Assembly test process for solenoid valve

Abstract

The present application relates to electromagnetic valve quality inspection field, disclose a kind of assembly test process of electromagnetic valve, comprising: step one, the parts of electromagnetic valve are assembled, the first cleaning of the parts obtained by assembling is carried out and the pre-installation of the parts with cooperation relationship is carried out;Step two, the function detection of the parts is carried out, and the electromagnetic valve is assembled after function detection is completed;Step three, the preliminary inspection of the electromagnetic valve completed assembly is carried out, and the first storage of the electromagnetic valve qualified in preliminary inspection is carried out;Step four, the reliability detection of the electromagnetic valve stored for the first time is carried out;Wherein, step one to step three carry out full inspection to product, and step four carries out sampling inspection according to sampling rate to the product stored in step three;The pre-installation includes the action test capable of detecting the cooperation precision of parts.The assembly test process of the electromagnetic valve can detect the cooperation precision of the electromagnetic valve before the electromagnetic valve is assembled, and the product qualified rate is improved.

Description

Technical Field

[0001] This invention relates to the field of solenoid valve quality inspection, and more specifically to an assembly and testing process for solenoid valves. Background Technology

[0002] Solenoid valves used in certain fields require high consistency and reliability; therefore, these valves undergo rigorous quality testing after assembly. In actual production, the solenoid valves are typically assembled after the components have passed quality inspection, and then the assembled product undergoes quality testing.

[0003] However, the quality of the components does not guarantee that the fitting accuracy between the components will meet the requirements. If the fitting accuracy is not up to standard, the airtightness and operation test of the assembled solenoid valve will be unqualified. Therefore, the product qualification rate is low when the quality inspection is carried out after the solenoid valve is assembled. Summary of the Invention

[0004] To overcome the problem of low product qualification rate of solenoid valves in the existing technology, the present invention provides an assembly and testing process for solenoid valves. This assembly and testing process can detect the fitting accuracy of the solenoid valves before assembly, thereby improving the product qualification rate.

[0005] To achieve the above objectives, the present invention provides an assembly and testing process for a solenoid valve, the assembly and testing process for the solenoid valve comprising:

[0006] Step 1: Assemble the components of the solenoid valve, perform a first cleaning on the assembled components, and pre-install the components that have a mating relationship.

[0007] Step 2: Perform functional testing on the components, and assemble the solenoid valve after the functional testing is completed;

[0008] Step 3: Perform a preliminary inspection on the assembled solenoid valves, and store the solenoid valves that pass the preliminary inspection for the first time.

[0009] Step 4: Perform a reliability test on the solenoid valve stored for the first time;

[0010] In this process, steps one through three involve full inspection of the products, and step four involves random inspection of the products stored in step three according to the sampling rate.

[0011] The pre-installation includes motion tests that can detect the fitting accuracy of components.

[0012] Preferably, the assembly in step one includes all components collected according to the component list of the solenoid valve;

[0013] Said first cleaning comprises cleaning and deburring all parts obtained by assembling;

[0014] Said cleaning of parts comprises cleaning of metal parts and cleaning of non-metal parts;

[0015] Preferably, the cleaning of said metal parts is: placing said metal parts in an ultrasonic cleaning machine using a water-based solution cleaning agent to clean to remove oil stains, then rinsing with water, then rinsing said metal parts with anhydrous ethanol to displace water on the surfaces of said metal parts, and finally blow-drying said metal parts with compressed air or nitrogen;

[0016] Preferably, the cleaning of said non-metal parts is: placing said non-metal parts in an ultrasonic cleaning machine using anhydrous ethanol for cleaning, then blow-drying said non-metal parts with compressed air or nitrogen;

[0017] Preferably, said deburring of parts comprises observing and removing dirt, impurities, burrs and sharp corners on said parts;

[0018] Preferably, after completing the deburring work on said parts, said parts are cleaned and dried again.

[0019] Preferably, the pre-installation in step 1 sequentially comprises thread pre-assembly, sealing ring inspection and said action test, wherein,

[0020] Said thread pre-assembly mainly comprises the following steps: shielding positions that are not connected by threads, then pre-tightening each threaded connection, then disassembling the tightened threads and cleaning and drying the parts;

[0021] Said sealing ring inspection comprises the following steps: first rejecting defective products with obvious protrusions or depressions on the inner and outer parting surfaces; then checking the rest of the surface quality of the sealing rings, rejecting said sealing rings with indentations, scratches and rust spots on the surfaces that affect the sealing performance, and the remaining said sealing rings are qualified;

[0022] Before said action test, all parts need to be cleaned and dried, then the spring is loaded into the spring mounting hole of the coil assembly to carry out said action test;

[0023] Preferably, said action test comprises:

[0024] First, gently stir the spring with tweezers, tilt the assembly by 45°, and it is qualified if the valve core moves without jamming;

[0025] Then, load the spring into the spring mounting hole of the valve core, gently stir the spring with tweezers, tilt the assembly by 45°, and it is qualified if the valve core moves without jamming;

[0026] Finally, without assembling the spring, load the valve core into the inner cavity of the coil assembly, block the outlet with the valve seat, and conduct a movement flexibility inspection: tilt the axis of the solenoid valve housing by 45°, and it is qualified if the valve core can slide freely under its own weight without jamming.

[0027] Preferably, before said functional detection, it is necessary to first connect said solenoid valve to the inlet and outlet connectors of the detection equipment, assemble the sealing ring, and connect the power supply;

[0028] Said functional detection comprises a first margin detection and a first response characteristic detection;

[0029] After said functional detection is completed, the qualified solenoid valve is welded to complete the assembly of said solenoid valve.

