A performance testing method and device for air compressor

Abstract

The present invention discloses a performance testing method for an air compressor, which relates to the field of air compressors. The method starts the performance test of the air compressor through a real-time switch signal. During the test, after initializing the performance test parameters, a preset pressure and rate test module is executed to calculate the maximum inflation pressure and the inflation rate. At this time, the preset durability test module is executed again according to the on-off state of the real-time switch signal. In the process of executing the preset durability test module, the remaining number of cycles is recorded according to the real-time detection information and the performance test parameters, and it is determined whether the air compressor has a fault. In the event of a fault, the durability test cycle is exited. When the air compressor has not failed, the durability test cycle is continuously repeated until the number of cycles is equal to the number of inflation cycles Z. The method realizes the testing of multiple performance indicators through an air compressor performance testing device, and solves the problem that a single test device can only test a single performance indicator and that multiple devices are required to test multiple performance indicators.

Description

Technical Field

[0001] The present invention relates to the field of air compressors, and in particular to a performance testing method and device for air compressors. Background Art

[0002] With the increasing popularity of new energy vehicles, especially buses with air brakes, electric air compressors are essential. These provide air for the vehicle's braking system, air suspension system, pneumatic door systems, and other systems. Their performance and reliability are directly related to vehicle safety and comfort, making them core components of new energy buses. For parts manufacturers, air compressors are tested before shipment to ensure product quality. For vehicle manufacturers, air compressors are tested before installation to ensure optimal performance. Reliability and performance testing are essential for both air compressor manufacturers and vehicle manufacturers. Performance testing of electric air compressors primarily focuses on pumping rate, pressure, and durability to ensure optimal performance. Currently, there is no professional automated testing equipment for electric air compressors on the market. Many performance testing devices rely on traditional manual or semi-automatic testing methods, relying solely on inverter-controlled compressors that either operate continuously or shut down, failing to simulate the compressor's post-installation state. Moreover, a single test device can only test a single item (a single performance indicator). Testing multiple performance indicators requires multiple devices, which reduces work efficiency. In particular, durability testing cannot be automated according to the vehicle status after installation. Summary of the Invention

[0003] In order to solve the problem that a single test device can only test a single item (a single performance indicator), multiple devices are required to test multiple performance indicators, and the durability test cannot be automatically tested according to the vehicle status after installation, the present invention proposes a performance testing method for an air compressor, which is applied to an air compressor performance testing device, and the air compressor performance testing device includes:

[0004] System controller;

[0005] The performance test air circuit includes: multiple air storage tanks, an air compressor, a flow meter and a water removal mechanism that are in communication with the system controller; the water removal mechanism and each air storage tank are provided with an air pressure sensor and an exhaust solenoid valve that are in communication with the system controller;

[0006] An air compressor controller and a test switch in communication with the system controller; wherein:

[0007] One end of the flow meter is connected to the air compressor, and the other end is connected to the dewatering mechanism, so as to detect the amount of gas pumped out by the air compressor; the test switch is used to generate a switch signal; the system controller is used to start or terminate the performance test of the air compressor according to the switch signal, and during the performance test, initialize the performance test parameters, generate and execute the control commands for starting and stopping the air compressor, opening and closing the exhaust solenoid valve, and starting and stopping the dewatering mechanism, obtain real-time detection information during the execution of the control commands, and generate performance test information based on the real-time detection information and the performance test parameters; the air compressor controller is used to control the start and stop state of the air compressor according to the start and stop control commands of the air compressor; the dewatering mechanism is used to remove moisture in the performance test gas path according to the start and stop control commands of the dewatering mechanism and then input it into each gas storage tank; the performance testing method includes:

[0008] S1: Obtain the real-time switch signal of the test switch, determine whether the real-time switch signal is equal to 1, and if so, initialize the performance test parameters and proceed to the next step;

[0009] S2: Execute the preset pressure and rate test module, generate control commands during the execution process, control the start and stop status of the air compressor and water removal mechanism, and the opening and closing status of each exhaust solenoid valve through the control commands, so as to inflate or exhaust the gas tank, and obtain real-time detection information during the inflation process. According to the real-time detection information and performance test parameters, the maximum inflation pressure and inflation rate are obtained, and it is determined whether the real-time switch signal is equal to 1. If so, proceed to the next step;

[0010] S3: Execute the preset durability test module; the preset durability test module includes a durability test cycle; and in the process of executing the preset durability test module, enter the durability test cycle according to the number of inflation cycles Z included in the performance test parameters, and generate a control command during the cycle, and control the start and stop status of the air compressor and the water removal mechanism, as well as the opening and closing status of each exhaust solenoid valve through the control command to inflate or exhaust the air tank, and obtain real-time detection information during the inflation and exhaust process, record the remaining number of cycles according to the real-time detection information and the performance test parameters, determine whether the air compressor is faulty, and exit the durability test cycle in case of a fault. When the air compressor does not fail, the durability test cycle is repeated until the number of cycles is equal to the number of inflation cycles Z.

[0011] Furthermore, between step S1 and step S2, the following steps are further included:

[0012] Execute the preset self-test module. During the execution process, generate control commands, control the start and stop status of the air compressor and the water removal mechanism, and the opening and closing status of each exhaust solenoid valve through the control commands, exhaust and inflate the air tank, and obtain the detection value of each air pressure sensor during the exhaust and inflation process. According to the detection value, determine whether each air tank and water removal mechanism is normal, and when each air tank and water removal mechanism is in normal state, execute the preset pressure and rate test module.

