Test apparatus and method for simulating radiator tube clogging by flux

Abstract

The present application provides a test device for simulating radiator pipe blockage caused by flux, comprising: a container having a container body and a cover, the container body being adapted to contain a coolant; a rotating shaft extending into the container body via the cover; a motor located outside the container and driving the rotating shaft to rotate; a current measuring unit for measuring the current of the motor; a test piece provided with a through groove and connected to the rotating shaft to be driven to rotate by the rotating shaft, thereby simulating the flow of coolant flowing through the radiator pipe; and a flux dosing platform adapted to attach at least one flux dosing piece. The present application also provides a test method for simulating radiator pipe blockage caused by flux. The present application quantitatively studies the effect of flux content on radiator pipe blockage, providing a reference for the control of residual flux in the radiator manufacturing process.

Description

Technical Field

[0001] This invention relates to the field of testing equipment technology, and more specifically, to a testing apparatus for simulating radiator tube blockage caused by flux, and a testing method for simulating radiator tube blockage caused by flux using the testing apparatus. Background Technology

[0002] Vehicle radiators are generally used to cool heat-generating components such as engines, power batteries, motors, and high-power electronic devices.

[0003] like Figures 1 to 2 As shown, the ends of the radiator pipes 101 of the vehicle radiator 100 are embedded in the first water chambers 102 and the second water chambers 103 at both ends. Specifically, the ends of the radiator pipes 101 are welded to the main board 1001 of the water chambers. After entering from the first water chamber 102 at one end, the coolant is distributed to each radiator pipe 101, and then flows out from the second water chamber 103 at the other end.

[0004] Vehicle radiators, especially aluminum flat-tube radiators, use alkali metal-based fluoroaluminate flux (also known as soldering flux) to weld the radiator tubes to the mainplate of the water chamber. Flux residue often remains after welding. This flux, suitable for aluminum flat tubes, is generally considered non-corrosive. However, in actual use, prolonged contact between the flux and coolant can lead to corrosion and the formation of a gel-like substance. This substance can eventually clog the aluminum flat tubes, causing reduced radiator efficiency or even malfunction.

[0005] Therefore, it is necessary to quantitatively simulate the impact of residual flux on radiator tube blockage in order to conduct subsequent operations that may control the amount of residual flux. Additionally, it is necessary to study the effect of coolant and / or flux formulation on radiator tube blockage. In existing designs, there is no experimental apparatus or equipment to quantitatively simulate the impact of residual flux on radiator tube blockage, and consequently, no specific measures are available to address the problem of radiator tube blockage. Summary of the Invention

[0006] The purpose of this invention is to overcome the defects existing in the prior art and to provide a test apparatus for simulating radiator tube blockage caused by flux, and a test method for simulating radiator tube blockage caused by flux using the test apparatus.

[0007] According to a first aspect of the present invention, a test apparatus is provided for simulating radiator tube blockage caused by flux, wherein the test apparatus comprises:

[0008] A container having a container body and a lid, the container body being adapted to contain coolant;

[0009] a rotating shaft which extends into the container body through the cover;

[0010] a motor which is located outside the container and drives the rotating shaft to rotate;

[0011] a current measuring unit for measuring the current of the motor;

[0012] a test piece which is provided with a through groove and connected to the rotating shaft so as to be driven to rotate by the rotating shaft, thereby simulating the flow of the cooling liquid through the radiator pipe;

[0013] a flux metering platform which is adapted to attach at least one flux metering piece.

[0014] According to the above technical concept, the present application can further comprise any one or more of the following optional forms.

[0015] In some optional forms, the test device further comprises a temperature control unit which is adapted to maintain the cooling liquid at a set temperature.

[0016] In some optional forms, the flux metering piece is an aluminum piece coated with flux, and the flux coating amount of each flux metering piece is the same or different, wherein the flux is the flux subjected to simulated brazing on the aluminum piece.

[0017] In some optional forms, the test device comprises at least two test pieces which are uniformly spaced around the rotating shaft.

[0018] In some optional forms, in the rotating direction of the test piece, the edge of the through groove of each test piece extends with an annular protruding edge.

