Overall air source heat pump water heater water-free commodity inspection algorithm operation method

Abstract

The invention discloses a water-free commodity inspection algorithm operation method for an integral air source heat pump water heater, and belongs to the technical field of commodity inspection of air source heat pump water heaters. The method comprises seven steps of a water-free commodity inspection heat exchange safety control strategy, an operation parameter test and data packet collection, water-free commodity inspection operation parameter correction, a water-free commodity inspection heating operation control strategy, an operation judgment strategy, dynamic error threshold adjustment and continuous optimization and commodity inspection under repeated PID control. According to the method, the air inlet temperature and the air outlet temperature are set, the rotating speed of a draught fan and the frequency of a compressor are determined, key parameters of the water heater in the water state and the water-free state are tested before mass production, a reference data packet A1 and a reference data packet A2 are formed, a correction data packet A3 is constructed after comparison, and an initial error allowable value k1 is set. A feedforward PID algorithm is used for adjusting the rotating speed of a compressor and a fan, and it is ensured that the air outlet temperature is stable. And commodity inspection data A4 is collected in real time and compared with A1, and the state of the water heater is evaluated by combining an error judgment standard k1 + A3.

Description

Technical Field

[0001] The present invention relates to the technical field of commercial inspection of air source heat pump water heaters, and in particular to an algorithm operation method for waterless commercial inspection of an integral air source heat pump water heater. Background Art

[0002] At present, with the safety, environmental protection and energy-saving characteristics of air source heat pump water heaters and the continuous support and support of the country's new energy policies, it has become the first choice for people to pursue green life. The market demand is increasing and the output is increasing. This puts forward greater requirements for the production efficiency of household integrated air source heat pump water heaters. Among them, the traditional online water injection commodity inspection link related technology is the bottleneck of the production efficiency of air source heat pump water heaters. First of all, the traditional water injection test requires a huge production line layout space for the water heater to be inspected to accommodate water storage tanks, cooling systems, connecting pipes, drainage systems and electronic control valves and other hardware equipment. This not only increases the floor space of the production workshop, but also limits the flexibility of the production line layout, making it difficult to improve the overall production efficiency. Secondly, the time to heat water is significantly extended because the specific heat capacity of water is much higher than that of air, which increases the commodity inspection cycle and greatly affects the efficiency of commodity inspection. In addition, during the commercial inspection of water-filled water heaters, a larger water temperature increase range is required to fully evaluate their performance. However, within the limited commercial inspection time, we can only capture the operating parameters of the water temperature within a relatively narrow range of changes. This limitation directly weakens the comprehensiveness and accuracy of fault identification, resulting in a low fault identification rate and increased after-sales problems. Summary of the invention

[0003] The object of the present invention is to provide an integrated air source heat pump water heater waterless commercial inspection algorithm operation method to solve the problems of low space utilization, long water injection and heating time and low fault recognition rate in the water heater commercial inspection process in the above-mentioned background technology.

[0004] To achieve the above object, the present invention provides the following technical solutions:

[0005] A method for operating an integral air source heat pump water heater waterless commercial inspection algorithm comprises the following steps:

[0006] S1. Waterless commercial inspection heat exchange safety control strategy

[0007] The water heater comprises an air source heat pump and a water exchange tank, wherein the air source heat pump is provided with a control system, wherein the control system calculates the enthalpy difference Δh required for the water exchange tank to heat the medium during the waterless commercial inspection according to the law of conservation of energy and the set air inlet temperature t0 and air outlet temperature t1, and determines the fan speed r1 and compressor frequency r2 that match the enthalpy difference value by using the correlation between the enthalpy difference Δh and the fan speed and the compressor frequency;

[0008] S2. Run parameter test and data packet collection

[0009] Before the water heater is put into mass production, the key parameters of the water heater are tested by simulating the actual operating environment, with and without water in the water heater, and under the same conditions of inlet air temperature, outlet air temperature and heating medium target temperature. The key parameters include power, exhaust temperature, exhaust pressure, coil temperature, return air temperature and return air pressure;

