A pure gas-operated new energy vehicle air-conditioning compressor life test device and method

Abstract

The present invention discloses a life test device and method for a new energy vehicle air conditioning compressor that operates in a pure gas state, including an alternative refrigeration system, a measurement and control system, and a test environment chamber. The refrigeration cycle main system of the alternative refrigeration system operates in a full gas state. The test compressor gas is discharged through an exhaust throttle valve, and then enters the intake end through an intake throttle valve and an electronic expansion valve. No phase change occurs, so the heat exchange amount is small; and the exhaust throttle valve, the intake throttle valve, and the electronic expansion valve have a wide adjustable range; based on the above system structure, a smaller refrigeration system can be used to test a compressor with a large cooling capacity range, and at the same time, the amount of refrigerant required by the system is small and the target working condition can be quickly reached. The measurement and control system uses PLC as the control core to realize data measurement and system control of the test device. The test environment chamber has a heating system and a low-temperature refrigeration unit, which can realize temperature control of the test environment chamber. This test device is compatible with compressors with different types of drivers.

Description

Technical Field

[0001] The present invention belongs to the technical field of manufacturing testing equipment for air-conditioning compressors of new energy vehicles, and specifically relates to a life testing device and method for air-conditioning compressors of new energy vehicles that operate in a pure gas state. Background Art

[0002] As the environmental and energy problems of traditional fuel vehicles become increasingly prominent, governments around the world have begun to pay attention to the development of new energy vehicles. The new energy vehicle industry has entered an era of rapid global development. New energy vehicles have the characteristics of environmental protection, energy saving, and high efficiency, and will gradually become people's preferred means of transportation in the future.

[0003] The air conditioning system is an important component of new energy vehicles, and the compressor is a core component of the air conditioning system of new energy vehicles. The importance of its life is self-evident. In order to ensure the reliability of the compressor, the compressor must undergo strict life testing before leaving the factory. At present, the intelligence level of compressor life test equipment is not high, and manual switching of working conditions is required. The heat exchange capacity of the system is large, and many of them require water cooling units. Therefore, it is necessary to develop a compressor life test equipment with a high degree of intelligence and a small system heat exchange capacity to perform reliable and convenient life tests. The present invention is carried out under such a background and has very important practical significance. Summary of the invention

[0004] In view of the above-mentioned deficiencies in the prior art, the present invention provides a life test device and method for a new energy vehicle air-conditioning compressor operating in a pure gas state.

[0005] The present invention provides the following technical solution: A pure gas-operated new energy automobile air-conditioning compressor life test device comprises a substitute refrigeration system, a measurement and control system and a test environment chamber.

[0006] The substitute refrigeration system includes a refrigeration cycle main system, a recovery subsystem, a return air refrigeration subsystem, an environmental refrigeration subsystem and auxiliary parts. The refrigeration cycle main system ensures that the test compressor operates under the set working conditions, and includes a test compressor, a solenoid valve 1, an exhaust throttle valve 1, an exhaust throttle valve 2, an exhaust throttle valve 3, an intermediate buffer coil, a solenoid valve 2, an intake throttle valve 1, an intake throttle valve 2, an electronic expansion valve, and a return air tank, wherein the return air tank has an evaporation coil and an electric heating pipe; the recovery subsystem is used to recover refrigerant, and includes a recovery valve, a recovery compressor, a condenser and a recovery liquid storage tank, wherein the recovery liquid storage tank is used to store refrigerant; the return air refrigeration subsystem and the electric heating pipe in the return air tank realize the control of the suction temperature, and the return air refrigeration subsystem includes a return air refrigeration compressor, a condenser, an expansion valve and an evaporation coil. The environmental refrigeration subsystem and the ambient temperature electric heating pipe realize the control of the ambient temperature of the test compressor, and the ambient refrigeration subsystem includes an ambient refrigeration compressor, a condenser, an expansion valve and an evaporator. The auxiliary parts include a balancing valve, a vacuum valve and a liquid filling valve.

[0007] The measurement and control system uses PLC as the control core to realize data measurement and system control of the test device. PLC communicates with the DC power supply, touch screen and industrial control machine by connecting to the network switch; PLC communicates with the test compressor driver by connecting to the PCAN-LIN module through the extended RS232 interface to control the start and stop of the test compressor, as well as the speed; PLC controls the DC power supply, recovery compressor, environmental circulation fan and various valves by connecting to the relay; PLC controls the return air tank electric heating pipe and the ambient temperature electric heating pipe by connecting to the solid-state relay; PLC controls the number of pulses of the electronic expansion valve by controlling the forward and reverse rotation of the electronic expansion valve driver; PLC connects to the thermocouple input module through the RS485 interface to collect temperature data; PLC connects to the analog input module through the RS485 interface, and the analog input module is connected to the sensor to collect pressure, current and voltage data; PLC connects to the sensor through the extended analog input and output module to collect current and pressure data and control the output pressure of the electric proportional valve.

[0008] The test environment chamber is equipped with a test compressor, a circulating fan is installed directly above it, and an ambient temperature electric heating tube and an evaporator of the ambient refrigeration subsystem are installed on the side. The function of the circulating fan is to ensure the air circulation in the test environment chamber so that the temperature distribution inside the test environment chamber is uniform; the ambient temperature electric heating tube and the evaporator of the ambient refrigeration subsystem are used to control the temperature of the test environment chamber, and the temperature of the test environment chamber can be arbitrarily controlled within the range of -30℃ to 120℃.

[0009] The control software of the new energy vehicle air conditioning compressor life test device includes functions such as parameter setting, data acquisition, system control, data transmission and alarm information. The parameter setting includes the test compressor basic parameter setting, test condition parameter setting and corresponding communication message setting; the system control includes manual control and automatic control, among which the automatic control includes test condition automatic control and test process automatic control; the data transmission transmits the data collected by PLC to the industrial control machine through the network switch.