[0019] In some optional forms, the test piece is made of stainless steel, resin or graphite.

[0020] In some optional forms, the through groove has a cross-sectional shape which is adapted to simulate the flat tube of the radiator.

[0021] In some optional forms, the flux metering platform comprises a base provided at the bottom of the container, and the at least one flux metering piece is sleeved on the base.

[0022] In some optional forms, the flux metering platform further comprises a gasket, and two adjacent flux metering pieces are separated by the gasket.

[0023] In some optional forms, the test piece is connected to the rotating shaft through an extension rod, one end of the extension rod is embedded in the rotating shaft, and the other end of the extension rod is provided with a clamping groove, and the test piece is inserted into the clamping groove and fixed.

[0024] In some optional forms, the container is a cylindrical container, and the container is made of glass, stainless steel or resin.

[0025] According to a second aspect of the present application, there is provided a test method for simulating radiator pipe blockage caused by flux, wherein the test method employs the test device according to the first aspect of the present application, and comprises the following steps:

[0026] Step S1: cleaning and drying the test device;

[0027] Step S2: selecting appropriate specifications and / or quantities of flux tablets according to the preset flux content, and assembling the selected flux tablets to the flux dosing table;

[0028] Step S3: injecting the cooling liquid into the container until the set liquid level, so that the cooling liquid immerses the test piece, and sealing the container;

[0029] Step S4: starting the motor to drive the rotating shaft to rotate, and then driving the test piece to rotate in the cooling liquid, simulating the flow of the cooling liquid through the radiator pipe, and recording the initial value of the stable motor current;

[0030] Step S5: when the motor current rises to the preset motor current value, the motor is turned off, and the test duration from the initial value of the motor current to the preset motor current value is recorded;

[0031] Step S6: statistics the relationship between the test duration and the flux content.

[0032] In some optional forms, before step S4, the method further comprises the following step: heating the cooling liquid to a preset temperature value and maintaining the preset temperature value by using the temperature control unit.

[0033] In some optional forms, the flux content is the number of grams of flux contained per liter of cooling liquid.

[0034] In some optional forms, the preset motor current value is 2 to 5 times the initial value of the motor current.

[0035] In some optional forms, the preset temperature value is 40-100℃.

[0036] The present application is to quantitatively study the radiator pipe blockage caused by the flux, and proposes a test device which can simulate the flow of the cooling liquid through the radiator pipe and the corrosion reaction of the cooling liquid with the residual flux in the radiator. According to the simulation results, the influence degree of the flux content on the radiator pipe blockage is obtained, so as to better control the amount of residual flux in the radiator. In addition, using the test device, the influence of cooling liquid and / or flux with different formulations on the radiator pipe can also be tested, thereby providing a basis for selecting appropriate formulations of cooling liquid and / or flux. In addition, the present application also provides a test method for simulating the radiator pipe blockage caused by the flux, and according to the test method, quantitative tests can be carried out. BRIEF DESCRIPTION OF DRAWINGS

[0037] Other features and advantages of the present application will be better understood by the following preferred embodiments described in detail in conjunction with the accompanying drawings, in which the same reference numerals represent the same or similar components, wherein:

[0038] Figure 1 A vehicle radiator according to an embodiment simulated by the test device of the present application is shown;

[0039] Figure 2 A connection between the radiator pipe and the main plate of the water chamber in Figure 1 is shown;

[0040] Figure 3 A test device according to an embodiment of the present application is shown;

[0041] Figure 4 An enlarged view of A in Figure 3 is shown;

[0042] Figure 5 An enlarged view of B in Figure 3 is shown.

[0043] The skilled person will appreciate that the elements in the drawings are shown for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the drawings can be exaggerated relative to other elements to help improve understanding of the embodiments of the application. DETAILED DESCRIPTION

[0044] As will be appreciated by persons skilled in the art, various features of the embodiments shown and described with reference to any one of the drawings can be combined with features shown in one or more other drawings to produce other embodiments that are not explicitly shown or described. The combination of features shown provides representative embodiments for typical applications. However, for particular applications or implementations, various combinations and modifications of features can be desired in accordance with the teachings of the present disclosure.

