Component ignition source testing device and method for refrigeration appliances using flammable refrigerants

Abstract

The present invention relates to a device and method for testing the ignition source of components used in flammable refrigerant refrigeration appliances. The device comprises a dimension measurement module, a test module, and a data processing terminal. By providing the dimension measurement module, six-sided scanning of components such as relays, contactors, and electrical boxes used in flammable refrigerant refrigeration appliances can be performed, achieving high dimension scanning and volume measurement accuracy, thereby improving the dimension measurement accuracy of subsequent components. By providing the test module, multi-environment coupling testing can be performed to meet the ignition source testing requirements of the tested components under various environmental coupling conditions. By integrating a PLC control module and simulation modeling software, digital twin technology is utilized to achieve closed-loop verification of test data and a mathematical model for the ignition source test. Multimodal self-learning is then used to improve and optimize the mathematical model for the ignition source test, ensuring its accuracy and reliability.

Description

Technical Field

[0001] The present invention relates to the technical field of component ignition testing for flammable refrigerant refrigeration appliances, and in particular to a component ignition source testing device and method for flammable refrigerant refrigeration appliances. Background Art

[0002] Currently, propane (R290) and difluoromethane (R32) natural hydrocarbon refrigerants have low ozone depletion potential (ODP) and low global warming potential (GWP). They are considered highly promising next-generation refrigerants, replacing R22 and R410A refrigerants and are widely used in household air conditioners and heat pumps. However, R290 and R32 are flammable refrigerants. One way to reduce the risk of refrigerant ignition is to ensure that components such as relays, contactors, and electrical boxes meet explosion-proof requirements or are not ignition sources. This ensures that refrigerant leaks will not ignite electrical components and cause a fire.

[0003] Currently, relay products are certified for explosion-proof according to the IEC 60079 standard. The test equipment for this certification is expensive and requires high laboratory space, making it unsuitable for large-scale promotion in the home appliance field. At the same time, existing test equipment for explosion-proof certification, such as the Chinese patent with publication number CN119023895A, discloses a test platform and test method for flammable refrigerant sensors. This test platform is in accordance with IEC The requirements of Appendix LL of 60335-2-40 are used to test the calibration, short-term stability, long-term stability, response time, oil injection test, electromagnetic compatibility, high and low temperature, humidity and ignition test of flammable refrigerant sensors. In addition, the principle of the sensor ignition test is disclosed as follows: placing the sensor under test in a refrigerant mixture with a chemical equivalent concentration of 110% to test whether the sensor can ignite the refrigerant mixture with a flammable concentration around it; while the principle of the ignition source verification test for components such as relays, contactors, and electrical boxes of refrigeration appliances with flammable refrigerants is as follows: placing the component under test in a flammable refrigerant mixture with a target chemical equivalent concentration, and arranging a discharge electrode at the contact position of the component under test to ensure that the refrigerant mixture at the contact position of the component under test is ignited, and then observing whether the refrigerant mixture outside the component under test is ignited. Due to the differences in the test scenarios of the two, the test platform cannot be used for ignition source verification testing of components such as relays, contactors, and electrical boxes of refrigeration appliances with flammable refrigerants.

[0004] To this end, the present application provides a device and method for testing the ignition source of components of flammable refrigerant refrigeration appliances, which is a detection device for verifying whether components such as relays, contactors, and electrical boxes of flammable refrigerant refrigeration appliances are ignition sources. Summary of the Invention

[0005] Based on this, it is necessary to provide an ignition source testing device and method for components of refrigeration appliances using flammable refrigerants to address the above technical problems.

[0006] According to a first aspect of the present invention, there is provided a component ignition source testing device for flammable refrigerant refrigeration appliances, comprising: a dimension measurement module for acquiring six-sided scanning data of the component under test, and importing the data into a data processing terminal for image processing to obtain dimension data of the component under test; a testing module for performing an ignition source verification test on the component under test; a data processing terminal for receiving the dimension data of the component under test, calling the refrigerant physical property parameters in the Refprop database, constructing an ignition source test mathematical model using simulation modeling software and performing an ignition source test simulation test to obtain simulation data, and performing an ignition source verification test through the testing module to obtain test data, comparing the test data with the simulation data, and if the difference between the test data and the simulation data is greater than a preset difference threshold, adjusting the model parameters and reconstructing the ignition source test mathematical model, repeating the ignition source verification test until the difference between the test data and the simulation data is less than the preset difference threshold, solidifying the model parameters, and uploading the adjusted ignition source test mathematical model to the cloud for storage.

