Liquid heater fault simulation test device with self-adaptive clamping mechanism

Abstract

The invention discloses a liquid heater fault simulation test device with a self-adaptive clamping mechanism, which comprises a simulation seat and a detection device, and is characterized in that the simulation seat is provided with a turnover platform, the turnover platform is provided with an opening and closing mechanism, the opening and closing mechanism is provided with a plurality of lifting adjusting assemblies, and the lifting adjusting assemblies are connected with the detection device. A height synchronization assembly is arranged between the multiple lifting adjusting assemblies, overturning adjusting hinge bases are arranged on the lifting adjusting assemblies, the lifting adjusting assemblies can adapt to clamping of liquid container products of different sizes and models, meanwhile, the multiple clamping parts capable of being adjusted in a universal mode can adapt to attaching and clamping of surfaces of different radians, and the clamping efficiency is improved. Through the height synchronization assembly, it is guaranteed that the multiple clamping parts rapidly and synchronously select the optimal clamping position, the fitting performance is better, adjustment is convenient, adaptability is high, and clamping and fixing fault simulation tests of products of various models are met.

Description

Technical Field

[0001] The invention relates to a liquid heater fault simulation test device, in particular to a liquid heater fault simulation test device with an adaptive clamping mechanism. Background Art

[0002] With the improvement of living standards and living conditions of urban residents, electric kettles and other liquid heaters have rapidly become popular and have become the most commonly used household necessities in ordinary people's homes. The quality of their safety is directly related to the safety of family members and property. Fault simulation test is an important project involving the safety performance of household appliances. It is the safety standard for electric kettles and other liquid heaters GB 4706.1-2005 "Safety of Household and Similar Electrical Appliances Part 1: General Requirements", GB The safety performance test items specified in household appliance standards such as 4706.19-2008 "Particular requirements for safety of liquid heaters for household and similar electrical appliances" are mainly to simulate unnoticed damage to the equipment by applying simulated faults (such as short-circuit thermostats, sequential short-circuit protection devices, etc.) to liquid heater products, so as to achieve the purpose of testing its safety during abnormal operation. The fault simulation test is also subject to many human factors, high labor intensity of inspection personnel, low inspection efficiency and other problems during the test process. Therefore, an automatic and repetitive inspection device is designed to replace manual repetitive inspection work. Due to the different models and volume sizes of liquid containers, and the different curved surfaces on the product surface, it is necessary to design a clamping device that can be suitable for various container products.

[0003] Therefore, the existing liquid heater fault simulation test device needs to be further improved. Summary of the invention

[0004] The purpose of the present invention is to provide a liquid heater fault simulation test device with an adaptive clamping mechanism, which can adapt to the clamping of products of different models and curved surfaces and achieve stable clamping according to product size and optimal clamping position.

[0005] In order to achieve the above object, the present invention adopts the following scheme:

[0006] A liquid heater fault simulation test device with an adaptive clamping mechanism comprises a simulation seat and a detection device, wherein the simulation seat is provided with a flip platform, the flip platform is provided with an opening and closing mechanism, the opening and closing mechanism is provided with a plurality of lifting and closing adjustment components, a height synchronization component is provided between the plurality of lifting and closing adjustment components, the lifting and closing adjustment components are provided with a flip adjustment hinge seat, the flip adjustment hinge seat is hinged with an adjustment swing seat, both sides of the adjustment swing seat are provided with a rotating shaft structure, and a clamping part is installed on the rotating shaft structure.

[0007] Furthermore, the flip platform includes a first articulated seat arranged on the simulation seat, a flip fixture plate is hinged on the first articulated seat, and a flip driving mechanism for driving the flip fixture plate to flip is arranged on the simulation seat.

[0008] Furthermore, the flip driving mechanism includes a second hinged seat arranged on the simulation seat, a third hinged seat is arranged at the bottom of the flip fixture plate, and a push rod motor is hinged between the second hinged seat and the third hinged seat.

[0009] Furthermore, the opening and closing mechanism includes a plurality of linear guide grooves arranged on the flip fixture plate, the plurality of linear guide grooves are evenly distributed around the central circumference of the flip fixture plate, sliding blocks are movably arranged in the linear guide grooves, and the flip fixture plate is provided with a synchronous driving mechanism for driving the plurality of sliding blocks to open and close synchronously.

[0010] Furthermore, the synchronous drive mechanism includes an intermediate rotating circular plate arranged at the bottom of the flip fixture plate, there are four sliding blocks, the intermediate rotating circular plate is provided with four eccentric shafts evenly distributed around the center circumference of the intermediate rotating circular plate, the sliding block is provided with a synchronous shaft, a synchronous connecting rod is hinged between the eccentric shaft and a corresponding one of the synchronous shafts, and the flip fixture plate is provided with an angle adjustment structure for adjusting the angle of the intermediate rotating circular plate.

