A leak detection system for a plastic switch

Abstract

This invention belongs to the field of plastic switches and relates to leakage detection technology. It addresses the problems of traditional leakage detection methods being imprecise and having low accuracy. Specifically, it is a leakage detection system for plastic switches, including a leakage testing module, a test analysis module, a leakage investigation module, and a test evaluation module. These modules are sequentially connected, with the leakage investigation module also connected to the leakage testing module. The leakage testing module performs leakage tests on the plastic switch. This invention can analyze the test data of the plastic switch, determine the compliance of the testing process based on the pressure performance value, and re-perform the leakage test if non-compliant. It also determines the probability of leakage during the testing process based on the pressure deviation value, thereby triggering leakage investigation and analysis when leakage is detected.

Description

Technical Field

[0001] This invention belongs to the field of plastic switches and relates to leakage detection technology, specifically a leakage detection system for plastic switches. Background Technology

[0002] Plastic switches are devices that combine plastic materials and electronic technology. They are widely used in various fields and play an important role in liquid level control, electronic communication, industrial control and many other aspects due to their simple structure and ease of use.

[0003] Existing leak detection systems for plastic switches can only detect leaks through water pipe pressure. They determine that the plastic switch is leaking when there is a pressure difference at different locations in the water pipe. However, the test pipes and valves themselves also have the risk of leakage. Therefore, traditional leak detection methods are not rigorous and their detection results are not accurate.

[0004] To address the aforementioned technical problems, this application proposes a solution. Summary of the Invention

[0005] The purpose of this invention is to provide a leakage detection system for plastic switches, which solves the problem that traditional leakage detection methods are not rigorous and the accuracy of their detection results is not high;

[0006] The technical problem to be solved by this invention is: how to provide a leakage detection system for plastic switches that can eliminate interference from leakage of test elements.

[0007] The objective of this invention can be achieved through the following technical solutions:

[0008] A leakage detection system for plastic switches includes a leakage testing module, a test analysis module, a leakage investigation module, and a test evaluation module. The leakage testing module, test analysis module, leakage investigation module, and test evaluation module are sequentially connected in communication, and the leakage investigation module is also connected in communication with the leakage testing module.

[0009] The leakage testing module is used to perform leakage tests on plastic switches: finished plastic switches from the same production batch are marked as test objects, the test objects are installed at one end of the test pipe, and test points are set along the axial direction on the inner wall of the test pipe. i Let i = 1, 2, ..., n, where n is a positive integer. This involves obtaining test points during the testing process. i Test value CS i ; Put all test points i Test value CS i Send to the test analysis module;

[0010] The test analysis module is used to analyze the test data of the plastic switch and obtain the pressure performance value and pressure deviation value of the test object. The pressure performance value and pressure deviation value are used to determine whether there is leakage during the test process.

[0011] The leakage detection module is used to perform forward and reverse detection of leakage points during the testing process of plastic switches;

[0012] The test evaluation module is used to evaluate and analyze the test results of the plastic switches.

[0013] Furthermore, test points i Test value CS i The acquisition process includes: test point 1 is closest to the test object, test point n The furthest distance from the test object is at the test point. i A pressure sensor is installed, and a water pump and water tank are set up at the other end of the test pipeline. Water from the tank is pumped into the test pipeline. After the water flows out of the test object, the test object is closed, and the water pump continues to pressurize until the pump pressure reaches L1PA. The valve at the other end of the test pipeline is then closed, and the test is allowed to stand for L2 minutes. All test points are then recorded. i The pressure value of the pressure sensor is marked as the test value CS at the test point. i .

[0014] Furthermore, the process of obtaining the pressure performance value and the pressure deviation value includes: for all test points i Test value CS i The pressure performance value is obtained by summing and averaging the results for all test points. i Test value CS i The pressure deviation value is obtained by performing variance calculation.

