Pipeline water pressure test device

Abstract

The invention relates to the technical field of pipeline water pressure testing, in particular to a pipeline water pressure testing device. The device aims at solving the technical problems of monitoring and controlling pressure, temperature and flow in the pipeline water pressure testing process, coping with water flow impact, guaranteeing testing safety and stability and the like. A pressure sensor I, a temperature sensor and a flow sensor I are arranged to collect data, and a data collection and control system receives the data and generates a control instruction to control a pressure pump, a regulating valve and a pressure release valve to work in combination with parameters input by an operator. Meanwhile, a plurality of energy accumulators, buffer units and other components are arranged to stabilize pressure and buffer water flow impact. The device is mainly used for water pressure testing of various pipeline systems, and ensures the pressure resistance and safety of pipelines.

Description

Technical Field

[0001] The present invention relates to the technical field of pipeline testing, and more specifically, to a pipeline water pressure testing device. Background Art

[0002] In the construction and maintenance of pipeline systems, pipeline water pressure testing is a crucial link, and its purpose is to test the pressure resistance, sealing and overall quality of the pipeline system. At present, there are many problems with traditional pipeline water pressure testing devices. First, in terms of data monitoring, the collection of pressure, temperature and flow is not accurate and comprehensive enough. Some devices can only simply measure pressure and cannot monitor changes in temperature and flow in real time, which makes it difficult to fully understand the state of the fluid in the pipeline during the test. For example, when the water flow velocity in the pipeline changes, it may cause local pressure fluctuations and temperature changes. If these parameters cannot be monitored in a timely and accurate manner, potential problems cannot be discovered in time. Secondly, in terms of pressure control, it is difficult for traditional devices to achieve accurate pressure rise and fall rate control. The output power of the booster pump cannot be effectively adjusted according to the set pressure rise rate, resulting in large pressure fluctuations during the test, which may cause unnecessary impact on the pipeline and affect the accuracy of the test results. At the same time, in the pressure drop stage, it is also impossible to steadily reduce the pressure at the set rate, which increases the risk of the test. Thirdly, the ability to handle water flow impact is insufficient. At the corners of the pipeline or in areas where the water flow velocity changes greatly, the water flow is prone to turbulence and impact. Traditional devices lack effective buffering and diversion measures, which will not only damage the pipeline itself, but also affect the stability and safety of the entire test device. For example, in some complex pipeline systems, water flow impact may cause the pipeline joints to loosen, causing leakage and other problems. In addition, when dealing with pressure changes under different working conditions, the energy storage and pressure stabilization capabilities of traditional devices are limited. When pressure fluctuations or sudden changes occur during the test, energy cannot be stored and released in time to maintain the stability of the pressure in the pipeline, which may cause the test to be interrupted or the test results to be inaccurate.

[0003] Therefore, the existing pipeline water pressure test device has obvious deficiencies in data monitoring, pressure control, water flow impact processing and pressure stabilization capabilities, and a more complete and efficient pipeline water pressure test device is urgently needed to solve these problems. Summary of the invention

[0004] An object of the present invention is to solve at least the above problems and to provide at least the advantages which will be described hereinafter.

[0005] In order to achieve these purposes and other advantages according to the present invention, a pipeline water pressure test device is provided, comprising: Pressure sensor I, which is connected to the pipeline and is used to collect pressure data; A temperature sensor is connected to the pipeline and is used to collect temperature data; Flow sensor I, which is connected to the pipeline and is used to collect flow data; A booster pump connected to the pipeline and controlled by a data acquisition and control system to control the output power according to a set pressure rise rate; A plurality of accumulators, which are installed on the output end of the booster pump and the pipeline, store excess pressure energy and release energy to stabilize the pressure when the pressure drops, and the accumulators have a set capacity and a working pressure range; A plurality of buffer units, wherein the buffer units include a buffer tank, a buffer pad and a guide plate, wherein the buffer tank is installed at the front end of the accumulator, the buffer pad is installed at the connection between the accumulator and the pipeline, and the guide plate is installed at the corner of the pipeline or near the area where the water flow velocity changes greatly; A regulating valve I, which is connected to the pipeline and cooperates to adjust the pipeline state in different test stages according to the instructions of the data acquisition and control system; The pressure relief valve is connected to the pipeline and has a set safety pressure threshold. When the pipeline pressure exceeds the safety pressure threshold, it automatically opens to relieve pressure. The data acquisition and control system receives the data collected by the pressure sensor, the temperature sensor, and the flow sensor, as well as the pipeline diameter, length, material, test time, pressure rise and drop rate parameters input by the operator through the human-machine interface, and generates control instructions to control the operation of the booster pump, the regulating valve, and the pressure relief valve.

[0006] A human-machine interface is connected to the data acquisition and control system for operators to input parameters and view real-time data.

[0007] Preferably, the buffer tank comprises: The tank body has a water inlet and a water outlet at both ends; A rubber diaphragm is disposed in the tank body and is sealed to the inner wall of the tank body, dividing the tank body into two upper and lower chambers, wherein the gas chamber located above the diaphragm is pre-filled with inert gas, and the water chamber located below the diaphragm is in communication with the pipeline water flow; A gas compressor connected to the gas chamber, the gas compressor fills or releases gas into the gas chamber according to the instruction of the data acquisition and control system, changes the gas pressure, and adjusts the position of the diaphragm; A regulating valve II, which is connected to the gas chamber and is used to assist the gas compressor in regulating the gas pressure in the gas chamber; An electromagnetic damper is installed in the water chamber near the water inlet; Pressure sensor II, which is installed on the pipeline near the water inlet of the tank body to monitor water flow pressure data in real time; Flow sensor II, which is installed on the pipeline near the water outlet of the tank to monitor water flow data in real time; The data acquisition and control system receives the data monitored by the pressure sensor II and the flow sensor II, and after analysis by a preset algorithm, issues control instructions to the gas compressor, the regulating valve II and the electromagnetic damper.

[0008] Preferably, the preset algorithm analysis in the data acquisition and control system specifically includes: filtering the received monitoring data using a sliding average filtering method, using the Bernoulli equation and momentum theorem to establish a water flow impact model, evaluating the water flow impact intensity through the pressure change rate and flow change rate, and setting a water flow impact intensity threshold; And, when the water flow impact intensity exceeds the set water flow impact intensity threshold, the volume of the buffer tank that needs to be increased is calculated, wherein the ideal gas state equation is used to calculate the gas volume that needs to be changed to balance the pressure, that is, the change in the volume of the buffer tank is obtained; And, when the water flow impact intensity exceeds a set water flow impact intensity threshold, a control instruction is sent to the electromagnetic damper to adjust the current of the electromagnetic damper.

[0009] Preferably, the buffer pad comprises: The rubber base is in the shape of a disk, and a circular through hole is opened at the center of the rubber base; A plurality of shape memory alloy wires are evenly embedded in the rubber matrix at a certain interval and angle, wherein the shape memory alloy wires are radially distributed and extend from the central through hole of the rubber matrix to the edge to form a mesh structure; The carbon fiber cloth layer is laid on the surface of the rubber matrix by bonding with an adhesive.

[0010] Preferably, the thickness of the rubber matrix is ​​10 mm to 30 mm, the shape memory alloy wire is a nickel-titanium alloy wire with a diameter of 0.5 mm to 1 mm, and the thickness of the carbon fiber cloth layer is 0.1 mm to 0.3 mm.