[0011] Furthermore, the angle adjustment structure includes a sleeve seat arranged on the flip fixture plate, an adjusting rod shaft is inserted in the sleeve seat, a worm structure is arranged in the middle of the adjusting rod shaft, a worm gear structure is arranged on the intermediate rotating circular plate, the worm structure and the worm structure are meshed for transmission, a locking thread is arranged at one end of the adjusting rod shaft, and a locking nut is threadedly connected to the locking thread and can tighten the sleeve seat.

[0012] Furthermore, there are four lifting and adjusting components, which are respectively arranged on the four sliding blocks;

[0013] The lifting and lowering adjustment assembly comprises a vertical guide shaft arranged on the sliding block, and a vertical guide sleeve is arranged on the vertical guide shaft.

[0014] Furthermore, the height synchronization component includes a transverse axial hole arranged on the vertical guide sleeve, a synchronous lifting shaft is movably arranged in the transverse axial hole, two adjacent synchronous lifting shafts are arranged perpendicular to each other, a synchronous connecting piece is arranged between the two adjacent synchronous lifting shafts, and the synchronous connecting piece is provided with a transverse through hole and a longitudinal through hole spaced apart vertically, and one end of the two adjacent synchronous lifting shafts are respectively inserted into the transverse through hole and the longitudinal through hole.

[0015] Furthermore, the inner wall of the clamping portion is arranged as an arc-shaped surface.

[0016] Furthermore, a water inlet device is provided above the simulation seat, and a water storage tank is provided below the simulation seat.

[0017] In summary, the present invention has the following beneficial effects compared with the prior art:

[0018] The present invention solves the shortcomings of the existing liquid heater fault simulation test device. Through the structural setting of the present invention, it has the following advantages: it can adapt to the clamping of liquid container products of different volumes and models. At the same time, multiple universally adjustable clamping parts can adapt to the fitting clamping of different curvature surfaces. Through the high-speed synchronization component, multiple clamping parts can quickly and synchronously select the best clamping position, with better fit, convenient adjustment, strong adaptability, and meet the clamping and fixing fault simulation test of various models of products. It has a simple structure and is easy to use. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 A perspective view of the present invention;

[0020] Figure 2 for Figure 1 A local enlarged view of point A;

[0021] Figure 3 It is a right side view of the present invention;

[0022] Figure 4 A top view of the present invention;

[0023] Figure 5 for Figure 4 A partial enlarged view of

[0024] Figure 6 It is a schematic diagram of the internal structure of the present invention. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0026] See also Figure 1-6The present invention provides a liquid heater fault simulation test device with an adaptive clamping mechanism, comprising a simulation seat 1 and a detection device 2, wherein the simulation seat 1 is provided with a flip platform 3, the flip platform 3 is provided with an opening and closing mechanism 4, the opening and closing mechanism 4 is provided with a plurality of lifting and adjusting components 5, a height synchronization component 6 is provided between the plurality of lifting and adjusting components 5, the lifting and adjusting components 5 are provided with a flip adjustment hinge seat 7, the flip adjustment hinge seat 7 is hinged with an adjustment swing seat 8, the adjustment swing seat 8 is provided with a rotating shaft structure 9 on both sides, and a clamping portion 10 is installed on the rotating shaft structure 9;

[0027] Adjust the following parameters according to the selected product model and volume size:

[0028] Controlling the opening and closing size of the plurality of clamping parts 10 according to the volume of the product: adjusting the opening and closing mechanism 4 can adjust the opening and closing of the plurality of clamping parts 10;

[0029] According to the optimal clamping height position of the product, the height positions of the multiple clamping parts 10 are adjusted; the multiple lifting adjustment components 5 are driven to move up and down synchronously by the height synchronization component 6 to ensure height consistency;

[0030] The mutual cooperation between the flip adjustment hinge seat 7 and the adjustment swing seat 8 enables the clamping portion 10 to better fit the upper and lower arc surfaces of the product;

[0031] The two rotating shaft structures 9 capable of adjusting angles left and right can ensure that the clamping portion 10 better fits the left and right curved surfaces of the product.

[0032] The flip platform 3 of the present invention includes a first articulated seat 301 arranged on the simulation seat 1, a flip fixture plate 302 is hinged on the first articulated seat 301, and a flip driving mechanism 303 for driving the flip fixture plate 302 to flip is arranged on the simulation seat 1.

[0033] The flip driving mechanism 303 of the present invention comprises a second hinge seat 3031 arranged on the simulation seat 1, a third hinge seat 3032 is arranged at the bottom of the flip fixture plate 302, and a push rod motor 3033 is hinged between the second hinge seat 3031 and the third hinge seat 3032.

[0034] The opening and closing mechanism 4 described in the present invention includes a plurality of linear guide grooves 401 arranged on the flip fixture plate 302, and the plurality of linear guide grooves 401 are evenly distributed around the central circumference of the flip fixture plate 302. A sliding block 402 is movably arranged in the linear guide groove 401, and a synchronous driving mechanism 403 for driving the plurality of sliding blocks 402 to open and close synchronously is arranged on the flip fixture plate 302.