[0015] Furthermore, the specific process for determining whether a leak exists during the testing process includes: comparing the pressure performance value and pressure deviation value with preset pressure performance thresholds and pressure deviation thresholds, respectively; if the pressure deviation value is greater than or equal to the pressure deviation threshold, a leak is determined to exist during the testing process, a leak detection signal is generated, and the leak detection signal is sent to the leak detection module; if the pressure deviation value is less than the pressure deviation threshold and the pressure performance value is greater than or equal to the pressure performance threshold, a leak is determined to exist during the testing process, and the test object is marked as a qualified object; if the pressure deviation value is less than the pressure deviation threshold and the pressure performance value is less than the pressure performance threshold, a non-compliant testing process is determined, a retest signal is generated, and the retest signal is sent to the leak testing module.

[0016] Furthermore, the specific process of forward investigation includes: using test point 1 as the reference point, determining CS along the axis. i+1 Is it greater than CS?i If so, then CS i+1 The corresponding test point is marked as a forward coincidence point; otherwise, CS is marked as a forward coincidence point. i+1 Corresponding test points i Marked as the forward termination point; all test points i All forward investigations have been completed or test points have been identified. i When a point is marked as a forward termination point, the forward investigation is terminated. When the forward investigation ends, it is determined whether the number of forward matching points is n-1. If yes, the test object is determined to have a leakage phenomenon and the test object is marked as a leakage object. If no, the test pipeline is investigated in reverse.

[0017] Furthermore, the specific process of reverse investigation includes: using test points n Using the reference point, determine CS along the axis. i-1 Is it greater than CS? i If so, then CS i-1 The corresponding test point is marked as a reverse coincidence point; otherwise, CS is marked as a reverse coincidence point. i-1 Corresponding test points i Marked as the reverse termination point; all test points i All reverse engineering or test points have been completed. i The reverse investigation terminates when a point is marked as a reverse termination point. At the end of the reverse investigation, it is determined whether the number of reverse matching points is [value missing]. n-1 If yes, the valve is determined to be leaking, a valve replacement signal is generated and sent to the leakage test module. After receiving the valve replacement signal, the leakage test module replaces the valve and then re-performs the leakage test on the test object. If no, the test pipeline is determined to be leaking, a pipeline replacement signal is generated and sent to the leakage test module. After receiving the pipeline replacement signal, the leakage test module replaces the test pipeline and then re-performs the leakage test on the test object.

[0018] Furthermore, the specific process for the test evaluation module to evaluate and analyze the test results of the plastic switches includes: after all test objects in the same batch have completed leakage tests, obtaining the switch value KG, valve value FM, and pipeline value GD, where the switch value KG represents the number of leaking objects, the valve value FM represents the number of times the leakage test module received valve replacement signals, and the pipeline value GD represents the number of times the leakage test module received pipeline replacement signals; and using the formula... The evaluation coefficient PG is obtained, where k1, k2, and k3 are proportional coefficients, and k1>k2>k3>1. ZS is the total number of finished plastic switches in this batch. The evaluation coefficient is used to determine whether the overall test results of this batch of plastic switches meet the requirements.

[0019] Furthermore, the specific process for determining whether the overall test results of this batch of plastic switches meet the requirements includes: comparing the evaluation coefficient PG with the preset evaluation threshold PGmax; if the evaluation coefficient PG is less than the evaluation threshold PGmax, the overall test results of this batch of plastic switches are determined to meet the requirements, and the leaking objects are sorted out; if the evaluation coefficient PG is greater than or equal to the evaluation threshold PGmax, the overall test results of this batch of plastic switches are determined to not meet the requirements, the leaking objects are removed, and the qualified objects in this batch are subjected to a second test.

[0020] The present invention has the following beneficial effects:

[0021] 1. The leakage test module can be used to test plastic switches for leakage. Test points set in the test pipeline can monitor the pressure value of the test points after the water pressure stabilizes. Then, the leakage can be detected based on the degree of deviation of the pressure value of the test points at different locations, providing data support for the test analysis process.

