A method for operating an algorithm for waterless commercial inspection of an integrated air source heat pump water heater

Abstract

This invention discloses a method for operating an algorithm for waterless inspection of an integrated air source heat pump water heater, belonging to the field of air source heat pump water heater inspection technology. The method includes seven steps: waterless inspection heat exchange safety control strategy, operating parameter testing and data package collection, waterless inspection operating parameter correction, waterless inspection heating operation control strategy, operation judgment strategy, dynamic error threshold adjustment and continuous optimization, and inspection under repetitive PID control. The method sets the inlet and outlet air temperatures and determines the fan speed and compressor frequency. Before mass production, key parameters of the water heater are tested under both water-filled and waterless states to form baseline data packages A1 and A2. After comparison, a correction data package A3 is constructed, and an initial error allowable value k1 is set. The compressor and fan speeds are adjusted using a feedforward PID algorithm to ensure stable outlet air temperature. Inspection data A4 is collected in real time and compared with A1. The water heater status is evaluated based on the error judgment standard k1+A3.

Description

Technical Field

[0001] This invention relates to the field of commercial inspection technology for air source heat pump water heaters, and in particular to a method for operating an algorithm for commercial inspection of an overall air source heat pump water heater without water. Background Technology

[0002] Currently, with the safety, environmental protection, and energy-saving characteristics of air source heat pump water heaters, coupled with the government's continuous support for new energy policies, they have become a preferred choice for people pursuing a green lifestyle. Market demand is constantly increasing, and production is continuously rising. This places greater demands on the production efficiency of household integrated air source heat pump water heaters. Among these challenges, the traditional online water injection inspection process is a bottleneck in production efficiency. Firstly, traditional water injection testing requires a large production line layout to accommodate the water tank, cooling system, connecting pipes, drainage system, and electronically controlled valves. This not only increases the floor space required in the production workshop but also limits the flexibility of the production line layout, making it difficult to improve overall production efficiency. Secondly, the heating time for water is significantly longer due to water's much higher specific heat capacity than air, increasing the inspection cycle and greatly affecting inspection efficiency. Furthermore, during the commercial inspection of water heaters that require water to be heated, a large range of water temperature increases is needed to fully assess their performance. However, within the limited inspection time, we can only capture the operating parameters of the water temperature within a relatively narrow range of variation. This limitation directly weakens the comprehensiveness and accuracy of fault identification, resulting in a low fault identification rate and increasing after-sales issues. Summary of the Invention

[0003] The purpose of this invention is to provide a method for operating an algorithm for the waterless commercial inspection of an integrated air source heat pump water heater, so as to solve the problems of low space utilization, long water injection and heating time, and low fault identification rate in the commercial inspection process of water heaters mentioned above.

[0004] To achieve the above objectives, the present invention provides the following technical solution:

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

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

[0007] The water heater includes an air source heat pump and a hot water exchange tank. The air source heat pump is equipped with a control system. The control system calculates the enthalpy difference Δh required for heating the medium in the hot water exchange tank during the waterless inspection process based on the law of conservation of energy and the set inlet air temperature t0 and outlet air temperature t1. Using the correlation between the enthalpy difference Δh and the fan speed and compressor frequency, the fan speed r1 and compressor frequency r2 that match the enthalpy difference value are determined.

[0008] S2, Operation Parameter Testing and Data Packet Collection

[0009] Before mass production of water heaters, the key parameters of the water heaters were tested by simulating the actual operating environment, with and without water in the water heater, and under the condition that the inlet air temperature, outlet air temperature and target temperature of the heating medium were the same. The key parameters included power, exhaust temperature, exhaust pressure, coil temperature, return gas temperature and return gas pressure.

[0010] Based on the key parameters obtained from the test, two benchmark data packets, A1 and A2, are generated. The A1 data packet represents the set of normal operating parameters of the water heater when there is water, while the A2 data packet reflects the set of normal operating characteristics of the water heater when there is no water.

[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 gas temperature and return gas pressure difference between the two, and construct the calculated differences into a correction data package A3.

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

[0014] S4. Waterless Inspection Heating Operation Control

[0015] a. Start the control system and select the initial fan speed and compressor frequency as the start-up parameters based on the pre-calculated fan speed r1, compressor frequency r2 and enthalpy difference Δh;

[0016] b. The heating process begins. 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... After this, k increases by 1 for each completed heating cycle;

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

[0018]

[0019] Where A is the slope value obtained by fitting the outlet air temperature, and P1, P2, I1 are the feedforward PID parameters;

[0020] d. Continuously monitor the value of Δr. If Δr < 0, decrease 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 air temperature t1 stabilizes within the target range, collect real-time commercial inspection data, mark it as A4, and determine whether the commercial inspection data is within the error tolerance range;

[0022] S5, Operation Judgment Strategy

[0023] In the actual commodity inspection process, the control system first compares the real-time collected commodity inspection data A4 with the benchmark data package A1, calculates the parameter difference between the two, and then generates the difference data package A5; subsequently, 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 establishes a parameter error collection and dynamic adjustment mechanism for the k1 value. In step S5, the parameter error data of all machines identified as faulty will be automatically collected and stored. Subsequently, the system periodically conducts in-depth analysis of these error data to assess the impact of actual fluctuations, measurement errors, and changes in environmental factors during the production process on the 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 tracking strategy, the control system can continuously monitor and optimize the inspection standards.