[0013] Furthermore, the performance test parameters include: the number of pumping cycles Z and the rated power Pe, working efficiency value N, rated speed R0, working voltage U, and output current I0 corresponding to the rated power Pe of the air compressor.

[0014] Furthermore, the air compressor performance testing device also includes:

[0015] A high-voltage DC power supply connected to the mains is used to convert AC power into DC power and input it into the air compressor controller;

[0016] A touch screen connected to the system controller can display performance test information during the test.

[0017] The performance test gas circuit also includes a multi-circuit protection valve, and the water removal mechanism is connected to each gas storage tank through the multi-circuit protection valve.

[0018] Furthermore, the water removal mechanism includes:

[0019] A back-blowing tank, a buffer tank, and a dryer and a condenser that are in communication with the system controller; the back-blowing tank and the buffer tank are both provided with an air pressure sensor and an exhaust solenoid valve that are in communication with the system controller;

[0020] One end of the buffer tank is connected to the flow meter, and the other end is connected to the air inlet of the condenser; the air outlet of the condenser is connected to the air inlet of the dryer, the air outlet of the dryer is connected to the air inlet of the multi-circuit protection valve, and the air outlet of the multi-circuit protection valve is connected to the air storage tank in a one-to-one correspondence; the backflush tank is connected to the dryer.

[0021] Furthermore, the dehydration mechanism start-stop control command includes a condenser discharge control command K1 and a dryer start-stop control command K2; the system controller controls the discharge state of the condenser by generating and executing the condenser discharge control command K1, and controls the start-stop state of the dryer by generating and executing the dryer start-stop control command K2.

[0022] Furthermore, the real-time detection information includes the rotation speed, real-time current value, temperature of the air compressor, and detection values ​​of the flow meter and each air pressure sensor.

[0023] The present invention also proposes an air compressor performance testing device, comprising:

[0024] System controller;

[0025] The performance test air circuit includes: multiple air storage tanks, an air compressor, a flow meter and a water removal mechanism that are in communication with the system controller; the water removal mechanism and each air storage tank are provided with an air pressure sensor and an exhaust solenoid valve that are in communication with the system controller;

[0026] An air compressor controller and a test switch in communication with the system controller; wherein:

[0027] One end of the flow meter is connected to the air compressor, and the other end is connected to the water removal mechanism, and is used to detect the amount of gas pumped out by the air compressor;

[0028] The test switch is used to generate a switch signal;

[0029] The system controller is used to start or terminate the performance test of the air compressor according to the switch signal. During the performance test, the performance test parameters are initialized, and control commands for starting and stopping the air compressor, opening and closing the exhaust solenoid valve, and starting and stopping the water removal mechanism are generated and executed. Real-time detection information is obtained during the execution of the control commands, and performance test information is generated based on the real-time detection information and the performance test parameters.

[0030] The air compressor controller is used to control the start and stop state of the air compressor according to the air compressor start and stop control command;

[0031] The dehydration mechanism is used to remove moisture from the performance test gas path according to the start and stop control command of the dehydration mechanism and then input the moisture into each gas storage tank.

[0032] Furthermore, the air compressor performance testing device also includes:

[0033] A high-voltage DC power supply connected to the mains is used to convert AC power into DC power and input it into the air compressor controller;

[0034] A touch screen connected to the system controller can display performance test information during the test;

[0035] The performance test gas circuit also includes a multi-circuit protection valve, and the water removal mechanism is connected to each gas storage tank through the multi-circuit protection valve.

[0036] Furthermore, the water removal mechanism includes:

[0037] A back-blowing tank, a buffer tank, and a dryer and a condenser that are in communication with the system controller; the back-blowing tank and the buffer tank are both provided with an air pressure sensor and an exhaust solenoid valve that are in communication with the system controller;

[0038] One end of the buffer tank is connected to the flow meter, and the other end is connected to the air inlet of the condenser; the air outlet of the condenser is connected to the air inlet of the dryer, the air outlet of the dryer is connected to the air inlet of the multi-circuit protection valve, and the air outlet of the multi-circuit protection valve is connected to the air storage tank in a one-to-one correspondence; the backflush tank is connected to the dryer.

[0039] Compared with the prior art, the present invention has at least the following beneficial effects:

[0040] (1) The present invention starts the performance test of the air compressor through a real-time switch signal. During the test, after initializing the performance test parameters, the preset pressure and rate test module is executed to obtain the maximum inflation pressure and the inflation rate. At this time, the preset durability test module is executed again according to the on / off state of the real-time switch signal. During the execution of the preset durability test module, the remaining number of cycles is recorded according to the real-time detection information and the performance test parameters, and whether the air compressor fails is determined. The durability test cycle is exited in the event of a failure. When the air compressor does not fail, the durability test cycle is continuously repeated until the number of cycles is equal to the inflation cycle number Z. This realizes the testing of multiple performance indicators (maximum inflation pressure, inflation rate and remaining number of cycles) by an air compressor performance test device, which solves the problem that a single test device can only test a single item (a single performance indicator) and that multiple devices are required to test multiple performance indicators.