[0010] The new energy vehicle air-conditioning compressor life test device can automatically control the suction and exhaust pressures of the test compressor: the test device controls the electrical proportional valve through PLC to output appropriate pressure to adjust the opening of the suction throttle valve and the exhaust throttle valve, and controls the pulse number of the electronic expansion valve to accurately and stably control the suction and exhaust pressures.

[0011] The new energy vehicle air conditioning compressor life test device can automatically add liquid and automatically recover refrigerant according to the different refrigerant quantities required for different working conditions. When the test working condition requires more refrigerant, the refrigerant is added from the recovery liquid storage tank to the refrigeration cycle main system by opening the liquid adding valve; when the test working condition requires less refrigerant, the refrigerant is recovered to the recovery liquid storage tank by opening the recovery valve. This can reduce the waste of refrigerant, reduce carbon emissions, and help achieve the "dual carbon goals".

[0012] The described new energy vehicle air conditioning compressor life test device can automatically control the ambient temperature and the suction temperature of the test compressor. The ambient temperature is controlled by the ambient refrigeration subsystem and the electric heating tube; the suction temperature is controlled by the return air tank, which contains the evaporating coil and the electric heating tube of the return air refrigeration subsystem. The test device collects data on the ambient temperature and suction temperature through a thermocouple module and compares it with the set temperature. The control algorithm is used to adjust the proportion of electric heating to achieve accurate and stable control of the ambient temperature and suction temperature. In order to prevent excessive heating from causing excessive pressure inside the return air tank and causing safety hazards, a pressure protection switch is connected to the return air tank. When the pressure inside the tank reaches the set upper limit, the heating power supply is automatically cut off, the system test ends, and the fault information is displayed on the main interface of the measurement and control software.

[0013] By adopting the above technology, compared with the prior art, the beneficial effects of the present invention are as follows:

[0014] (1) The main refrigeration cycle system of the test device of the present invention operates in a full gas state without phase change, so the heat exchange is small. In addition, a smaller refrigeration system can be used to test compressors with a large cooling capacity range, and can be applicable to compressors of 500W to 10kW. At the same time, the amount of refrigerant required by the system is less.

[0015] (2) The suction pressure and exhaust pressure of the test device of the present invention are controlled by controlling the opening of the suction throttle valve and the exhaust throttle valve, and controlling the number of pulses of the electronic expansion valve. Such a control method can achieve rapid adjustment of the working conditions.

[0016] (3) The testing device of the present invention can automatically add liquid and automatically recover refrigerant according to the different refrigerant quantities required under different working conditions, which can reduce the waste of refrigerant, reduce carbon emissions, and help achieve the "dual carbon goals".

[0017] (4) The test device of the present invention is compatible with compressors with different types of drivers and can be applied to compressors with various communication speed control methods such as CAN, LIN and PWM. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the appearance structure of the device of the present invention;

[0019] Figure 2 It is a schematic diagram of the testing principle of the device of the present invention;

[0020] Figure 3 It is a hardware framework diagram of the control system of the device of the present invention;

[0021] Figure 4 It is a functional diagram of the measurement and control software of the device of the present invention;

[0022] Figure 5 is a flow chart of suction pressure control of the device of the present invention;

[0023] Figure 6 is an exhaust pressure control flow chart of the device of the present invention;

[0024] Figure 7 It is a flow chart of automatic liquid adding control of the device of the present invention;

[0025] Figure 8 It is the automatic recovery control flow chart of the device of the present invention;

[0026] Fig. 9 It is a test flow chart of the device of the present invention.

[0027] The figure includes: 1-test compressor, 2-test environment chamber, 3-DC power supply, 4-emergency stop switch, 5-touch screen, 6-intake pressure gauge, 7-exhaust pressure gauge, 8-nitrogen pressure gauge, 9-environmental unit high pressure gauge, 10-environmental unit low pressure gauge, 11-return air unit high pressure gauge, 12-return air unit low pressure gauge, 13-recovery valve, 14-recovery compressor, 15-recovery subsystem condenser, 16-recovery liquid storage tank, 17-solenoid valve one, 18-exhaust throttle valve one, 19-exhaust throttle valve two, 20-recovery valve -Exhaust throttle valve three, 21-intermediate buffer coil, 22-solenoid valve two, 23-intake throttle valve one, 24-intake throttle valve two, 25-electronic expansion valve, 26-return air tank, 27-return air refrigeration compressor, 28-return air unit condenser, 29-return air unit expansion valve, 30-return air tank electric heating pipe, 31-balance valve, 32-vacuum valve, 33-liquid filling valve, 34-environmental refrigeration compressor, 35-environmental unit condenser, 36-environmental unit expansion valve, 37-environmental unit evaporator, 38-environmental temperature electric heating pipe , 39-PLC, 40-network switch, 41-industrial control machine, 42-PCAN-LIN module, 43-relay, 44-environmental circulation fan, 45-solid relay, 46-electronic expansion valve driver, 47-thermocouple input module, 48-suction temperature, 49-return air tank wall heat temperature, 50-environmental unit return air temperature, 51-return air unit return air temperature, 52-environmental temperature, 53-exhaust temperature, 54-shell temperature, 55-analog input module, 56-suction pressure sensor, 57-exhaust Air pressure sensor, 58-intermediate pressure sensor, 59-environmental unit low pressure sensor, 60-return air unit low pressure sensor, 61-recovery unit current sensor, 62-test DC voltage sensor, 63-test DC current sensor, 64-analog input and output module, 65-environmental unit current sensor, 66-return air unit current sensor, 67-intake air control pressure sensor, 68-exhaust air control pressure sensor, 69-intake air control pressure electrical proportional valve, 70-exhaust air control pressure electrical proportional valve. DETAILED DESCRIPTION