[0007] Optionally, the dimension measurement module includes a test bench, a mounting frame and a laser three-dimensional scanner, the mounting frame is fixedly installed on the test bench, the laser three-dimensional scanner is fixedly installed on the mounting frame, and the laser three-dimensional scanner is connected to the data processing terminal to obtain six-sided scanning data of the component under test, and import it into the data processing terminal for image processing to obtain the dimension data of the component under test.

[0008] Optionally, the test module includes a protective shell that has both a pressure relief function and a function of generating heat when the refrigerant in the diffusion test chamber explodes, a test chamber arranged inside the protective shell and used to provide target test conditions for the components under test and perform an ignition source test, a gas distribution module connected to the interior of the test chamber and used to provide target gas and pressure to the test chamber, a detection module, a temperature, humidity and pressure control module for regulating the target test conditions in the test chamber, a reaction product processing module connected to the interior of the protective shell and used for exhaust gas treatment, and a control cabinet.

[0009] Optionally, the protective shell includes a shell, a cavity is provided between the shell and the test chamber, the cavity is provided with a water inlet and a water outlet for diffusing the heat generated when the refrigerant in the test chamber explodes, a first opening and closing door is provided at the front end of the shell, an observation window is provided on the first opening and closing door, a pressure release device is provided on the top of the shell, a pressure detection unit is provided on the inner side of the wall of the shell, for obtaining the real-time pressure in the shell, and starting the pressure release device when the real-time pressure exceeds a preset pressure threshold, and the shell is connected to a liquid nitrogen fire extinguishing device and a vacuum pump.

[0010] Optionally, the test box includes a box body, the bottom of which is fixedly installed in the shell by a first bracket, and a second opening and closing door is provided at the front end of the box body. The position of the second opening and closing door corresponds to the position of the first opening and closing door, so as to facilitate placing the components under test inside the box body, and a second bracket is provided inside the box body for fixing the components under test and the discharge electrode.

[0011] Optionally, the detection module includes a test chamber environment detection unit, a pH detection unit, a gas composition detection unit, a discharge device detection unit and a test process detection unit.

[0012] Optionally, the air distribution module includes an air unit and a refrigerant unit, the air unit includes an air compressor, an air storage tank and a filter structure connected in sequence, the output end of the filter structure is connected to the interior of the test box, the refrigerant unit includes a standard refrigerant cylinder and a gas concentration analysis device, the output pipe of the standard refrigerant cylinder is connected to the interior of the test box, and a pressure reducing valve and an electric regulating valve are provided on the output pipe of the standard refrigerant cylinder. The detection end of the gas concentration analysis device is connected to the interior of the test box for real-time detection of the refrigerant concentration inside the test box, and the refrigerant concentration is fed back to the control cabinet, and the on-off state of the electric regulating valve is adjusted to control the refrigerant filling amount to reach the target concentration.

[0013] Optionally, the control cabinet includes a display touch screen, a PLC control module, an AD conversion module and an adjustable power supply. The PLC control module is respectively connected to the display touch screen, the AD conversion module and the adjustable power supply. The PLC control module is respectively connected to the protective shell, the test chamber, the gas distribution module, the detection module, the temperature, humidity and pressure control module, and the reaction product processing module through the AD conversion module, and is used to control the protective shell, the test chamber, the gas distribution module, the detection module, the temperature, humidity and pressure control module, and the reaction product processing module, and is connected to the data processing terminal via a wired or wireless network. The adjustable power supply is connected to the discharge electrode for regulating the voltage, discharge current, discharge energy and discharge time of the discharge electrode.

[0014] According to a second aspect of the present invention, a component ignition source testing method for flammable refrigerant refrigeration appliances is provided, which is applied to the component ignition source testing device for flammable refrigerant refrigeration appliances, comprising: obtaining six-sided scanning data of the component under test through a size measurement module, and importing it into a data processing terminal for image processing to obtain the size data of the component under test; comparing the size data of the component under test with a preset opening effective size threshold; if the size data of the component under test meets the preset opening effective size threshold, constructing an ignition source test mathematical model using simulation modeling software, and adjusting the ignition source test according to the type of refrigerant applicable to the component under test; Using the refrigerant physical properties in the Refprop database, the ignition source test simulation test is performed on the components under test through the constructed ignition source test mathematical model to obtain simulation data; the ignition source verification test is performed through the test module to obtain test data; the test data is compared with the simulation data. If the difference between the test data and the simulation data is greater than the preset difference threshold, the model parameters are adjusted and the ignition source test mathematical model is reconstructed. The ignition source verification test is repeated until the difference between the test data and the simulation data is less than the preset difference threshold. The model parameters are solidified, and the adjusted ignition source test mathematical model is uploaded to the cloud for storage.