[0035] The synchronous drive mechanism 403 of the present invention comprises an intermediate rotating circular plate 4031 arranged at the bottom of the flip fixture plate 302, the number of the sliding blocks 402 is four, the intermediate rotating circular plate 4031 is provided with four eccentric shafts 4032 evenly distributed around the central circumference of the intermediate rotating circular plate 4031, the sliding block 402 is provided with a synchronous shaft 4033, a synchronous connecting rod 4034 is hinged between the eccentric shaft 4032 and a corresponding one of the synchronous shafts 4033, and the flip fixture plate 302 is provided with an angle adjustment structure 100 for adjusting the angle of the intermediate rotating circular plate 4031;

[0036] The middle rotating circular plate 4031 is rotated to drive the multiple eccentric shafts 4032 to rotate synchronously, and the eccentric shaft 4032 pushes and pulls a corresponding synchronous connecting rod 4034, so that the synchronous connecting rod 4034 pulls or pushes the corresponding synchronous shaft 4033, so that the sliding block 402 moves in a linear path, thereby realizing the synchronous linear path movement of the multiple sliding blocks 402;

[0037] The angle adjustment structure 100 of the present invention comprises a sleeve seat 101 arranged on the flip fixture plate 302, an adjusting rod shaft 102 is inserted into the sleeve seat 101, a worm structure 103 is arranged in the middle of the adjusting rod shaft 102, a worm gear structure 104 is arranged on the outer wall of the circumference of the intermediate rotating circular plate 4031, the worm gear structure 104 and the worm gear structure 103 are meshed and transmitted with each other, a locking thread 105 is arranged at one end of the adjusting rod shaft 102, and a locking nut 106 that can compress the sleeve seat 101 is threadedly connected to the locking thread 105;

[0038] When adjusting the intermediate rotating circular plate 4031 , the locking nut 106 is loosened, and the worm structure 103 is rotated. The worm structure 103 drives the worm wheel structure 104 to rotate and drives the intermediate rotating circular plate 4031 to rotate.

[0039] The lifting and adjusting components 5 of the present invention are four, which are respectively arranged on the four sliding blocks 402;

[0040] The lifting adjustment assembly 5 includes a vertical guide shaft 501 disposed on the sliding block 402 , and a vertical guide sleeve 502 is disposed on the vertical guide shaft 501 .

[0041] The height synchronization component 6 of the present invention comprises a transverse shaft hole 601 provided on the vertical guide sleeve 502, a synchronous lifting shaft 602 is movably provided in the transverse shaft hole 601, two adjacent synchronous lifting shafts 602 are vertically provided, a synchronous connecting member 603 is provided between the two adjacent synchronous lifting shafts 602, and the synchronous connecting member 603 is provided with a transverse through hole 604 and a longitudinal through hole 605 spaced apart from each other, and one end of the two adjacent synchronous lifting shafts 602 is respectively inserted into the transverse through hole 604 and the longitudinal through hole 605;

[0042] Since the opening and closing sizes of the multiple clamping parts 10 will change, and the height positions of the multiple clamping parts 10 must be adjusted synchronously, the above structure is used to achieve:

[0043] The transverse through holes 604 and the longitudinal through holes 605 on the four synchronous connecting members 603 ensure that the corresponding synchronous lifting shafts 602 are at the same height position, and realize synchronous height adjustment of the multiple synchronous lifting shafts 602;

[0044] The synchronous lifting shaft 602 can move in the corresponding transverse through hole 604 and longitudinal through hole 605 , and therefore, the opening and closing movement of the clamping part 10 will not be hindered.

[0045] The inner wall of the clamping portion 10 of the present invention is an arc-shaped surface.

[0046] The simulation seat 1 of the present invention is provided with a water inlet device 200 above, and the simulation seat 1 is provided with a water storage tank 300 below.

[0047] Place the electric kettle on a plywood with a thickness of about 20mm. The electric kettle equipped with two self-resetting thermal circuit breakers is operated with one of the thermal circuit breakers short-circuited; the electric kettle is operated at no-load at 0.85 times the rated power input or 1.15 times the rated power output, whichever is more unfavorable; within 2s after the other thermal circuit breaker is operated, fill the electric kettle with water at a temperature of 15℃±5℃, and pour out the water in the electric kettle after 1 minute; the test is carried out 100 times.

[0048] During the test, the kettle should not emit flames, molten metal, toxic or flammable gases in dangerous quantities, and its temperature rise should not exceed the specified value of the standard.

[0049] After the test, the shell deformation degree and electrical strength test should meet the standard requirements.