[0028] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0029] On the contrary, the present invention covers any substitution, modification, equivalent method and scheme made on the essence and scope of the present invention as defined by the claims. Further, in order to enable the public to have a better understanding of the present invention, some specific details are described in detail in the following detailed description of the present invention. For those skilled in the art, the present invention can be fully understood without the description of these details. The present invention is further described below in conjunction with the drawings of the specification, but the protection scope of the present invention is not limited thereto:

[0030] The schematic diagram of the appearance structure of the new energy vehicle air-conditioning compressor life test device of this embodiment is as follows: Figure 1 As shown, it is composed of a substitute refrigeration system, a measurement and control system and a test environment chamber 2. The test device has an emergency stop switch 4, which can shut down the total power supply of the test device in an emergency when an emergency fault occurs during the test, thus playing a protective role. The touch screen 5 is an input and output device of the test device, which plays the role of a human-computer interaction interface. Parameters can be set on the touch screen 5, and the test process and test status can also be understood through the touch screen 5. The test device is equipped with a DC power supply 3, an intake pressure gauge 6, an exhaust pressure gauge 7, a nitrogen pressure gauge 8, an environmental unit high-pressure pressure gauge 9, an environmental unit low-pressure pressure gauge 10, a return air unit high-pressure pressure gauge 11 and a return air unit low-pressure pressure gauge 12. The pressure gauge can intuitively display the size of the above pressures, thereby judging whether there is any fault in the test process.

[0031] The test principle diagram of the new energy vehicle air-conditioning compressor life test device of this embodiment is as follows: Figure 2As shown, it is composed of a refrigeration cycle main system, a recovery subsystem, a return air refrigeration subsystem, an environmental refrigeration subsystem and auxiliary parts. The refrigeration cycle main system ensures that the test compressor 1 operates under the set working conditions. The exhaust end of the test compressor 1 is connected to an exhaust pressure gauge 7, which can display the size of the exhaust pressure in real time. The exhaust end of the test compressor 1 is connected to three parallel exhaust throttle valves, wherein the front of the exhaust throttle valve 3 20 is connected to the electromagnetic valve 1 17, and the function of the electromagnetic valve 1 17 is to control the on-off of the pipeline where the exhaust throttle valve 3 20 is located. An intermediate buffer coil 21 is connected behind the three exhaust throttle valves, and the back of the intermediate buffer coil 21 is connected to the parallel suction throttle valve 1 23, the suction throttle valve 2 24 and the electronic expansion valve 25, wherein the front of the suction throttle valve 2 24 is connected to the electromagnetic valve 2 22, and the function of the electromagnetic valve 2 22 is to control the on-off of the pipeline where the suction throttle valve 2 24 is located. The back of the suction throttle valve is connected to the return air tank 26, which contains the return air tank electric heating tube 30 and the evaporation coil, which can control the suction temperature 48 of the test compressor. The outlet of the return air tank 26 is connected to the suction end of the test compressor 1. The suction end is connected to the suction pressure gauge 6, which can display the suction pressure of the test compressor 1 in real time. The function of the recovery subsystem is to recover the refrigerant. The recovery subsystem includes a recovery valve 13, a recovery compressor 14, a recovery subsystem condenser 15 and a recovery liquid storage tank 16. One end of the recovery valve 13 is connected to the exhaust end of the test compressor 1, and the other end is connected to the suction end of the recovery compressor 14. The exhaust end of the recovery compressor 14 is connected to the recovery subsystem condenser 15, and the back of the recovery subsystem condenser 15 is connected to the recovery liquid storage tank 16 to store the recovered refrigerant. The return air refrigeration subsystem includes a return air refrigeration compressor 27, a return air unit condenser 28, a return air unit expansion valve 29 and an evaporating coil. Pressure gauges are connected to the exhaust and intake ends of the return air refrigeration compressor to display the pressure of the high pressure of the return air unit and the low pressure of the return air unit in real time. The environmental refrigeration subsystem includes an environmental refrigeration compressor 34, an environmental unit condenser 35, an environmental unit expansion valve 36 and an environmental unit evaporator 37. Pressure gauges are connected to the intake and exhaust ends of the environmental refrigeration compressor to display the pressure of the high pressure of the environmental unit and the low pressure of the environmental unit in real time. The auxiliary parts include a balancing valve 31, a vacuum valve 32 and a liquid adding valve 33. One end of the balancing valve 31 is connected to the suction end of the test compressor 1, and the other end is connected to the exhaust end of the test compressor 1. The purpose of opening the balancing valve 31 is to facilitate the start-up of the test compressor 1; one end of the vacuum valve 32 is connected to the refrigeration cycle main system, and the other end is connected to the vacuum pump. The vacuum valve 32 is opened so that the vacuum pump can evacuate the refrigeration cycle main system; one end of the liquid adding valve 33 is connected to the suction end of the test compressor 1, and the other end is connected to the recovery liquid storage tank 16. The opening of the liquid adding valve 33 adds refrigerant to the refrigeration cycle main system.

[0032] The hardware framework of the control system of the new energy vehicle air-conditioning compressor life test device of this embodiment is shown in the figure below: Figure 3 As shown, the measurement and control system uses PLC39 as the control core to achieve data measurement and system control of the entire test device:

[0033] Specifically, PLC39 communicates with DC power supply 3, touch screen 5 and industrial control computer 41 through network switch 40. DC power supply 3 provides the required DC working voltage for testing compressor 1, and touch screen 5 is an input and output device of the testing device, thereby realizing human-computer dialogue; data collected during the test are sent to industrial control computer 41 through network switch 40 for storage;

[0034] Specifically, PLC39 communicates with the test compressor 1 by connecting to the PCAN-LIN module 42. The test device sends instructions to the PCAN-LIN module 42 through the RS232 port extended by PLC39. The PCAN-LIN module 42 sends instructions to the driver of the test compressor 1 to control the start or stop of the test compressor 1 and the speed. PLC39 sends the data fed back by the test compressor 1 to the industrial control computer 41 through the network switch 40. The operating information of the test compressor 1 can be understood according to the data fed back by the test compressor 1.