[0045] As Figure 3The experimental apparatus 20 shown is used to simulate radiator tube blockage caused by flux. To simulate the process, the experimental apparatus 20 mainly includes a container 21, a rotating shaft 22, a motor 23, a test piece 24, and a flux metering stage 25. The container 21 has a container body 211 and a cover 212. The container body 211 is adapted to contain coolant, and the cover 212 is used to seal the container body 211. The rotating shaft 22 extends into the container body 211 via the cover 212. The rotating shaft 22 is driven to rotate by the motor 23 located outside the container 21. Specifically, the motor 23 is fixed to the cover 212 via a motor mounting bracket 26.

[0046] Combination Figure 4 As shown, several test pieces 24 are provided with through grooves 240 and connected to the end of a rotating shaft 22. The test pieces 24 are driven to rotate by the rotating shaft 22 to simulate cooling. Liquid The flow through the radiator tube, wherein the through groove 240 has the cross-sectional shape of the radiator tube, for example... Figure 4 The image shows the cross-sectional shape of the flat tube in the radiator. It should be understood that in radiators made of flat tubes, the minimum width of the flat tube cross-section is smaller than that of a round tube, making it more susceptible to blockage by gel-like or flocculent substances.

[0047] Combination Figure 5 As shown, the flux metering station 25 is adapted to attach at least one flux metering sheet 250. Figure 5 A plurality of flux metering sheets 250 stacked together are shown, wherein each flux metering sheet 250 is an aluminum sheet coated with flux, and the flux coating amount of each flux metering sheet 250 may be the same or different. It is worth noting that the flux is flux that has undergone simulated brazing on the aluminum sheet. In a preferred embodiment, the flux coating amount of each flux metering sheet 250 is the same, and the flux can completely cover the surface of the aluminum sheet by coating, wherein each aluminum sheet has the same coating surface area. The flux coating amount before simulated brazing is 10-20 g / m². 2Simulated brazing refers to a process in which brazing flux coated on the aluminum sheet is subjected to melting and cooling in, for example, a brazing apparatus, and then adheres to the aluminum sheet. Since the two components are not actually connected, and only the brazing flux is melted and cooled on the aluminum sheet, the process is referred to as simulated brazing. The brazing flux coated on each of the test pieces has the same amount, so that the tester can quantitatively determine the brazing flux by selecting the number of test pieces. Alternatively, for test pieces having different amounts of brazing flux coated thereon, the aluminum sheet used for each of the test pieces can have a different coated surface area, and the amount of brazing flux coated can be calculated based on the coated surface area, so that the tester can more finely quantitatively determine the brazing flux by selecting the size (dimension) and the number of test pieces. It should be understood that the coating of the brazing flux on the aluminum sheet simulates the actual brazing process of the aluminum heat sink, and when the amount of brazing flux used in the actual brazing process is the same as the amount of brazing flux coated on the test pieces in the test apparatus of the present application, the amount of brazing flux remaining in the actual brazing process can be quantitatively determined based on the size and / or the number of test pieces after the simulated brazing. Alternatively, the aluminum sheet used for the brazing flux quantification test piece 250 can be configured to have any shape, such as a circular shape, a square shape, a rectangular shape, etc., with a known surface area.

[0048] When the motor 23 drives the rotating shaft 22 to rotate and in turn drives the test pieces 24 to rotate in the cooling liquid in which the test pieces 24 are immersed, the motor 23 has an output power or an output current, which depends on the opening size of the through groove 240 in each of the test pieces 24 when the number, size, and rotational speed of the test pieces 24 are constant. When the cooling liquid reacts with the brazing flux, the through groove 240 can be blocked by the gelatinous or flocculent substance generated by the corrosion reaction, and the blocked through groove 240 can cause the output power or the output current of the motor 23 to increase. In order to quantitatively study the degree of blocking of the through groove 240, the test apparatus 20 further includes a current measurement unit (not shown) for measuring the current of the motor 23, including a sampling resistor, a current sensor, or a current transformer, etc.