[0041] (2) In the process of executing the preset durability test module, the present invention enters the durability test cycle according to the number of inflation cycles Z included in the performance test parameters, and generates a control command during the cycle. The control command is used to control the start and stop status of the air compressor and the water removal mechanism, as well as the opening and closing status of each exhaust solenoid valve, so as to inflate or exhaust the gas tank, and obtain real-time detection information during the inflation and exhaust process. According to the real-time detection information and the performance test parameters, the remaining number of cycles is recorded, and whether the air compressor fails is determined. The durability test cycle is exited in the event of a failure. When the air compressor does not fail, the durability test cycle is repeated until the number of cycles is equal to the number of inflation cycles. The number of cycles Z, the present invention automatically controls the operation of the cycle according to the fault condition of the air compressor to obtain the remaining number of cycles (through the number of air pumping cycles Z-the remaining number of cycles=the actual number of cycles), and then obtains the durability of the air compressor through the actual number of cycles in the test process. The entire cycle process is automatically operated according to the number of air pumping cycles Z and the fault status of the air compressor, realizing fully automatic testing, avoiding the traditional manual or semi-automatic detection method that can only use the frequency converter to control the air compressor, either running all the time or stopping, and cannot simulate the state of the air compressor after being installed on the vehicle, and the durability test cannot be automatically tested according to the vehicle state after installation. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1The present invention is a flow chart of a performance test method for an air compressor;

[0043] Figure 2 This is a structural diagram of an air compressor performance testing device.

[0044] In the figure: 1. Gas storage tank 1; 2. Gas storage tank 2; 3. Gas storage tank 3; 4. Gas storage tank 4; 5. Exhaust solenoid valve; 6. Pressure relief valve; 7. Air pressure sensor; 8. Backflush tank; 9. System controller; 10. Test switch; 11. Touch screen; 12. High-voltage DC power supply; 13. Air compressor controller; 14. Air compressor; 15. Flow meter; 16. Buffer tank; 17. Condenser; 18. Dryer; 19. Four-circuit protection valve. DETAILED DESCRIPTION

[0045] The following are specific embodiments of the present invention and the accompanying drawings to further describe the technical solutions of the present invention, but the present invention is not limited to these embodiments.

[0046] Example 1

[0047] In order to solve the problem that a single test device can only test a single item (single performance indicator), and multiple devices are required to test multiple performance indicators, and the traditional manual or semi-automatic detection method can only use the frequency converter to control the air compressor, which is either running all the time or stopping, and cannot simulate the state of the air compressor after installation. The durability test cannot be automatically tested according to the vehicle state after installation. Figure 1 As shown, the present invention proposes a performance testing method for an air compressor, which is applied to an air compressor performance testing device, and the air compressor performance testing device includes:

[0048] System controller;

[0049] The performance test air circuit includes: multiple air storage tanks, an air compressor, a flow meter and a water removal mechanism that are in communication with the system controller; the water removal mechanism and each air storage tank are provided with an air pressure sensor and an exhaust solenoid valve that are in communication with the system controller;

[0050] An air compressor controller and a test switch in communication with the system controller; wherein:

[0051] One end of the flow meter is connected to the air compressor, and the other end is connected to the dewatering mechanism, so as to detect the amount of air pumped out by the air compressor; the test switch is used to generate a switch signal; the system controller is used to start or terminate the performance test of the air compressor according to the switch signal, and during the performance test, initialize the performance test parameters, generate and execute the control commands for starting and stopping the air compressor, opening and closing the exhaust solenoid valve, and starting and stopping the dewatering mechanism, obtain real-time detection information during the execution of the control commands, and generate performance test information based on the real-time detection information and the performance test parameters; the air compressor controller is used to control the start and stop state of the air compressor according to the air compressor start and stop control command; the dewatering mechanism is used to remove moisture in the performance test gas path according to the start and stop control command of the dewatering mechanism and then input the moisture into each gas storage tank;

[0052] The air compressor performance testing device also includes:

[0053] A high-voltage DC power supply connected to the mains (AC380V) is used to convert AC power into DC power and input it into the air compressor controller. Its main purpose is to simulate the battery power supply on the car (which outputs DC power) to simulate the power supply environment of the air compressor after installation. It should be noted that the air compressor controller is also used to convert DC power into AC power and input it into the air compressor.

[0054] A touch screen connected to the system controller can display performance test information during the test;

[0055] The performance test gas circuit also includes a multi-circuit protection valve (a four-circuit protection valve in this embodiment), and the water removal mechanism is connected to each gas storage tank through the multi-circuit protection valve.

[0056] In this embodiment, the system controller and the touch screen, and the system controller and the air compressor controller are connected via a CAN bus.

[0057] The water removal mechanism comprises:

[0058] A back-blowing tank, a buffer tank, and a dryer and a condenser that are in communication with the system controller; the back-blowing tank and the buffer tank are both provided with an air pressure sensor and an exhaust solenoid valve that are in communication with the system controller;

[0059] One end of the buffer tank is connected to the flow meter, and the other end is connected to the air inlet of the condenser; the air outlet of the condenser is connected to the air inlet of the dryer, the air outlet of the dryer is connected to the air inlet of the multi-circuit protection valve, and the air outlet of the multi-circuit protection valve is connected to the air storage tank in a one-to-one correspondence; the backflush tank is connected to the dryer; the buffer tank is mainly used to store water in the performance test gas circuit and discharge it;

[0060] In this embodiment, the blowback tank, buffer tank and each gas storage tank are provided with a pressure relief valve, which automatically opens when the pressure of the pressure relief valve is greater than 1.5 MPa to relieve the pressure of the corresponding components (i.e., the blowback tank, buffer tank and gas storage tank).