[0035] Specifically, PLC39 is connected to relay 43 to realize the control of the DC power supply 3, recovery valve 13, recovery compressor 14, balance valve 31, vacuum valve 32, liquid adding valve 33, and environmental circulation fan 44 switches;

[0036] Specifically, the PLC 39 is connected to the solid state relay 45 to realize the on-off control of the return air tank electric heating pipe 30 and the ambient temperature electric heating pipe 38;

[0037] Specifically, PLC 39 controls the number of pulses of electronic expansion valve 25 by controlling the forward or reverse rotation of electronic expansion valve driver 46;

[0038] Specifically, PLC39 realizes data collection of suction temperature 48, return air tank wall heat temperature 49, ambient unit return air temperature 50, return air unit return air temperature 51, ambient temperature 52, exhaust temperature 53, and shell temperature 54 by connecting with thermocouple input module 47;

[0039] Specifically, PLC39 is connected to the suction pressure sensor 56, the exhaust pressure sensor 57, the intermediate pressure sensor 58, the environmental unit low pressure sensor 59, the return air unit low pressure sensor 60, the recovery unit current sensor 61, the test DC voltage sensor 62 and the test DC current sensor 63 through the analog input module 55 to realize the measurement of pressure, current and voltage;

[0040] Specifically, PLC39 connects with the environment unit current sensor 65, the return air unit current sensor 66, the suction air control pressure sensor 67 and the exhaust air control pressure sensor 68 through the extended analog input and output module 64 to achieve the measurement of current and pressure, as well as the control of the output pressure of the suction air control pressure electrical proportional valve 69 and the exhaust air control pressure electrical proportional valve 70;

[0041] The function diagram of the measurement and control software of the new energy vehicle air-conditioning compressor life test device of this embodiment is as follows: Figure 4 As shown, it includes functions such as parameter setting, data acquisition, system control, data transmission and alarm information. The parameter setting includes basic parameter setting, test condition parameter setting and corresponding communication message setting, wherein the basic parameter setting includes the model of the test compressor 1, the communication mode selection of the test compressor 1, the selection of the refrigerant type and the size of the rated voltage; the test condition parameter setting includes suction pressure 6, exhaust pressure 7, suction temperature 48, ambient temperature 52, test voltage, test time and speed. The system control includes manual control and automatic control, and the automatic control includes test condition automatic control and test process automatic control, wherein the test condition automatic control includes suction pressure automatic control, exhaust pressure automatic control, automatic liquid addition, automatic recovery, ambient temperature automatic control and suction temperature automatic control. The data transmission is to transmit the data collected by PLC39 to the industrial control machine 41 through the network switch 40.

[0042] The control flow chart of the suction pressure 6 of the new energy vehicle air-conditioning compressor life test device of this embodiment is as follows: Figure 5 As shown:

[0043] When the suction pressure 6 is low, the first step is to determine whether the suction air control pressure is less than the maximum value 0.9Mpa output by the suction air control pressure electrical proportional valve 69. If it is less than 0.9Mpa, the suction air control pressure is increased; otherwise, the second step is to determine whether the solenoid valve 22 is open. If not, the solenoid valve 22 is opened; otherwise, the third step is to determine whether the exhaust air control pressure is less than the maximum value 0.9Mpa output by the exhaust air control pressure electrical proportional valve 70. If it is less than 0.9Mpa, or equal to 0.9Mpa and the solenoid valve 17 is closed, the fourth step is to determine whether the exhaust pressure 7 is greater than the set exhaust pressure. If it is greater than the set value, no operation is required; otherwise, the fifth step is to determine whether the intermediate pressure is less than 0.9Mpa. If it is less than 0.9 Mpa, it means that the refrigerant in the main system of the refrigeration cycle is insufficient, and it is necessary to open the liquid adding valve 33 to add refrigerant to the main system of the refrigeration cycle; if the intermediate pressure is equal to 0.9Mpa, the sixth step is performed to determine whether the pulse number of the electronic expansion valve 25 is less than 2000, if it is less than 2000, the electronic expansion valve 25 is adjusted up; otherwise, it means that the evaporation temperature is too high, and an alarm for excessive evaporation temperature is issued; if the exhaust gas control pressure has reached the maximum value of 0.9Mpa output by the exhaust gas control pressure electrical proportional valve 70 and the solenoid valve 17 has been opened, the sixth step is performed to determine whether the pulse number of the electronic expansion valve 25 is less than 2000, if it is less than 2000, the electronic expansion valve 25 is adjusted up; otherwise, it means that the evaporation temperature is too high, and an alarm for excessive evaporation temperature is issued.

[0044] When the suction pressure 6 is too high, the first step is to determine whether the suction air control pressure is greater than the minimum output value 0.01Mpa of the suction air control pressure electrical proportional valve 69. If it is greater than 0.01Mpa, the suction air control pressure is reduced; otherwise, the second step is to determine whether the solenoid valve 2 is closed. If it is not closed, the solenoid valve 22 is closed; otherwise, the third step is to determine whether the pulse number of the electronic expansion valve 25 is greater than 0. If it is greater than 0, the electronic expansion valve 25 is reduced; otherwise, it means that the evaporation temperature is too low, and an alarm for low evaporation temperature is issued.