[0050] The following are the control methods:

[0051] 2 Development plan

[0052] 2.1 Basis and principle of development

[0053] The liquid heater fault simulation test device developed this time is mainly developed based on the detection methods and detection requirements stipulated in Article 19.102 of "Safety of Household and Similar Electrical Appliances Part 1: General Requirements" (GB 4706.1-2005) and "Safety of Liquid Heaters for Household and Similar Electrical Appliances" (GB 4706.19-2008). It adopts PLC control technology and PID control algorithm, and effectively combines multifunctional general fixtures and automatic flipping systems, automatic test control systems, data acquisition and alarm systems, so as to achieve the purpose of automatically conducting liquid heater fault simulation tests.

[0054] 2.2 Main technical indicators and technical parameters of research and development

[0055] (1) Main technical indicators

[0056] This device can realize the automatic control of the liquid heater fault simulation test, dynamically monitor and collect and record the water temperature, water injection capacity, voltage, current, power and other data during the test, and accurately control the parameters of water temperature, water injection capacity and test time, thereby improving the detection efficiency of the test.

[0057] (2) Main technical parameters

[0058] 1. Water filling capacity: (0-4.0) L, maximum allowable error: ±0.2 L

[0059] 2. Water injection temperature: 15℃±5℃.

[0060] 3. Water injection time: (0-60)s, maximum allowable error: ±1s.

[0061] 4. Sample input voltage: (0-300)V, maximum allowable error: ±5V.

[0062] Flipping device: The standard requires that the water in the electric kettle be poured out after 1 minute. This test device has the function of clamping a variety of kettle bodies and automatically flipping and pouring water, realizing the versatility and applicability of the test device.

[0063] (2) Automatic test control system

[0064] The standard requires that the electric kettle be filled with water at a temperature of 15℃±5℃, and the water in the kettle be poured out after 1 minute; the test was conducted 100 times. This test device automatically sets the number of tests, interval time, and water filling capacity, automatically adjusts the water temperature of the injected water according to the settings, and has functions such as automatic water addition to achieve automated operation.

[0065] (3) Data acquisition and alarm system

[0066] The standard requires that the electric kettle be operated at no-load at 0.85 times the rated power input or 1.15 times the rated power output, whichever is more unfavorable. During the test, the electric kettle should not spray flames, molten metal, or dangerous amounts of toxic or flammable gases, and its temperature rise should not exceed the specified value of the standard. After the test, the degree of deformation of its shell and the electrical strength test should meet the requirements of the standard. This test device has the function of dynamically monitoring and collecting and recording data such as water temperature, water filling capacity, voltage, current, and component temperature rise during the test, and has the function of connection and operation fault alarm, realizing the intelligence of the test device.

[0067] (1) This device adopts an adjustable kettle body clamping device according to the diversity of the equipment test samples;

[0068] (2) Considering the reliability of the automatic flipping of the kettle body, the device uses a synchronous rotating motor as the power source, and realizes the automatic flipping and pouring function by setting the flipping angle;

[0069] (3) This device uses a PLC programmable controller to build an automatic control system, automatically setting parameters such as the number of tests, interval time, and water injection capacity. It automatically adjusts the water temperature of the injected water according to the settings and has functions such as automatic water addition to achieve automated operations.

[0070] (4) This device uses a PLC programmable controller to build an automatic monitoring system, which automatically monitors and collects data such as water temperature, water injection capacity, voltage, current, and component temperature rise during the test. It also has connection and operation fault alarm functions to realize the intelligence of the test device.

[0071] (5) This device uses LCD display touch as the human-computer interaction interface, and develops a corresponding visualization software system to realize the input of test parameters and the output of test results, thereby realizing the human-computer interaction function.

[0072] 1. Research on key technologies of multifunctional universal fixture

[0073] According to the diversity of the equipment test samples, consideration is given to designing the test device with an adjustable clamping device to meet the clamping requirements of various types of pot bodies and achieve the versatility and applicability of the test device.

[0074] 2. Research on key technologies of automatic flipping and pouring system

[0075] The standard requires that the water in the electric kettle be poured out after 1 minute. Therefore, the test device is designed with an automatic flipping and pouring function to realize the automation of the test device.

[0076] 3. Research on key technologies of automatic test control system

[0077] The standard requires that the electric kettle be filled with water at a temperature of 15℃±5℃, and the water in the kettle be poured out after 1 minute; the test was conducted 100 times. For this purpose, the test device was designed to automatically set the number of tests, interval time, and water filling capacity, automatically adjust the water temperature of the injected water according to the settings, and have functions such as automatic water addition to achieve automation of operation.

[0078] 4. Research on key technologies of automatic monitoring, data acquisition and alarm systems

[0079] An automatic monitoring system is built through a PLC programmable controller to dynamically monitor and collect and record data such as water temperature, water injection capacity, voltage, current, component temperature rise, etc. during the test. It also has connection and operation fault alarm functions to realize the intelligence of the test device.