[0011] Preferably, the guide plate is a multi-stage composite guide plate, and the multi-stage composite guide plate comprises: The first-stage guide plate is in a straight plate shape, and the inclination angle is set to 45°~60°. A dense oxide film is formed on the surface of the first-stage guide plate, and the material of the first-stage guide plate is aluminum alloy; The second-stage guide plate is in a curved and parabolic shape, and the material of the second-stage guide plate is a composite material of polyurethane rubber embedded with 15% to 20% glass fiber filaments; The third-stage guide plate is in the shape of a straight plate, and is provided with a plurality of diversion holes with a diameter of 5 mm to 10 mm, and the plurality of diversion holes are arranged in an array of equilateral triangles, and the distance between the diversion holes is 10 mm to 20 mm, and the material of the third-stage guide plate is stainless steel; A plurality of hinges are provided, one end of the hinge is fixedly connected to the upper level guide plate by bolts, and the other end is movably connected to the lower level guide plate by a pin shaft, and the material of the hinge is titanium alloy.

[0012] The present invention has at least the following beneficial effects: First, a variety of sensors are used to fully monitor the pressure, temperature and flow in the pipeline, providing rich and accurate data support for the test. The data acquisition and control system, combined with the parameters input by the operator, can accurately control the operation of the booster pump, regulating valve I and pressure relief valve to ensure that the pressure rises and falls at the set rate, greatly improving the accuracy and stability of the test. The accumulator can effectively store and release pressure energy, stabilize the pressure in the pipeline, and reduce the impact of pressure fluctuations on the pipeline. The buffer tank, buffer pad and guide plate in the buffer unit work together to effectively buffer the impact of water flow and protect the pipeline and test equipment. The human-machine interface facilitates operators to input parameters and view real-time data, improves the convenience of operation and the controllability of the test, and fully guarantees the smooth progress of the pipeline water pressure test.

[0013] Second, the present invention separates the gas chamber and the water chamber through a rubber diaphragm, and uses the compressibility of the gas to buffer the pressure. The gas compressor and the regulating valve II work together to accurately adjust the gas pressure, and then accurately control the position of the diaphragm to efficiently buffer the water flow impact and pressure changes. The pressure sensor II and the flow sensor II monitor the data in real time, providing accurate information for the data acquisition and control system, so that it can intelligently control the gas compressor, regulating valve II and electromagnetic damper according to the preset algorithm analysis results, and realize intelligent control of the buffer tank. The electromagnetic damper further enhances the suppression of water flow impact, comprehensively protects the pipeline and buffer tank, and improves the stability and reliability of the entire test device.

[0014] Other advantages, objectives and features of the present invention will be embodied in part through the following description, and in part will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 A schematic diagram of the layout of the pipeline water pressure test device according to one of the technical solutions of the present invention; Figure 2 This is a schematic structural diagram of the buffer tank according to one of the technical solutions of the present invention; Figure 3 A detailed view of the cushion according to one of the technical solutions of the present invention; Figure 4 This is a schematic diagram of the connection of the multi-stage composite guide plate according to one of the technical solutions of the present invention.

[0016] Figure numerals in the specification: pipeline system 100, pressure sensor I1, temperature sensor 2, flow sensor I3, booster pump 4, accumulator 5, buffer tank 6, buffer pad 7, guide plate 8, regulating valve I9, pressure relief valve 10, data acquisition and control system 11, human-machine interface 12, tank body 61, rubber diaphragm 62, gas chamber 63, water chamber 64, gas compressor 65, regulating valve II 66, electromagnetic damper 67, pressure sensor II 68, flow sensor II 69, rubber matrix 71, through hole 72, shape memory alloy wire 73, first-stage guide plate 81, second-stage guide plate 82, third-stage guide plate 83, hinge 84. DETAILED DESCRIPTION

[0017] The present invention is further described in detail below in conjunction with the accompanying drawings so that those skilled in the art can implement the invention with reference to the description.

[0018] It should be noted that the experimental methods described in the following embodiments are conventional methods unless otherwise specified, and the reagents and materials are commercially available unless otherwise specified; in the description of the present invention, the orientation or positional relationship indicated by the terms is based on the orientation or positional relationship shown in the accompanying drawings, which is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0019] like Figures 1 to 4 As shown, the present invention provides a pipeline water pressure test device, comprising: Multiple pressure sensors Ⅰ1 are connected to the pipeline to collect pressure data; specifically, pressure sensor Ⅰ1 uses a high-precision strain gauge pressure sensor with an accuracy of ±0.1%FS, which can accurately capture the slight changes in the pressure in the pipeline. It is installed near the output end of the booster pump to monitor the pressure at the initial stage of pressurization in a timely manner; one is also installed at the end of the pipeline to compare the pressure difference at different positions and detect whether there is abnormal pressure loss along the pipeline.

[0020] The temperature sensor 2 is connected to the pipeline and used to collect temperature data. Specifically, the temperature sensor 2 is a platinum resistance temperature sensor 2, which has high temperature measurement accuracy and good stability. It is installed in the middle of the pipeline, where the interference from the external environment is relatively small, and the actual temperature of the fluid in the pipeline can be measured more accurately.

[0021] The flow sensor I3 is connected to the pipeline and used to collect flow data. Specifically, the flow sensor I3 is an electromagnetic flowmeter, which is suitable for measuring the flow of conductive liquids, has high measurement accuracy and fast response speed. It is installed in a straight pipe section with stable water flow to ensure accurate and reliable measurement data.

[0022] The booster pump is connected to the pipeline and controlled by a data acquisition and control system 11. The output power is controlled according to the set pressure rise rate. Specifically, an electric plunger pump with appropriate power is selected according to the pressure and flow requirements of the pipeline system 100. For example, for a pipeline system 100 with a diameter of 200mm and a length of 500m, if the design test pressure is 2.0MPa, an electric plunger pump with a rated pressure of 3.0MPa and a flow rate of 50m³ / h is selected after calculation. The booster pump is connected to the data acquisition and control system 11 through a control line. The operator inputs the pressure rise rate, such as 0.1MPa / min, in the human-machine interface 12. The data acquisition and control system 11 changes the motor speed by adjusting the variable frequency controller of the booster pump motor, thereby achieving precise control of the booster pump output power and making the pressure rise steadily.

[0023] A plurality of accumulators 5 are installed on the output end of the booster pump and the pipeline, storing excess pressure energy and releasing energy to stabilize pressure when the pressure drops. The accumulator 5 has a set capacity and a working pressure range. Specifically, according to the pressure and flow fluctuation of the pipeline system 100, an accumulator 5 with a suitable capacity and working pressure range is selected. For example, for the above-mentioned pipeline system 100, a bladder accumulator with a working pressure range of 1.5MPa~2.5MPa and a capacity of 30L is selected. An accumulator 5 is installed at a certain distance at the output end of the booster pump and along the pipeline, such as one every 100m, to ensure that when the pressure fluctuates, the accumulator 5 can store or release energy in time to stabilize the pipeline pressure.

[0024] Multiple buffer units, the buffer units include a buffer tank 6, a buffer pad 7 and a guide plate 8, the buffer tank 6 is installed at the front end of the accumulator 5, the buffer pad 7 is installed at the connection between the accumulator 5 and the pipeline, and the guide plate 8 is installed at the corner of the pipeline or near the area where the water flow velocity changes greatly; specifically, the buffer tank 6 is installed at the front end of the accumulator 5 to ensure that the water flow first passes through the buffer tank 6 for preliminary buffering. The buffer pad 7 is put on the connecting part between the accumulator 5 and the pipeline, and fixed with bolts to ensure a firm installation. The guide plate 8 is installed according to the actual layout of the pipeline and the direction of water flow. At the corner of the pipeline, the guide plate 8 is installed according to the design angle.

[0025] The regulating valve Ⅰ9 is connected to the pipeline and cooperates to adjust the pipeline state in different test stages according to the instructions of the data acquisition and control system 11; specifically, the regulating valve Ⅰ9 uses an electric regulating valve, which has high adjustment accuracy and fast response speed. It is installed at a key position of the pipeline, such as near the outlet of the booster pump or the branch of the pipeline, and is connected to the data acquisition and control system 11 through a control line. According to different test stages, the data acquisition and control system 11 sends instructions to control the opening of the regulating valve Ⅰ9 to adjust the water flow and pressure in the pipeline.