[0030] Preferably, said first margin detection comprises measurement of the loaded pull-in voltage U1, loaded drop-out current I1, no-load pull-in voltage U2 and no-load drop-out current I2 of the solenoid valve;

[0031] First, measure said loaded pull-in voltage U1: during measurement, first input detection gas into the inlet of the detection equipment, slowly increase the voltage until the valve opens, record the voltage value at this time as said loaded pull-in voltage U1, repeat the measurement for N1 times, where N1 is not less than 3;

[0032] Compare said loaded pull-in voltage U1 obtained from N1 measurements with the designed loaded pull-in voltage, and it is qualified if said loaded pull-in voltage U1 is not higher than said designed loaded pull-in voltage;

[0033] it is qualified if the deviation between the loaded pull-in voltage U1 obtained from N1 measurements and the designed loaded pull-in voltage is not more than ±1V (it is preferable to state the design deviation here);

[0034] Subsequently, measure said loaded drop-out current I1: during measurement, keep the gas input to the detection equipment, increase the voltage across the solenoid valve to the designed maximum load voltage, then slowly reduce the voltage across the solenoid valve until the valve core is completely released, record the current value at this time as said loaded drop-out current I1, repeat the measurement for N2 times, where N2 is not less than 3;

[0035] Compare said loaded drop-out current I1 obtained from N2 measurements with the designed loaded drop-out current, and it is qualified if said loaded drop-out current I1 is not higher than said designed loaded drop-out current;

[0036] it is qualified if the deviation between the loaded drop-out current I1 obtained from N2 measurements and the designed loaded drop-out current is not more than 10mA (it is preferable to state the design deviation here);

[0037] Next, measure the no-load pull-in voltage U2. During the measurement, stop inputting gas into the detection device, slowly increase the voltage until the valve opens, and record the voltage value at this time as the no-load pull-in voltage U2. Repeat this process N3 times, where N3 is not less than 3.

[0038] The measured no-load pull-in voltage U2 is compared with the designed no-load pull-in voltage. If the no-load pull-in voltage is not higher than the designed no-load pull-in voltage, it is considered qualified.

[0039] The deviation between the no-load pull-in voltage U2 value obtained from N3 measurements and the designed no-load pull-in voltage value is no greater than ±1V (it is best to write the design deviation here) to be considered qualified;

[0040] Finally, measure the no-load release current I2. When measuring, first increase the voltage across the solenoid valve to the designed maximum load voltage, and then slowly decrease the voltage until the valve is fully released. Record the current value at this time as the no-load release current I2. Repeat this process N4 times, where N4 is not less than 3.

[0041] The measured no-load release current I2 is compared with the designed no-load release current. If the no-load release current I2 is not higher than the designed no-load release current, it is considered qualified.

[0042] The deviation between the no-load discharge current I2 value obtained from N4 measurements and the designed no-load discharge current value is no greater than 10mA (it is best to write the design deviation here) to be considered qualified.

[0043] Preferably, the detection gas is nitrogen, and the pressure of the detection gas is 3-4 MPa;

[0044] Preferably, N1 = N2 = N3 = N4.

[0045] Preferably, after the first margin test is completed, the solenoid valves that pass the first margin test are subjected to the first response characteristic test.

[0046] First, connect the solenoid valve to its rated voltage and check the response characteristics of the solenoid valve in two states: when the detection gas is connected and when the detection gas is not connected. Compare the measured results with the design requirements. If the design requirements are met, the valve is considered qualified.

[0047] Subsequently, the minimum voltage for the solenoid valve to be connected for testing was applied, and the response characteristics of the solenoid valve were checked in two states: when the detection gas was connected and when the detection gas was not connected. The measured results were compared with the design requirements, and the valve was considered qualified if it met the design requirements.

[0048] Finally, the highest voltage for the solenoid valve connection test is applied to check the response characteristics of the solenoid valve under two states: when the detection gas is connected and when the detection gas is not connected. The measured results are then compared with the design requirements. If the design requirements are met, the valve is considered qualified.

[0049] Preferably, after the first response characteristic test is completed, the solenoid valve that has passed the response characteristic test is welded.

[0050] Preferably, the initial inspection includes, in sequence, a first bubble detection, a helium mass spectrometry leak detection, a stroke check, an electrical interface check, an insulation resistance test, a dielectric strength test, a second margin test, a second response characteristic test, a second bubble detection, and a weight test;

[0051] Before the first storage, the solenoid valve that has passed all test items needs to be cleaned a third time.

[0052] Preferably, the third cleaning involves manually cleaning the outside of the solenoid valve with a brush dipped in alcohol and then drying it with nitrogen gas.

[0053] Preferably, the solenoid valve is stored in a nitrogen cabinet.

[0054] Preferably, after the solenoid valve is welded, the first bubble detection is performed, which includes:

[0055] First, block the outlet of the solenoid valve, introduce the detection gas into the inlet of the solenoid valve, and immerse the solenoid valve in the test liquid. Visually inspect the airtightness of the solenoid valve.

[0056] The visual inspection includes visually inspecting whether bubbles are emerging from the outlet of the solenoid valve, the diameter of the bubbles, and counting the number of bubbles emerging.

[0057] If the bubble diameter is no greater than 1 mm and the leakage frequency is no greater than 1 bubble / min, then it is qualified.

[0058] Preferably, the test liquid is purified water or anhydrous ethanol;

[0059] Preferably, the visual inspection time is not less than 1 minute.

[0060] Preferably, the solenoid valves in the nitrogen cabinet are randomly selected according to the sampling rate for the reliability test;

[0061] The reliability testing includes, in sequence: humidity test, random vibration test, first appearance inspection, second bubble inspection, third response characteristic test, sinusoidal vibration test, third bubble inspection, fourth response characteristic test, impact test, fourth bubble inspection, fifth response characteristic test, and life test.

[0062] The solenoid valves that pass the reliability test undergo a final visual inspection and are then stored a second time.