[0049] In the preferred embodiment shown in Figures 3 to 4 Alternatively, the test apparatus 20 includes at least two test pieces 24 uniformly spaced around the rotating shaft 22 to achieve balance in rotation. More specifically, in the preferred embodiment shown in Figure 4 In the rotating direction R of the test piece 24 shown in Figure 2As shown, the end of the radiator tube 101 is welded to the main plate 1001 of the water chamber and a part of the end of the radiator tube 101 protrudes from the main plate 1001 of the water chamber, the setting of the annular protruding edge 241 simulates the flow of the cooling liquid from the radiator water chamber into the radiator tube. When the rotating shaft 22 rotates in the direction shown by the arrow R, the cooling liquid flows through the through groove 240 in a direction substantially perpendicular to the through groove 240.

[0050] In an alternative embodiment, as shown in Figure 4 As shown, each test piece 24 is connected to the rotating shaft 22 through an extension rod 220, one end of the extension rod 220 is embedded in the end part 221 of the rotating shaft 22, and the other end of the extension rod 220 is provided with a clamping groove 222, each test piece 24 is inserted into the clamping groove 222 and fixed by a fastener (such as a screw), the firm connection of each test piece 24 can avoid the change of the motor current caused by the displacement when each test piece 24 rotates in the cooling liquid. In order to avoid the influence of each test piece 24 on the flow state of the fluid entering the respective through groove 240, the number of test pieces can be adjusted according to the size of the container 21 and the length of the extension rod 220, so that the cooling liquid flows through the through groove 240 in a direction substantially perpendicular to the through groove 240.

[0051] In particular, the test device of the present application is used to simulate the flow of the cooling liquid in the vehicle radiator. In the vehicle radiator, the cooling liquid is generally used to cool the engine, therefore, the cooling liquid has a relatively high temperature. As shown in Figure 3 The test device of the present application further comprises a temperature control unit 27, which is adapted to maintain the cooling liquid at a set temperature, for example, at the inlet temperature of the cooling liquid for the engine, such as 85-90°C. Therefore, the cooling liquid enters the through groove 240 from the side where the annular protruding edge 241 is located, which not only simulates the flow state of the cooling liquid, but also simulates the temperature of the cooling liquid when it flows, which is closer to the actual use process of the vehicle radiator. For the cooling liquid used to cool the heat generating components such as power battery, motor, high-power electronic devices, etc. in the vehicle radiator, the temperature control unit is used to maintain the cooling liquid at a different preset temperature value. Therefore, the preset temperature value is optionally in the range of 40-100°C. In an alternative embodiment, the temperature control unit 27 is a heating element with a temperature sensor, and the temperature control unit 27 can be attached to the cover 212 of the container 21.

[0052] It is worth noting that each test piece 24 only simulates the structure of the radiator tube, and each test piece 24 can be made of stainless steel, resin or graphite. For the test piece 24 provided with the annular protruding edge 241, the annular protruding edge 241 can be integrally formed with the test piece 24, for example, by stamping a stainless steel plate. Therefore, each test piece 24 is stable in the cooling liquid and does not react with the cooling liquid.

[0053] As shown in FIG. 1, the test device 20 comprises a container 21, a motor 23, a shaft 22, a plurality of test pieces 24, and a flux quantification platform 25. The container 21 is used to hold the cooling liquid. The motor 23 is used to drive the rotation of the shaft 22. The shaft 22 is used to hold the test pieces 24. The test pieces 24 are used to simulate the flow of the cooling liquid through the radiator pipes. The flux quantification platform 25 is used to hold the flux quantification pieces 250. Figure 5 As shown in FIG. 1, the flux quantification platform 25 comprises a base 251 arranged at the bottom of the container 21, and at least one flux quantification piece 250 arranged on the base 251. The flux quantification pieces 250 are arranged at intervals to ensure that the cooling liquid can fully contact the flux on the flux quantification pieces 250. Optionally, the flux quantification platform 25 further comprises a spacer 252, and two adjacent flux quantification pieces 250 are separated by the spacer 252. The spacer 252 is also arranged on the base 251. It should be understood that the flux quantification platform 25 can be made of stainless steel, graphite, plastic, glass, or other materials that do not react with the cooling liquid, so as to avoid affecting the simulation results.