[0026] The pressure relief valve 10 is connected to the pipeline and sets a safety pressure threshold. When the pipeline pressure exceeds the safety pressure threshold, it automatically opens to relieve pressure. Specifically, the pressure relief valve 10 selects a spring-type pressure relief valve and sets the safety pressure threshold to 2.2MPa. When the pipeline pressure exceeds the threshold, the spring is compressed and the pressure relief valve 10 automatically opens to relieve pressure to ensure the safety of the pipeline.

[0027] The data acquisition and control system 11 receives the data collected by the pressure sensor, the temperature sensor 2, and the flow sensor, as well as the pipe diameter, length, material, test time, pressure rise and drop rate parameters input by the operator through the human-machine interface 12, and generates control instructions to control the operation of the booster pump, the regulating valve, and the pressure relief valve 10.

[0028] The human-machine interface 12 is connected to the data acquisition and control system 11 for the operator to input parameters and view real-time data. Specifically, PLC can be selected as the core of the data acquisition and control system 11. The data transmission lines of the pressure sensor Ⅰ1, the temperature sensor 2, and the flow sensor Ⅰ3 are connected to the analog input module of the PLC, and the control lines of the booster pump, the regulating valve Ⅰ9, and the pressure relief valve 10 are connected to the digital output module of the PLC. The operator can input parameters such as the pipe diameter, length, material, test time, pressure rise and fall rate, etc. on the human-machine interface 12. The PLC generates control instructions according to the preset algorithm based on these parameters and the data collected in real time by the sensor to control the operation of each component. During the test, the real-time collected data is intuitively displayed in the form of charts on the human-machine interface 12, which is convenient for the operator to monitor. If abnormal data occurs, the system automatically issues an alarm.

[0029] In the above technical scheme, comprehensive monitoring of the pressure, temperature and flow in the pipeline is achieved through a variety of sensors, providing rich and accurate data support for the test. The data acquisition and control system 11, combined with the parameters input by the operator, can accurately control the operation of the booster pump, regulating valve I9 ​​and pressure relief valve 10 to ensure that the pressure rises and falls at the set rate, greatly improving the accuracy and stability of the test. The accumulator 5 can effectively store and release pressure energy, stabilize the pressure in the pipeline, and reduce the impact of pressure fluctuations on the pipeline. The buffer tank 6, buffer pad 7 and guide plate 8 in the buffer unit work together to effectively buffer the impact of water flow and protect the pipeline and test equipment. The human-machine interface 12 facilitates the operator to input parameters and view real-time data, improves the convenience of operation and the controllability of the test, and comprehensively guarantees the smooth progress of the pipeline water pressure test.

[0030] In another technical solution, the buffer tank 6 comprises: The tank body 61 has a water inlet and a water outlet at both ends; specifically, the tank body 61 uses Q345 carbon steel as the material of the tank body 61, which has high strength and good welding performance and can withstand high pressure. According to the flow and pressure requirements of the pipeline system 100, the size of the tank body 61 is designed, for example, the diameter is 1m and the height is 2m. The water inlet and the water outlet are processed at both ends of the tank body 61, and the flange connection method is adopted to ensure that the connection with the pipeline is tight to prevent water leakage. During installation, fix the tank body 61 on a stable bracket to ensure that it will not be displaced or shaken during operation.

[0031] The rubber diaphragm 62 is arranged in the tank body 61 and is sealed and connected to the inner wall of the tank body 61, dividing the tank body 61 into two upper and lower chambers, wherein the gas chamber 63 located above the diaphragm is pre-filled with inert gas, and the water chamber 64 located below the diaphragm is connected to the pipeline water flow; specifically, the rubber diaphragm 62 is made of water-resistant and high-pressure resistant nitrile rubber material, and is processed by mold customization to make its size accurately match the inside of the tank body 61. During installation, first clean the inside of the tank body 61, and then place the rubber diaphragm 62 in the tank body 61, and use a special sealing process, such as hot vulcanization sealing, to tightly connect the diaphragm to the inner wall of the tank body 61 to ensure that the gas chamber 63 and the water chamber 64 are completely isolated to prevent gas and water from penetrating each other.

[0032] The gas compressor 65 is connected to the gas chamber 63. The gas compressor 65 fills or releases gas into the gas chamber 63 according to the instructions of the data acquisition and control system 11, changes the gas pressure, and adjusts the position of the diaphragm. Specifically, the gas chamber 63 is pre-filled with nitrogen, and nitrogen is filled into the gas chamber 63 using professional filling equipment. The filling pressure is determined according to the design pressure of the pipeline system 100 and the design parameters of the buffer tank 6, and is generally between 0.5MPa and 1.0MPa. The gas compressor 65 uses a small electric piston compressor, and its exhaust volume and pressure can meet the filling and discharging requirements of the gas chamber 63. The gas compressor 65 is connected to the gas chamber 63 through a pressure-resistant pipeline. The pipeline is made of stainless steel to ensure sealing and corrosion resistance.

[0033] The regulating valve II 66 is connected to the gas chamber 63 and is used to assist the gas compressor 65 in regulating the gas pressure in the gas chamber 63. Specifically, the regulating valve II 66 is an electric regulating valve, which is installed on the pipeline between the gas chamber 63 and the gas compressor 65 and is connected to the data acquisition and control system 11 through a control line. During the debugging process, the control parameters of the gas compressor 65 and the regulating valve II 66 are set so that the gas pressure in the gas chamber 63 can be accurately adjusted according to the instructions of the data acquisition and control system 11.

[0034] The electromagnetic damper 67 is installed in the water chamber 64 near the water inlet; specifically, the electromagnetic damper 67 is a DC electromagnetic damper 67, and its damping force can be controlled by adjusting the current. A bracket is welded near the water inlet in the water chamber 64, and the electromagnetic damper 67 is fixed on the bracket to ensure that it will not loosen under the impact of water flow. The control circuit of the electromagnetic damper 67 is connected to the data acquisition and control system 11 so that the damping force can be adjusted in real time according to the impact of water flow.

[0035] The pressure sensor Ⅱ68 is installed on the pipeline near the water inlet of the tank 61 to monitor the water flow pressure data in real time; the flow sensor Ⅱ69 is installed on the pipeline near the water outlet of the tank 61 to monitor the water flow data in real time; specifically, the pressure sensor Ⅱ68 and the flow sensor Ⅱ69 are installed on the pipeline near the water inlet and outlet of the tank 61 respectively to ensure accurate monitoring of the water flow pressure and flow data. During installation, ensure that the installation position of the pressure sensor Ⅱ68 and the flow sensor Ⅱ69 is perpendicular to the center line of the pipeline to avoid measurement errors caused by installation angle problems. After installation, use a standard pressure source and flow source to calibrate the pressure sensor Ⅱ68 and the flow sensor Ⅱ69 to ensure the accuracy of the measurement data. Connect the data transmission lines of the pressure sensor Ⅱ68 and the flow sensor Ⅱ69 to the analog input module of the data acquisition and control system 11.

[0036] The data acquisition and control system 11 receives the data monitored by the pressure sensor II 68 and the flow sensor II 69, and after analysis by the preset algorithm, issues control instructions to the gas compressor 65, the regulating valve II 66 and the electromagnetic damper 67. Specifically, the data acquisition and control system 11 collects and analyzes the data of the pressure sensor II 68 and the flow sensor II 69, and controls the gas compressor 65, the regulating valve II 66 and the electromagnetic damper 67. The preset algorithm evaluates the impact strength of the water flow according to the pressure change rate and the flow change rate. When the impact strength exceeds the set threshold, the gas pressure and the current of the electromagnetic damper 67 that need to be adjusted are calculated, and then control instructions are issued to the relevant components. At the same time, the human-machine interface 12 is displayed to facilitate the operator to view the working status of the buffer tank 6 and adjust the relevant parameters.