[0045] The control flow chart of the exhaust pressure 7 of the new energy vehicle air-conditioning compressor life test device of this embodiment is as follows: Figure 6 As shown:

[0046] When the exhaust pressure 7 is low, the first step is to determine whether the exhaust gas control pressure is greater than the minimum output value of the exhaust gas control pressure electrical proportional valve 70, 0.01Mpa. If it is greater than 0.01Mpa, the exhaust gas control pressure is reduced; otherwise, the second step is to determine whether the solenoid valve 17 is closed. If it is not closed, the solenoid valve 17 is closed; otherwise, it means that there is not enough refrigerant in the main system of the refrigeration cycle, and it is necessary to open the liquid adding valve 33 to add refrigerant to the main system of the refrigeration cycle.

[0047] When the exhaust pressure 7 is too high, the first step is to determine whether the exhaust gas control pressure is less than the maximum output value of the exhaust gas control pressure electrical proportional valve 70, 0.9Mpa. If it is less than 0.9Mpa, the exhaust gas control pressure is increased; otherwise, the second step is to determine whether the solenoid valve 17 is open. If not, the solenoid valve 17 is opened; otherwise, it means that there is too much refrigerant in the main system of the refrigeration cycle, and the recovery valve 13 needs to be opened to recover the refrigerant.

[0048] The automatic liquid filling control flow chart of the new energy vehicle air-conditioning compressor life test device of this embodiment is as follows: Figure 7 As shown:

[0049] When adding liquid automatically, the first step is to open the adding valve 33, the second step is to determine whether the adding valve timer is started, if not, the adding valve timer is started, the third step is to determine whether the exhaust pressure 7 is greater than the set exhaust pressure, if the exhaust pressure 7 is greater than the set value, the adding valve 33 is closed, and the adding valve timer is stopped and reset; otherwise, the fourth step is performed to determine whether the adding valve timer is less than 5s, if the adding valve timer is less than 5s, the timing is continued; otherwise, the fifth step is performed to determine whether the recovery compressor 14 is started, if not, the recovery compressor 14 is started, and the recovery compressor timer is started; if the recovery compressor 14 has been started, the sixth step is performed to determine whether the recovery compressor timer is less than 5s, if the recovery compressor timer is less than 5s, the recovery compressor 14 is continued to be started; otherwise, it indicates that the adding liquid is abnormal, and it is necessary to close the adding valve 33, stop and reset the adding liquid timer, and display the adding liquid abnormality information on the main interface of the measurement and control software.

[0050] The automatic recovery control flow chart of the new energy vehicle air-conditioning compressor life test device of this embodiment is as follows: Figure 8 As shown:

[0051] When automatically recovering, the first step is to open the recovery valve 13, the second step is to determine whether the recovery valve timer is started, if not, the recovery valve timer is started, the third step is to determine whether the exhaust pressure 7 is less than the set exhaust pressure, if the exhaust pressure 7 is less than the set value, the recovery valve 13 is closed, and the recovery valve timer is stopped and reset; otherwise, the fourth step is performed to determine whether the recovery valve timer is less than 5s, if the recovery valve timer is less than 5s, the timing is continued; otherwise, the fifth step is performed to determine whether the recovery compressor 14 is started, if not, the recovery compressor 14 is started, and the recovery compressor timer is started; if the recovery compressor 14 has been started, the sixth step is performed to determine whether the recovery compressor timer is less than 5s, if the recovery compressor timer is less than 5s, the recovery compressor 14 is continued to be started; otherwise, it indicates that the recovery is abnormal, and it is necessary to close the recovery valve 13, stop and reset the recovery valve timer, and display the recovery abnormality information on the main interface of the measurement and control software.

[0052] The test conditions of the new energy vehicle air conditioner compressor life test device of this embodiment are divided into two stages. The first stage is a fixed speed test condition, with two test conditions, namely fixed speed test condition 1 and fixed speed test condition 2; the second stage is a speed cycle test condition, with three test conditions, namely speed cycle test condition 1, speed cycle test condition 2 and speed cycle test condition 3. The test process of the new energy vehicle air conditioner compressor life test device of this embodiment is as follows: Fig. 9 As shown, the specific steps include:

[0053] (1) Installation of the test compressor 1: Install the test compressor 1 in the test environment chamber 2, and connect the suction end and the exhaust end of the test compressor to the refrigeration cycle main system;

[0054] (2) Setting the test operating parameters: Enter the parameter setting interface on the touch screen 5, set the basic parameters of the test compressor 1, the test operating parameters and input the corresponding communication message;

[0055] (3) Entering the fixed speed test phase: Initializing the fixed speed test condition code n = 1;

[0056] (4) Initialize the parameters of the fixed speed test condition n;

[0057] (5) Adjusting the suction pressure 6, the exhaust pressure 7, the suction temperature 48 and the ambient temperature 52;

[0058] (6) Determine whether the suction pressure 6, the exhaust pressure 7, the suction temperature 48 and the ambient temperature 52 have reached the set values ​​of the fixed speed test condition n; if not, return to step 5 to continue adjustment; otherwise, proceed to the next step;

[0059] (7) Start the test at fixed speed test condition n;

[0060] (8) Data acquisition: The test device samples various required data at high speed;

[0061] (9) Determine whether the test time reaches the set time of the fixed speed test condition n; if not, return to step 8 to continue data collection, otherwise proceed to the next step;

[0062] (10) Determine whether the fixed speed test condition has been completed. If not, the fixed speed test condition code is incremented by 1, and then the test returns to step 4 to start a new fixed speed test condition test; otherwise, the speed cycle test is started;

[0063] (11) Entering the speed cycle test phase: Initializing the speed cycle test condition code n=1;

[0064] (12) Initialize the parameters of the speed cycle test condition n;

[0065] (13) Adjusting the suction pressure 6, the exhaust pressure 7, the suction temperature 48 and the ambient temperature 52;

[0066] (14) Determine whether the suction pressure 6, the exhaust pressure 7, the suction temperature 48 and the ambient temperature 52 have reached the set values ​​of the speed cycle test condition n; if not, return to step 13 to continue adjustment, otherwise proceed to the next step;

[0067] (15) Start the speed cycle test condition n;

[0068] (16) The speed increases from 0 rpm to the minimum speed within 30 s;

[0069] (17) Maintain the speed at the minimum speed;

[0070] (18) Determine whether the duration of the minimum speed reaches 1 minute. If not, return to step 17; otherwise, proceed to the next step.