[0061] It should be noted that the dryer is mainly used to adsorb and dry the compressed air from the air compressor to prevent rusting of the performance test air path and to increase the service life of the air compressor performance test device.

[0062] When a car is running, the compressed air provided by the air compressor can have an exhaust temperature of over 120°C and contain impurities such as water vapor. If it is directly input into the brake control device without effective treatment, it will cause serious rust on the internal metal parts. Once the impurities adhere to the surface of the moving parts and cannot be discharged in time, it will seriously affect the sealing, usability and service life, and create a hidden danger to driving safety. The condenser can condense and precipitate the water vapor in the compressed air passing through the condenser, and flow it to the drain port of the condenser together with the impurities. Each time the car is braked, the drain port can automatically discharge the sewage. In the present invention, a dryer and a condenser are set in the air compressor performance test device, firstly to simulate the use state of the air compressor after installation to improve the accuracy of the performance test, and secondly to prevent the performance test air path from rusting and increase the service life of the air compressor performance test device.

[0063] The dewatering mechanism start and stop control commands include a condenser discharge control command K1 and a dryer start and stop control command K2; the system controller controls the discharge state of the condenser by generating and executing the condenser discharge control command K1, and controls the start and stop state of the dryer by generating and executing the dryer start and stop control command K2; in this embodiment, when K1=0, it indicates that the condenser is in the closed state, when K1=1, it indicates that the condenser is in the discharge state, when K2=0, it indicates that the dryer is in the stopped state, and when K2=1, it indicates that the dryer is in the started state.

[0064] The real-time detection information includes the speed R of the air compressor, the real-time current value I, the temperature Q, the blowback signal S, and the detection values ​​of the flow meter and each air pressure sensor.

[0065] The performance test parameters include: the number of air pumping cycles Z and the rated power Pe of the air compressor, the working efficiency value N, the rated speed R0, the working voltage U, and the output current I0 corresponding to the rated power Pe.

[0066] Where: I0=1000*Pe / 1.732 / U / N;

[0067] This embodiment illustrates an air compressor performance test device comprising four air tanks. The exhaust solenoid valves corresponding to air tanks 1, 2, 3, 4, the blowback tank, and the buffer tank are W1, W2, W3, W4, W5, and W6, respectively, and the real-time detection values ​​of the corresponding air pressure sensors are P1, P2, P3, P4, P5, and P6, respectively. When Wi = 0 (i = 1…6), the corresponding exhaust solenoid valve is closed; when Wi = 1, the corresponding exhaust solenoid valve is open.

[0068] In addition, in this embodiment, the back-blowing tank will automatically back-blow when the internal pressure of the dryer reaches a preset value. During back-blowing, the back-blowing signal S=1, and when not back-blowing, the back-blowing signal S=0.

[0069] The performance testing method includes:

[0070] S1: Obtain the real-time switch signal SW of the test switch and determine whether the real-time switch signal SW is equal to 1. If so, initialize the performance test parameters and proceed to the next step; if not, continue to determine whether the real-time switch signal SW is equal to 1. It should be noted that SW=1 indicates that the test switch is in the closed state;

[0071] The steps S1 and S2 also include:

[0072] S11: Execute the preset self-test module. During the execution process, generate control commands, control the start and stop status of the air compressor and the water removal mechanism, and the opening and closing status of each exhaust solenoid valve through the control commands, exhaust and inflate the gas tank, and obtain the detection value of each air pressure sensor during the exhaust and inflation process. According to the detection value, determine whether each gas tank and water removal mechanism is normal, and when each gas tank and water removal mechanism is in normal state, execute the preset pressure and rate test module.

[0073] It should be noted that whether each gas storage tank and water removal mechanism is normal is determined based on the test value. If not, the performance test is terminated.

[0074] In this embodiment, the preset self-test module includes:

[0075] S111: Generate and execute control commands: X=0, K1=1, W1=1, W2=1, W3=1, W4=1, W5=1, W6=1, K2=0, so that the air compressor performance test device enters the exhaust state;

[0076] S112: Delay for a preset time (2 minutes in this embodiment);

[0077] S113: Determine whether P1 is less than 10 (a preset value). If so, the touch screen displays: "Gas tank 1 is normal" and sets the intermediate variable W1'=1, and proceeds to the next step. If not, the touch screen displays: "Gas tank 1 is faulty" and sets the intermediate variable W1'=0, and proceeds to the next step.

[0078] S114: Determine whether P2 is less than 10 (a preset value). If so, the touch screen displays: "Gas tank 2 is normal" and sets the intermediate variable W2'=1, and proceeds to the next step. If not, the touch screen displays: "Gas tank 2 is faulty" and sets the intermediate variable W2'=0, and proceeds to the next step.

[0079] S115: Determine whether P3 is less than 10 (a preset value). If so, the touch screen displays: "Gas tank 3 is normal" and sets the intermediate variable W3'=1, and proceeds to the next step. If not, the touch screen displays: "Gas tank 3 is faulty" and sets the intermediate variable W3'=0, and proceeds to the next step.