[0026] S7, Commercial Inspection under Repetitive PID Control

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

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

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

[0030] If A5≤k1+A3, then the water heater is determined to be fault-free at present;

[0031] If A5 > k1 + A3, the water heater is determined to be in a faulty state, and the fault warning mechanism is triggered, outputting out-of-range operating parameter codes.

[0032] In summary, compared with the prior art, the beneficial effects of the present invention are as follows:

[0033] 1. The waterless inspection system of the present invention judges the performance of heat pump water heaters by directly measuring key parameters in the inspection process. It eliminates the need for large hardware equipment such as water storage tanks, cooling systems, connecting pipes, drainage systems and electric control valves required in traditional inspection processes, thereby greatly saving space in the inspection area, making the production line layout more flexible, and more easily adapting to different production needs, thus improving overall production efficiency.

[0034] 2. This invention utilizes the fact that air has a much lower specific heat capacity than water, and that heating air takes significantly less time than heating water. By precisely controlling the fan speed and compressor frequency, a rapid and stable heating process is achieved, which greatly shortens the commercial inspection cycle and allows products to complete commercial inspection in a shorter time.

[0035] 3. This invention, by constructing a waterless commercial inspection heat exchange safety control strategy and an operating parameter testing and data packet collection mechanism, can accurately monitor and record the operating parameters of the water heater in a waterless state and compare them with the baseline data packet in a water-filled state. Simultaneously, by utilizing a feedforward PID algorithm and a dynamic error threshold adjustment mechanism, real-time monitoring and intelligent analysis of the water heater's performance are achieved, improving the comprehensiveness and accuracy of fault identification. It can capture more operating parameters within a limited inspection time, thereby more effectively identifying potential faults.

[0036] 4. This invention achieves automation and intelligence in the commodity inspection process through the integration of a control system and intelligent analysis algorithms. From system startup to data collection, analysis, and fault diagnosis, the entire process requires no manual intervention, reducing errors caused by human factors and lowering production and labor costs. Attached Figure Description

[0037] Figure 1 This is a flowchart of the operation method of the waterless commercial inspection algorithm for the overall air source heat pump water heater of the present invention. Detailed Implementation

[0038] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments given herein are for illustration and explanation only and are not intended to limit the present invention.

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

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

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

[0042] The water heater includes an air source heat pump and a hot water exchange tank. The air source heat pump is equipped with a control system. The control system calculates the enthalpy difference Δh required for heating the medium in the hot water exchange tank during the waterless inspection process based on the law of conservation of energy and the set inlet air temperature t0 and outlet air temperature t1. Using the correlation between the enthalpy difference Δh and the fan speed and compressor frequency, the fan speed r1 and compressor frequency r2 that match the enthalpy difference value are determined.

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

[0044] S2, Operation Parameter Testing and Data Packet Collection

[0045] Before mass production of water heaters, the key parameters of the water heaters were tested by simulating the actual operating environment, with and without water in the water heater, and under the condition that the inlet air temperature, outlet air temperature and target temperature of the heating medium were the same. The key parameters included power, exhaust temperature, exhaust pressure, coil temperature, return gas temperature and return gas pressure.

[0046] Based on the key parameters obtained from the test, two benchmark data packets, A1 and A2, are generated. The A1 data packet represents the set of normal operating parameters of the water heater when there is water, while the A2 data packet reflects the set of normal operating characteristics of the water heater when there is no water.

[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 gas temperature and return gas pressure difference between the two, and construct the calculated differences into a correction data package A3.

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

[0050] S4. Waterless Inspection Heating Operation Control

[0051] a. Start the control system and select the initial fan speed and compressor frequency as the start-up parameters based on the pre-calculated fan speed r1, compressor frequency r2 and enthalpy difference Δh;

[0052] b. The heating process begins. 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... After this, k increases by 1 for each completed heating cycle;

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

[0054]

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

[0056] d. Continuously monitor the value of Δr. If Δr < 0, decrease 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 air temperature t1 stabilizes within the target range, collect real-time commercial inspection data, mark it as A4, and determine whether the commercial inspection data is within the error tolerance range;

[0058] S5, Operation Judgment Strategy

[0059] In the actual commodity inspection process, the control system first compares the real-time collected commodity inspection data A4 with the benchmark data package A1, calculates the parameter difference between the two, and then generates the difference data package A5; subsequently, 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 establishes a parameter error collection and dynamic adjustment mechanism for the k1 value. In step S5, the parameter error data of all machines identified as faulty will be automatically collected and stored. Subsequently, the system periodically conducts in-depth analysis of these error data to assess the impact of actual fluctuations, measurement errors, and changes in environmental factors during the production process on the 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 tracking strategy, the control system can continuously monitor and optimize the inspection standards.