[0063] The humidity test measures the insulation resistance and dielectric strength of the solenoid valve; it includes: first, installing protective components at the inlet and outlet of the solenoid valve, and then placing the solenoid valve into a humidity chamber for testing;

[0064] The insulation resistance is not less than 10MΩ to be considered qualified;

[0065] When AC power is supplied to the pins of the electrical connector and the housing of the solenoid valve, the solenoid valve is not damaged, does not generate arcing, or the voltmeter pointer does not swing significantly, and the dielectric strength of the solenoid valve is qualified.

[0066] Preferably, the relative humidity of the humidity chamber is 95% ± 5%; the temperature is 40 ± 3℃.

[0067] Preferably, the solenoid valve is kept warm for 48 hours before the humidity test is conducted;

[0068] Preferably, the AC power supply is a 50Hz sine wave with a voltage of not less than 200V and a power of not less than 0.5kW;

[0069] Preferably, the measuring wires must be sealed, well-insulated, and led out of the box to allow for inspection of the valve resistance and appearance;

[0070] Preferably, the second bubble detection and the third bubble detection are the same as the first bubble detection;

[0071] Preferably, the second response characteristic detection and the third response characteristic detection are the same as the first response characteristic detection;

[0072] The life test includes repeatedly opening and closing the solenoid valve N5 times. The solenoid valve is considered qualified if it does not jam during the test. Each time the solenoid valve opens and closes is counted as one operation.

[0073] Preferably, N5 is not less than 3.6 × 10³;

[0074] Preferably, the life test further includes process bubble detection and process response characteristic detection. When N5 equals the design value, the process bubble detection and process response characteristic detection are performed on the solenoid valve.

[0075] Preferably, the process bubble detection is the same as the first bubble detection, and the process response characteristic detection is the same as the first response characteristic detection;

[0076] Preferably, the design value is set to a plurality of values, and the plurality of design values ​​are evenly distributed within the numerical range of N5;

[0077] Preferably, the second storage includes storing the packaged solenoid valve on a shelf in the cleanroom.

[0078] According to the above technical solution, before assembling the solenoid valve, it is necessary to first complete the solenoid valve's operation test to evaluate whether the fitting accuracy between the various mating parts of the solenoid valve meets the requirements. If the solenoid valve fails the operation test, these solenoid valve parts will not be assembled. Instead, the problematic parts will be repaired directly. After the repair is completed, the operation test will be conducted again. If the operation test is qualified at this time, these parts can be assembled. If they are still unqualified, the parts will continue to be repaired.

[0079] This method allows for the early detection of assembly precision issues in solenoid valve components, avoiding rework after assembly, reducing the difficulty of solenoid valve maintenance, and improving the solenoid valve's pass rate. Detailed Implementation

[0080] In this invention, unless otherwise stated, directional terms such as "away from," "up," "down," "side," and "both ends" generally refer to the orientation of the term in its conventional use or are common terms understood by those skilled in the art, and should not be regarded as limitations on the term.

[0081] An assembly and testing process for a solenoid valve, comprising:

[0082] Step 1: Assemble the components of the solenoid valve, perform the first cleaning on the assembled components, and pre-install the components that need to be matched.

[0083] Step 2: Perform functional testing on the components and assemble the solenoid valve;

[0084] Step 3: Perform an initial inspection on the assembled solenoid valves, and store the solenoid valves that pass the initial inspection for the first time.

[0085] Step 4: Perform a reliability test on the solenoid valves stored for the first time;

[0086] In this process, steps one through three involve full inspection of the products, and step four involves random inspection of the products stored in step three according to the sampling rate.

[0087] Pre-installation includes motion tests that can detect the fit accuracy of components.

[0088] To implement the above technical solution, firstly, all components that make up the solenoid valve need to be collected according to the parts list that matches the solenoid valve model. Then, these components are cleaned for the first time. After the first cleaning, the components that need to be fitted are pre-installed. Preferably, pre-installing the components that need to be threaded can effectively clean the debris in the threads and prevent these debris from affecting the cleanliness of the assembled solenoid valve.

[0089] Before assembling a solenoid valve, an operational test must be performed to evaluate whether the fitting accuracy between the various mating parts within the solenoid valve meets the requirements. If the solenoid valve fails the operational test, these parts will not be assembled. Instead, the problematic parts will be repaired directly. After repair, another operational test will be performed. If the operational test passes this time, the parts can be assembled. If they still fail, the parts will continue to be repaired.

[0090] This method allows for the early detection of assembly precision issues in solenoid valve components, avoiding rework after assembly, reducing the difficulty of solenoid valve maintenance, and improving the solenoid valve's pass rate.

[0091] In this embodiment, preferably, the assembly in step one includes collecting all components according to the component list of the solenoid valve;

[0092] The first cleaning process includes cleaning and deburring all components obtained from the assembly.

[0093] Cleaning of parts includes cleaning of metal parts and cleaning of non-metal parts;

[0094] Preferably, the cleaning of the metal parts is as follows: the metal parts are placed in an ultrasonic cleaner using a water-based cleaning solution to remove oil stains, then rinsed with water, then rinsed with anhydrous ethanol to replace the water on the surface of the metal parts, and finally dried with compressed air or nitrogen.

[0095] Preferably, the cleaning of non-metallic parts is performed by placing the non-metallic parts in an ultrasonic cleaner using anhydrous ethanol for cleaning, and then drying the non-metallic parts with compressed air or nitrogen.

[0096] Preferably, the cleaning time in the ultrasonic cleaner is not less than 15 minutes to ensure the cleaning effect in the ultrasonic cleaner.

[0097] Preferably, deburring the parts includes observing and removing dirt, impurities, burrs, and sharp corners from the parts;

[0098] Preferably, when deburring the parts, a 10x magnifying glass or a 30x microscope is used to observe the parts;

[0099] Preferably, after deburring the parts, the parts are cleaned and dried again to remove contaminants generated during the deburring operation.