[0080] S116: Determine whether P4 is less than 10 (a preset value). If so, the touch screen displays: "Gas tank 4 is normal" and sets the intermediate variable W4'=1, and proceeds to the next step. If not, the touch screen displays: "Gas tank 4 is faulty" and sets the intermediate variable W4'=0, and proceeds to the next step.

[0081] S117: Determine whether P5 is less than 10 (a preset value). If so, the touch screen displays: "Backflush tank is normal", and sets the intermediate variable W5'=1, and proceeds to the next step; if not, the touch screen displays: "Backflush tank is faulty", and sets the intermediate variable W5'=0, and proceeds to the next step;

[0082] S118: Determine whether P6 is less than 10 (a preset value). If so, the touch screen displays: "Buffer tank is normal" and sets the intermediate variable W6'=1, and proceeds to the next step. If not, the touch screen displays: "Buffer tank is faulty" and sets the intermediate variable W6'=0, and proceeds to the next step.

[0083] S119: Determine W1 ′ &W2 ′ &W3 ′ &W4 ′ &W5 ′ &W6 ′ Is it equal to 1? If so, generate and execute the control command: X=1, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=1, so that the air compressor performance test device enters the pumping state and proceeds to the next step; if not, proceed to step S129;

[0084] S120: Determine whether the real-time switch signal SW is equal to 1. If so, delay for a preset time (1 minute in this embodiment) and proceed to the next step; if not, proceed to step S128;

[0085] S121: Determine whether P1 is greater than 10 (a preset value). If so, the touch screen displays: Gas tank 1 is normal, and sets the intermediate variable W1'=1, and proceeds to the next step. If not, the touch screen displays: Gas tank 1 is faulty, and sets the intermediate variable W1'=0, and proceeds to the next step.

[0086] S122: Determine whether P2 is greater than 10 (a preset value). If so, the touch screen displays: "Gas tank 2 is normal" and sets the intermediate variable W2'=1, and proceeds to the next step. If not, the touch screen displays: "Gas tank 2 is faulty" and sets the intermediate variable W2'=0, and proceeds to the next step.

[0087] S123: Determine whether P3 is greater than 10 (a preset value). If so, the touch screen displays: "Gas tank 3 is normal" and sets the intermediate variable W3'=1, and proceeds to the next step. If not, the touch screen displays: "Gas tank 3 is faulty" and sets the intermediate variable W3'=0, and proceeds to the next step.

[0088] S124: Determine whether P4 is greater than 10 (a preset value). If so, the touch screen displays: "Gas tank 4 is normal" and sets the intermediate variable W4'=1, and proceeds to the next step. If not, the touch screen displays: "Gas tank 4 is faulty" and sets the intermediate variable W4'=0, and proceeds to the next step.

[0089] S125: Determine whether P5 is greater than 10 (a preset value). If so, the touch screen displays: "Backflush tank is normal", and sets the intermediate variable W5'=1, and proceeds to the next step; if not, the touch screen displays: "Backflush tank is faulty", and sets the intermediate variable W5'=0, and proceeds to the next step;

[0090] S126: Determine whether P6 is greater than 10 (a preset value). If so, the touch screen displays: "Buffer tank is normal" and sets the intermediate variable W6'=1, and proceeds to the next step. If not, the touch screen displays: "Buffer tank is faulty" and sets the intermediate variable W6'=0, and proceeds to the next step.

[0091] S127: Determine W1 ′ &W2 ′ &W3 ′ &W4 ′ &W5 ′ &W6 ′ Is it equal to 1? If so, go to step S128; if not, go to step S129;

[0092] S128: Generate and execute the control command: X=0, K1=1, W1=1, W2=1, W3=1, W4=1, W5=1, W6=1, K2=0, so that the air compressor performance test device enters the exhaust state; after a preset delay time (1 minute in this embodiment), generate and execute the control command: X=0, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=0, and display on the touch screen: system self-test is normal; end;

[0093] S129: Generate and execute the control command: X=0, K1=1, W1=1, W2=1, W3=1, W4=1, W5=1, W6=1, K2=0, so that the air compressor performance test device enters the exhaust state; after a preset delay time (1 minute in this embodiment), generate and execute the control command: X=0, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=0, and display on the touch screen: system self-test is abnormal; end.

[0094] S2: Execute the preset pressure and rate test module, generate control commands during the execution process, control the start and stop status of the air compressor and water removal mechanism, and the opening and closing status of each exhaust solenoid valve through the control commands, so as to inflate or exhaust the gas tank, and obtain real-time detection information during the inflation process, obtain the maximum inflation pressure and inflation rate based on the real-time detection information and performance test parameters, and determine whether the real-time switch signal is equal to 1. If so, proceed to the next step, if not, end the performance test.