[0080] This project uses two position sensors and installs them on both sides of the rotating shaft to monitor the rotation angle, thereby controlling the pouring angle and ensuring that the operating status of the flip mechanism can be accurately monitored. The control part uses a programmable logic controller (PLC) as the core controller of the system. PLC has the advantages of high reliability, flexible programming, and strong anti-interference ability, and can meet the control requirements of the automatic flip system. According to the control logic of the system, write the corresponding PLC program to achieve precise control of motors and other equipment. According to the control requirements of the system, write the controller program, debug and optimize it to ensure the stability, reliability and real-time performance of the controller.

[0081] Research on key technologies of automatic test control system

[0082] (1) Key technical solutions for automatic test control system

[0083] The standard requires that the electric kettle be filled with water at a temperature of 15℃±5℃, and the water in the kettle be poured out after 1 minute; the test was conducted 100 times. For this purpose, the test device was designed to automatically set the number of tests, interval time, and water filling capacity, automatically adjust the water temperature of the injected water according to the settings, and have functions such as automatic water addition to achieve automation of operation.

[0084] According to the standard requirements, the automatic test control system is designed for hardware, software, system integration and debugging.

[0085] First, the hardware part of the system is designed, mainly from the aspects of controller selection, sensor configuration, actuator drive, water tank heater and cooler control, communication and data acquisition.

[0086] ①Controller selection

[0087] The design adopts a high-performance programmable logic controller (PLC) to ensure the stability and reliability of the system. It has sufficient input and output points to connect various sensors and actuators to achieve automatic setting and control of the number of tests, interval time, water injection capacity, etc.

[0088] ②Sensor configuration

[0089] Equipped with a water temperature sensor, it is designed to measure the temperature of the test water in the water tank to ensure the accuracy and stability of the test water temperature measurement.

[0090] Equipped with a flow sensor, it is designed to measure the water injection flow rate and control the water injection capacity in conjunction with the water injection time setting.

[0091] ③Actuator drive

[0092] Water injection solenoid valve control: designed for the on-off injection of test water to achieve precise control of the water injection capacity.

[0093] Water tank heater and cooler control: According to the test requirements, control the working status of the heater and cooler to achieve temperature regulation to meet the test water requirement of 15℃±5℃.

[0094] ④Communication and data acquisition

[0095] Establish a reliable communication network to connect controllers, sensors and actuators. Choose communication methods such as Ethernet, serial communication or fieldbus to ensure the real-time and reliability of data transmission.

[0096] Secondly, the software part of the system is designed, mainly from the aspects of control algorithm design, human-computer interface design, etc.

[0097] ①Control algorithm design

[0098] Develop advanced control algorithms to achieve precise control of the test process. Use PID control algorithms to control temperature and flow to improve system stability and response speed.

[0099] ②Human-machine interface (HMI) design

[0100] Design and develop an intuitive and easy-to-use human-machine interface to facilitate operators to set test parameters. The human-machine interface has good visualization and interactivity.

[0101] Finally, the hardware equipment and software system are integrated, debugged, optimized and verified.

[0102] ①System Integration

[0103] Integrate hardware equipment and software systems to ensure coordination between various parts. Carry out system wiring, connection and debugging to ensure smooth communication and stable signals. Carry out system function and performance tests to verify whether the system's various functions and performance indicators meet the design requirements. Repair and optimize problems found in the test in a timely manner.

[0104] ②Debugging and optimization

[0105] Debug the system and adjust the control parameters and algorithms to improve the control accuracy and stability of the system. Carry out load test and reliability test of the system to ensure the reliability and stability of the system in long-term operation. Optimize the human-machine interface to improve the convenience and efficiency of user operation.

[0106] (2) Implementation of key technologies of automatic test control system

[0107] First, select hardware based on key technical solutions.

[0108] Programmable Logic Controller (PLC): OMRON SYSMAC CP1E programmable controller is selected, which has sufficient input and output points, processing speed and storage capacity to ensure the stability and reliability of the system. It has sufficient input and output points to connect various sensors and actuators to realize automatic setting control of test times, interval time, water injection capacity, etc.

[0109] Water temperature sensor: A thermocouple is used to measure the temperature of the injected water to ensure the accuracy and stability of the test water temperature measurement.

[0110] Flow sensor: SMC quantitative flow meter is used to measure the water injection flow rate, and control the water injection capacity in conjunction with the water injection time setting.

[0111] Water injection solenoid valve: Use DC24V normally closed solenoid valve to turn on and off the water injection of test water to achieve precise control of the water injection capacity.

[0112] Water tank heater and cooler: Select electric heaters and coolers of appropriate power to achieve temperature regulation to meet the test water requirement of 15℃±5℃.

[0113] Human-machine interface (HMI): Kunlun Tongtai's TPC7062KT (TD) embedded integrated touch screen is selected for parameter setting and system monitoring.

