Inverse Design and Continuous Damping Adjustment of a Hydraulic Damper Using an Improved Genetic Algorithm and a Proportional Solenoid Valve

Traditional passive hydraulic dampers face the challenges of extended design cycles, inefficient parameter matching, and fixed performance, limiting their adaptability. This paper proposes an integrated solution that combines inverse parametric design with active, continuously adjustable damping. First, a high-fidelity nonlinear model is developed based on valve plate elasticity and multi-valve coupling dynamics, achieving a simulation error of ≤4%. An improved genetic algorithm is then designed to inversely optimize five key parameters. This optimization reduces the deviation between the prototype’s damping force–velocity characteristics and the target curve to ≤3% and shortens the design cycle by approximately 40%. Building on this foundation, a pilot-operated electro-hydraulic proportional relief valve is integrated to enable continuous damping adjustment. Co-simulation using AMESim2404 and MatlabSimulinkR2022 reveals the influence of solenoid valve parameters on damping characteristics and calibrates the current–damping force mapping. A co-simulation of a skyhook-controlled quarter-vehicle model demonstrates that the semi-active suspension system reduces the root mean square (RMS) of vertical body acceleration by 21.7%, indicating a significant theoretical improvement in ride comfort. This study establishes a complete technical pathway of “modeling → inverse optimization → integration → verification,” providing an efficient and viable core component solution for intelligent suspension systems.