[0015] Optionally, if the difference between the test data and the simulation data is greater than a preset difference threshold, the model parameters are adjusted and the ignition source test mathematical model is reconstructed, and the ignition source verification test is repeatedly performed until the difference between the test data and the simulation data is less than the preset difference threshold, including: comparing the test data with the simulation data, if the difference between the test data and the simulation data is greater than the preset difference threshold, structuring the test data to obtain structured test data, constructing a time-space mapping relationship based on the structured test data, verifying the constraints of the ignition source test mathematical model through IEC 60335-1 standard, IEC 60335-2-24 standard and refrigerant physical properties, capturing unmodeled factors, and identifying the uncertainty of the test data, adjusting the model parameters based on Bayesian optimization technology and reconstructing the ignition source test mathematical model, and repeatedly performing the ignition source verification test until the difference between the test data and the simulation data is less than the preset difference threshold.

[0016] The advantages and beneficial effects of the present invention are as follows: by setting a dimension measurement module, the present invention can perform six-sided scanning of components such as relays, contactors, electrical boxes, etc. used in flammable refrigerant refrigeration appliances, with high dimension scanning accuracy and volume measurement accuracy, so as to improve the dimension measurement accuracy of subsequent components; by setting a test module, multi-environment coupling test can be realized, so as to realize the ignition source test requirements of the tested components under various environmental coupling conditions, and combined with the monitoring design of the detection module, the accuracy and repeatability of the test can be ensured; through the linkage control of the liquid nitrogen fire extinguishing device, the pressure release device, the water inlet and the water outlet, the safety of the test can be effectively improved; by integrating the PLC control module and the simulation modeling software, the digital twin technology is used to realize the closed-loop verification of the test data and the ignition source test mathematical model, and the ignition source test mathematical model is improved and optimized through multimodal self-learning to ensure the accuracy and reliability of the ignition source test mathematical model. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 The present invention is a structural block diagram of a component ignition source testing device for refrigeration appliances using flammable refrigerants.

[0018] Figure 2 The present invention is a flow chart of a component ignition source testing method for refrigeration appliances using flammable refrigerants.

[0019] Among them, there are control cabinet 1, components under test 2, test box 3, and protective shell 4. DETAILED DESCRIPTION

[0020] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that, unless there is a conflict, the embodiments of the present disclosure and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.

[0021] Example 1

[0022] Reference Attachment Figure 1 The present application provides a component ignition source testing device for flammable refrigerant refrigeration appliances, which mainly includes a size measurement module, a testing module and a data processing terminal.

[0023] In some optional implementations of the present application, the dimension measurement module is used to obtain six-sided scanning data of the component under test, and import the data into a data processing terminal for image processing to obtain dimension data of the component under test.

[0024] In some optional implementations of the present application, the dimension measurement module includes a test bench, a mounting frame and a laser three-dimensional scanner, the mounting frame is fixedly installed on the test bench, the laser three-dimensional scanner is fixedly installed on the mounting frame, and the laser three-dimensional scanner is connected to the data processing terminal to obtain six-sided scanning data of the component under test, and import it into the data processing terminal for image processing to obtain the dimension data of the component under test.

[0025] In some optional implementations of this application, the laser 3D scanner features four modes: high-speed scanning, fine scanning, deep-hole scanning, and photogrammetry. It utilizes a Class II (i.e., eye-safe) blue laser light source, effectively protecting the eyesight of measurement personnel. Its dimensional scanning accuracy is 0.01mm, its volume measurement accuracy is 0.015mm / m, its maximum scanning speed is 6,350,000 points / second, and its maximum scanning area is 1,000mm x 1,000mm. It can connect to a data processing terminal via both wired and wireless connections: a USB 4.0 port for wired connection and Wi-Fi 7 or StarFlash for wireless network connection. It supports multiple wireless protocols, including 802.11a / b / g / n / ac. After obtaining the six-sided scanning data of the component under test, it can be imported into the image processing software of the data processing terminal for image processing to obtain the dimensional data of the component under test. The image processing software includes but is not limited to pro-E, UG, SolidWorks, EINSENSE Q, Verisurf Inspect, Gromagic Control X and other software.