[0037] In the above technical scheme, the main problems are the structural design of the buffer tank 6 and how to achieve accurate adjustment of the internal gas pressure and the position of the diaphragm, as well as how to use the data monitored by the pressure sensor II 68 and the flow sensor II 69 to effectively control the gas compressor 65, the regulating valve II 66 and the electromagnetic damper 67 through the data acquisition and control system 11 to better cope with the water flow impact and pressure change. The present invention separates the gas chamber 63 and the water chamber 64 by the rubber diaphragm 62, and uses the compressibility of the gas to buffer the pressure. The gas compressor 65 and the regulating valve II 66 work together to accurately adjust the gas pressure, and then accurately control the diaphragm position, and efficiently buffer the water flow impact and pressure change. The pressure sensor II 68 and the flow sensor II 69 monitor the data in real time, providing accurate information for the data acquisition and control system 11, so that it can intelligently control the gas compressor 65, the regulating valve II 66 and the electromagnetic damper 67 according to the preset algorithm analysis results, and realize the intelligent control of the buffer tank 6. The electromagnetic damper 67 further enhances the suppression of water flow impact, protects the pipeline and the buffer tank 6 in all directions, and improves the stability and reliability of the entire test device.

[0038] In another technical solution, the preset algorithm analysis in the data acquisition and control system 11 specifically includes: filtering the received monitoring data using a sliding average filtering method, using the Bernoulli equation and momentum theorem to establish a water flow impact model, evaluating the water flow impact intensity through the pressure change rate and flow change rate, and setting a water flow impact intensity threshold; And, when the water flow impact intensity exceeds the set water flow impact intensity threshold, the volume of the buffer tank 6 that needs to be increased is calculated, wherein the ideal gas state equation is used to calculate the gas volume that needs to be changed to balance the pressure, that is, the change in the volume of the buffer tank 6; Furthermore, when the water flow impact intensity exceeds a set water flow impact intensity threshold, a control instruction is sent to the electromagnetic damper 67 to adjust the current of the electromagnetic damper 67 .

[0039] Specifically, in the data acquisition and control system 11, a sliding average filter algorithm program is written. The filter window size is set, for example, 5 consecutive sampled data are taken as a window. When new data arrives, the earliest data in the window is removed, the new data is added, and then the average value of the data in the window is calculated as the filtered data. In this way, the data curve is effectively smoothed, the influence of noise is reduced, and high-quality data is provided for subsequent analysis.

[0040] Specifically, based on the Bernoulli equation (Formula 1) and the momentum theorem (Formula 2) combined with the data collected by the pressure sensor II 68 and the flow sensor II 69, the energy and momentum changes of the water flow are calculated, and the water flow impact model is established. By calculating the pressure change rate per unit time Δ p / Δ t and flow rate change Δ Q / Δ t ( Q The water flow impact strength is evaluated by measuring the flow rate. Based on a large amount of test data and experience, an appropriate water flow impact strength threshold is set. For example, when the pressure change rate exceeds 0.1MPa / s and the flow change rate exceeds 5m³ / h / s, the impact strength is judged to be excessive.

[0041] Formula 1 in, p is the pressure, ρ is the fluid density, v is the flow rate, h is the height; F Δ t =Δ mv Formula 2 in, F is the force, Δ t is the action time, m For quality, v for speed; Specifically, when the water flow impact intensity exceeds the threshold, according to the ideal gas state equation PV = nRT (At a certain temperature, it can be simplified to P 1 V 1= P 2 V 2) Combined with the initial pressure of the gas chamber 63 of the buffer tank 6 P 1. Initial volume V 1 and current pressure P 2. Calculate the gas volume required to balance the pressure, that is, the change in the volume of the buffer tank 6 Δ VThe data acquisition and control system 11 sends control instructions to the gas compressor 65 and the regulating valve II 66 according to the calculation results, adjusts the pressure of the gas chamber 63, and then changes the position of the diaphragm of the buffer tank 6 to adjust the volume of the buffer tank 6.

[0042] Specifically, when the impact intensity exceeds the standard, the data acquisition and control system 11 sends a control instruction to the electromagnetic damper 67 according to the preset adjustment strategy. The damping force generated by the electromagnetic damper 67 is adjusted by changing the input current of the electromagnetic damper 67. For example, when the impact intensity is greater, the current of the electromagnetic damper 67 is increased to enhance the damping force and suppress the water flow impact; when the impact intensity decreases, the current is reduced accordingly to adapt to different water flow impact conditions.

[0043] In the above technical scheme, the main problem is how to effectively process and analyze the sensor data related to the buffer tank 6, establish a water flow impact model through scientific physical principles, accurately evaluate the water flow impact intensity, and intelligently adjust the volume of the buffer tank 6 and the current of the electromagnetic damper 67 according to the impact intensity, so as to ensure the stable operation of the pipeline water pressure test device under complex water flow impact conditions, improve the ability of the device to cope with different water flow conditions, and ensure the safety and accuracy of the test. The present invention uses the sliding average filter method to process data, which can effectively remove interference signals caused by factors such as pipeline vibration and equipment noise, make pressure and flow data more real and reliable, and provide a solid foundation for subsequent analysis. The water flow impact model constructed based on the Bernoulli equation and momentum theorem comprehensively considers the water flow state from the perspective of energy and momentum, evaluates the impact intensity through the pressure and flow rate change rate, and can accurately reflect the impact degree of water flow on pipelines and equipment. Set the impact intensity threshold and adjust the volume of the buffer tank 6 and the current of the electromagnetic damper 67 accordingly to achieve intelligent response of the device. When the impact is too large, the volume buffer pressure of the buffer tank 6 is adjusted in time, and the electromagnetic damper 67 is adjusted to suppress the water flow impact, effectively protecting the pipeline and equipment, ensuring the smooth progress of the test, and improving the stability and reliability of the device.

[0044] In another technical solution, the buffer pad 7 includes: The rubber matrix 71 is in the shape of a disk, and a circular through hole 72 is provided at the center of the rubber matrix 71; specifically, nitrile rubber or EPDM rubber with high elasticity, aging resistance and water resistance is selected as the raw material. The rubber raw material and additives such as vulcanizer, accelerator and antioxidant are put into an internal mixer in a certain proportion and fully mixed, so that the additives are evenly dispersed in the rubber to improve the comprehensive performance of the rubber. After the mixing is completed, the rubber is placed in a pre-designed disk-shaped mold with a circular through hole in the center of the mold to form a mounting hole in the center of the buffer pad 7. Through the hot pressing vulcanization process, the rubber is vulcanized and formed in the mold at a temperature of 150°C to 180°C and a certain pressure. The vulcanization time is determined according to the thickness of the rubber matrix 71. The vulcanization time of a 10mm thick matrix is ​​about 10 minutes, and the vulcanization time of a 30mm thick matrix is ​​about 30 minutes, ensuring that the rubber matrix 71 meets the specified hardness and elasticity requirements.

[0045] The rubber matrix 71 is evenly embedded with multiple strands of shape memory alloy wires 73 at a certain spacing and angle, wherein the shape memory alloy wires 73 are radially distributed and extend from the central through hole 72 of the rubber matrix 71 to the edge to form a mesh structure; specifically, nickel-titanium alloy wires with a diameter of 0.5 mm to 1 mm are selected as reinforcing materials. When the rubber matrix 71 is not completely cooled after vulcanization, the alloy wires are evenly embedded in the rubber matrix 71 manually or by automated equipment according to the pre-calculated spacing and angle using a dedicated positioning device. The alloy wires are radially distributed from the central through hole 72 to the edge to form a stable mesh structure. In order to enhance the bonding force between the alloy wire and the rubber matrix 71, a layer of adhesive with good compatibility with rubber, such as an adhesive treated with a silane coupling agent, can be pre-coated on the surface of the alloy wire to ensure that the alloy wire will not fall off from the rubber matrix 71 under the impact of water flow, and its shape memory effect can be stably exerted.