[0095] In this embodiment, the preset pressure and rate test module includes:

[0096] S211: Generate and execute the control command: X=1, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=1, so that the air compressor performance test device enters the pumping state;

[0097] S212: After a delay of 10 seconds (preset value), set the initial time t0 = t and the initial gas volume value L0 = L, where t is the current time and L is the gas volume value currently read by the flow meter;

[0098] S213: Set intermediate variables:

[0099] P0=(P1+P2+P3+P4) / 4, P=MAX(P1,P2,P3,P4), and proceed to the next step;

[0100] S214: Determine whether R0-100≤R≤R0+100 is established. If so, proceed to the next step; if not, proceed to step S223;

[0101] S215: Determine whether I≤2*I0 is established. If so, proceed to the next step; if not, proceed to step S223;

[0102] S216: Determine whether Q≤Qmax is established. If so, proceed to the next step; wherein Qmax is a preset temperature threshold; if not, proceed to step S223;

[0103] S217: Determine whether the real-time switch signal SW is equal to 1. If so, after a preset delay time (10 seconds in this embodiment), set the intermediate variable: P0'=(P1+P2+P3+P4) / 4; P=MAX(P1, P2, P3, P4); if not, proceed to step S221;

[0104] S218: Determine whether P≥Pmax is established. If not, proceed to the next step; wherein Pmax is a preset pressure threshold. If so, proceed to step S220;

[0105] S219: Determine whether P0'-P0≥10 is true. If so, return to step S213; if not, proceed to the next step;

[0106] S220: Set the end time t1 = t, and the final gas volume L1 = L; where t is the current time, and L is the gas volume value currently read by the flow meter; set the intermediate variables: t2 = t1 - t0; L2 = L1 - L0; obtain the following through the intermediate variables:

[0107] The inflation rate K = L2*60 / t2, the maximum inflation pressure P = MAX(P1, P2, P3, P4); wherein the value 60 represents 60 seconds;

[0108] S221: Generate and execute the control command: X=0, K1=1, W1=1, W2=1, W3=1, W4=1, W5=1, W6=1, K2=0, so that the air compressor performance test device enters the exhaust state;

[0109] S222: After a preset delay time (1 minute), the control command is generated and executed: X=0, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=0, and the values ​​of the inflation rate K and the maximum inflation pressure P are displayed on the touch screen; end;

[0110] S223: Generate and execute the control command: X=0, K1=1, W1=1, W2=1, W3=1, W4=1, W5=1, W6=1, K2=0, so that the air compressor performance test device enters the exhaust state; after a preset delay time (1 minute), generate and execute the control command: X=0, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=0, and display on the touch screen: system abnormality; end;

[0111] S3: Execute the preset durability test module; the preset durability test module includes a durability test cycle; and in the process of executing the preset durability test module, enter the durability test cycle according to the number of inflation cycles Z included in the performance test parameters, and generate a control command during the cycle, and control the start and stop status of the air compressor and the water removal mechanism, as well as the opening and closing status of each exhaust solenoid valve through the control command to inflate or exhaust the air tank, and obtain real-time detection information during the inflation and exhaust process, record the remaining number of cycles according to the real-time detection information and the performance test parameters, determine whether the air compressor is faulty, and exit the durability test cycle in case of a fault. When the air compressor does not fail, the durability test cycle is repeated until the number of cycles is equal to the number of inflation cycles Z, and the performance test is ended.

[0112] In this embodiment, the preset pressure and rate test module includes:

[0113] S311: Generate and execute control commands: X=0, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=0;

[0114] S312: Determine whether the number of inflation cycles Z is equal to 0. If not, set the intermediate variable (remaining number) Z0=Z; PX=Pmax; where Pmax is the preset pressure threshold; proceed to the next step; if yes, proceed to step S323;

[0115] S313: Generate and execute the control command: X=1, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=1, so that the air compressor performance test device enters the pumping state;

[0116] S314: Set the intermediate variable PL = MAX(P1, P2, P3, P4) and proceed to the next step;

[0117] S315: Determine whether R0-100≤R≤R0+100 is established. If so, proceed to the next step; if not, proceed to step S324;

[0118] S316: Determine whether I≤2*I0 is true. If so, proceed to the next step; if not, proceed to step S324;

[0119] S317: Determine whether Q≤Qmax is established. If so, proceed to the next step; wherein Qmax is a preset temperature threshold; if not, proceed to step S324;

[0120] S318: Determine whether the real-time switch signal SW is equal to 1. If so, proceed to the next step; if not, proceed to step S324;

[0121] S319: Determine whether ((PL≥PX)|(S==1))=1 is established. If so, proceed to the next step; wherein: S is the backflush signal; if not, return to step S313;

[0122] S320: Generate and execute the control command: X=0, K1=1, W1=1, W2=1, W3=1, W4=1, W5=1, W6=1, K2=0, so that the air compressor performance test device enters the exhaust state;

[0123] S321: Determine whether P1+P2+P3+P4<40. If not, return to step S320. If so, set Z0=Z0-1 to obtain the remaining number Z0 (i.e., the remaining number of cycles), and display it on the touch screen:

[0124] Required test times: number of inflation cycles Z;

[0125] Remaining times: Z0;

[0126] S322: Determine whether Z0≤0 holds. If not, return to step S313; if so, proceed to the next step.