[0062] S7, Commercial Inspection under Repetitive PID Control

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

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

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

[0066] If A5≤k1+A3, then the water heater is determined to be fault-free at present;

[0067] If A5 > k1 + A3, the water heater is determined to be in a faulty state, and the fault warning mechanism is triggered, outputting out-of-range operating parameter codes.

[0068] The embodiments of the present invention have been 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 can be made to these embodiments without departing from the principles and spirit of the present invention, and these variations still fall within the protection scope of the present invention.

Claims

1. A method for operating an algorithm for waterless commercial inspection of an integrated air source heat pump water heater, characterized in that, Includes the following steps: S1. Waterless commercial inspection heat exchanger safety control strategy The water heater includes an air source heat pump and a hot water tank. The air source heat pump is equipped with a control system, which operates based on the law of conservation of energy and a set air intake temperature. and air outlet temperature The enthalpy difference required for the heating medium in the hot water exchange tank during the waterless commercial inspection process was calculated. And utilize enthalpy difference The correlation between fan speed and compressor frequency determines the appropriate fan speed. and compressor frequency ; S2, Operation Parameter Testing and Data Packet Collection Before the water heater is mass-produced, the actual operating environment is simulated, and the key parameters of the water heater are tested in both water-filled and waterless states 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 packet A3, and set the initial error allowable value k1 to form the error judgment standard k1+A3; S4. Waterless Inspection Heating Operation Control Start the control system and select the fan speed. compressor frequency Heating is started using the parameters as startup parameters. The compressor frequency and fan speed are adjusted using a feedforward PID algorithm to ensure that the outlet air temperature is stable at the target value. Waiting for the air outlet temperature Once the data stabilizes 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. Execution judgment strategy: The real-time collected commodity inspection data A4 is compared with the baseline data package A1 to generate the difference data package A5. The error judgment standard k1+A3 is used for analysis to determine whether A5 is within the error tolerance range. S6. Dynamic Error Threshold Adjustment and Continuous Optimization Establish a mechanism for collecting parameter errors and dynamically adjusting the k1 value, regularly analyze error data, adjust the k1 value to adapt to the production line status, and continuously monitor and optimize commercial inspection standards. S7, Commercial Inspection under Repetitive PID Control Repeat step S4 to ensure that the PID algorithm maintains dynamic control of the fan speed and compressor frequency throughout the quality inspection process until all products have completed commercial inspection.

2. The method for operating the waterless commercial inspection algorithm of the integrated air source heat pump water heater according to claim 1, characterized in that, In step S2, the key parameters include power, exhaust temperature, exhaust pressure, coil temperature, return gas temperature, and return gas pressure; the A1 data packet represents the set of normal operating parameters of the water heater when there is water, while the A2 data packet reflects the set of normal operating characteristics of the water heater when there is no water.

3. The method for operating the waterless commercial inspection algorithm of the integrated air source heat pump water heater according to claim 2, characterized in that, In step S3, the power difference, exhaust temperature difference, exhaust pressure difference, coil temperature difference, return gas temperature and return gas pressure difference between A1 and A2 are calculated to construct the correction data package A3; the initial error allowable value k1 takes into account normal fluctuations, measurement errors and changes in environmental factors during the production process.

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

5. The method for operating the waterless commercial inspection algorithm of the integrated air source heat pump water heater according to claim 4, characterized in that, In step S4, continuous monitoring Value, if Then The larger one decreases ;if Then The smaller one increases ,in All comparisons and operations are performed using normalized values.

6. The method for operating the waterless commercial inspection algorithm of the integrated 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 integrated air source heat pump water heater according to claim 6, characterized in that, The specific decision-making strategy in step S5 is as follows: If A5≤k1+A3, then the water heater is determined to be fault-free at present; If A5 > k1 + A3, the water heater is determined to be in a faulty state, and the fault warning mechanism is triggered, outputting out-of-range operating parameter codes.

8. The method for operating the waterless commercial inspection algorithm of the integrated air source heat pump water heater according to claim 1, characterized in that, In step S6, the system periodically conducts in-depth analysis of error data, assesses the impact of actual fluctuations, measurement errors, and changes in environmental factors during the production process on commodity inspection standards, and intelligently adjusts the k1 value.

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