[0100] In this embodiment, preferably, the pre-installation in step one includes, in sequence: thread pre-assembly, sealing ring inspection, and operational test, wherein,

[0101] The threaded pre-assembly mainly includes the following steps: covering the non-threaded connection positions, then pre-tightening each thread, and then disassembling the tightened threads and cleaning and drying the parts.

[0102] Preferably, the pre-tightening includes first tightening the threaded part, then disassembling the threaded part, and repeatedly tightening and loosening it 2-3 times to ensure smooth and unobstructed thread engagement, which is beneficial for subsequent formal assembly.

[0103] After pre-assembly, disassemble and clean and dry the parts. During cleaning, carefully inspect and remove the excess material generated during the screwing process with a 10X magnifying glass or a 30X microscope, and wipe the threaded connection with a lint-free cloth soaked in anhydrous ethanol until there is no black excess material.

[0104] When pre-assembling threads, parts without threads should be protected to prevent foreign objects from adhering.

[0105] The sealing ring inspection includes the following steps: First, reject defective products with obvious protrusions or depressions on the inner and outer parting surfaces; next, inspect the surface quality of the remaining sealing rings, and reject sealing rings with dents, scratches, or rust spots that affect the sealing performance. The remaining sealing rings are qualified.

[0106] Before the operational test, all components need to be cleaned and dried. Then, the spring is installed into the spring mounting hole of the coil assembly, and the operational test is conducted. During cleaning, the components are placed in an ultrasonic cleaner using anhydrous ethanol for at least 15 minutes, and then dried with compressed air or nitrogen. Components should not rely excessively on ultrasonic cleaning; manual cleaning is still required before the operational test.

[0107] The action test includes: First, gently poke the spring with tweezers and tilt the component at 45°. If the valve core moves without any jamming, it is considered qualified.

[0108] Then, insert the spring into the valve core spring mounting hole, gently wiggle the spring with tweezers, tilt the assembly at 45°, and the valve core moves without any jamming, which is considered qualified;

[0109] Finally, without assembling the spring, insert the valve core into the inner cavity of the coil assembly, block the outlet with the valve seat, and check the flexibility of movement. Tilt the axis of the solenoid valve housing at 45°. If the valve core can slide freely under its own weight without any jamming, it is qualified.

[0110] In this embodiment, preferably, before functional testing, the solenoid valve should be connected to the inlet and outlet connectors of the testing equipment, the sealing ring should be installed, and the power supply should be turned on.

[0111] Functional testing includes the first margin test and the first response characteristic test;

[0112] After the functional tests are completed, the solenoid valves that pass the tests are welded together to complete the assembly of the solenoid valves.

[0113] After the operational test is completed, the solenoid valve can be assembled. After assembly, welding is not performed immediately; instead, the components are kept in a state of accurate relative positioning, but still freely detachable. At this point, the solenoid valve undergoes functional testing to determine if its various functions meet the requirements.

[0114] If the functional testing shows that all tests of the assembled solenoid valve are qualified, the solenoid valve will enter the welding process for final welding. After welding, the finished solenoid valve is completed and can continue to other finished product testing stages to test the solenoid valve's sealing performance and other properties.

[0115] If the assembled solenoid valve fails any tests during functional testing, the functional tests still need to be completed. However, the solenoid valve will no longer be welded and will instead proceed directly to the rework process. Based on the test data, the operator will repair the solenoid valve. After the repair is completed, the components that make up the solenoid valve will restart the assembly and testing process.

[0116] Welding the solenoid valve after the functional test is completed ensures that solenoid valve parts that fail the functional test will not enter the welding stage, thus reducing the difficulty of repairing these solenoid valves.

[0117] In this embodiment, preferably, the first margin detection includes measuring the load pull-in voltage U1, load release current I1, no-load pull-in voltage U2, and no-load release current I2 of the solenoid valve;

[0118] First, measure the load pull-in voltage U1. During the measurement, first input the detection gas into the inlet of the detection equipment, slowly increase the voltage until the valve opens, and record the voltage value at this time as the load pull-in voltage U1. Repeat the measurement N1 times, where N1 is not less than 3.

[0119] Comparing the load pull-in voltage U1 obtained from N1 measurements with the designed load pull-in voltage, it is qualified if the load pull-in voltage U1 is not higher than the designed load pull-in voltage;

[0120] It is qualified if the deviation between the load pull-in voltage U1 obtained from N1 measurements and the designed load pull-in voltage is not greater than ±1V (it is better to write the designed deviation here);

[0121] Subsequently, measure the load release current I1. During measurement, continuously input gas into the detection equipment, increase the voltage across the solenoid valve to the designed maximum load voltage, then slowly reduce the voltage across the solenoid valve until the valve core is completely released, record the current value at this time as the load release current I1, repeat the measurement for N2 times, and N2 is not less than 3;

[0122] Comparing the load release current I1 obtained from N2 measurements with the designed load release current, it is qualified if the load release current I1 is not higher than the designed load release current;

[0123] It is qualified if the deviation between the load release current I1 obtained from N2 measurements and the designed load release current is not greater than 10mA (it is better to write the designed deviation here);

[0124] Next, measure the no-load pull-in voltage U2. During measurement, stop inputting gas into the detection equipment, slowly increase the voltage until the valve opens, record the voltage value at this time as the no-load pull-in voltage U2, repeat the measurement for N3 times, and N3 is not less than 3;

[0125] Comparing the no-load pull-in voltage U2 obtained from measurements with the designed no-load pull-in voltage, it is qualified if the no-load pull-in voltage is not higher than the designed no-load pull-in voltage;

[0126] It is qualified if the deviation between the no-load pull-in voltage U2 obtained from N3 measurements and the designed no-load pull-in voltage is not greater than ±1V (it is better to write the designed deviation here);

[0127] Finally, measure the no-load release current I2. During measurement, first increase the voltage across the solenoid valve to the designed maximum load voltage, then slowly reduce the voltage until the valve is completely released, record the current value at this time as the no-load release current I2, repeat the measurement for N4 times, and N4 is not less than 3;

[0128] Comparing the no-load release current I2 obtained from measurements with the designed no-load release current, it is qualified if the no-load release current I2 is not higher than the designed no-load release current;

[0129] It is qualified if the deviation between the no-load release current I2 obtained from N4 measurements and the designed no-load release current is not greater than 10mA (it is better to write the designed deviation here);

[0130] Preferably, the detection gas is nitrogen, and the pressure of the detection gas is 3 to 4 MPa;

[0131] Preferably, N1=N2=N3=N4.