[0071] (19) The speed increases by 1000 rpm within 15 s;

[0072] (20) Maintain the speed at the speed after the speed increase;

[0073] (21) After the speed is increased, determine whether the speed duration reaches 1 minute: if it does not reach 1 minute, return to step 20, otherwise proceed to the next step;

[0074] (22) Determine whether the speed has reached the maximum speed: if the speed is not the maximum speed, return to step 19 to continue to increase the speed; otherwise, proceed to the next step;

[0075] (23) Determine whether the set time of the speed cycle test condition n is reached: If the set time of the speed cycle test condition n is not reached, the maximum speed is reduced to 0 rpm within 30 seconds, and after staying for 30 seconds, return to step 16 to continue the test; otherwise, proceed to the next step;

[0076] (24) Determine whether the speed cycle test condition has been completed. If not, the speed cycle test condition code is increased by 1, and then return to step 12 to start a new speed cycle test condition test; otherwise, proceed to the next step;

[0077] (25) Stop the test;

[0078] (26) Saving data and generating reports: The test data is saved to the industrial control computer 39 via the network switch 38, and a test report is automatically generated.

[0079] The adjustment of relevant process parameters in this process is carried out in accordance with the national standard GB / T 22068-2018 Electric compressor assembly for automobile air conditioner. After the compressor completes the life test of the device of the present invention, the compressor life is judged to be qualified according to the relevant parameters specified in the above section 5.8.

[0080] In summary, the main system of the refrigeration cycle of the present invention is operated in a fully gaseous state. The test compressor gas is discharged through the exhaust throttle valve, and then enters the intake end through the intake throttle valve and the electronic expansion valve. There is no phase change, so the heat exchange is small; and the exhaust throttle valve, the intake throttle valve and the electronic expansion valve have a wide adjustable range; based on the above system structure, a smaller refrigeration system can be used to test compressors with a large cooling capacity range, and can be used for compressors of 500W to 10kW. At the same time, the system requires less refrigerant and can quickly reach the target working condition. The measurement and control system uses PLC as the control core to realize data measurement and system control of the test device. The test environment chamber has a heating system and a low-temperature refrigeration unit, which can realize the temperature of the test environment chamber in the range of -30℃ to 120℃. The test device is compatible with compressors with different types of drivers and can be used for compressors with various communication speed control methods such as CAN, LIN and PWM.

Claims

1. A pure gas-state operating new energy vehicle air-conditioning compressor life test device, characterized in that: include: Surrogate refrigeration system to ensure specific operating conditions for compressor testing; The measurement and control system uses PLC as the control core to achieve data measurement and system control of the entire test device; Test environment chamber, used to provide the ambient temperature required for compressor testing; The substitute refrigeration system includes a refrigeration cycle main system, a recovery subsystem, a return air refrigeration subsystem, an environmental refrigeration subsystem and auxiliary parts; the refrigeration cycle main system ensures that the test compressor operates under the set working conditions, and includes a test compressor, a solenoid valve 1, an exhaust throttle valve 1, an exhaust throttle valve 2, an exhaust throttle valve 3, an intermediate buffer coil, a solenoid valve 2, an intake throttle valve 1, an intake throttle valve 2, an electronic expansion valve, and a return air tank; the return air tank contains an evaporating coil and an electric heating tube for the return air tank; the recovery subsystem is used to recover the refrigerant, and includes a recovery valve, a recovery compressor, and a recovery valve. , recovery subsystem condenser and recovery liquid storage tank, the recovery liquid storage tank is used to store refrigerant; the return air refrigeration subsystem and the electric heating tube in the return air tank realize the control of the suction temperature, the return air refrigeration subsystem includes the return air refrigeration compressor, the return air unit condenser, the return air unit expansion valve and the evaporating coil; the environmental refrigeration subsystem and the environmental temperature electric heating tube realize the control of the test compressor ambient temperature, the environmental refrigeration subsystem includes the environmental refrigeration compressor, the environmental unit condenser, the environmental unit expansion valve and the environmental unit evaporator; the auxiliary parts include a balancing valve, a vacuum valve and a liquid filling valve; The exhaust end of the test compressor is connected with an exhaust pressure gauge, and the exhaust end of the test compressor is connected with three exhaust throttle valves in parallel, wherein the front of exhaust throttle valve three is connected with solenoid valve one, and the back of the three exhaust throttle valves is connected with an intermediate buffer coil, and the back of the intermediate buffer coil is connected with parallel suction throttle valve one, suction throttle valve two and electronic expansion valve, wherein the front of suction throttle valve two is connected with solenoid valve two, and the back of suction throttle valve is connected with a return air tank, and the return air tank contains a return air tank electric heating tube and an evaporating coil, which can control the suction temperature of the test compressor; the outlet of the return air tank is connected with the suction end of the test compressor; the suction end is connected with an suction pressure gauge; one end of the recovery valve is connected with the exhaust end of the test compressor, and the other end is connected with the recovery pressure The recovery subsystem condenser is connected to the suction end of the recovery compressor, and the recovery subsystem condenser is connected to the recovery liquid storage tank behind the recovery subsystem condenser to store the recovered refrigerant; pressure gauges are connected to the exhaust end and suction end of the return air refrigeration compressor, and pressure gauges are connected to the suction end and exhaust end of the ambient refrigeration compressor; one end of the balancing valve is connected to the suction end of the test compressor, and the other end is connected to the exhaust end of the test compressor, one end of the vacuum valve is connected to the refrigeration cycle main system, and the other end is connected to the vacuum pump, and the vacuum valve is opened so that the vacuum pump can evacuate the refrigeration cycle main system; one end of the liquid adding valve is connected to the suction end of the test compressor, and the other end is connected to the recovery liquid storage tank, and the opening of the liquid adding valve adds refrigerant to the refrigeration cycle main system.

