulated power supply 72, a driving circuit board 74 and a potentiometer 76, the regulated power supply 72 is configured to provide power to the driving circuit board 74, the driving circuit board 74 is configured to output a driving current according to an output control signal, and the potentiometer 76 is configured to adjust a magnitude of the driving current, so that the magnitude of the driving current is within a working range of a current required by damping adjustment of the suspension system 38, thereby achieving a purpose of adjusting damping of the suspension system 38.

Referring to fig. 7, the present invention further provides a hardware-in-loop testing method, which employs the hardware-in-loop testing system for implementing the testing method. Specifically, the test method comprises the following steps:

step S110: in the vibration excitation test, the base 20 is connected with the vibration excitation table 10 and the movable rack 30, and the vibration excitation table 10 applies vibration excitation force to the tire 366 to simulate the motion process of the suspension system 38 under the action of road excitation.

Specifically, in the vibration excitation test, the base 20 connects the vibration excitation table 10 with the movable platform 30, and the vibration excitation table 10 applies an excitation force to the tire 366 to simulate the motion process of the suspension system 38 under the action of road excitation. The excitation stage 10 outputs at least one road spectrum excitation signal, which includes one or more of a sine wave signal, a cosine wave signal, a triangular wave signal, a square wave signal, and a random signal.

Step S120: in performing the impact test, the movable stand 30 is lifted by the lifting device 40 with the guide posts 326 of different lengths replaced and released, simulating the motion of the suspension system 38 under transient impact conditions when the tire 366 moves away from the ground and falls back.

Specifically, the guide posts 326 of longer length need to be replaced when performing impact testing. Then, after the crane of the lifting device 40 lifts the movable platform 30 to a certain height through the unhooking device 44, the weight is released through the unhooking device 44 to be freely dropped, and the impact motion process that the tire 366 leaves the ground and then falls back to the ground when the vehicle crosses an obstacle is simulated.

Step S130: in the test process, the signal acquisition system 50 acquires the motion signal of the movable stage 30 and transmits the motion signal to the control system 60, the control system 60 executes corresponding control algorithm calculation according to the input motion signal and outputs a control signal to the execution system 70, and the execution system 70 completes the control of the suspension system 38 according to the control signal.

Specifically, the signal acquisition system 50 acquires acceleration signals of the sprung mass 34 and the unsprung mass 36 through the acceleration sensor 52, the displacement sensor 54 acquires displacement signals of the sprung mass 34 and the unsprung mass 36, amplifies the acceleration signals and the displacement signals through the charge amplifier 56, integrates the acceleration signals to obtain velocity signals, and converts and filters the acceleration signals, the displacement signals, and the velocity signals through the data acquisition device 58.

In the control system 60, the PC 62 displays the motion signal, the PC 62 writes a control algorithm into the lower computer 64, and the lower computer 64 performs calculation on the control algorithm and outputs a control signal.

In the execution system 70, the voltage-stabilized power supply 72 supplies power to the driving circuit board 74, the driving circuit board 74 outputs driving current according to the output control signal, and the magnitude of the driving circuit is adjusted through the potentiometer 76, so that the magnitude of the current is within the working range of the current required by the damping adjustment of the suspension system 38.

The suspension test bed, the hardware-in-loop test system and the hardware-in-loop test method can be applied to shock excitation tests and impact tests of the suspension system 38, and control test simulation can be performed on motion conditions of the suspension system 38 under shock excitation and impact working conditions through the hardware-in-loop test method. In the excitation test, the base 20 is added into the excitation table 10 and the movable table frame 30, so that the stability of the table frame can be improved, the movable table frame 30 can be connected with the excitation tables 10 of different models by matching with the bases 20 of different sizes, and the expandability of the movable table frame 30 is improved. The movable rack 30 can be applied to an impact test by changing the length of the guide rod of the movable rack 30, so that the movable rack 30 has universality, the test cost is effectively reduced, and the development period of the suspension system 38 is shortened. The hardware-in-the-loop test can be used for verifying the effectiveness of various control algorithms for different types of shock absorbers, has wide application range, expandability and simple and stable structure, and can accurately simulate the motion condition of the suspension system 38 of a vehicle under two working conditions of shock excitation and impact.

The above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit and scope of the present invention, and they should be construed as being included in the following claims and description.

Claims

1. A hardware-in-the-loop test system, comprising:

the suspension test bed comprises an excitation table, a base and a movable bed, wherein the base is installed on the excitation table, the movable bed comprises a frame body, a sprung mass, an unsprung mass and a suspension system, the frame body comprises an upper support, a lower support and a guide pillar, the lower support is installed on the base, and two ends of the guide pillar are detachably connected with the upper support and the lower support respectively; the sprung mass comprises an upper bearing plate and a mass block, the upper bearing plate is slidably sleeved on the guide post, and the mass block is arranged on the upper bearing plate; the unsprung mass comprises a lower bearing plate, a fork arm and a tire, the lower bearing plate is slidably sleeved on the guide pillar, the fork arm is connected with the lower bearing plate, and the tire is mounted on the fork arm; the suspension system comprises a damper and an elastic piece, the damper is connected with the upper bearing plate and the lower bearing plate, and the elastic piece is sleeved outside the damper;

2. The hardware-in-the-loop test system of claim 1, wherein the movable stage further comprises a flange seat mounted on an end of the guide pillar, the flange seats on both ends of the guide pillar being connected to the upper bracket and the lower bracket, respectively.

3. The hardware-in-loop testing system of claim 1, wherein the movable stage further comprises a connecting member through which the dampers are respectively connected to the upper and lower load bearing plates.

4. The hardware-in-loop testing system of claim 1, wherein the movable stage further comprises linear bearings through which the upper bearing plate and the lower bearing plate are slidably mounted on the guide posts.

5. The hardware-in-the-loop test system of claim 1, wherein the mass block is provided with a protrusion, and the upper bearing plate is provided with a groove which is in plug fit with the protrusion.

6. The hardware-in-loop test system of claim 1, wherein the lifting device comprises a crane, a rope and a detacher, the detacher is connected with the crane through the rope, and the detacher can hook or release the movable rack.

7. The hardware-in-the-loop test system of claim 1, wherein the signal acquisition system comprises an acceleration sensor, a displacement sensor, a charge amplifier and a data collector;

8. A hardware-in-the-loop testing method using the hardware-in-the-loop testing system according to any one of claims 1 to 7, comprising the steps of:

9. The hardware-in-loop test method of claim 8, wherein the step of the signal acquisition system acquiring the motion signal of the movable stage and transmitting the motion signal to the control system comprises: the method comprises the following steps that an acceleration sensor collects acceleration signals of a sprung mass and an unsprung mass, a displacement sensor collects displacement signals of the sprung mass and the unsprung mass, the acceleration signals and the displacement signals are amplified through a charge amplifier, the acceleration signals are integrated to obtain speed signals, and then the acceleration signals, the displacement signals and the speed signals are subjected to signal conversion and signal filtering through a data collector;