[0132] In this embodiment, preferably, after the first margin detection is completed, a first response characteristic detection is performed on the solenoid valve that has passed the first margin detection;

[0133] First, the rated voltage is applied to the solenoid valve, the response characteristics of the solenoid valve in two states: with the detection gas connected and without the detection gas connected are checked, the measured results are compared with the design requirements, and those meeting the design requirements are qualified;

[0134] Subsequently, the minimum voltage is applied to the solenoid valve, the response characteristics of the solenoid valve in two states: with the detection gas connected and without the detection gas connected are checked, the measured results are compared with the design requirements, and those meeting the design requirements are qualified;

[0135] Finally, the maximum voltage is applied to the solenoid valve, the response characteristics of the solenoid valve in two states: with the detection gas connected and without the detection gas connected are checked, the measured results are compared with the design requirements, and those meeting the design requirements are qualified.

[0136] The rated voltage is set to 28V, the maximum voltage is 31V, and the minimum voltage is 25V.

[0137] The detection gas is nitrogen, and the pressure of the detection gas is 3 to 4 MPa.

[0138] In this embodiment, preferably, after the first response characteristic detection is completed, welding is performed on the solenoid valve that has passed the first response characteristic detection.

[0139] Welding is performed according to the design drawings during welding.

[0140] In this embodiment, preferably, the preliminary inspection sequentially includes first bubble detection, helium mass spectrometry leak detection, stroke inspection, electrical interface inspection, insulation resistance detection, dielectric strength detection, second margin detection, second response characteristic detection, second bubble detection and weight detection;

[0141] Before the first storage, a third cleaning is required for the solenoid valves that have passed all detection items;

[0142] Preferably, the third cleaning is performed manually by using a brush dipped in alcohol to clean the exterior of the solenoid valve, and then blowing it dry with nitrogen;

[0143] Preferably, the solenoid valves are stored in a nitrogen cabinet.

[0144] After the solenoid valve is welded, an air bubble test is performed first. Specifically, the valve outlet is sealed, air is introduced into the valve inlet at 3.5 MPa, and the airtightness of the O-ring at 0-05A is checked from the valve outlet.

[0145] The test liquid should be pure water or anhydrous ethanol, and the visual inspection time should be no less than 1 minute. Observe the regularity of the bubbles emerging from the valve outlet; the bubble diameter should not be greater than 1 mm, and the leakage rate should not be greater than 1 bubble / min.

[0146] Subsequently, helium mass spectrometry leak detection was performed: total internal leakage was detected at a helium pressure of 3.5 MPa, which should meet the design requirements, and the measured values ​​were recorded.

[0147] Subsequently, the valve core assembly stroke is checked and should meet the design requirements.

[0148] Next, the electrical interfaces will be checked to ensure they meet design requirements.

[0149] Afterwards, an insulation resistance test should be performed, which should meet the design requirements.

[0150] Next, a dielectric strength test is performed using a frequency of 50Hz and an effective voltage of 750V. A high-voltage power supply with a power output of not less than 0.6kW is used to test the dielectric strength between the socket pins and the surface of the coil assembly, and between the pins and the socket housing, for 1 minute. No abnormal phenomena such as arcing, breakdown, or significant voltmeter pointer fluctuations should occur.

[0151] Then a second margin test is performed, following the same procedure as the first margin test.

[0152] Then, a second response characteristic test is performed, following the same procedure as the first response characteristic test.

[0153] Then a second bubble test is performed, following the same procedure as the first bubble test.

[0154] Then the solenoid valve is weighed, and the valve weight should meet the design requirements.

[0155] Then, a visual inspection is conducted, and the appearance should be free of dents, bumps, and mechanical damage.

[0156] After visual inspection, the solenoid valve is cleaned manually with a brush dipped in alcohol, and then dried with nitrogen.

[0157] Finally, the solenoid valve is placed in a nitrogen cabinet for storage.

[0158] In this embodiment, preferably, after the solenoid valve is welded, a first bubble detection is performed. The first bubble detection includes:

[0159] First, block the outlet of the solenoid valve, connect a test gas to the inlet of the solenoid valve, immerse the solenoid valve in the test liquid, and visually inspect the air tightness of the solenoid valve;

[0160] The visual inspection includes visually checking whether bubbles emerge from the outlet of the solenoid valve, the diameter of the bubbles, and counting the number of emerging bubbles;

[0161] If the bubble diameter is not more than 1 mm and the leakage frequency is not more than 1 bubble per minute, the solenoid valve is qualified;

[0162] Preferably, purified water or absolute ethanol is selected as the test liquid;

[0163] Preferably, the visual inspection time is not less than 1 minute.