2. A pure gas-state operated new energy vehicle air conditioning compressor life test device according to claim 1, characterized in that: The PLC of the measurement and control system communicates with the DC power supply, touch screen and industrial control machine by connecting to the network switch; the PLC communicates with the test compressor driver by connecting to the PCAN-LIN module through the extended RS232 interface to control the start and stop of the test compressor, as well as the speed; the PLC controls the DC power supply, recovery compressor, environmental circulation fan and various valves by connecting to the relay; the PLC controls the return air tank electric heating tube and the ambient temperature electric heating tube by connecting to the solid-state relay; the PLC controls the number of pulses of the electronic expansion valve by controlling the forward and reverse rotation of the electronic expansion valve driver; the PLC is connected to the thermocouple input module through the RS485 interface to collect temperature data; the PLC is connected to the analog input module through the RS485 interface, and the analog input module is connected to the sensor to collect pressure, current and voltage data; the PLC is connected to the sensor through the extended analog input and output module to collect current and pressure data and control the output pressure of the electric proportional valve.

3. A pure gas-state operated new energy vehicle air conditioning compressor life test device according to claim 2, characterized in that: The test environment chamber is loaded with a test compressor, an environmental circulation fan is installed directly above the test environment chamber, and an environmental temperature electric heating tube and an evaporator of the environmental refrigeration subsystem are installed on the side; the function of the environmental circulation fan is to ensure the air circulation in the test environment chamber so that the temperature distribution inside the test environment chamber is uniform; the environmental temperature electric heating tube and the evaporator of the environmental refrigeration subsystem are used to control the temperature of the test environment chamber, and can realize the temperature of the test environment chamber arbitrarily controlled within the range of -30℃~120℃.

4. A testing method for the life test device of the new energy vehicle air-conditioning compressor in pure gas state operation as claimed in claim 3, characterized in that: The compressor operating condition test consists of two stages. The first stage is the fixed speed test condition, and the second stage is the speed cycle test condition. The specific steps include the following: (1) Installation of the test compressor: Install the test compressor in the test environment room, and connect the suction and exhaust ends of the test compressor to the main refrigeration cycle system; (2) Set the test operating parameters: Enter the parameter setting interface on the touch screen, set the basic parameters of the test compressor, the test operating parameters and enter the corresponding communication message; (3) Entering the fixed speed test phase: Initialize the fixed speed test condition code n=1; (4) Initialize the parameters of the fixed speed test condition n; (5) Adjust the suction pressure, exhaust pressure, suction temperature and ambient temperature; (6) Determine whether the suction pressure, exhaust pressure, suction temperature and ambient temperature have reached the set value of the fixed speed test condition n; if not, return to step 5 to continue adjustment; otherwise, proceed to the next step; (7) Start the test at fixed speed test condition n; (8) Data acquisition: The test device samples various required data at high speed; (9) Determine whether the test time reaches the set time of the fixed speed test condition n; if not, return to step 8 to continue data collection, otherwise proceed to the next step; (10) Determine whether the fixed speed test conditions have been completed; if not, the fixed speed test condition code is increased by 1, and then return to step 4 to start a new fixed speed test condition test; otherwise, enter the speed cycle test; (11) Entering the speed cycle test phase: Initializing the speed cycle test condition code n=1; (12) Initialize the parameters of the speed cycle test condition n; (13) Adjust the suction pressure, exhaust pressure, suction temperature and ambient temperature; (14) Determine whether the suction pressure, exhaust pressure, suction temperature and ambient temperature have reached the set value of the speed cycle test condition n; if not, return to step 13 to continue adjustment, otherwise proceed to the next step; (15) Start the test at speed cycle test condition n; (16) The speed increases from 0 rpm to the minimum speed within 30 s; (17) Keep the speed at the minimum; (18) Determine whether the duration of the minimum speed reaches 1 minute. If not, return to step 17; otherwise, proceed to the next step. (19) The speed increases by 1000 rpm within 15 s; (20) Maintain the speed at the speed after the speed increase; (21) After the speed is increased, determine whether the speed duration reaches 1 minute: if it does not reach 1 minute, return to step 20, otherwise proceed to the next step; (22) Determine whether the speed has reached the maximum speed: If the speed is not the maximum speed, return to step 19 to continue to increase the speed; Otherwise proceed to the next step; (23) Determine whether the set time of the speed cycle test condition n has been reached: If the set time of the speed cycle test condition n has not been reached, the maximum speed is reduced to 0 rpm within 30 seconds, and after staying for 30 seconds, the test is returned to step 16 to continue; otherwise, proceed to the next step; (24) Determine whether the speed cycle test conditions have been completed; if not, the speed cycle test condition code is increased by 1, and then return to step 12 to start a new speed cycle test condition test; otherwise, proceed to the next step; (25) Stop the test; (26) Save data and generate reports: Save the test data to the industrial control computer through the network switch and automatically generate a test report.

