An intelligent leak detection device and detection method for a scroll air-conditioning compressor

Abstract

The present invention discloses an intelligent leak detection device for scroll air-conditioning compressors, which relates to the technical field of leak detection equipment for scroll air-conditioning compressors. It includes two or more detection stations. The scroll air-conditioning compressors in the detection stations are connected in series in sequence through air ducts and are connected to a high-pressure air source. A pressure sensor, a mobile leak detection vehicle, a control system and a display unit are arranged on the air ducts. The present invention can perform batch detection on scroll air-conditioning compressors, can automatically find out the detection station where the products with unqualified airtightness are located in a detection batch, and can further find out the location of the leakage point of the products with unqualified airtightness, replacing the manual detection process and improving the detection efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of leak detection equipment for scroll air-conditioning compressors, and specifically relates to an intelligent leak detection device and detection method for scroll air-conditioning compressors. Background Art

[0002] The scroll air-conditioning compressor is the fourth generation of automotive air-conditioning compressors, which has the advantages of compact structure, high efficiency, energy saving, low vibration and noise, and working reliability, and its application field is becoming wider and wider.

[0003] After the scroll air-conditioning compressor is assembled, leak detection operation needs to be carried out to detect whether there is a situation of unqualified sealing in the assembled scroll air-conditioning compressor. In the prior art, currently the main leak detection process is that workers place the assembled scroll air-conditioning compressor on a test bench, use a plug to block the outlet or inlet of the scroll air-conditioning compressor, and then fill it with a mixed gas (R134a: nitrogen = 1:4) through the inlet or outlet to keep its pressure at 1.0 - 1.15 Mpa, and then use a leak detector for detection. During the detection process, the probe of the leak detector is moved along the gap of the assembled scroll air-conditioning compressor to detect whether these gaps meet the sealing requirements.

[0004] However, in the above process, due to mainly relying on manual operation, the efficiency is low. In addition, the accuracy of the detection result is also affected to a certain extent by factors such as the proficiency and work attitude of workers, and has a certain degree of randomness, making it difficult to ensure the reliability of the detection result of the product. Summary of the Invention

[0005] Based on the above deficiencies of the prior art, the present invention proposes an intelligent leak detection device and detection method for scroll air-conditioning compressors, aiming to solve one of the technical problems in the foregoing background art.

[0006] The present invention adopts the following technical solutions to solve its technical problems:

[0007] An intelligent leak detection device for a scroll air-conditioning compressor includes two or more detection stations. Each of the detection stations is used to place the scroll air-conditioning compressor to be detected. The scroll air-conditioning compressors in the detection stations are connected in series in sequence through air ducts and are connected to a high-pressure air source. A pressure sensor is provided on the air duct, and an electromagnetic valve is provided on the air duct between two adjacent scroll air-conditioning compressors; a mobile leak detection vehicle, which can be fixed at the detection position corresponding to the detection station. A gas leak detector is provided on the mobile leak detection vehicle, and the probe of the gas leak detector is movably arranged and can detect the gaps of the scroll air-conditioning compressors in the detection station; a control system, which is used to receive the signal of the pressure sensor, control the opening and closing of the electromagnetic valve, control the movement of the mobile leak detection vehicle, and control the operation of the gas leak detector; a display unit, which is used to output the detection results, including the detection station where the scroll air-conditioning compressor with unqualified airtightness is located and the location of the leakage point of the scroll air-conditioning compressor with unqualified airtightness.

[0008] As a further improvement of the present invention, in adjacent detection stations, the outlet of the scroll air-conditioning compressor in the previous detection station and the inlet of the scroll air-conditioning compressor in the next detection station are connected through an air duct, and the inlet of the scroll air-conditioning compressor in the first detection station is connected to the high-pressure air source through an air duct, and a plug is connected to the outlet of the scroll air-conditioning compressor in the last detection station.

[0009] As a further improvement of the present invention, a pressure relief valve and a one-way inflation valve are also provided on the air duct. The one-way inflation valve is located between the high-pressure air source and the pressure sensor on the air duct, and the pressure relief valve is located on the side of the air duct away from the high-pressure air source of the one-way inflation valve.

[0010] As a further improvement of the present invention, the mobile leak detection vehicle includes a carrier platform. A gas leak detector and a movable arched track are placed above the carrier platform. One end of the arched track is connected to the carrier platform through a telescopic rod. The fixed end of the telescopic rod is fixedly connected to the carrier platform, and the movable end of the telescopic rod is fixedly connected to one end of the arched track. The extension or shortening of the telescopic rod can drive the forward or backward movement of the arched track. An electric slider is movably arranged on the arched track, and the probe of the gas leak detector is fixed on the electric slider. The electric slider can drive the probe of the gas leak detector to move along the arched track.