[0127] S323: Generate and execute control commands: X=0, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=0; and display on the touch screen:

[0128] Testing completed;

[0129] Required test times: number of inflation cycles Z;

[0130] Remaining times: Z0; End;

[0131] S324: Generate and execute the control command: X=0, K1=1, W1=1, W2=1, W3=1, W4=1, W5=1, W6=1, K2=0, so that the air compressor performance test device enters the exhaust state; after a preset delay time (1 minute), generate and execute the control command: X=0, K1=0, W1=0, W2=0, W3=0, W4=0, W5=0, W6=0, K2=0, and display on the touch screen:

[0132] Test exceptions;

[0133] Required number of tests: number of inflation cycles Z;

[0134] Remaining times: Z0; End;

[0135] The present invention starts the performance test of the air compressor through a real-time switch signal. During the test, after initializing the performance test parameters, the preset pressure and rate test module is executed to obtain the maximum inflation pressure and the inflation rate. At this time, the preset durability test module is executed again according to the on-off state of the real-time switch signal. In the process of executing the preset durability test module, the remaining number of cycles is recorded according to the real-time detection information and the performance test parameters, and it is determined whether the air compressor is faulty. The durability test cycle is exited in case of a fault. When the air compressor does not fail, the durability test cycle is continuously repeated until the number of cycles is equal to the inflation cycle number Z. It realizes the testing of multiple performance indicators (maximum inflation pressure, inflation rate and remaining number of cycles) through an air compressor performance test device, which solves the problem that a single test device can only test a single item (a single performance indicator) and that multiple devices are required to test multiple performance indicators.

[0136] In addition, in the process of executing the preset durability test module, the present invention enters the durability test cycle according to the number of inflation cycles Z included in the performance test parameters, and generates a control command during the cycle, and controls the start and stop status of the air compressor and the water removal mechanism, as well as the opening and closing status of each exhaust solenoid valve through the control command to inflate or exhaust the gas tank, and obtains real-time detection information during the inflation and exhaust process, records the remaining number of cycles according to the real-time detection information and the performance test parameters, determines whether the air compressor is faulty, and exits the durability test cycle in case of a fault. When the air compressor does not fail, the durability test cycle is repeated until the number of cycles is equal to the inflation cycle. The number of cycles Z, the present invention automatically controls the operation of the cycle according to the fault condition of the air compressor to obtain the remaining number of cycles (through the number of air pumping cycles Z-the remaining number of cycles=the actual number of cycles), and then obtains the durability of the air compressor through the actual number of cycles in the test process. The entire cycle process is automatically operated according to the number of air pumping cycles Z and the fault status of the air compressor, realizing fully automatic testing, avoiding the traditional manual or semi-automatic detection method that can only use the frequency converter to control the air compressor, either running all the time or stopping, and cannot simulate the state of the air compressor after being installed on the vehicle, and the durability test cannot be automatically tested according to the vehicle state after installation.

[0137] Example 2

[0138] like Figure 2 As shown, the present invention also proposes an air compressor performance testing device, comprising:

[0139] System controller 9;

[0140] The performance test air circuit includes: multiple air storage tanks, an air compressor 14, a flow meter 15 and a water removal mechanism that are in communication with the system controller 9; the water removal mechanism and each air storage tank are provided with an air pressure sensor 7 and an exhaust solenoid valve 5 that are in communication with the system controller 9;

[0141] The air compressor controller 13 and the test switch 10 are in communication with the system controller 9; wherein:

[0142] One end of the flow meter 15 is connected to the air compressor 14, and the other end is connected to the water removal mechanism, and is used to detect the amount of gas pumped out by the air compressor 14;

[0143] The test switch 10 is used to generate a switch signal;

[0144] The system controller 9 is used to start or terminate the performance test of the air compressor according to the switch signal. During the performance test, it initializes the performance test parameters, generates and executes the control commands for starting and stopping the air compressor, opening and closing the exhaust solenoid valve, and starting and stopping the water removal mechanism, obtains real-time detection information during the execution of the control commands, and generates performance test information based on the real-time detection information and the performance test parameters;

[0145] The air compressor controller 13 is used to control the start and stop status of the air compressor 14 according to the air compressor start and stop control command;

[0146] The dehydration mechanism is used to remove moisture from the performance test gas path according to the start and stop control command of the dehydration mechanism and then input the moisture into each gas storage tank.

[0147] The air compressor performance testing device also includes:

[0148] A high-voltage DC power supply 12 connected to the mains is used to convert AC power into DC power and input it into the air compressor controller 13;

[0149] The touch screen 11 in communication with the system controller 9 can display performance test information during the test.

[0150] The performance test gas circuit also includes a multi-circuit protection valve, and the water removal mechanism is connected to each gas storage tank through the multi-circuit protection valve.

[0151] The water removal mechanism comprises:

[0152] The back-blowing tank 8, the buffer tank 16, and the dryer 18 and the condenser 17 which are in communication with the system controller 9; the back-blowing tank 8 and the buffer tank 16 are both provided with an air pressure sensor 7 and an exhaust solenoid valve 5 which are in communication with the system controller 9;

[0153] One end of the buffer tank 16 is connected to the flowmeter 15, and the other end is connected to the air inlet of the condenser 17; the air outlet of the condenser 17 is connected to the air inlet of the dryer 18, and the air outlet of the dryer 18 is connected to the air inlet of the multi-circuit protection valve, and the air outlet of the multi-circuit protection valve is connected to the air storage tank in a one-to-one correspondence; the back-blowing tank 8 is connected to the dryer 18.