[0010] Based on the key parameters of the test, two reference data packets are formed, namely A1 and A2; wherein the A1 data packet represents the normal operating parameter set of the water heater in the water state, and the A2 data packet reflects the normal operating characteristic set of the water heater in the waterless state;

[0011] S3, waterless commodity inspection operation parameter correction

[0012] Compare A1 and A2, calculate the power difference, exhaust temperature difference, exhaust pressure difference, coil temperature difference, return air temperature and return air pressure difference between the two, and construct the difference between the two into the correction data package A3;

[0013] Considering the normal fluctuations in the production process, measurement errors and changes in environmental factors, the initial error allowable value k1 is set to form the error judgment standard k1+A3 for the first batch;

[0014] S4, waterless commercial inspection heating operation control

[0015] a. Start the control system and select the initial fan speed and compressor frequency as the starting parameters according to the fan speed r1, compressor frequency r2 and enthalpy difference Δh determined in advance;

[0016] b. Start the heating process. After a preset heating cycle T, the heated air is discharged and the current time is recorded as k = 0. The outlet air temperature at this time is recorded as Thereafter, k increases by 1 each time a heating cycle is completed;

[0017] c. Use the feedforward PID algorithm to calculate and adjust the error term Δr of the compressor frequency and fan speed to ensure that the outlet temperature can be stably maintained at the target value. The error term formula is:

[0018]

[0019] Among them, A is the slope value fitted by the outlet temperature, P1, P2, I1 are the feedforward PID parameters;

[0020] d. Continuously monitor the Δr value. If Δr < 0, reduce the larger of r1 and r2 by |Δr|; if Δr > 0, increase the smaller of r1 and r2 by Δr;

[0021] e. After the outlet temperature t1 is stabilized within the target range, real-time commodity inspection data is collected, marked as A4, and it is determined whether the commodity inspection data is within the error tolerance range;

[0022] S5. Operation judgment strategy

[0023] In the actual commodity inspection process, the control system will first compare the commodity inspection data A4 collected in real time with the reference data package A1, calculate the parameter difference between the two, and then generate a difference data package A5; then, the control system uses the preset error judgment standard k1+A3 to perform intelligent analysis on A5 to determine whether A5 exceeds the range of k1+A3;

[0024] S6. Dynamic error threshold adjustment and continuous optimization

[0025] The control system has established a parameter error collection and k1 value dynamic adjustment mechanism. In step S5, the parameter error data of all machines that are judged to be faulty will be automatically collected and stored; then, the system regularly conducts in-depth analysis of these error data to evaluate the impact of actual fluctuations in the production process, measurement errors and changes in environmental factors on commodity inspection standards; based on the analysis results, the system can intelligently adjust the k1 value to adapt to the latest status of the production line; in addition, by implementing a batch dynamic follow-up strategy, the control system can continuously monitor and optimize commodity inspection standards;

[0026] S7, commodity inspection under repeated PID control

[0027] Repeat step S4 to ensure that the quality inspection process always maintains the dynamic control of the fan speed and compressor frequency by the PID algorithm until all products have completed the commodity inspection.

[0028] Specifically, in step S4, both r1 and r2 are compared and operated using normalized values.

[0029] Specifically, the specific operation judgment strategy in step S5 is:

[0030] If A5≤k1+A3, the water heater is judged to be in a fault-free state;

[0031] If A5>k1+A3, the current state of the water heater is determined to be faulty, and the fault warning mechanism is triggered and an out-of-range operating parameter code is output.