[0026] In some optional implementations of the present application, the test module is used to perform an ignition source verification test on the components under test.

[0027] In some optional implementations of the present application, the test module includes a protective shell that has both a pressure relief function and a function of generating heat when the refrigerant in the diffusion test chamber explodes, a test chamber arranged inside the protective shell and used to provide target test conditions to the components under test and perform ignition source testing, a gas distribution module connected to the interior of the test chamber and used to provide target gas and pressure to the test chamber, a detection module, a temperature, humidity and pressure control module for regulating the target test conditions in the test chamber, a reaction product processing module connected to the interior of the protective shell and used for exhaust gas treatment, and a control cabinet.

[0028] In some optional implementations of the present application, the protective shell includes a shell, a cavity is provided between the shell and the test chamber, the cavity is provided with a water inlet and a water outlet for diffusing the heat generated when the refrigerant in the test chamber explodes, a first opening and closing door is provided at the front end of the shell, an observation window is provided on the first opening and closing door, a pressure release device is provided on the top of the shell, a pressure detection unit is provided on the inner side of the wall of the shell, for obtaining the real-time pressure in the shell, and starting the pressure release device when the real-time pressure exceeds a preset pressure threshold, and the shell is connected to a liquid nitrogen fire extinguishing device and a vacuum pump.

[0029] In some optional implementations of the present application, the shell surface is made of SUS304 stainless steel with a thickness of 2mm, the inner wall of the shell is made of 316L stainless steel with a thickness of 25mm, and the inner wall of the shell is provided with reinforcing ribs with a height of 90mm, a thickness of 50mm and an interval of 300mm. A heat-insulating material layer is embedded between the shell surface and the inner wall of the shell, wherein the heat-insulating material layer is composed of a polyurethane board with a thickness of 100mm and glass wool with a thickness of 10mm. The volume inside the shell is 80L and the pressure-bearing capacity is greater than 20MPa. A cavity is provided between the shell and the internal test chamber, and the cavity is provided with a water inlet and a water outlet, and a water inlet valve and a water outlet valve are respectively provided on the pipes connecting the water inlet and the water outlet to the outside world, so as to diffuse the heat generated by the explosion of the refrigerant in the test chamber by injecting water into the cavity. The front of the shell is equipped with a first opening and closing door, which features an explosion-proof safety handle. It also includes an observation window made of four layers of tempered glass for easy observation and is equipped with an explosion-proof chain. A pressure relief device is installed on the top of the shell. A uniform pressure detection unit (i.e., a pressure sensor) is located on the inside of each shell wall to detect the real-time pressure within the shell. If the real-time pressure exceeds a preset pressure threshold, the pressure relief device is activated, which can also sound a pressure relief alarm. The shell is connected to a liquid nitrogen fire extinguishing device and a vacuum pump.

[0030] In some optional implementations of the present application, the test box includes a box body, the bottom of which is fixedly installed in the shell by a first bracket, and a second opening and closing door is provided at the front end of the box body. The position of the second opening and closing door corresponds to the position of the first opening and closing door, so as to facilitate the placement of the components under test inside the box body, and a second bracket is provided inside the box body for fixing the components under test and the discharge electrode.

[0031] In some optional implementations of the present application, the chamber is made of 15mm thick 316L stainless steel, with an inner layer made of 2mm thick polytetrafluoroethylene, which is highly corrosion-resistant. It has a volume of 40L and a pressure resistance greater than 10MPa. It is fixedly mounted within the shell by a first bracket. A second opening and closing door is located at the front end of the chamber, corresponding to the position of the first opening and closing door, to facilitate the placement of the components under test inside the chamber. The second opening and closing door and the chamber can be connected by a quick-release flange. A second bracket is provided inside the chamber to secure the components under test and the discharge electrode. The discharge electrode can be a circular tungsten electrode to reduce the corona effect during discharge, and the electrode gap can be adjusted from 2mm to 10mm. Four electric valves connected to the shell are installed on the side walls of the chamber to adjust the temperature, humidity, and pressure of the test chamber. The chamber is connected to the gas distribution module and the reaction product processing module by pipelines, each of which is equipped with electric control valves.