[0046] The carbon fiber cloth layer is bonded and laid on the surface of the rubber matrix 71 by an adhesive; specifically, prepare a carbon fiber cloth with a thickness of 0.1mm~0.3mm, and cut it into a circle of the same size as the rubber matrix 71 disc. Apply the adhesive evenly on the surface of the rubber matrix 71 and one side of the carbon fiber cloth. The adhesive can be an epoxy resin-based adhesive, which has good bonding strength and water resistance. After the coating is completed, the carbon fiber cloth is accurately laid on the surface of the rubber matrix 71 to ensure that the two are completely fitted without bubbles and gaps in the middle. Then, the buffer pad 7 with the carbon fiber cloth laid is placed in a hot press and hot-pressed at a temperature of 120℃~150℃ and a pressure of 0.5MPa~1MPa for curing. The curing time is about 5min~10min, so that the adhesive is fully cured and the bonding strength between the carbon fiber cloth and the rubber matrix 71 is enhanced.

[0047] In the above technical scheme, the main problem is how to design a high-performance buffer pad 7, so that it can make full use of the elasticity of the rubber matrix 71, the shape memory effect of the shape memory alloy wire 73 and the reinforcing effect of the carbon fiber cloth layer, effectively absorb the impact energy of the water flow, enhance the buffering effect, and at the same time improve the strength and wear resistance of the buffer pad 7, extend its service life, and meet the needs of the pipeline water pressure test device for water flow impact buffering under complex working conditions. The rubber matrix 71 of the present invention provides basic buffering performance for the buffer pad 7 by virtue of its own good elasticity, and can initially absorb the energy of the water flow impact. When subjected to a large water flow impact, the radially distributed nickel-titanium alloy shape memory alloy wire 73 exerts a shape memory effect, produces additional deformation to absorb more energy, and greatly enhances the buffering effect. The carbon fiber cloth layer is tightly bonded to the surface of the rubber matrix 71, which effectively enhances the strength and wear resistance of the buffer pad 7, so that it can still maintain good performance under the condition of long-term water flow impact and friction, reduce wear and damage, extend the service life of the buffer pad 7 and even the entire test device, and improve the reliability of the device under complex water flow conditions. Reasonable size parameter design allows each component to work together to achieve optimal performance, fully guaranteeing the performance of the cushion 7.

[0048] In another technical solution, the guide plate 8 is a multi-stage composite guide plate, and the multi-stage composite guide plate includes: The first-stage guide plate 81 is in the shape of a straight plate, and the inclination angle is set to 45°~60°. A dense oxide film is formed on the surface of the first-stage guide plate 81. The material of the first-stage guide plate 81 is aluminum alloy; specifically, a high-strength aluminum alloy plate, such as 6061 aluminum alloy, is selected, which has good strength and corrosion resistance. According to the design requirements, a CNC cutting machine is used to cut the aluminum alloy plate into a straight plate shape to ensure dimensional accuracy. The edges of the straight plate are polished and chamfered using mechanical processing equipment to prevent sharp corners from affecting the water flow. A dense oxide film is formed on the surface of the straight plate through an anodizing process, and the thickness of the oxide film is controlled to be 10μm~15μm, which enhances its corrosion resistance and wear resistance. During installation, according to the actual layout of the pipeline and the direction of water flow, at the corner of the pipeline or near the area where the water flow velocity changes greatly, a bracket is used to fix the first-stage guide plate 81 to the inner wall of the pipeline, and the inclination angle is adjusted between 45°~60° to ensure that it is firmly installed and prevent displacement under the impact of water flow.

[0049] The second-stage guide plate 82 is curved and parabolic in shape. The material of the second-stage guide plate 82 is a composite material of polyurethane rubber embedded with glass fiber filaments containing 15% to 20%; specifically, prepare polyurethane rubber raw materials and glass fiber filaments, mix the glass fiber filaments into the polyurethane rubber at a content of 15% to 20%, and fully blend the two through stirring, mixing and other processes. Using the mold injection molding process, the mixed material is injected into a pre-made parabolic mold and molded at a certain temperature and pressure. The molding temperature is controlled at 120°C to 150°C, and the pressure is 0.5MPa to 1MPa to ensure the shape accuracy and material properties of the second-stage guide plate 82. After molding, take it out, perform surface finishing and quality inspection to ensure that there are no defects such as bubbles and cracks. During installation, the second-stage guide plate 82 is connected to the first-stage guide plate 81 through a titanium alloy hinge 84. One end of the hinge 84 is fixed to the first-stage guide plate 81 through a bolt, and the other end is movably connected to the second-stage guide plate 82 through a pin shaft to ensure a firm connection and flexible rotation. The second-stage guide plate 82 is installed downstream of the first-stage guide plate 81 so that it can receive the water flow after the first-stage guide.

[0050] The third-level guide plate 83 is in the shape of a straight plate. A plurality of diversion holes with a diameter of 5 mm to 10 mm are provided on the third-level guide plate 83. The plurality of diversion holes are arranged in an equilateral triangle array. The distance between the diversion holes is 10 mm to 20 mm. The material of the third-level guide plate 83 is stainless steel. Specifically, a stainless steel plate of suitable thickness is selected, such as 304 stainless steel, which has good corrosion resistance and strength. A laser punching machine is used to process the diversion holes on the stainless steel plate in an equilateral triangle array. The diameter of the holes is controlled at 5 mm to 10 mm, and the hole spacing is 10 mm to 20 mm to ensure uniform diversion effect. The stainless steel plate after drilling is surface treated to remove burrs and impurities generated during the processing. During installation, the third-level guide plate 83 is also connected to the second-level guide plate 82 through a titanium alloy hinge 84, and the position is adjusted so that it can effectively receive the water flow after the second-level diversion and evenly disperse the water flow.

[0051] A plurality of hinges 84 are provided, one end of the hinge 84 is fixedly connected to the upper level guide plate by bolts, and the other end is movably connected to the lower level guide plate by a pin shaft. The material of the hinge 84 is titanium alloy material. The titanium alloy hinge 84 is processed and manufactured according to the design requirements to ensure dimensional accuracy and strength. When installing the hinge 84, first align the bolt with the mounting hole of the upper level guide plate, tighten it with a tool, and ensure a firm connection. Then insert the pin shaft into the connecting hole of the lower level guide plate and the corresponding hole of the hinge 84, and install the cotter pin or other locking device to prevent the pin shaft from falling off. After the installation is completed, the multi-stage composite guide plate is debugged as a whole to check whether the connection between the guide plates at each level is firm and whether the rotation is flexible, to ensure that the multi-stage composite guide plate can work normally under the impact of the water flow, and achieve effective buffering and diversion of the water flow.

[0052] In the above technical scheme, the present invention mainly solves how to design an efficient guide plate, through a multi-stage composite structure, to achieve all-round, multi-level buffering and diversion for water flows with different flow rates and directions, effectively reduce the turbulence and impact of water flow at the corners of the pipeline or in areas with large flow rate changes, protect the pipeline and the test device, so as to meet the requirements of water flow control for pipeline water pressure tests under complex working conditions, ensure the safety and accuracy of the test, and improve the stability and reliability of the test device. The unique design of the multi-stage composite guide plate of the present invention enables it to process the water flow in stages. The first-stage guide plate 81, with an inclination angle of 45°~60°, preliminarily changes the direction of the water flow, preliminarily guides the high-speed and turbulent water flow, and lays the foundation for subsequent buffering and diversion. The oxide film on its surface enhances corrosion resistance and wear resistance, and prolongs its service life. The second-stage guide plate 82, using the curved surface characteristics and the material characteristics of glass fiber reinforcement, further smoothes the water flow, effectively reduces the turbulence of the water flow, and makes the water flow velocity distribution more uniform. The third-stage guide plate 83 disperses the water flow evenly through the diversion holes, greatly reducing the concentrated impact force of the water flow. The hinge 84 connects the guide plates at each level, ensuring the stability of the structure while allowing a certain degree of relative displacement, so that the multi-stage composite guide plate can flexibly adapt to the changes in water flow under different working conditions, comprehensively protect the pipeline and test equipment, and improve the stability and reliability of the entire test system.