[0164] In this embodiment, preferably, solenoid valves in the nitrogen cabinet are sampled according to a sampling rate for reliability detection;

[0165] The reliability detection sequentially includes: humidity test, random vibration test, first appearance inspection, second bubble detection, third response characteristic detection, impact test, third bubble detection, fourth response characteristic detection and life test;

[0166] Perform a final appearance inspection on the solenoid valves qualified in reliability detection, and store them for the second time;

[0167] The humidity test measures the insulation resistance and electric strength of the solenoid valve; the method comprises: first installing protective parts on the inlet and outlet of the solenoid valve, then placing the solenoid valve in a humidity chamber for the test;

[0168] An insulation resistance of not less than 10 MΩ is qualified;

[0169] Apply an alternating current power supply between each pin of the electrical connector and the housing of the solenoid valve. If the solenoid valve is not punctured, does not generate arcing, or the pointer of the voltmeter has no significant swing, the electric strength of the solenoid valve is qualified

[0170] Preferably, the relative humidity of the humidity chamber is 95%±5%, and the temperature is 40±3°C;

[0171] Preferably, the solenoid valve is incubated for 48 hours before the humidity test is performed;

[0172] Preferably, the alternating current power supply is a 50 Hz sine wave with a voltage of not less than 200 V, and a power of not less than 0.5 kW;

[0173] Preferably, the wires used for measurement must be sealed, have good insulation, and be led out of the humidity chamber to facilitate checking the resistance and appearance of the valve;

[0174] Preferably, the second bubble detection and the third bubble detection are the same as the first bubble detection;

[0175] Preferably, the second and third response characteristic detections are the same as the first response characteristic detection;

[0176] The life test includes repeatedly opening and closing the solenoid valve N5 times. The solenoid valve is considered qualified if it does not jam during the test. Each time the solenoid valve opens and closes, it is counted as one working cycle.

[0177] Preferably, N5 is not less than 3.6 × 10³;

[0178] Preferably, the life test also includes process bubble detection and process response characteristic detection. When N5 equals the design value, process bubble detection and process response characteristic detection are performed on the solenoid valve.

[0179] Preferably, the process bubble detection is the same as the first bubble detection, and the process response characteristic detection is the same as the first response characteristic detection;

[0180] Preferably, multiple design values ​​are set, and these multiple design values ​​are evenly distributed within the numerical range of N5;

[0181] Preferably, the second storage includes storing the solenoid valve on a shelf in the cleanroom after it has been packaged.

[0182] When conducting humidity tests, it is essential to first install protective devices at the inlet and outlet of the solenoid valve, and then place the solenoid valve inside the humidity chamber for testing. The test leads must be sealed, well-insulated, and extended outside the chamber to allow for inspection of the valve's resistance and appearance.

[0183] Test conditions: relative humidity 95%±5%, temperature 40±3℃, after heat preservation for 48h, the following tests were conducted.

[0184] Insulation resistance: The insulation resistance between the coil winding and the housing is not less than 10MΩ.

[0185] Dielectric strength: An insulation strength test is conducted between each pin of the electrical connector and the housing with a 200V (RMS) 50Hz sine wave, a power of not less than 0.5kW, and a leakage current of not more than 0.5mA for 1 minute. No abnormal phenomena such as breakdown, arcing, or significant swing of the voltmeter pointer are allowed.

[0186] After completing the humidity test, a random vibration test is conducted according to the technical specifications.

[0187] The first visual inspection is then carried out, mainly checking the appearance of the solenoid valve, which should be free of pressure marks, bumps, and mechanical damage.

[0188] Then a second bubble test is performed, following the same procedure as the first bubble test.

[0189] Then, a third response characteristic test is performed, following the same procedure as the first response characteristic test.

[0190] Then, sinusoidal vibration testing was conducted, followed by random vibration testing according to the technical specifications.

[0191] Next, a visual inspection is performed on the solenoid valve. The valve should be free of dents, bumps, and mechanical damage.

[0192] Then, a third bubble test is performed, following the same procedure as the first bubble test.

[0193] The next step is the fourth response characteristic test, which follows the same procedure as the first response characteristic test.

[0194] Next comes the impact test, followed by random vibration testing according to the technical specifications.

[0195] Next is the visual inspection, checking the appearance of the solenoid valve. There should be no pressure marks, bumps, or mechanical damage.

[0196] Then, a fourth bubble test is performed, following the same procedure as the first bubble test.

[0197] Then, a fifth response characteristic test is performed, following the same procedure as the first response characteristic test.

[0198] Finally, a life test is conducted.

[0199] In the life test, each opening and closing of the solenoid valve is counted as one operation.

[0200] The solenoid valve inlet is supplied with high-purity nitrogen gas at a pressure of 3.5 MPa, and it operates in cycles of 3.6 × 10³ times. Jamming is not permitted during operation. Taking N5 = 4 as an example, after the 500th, 1000th, 1800th, and 3600th cycles, process bubble detection is performed following the procedure for the first bubble detection, and process response characteristic detection is performed following the procedure for the first response characteristic detection.

[0201] After the life test is completed, a final visual inspection can be performed to check the appearance of the solenoid valve. There should be no pressure marks, bumps, or mechanical damage.

[0202] Finally, the solenoid valves were packaged in plastic bags and placed on the shelves in the cleanroom for secondary storage.

[0203] In the above-mentioned assembly and testing process for solenoid valves, the first and third steps are Group A inspections, and the fourth step is Group C inspection. Group A, the quality consistency inspection, is a simple, routine, non-destructive test conducted to verify whether the product meets the specified requirements. Group A involves 100% inspection and is the delivery inspection.

[0204] In Group A inspection, if any item fails to meet the requirements, the cause should be identified, measures taken, and the fault eliminated. If the faulty product does not affect the results of the completed tests, the completed tests can be discontinued; if the fault affects the completed tests or the impact of the fault cannot be determined, the relevant tests must be repeated before continuing with the unfinished tests.

[0205] From the same batch of valves that passed Group A, 3% of the products, and no fewer than 3 products, were randomly selected for Group C quality consistency inspection.

[0206] Products that pass acceptance and inspection are considered qualified products. If a product fails to meet requirements, and the problem is found to be non-batch-related and the cause of the malfunction is clear, it can be resubmitted for acceptance after corrective measures are taken. If the problem is found to be batch-related, the entire batch can be resubmitted for acceptance after corrective measures are taken. If the same problem reappears in the second inspection, the entire batch is deemed unqualified. If the second inspection still fails to meet requirements, but not due to the same problem, the cause can be identified and corrective measures taken, and the quantity can be doubled for acceptance. If one of the requirements is still not met, the entire batch is deemed unqualified.