[0032] In some optional implementations of the present application, the detection module includes a test chamber environment detection unit, a pH detection unit, a gas composition detection unit, a discharge device detection unit, and a test process detection unit.

[0033] In some optional implementations of the present application, the detection module includes a test chamber environment detection unit, a pH detection unit, a gas composition detection unit, a discharge device detection unit and a test process detection unit. The sensors of each detection unit adopt an explosion-proof design. It should be noted that each detection unit includes a sensor probe acquisition unit and a data reading unit, wherein the sensor probe acquisition unit is arranged in the test chamber, and the data reading unit is arranged outside the shell. The signal lines of the sensor probe acquisition unit are connected to the waterproof and explosion-proof terminals on the shell, and are connected to the corresponding data reading unit through the waterproof and explosion-proof terminals, and are respectively connected to the control cabinet and the data processing terminal through the data reading unit. See Table 1 below for details.

[0034] Table 1 Composition, implementation functions and test performance of the detection module

[0035]

[0036] In some optional implementations of the present application, the air distribution module includes an air unit and a refrigerant unit, the air unit includes an air compressor, an air storage tank and a filter structure connected in sequence, the output end of the filter structure is connected to the interior of the test box, the refrigerant unit includes a standard refrigerant cylinder and a gas concentration analysis device, the output pipe of the standard refrigerant cylinder is connected to the interior of the test box, and a pressure reducing valve and an electric regulating valve are provided on the output pipe of the standard refrigerant cylinder. The detection end of the gas concentration analysis device is connected to the interior of the test box for real-time detection of the refrigerant concentration inside the test box, and the refrigerant concentration is fed back to the control cabinet, and the on-off state of the electric regulating valve is adjusted to control the refrigerant filling amount to reach the target concentration.

[0037] In some optional implementations of the present application, the air distribution module consists of an air unit and a refrigerant unit. The air unit collects and compresses ambient air using an air compressor, storing it in a gas tank. The air is then purified and dried through a filter structure (e.g., a silica gel filter chamber) before being output to the test chamber. A control cabinet automatically controls the air compressor's operating status based on real-time pressure feedback from a pressure sensor. Furthermore, a pressure control system (e.g., a pressure reducing valve and an electric regulating valve) is installed on the pipe connecting the filter structure to the test chamber to ensure pressure stability of the output air. The output air has a relative hydrocarbon concentration of less than 0.1 ppm, and the output pressure is between 0 and 10 MPa. The refrigerant unit consists of a standard refrigerant cylinder, a gas concentration analyzer, a pressure reducing valve, and an electric regulating valve. The gas concentration analyzer monitors the refrigerant concentration inside the test chamber in real time and transmits this information to the control cabinet. By adjusting the on / off state of the electric regulating valve, the refrigerant filling amount is controlled to achieve the target concentration.

[0038] In some optional implementations of the present application, the control cabinet includes a display touch screen, a PLC control module, an AD conversion module and an adjustable power supply. The PLC control module is respectively connected to the display touch screen, the AD conversion module and the adjustable power supply. The PLC control module is respectively connected to the protective shell, the test chamber, the gas distribution module, the detection module, the temperature, humidity and pressure control module, and the reaction product processing module through the AD conversion module, and is used to execute control of the protective shell, the test chamber, the gas distribution module, the detection module, the temperature, humidity and pressure control module, and the reaction product processing module, and is connected to the data processing terminal via a wired or wireless network. The adjustable power supply is connected to the discharge electrode for regulating the voltage, discharge current, discharge energy and discharge time of the discharge electrode.

[0039] In some optional implementations of the present application, the control cabinet is composed of a display touch screen, a PLC control module, an AD conversion module and an adjustable power supply. The PLC control module is connected to the protective housing, the test chamber, the gas distribution module, the detection module, the temperature, humidity and pressure control module, and the reaction product processing module respectively through the AD conversion module, and is connected to the data processing terminal through methods including but not limited to serial port, Ethernet, USB, wireless, etc. The protective housing, the test chamber, the gas distribution module, the detection module, the temperature, humidity and pressure control module, and the reaction product processing can be controlled by the PLC control module. The display touch screen is connected to the PLC control module and can be controlled by the display touch screen. The adjustable power supply is connected to the discharge electrode in the test chamber, and the voltage adjustment range is 0 to 100 kV, the discharge current adjustment range is 0 to 10 A, the discharge energy adjustment range is 0 to 100 J, and the discharge time adjustment range is 0 to 60 s.