[0022] 2. The test analysis module can analyze the test data of plastic switches, determine whether the test process is compliant based on the pressure performance value, and re-perform the leakage test if it is non-compliant. It can also determine the possibility of leakage in the test process based on the pressure deviation value, thereby triggering leakage investigation and analysis when leakage is found.

[0023] 3. The leakage detection module can be used to investigate and analyze the leakage points in the plastic switch testing process. The leakage location can be marked according to the distribution pattern of the test values ​​of the test points in the test pipe along the axial direction when a leakage occurs, thereby avoiding the leakage of the test element from affecting the workpiece test results and improving the test accuracy.

[0024] 4. The test evaluation module can evaluate and analyze the test results of plastic switches and obtain evaluation coefficients. If the evaluation coefficient exceeds the threshold, it indicates that there are many leakage objects in the batch of plastic switches or that there is a lot of interference in the leakage detection process of the batch of plastic switches. Therefore, it is necessary to conduct secondary testing on qualified objects to ensure the accuracy of the test results. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a system block diagram of Embodiment 1 of the present invention;

[0027] Figure 2 This is a flowchart of the method in Embodiment 2 of the present invention. Detailed Implementation

[0028] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Example 1

[0030] like Figure 1 As shown, a leakage detection system for plastic switches includes a leakage testing module, a test analysis module, a leakage investigation module, and a test evaluation module. The leakage testing module, test analysis module, leakage investigation module, and test evaluation module are sequentially connected in communication, and the leakage investigation module is connected in communication with the leakage testing module.

[0031] The leakage testing module is used to perform leakage tests on plastic switches: finished plastic switches from the same production batch are marked as test objects, the test objects are installed at one end of the test pipe, and test points are set axially on the inner wall of the test pipe. i Let i = 1, 2, ..., n, where n is a positive integer. Test point 1 is the closest to the test object. n The furthest distance from the test object is at the test point. i A pressure sensor is installed, and a water pump and water tank are set up at the other end of the test pipeline. Water from the tank is pumped into the test pipeline. After the water flows out of the test object, the test object is closed, and the water pump continues to pressurize until the pump pressure reaches L1PA. The valve at the other end of the test pipeline is then closed, and the test is allowed to stand for L2 minutes. All test points are then recorded. i The pressure value of the pressure sensor is marked as the test value CS at the test point. i All test points i Test value CS i The data is sent to the test analysis module; a leakage test is performed on the plastic switch. Test points are set up in the test pipeline, and the pressure value of the test points can be monitored after the water pressure stabilizes. Then, the leakage is detected based on the degree of deviation of the pressure value of the test points at different locations, providing data support for the test analysis process.

[0032] The test analysis module is used to analyze the test data of plastic switches: for all test points i Test value CS i The pressure performance value is obtained by summing and averaging the results for all test points. i Test value CS iThe pressure deviation value is obtained by variance calculation. The pressure performance value and pressure deviation value are compared with preset pressure performance thresholds and pressure deviation thresholds, respectively. If the pressure deviation value is greater than or equal to the pressure deviation threshold, a leak is determined to exist in the test process, a leak investigation signal is generated, and the leak investigation signal is sent to the leak investigation module. If the pressure deviation value is less than the pressure deviation threshold and the pressure performance value is greater than or equal to the pressure performance threshold, a leak is determined to exist in the test process, and the test object is marked as qualified. If the pressure deviation value is less than the pressure deviation threshold and the pressure performance value is less than the pressure performance threshold, a non-compliant test process is determined, a retest signal is generated, and the retest signal is sent to the leak test module. The test data of the plastic switch is analyzed. The compliance of the test process is determined based on the pressure performance value. If non-compliant, the leak test is re-performed. The possibility of a leak in the test process is determined based on the pressure deviation value, thereby triggering a leak investigation analysis when a leak is found.