[0207] In the aforementioned re-inspection, if the measures taken do not affect the results of the tests already performed, then the tests already performed need not be repeated; if the measures affect the tests already performed or the impact cannot be determined, then the relevant tests must be repeated, and then the tests not yet performed can continue. If the product fails the quality consistency Group C inspection, the acceptance of the product should be stopped, and it should be placed separately. The manufacturer should notify the purchaser.

[0208] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0209] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

[0210] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed by the present invention.

Claims

1. An assembly and testing process for a solenoid valve, characterized in that, The assembly testing process of the electromagnetic valve includes: Step 1: Collecting the components of the electromagnetic valve, performing first cleaning on the components obtained from the collection, and pre-installing the components with a fitting relationship; Step 2: Performing a functional test on the components, and assembling the electromagnetic valve after the functional test is completed; Step 3: Performing an initial inspection on the assembled electromagnetic valve, and storing the electromagnetic valves that passed the initial inspection for the first time; Step 4: Performing a reliability test on the electromagnetic valves stored after the first storage; Wherein, 100% inspection is performed on products in Step 1 to Step 3, and sampling inspection is performed on the products stored in Step 3 according to a sampling rate in Step 4; The pre-installation includes an action test capable of detecting the fitting accuracy of the components.

2. The assembly and testing process of the solenoid valve according to claim 1, characterized in that, The component collection in Step 1 includes collecting all components according to the component list of the electromagnetic valve; The first cleaning includes cleaning and deburring all components obtained from the component collection; The cleaning includes: cleaning of metal components and cleaning of non-metal components; The cleaning of the metal components is: placing the metal components in an ultrasonic cleaning machine using a water-based solution detergent to clean to remove oil stains, then rinsing with water, and then rinsing the metal components with absolute ethanol to displace water on the surface of the metal components, and finally drying the metal components with compressed air or nitrogen; The cleaning of the non-metal components is: placing the non-metal components in an ultrasonic cleaning machine using absolute ethanol for cleaning, and then drying the non-metal components with compressed air or nitrogen; The deburring includes observing and removing dirt, impurities, burrs and sharp corners on the components; After completing the deburring work on the components, the components are cleaned and dried again.

3. The assembly and testing process of the solenoid valve according to claim 2, characterized in that, The pre-installation in Step 1 sequentially includes: thread pre-assembly, sealing ring inspection and the action test, wherein, The thread pre-assembly includes the following steps: shielding non-threaded connection positions, then pre-tightening each threaded connection, then removing the pre-tightened bolts and cleaning and drying the components; The sealing ring inspection includes the following steps: first rejecting defective products with obvious protrusions or depressions on the inner and outer parting surfaces; then inspecting the rest of the surface quality of the sealing rings, rejecting sealing rings with dents, scratches and rust spots on the surface that affect the sealing performance, and the remaining sealing rings are qualified; Before the action test, all components need to be cleaned and dried, then the spring is loaded into the spring mounting hole of the coil assembly to perform the action test; The action test includes: First, tilting the assembly by 45°, gently stirring the spring with tweezers, and the product is qualified if the valve core moves without jamming; Then, loading the spring into the spring mounting hole of the valve core, tilting the assembly by 45°, gently stirring the spring with tweezers, and the product is qualified if the valve core moves without jamming; Finally, without loading the spring, loading the valve core into the inner cavity of the coil assembly, blocking the outlet with a valve seat, and checking the movement flexibility: tilting the axis of the electromagnetic valve housing by 45°, the valve core can slide freely under its own weight, and the product is qualified if there is no jamming.

4. The solenoid valve assembly testing process of claim 1, wherein, Before the functional test, the electromagnetic valve needs to be first connected to the inlet and outlet joints of the testing equipment, the sealing ring is assembled, and the power is switched on; Said function detection includes a first margin detection and a first response characteristic detection; After the function detection is completed, welding is performed on the solenoid valves that have passed the detection, and the assembly of the solenoid valves is completed.

5. The assembly and testing process of the solenoid valve according to claim 4, characterized in that, Said first margin detection includes measurement of the loaded pull-in voltage U1, loaded drop-out current I1, no-load pull-in voltage U2 and no-load drop-out current I2 of the solenoid valve; First, the loaded pull-in voltage U1 is measured. During measurement, detection gas is first input into the inlet of the detection equipment, the voltage is slowly increased until the valve opens, the voltage value at this time is recorded as the loaded pull-in voltage U1, and the measurement is repeated N1 times, where N1 is not less than 3; The loaded pull-in voltage U1 obtained from N1 measurements is compared with the designed loaded pull-in voltage, and it is qualified if the loaded pull-in voltage U1 is not higher than the designed loaded pull-in voltage; It is qualified if the deviation between the loaded pull-in voltage U1 obtained from N1 measurements and the designed loaded pull-in voltage value is not more than ±1V; Subsequently, the loaded drop-out current I1 is measured. During measurement, gas is continuously input into the detection equipment, the voltage across the solenoid valve is increased to the designed maximum load voltage, then the voltage across the solenoid valve is slowly decreased until the valve core is completely released, the current value at this time is recorded as the loaded drop-out current I1, and the measurement is repeated N2 times, where N2 is not less than 3; The loaded drop-out current I1 obtained from N2 measurements is compared with the designed loaded drop-out current, and it is qualified if the loaded drop-out current I1 is not higher than the designed loaded drop-out current; It is qualified if the deviation between the loaded drop-out current I1 obtained from N2 measurements and the designed loaded drop-out current value is not more than 10mA; Next, the no-load pull-in voltage U2 is measured. During measurement, gas input into the detection equipment is stopped, the voltage is slowly increased until the valve opens, the voltage value at this time is recorded as the no-load pull-in voltage U2, and the measurement is repeated N3 times, where N3 is not less than 3; The measured no-load pull-in voltage U2 is compared with the designed no-load pull-in voltage, and it is qualified if the no-load pull-in voltage is not higher than the designed no-load pull-in voltage; It is qualified if the deviation between the no-load pull-in voltage U2 obtained from N3 measurements and the designed no-load pull-in voltage value is not more than the design deviation; Finally, the no-load drop-out current I2 is measured. During measurement, the voltage across the solenoid valve is first increased to the designed maximum load voltage, then the voltage is slowly decreased until the valve is completely released, the current value at this time is recorded as the no-load drop-out current I2, and the measurement is repeated N4 times, where N4 is not less than 3; The measured no-load drop-out current I2 is compared with the designed no-load drop-out current, and it is qualified if the no-load drop-out current I2 is not higher than the designed no-load drop-out current; It is qualified if the deviation between the no-load drop-out current I2 obtained from N4 measurements and the designed no-load drop-out current value is not more than the design deviation; Said detection gas is nitrogen, and the pressure of the detection gas is 3~4MPa; N1=N2=N3=N4.