[0011] As a further improvement of the present invention, electric rollers are provided at the bottom of the carrier platform. The intelligent leak detection device for the scroll air-conditioning compressor further includes a connecting track, which sequentially connects each detection position, and the electric rollers are movably installed in the connecting track.

[0012] A detection method for an intelligent leak detection device of a scroll air conditioner compressor includes the following steps: S1. Sequentially place the scroll air conditioner compressor to be detected into the detection station and connect it properly; S2. Charge compressed mixed gas into the scroll air conditioner compressor in the detection station. After the pressure reaches the preset value, enter the pressure holding stage and wait for the preset time; S3. According to whether the change in pressure in the intelligent leak detection device of the scroll air conditioner compressor before and after the pressure holding stage exceeds the allowable range, that is, the difference between P0 and P1. If it does not exceed the allowable range, it means that all the scroll air conditioner compressors are qualified. If it exceeds the allowable range, adjust the number of scroll air conditioner compressors participating in the pressure holding test and re-perform the pressure holding test. Repeat the above process, and the scroll air conditioner compressors participating in the detection can be divided into airtightness qualified products, unqualified products (with a quantity of one), and products to be re-detected; S4. Use a gas leak detector to detect the scroll air conditioner compressor with unqualified airtightness and find the leakage point; S5. Output the detection result to the user.

[0013] As a further improvement of the present invention, when the difference between P0 and P1 in S3 exceeds the allowable range, that is, P0 - P1 > Δx, close one of the solenoid valves to divide the series-connected scroll air conditioner compressors into a part participating in the detection and a part suspended from the detection. Then, the high-pressure gas source re-charges compressed mixed gas into the scroll air conditioner compressors in the part participating in the detection. After the preset time, if P0 - P1 ≤ Δx, it means that the airtightness of the scroll air conditioner compressors in this part meets the requirements, and the scroll air conditioner compressors with unqualified airtightness exist in the part suspended from the detection. Open the originally closed solenoid valve and close one of the solenoid valves in the part suspended from the detection, re-divide the part participating in the detection and the part suspended from the detection, and then repeat the above detection process; if P0 - P1 > Δx, it means that there are products with unqualified airtightness in the scroll air conditioner compressors in this part. Close one of the solenoid valves in the part participating in the detection, re-divide the part participating in the detection and the part suspended from the detection, and repeat the above detection process to find the scroll air conditioner compressor with unqualified airtightness closest to the high-pressure gas source.

[0014] As a further improvement of the present invention, in S5, the scroll air conditioner compressors with unqualified airtightness are distinguished by prominent color marks.

[0015] The beneficial effects of the present invention are:

[0016] The present invention can perform batch detection on scroll air conditioner compressors, can automatically find the detection station where the products with unqualified airtightness are located in a detection batch, and can further find the location of the leakage point of the products with unqualified airtightness, replacing the manual detection process and improving the detection efficiency. Description of the Drawings

[0017] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0018] Figure 1 It is the front view of this specific embodiment;

[0019] Figure 2 It is the schematic diagram of the working state of this specific embodiment;

[0020] Figure 3 It is the partial detailed drawing of the high-pressure gas source of this specific embodiment;

[0021] Figure 4 It is the top view of the mobile leak detection vehicle of this specific embodiment;

[0022] Figure 5 It is the left view of the mobile leak detection vehicle of this specific embodiment.

[0023] Wherein: 1 - high-pressure gas source, 2 - scroll air-conditioning compressor, 21 - inlet, 22 - outlet, 3 - first guide pipe, 4 - mobile leak detection vehicle, 41 - carrier platform, 42 - electric roller, 43 - arched track, 44 - gas leak detector, 45 - electric slider, 46 - telescopic rod, 47 - probe, 5 - connecting track, 6 - one-way inflation valve, 7 - pressure sensor, 8 - pressure relief valve, 9 - solenoid valve. Specific Embodiment

[0024] The following is a further detailed description of the specific embodiments of the present invention, such as the shapes, structures, mutual positions and connection relationships of the various components involved, the functions and working principles of each part, the manufacturing process and the operation and use methods, etc., to help those skilled in the art have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention.

