To improve the characteristics of traditional model predictive control (MPC) semi-active suspension that cannot achieve the optimal suspension control effect under different conditions, a variable horizon model predictive control (VHMPC) method is devised for magnetorheological semi-active suspension with air springs. Mathematical models are established for the magnetorheological dampers and air springs. Based on the improved hyperbolic tangent model, a forward model is established for the magnetorheological damper. The adaptive fuzzy neural network method is used to establish the inverse model of the magnetorheological damper. The relationship between different road excitation frequencies and the control effect of magnetorheological semi-active suspension with air springs is simulated, and the optimal prediction horizons under different conditions are obtained. The VHMPC method is designed to automatically switch the predictive horizon according to the road surface excitation frequency. The results demonstrate that under mixed conditions, compared with the traditional MPC, the VHMPC can improve the smoothness of the suspension by 2.614% and reduce the positive and negative peaks of the vertical vibration acceleration by 11.849% and 6.938%, respectively. Under variable speed road conditions, VHMPC improved the sprung mass acceleration, dynamic tire deformation, and suspension deflection by 7.191%, 7.936%, and 22.222%, respectively, compared to MPC.
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