[0033] The leakage detection module is used to investigate and analyze leakage points during the testing process of plastic switches: It performs forward inspection of the test pipeline: using test point 1 as a reference point, it determines the CS along the axis. i+1 Is it greater than CS? i If so, then CS i+1 The corresponding test point is marked as a forward coincidence point; otherwise, CS is marked as a forward coincidence point. i+1 Corresponding test points i Marked as the forward termination point; all test points i All forward investigations have been completed or test points have been identified. i The forward inspection terminates when a point is marked as a forward termination point. At the end of the forward inspection, it is determined whether the number of forward matching points is n-1: if yes, the test object is determined to have a leak and is marked as a leaking object; otherwise, a reverse inspection is performed on the test pipeline: starting from the test point... n Using the reference point, determine CS along the axis. i-1 Is it greater than CS? i If so, then CS i-1 The corresponding test point is marked as a reverse coincidence point; otherwise, CS is marked as a reverse coincidence point. i-1 Corresponding test points i Marked as the reverse termination point; all test points i All reverse engineering or test points have been completed. i The reverse investigation terminates when a point is marked as a reverse termination point. At the end of the reverse investigation, it is determined whether the number of reverse matching points is [value missing]. n-1If the leak is detected, the valve is determined to be leaking. A valve replacement signal is generated and sent to the leakage test module. Upon receiving the signal, the leakage test module replaces the valve and then re-tests the object for leakage. If the leak is not detected, the test pipeline is determined to be leaking. A pipeline replacement signal is generated and sent to the leakage test module. Upon receiving the signal, the pipeline is replaced and then re-tests the object for leakage. The leakage points in the plastic switch testing process are investigated and analyzed. Based on the axial distribution of test values ​​at test points within the test pipeline during leakage, the leakage location is marked to prevent leakage of the test element from affecting the workpiece testing results and improve testing accuracy.

[0034] The testing and evaluation module is used to evaluate and analyze the test results of plastic switches: after all test objects in the same batch have completed leakage tests, the switch value KG, valve value FM, and pipeline value GD are obtained. The switch value KG represents the number of leaking objects, the valve value FM represents the number of valve replacement signals received by the leakage test module, and the pipeline value GD represents the number of pipeline replacement signals received by the leakage test module. This is achieved through the following formula: The evaluation coefficient PG is obtained, where k1, k2, and k3 are proportionality coefficients, and k1>k2>k3>1, and ZS is the total number of finished plastic switches in the batch. The evaluation coefficient PG is compared with the preset evaluation threshold PGmax: if the evaluation coefficient PG is less than the evaluation threshold PGmax, the overall test results of the batch of plastic switches are deemed to meet the requirements, and the leaking objects are sorted out; if the evaluation coefficient PG is greater than or equal to the evaluation threshold PGmax, the overall test results of the batch of plastic switches are deemed to not meet the requirements, the leaking objects are removed, and the qualified objects in the batch are subjected to a second test; the test results of the plastic switches are evaluated and analyzed to obtain the evaluation coefficient. If the evaluation coefficient exceeds the threshold, it indicates that there are many leaking objects in the batch of plastic switches or that there is a lot of interference in the leakage detection process of the batch of plastic switches. Therefore, the qualified objects need to be tested again to ensure the accuracy of the test results.

[0035] Example 2

[0036] like Figure 2 As shown, a leakage detection method for plastic switches includes the following steps:

[0037] Step 1: Leakage test on plastic switches: Mark the finished plastic switches from the same production batch as the test objects, and set test points along the axial direction on the inner wall of the test pipe. i Record all test points i The pressure value of the pressure sensor is marked as the test value CS at the test point. i ;

[0038] Step 2: Analyze the test data of the plastic switch and obtain the pressure performance value and pressure deviation value of the test object. Determine whether there is leakage during the test process by using the pressure performance value and pressure deviation value.