[0114] Secondly, build the system architecture based on key technical solutions.

[0115] The signals of water temperature and liquid level sensors are connected to PLC through digital input modules. Actuators such as heaters, coolers and solenoid valves are connected to PLC through relay output modules. The human-machine interface is connected to PLC through the communication interface to realize data interaction.

[0116] Third, implement control process based on key technical solutions

[0117] Parameter setting: Set the test number, interval time, water filling capacity, water temperature and other parameters on the human-machine interface. PLC reads these parameters and stores them in the internal memory.

[0118] Water temperature adjustment: PLC reads the signal of the water temperature sensor to get the current water temperature. Compare the current water temperature with the set water temperature target value. If the current water temperature is lower than the target value, PLC starts the heater to increase the water temperature; if the current water temperature is higher than the target value, PLC starts the cooler to lower the water temperature. Using PID control algorithm, the output power of the heater or cooler is automatically adjusted according to the water temperature deviation to achieve precise water temperature control.

[0119] Test control: PLC performs cycle control according to the set number of tests. At the beginning of each test, the water injection solenoid valve is opened according to the set water injection capacity to inject a certain amount of water into the test container. Then wait for a period of time according to the set interval to allow the system to stabilize. During the test, the water temperature is continuously monitored and automatically adjusted. When a test is completed, the test data is recorded and prepared for the next test.

[0120] Fourth, programming implementation based on key technical solutions

[0121] Use PLC programming software to write ladder diagram programs according to the control process. The main program modules include:

[0122] Parameter reading and storage module: reads the parameters set on the human-machine interface and stores them in the internal memory of the PLC.

[0123] Automatic water adding module: controls the switch of the water filling solenoid valve according to the signal of the liquid level sensor.

[0124] Water temperature regulation module: uses PID control algorithm to control the output power of the heater or cooler according to the water temperature deviation.

[0125] Test control module: perform test control according to the set test times and interval time, and record test data.

[0126] Finally, program debugging and optimization are performed to ensure stable and reliable operation of the system.

[0127] Including test system response time, data acquisition speed, temperature control and other performance indicators to ensure that the test requirements and temperature control accuracy and stability are met. At the same time, long-term operation tests are carried out to verify the reliability and stability of the system.

[0128] Through the research on the key technologies of the automatic test control system, a fully functional automatic control system based on PLC programmable controller has been realized, which meets the functional requirements of automatic setting of test parameters, automatic water temperature adjustment and automatic water addition, and improves the degree of automation of operation and test efficiency.

[0129] 4. Research on key technologies of automatic monitoring, data acquisition and alarm systems

[0130] (1) Key technical solutions for automatic monitoring, data collection and alarm systems

[0131] The standard requires monitoring of water temperature, water filling capacity, voltage, current, component temperature rise and other data. To this end, the design of the test device is considered to automatically dynamically monitor and collect and record the water temperature, water filling capacity, voltage, current, component temperature rise and other data during the test, and has the function of connection and operation fault alarm to realize the intelligence of the test device.

[0132] According to the standard requirements, the automatic monitoring system is designed for hardware, software, system integration and debugging.

[0133] First, the hardware part of the system is designed, mainly from the aspects of controller selection, sensor configuration, alarm equipment, human-machine interface (HMI), communication and data acquisition.

[0134] ①Controller selection

[0135] The design adopts a high-performance programmable logic controller (PLC) to ensure the stability and reliability of the system. It is equipped with an analog input module for collecting analog signals such as water temperature, voltage, and current; it is equipped with a digital input and output module for collecting switch signals and controlling alarm outputs.

[0136] ②Sensor configuration

[0137] Equipped with a water temperature sensor, it is designed to measure the temperature of the test water in the water tank to ensure the accuracy and stability of the test water temperature measurement.

[0138] Equipped with a flow sensor, it is designed to measure the water injection flow rate and control the water injection capacity in conjunction with the water injection time setting.

[0139] Configure water temperature sensor: Design and select high-precision thermal resistance sensors to ensure that the sensor's measurement range and accuracy meet the test requirements.

[0140] Configure voltage sensor and current sensor: Design and select appropriate AC sensors to ensure that the working voltage and current of the electric kettle can be accurately measured.

[0141] Component temperature rise sensor: The design uses contact temperature sensors to measure temperature changes of key components.

[0142] ③Alarm equipment

[0143] The design selects sound and light alarms for fault alarms.

[0144] ④Human-machine interface (HMI)

[0145] The design selects a touch screen as the HMI device, such as a touch screen, which is used to display the system's operating status, collected data, and alarm information.

[0146] ⑤Communication and data acquisition

[0147] Design and establish a reliable communication network to connect controllers, sensors, alarm devices and human-machine interfaces. Choose communication methods such as Ethernet, serial communication or fieldbus to ensure real-time and reliable data transmission.

[0148] Secondly, the software part of the system is designed, mainly from the aspects of signal acquisition and analysis design, human-computer interface design, etc.