[0040] In some optional implementations of the present application, the control cabinet can realize the following functions: (1) control of the temperature, humidity and pressure in the inner cavity of the protective shell to simulate different climate and altitude scenarios; (2) setting of a preset pressure threshold in the protective shell; (3) execution of the pressure release device on the protective shell; (4) control of the water inlet valve and the water outlet valve in the inner cavity of the protective shell; (5) control of each electric valve on the test chamber; (6) control of the temperature, humidity and pressure in the test chamber; (7) on and off of the discharge electrode in the test chamber; (8) control of the gas distribution module, including setting the concentration, humidity, intake speed and pressure of oxygen and refrigerant; (9) reading the data of each sensor of the detection module; (10) control of the reaction product processing module; (11) control of the display touch screen; (12) control of the voltage, current and on-off time of the discharge electrode; (13) transmission of the test data of the detection module to the data processing terminal.

[0041] In some optional implementations of the present application, the temperature, humidity and pressure control module is used to control the temperature, humidity and pressure inside the test chamber. The temperature adjustment range is -60℃~160℃, the humidity adjustment range is 10%RH~99%RH, the pressure adjustment range is 0.1~200kPa, the heating rate is 5℃ / min, the cooling rate is 1℃ / min, the temperature control accuracy is 0.1℃, the humidity control accuracy is 0.1%RH, and the pressure control accuracy is 0.1Pa.

[0042] In some optional implementations of this application, the reaction product processing module uses a combined physical adsorption and chemical catalysis exhaust gas treatment method to treat the exhaust gas within the protective housing. Its operating principle is as follows: Harmful substances in the exhaust gas are first adsorbed by a physical adsorbent, and then catalytically decomposed by a catalyst. The adsorption-catalysis method offers the advantages of effective treatment and a high exhaust gas purification rate.

[0043] In some optional implementations of the present application, a data processing terminal is used to receive dimensional data of components under test, call refrigerant physical property parameters in the Refprop database, use simulation modeling software to construct an ignition source test mathematical model and perform ignition source test simulation test to obtain simulation data, and perform an ignition source verification test through a test module to obtain test data, compare the test data with the simulation data, and if the difference between the test data and the simulation data is greater than a preset difference threshold, adjust the model parameters and reconstruct the ignition source test mathematical model, repeat the ignition source verification test until the difference between the test data and the simulation data is less than the preset difference threshold, solidify the model parameters, and upload the adjusted ignition source test mathematical model to the cloud for storage.

[0044] In some optional implementations of the present application, the data processing terminal may be composed of an Intel i9-13900K processor and NVIDIA RTX 6000 Ada GPU hardware, which receives the dimensional data of the components under test, calls the refrigerant physical properties in the Refprop database, uses simulation modeling software (ANSYS Chemkin and MATLAB software) to construct an ignition source test mathematical model and conducts an ignition source test simulation test, and conducts an ignition source verification test through a test module, compares the simulation data with the ignition source verification test, improves the ignition source test mathematical model to improve the accuracy of the simulation test, and analyzes the causes of unqualified test results, and proposes improvement and optimization measures for components.

[0045] Example 2

[0046] This embodiment provides a component ignition source testing method for refrigeration appliances using flammable refrigerants based on the above embodiment 1. Figure 2 , applied to the component ignition source testing device for flammable refrigerant refrigeration appliances of Example 1, the method includes the following steps.

[0047] S1: The six-sided scanning data of the measured component is obtained through the dimension measurement module and imported into the data processing terminal for image processing to obtain the dimension data of the measured component.

[0048] In some optional implementations of the present application, the specific implementation process of the size measurement of the component under test is as follows: (1) placing the component under test on the test bench, starting the laser three-dimensional scanner, and connecting the laser three-dimensional scanner to the data processing terminal to start six-sided scanning measurement; (2) after the six-sided scanning of the component under test is completed, the six-sided scanning data is output to the data processing terminal to obtain a three-dimensional structure diagram of the component under test; (3) using one of the image processing software such as pro-E, UG, SolidWorks, EINSENSEQ, Verisurf Inspect and Gromagic Control X to measure the shell opening size and external dimensions of the component under test to obtain the size data of the component under test; (4) importing the size data of the component under test (i.e., the shell opening size and external dimensions of the component under test) into ANSYS Chemkin and MATLAB software for modeling and ignition source test simulation.