[0032] In summary, compared with the prior art, the present invention has the following beneficial effects:

[0033] 1. The waterless commercial inspection system of the present invention determines the performance of the heat pump water heater by directly measuring the key parameters of the commercial inspection process of the heat pump water heater. There is no need to set up additional large hardware equipment such as water storage tanks, cooling systems, connecting pipes, drainage systems and electric control valves required in the traditional commercial inspection process, thereby greatly saving space in the inspection area, making the production line layout more flexible and able to more easily adapt to different production needs, thereby improving the overall production efficiency.

[0034] 2. The present invention utilizes the fact that the specific heat capacity of air is much lower than that of water and the time required to heat air is significantly shorter than that of heating water. By precisely controlling the fan speed and compressor frequency, a fast and stable heating process is achieved, which greatly shortens the commodity inspection cycle and enables products to complete commodity inspection in a shorter time.

[0035] 3. The present invention can accurately monitor and record the operating parameters of the water heater in the waterless state by constructing a waterless commercial inspection heat exchange safety control strategy and an operating parameter test and data packet collection mechanism, and compare and analyze the benchmark data packets in the water state. At the same time, the feedforward PID algorithm and dynamic error threshold adjustment mechanism are used to achieve real-time monitoring and intelligent analysis of the water heater performance, improve the comprehensiveness and accuracy of fault identification, and capture more operating parameters within the limited commercial inspection time, so as to more effectively identify potential faults.

[0036] 4. The present invention realizes the automation and intelligence of the commodity inspection process through the integrated control system and intelligent analysis algorithm. From starting the system to collecting data, analyzing data, and judging faults, the entire process does not require human intervention, which reduces errors caused by human factors and also reduces production costs and labor costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 This is a flow chart of the operation method of the waterless commercial inspection algorithm of the overall air source heat pump water heater of the present invention. DETAILED DESCRIPTION

[0038] The specific embodiments of the present invention are described in detail below in conjunction with the accompanying drawings. It should be understood that the specific embodiments given here are only used to illustrate and explain the present invention, and cannot be used to limit the present invention.

[0039] It should be noted that many specific details are set forth in the following description to facilitate a full understanding of the present invention. However, the present invention may also have other implementation modes. Therefore, the protection scope of the present invention is not limited to the specific embodiments disclosed below.

[0040] Combined with Figure 1 It can be seen that a method for operating an integral air source heat pump water heater waterless commercial inspection algorithm includes the following steps:

[0041] S1. Waterless commercial inspection heat exchange safety control strategy

[0042] The water heater comprises an air source heat pump and a water exchange tank, wherein the air source heat pump is provided with a control system, wherein the control system calculates the enthalpy difference Δh required for the water exchange tank to heat the medium during the waterless commercial inspection according to the law of conservation of energy and the set air inlet temperature t0 and air outlet temperature t1, and determines the fan speed r1 and compressor frequency r2 that match the enthalpy difference value by using the correlation between the enthalpy difference Δh and the fan speed and the compressor frequency;

[0043] In this specific embodiment, the outlet temperature t1 is controlled at 60°C;

[0044] S2. Run parameter test and data packet collection

[0045] Before the water heater is put into mass production, the key parameters of the water heater are tested by simulating the actual operating environment, with and without water in the water heater, and under the same conditions of inlet air temperature, outlet air temperature and heating medium target temperature. The key parameters include power, exhaust temperature, exhaust pressure, coil temperature, return air temperature and return air pressure;

[0046] Based on the key parameters of the test, two reference data packets are formed, namely A1 and A2; wherein the A1 data packet represents the normal operating parameter set of the water heater in the water state, and the A2 data packet reflects the normal operating characteristic set of the water heater in the waterless state;

[0047] S3, waterless commodity inspection operation parameter correction

[0048] Compare A1 and A2, calculate the power difference, exhaust temperature difference, exhaust pressure difference, coil temperature difference, return air temperature and return air pressure difference between the two, and construct the difference between the two into the correction data package A3;

[0049] Considering the normal fluctuations in the production process, measurement errors and changes in environmental factors, the initial error allowable value k1 is set to form the error judgment standard k1+A3 for the first batch;