[0149] ①Signal acquisition, analysis and design

[0150] Develop data analysis algorithms to make judgments and early warnings based on the extracted features to improve the stability and response speed of the system.

[0151] ②Human-machine interface (HMI) design

[0152] Design and develop an intuitive and easy-to-use human-machine interface to display collected data, alarm information, operation buttons, etc.

[0153] Finally, the hardware equipment and software system are integrated, debugged, optimized and verified.

[0154] ①System Integration

[0155] Integrate hardware equipment and software systems to ensure coordination between various parts. Carry out system wiring, connection and debugging to ensure smooth communication and stable signals. Carry out system function and performance tests to verify whether the system's various functions and performance indicators meet the design requirements. Repair and optimize problems found in the test in a timely manner.

[0156] ②Debugging and optimization

[0157] Debug the system to improve the control accuracy and stability of the system. Carry out load test and reliability test of the system to ensure the reliability and stability of the system in long-term operation. Optimize the human-machine interface to improve the convenience and efficiency of user operation.

[0158] (2) Implementation of key technologies for automatic monitoring, data collection and alarm systems

[0159] First, select hardware based on key technical solutions.

[0160] Programmable Logic Controller (PLC): OMRON SYSMAC CP1E programmable controller is selected, which has sufficient input and output points, processing speed and storage capacity to ensure the stability and reliability of the system. It has analog input modules that can be used to collect analog signals such as water temperature, voltage, and current; it has digital input and output modules that can be used to collect switch signals and control alarm outputs, etc.

[0161] Water temperature sensor: Use a high-precision PT100 thermal resistor sensor to ensure that the sensor's measurement range and accuracy meet the test requirements.

[0162] Voltage sensor and current sensor: Use T4W-AV-AN AC sensor to ensure accurate measurement of the heater's operating voltage and current.

[0163] Component temperature rise sensor: A contact temperature sensor is used to measure the temperature changes of key components.

[0164] Alarm equipment: Use sound and light alarm for fault alarm. Connect the alarm signal to the digital output module of PLC and control the triggering of alarm through programming.

[0165] Human-machine interface (HMI): Human-machine interface: Kunlun Tongtai's TPC7062KT (TD) embedded integrated touch screen is selected to display the system's operating status, collected data and alarm information, etc.

[0166] Secondly, build the system architecture based on key technical solutions.

[0167] Signal acquisition and processing: Connect the output signal of the sensor to the analog input module or digital input module of the PLC. The PLC processes the collected signal, such as filtering, amplification, A / D conversion, etc., to improve the quality and accuracy of the signal.

[0168] Data storage and recording: Set up a data storage area in the PLC to store the collected data. You can use the PLC's internal memory or an external memory card. Program to achieve timed storage and recording of data for subsequent analysis and processing.

[0169] Fault alarm function: Set the fault judgment conditions. When the collected data exceeds the set range or an abnormal situation occurs, the fault alarm is triggered. The PLC controls the alarm device to send out sound and light alarm signals and display the fault information on the HMI.

[0170] Communication and control: PLC is connected to HMI, host computer and other equipment through the communication interface to realize data transmission and remote monitoring. Communication can be carried out through Ethernet, serial port communication and other methods.

[0171] By setting the operation interface on the HMI, the user can control the test device through the touch screen, such as starting, stopping, parameter setting, etc.

[0172] Third, programming implementation based on key technical solutions

[0173] Use PLC programming software and function block diagram to write programs to achieve signal acquisition, data processing, fault judgment, alarm control, data storage and other functions.

[0174] Use HMI programming software to design HMI interface to display collected data, alarm information, operation buttons, etc. Realize communication with PLC to realize data interaction and operation control.

[0175] Finally, program debugging and optimization are performed to ensure stable and reliable operation of the system.

[0176] Hardware debugging: Check whether the connection of sensors, PLC, HMI and other equipment is correct and whether the signal is stable. Calibrate the sensor to ensure the accuracy of the measurement data. Test whether the alarm device is working properly.

[0177] Software debugging: Perform online debugging in the PLC programming software to check whether the program logic is correct and whether data acquisition and processing are normal. Perform simulation operation in the HMI programming software to check whether the interface display and operation are normal.

[0178] System optimization: Optimize and adjust the system based on the debugging results to improve the stability and reliability of the system.

[0179] Through the research on key technologies of automatic monitoring, data acquisition and alarm systems, an automatic monitoring system for liquid heater fault simulation test equipment was realized using PLC programmable controller, which realizes dynamic monitoring and collection and recording of water temperature, water injection capacity, voltage, current, component temperature rise and other data during the test, and has a fault alarm function, thus improving the intelligence level of the test equipment.