[0053] Testing: The components used in the test are customized by the manufacturer, and the manufacturing method of the components is used to more clearly reveal the formation principle of the components.

[0054] Test 1 The newly built industrial water supply pipeline was subjected to a water pressure test. The pipeline has a diameter of 300mm, a length of 800m, is made of carbon steel, and has a design pressure of 1.6MPa.

[0055] 1. Build the test device: Select pressure sensor I (strain gauge pressure sensor, accuracy can reach ±0.1%FS), temperature sensor (platinum resistance temperature sensor), and flow sensor I (electromagnetic flowmeter) for installation. Pressure sensor I is installed at the outlet of the booster pump and the end of the pipeline, the temperature sensor is installed at 400m in the middle of the pipeline, and the flow sensor I is installed in the straight pipe section 100m away from the outlet of the booster pump. An electric plunger pump with a rated pressure of 2.5MPa and a flow rate of 80m³ / h is selected as the pressurizing equipment, which is connected to the data acquisition and control system through a control line. According to the pipeline pressure and flow requirements, an accumulator with a working pressure range of 1.2MPa~2.0MPa and a capacity of 50L is selected, and one is installed at the output end of the booster pump, 400m and 700m of the pipeline. The buffer tank of the buffer unit is installed at the front end of each accumulator, the buffer pad is installed at the connection between the accumulator and the pipeline, and the guide plate is installed at the two corners of the pipeline. The regulating valve I is installed near the outlet of the booster pump, and the pressure relief valve is set to a safety pressure threshold of 1.8MPa and installed near the end of the pipeline. Siemens S7-1200 series PLC is selected as the data acquisition and control system, the lines of various sensors and actuators are connected, and the human-machine interface software is developed.

[0056] 2. Test preparation: The operator inputs the following parameters on the human-machine interface: pipe diameter 300mm, length 800m, material carbon steel, test time 60 minutes, pressure rise rate 0.08MPa / min, pressure drop rate 0.05MPa / min, etc. Check whether each component is firmly installed and the line connection is correct. After ensuring that everything is correct, start the data acquisition and control system and calibrate and initialize each sensor.

[0057] 3. Test process: Start the booster pump, and the data acquisition and control system adjusts the motor speed of the booster pump according to the set pressure rise rate of 0.08MPa / min to make the pressure rise steadily. During the pressure rise process, the pressure sensor I, temperature sensor, and flow sensor I collect data in real time and transmit it to the data acquisition and control system, and the data is displayed in real time on the human-machine interface. When the pressure reaches the test pressure of 1.6MPa, it enters the pressure holding stage, which lasts for 60min. During this period, the data acquisition and control system fine-tunes the pipeline state through the regulating valve I to maintain the pressure stability. If the pressure fluctuates, the accumulator stores or releases energy in time to stabilize the pressure. After the pressure holding is completed, the data acquisition and control system controls the regulating valve I to open slowly, and the pressure drops steadily at a pressure drop rate of 0.05MPa / min. During the entire test process, if the pipeline pressure exceeds the safety pressure threshold of 1.8MPa, the pressure relief valve automatically opens to release the pressure to ensure the safety of the test. At the same time, when the water flows through the buffer unit, the buffer tank, buffer pad and guide plate work together to effectively buffer the impact of the water flow and protect the pipeline and test equipment.

[0058] 4. Test results and analysis: The pressure data results show that during the pressurization stage, the pressure rose steadily at the set rate of 0.08MPa / min, and smoothly reached the test pressure of 1.6MPa from the initial pressure of 0MPa. The pressure fluctuation was controlled within the range of ±0.02MPa during the entire rising process, which shows that the booster pump can accurately increase the pressure at the set rate under the control of the data acquisition and control system. Within 60 minutes of pressure maintenance, the pressure drop rate was maintained at 0.005MPa / min, which is far below the allowable pressure drop rate standard, indicating that the pipeline system has good sealing and no obvious leakage points. During the pressure drop stage, the pressure dropped steadily at a rate of 0.05MPa / min until the pressure dropped to 0MPa. The pressure change was stable throughout the process, verifying the accuracy and stability of the device's pressure control.

[0059] Temperature data results: During the entire test, the temperature of the fluid in the pipeline remained between 25℃ and 27℃. In the early stage of pressurization, the temperature rose slightly due to the friction between the water flow and the inner wall of the pipeline and the work of the pressure pump, but as the test progressed, the temperature gradually stabilized. This shows that the pipeline system did not cause a large temperature fluctuation due to abnormal conditions during the test, and also verified that the temperature sensor can accurately monitor temperature changes and provide reliable data support for the test.

[0060] Flow data results: The flow data monitored in real time by flow sensor I shows that during the pressurization stage, the flow rate gradually increases and remains between 70m³ / h and 72m³ / h after reaching a stable value. This matches the output flow of the booster pump and the water flow capacity of the pipeline, indicating that there is no abnormality such as blockage in the pipeline system that affects the water flow. At the same time, the stability of the flow data also reflects the reliability of the entire test device in terms of water flow control.

[0061] Results of pipeline system assessment: Through comprehensive analysis of pressure, temperature and flow data, as well as visual inspection of the pipeline system during the test, it was confirmed that the pressure resistance of the newly built industrial water supply pipeline meets the design requirements, and the pipeline joints are well sealed without leakage. At the corners of the pipeline where water flow impact is more obvious and in the area of ​​flow velocity change, the synergistic effect of the multi-stage composite guide plate, buffer tank and buffer pad effectively reduces the impact of water flow impact on the pipeline, and the pipeline does not deform or damage. This fully verifies the effectiveness of the pipeline water pressure test device in ensuring the accuracy and safety of water pressure testing of pipeline systems.

[0062] Test 2 For the water supply pipeline, a newly laid pipeline with a length of 500m and a diameter of 200mm was selected for water pressure test. The pipeline water pressure test device was installed according to the design requirements, and the pressure sensor II and flow sensor II were accurately installed in the pipeline position close to the water inlet and outlet of the buffer tank to ensure the accuracy of data collection. The tank body is a carbon steel tank with a diameter of 1m and a height of 1.5m. A water-resistant and high-pressure resistant nitrile rubber diaphragm was installed, and the gas chamber was pre-filled with nitrogen to 0.65MPa. A small electric piston gas compressor and an electric regulating valve II were installed, and the control circuit was connected. A DC electromagnetic damper was installed near the water inlet in the water cavity. Pressure sensor II and flow sensor II were installed near the water inlet and outlet of the tank body on the pipeline, and calibrated.

[0063] Set initial parameters: In the data acquisition and control system, set the sliding average filter window size to 7. Based on previous similar project experience, set the water flow impact intensity threshold to a pressure change rate of 0.12MPa / s and a flow change rate of 6m³ / h / s. The initial pressure of the gas chamber of the buffer tank is 0.65MPa, and the initial volume is 0.4m³. The initial current of the electromagnetic damper is set to 0.7A.

[0064] 1. Start the test: Start the booster pump, and water begins to flow into the pipeline and rush to the buffer tank. 5 minutes after the start of the test, due to a brief failure of the booster pump, the pressure sensor II detected that the pressure rose rapidly from 0.4MPa to 0.58MPa within 0.3s, and the pressure change rate reached 0.6MPa / s. The flow sensor II detected that the flow rate increased from 12m³ / h to 22m³ / h in the same time, and the flow change rate was 33.3m³ / h / s, far exceeding the set impact strength threshold.