[0054] In an optional embodiment, the container 21 is a cylindrical container to accommodate the rotational flow of the cooling liquid. The container 21 can be made of glass, stainless steel, or resin. In particular, the container 21 is made of transparent glass to facilitate the observation of the color of the cooling liquid and the blocking of the through grooves 240 on the test pieces 24 by the test personnel.

[0055] By using the test device 20 described above, the test personnel can quantitatively study the effect of the flux content on the radiator pipes. The test method can comprise the following steps:

[0056] Step S1: cleaning and drying each component in the test device 20;

[0057] Step S2: selecting the flux quantification pieces 250 of appropriate specifications and / or quantities according to the preset flux content, and assembling the selected flux quantification pieces 250 to the base 251 of the flux quantification platform 25. The flux content is the gram of flux contained in each liter of the cooling liquid, for example, 0.1-2.0 g / L, preferably 0.5-1.5 g / L.

[0058] Step S3: pouring the cooling liquid into the container 21 until the set liquid level, so that the cooling liquid can immerse the test pieces 24, and sealing the container 21. Generally, the same test device has the same set liquid level to calculate the flux content according to the volume of the cooling liquid. Moreover, since the test duration is long, the container 21 should be sealed to prevent the evaporation of the cooling liquid.

[0059] Step S4: starting the motor 23 to drive the rotation of the shaft 22, and then driving the rotation of the test pieces 24 in the cooling liquid to simulate the flow of the cooling liquid through the radiator pipes, and recording the initial value I1 of the stable motor current. Generally, the motor has a transient current at the initial stage of starting. The initial value I1 of the stable motor current can be recorded at the 5th-10th minute after the starting of the motor.

[0060] Step S5: when the motor current rises to the preset value I2 of the motor current, the motor 23 is turned off, and the test duration from the initial value I1 of the motor current to the preset value I2 of the motor current is recorded.

[0061] Step S6: Statistics of the relationship between the test duration and the flux content.

[0062] For the vehicle radiator, before step S4, the following step is further included: heating the coolant to a preset temperature value and keeping the preset temperature value by the temperature control unit 27, the preset temperature value can be selected as 40-100℃, to simulate the inlet temperature of the coolant in the vehicle radiator.

[0063] The statistics of the relationship between the test duration and the flux content, i.e. based on the data obtained by the above test method, a graph of the test duration and the flux content is drawn, and the influence of the flux content on the radiator pipe blockage is quantitatively studied, to provide a reference for the control of the residual flux content of the radiator during the manufacturing process. In other words, the residual flux amount can be controlled within a certain range according to the circulation amount of the coolant in the radiator, to ensure that the radiator will not be blocked by the gel-like or flocculent material after long-term use, and thus to ensure the cooling efficiency and service life of the radiator. The test duration can last for 10-50 days or more.

[0064] In the test method of the present application, the motor current preset value I2 can be 2-5 times of the motor current initial value I1, preferably, I2=2I1, I2=3I1 or I2=4I1. In other words, when the motor current value rises to 2-5 times of the motor current initial value, it can be judged that the through hole 240 of the test piece 24 is blocked by the gel-like or flocculent material for 30%-100% of the passage cross section. In the alternative embodiment, the ratio between the motor current preset value I2 and the motor current initial value I1 depends on the formula of the coolant, the formula of the flux, the test piece 24 and the size of the through hole 240 thereof, the rotation speed of the rotating shaft 22 and other test factors. It is worth noting that the test method of the present application provides a single variable test method to determine the influence of a certain test factor on the simulation result. Generally, for the test of quantitatively studying the flux, the flux content is the variable, and other test factors should be invariable, to assist the researchers to control the content of the residual flux in the unit coolant according to the simulation result.

[0065] Generally, the coolant includes antifreeze and corrosion inhibitor, and different formulas of the coolant and the flux can be selected for the corrosion reaction between the coolant and the flux based on alkali metal-based fluoroaluminate (such as potassium fluoroaluminate). By the test device and the test method of the present application, the corrosion reaction between different coolants and different fluxes can be tested, to assist the researchers to adjust the formula of the coolant and the flux. For example, when the motor current value does not change significantly after a sufficient test duration, it can be judged that the selected coolant and the flux will not produce gel-like or flocculent material.