[0154] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement status, etc. between the various components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0155] In addition, in the present invention, descriptions such as "first," "second," and "one" are for descriptive purposes only and should not be understood to indicate or imply their relative importance or implicitly specify the number of the technical features indicated. Therefore, a feature specified as "first" or "second" may explicitly or implicitly include at least one of such features. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0156] In the present invention, unless otherwise specified or limited, the terms "connection" and "fixation" should be understood in a broad sense. For example, "fixation" can mean fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. Those skilled in the art will be able to understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0157] In addition, the technical solutions between the various embodiments of the present invention can be combined with each other, but it must be based on the fact that ordinary technicians in this field can implement it. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

Claims

1. A performance testing method for an air compressor, applied to an air compressor performance testing device, the air compressor performance testing device comprising: System controller; The performance test air circuit includes: multiple air storage tanks, an air compressor, a flow meter and a water removal mechanism that are in communication with the system controller; the water removal mechanism and each air storage tank are provided with an air pressure sensor and an exhaust solenoid valve that are in communication with the system controller; An air compressor controller and a test switch in communication with the system controller; wherein: One end of the flow meter is connected to the air compressor, and the other end is connected to the dewatering mechanism, so as to detect the amount of gas pumped out by the air compressor; the test switch is used to generate a switch signal; the system controller is used to start or terminate the performance test of the air compressor according to the switch signal, and during the performance test, initialize the performance test parameters, generate and execute the control commands for starting and stopping the air compressor, opening and closing the exhaust solenoid valve, and starting and stopping the dewatering mechanism, obtain real-time detection information during the execution of the control commands, and generate performance test information based on the real-time detection information and the performance test parameters; the air compressor controller is used to control the start and stop state of the air compressor according to the start and stop control commands of the air compressor; the dewatering mechanism is used to remove moisture in the performance test gas path according to the start and stop control commands of the dewatering mechanism and then input it into each gas storage tank; it is characterized in that the performance testing method comprises: S1: Obtain the real-time switch signal of the test switch, determine whether the real-time switch signal is equal to 1, and if so, initialize the performance test parameters and proceed to the next step; S2: Execute the preset pressure and rate test module, generate control commands during the execution process, control the start and stop status of the air compressor and water removal mechanism, and the opening and closing status of each exhaust solenoid valve through the control commands, so as to inflate or exhaust the gas tank, and obtain real-time detection information during the inflation process. According to the real-time detection information and performance test parameters, the maximum inflation pressure and inflation rate are obtained, and it is determined whether the real-time switch signal is equal to 1. If so, proceed to the next step; S3: Execute the preset durability test module; the preset durability test module includes a durability test cycle; and in the process of executing the preset durability test module, enter the durability test cycle according to the number of inflation cycles Z included in the performance test parameters, and generate a control command during the cycle, and control the start and stop status of the air compressor and the water removal mechanism, as well as the opening and closing status of each exhaust solenoid valve through the control command to inflate or exhaust the air tank, and obtain real-time detection information during the inflation and exhaust process, record the remaining number of cycles according to the real-time detection information and the performance test parameters, determine whether the air compressor is faulty, and exit the durability test cycle in case of a fault. When the air compressor does not fail, the durability test cycle is repeated until the number of cycles is equal to the number of inflation cycles Z.

2. A performance testing method for an air compressor according to claim 1, characterized in that: The steps S1 and S2 also include: Execute the preset self-test module. During the execution process, generate control commands, control the start and stop status of the air compressor and the water removal mechanism, and the opening and closing status of each exhaust solenoid valve through the control commands, exhaust and inflate the air tank, and obtain the detection value of each air pressure sensor during the exhaust and inflation process. According to the detection value, determine whether each air tank and water removal mechanism is normal, and when each air tank and water removal mechanism is in normal state, execute the preset pressure and rate test module.

3. A performance testing method for an air compressor according to claim 2, characterized in that: The performance test parameters include: the number of air pumping cycles Z and the rated power Pe of the air compressor, the working efficiency value N, the rated speed R0, the working voltage U, and the output current I0 corresponding to the rated power Pe.

4. A performance testing method for an air compressor according to claim 3, characterized in that: The air compressor performance testing device also includes: A high-voltage DC power supply connected to the mains is used to convert AC power into DC power and input it into the air compressor controller; A touch screen connected to the system controller can display performance test information during the test; The performance test gas circuit also includes a multi-circuit protection valve, and the water removal mechanism is connected to each gas storage tank through the multi-circuit protection valve.

5. A performance testing method for an air compressor according to claim 4, characterized in that: The water removal mechanism comprises: A back-blowing tank, a buffer tank, and a dryer and a condenser that are in communication with the system controller; the back-blowing tank and the buffer tank are both provided with an air pressure sensor and an exhaust solenoid valve that are in communication with the system controller; One end of the buffer tank is connected to the flow meter, and the other end is connected to the air inlet of the condenser; the air outlet of the condenser is connected to the air inlet of the dryer, the air outlet of the dryer is connected to the air inlet of the multi-circuit protection valve, and the air outlet of the multi-circuit protection valve is connected to the air storage tank in a one-to-one correspondence; the backflush tank is connected to the dryer.

6. A performance testing method for an air compressor according to claim 5, characterized in that: The dewatering mechanism start and stop control commands include a condenser discharge control command K1 and a dryer start and stop control command K2; The system controller controls the discharge state of the condenser by generating and executing the condenser discharge control command K1, and controls the start and stop state of the dryer by generating and executing the dryer start and stop control command K2.

7. A performance testing method for an air compressor according to any one of claims 1 to 6, characterized in that: The real-time detection information includes the rotation speed, real-time current value, temperature of the air compressor, and detection values ​​of the flow meter and each air pressure sensor.

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