[0065] Responding to the impact: The data acquisition and control system quickly performs sliding average filtering on the sensor data to eliminate interference signals. Based on the Bernoulli equation and the momentum theorem, it is assessed that the water flow impact strength exceeds the standard. Then, the data acquisition and control system calculates the volume change of the buffer tank according to the ideal gas state equation. The current pressure rises to 0.8MPa, and it is calculated that the gas volume that needs to be increased is about 0.09m³. The data acquisition and control system immediately issues instructions to the gas compressor and regulating valve II, so that the gas compressor quickly fills the gas cavity with gas. The regulating valve II assists in adjusting the gas pressure, pushing the diaphragm down, and increasing the volume of the water cavity. At the same time, the data acquisition and control system issues instructions to the electromagnetic damper, increasing its current from 0.7A to 1.3A, enhancing the damping force to suppress the water flow impact.

[0066] Stable operation: During the subsequent test, the data acquisition and control system continuously monitors the data of pressure sensor II and flow sensor II. As the test progresses, when the pressure and flow return to normal, the data acquisition and control system controls the gas compressor and regulating valve II to slowly adjust the gas pressure according to the sensor data, and adjusts the gas pressure back to 0.75MPa within 5 minutes, so that the diaphragm returns to the appropriate position and maintains the normal working state of the buffer tank. During the entire test process, the operator views the working parameters of the buffer tank in real time through the human-machine interface, such as gas pressure, water flow pressure and flow. At the same time, the current of the electromagnetic damper is reduced to restore it to a suitable working state to adapt to the changing water flow impact.

[0067] 2. Test results: Accuracy of impact strength assessment: During the entire test process, the assessment of water flow impact strength is accurate and reliable through the preset algorithm, which can promptly determine whether the impact strength exceeds the standard, providing an accurate basis for subsequent adjustment and control.

[0068] Pressure buffering effect: In the case of multiple water flow impacts, the buffer tank can respond quickly and control the pressure fluctuation range of the water inlet within ±0.1MPa, effectively protecting the subsequent pipelines and equipment. When the water flow impact intensity exceeds the standard, the buffer tank can respond quickly and accurately adjust the volume according to the calculation results. After multiple impact adjustments, the pressure fluctuation in the pipeline is significantly reduced and stabilized within a safe range, effectively protecting the pipeline system from excessive pressure shocks.

[0069] Stable flow: The monitoring data of flow sensor II shows that after buffering in the buffer tank, the flow fluctuation is significantly reduced and maintained in a stable range of 20m³ / h~22m³ / h, ensuring the smooth delivery of water flow.

[0070] Adjustment effect of electromagnetic damper: Under system control, the electromagnetic damper adjusts the current and changes the damping force in time according to the impact intensity of the water flow. When the impact is large, the enhanced damping force effectively suppresses the turbulence and impact of the water flow and reduces the damage to the pipeline and buffer tank. After the impact weakens, the damping force is reduced in time to avoid excessive energy consumption.

[0071] Intelligent control: The data acquisition and control system can accurately control the gas compressor, regulating valve II and electromagnetic damper according to the preset algorithm based on the data of pressure sensor II and flow sensor II, realizing the intelligent control of the buffer tank and improving the buffer effect and stability of the device.

[0072] Component protection: During the entire test process, due to the effective buffering of the buffer tank and the action of the electromagnetic damper, the pipeline and buffer tank did not show any damage or deformation, which verified the protective effect of the structural design and control method on the pipeline and buffer tank.

[0073] Test 3 Test equipment and parameters: On the simulated pipeline water pressure test platform, the inner diameter of the pipeline is set to 400mm, the test pressure range is 0~1.5MPa, and the pressurization rate is 0.1MPa / min. The cushion is made according to the rubber matrix thickness of 20mm, the nickel-titanium alloy wire diameter of 0.8mm, and the carbon fiber cloth layer thickness of 0.2mm.

[0074] Pressure fluctuation data: During the test, the pressure sensor was used to monitor the pressure fluctuation at the pipe joint. When the buffer pad was not installed, when the pressure reached 1.0MPa, the pressure pump fluctuated briefly, and the pressure instantly rose to 1.25MPa, with a fluctuation range of ±0.25MPa. After the buffer pad was installed, under the same circumstances, the pressure rose to 1.1MPa, and the fluctuation range was reduced to ±0.1MPa. As the test pressure further increased to 1.5MPa, when the buffer pad was not installed, the pressure fluctuation range was around ±0.3MPa; after the buffer pad was installed, the pressure fluctuation stabilized at ±0.12MPa.

[0075] Cushion deformation data: A high-precision displacement sensor is used to monitor the deformation of the cushion under different pressures. When the pressure is 0.5MPa, the compression deformation of the cushion rubber matrix is ​​2mm, and the nickel-titanium alloy wire begins to deform slightly; when the pressure reaches 1.0MPa, the deformation of the rubber matrix is ​​4mm, and the deformation of the nickel-titanium alloy wire increases to 1mm; when the pressure rises to 1.5MPa, the deformation of the rubber matrix is ​​6mm, and the deformation of the nickel-titanium alloy wire is 2mm. The deformation of the shape memory alloy wire shows obvious nonlinearity, and the shape memory effect is used to absorb a large amount of energy under pressure shock.

[0076] Energy absorption data: The water flow impact energy and the energy absorbed by the buffer pad are estimated by calculating the area under the pressure-time curve. In a typical pressure impact process, the water flow impact energy is 100J. When the buffer pad is not installed, the energy absorbed by the pipe connection is only 20J, and most of the energy directly acts on the pipe and accumulator; after the buffer pad is installed, the buffer pad absorbs 60J of energy, effectively reducing the impact force on the pipe and accumulator.

[0077] It shows that the buffer pad of the present invention has significant effects in reducing pressure fluctuations, absorbing water flow impact energy and responding to impact by self-deformation, and provides a strong guarantee for the stable operation of the pipeline water pressure test device.

[0078] Test 4 A simulated pipeline water pressure test platform was built, a pipe with a diameter of 300 mm was set up, and multi-stage composite guide plates were installed at the two corners of the pipe. The test set three different water pressure conditions, namely low water pressure (0.5MPa), medium water pressure (1.0MPa) and high water pressure (1.5MPa). Multiple repeated tests were carried out under each condition, and relevant data were recorded.

[0079] Test results: Pressure fluctuation data: The pressure sensor is used to monitor the pressure fluctuation before and after the guide plate is installed in the pipeline. At low water pressure of 0.5MPa, the pressure fluctuation range of the pipeline without the guide plate is ±0.1MPa; after installing the multi-stage composite guide plate, the pressure fluctuation range is reduced to ±0.03MPa. At medium water pressure of 1.0MPa, the pressure fluctuation range without the guide plate is ±0.15MPa, which is reduced to ±0.05MPa after installation. At high water pressure of 1.5MPa, the pressure fluctuation range without the guide plate is ±0.2MPa, which is reduced to ±0.08MPa after installation.

[0080] Water flow turbulence data: The water flow velocity distribution in the pipe is measured using a velocity meter to assess the water flow turbulence. Under low water pressure, the standard deviation of the water flow velocity distribution is 0.3m / s when the guide plate is not installed; after installation, the standard deviation is reduced to 0.1m / s. Under medium water pressure, the standard deviation of the velocity without the guide plate is 0.5m / s, and after installation it is 0.15m / s. Under high water pressure, the standard deviation of the velocity without the guide plate is 0.7m / s, and after installation it is reduced to 0.2m / s.

[0081] It is shown that the multi-stage composite guide plate of the present invention can effectively reduce the pressure fluctuation and water flow turbulence in the pipeline under different water pressure test conditions, and improve the stability and reliability of the pipeline water pressure test device.