[0180] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A liquid heater fault simulation test device with an adaptive clamping mechanism, comprising a simulation seat (1) and a detection device (2), characterized in that: The simulation seat (1) is provided with a flipping platform (3), the flipping platform (3) is provided with an opening and closing mechanism (4), the opening and closing mechanism (4) is provided with a plurality of lifting and lowering adjustment components (5), a height synchronization component (6) is provided between the plurality of lifting and lowering adjustment components (5), the lifting and lowering adjustment components (5) are provided with a flipping adjustment hinge seat (7), the flipping adjustment hinge seat (7) is hinged with an adjustment swing seat (8), both sides of the adjustment swing seat (8) are provided with a rotating shaft structure (9), and a clamping part (10) is installed on the rotating shaft structure (9).

2. A liquid heater fault simulation test device with an adaptive clamping mechanism according to claim 1, characterized in that: The flip platform (3) comprises a first hinged seat (301) arranged on the simulation seat (1), a flip fixture plate (302) is hinged on the first hinged seat (301), and a flip driving mechanism (303) for driving the flip fixture plate (302) to flip is arranged on the simulation seat (1).

3. A liquid heater fault simulation test device with an adaptive clamping mechanism according to claim 2, characterized in that: The flip driving mechanism (303) comprises a second hinge seat (3031) arranged on the simulation seat (1), a third hinge seat (3032) is arranged at the bottom of the flip fixture plate (302), and a push rod motor (3033) is hinged between the second hinge seat (3031) and the third hinge seat (3032).

4. A liquid heater fault simulation test device with an adaptive clamping mechanism according to claim 3, characterized in that: The opening and closing mechanism (4) comprises a plurality of linear guide grooves (401) arranged on the flip fixture plate (302), the plurality of linear guide grooves (401) being evenly distributed around the central circumference of the flip fixture plate (302), a sliding block (402) being movably arranged in the linear guide groove (401), and a synchronous driving mechanism (403) for driving the plurality of sliding blocks (402) to open and close synchronously is arranged on the flip fixture plate (302).

5. A liquid heater fault simulation test device with an adaptive clamping mechanism according to claim 4, characterized in that: The synchronous drive mechanism (403) comprises an intermediate rotating circular plate (4031) arranged at the bottom of the flip fixture plate (302), there are four sliding blocks (402), the intermediate rotating circular plate (4031) is provided with four eccentric shafts (4032) evenly distributed around the central circumference of the intermediate rotating circular plate (4031), the sliding block (402) is provided with a synchronous shaft (4033), a synchronous connecting rod (4034) is hinged between the eccentric shaft (4032) and a corresponding one of the synchronous shafts (4033), and the flip fixture plate (302) is provided with an angle adjustment structure (100) for adjusting the angle of the intermediate rotating circular plate (4031).

6. A liquid heater fault simulation test device with an adaptive clamping mechanism according to claim 5, characterized in that: The angle adjustment structure (100) comprises a shaft sleeve seat (101) arranged on the flip fixture plate (302), an adjusting rod shaft (102) is inserted into the shaft sleeve seat (101), a worm structure (103) is arranged in the middle of the adjusting rod shaft (102), a worm gear structure (104) is arranged on the intermediate rotating circular plate (4031), the worm gear structure (103) and the worm gear structure (103) are meshed and transmitted, a locking thread (105) is arranged at one end of the adjusting rod shaft (102), and a locking nut (106) is threadedly connected to the locking thread (105) and can press the shaft sleeve seat (101) tightly.

7. A liquid heater fault simulation test device with an adaptive clamping mechanism according to claim 6, characterized in that: There are four lifting adjustment components (5), which are respectively arranged on the four sliding blocks (402); The lifting and lowering adjustment component (5) comprises a vertical guide shaft (501) arranged on the sliding block (402), and a vertical guide sleeve (502) is arranged on the vertical guide shaft (501).

8. A liquid heater fault simulation test device with an adaptive clamping mechanism according to claim 7, characterized in that: The height synchronization component (6) includes a transverse shaft hole (601) arranged on the vertical guide sleeve (502), a synchronous lifting shaft (602) is movably arranged in the transverse shaft hole (601), two adjacent synchronous lifting shafts (602) are arranged perpendicular to each other, a synchronous connecting piece (603) is arranged between the two adjacent synchronous lifting shafts (602), and the synchronous connecting piece (603) is provided with a transverse through hole (604) and a longitudinal through hole (605) spaced apart from each other, and one end of the two adjacent synchronous lifting shafts (602) is respectively inserted into the transverse through hole (604) and the longitudinal through hole (605).

9. A liquid heater fault simulation test device with an adaptive clamping mechanism according to claim 8, characterized in that: The inner wall of the clamping portion (10) is arranged as an arc-shaped surface.

10. A liquid heater fault simulation test device with an adaptive clamping mechanism according to any one of claims 1 to 9, characterized in that: A water inlet device (200) is arranged above the simulation seat (1), and a water storage tank (300) is arranged below the simulation seat (1).

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