[0025] As Figures 1 to 5 shown, a scroll air-conditioning compressor intelligent leak detection device includes two or more detection stations. Each detection station is used to place the scroll air-conditioning compressor 2 to be detected. Adjacent detection stations are connected in series through the first guide pipe 3. The two ends of the first guide pipe 3 are respectively connected to the outlet 22 of the scroll air-conditioning compressor 2 in the previous detection station and the inlet 21 of the scroll air-conditioning compressor 2 in the next detection station. The inlet 21 of the scroll air-conditioning compressor 2 in the first detection station is connected to the high-pressure gas source 1 through the second guide pipe. The second guide pipe is provided with a pressure relief valve 8, a pressure sensor 7 and a one-way inflation valve 6. The one-way inflation valve 6 is located between the pressure relief valve 8 and the high-pressure gas source 1. By adjusting the pressure relief valve 8, the pressure in the second guide pipe can reach 1.0 - 1.15 Mpa to meet the detection requirements. The outlet 22 of the scroll air-conditioning compressor 2 in the last detection station is connected with a plug. In addition, a solenoid valve 9 is provided on the first guide pipe 3 between adjacent detection stations.

[0026] The intelligent leak detection device for the scroll air-conditioning compressor further includes a mobile leak detection vehicle 4, which can be fixed at the detection positions corresponding to each detection station. Specifically, the mobile leak detection vehicle 4 includes a carrier table 41, and electric rollers 42 are provided at the bottom of the carrier table 41. The intelligent leak detection device for the scroll air-conditioning compressor further includes a connecting track 5, which sequentially connects each detection position, and the electric rollers 42 are movably installed in the connecting track 5. A gas leak detector 44 and a movable arched track 43 are placed above the carrier table 41. One end of the arched track 43 is connected to the carrier table 41 through a telescopic rod 46. Specifically, the telescopic rod 46 can be a hydraulic telescopic rod or an electric telescopic rod. The fixed end of the telescopic rod 46 is fixedly connected to the carrier table 41 through fasteners such as bolts. The movable end of the telescopic rod 46 is fixedly connected to one end of the arched track 43, and the plane where the arched track 43 is located is perpendicular to both the carrier table 41 and the telescopic rod 46. The extension or shortening of the telescopic rod 46 can drive the forward or backward movement of the arched track 43. An electric slider 45 is movably arranged on the arched track 43, and the probe 47 of the gas leak detector 44 is fixed on the electric slider 45. The electric slider 45 can drive the probe 47 of the gas leak detector 44 to move along the arched track 43.

[0027] It further includes a control system and a display unit. The control system can receive the signal of the pressure sensor 7, control the opening and closing of the solenoid valve 9, control the movement of the electric rollers 42 and the electric slider 45, and control the operation of the gas leak detector 44. The display unit is used to display the test results to inform the operator. The display unit, the high-pressure gas source 1, the pressure sensor 7, the solenoid valve 9, the electric rollers 42, the telescopic rod 46, the electric slider 45 and the gas leak detector 44 are respectively electrically connected to the control system.