6. The solenoid valve assembly testing process of claim 5, wherein, After the first margin detection is completed, a first response characteristic detection is performed on the solenoid valves that have passed the first margin detection; First, connect the solenoid valve to its rated voltage and check the response characteristics of the solenoid valve in two states: when the detection gas is connected and when the detection gas is not connected. Compare the measured results with the design requirements. If the design requirements are met, the valve is considered qualified. Subsequently, the minimum voltage for the solenoid valve to be connected for testing was applied, and the response characteristics of the solenoid valve were checked in two states: when the detection gas was connected and when the detection gas was not connected. The measured results were compared with the design requirements, and the valve was considered qualified if it met the design requirements. Finally, the highest voltage for the solenoid valve connection test is applied to check the response characteristics of the solenoid valve under two states: when the detection gas is connected and when the detection gas is not connected. The measured results are then compared with the design requirements. If the design requirements are met, the valve is considered qualified.

7. The solenoid valve assembly testing process of claim 6, wherein, After the first response characteristic test is completed, the solenoid valve that passes the response characteristic test is welded.

8. The assembly and testing process of the solenoid valve according to claim 1, characterized in that, The initial inspection includes, in sequence, a first bubble detection, a helium mass spectrometry leak detection, a stroke check, an electrical interface check, an insulation resistance test, a dielectric strength test, a second margin test, a second response characteristic test, a second bubble detection, and a weight test; Before the first storage, the solenoid valve that has passed all test items needs to be cleaned a third time. The third cleaning involves manually cleaning the outside of the solenoid valve with a brush dipped in alcohol, and then drying it with nitrogen gas. The solenoid valve is stored in a nitrogen cabinet.

9. The assembly and testing process of the solenoid valve according to claim 8, characterized in that, After the solenoid valve is welded, the first bubble detection is performed. The first bubble detection includes: First, block the outlet of the solenoid valve, introduce the detection gas into the inlet of the solenoid valve, and immerse the solenoid valve in the test liquid. Visually inspect the airtightness of the solenoid valve. The visual inspection includes visually inspecting whether bubbles are emerging from the outlet of the solenoid valve, the diameter of the bubbles, and counting the number of bubbles emerging. If the bubble diameter is no greater than 1 mm and the leakage frequency is no greater than 1 bubble / min, then it is qualified. The test liquid is either purified water or anhydrous ethanol; The visual inspection time shall not be less than 1 minute.

10. The solenoid valve assembly testing process of claim 9, wherein, The reliability test is performed on the solenoid valves in the nitrogen cabinet by sampling according to the aforementioned sampling rate. The reliability testing includes, in sequence: humidity test, random vibration test, first appearance inspection, second bubble inspection, third response characteristic test, sinusoidal vibration test, third bubble inspection, fourth response characteristic test, impact test, fourth bubble inspection, fifth response characteristic test, and life test. The solenoid valves that pass the reliability test undergo a final visual inspection and are then stored a second time. The humidity test measures the insulation resistance and dielectric strength of the solenoid valve; it includes: first, installing protective components at the inlet and outlet of the solenoid valve, and then placing the solenoid valve into a humidity chamber for testing; The insulation resistance is not less than 10MΩ to be considered qualified; When AC power is supplied to the pins of the electrical connector and the housing of the solenoid valve, the solenoid valve is not damaged, does not generate arcing, or the voltmeter pointer does not swing significantly, and the dielectric strength of the solenoid valve is qualified. The relative humidity of the humidity chamber is 95%±5%; the temperature is 40±3℃. The solenoid valve was kept warm for 48 hours before the humidity test was conducted. The AC power supply is a 50Hz sine wave with a voltage of not less than 200V and a power of not less than 0.5kW; The measuring wires must be sealed, well-insulated, and led out of the box to check the valve resistance and appearance; The second and third bubble detections are the same as the first bubble detection; The second and third response characteristic detections are the same as the first response characteristic detection; The life test includes repeatedly opening and closing the solenoid valve N5 times. The solenoid valve is considered qualified if it does not jam during the test. Each time the solenoid valve opens and closes is counted as one operation. N5 is not less than 3.6 × 10 3 ; The life test also includes process bubble detection and process response characteristic detection. When N5 equals the design value, the process bubble detection and process response characteristic detection are performed on the solenoid valve. The process bubble detection is the same as the first bubble detection, and the process response characteristic detection is the same as the first response characteristic detection; The design value is set to multiple values, and the multiple design values ​​are evenly distributed within the numerical range of N5; The second storage includes placing the packaged solenoid valve on a shelf in the cleanroom for storage.