[0039] Step 3: Investigate and analyze the leakage points during the plastic switch testing process: Conduct forward and reverse inspections of the test pipeline, and mark the leakage points based on the results of the forward and reverse inspections;

[0040] Step 4: Evaluate and analyze the test results of the plastic switches: After all test objects in the same batch have completed the leakage test, obtain the switch value KG, valve value FM, and pipeline value GD, and calculate the evaluation coefficient PG. Use the evaluation coefficient to determine whether the overall test results of the batch of plastic switches meet the requirements.

[0041] A leakage detection system for plastic switches involves marking finished plastic switches from a uniform production batch as test objects and setting test points axially along the inner wall of the test pipe. i Record all test points i The pressure value of the pressure sensor is marked as the test value CS at the test point. i The test data of the plastic switches are analyzed to obtain the pressure performance value and pressure deviation value of the test objects. The presence of leakage during the test process is determined by the pressure performance value and pressure deviation value. The test pipeline is inspected in both forward and reverse directions, and the leakage points are marked according to the results of the forward and reverse inspections. After all test objects in the same batch have completed the leakage test, the switch value KG, valve value FM, and pipeline value GD are obtained and numerically calculated to obtain the evaluation coefficient PG. The overall test results of the batch of plastic switches are used to determine whether they meet the requirements.

[0042] The above description is merely an example and illustration of the structure of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the structure of the invention or exceed the scope defined in the claims, all of which should fall within the protection scope of the present invention.

[0043] The above formulas are all derived from software simulations using a large amount of data, and are selected to be close to the true values. The coefficients in the formulas are set by those skilled in the art based on the actual situation; for example: formula Multiple sets of sample data were collected by a person skilled in the art, and corresponding evaluation coefficients were set for each set of sample data. The set evaluation coefficients and the collected sample data were substituted into the formulas, and any three formulas constituted a system of three linear equations. The calculated coefficients were filtered and the average value was taken, and the values ​​of k1, k2 and k3 were 4.32, 2.27 and 2.05, respectively.

[0044] The size of the coefficient is a specific value obtained by quantifying each parameter to facilitate subsequent comparison. The size of the coefficient depends on the amount of sample data and the evaluation coefficient initially set by those skilled in the art for each set of sample data. As long as it does not affect the proportional relationship between the parameter and the quantified value, such as the evaluation coefficient being proportional to the value of the switch.