[0028] The working principle of the present invention is as follows: The scroll air-conditioning compressor 2 to be detected is sequentially placed in the detection stations. The inlet 21 of the scroll air-conditioning compressor 2 in the first detection station is connected to the high-pressure gas source 1 through the second air duct. The adjacent scroll air-conditioning compressors 2 are connected in series through the first air duct 3. The outlet 22 of the scroll air-conditioning compressor 2 in the last detection station is connected to a plug. Then, the start button of the control system is pressed. The control system controls the high-pressure gas source 1 to fill the scroll air-conditioning compressor 2 in the detection station with compressed mixed gas (R134a: nitrogen = 1:4). After the pressure reaches the preset value (1.0 - 1.15 Mpa), the pressure sensor 7 feeds back a signal to the control system. The control system controls the high-pressure gas source 1 to stop inflating, and enters the pressure-holding stage. Wait for the preset time (for example, 3 - 5 min). If the difference between the initial pressure value P0 in the pressure-holding stage and the pressure value P1 fed back by the pressure sensor 7 after the preset time is within the allowable range, that is, P0 - P1 ≤ Δx, it means that the scroll air-conditioning compressors 2 in each detection station all meet the airtightness requirements, and the detection is completed; If the difference between the initial pressure value P0 in the pressure-holding stage and the pressure value P1 fed back by the pressure sensor 7 after the preset time exceeds the allowable range, that is, P0 - P1 > Δx, it means that the airtightness of at least one scroll air-conditioning compressor 2 does not meet the requirements, and a second test is required. The control system controls one of the solenoid valves 9 to close, so that the series-connected scroll air-conditioning compressors 2 are divided into the part participating in the detection and the part suspended from the detection. Then, the high-pressure gas source 1 re-fills the scroll air-conditioning compressor 2 in the part participating in the detection with compressed mixed gas and maintains the same preset time as before. If P0 - P1 ≤ Δx, it means that the airtightness of the scroll air-conditioning compressors 2 in this part meets the requirements, and the scroll air-conditioning compressor 2 with unqualified airtightness exists in the other part. Open the originally closed solenoid valve 9 and close one of the solenoid valves 9 in the part suspended from the detection, re-divide the part participating in the detection and the part suspended from the detection, and then repeat the above detection process; If P0 - P1 > Δx, it means that there are products with unqualified airtightness in the scroll air-conditioning compressors 2 in this part. Close one of the solenoid valves 9 in the part participating in the detection, re-divide the part participating in the detection and the part suspended from the detection, and repeat the above detection process to find out the scroll air-conditioning compressor 2 closest to the high-pressure gas source 1 with unqualified airtightness. For the convenience of description, the detection stations are sequentially numbered (1, 2, 3... N). Through the above detection process, if the scroll air-conditioning compressors 2 connected in series in the first M (M can be 0, 1, 2,...) detection stations meet the airtightness requirements, that is, P0 - P1 M ≤ Δx, and the scroll air-conditioning compressors 2 connected in series in the first M + 1 detection stations do not meet the airtightness requirements, that is, P0 - P1 M+1> △x, it indicates that the airtightness of the scroll air-conditioning compressors 2 in the inspection stations numbered from 1 to M meets the requirements, the airtightness of the scroll air-conditioning compressor 2 in the inspection station numbered M + 1 does not meet the requirements. In addition, the airtightness of the scroll air-conditioning compressors 2 in the inspection stations numbered M + 2 to N cannot be determined temporarily. After finding that the airtightness of the scroll air-conditioning compressor 2 in the inspection station numbered M + 1 does not meet the requirements, the control system controls the mobile leak detection vehicle 4 to move to the corresponding detection position, then controls the telescopic rod 46 to extend, and at the same time controls the electric slider 45 to move along the arched track 43 according to a pre-set trajectory, so that the probe 47 of the gas leak detector 44 can move along the gap of the scroll air-conditioning compressor 2, thereby finding the leak point. Finally, the control system displays the detection result through the display unit. For example, the inspection stations numbered from 1 to M are displayed in the display unit using a green identifier, the inspection station numbered M + 1 is displayed in the display unit using a red identifier, and the inspection stations numbered M + 2 to N are displayed in the display unit using a yellow identifier, indicating that the airtightness meets the requirements, the airtightness does not meet the requirements, and the airtightness cannot be determined temporarily respectively. And a highlighted color code, such as a highlighted color code or an enlarged color code or a color code of other colors, can be used to display the position of the leak point on the (M + 1)-th scroll air-conditioning compressor 2, so that the operator can conveniently know the products with unqualified airtightness and the position where the leak point is located. Finally, replace the scroll air-conditioning compressors 2 in the inspection stations numbered from 1 to M + 1, and repeat the above detection process.

[0029] The present invention can perform batch detection on the scroll air-conditioning compressor 2, can automatically find out the inspection station where the product with unqualified airtightness is located in a detection batch, and can further find out the location of the leak point of the product with unqualified airtightness, replacing the manual detection process and improving the detection efficiency.

[0030] The above is an exemplary description of the present invention. Obviously, the specific implementation of the present invention is not limited by the above methods. As long as various non-substantive improvements are made by adopting the method concept and technical solution of the present invention, or the concept and technical solution of the present invention are directly applied to other occasions without improvement, they are all within the protection scope of the present invention. The protection scope of the present invention should be subject to the protection scope defined by the claims.