[0050] S4, waterless commercial inspection heating operation control

[0051] a. Start the control system and select the initial fan speed and compressor frequency as the starting parameters according to the fan speed r1, compressor frequency r2 and enthalpy difference Δh determined in advance;

[0052] b. Start the heating process. After a preset heating cycle T, the heated air is discharged and the current time is recorded as k = 0. The outlet air temperature at this time is recorded as Thereafter, k increases by 1 each time a heating cycle is completed;

[0053] c. Use the feedforward PID algorithm to calculate and adjust the error term Δr of the compressor frequency and fan speed to ensure that the outlet temperature can be stably maintained at the target value. The error term formula is:

[0054]

[0055] Where A is the slope value fitted by the outlet temperature, P1, P2, I1 are the feedforward PID parameters;

[0056] d. Continuously monitor the Δr value. If Δr < 0, reduce the larger of r1 and r2 by |Δr|; if Δr > 0, increase the smaller of r1 and r2 by Δr;

[0057] e. After the outlet temperature t1 is stabilized within the target range, real-time commodity inspection data is collected, marked as A4, and it is determined whether the commodity inspection data is within the error tolerance range;

[0058] S5. Operation judgment strategy

[0059] In the actual commodity inspection process, the control system will first compare the commodity inspection data A4 collected in real time with the reference data package A1, calculate the parameter difference between the two, and then generate a difference data package A5; then, the control system uses the preset error judgment standard k1+A3 to perform intelligent analysis on A5 to determine whether A5 exceeds the range of k1+A3;

[0060] S6. Dynamic error threshold adjustment and continuous optimization

[0061] The control system has established a parameter error collection and k1 value dynamic adjustment mechanism. In step S5, the parameter error data of all machines that are judged to be faulty will be automatically collected and stored; then, the system regularly conducts in-depth analysis of these error data to evaluate the impact of actual fluctuations in the production process, measurement errors and changes in environmental factors on commodity inspection standards; based on the analysis results, the system can intelligently adjust the k1 value to adapt to the latest status of the production line; in addition, by implementing a batch dynamic follow-up strategy, the control system can continuously monitor and optimize commodity inspection standards;

[0062] S7, commodity inspection under repeated PID control

[0063] Repeat step S4 to ensure that the quality inspection process always maintains the dynamic control of the fan speed and compressor frequency by the PID algorithm until all products have completed the commodity inspection.

[0064] Specifically, in step S4, both r1 and r2 are compared and operated using normalized values.

[0065] Specifically, the specific operation judgment strategy in step S5 is:

[0066] If A5≤k1+A3, the water heater is judged to be in a fault-free state;

[0067] If A5>k1+A3, the current state of the water heater is determined to be faulty, and the fault warning mechanism is triggered and an out-of-range operating parameter code is output.

[0068] The embodiments of the present invention are described in detail above with reference to the accompanying drawings, but the present invention is not limited to the described embodiments. For those skilled in the art, various changes, modifications, substitutions and variations of these embodiments are made without departing from the principles and spirit of the present invention, and still fall within the scope of protection of the present invention.