[0082] Test 5 The fatigue data of the guide plate material under different water pressures can directly reflect its durability under complex working conditions: 1. Aluminum alloy first-stage guide plate: Under the conditions of low water pressure of 0.5MPa, loading frequency of 0.1Hz, and 1000 cycles, the surface showed slight wear and no cracks; when the number of cycles increased to 5000, a small number of fine cracks appeared; after 10,000 cycles, the cracks expanded to a certain extent, but still did not affect the basic structure and guide function of the guide plate. Under medium water pressure of 1.0MPa, loading frequency of 0.5Hz, fine cracks appeared after 1000 cycles, and cracks increased significantly after 5000 cycles. After 10,000 cycles, the strength of the guide plate decreased and local deformation occurred. Under high water pressure of 1.5MPa, loading frequency of 1Hz, more cracks appeared after 1000 cycles, and some areas showed obvious deformation after 5000 cycles. After 10,000 cycles, the guide plate basically lost its guide function.

[0083] 2. Polyurethane rubber composite second-stage guide plate: low water pressure 0.5MPa, loading frequency 0.1Hz, slight wear on the surface after 1000 cycles, no obvious cracks; after 5000 cycles, the wear is slightly aggravated, but still no cracks; after 10000 cycles, a small number of fine cracks appear. Medium water pressure 1.0MPa, loading frequency 0.5Hz, slight wear after 1000 cycles, obvious wear after 5000 cycles, and fine cracks begin to appear; after 10000 cycles, the cracks expand and local depressions appear on the surface. High water pressure 1.5MPa, loading frequency 1Hz, obvious wear after 1000 cycles, more cracks after 5000 cycles, after 10000 cycles, the curved surface structure of the guide plate is deformed, and the diversion effect is greatly affected.

[0084] 3. Stainless steel third-level guide plate: low water pressure 0.5MPa, loading frequency 0.1Hz, only slight wear on the surface after 10,000 cycles, no cracks. Medium water pressure 1.0MPa, loading frequency 0.5Hz, a small number of fine cracks appeared after 5,000 cycles, and the cracks slightly expanded after 10,000 cycles, but did not affect the diversion function. High water pressure 1.5MPa, loading frequency 1Hz, fine cracks appeared after 3,000 cycles, cracks increased after 5,000 cycles, and more cracks appeared around the diversion holes after 10,000 cycles. Some holes were deformed, but the basic diversion and diversion function could still be maintained.

[0085] Although the embodiments of the present invention have been disclosed as above, they are not limited to the applications listed in the specification and the implementation modes, and they can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and the illustrations shown and described herein.

Claims

1. A pipeline water pressure test device, characterized in that: include: Pressure sensor I, which is connected to the pipeline and is used to collect pressure data; A temperature sensor is connected to the pipeline and is used to collect temperature data; Flow sensor I, which is connected to the pipeline and is used to collect flow data; A booster pump connected to the pipeline and controlled by a data acquisition and control system to control the output power according to a set pressure rise rate; A plurality of accumulators, which are installed on the output end of the booster pump and the pipeline, store excess pressure energy and release energy to stabilize the pressure when the pressure drops, and the accumulators have a set capacity and a working pressure range; A plurality of buffer units, wherein the buffer units include a buffer tank, a buffer pad and a guide plate, wherein the buffer tank is installed at the front end of the accumulator, the buffer pad is installed at the connection between the accumulator and the pipeline, and the guide plate is installed at the corner of the pipeline or near the area where the water flow velocity changes greatly; A regulating valve I, which is connected to the pipeline and cooperates to adjust the pipeline state in different test stages according to the instructions of the data acquisition and control system; The pressure relief valve is connected to the pipeline and has a set safety pressure threshold. When the pipeline pressure exceeds the safety pressure threshold, it automatically opens to release the pressure. The data acquisition and control system receives the data collected by the pressure sensor, the temperature sensor, and the flow sensor, as well as the pipe diameter, length, material, test time, and pressure rise and fall rate parameters input by the operator through a human-machine interface, and generates control instructions to control the operation of the booster pump, the regulating valve, and the pressure relief valve; The human-machine interface is connected to the data acquisition and control system for operators to input parameters and view real-time data.

2. The pipeline water pressure testing device according to claim 1, characterized in that: The buffer tank comprises: The tank body has a water inlet and a water outlet at both ends; A rubber diaphragm is disposed in the tank body and is sealed to the inner wall of the tank body, dividing the tank body into two upper and lower chambers, wherein the gas chamber located above the diaphragm is pre-filled with inert gas, and the water chamber located below the diaphragm is in communication with the pipeline water flow; A gas compressor connected to the gas chamber, the gas compressor fills or releases gas into the gas chamber according to the instruction of the data acquisition and control system, changes the gas pressure, and adjusts the position of the diaphragm; A regulating valve II, which is connected to the gas chamber and is used to assist the gas compressor in regulating the gas pressure in the gas chamber; An electromagnetic damper is installed in the water chamber near the water inlet; Pressure sensor II, which is installed on the pipeline near the water inlet of the tank body to monitor water flow pressure data in real time; Flow sensor II, which is installed on the pipeline near the water outlet of the tank to monitor water flow data in real time; The data acquisition and control system receives the data monitored by the pressure sensor II and the flow sensor II, and after analysis by a preset algorithm, issues control instructions to the gas compressor, the regulating valve II and the electromagnetic damper.

3. The pipeline water pressure testing device according to claim 2, characterized in that: The preset algorithm analysis in the data acquisition and control system specifically includes: filtering the received monitoring data using a sliding average filtering method, using the Bernoulli equation and momentum theorem to establish a water flow impact model, evaluating the water flow impact intensity through the pressure change rate and flow change rate, and setting a water flow impact intensity threshold; And, when the water flow impact intensity exceeds the set water flow impact intensity threshold, the volume of the buffer tank that needs to be increased is calculated, wherein the ideal gas state equation is used to calculate the gas volume that needs to be changed to balance the pressure, that is, the change in the volume of the buffer tank is obtained; And, when the water flow impact intensity exceeds a set water flow impact intensity threshold, a control instruction is sent to the electromagnetic damper to adjust the current of the electromagnetic damper.

4. The pipeline water pressure testing device according to claim 2, characterized in that: The buffer pad comprises: The rubber base is in the shape of a disk, and a circular through hole is opened at the center of the rubber base; A plurality of shape memory alloy wires are evenly embedded in the rubber matrix at a certain interval and angle, wherein the shape memory alloy wires are radially distributed and extend from the central through hole of the rubber matrix to the edge to form a mesh structure; The carbon fiber cloth layer is laid on the surface of the rubber matrix by bonding with an adhesive.

5. The pipeline water pressure testing device according to claim 4, characterized in that: The thickness of the rubber matrix is ​​10 mm to 30 mm, the shape memory alloy wire is a nickel-titanium alloy wire with a diameter of 0.5 mm to 1 mm, and the thickness of the carbon fiber cloth layer is 0.1 mm to 0.3 mm.

6. The pipeline water pressure testing device according to claim 2, characterized in that: The guide plate is a multi-stage composite guide plate, and the multi-stage composite guide plate comprises: The first-stage guide plate is in a straight plate shape, and the inclination angle is set to 45°~60°. A dense oxide film is formed on the surface of the first-stage guide plate, and the material of the first-stage guide plate is aluminum alloy; The second-stage guide plate is in a curved and parabolic shape, and the material of the second-stage guide plate is a composite material of polyurethane rubber embedded with 15% to 20% glass fiber filaments; The third-stage guide plate is in the shape of a straight plate, and is provided with a plurality of diversion holes with a diameter of 5 mm to 10 mm, and the plurality of diversion holes are arranged in an array of equilateral triangles, and the distance between the diversion holes is 10 mm to 20 mm, and the material of the third-stage guide plate is stainless steel; A plurality of hinges are provided, one end of the hinge is fixedly connected to the upper level guide plate by bolts, and the other end is movably connected to the lower level guide plate by a pin shaft, and the material of the hinge is titanium alloy.

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