[0045] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0046] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to any specific implementation. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A leakage detection system for plastic switches, characterized in that, It includes a leakage testing module, a test analysis module, a leakage investigation module, and a test evaluation module. The leakage testing module, test analysis module, leakage investigation module, and test evaluation module are sequentially connected in communication, and the leakage investigation module is connected in communication with the leakage testing module. The leakage test module is used for leakage test of the plastic switch: marking finished product plastic switches of a unified production batch as test objects, installing the test objects at one end of a test pipeline, and setting test points on the inner wall of the test pipeline in the axial direction i , i = 1, 2, …, n, n is a positive integer, obtaining test values CS i of the test points i during the test process i ; and sending the test values CS i of all the test points to a test analysis module The test analysis module is used to analyze the test data of the plastic switch and obtain the pressure performance value and pressure deviation value of the test object. The pressure performance value and pressure deviation value are used to determine whether there is leakage during the test process. The leakage detection module is used to perform forward and reverse detection of leakage points during the testing process of plastic switches; The test evaluation module is used to evaluate and analyze the test results of the plastic switch; Test points i Test value CS of test point i The acquisition process includes: test point 1 is closest to the test object, test point n is farthest from the test object, and test point i A pressure sensor is arranged, a water pump and a water tank are arranged at the other end of the test pipeline, water in the water tank is pumped into the test pipeline by the water pump, after the water in the test pipeline flows out of the test object, the test object is closed, and the water pump is continuously pressurized until the water pump pressure reaches L1PA, the valve at the other end of the test pipeline is closed, and all test points i The pressure value of the pressure sensor is recorded and marked as the test value CS of the test point i ; The process of obtaining pressure performance values ​​and pressure deviation values ​​includes: for all test points i Test value CS i The pressure performance value is obtained by summing and averaging the results for all test points. i Test value CS i The pressure deviation value is obtained by performing variance calculation; The specific process for determining whether a leak exists during the testing process includes: comparing the pressure reading and pressure deviation values ​​with preset pressure reading and pressure deviation thresholds, respectively; if the pressure deviation value is greater than or equal to the pressure deviation threshold, a leak is determined to exist during the testing process, a leak detection signal is generated, and the leak detection signal is sent to the leak detection module; if the pressure deviation value is less than the pressure deviation threshold and the pressure reading value is greater than or equal to the pressure reading threshold, no leak is determined to exist during the testing process, and the test object is marked as a qualified object; if the pressure deviation value is less than the pressure deviation threshold and the pressure reading value is less than the pressure reading threshold, the testing process is determined to be non-compliant, a retest signal is generated, and the retest signal is sent to the leak testing module. The specific process of forward inspection includes: taking test point 1 as the reference point, determining CS along the axis. i+1 Is it greater than CS? i If so, then CS i+1 The corresponding test point is marked as a forward coincidence point; otherwise, CS is marked as a forward coincidence point. i+1 Corresponding test points i Marked as the forward termination point; all test points i All forward investigations have been completed or test points have been identified. i When a point is marked as a forward termination point, the forward investigation is terminated; when the forward investigation ends, it is determined whether the number of forward matching points is n-1: if yes, it is determined that the test object has a leakage phenomenon and the test object is marked as a leaking object; if no, the test pipeline is investigated in reverse. The specific process of reverse investigation includes: using test points n Using the reference point, determine CS along the axis. i-1 Is it greater than CS? i If so, then CS i-1 The corresponding test point is marked as a reverse coincidence point; otherwise, CS is marked as a reverse coincidence point. i-1 Corresponding test points i Marked as the reverse termination point; all test points i All reverse engineering or test points have been completed. i The reverse investigation terminates when a point is marked as a reverse termination point. At the end of the reverse investigation, it is determined whether the number of reverse matching points is [value missing]. n-1 If yes, the valve is determined to be leaking, a valve replacement signal is generated and sent to the leakage test module. After receiving the valve replacement signal, the leakage test module replaces the valve and then re-performs the leakage test on the test object. If no, the test pipeline is determined to be leaking, a pipeline replacement signal is generated and sent to the leakage test module. After receiving the pipeline replacement signal, the leakage test module replaces the test pipeline and then re-performs the leakage test on the test object.

2. The leakage detection system for plastic switches according to claim 1, characterized in that, The specific process of evaluating and analyzing the test results of plastic switches by the test evaluation module includes: after all test objects in the same batch have completed the leakage test, the switch value KG, valve value FM, and pipeline value GD are obtained. The switch value KG is the number of leaking objects, the valve value FM is the number of times the leakage test module received the valve replacement signal, and the pipeline value GD is the number of times the leakage test module received the pipeline replacement signal. Through formula The evaluation coefficient PG is obtained, where k1, k2, and k3 are proportional coefficients, and k1>k2>k3>1. ZS is the total number of finished plastic switches in this batch. The evaluation coefficient is used to determine whether the overall test results of this batch of plastic switches meet the requirements.

3. A leakage detection system for plastic switches according to claim 2, characterized in that, The specific process for determining whether the overall test results of this batch of plastic switches meet the requirements includes: comparing the evaluation coefficient PG with the preset evaluation threshold PGmax; if the evaluation coefficient PG is less than the evaluation threshold PGmax, the overall test results of this batch of plastic switches are determined to meet the requirements, and the leaking objects are sorted out; if the evaluation coefficient PG is greater than or equal to the evaluation threshold PGmax, the overall test results of this batch of plastic switches are determined to not meet the requirements, the leaking objects are removed, and the qualified objects in this batch are subjected to a second test.

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