Claims

1. A method for operating an integral air source heat pump water heater waterless commercial inspection algorithm, characterized in that: The following steps are involved: S1. Waterless commercial inspection heat exchange safety control strategy The water heater includes an air source heat pump and a water exchange tank. The air source heat pump is provided with a control system. The control system calculates the enthalpy difference Δh required for heating the medium in the water exchange tank during the waterless commercial inspection according to the law of conservation of energy and the set air inlet temperature t0 and air outlet temperature t1, and determines the matching fan speed r1 and compressor frequency r2 by using the correlation between the enthalpy difference Δh and the fan speed and the compressor frequency; S2. Run parameter test and data packet collection Before the water heater is put into mass production, the actual operating environment is simulated to test the key parameters of the water heater in the water state and the water-free state to form two benchmark data packages A1 and A2; S3, waterless commodity inspection operation parameter correction Compare A1 and A2, calculate the difference, construct the correction data package A3, and set the initial error allowable value k1 to form the error judgment standard k1+A3; S4, waterless commercial inspection heating operation control Start the control system, select the fan speed r1 and compressor frequency r2 as the starting parameters to start heating, and use the feedforward PID algorithm to adjust the compressor frequency and fan speed to ensure that the outlet temperature is stable at the target value; After the outlet temperature t1 is stabilized within the target range, real-time commodity inspection data is collected, marked as A4, and it is determined whether the commodity inspection data is within the error tolerance range; S5. Operation judgment strategy: Compare the real-time collected commodity inspection data A4 with the reference data package A1 to generate a difference data package A5, and use the error judgment standard k1+A3 to analyze and determine whether A5 is within the error tolerance range; S6. Dynamic error threshold adjustment and continuous optimization Establish a parameter error collection and k1 value dynamic adjustment mechanism, regularly analyze error data, adjust k1 value to adapt to production line status, and continuously monitor and optimize commodity inspection standards; S7, commodity inspection under repeated PID control Repeat step S4 to ensure that the quality inspection process always maintains the dynamic control of the fan speed and compressor frequency by the PID algorithm until all products have completed the commodity inspection.

2. The method for operating the waterless commercial inspection algorithm for the integral air source heat pump water heater according to claim 1 is characterized in that: In step S2, the key parameters include power, exhaust temperature, exhaust pressure, coil temperature, return air temperature and return air pressure; the A1 data packet represents the normal operating parameter set of the water heater in the water state, and the A2 data packet reflects the normal operating characteristic set of the water heater in the waterless state.

3. The method for operating the waterless commercial inspection algorithm for the integral air source heat pump water heater according to claim 1, characterized in that: In step S3, the power difference, exhaust temperature difference, exhaust pressure difference, coil temperature difference, return air temperature and return air pressure difference between A1 and A2 are calculated to construct a correction data package A3; the initial error allowable value k1 takes into account normal fluctuations in the production process, measurement errors and changes in environmental factors.

4. The method for operating the waterless commercial inspection algorithm for the integral air source heat pump water heater according to claim 1, characterized in that: In step S4, the error terms of the compressor frequency and the fan speed are calculated and adjusted using a feedforward PID algorithm. The error term formula is: Among them, A is the slope value fitted by the outlet temperature, and P1, P2, and I1 are feedforward PID parameters.

5. The method for operating the waterless commercial inspection algorithm of the integral air source heat pump water heater according to claim 1, characterized in that: In step S4, the Δr value is continuously monitored. If Δr<0, the larger one of r1 and r2 is reduced by |Δr|; if Δr>0, the smaller one of r1 and r2 is increased by Δr, wherein both r1 and r2 are compared and operated using normalized values.

6. The method for operating the waterless commercial inspection algorithm of the integral air source heat pump water heater according to claim 1, characterized in that: In step S5, the control system uses a preset error judgment standard k1+A3 to perform intelligent analysis on the difference data packet A5.

7. The method for operating the waterless commercial inspection algorithm of the integral air source heat pump water heater according to claim 1, characterized in that: The specific operation judgment strategy in step S5 is: If A5≤k1+A3, the water heater is judged to be in a fault-free state; If A5>k1+A3, the current state of the water heater is determined to be faulty, and the fault warning mechanism is triggered and an out-of-range operating parameter code is output.

8. The method for operating the waterless commercial inspection algorithm for the integral air source heat pump water heater according to claim 1, characterized in that: In step S6, the system regularly and deeply analyzes the error data, evaluates the impact of actual fluctuations in the production process, measurement errors and changes in environmental factors on the commodity inspection standards, and intelligently adjusts the k1 value.

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