5. The method for life test of a pure gas-state operated new energy vehicle air-conditioning compressor according to claim 4 is characterized in that: The control process of suction pressure is: When the suction pressure is low, the first step is to determine whether the suction air control pressure is less than the maximum value of 0.9Mpa output by the suction air control pressure electrical proportional valve. If it is less than 0.9Mpa, the suction air control pressure is increased; otherwise, the second step is to determine whether the solenoid valve 2 is open. If not, the solenoid valve 2 is opened; otherwise, the third step is to determine whether the exhaust air control pressure is less than the maximum value of 0.9Mpa output by the exhaust air control pressure electrical proportional valve. If it is less than 0.9Mpa, or equal to 0.9Mpa and the solenoid valve 1 is closed, the fourth step is to determine whether the exhaust pressure is greater than the set exhaust pressure. If it is greater than the set value, no operation is required; otherwise, the fifth step is to determine whether the intermediate pressure is less than 0.9Mpa. If it is less than 0. 9Mpa, it means that the refrigerant in the main system of the refrigeration cycle is insufficient, and it is necessary to open the liquid adding valve to add refrigerant to the main system of the refrigeration cycle; if the intermediate pressure is equal to 0.9Mpa, the sixth step is to determine whether the pulse number of the electronic expansion valve is less than 2000. If it is less than 2000, the electronic expansion valve is adjusted larger; otherwise, it means that the evaporation temperature is too high, and an evaporation temperature over-high alarm is issued; if the exhaust gas control pressure has reached the maximum value of the exhaust gas control pressure electrical proportional valve output of 0.9Mpa and the solenoid valve is already opened, the seventh step is to determine whether the pulse number of the electronic expansion valve is less than 2000. If it is less than 2000, the electronic expansion valve is adjusted larger; otherwise, it means that the evaporation temperature is too high, and an evaporation temperature over-high alarm is issued; When the suction pressure is too high, the first step is to determine whether the suction air control pressure is greater than the minimum output value of the suction air control pressure electrical proportional valve 0.01Mpa. If it is greater than 0.01Mpa, the suction air control pressure is reduced; otherwise, the second step is to determine whether the solenoid valve 2 is closed. If it is not closed, the solenoid valve 2 is closed; otherwise, the third step is to determine whether the pulse number of the electronic expansion valve is greater than 0. If it is greater than 0, the electronic expansion valve is reduced; otherwise, it means that the evaporation temperature is too low, and an alarm for low evaporation temperature is issued.

6. The method for life test of a pure gas-state operated new energy vehicle air-conditioning compressor according to claim 5 is characterized in that: The control process of exhaust pressure is: When the exhaust pressure is low, the first step is to determine whether the exhaust gas control pressure is greater than the minimum output value of the exhaust gas control pressure electrical proportional valve 0.01Mpa. If it is greater than 0.01Mpa, the exhaust gas control pressure is reduced; otherwise, the second step is to determine whether the solenoid valve 1 is closed. If it is not closed, the solenoid valve 1 is closed; otherwise, it means that the refrigerant in the refrigeration cycle main system is insufficient, and the liquid adding valve needs to be opened to add refrigerant to the refrigeration cycle main system; When the exhaust pressure is too high, the first step is to determine whether the exhaust gas control pressure is less than the maximum output of the exhaust gas control pressure electrical proportional valve 0.9Mpa. If it is less than 0.9Mpa, increase the exhaust gas control pressure; otherwise, proceed to the second step to determine whether solenoid valve 1 is open. If not, open solenoid valve 1; otherwise, it means that there is too much refrigerant in the main system of the refrigeration cycle, and the recovery valve needs to be opened to recover the refrigerant.

7. The method for life test of a pure gas-state operated new energy vehicle air-conditioning compressor according to claim 6 is characterized in that: The automatic refrigerant addition control process is: When adding liquid automatically, the first step is to open the adding valve, the second step is to determine whether the adding valve timer is started, if not, then start the adding valve timer, the third step is to determine whether the exhaust pressure is greater than the set exhaust pressure, if the exhaust pressure is greater than the set value, then close the adding valve, stop and reset the adding valve timer; otherwise, proceed to the fourth step to determine whether the adding valve timer is less than 5s, if the adding valve timer is less than 5s, then continue timing; otherwise, proceed to the fifth step to determine whether the recovery compressor is started, if not, then start the recovery compressor and start the recovery compressor timer; If the recovery compressor has been started, the sixth step is to determine whether the recovery compressor timer is less than 5s. If the recovery compressor timer is less than 5s, the recovery compressor is started again; Otherwise, it indicates that the liquid addition is abnormal. It is necessary to close the liquid addition valve, stop and reset the liquid addition timer, and display the abnormal liquid addition information on the main interface of the measurement and control software.

8. The method for life test of a pure gas-state operated new energy vehicle air-conditioning compressor according to claim 7 is characterized in that: The control process of automatic refrigerant recovery is: When automatically recycling, the first step is to open the recycling valve, the second step is to determine whether the recycling valve timer is started, if not, then start the recycling valve timer, the third step is to determine whether the exhaust pressure is less than the set exhaust pressure, if the exhaust pressure is less than the set value, then close the recycling valve, stop and reset the recycling valve timer; otherwise, proceed to the fourth step to determine whether the recycling valve timer is less than 5s, if the recycling valve timer is less than 5s, then continue timing; otherwise, proceed to the fifth step to determine whether the recycling compressor is started, if not, then start the recycling compressor and start the recycling compressor timer; If the recovery compressor has been started, the sixth step is to determine whether the recovery compressor timer is less than 5s. If the recovery compressor timer is less than 5s, the recovery compressor is started again; Otherwise, it indicates that the recovery is abnormal. You need to close the recovery valve, stop and reset the recovery valve timer, and display the recovery abnormality information on the main interface of the measurement and control software.

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