Claims

1. Detection method of intelligent leak detection device for scroll air-conditioning compressor, characterized in that: It includes more than three detection stations, each of which is used to place the scroll air-conditioning compressor to be detected. The scroll air-conditioning compressors in the detection stations are connected in series in sequence through air ducts and connected to a high-pressure air source. A pressure sensor is provided on the air duct, and an electromagnetic valve is provided on the air duct between two adjacent scroll air-conditioning compressors; A mobile leak detection vehicle, which can be fixed at the detection position corresponding to the detection station. A gas leak detector is provided on the mobile leak detection vehicle, and the probe of the gas leak detector is movably arranged and can detect the gaps of the scroll air-conditioning compressors in the detection station; A control system, which is used to receive the signal of the pressure sensor, control the opening and closing of the electromagnetic valve, control the movement of the mobile leak detection vehicle, and control the operation of the gas leak detector; A display unit, which is used to output the detection results, including the detection station where the scroll air-conditioning compressor with unqualified airtightness is located and the location of the leakage point of the scroll air-conditioning compressor with unqualified airtightness; The mobile leak detection vehicle includes a carrier platform. A gas leak detector and a movable arched track are placed above the carrier platform. One end of the arched track is connected to the carrier platform through a telescopic rod. The fixed end of the telescopic rod is fixedly connected to the carrier platform, and the movable end of the telescopic rod is fixedly connected to one end of the arched track. The extension or shortening of the telescopic rod can drive the forward or backward movement of the arched track. An electric slider is movably arranged on the arched track, and the probe of the gas leak detector is fixed on the electric slider. The electric slider can drive the probe of the gas leak detector to move along the arched track; Electric rollers are provided at the bottom of the carrier platform. The intelligent leak detection device for scroll air-conditioning compressor also includes a connecting track, which sequentially connects each detection position, and the electric rollers are movably installed in the connecting track; The detection method includes the following steps: S1. Sequentially place the scroll air-conditioning compressors to be detected into the detection stations and connect them; S2. Fill the scroll air-conditioning compressors in the detection stations with compressed mixed gas. After the pressure reaches the preset value, enter the pressure holding stage and wait for the preset time; S3. According to whether the change in the pressure in the intelligent leak detection device for scroll air-conditioning compressor before and after the pressure holding stage exceeds the allowable range, that is, the difference between P0 and P1. If it does not exceed the allowable range, it means that all the scroll air-conditioning compressors are qualified. If it exceeds the allowable range, adjust the number of scroll air-conditioning compressors participating in the pressure holding test and re-perform the pressure holding test; S4. Repeat steps S2 and S3 to divide the scroll air-conditioning compressors participating in the detection into airtightness qualified products, unqualified products, and products to be re-detected; S5. Use a gas leak detector to detect the scroll air-conditioning compressor with unqualified airtightness and find the leakage point; S6. Output the detection results to the user.

2. The detection method of the intelligent leak detection device for scroll air-conditioning compressor according to claim 1, characterized in that: Among the adjacent detection stations, the outlet of the scroll air-conditioning compressor in the previous detection station and the inlet of the scroll air-conditioning compressor in the next detection station are connected by a gas guide pipe. Moreover, the inlet of the scroll air-conditioning compressor in the first detection station is connected to a high-pressure gas source through a gas guide pipe, and a plug is connected to the outlet of the scroll air-conditioning compressor in the last detection station.

3. The detection method of the intelligent leak detection device for scroll air-conditioning compressors according to claim 1, characterized in that: a pressure relief valve and a one-way inflation valve are further provided on the gas guide pipe. The one-way inflation valve is located between the high-pressure gas source and the pressure sensor on the gas guide pipe, and the pressure relief valve is located on the side of the gas guide pipe away from the high-pressure gas source of the one-way inflation valve.

4. The detection method of the intelligent leak detection device for scroll air-conditioning compressors according to claim 1, characterized in that: If the difference between P0 and P1 in S3 exceeds the allowable range, that is, P0 - P1 > △x, one of the solenoid valves is closed, so that the series-connected scroll air-conditioning compressors are divided into a part participating in the detection and a part suspended from the detection. Then, the high-pressure gas source re-inflates the compressed mixed gas into the scroll air-conditioning compressors in the part participating in the detection. After a preset time, if P0 - P1 ≤ △x, it means that the airtightness of the scroll air-conditioning compressors in this part meets the requirements, and the scroll air-conditioning compressors with unqualified airtightness exist in the part suspended from the detection. Open the originally closed solenoid valve and close one of the solenoid valves in the part suspended from the detection, re-divide the part participating in the detection and the part suspended from the detection, and then repeat the above detection process; if P0 - P1 > △x, it means that there are products with unqualified airtightness in this part of the scroll air-conditioning compressors. Close one of the solenoid valves in the part participating in the detection, re-divide the part participating in the detection and the part suspended from the detection, and repeat the above detection process, and the scroll air-conditioning compressor with unqualified airtightness closest to the high-pressure gas source can be found.

5. The detection method of the intelligent leak detection device for scroll air-conditioning compressors according to claim 4, characterized in that: In S5, the scroll air-conditioning compressors with unqualified airtightness are distinguished by the highlighted color codes.

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