[0066] According to the above detailed description of the embodiments, the application provides a test device which simulates the flow of the cooling liquid into the radiator pipe, quantitatively studies the influence of the brazing flux content on the blockage of the radiator pipe, and provides a reference for the control of the residual brazing flux in the manufacturing process of the radiator. The application also provides a test method using the test device, which can provide a simulation result with reference significance.

[0067] The exemplary embodiments disclosed in the present application can be variously replaced, combined or modified without departing from the essence of the present application, and all these modifications still belong to the concept of the present application and fall within the scope of protection defined by the claims of the present application.

Claims

1. A testing apparatus for simulating radiator tube blockage caused by flux, characterized in that, The test apparatus includes: A container having a container body and a lid, the container body being adapted to contain coolant; A pivot shaft extends into the container body via the cover; An electric motor, located outside the container, drives the rotating shaft to rotate; A current measuring unit, wherein the current measuring unit is used to measure the current of the motor; At least two test pieces are evenly spaced around and connected to the rotating shaft to be driven to rotate by the shaft, thereby simulating the flow of coolant through a radiator tube; each test piece is provided with a through groove; in the direction of rotation of the test piece, the edge of the through groove of each test piece extends with an annular protrusion; the through groove has a cross-sectional shape suitable for simulating a flat radiator tube. A flux metering station is provided, the flux metering station being adapted to attach at least one flux metering sheet; the flux metering sheet is an aluminum sheet coated with flux, the flux coating amount of each flux metering sheet being the same or different, wherein the flux is flux that has undergone simulated brazing on the aluminum sheet; the flux metering station includes a base disposed at the bottom of the container, the at least one flux metering sheet being sleeved on the base; When the coolant reacts with the flux, the through groove will be blocked by the gel-like or flocculent substances produced by the corrosion reaction, and the blocked through groove will cause the motor current to increase.

2. The experimental apparatus according to claim 1, characterized in that, The test apparatus also includes a temperature control unit adapted to maintain the coolant at a set temperature.

3. The experimental apparatus according to claim 1, characterized in that, The test piece is made of stainless steel, resin, or graphite.

4. The experimental apparatus according to claim 1, characterized in that, The flux metering station also includes a gasket, and two adjacent flux metering sheets are separated by the gasket.

5. The testing apparatus according to any one of claims 1 to 4, characterized in that, The test piece is connected to the rotating shaft via an extension rod. One end of the extension rod is embedded in the rotating shaft, and the other end of the extension rod is provided with a clamping groove. The test piece is inserted into the clamping groove and fixed.

6. The testing apparatus according to any one of claims 1 to 4, characterized in that, The container is a cylindrical container, and the container is made of glass, stainless steel or resin.

7. A test method for simulating radiator tube blockage caused by flux, characterized in that, The test method employs the test apparatus as described in any one of claims 1 to 6, and includes the following steps: Step S1: Clean and dry the test apparatus; Step S2: Select appropriate specifications and / or quantity of flux metering sheets according to the preset flux content, and assemble the selected flux metering sheets onto the flux metering station; Step S3: Inject coolant into the container until the set liquid level is reached, so that the coolant submerges the test piece, and then seal the container; Step S4: Start the motor to drive the shaft to rotate, which in turn drives the test piece to rotate in the coolant, simulating the flow of coolant through the radiator tube, and record the stable initial value of the motor current. Step S5: When the motor current rises to the preset value, turn off the motor and record the test time from the initial value of the motor current to the preset value of the motor current. Step S6: Statistically analyze the relationship between test duration and flux content.

8. The test method according to claim 7, characterized in that, Before step S4, the following steps are also included: using a temperature control unit to heat the coolant to a preset temperature value and maintain the preset temperature value.

9. The test method according to claim 8, characterized in that, The flux content is the number of grams of flux contained in each liter of coolant.

10. The test method according to claim 8, characterized in that, The preset value of the motor current is 2 to 5 times the initial value of the motor current.

11. The test method according to any one of claims 8 to 10, characterized in that, The preset temperature value is 40-100℃.

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