[0049] S2: Compare the size data of the tested component with the preset opening effective size threshold. If the size data of the tested component meets the preset opening effective size threshold, use simulation modeling software to construct an ignition source test mathematical model. According to the refrigerant type applicable to the tested component, call the refrigerant physical properties in the Refprop database, and perform an ignition source test simulation test on the tested component through the constructed ignition source test mathematical model to obtain simulation data.

[0050] In some optional implementations of the present application, before comparing the size data of the component under test with a preset opening effective size threshold (such as greater than 7mm and less than 12mm), it also includes: constructing a component size model based on the size data of the component under test, and comparing the size data of the component under test with the preset opening effective size threshold. If the size data of the component under test is less than the preset opening effective size threshold (less than or equal to 7mm), the component under test is judged to be qualified; if the size data of the component under test is greater than the preset opening effective size threshold (greater than or equal to 12mm), the component under test is judged to be unqualified, and improvement suggestions are output for the unqualified products. If the size data of the component under test meets the preset opening effective size threshold (greater than 7mm and less than 12mm), the mathematical model of the ignition source test is modeled using simulation modeling software and an ignition source test simulation test is performed.

[0051] In some optional implementations of the present application, the specific implementation process of the ignition source test simulation test is as follows: (1) according to the type of refrigerant applicable to the tested component, the refrigerant physical property parameters in the Refprop database are called from the data processing terminal; (2) the ignition source test mathematical model is established according to the dimensional data of the tested component; (3) the ignition source test simulation test is performed on the tested component through the ignition source test mathematical model in combination with the relevant parameters of the refrigerant and oxygen oxidation reaction; (4) the ignition source test simulation test is repeated multiple times and the simulation data is obtained by averaging.

[0052] S3: Perform an ignition source verification test through the test module to obtain test data.

[0053] In some optional implementations of the present application, the specific implementation process of the ignition source verification test is as follows: (1) fix the discharge electrode to the contact position of the component under test, and arrange the pH sensor, temperature sensor, pressure sensor, and video sensor; (2) place the component under test in the test chamber, connect the temperature sensor, pressure sensor, pH sensor, video sensor, gas concentration tester, and connect the gas distribution module, discharge electrode, and adjustable power supply; (3) set the voltage, current, and discharge time of the discharge electrode, perform a discharge test, verify the voltage, current, and discharge time of the discharge electrode through an oscilloscope, and then seal the test chamber; (4) open the air unit and replace the gas in the test chamber with filtered and dried impurity-free air; (5) set the test chamber temperature to the target temperature, target humidity, and target pressure (such as 25°C, 50%RH, 101kPa, 25°C, 50%RH, 95kPa), and turn on the gas concentration analyzer and the standard refrigerant cylinder according to the refrigerant applicable to the component under test. Set the equivalent concentration (e.g., the equivalent concentration of R32 refrigerant is about 18%, and the equivalent concentration of R290 refrigerant is about 4.6%), and configure the refrigerant and air mixture with the equivalent concentration; (6) Turn on the detection modules such as temperature sensor, pressure sensor, pH sensor, video sensor, etc. to detect the temperature, pressure, pH value, image and other parameters inside the tested component and the temperature, pressure, pH value, image, gas concentration and other parameters inside the test chamber; (7) Perform the ignition source verification test; (8) According to the changes in the temperature, pressure and pH value inside the tested component, determine whether the refrigerant at its internal contact position is burning; (9) Then, according to the changes in the temperature, pressure, pH value, reaction material composition, image and other data inside the test chamber, determine whether the refrigerant outside the tested component is burning; (10) Turn on the air unit to output the reaction gas in the test chamber to the reaction product processing module and replace it with filtered and dried impurity-free air; (11) Repeat the above steps (3)-(10) multiple times and take the average to obtain the simulation data.

[0054] S4: Compare the test data with the simulation data. If the difference between the test data and the simulation data is greater than the preset difference threshold, adjust the model parameters and rebuild the ignition source test mathematical model. Repeat the ignition source verification test until the difference between the test data and the simulation data is less than the preset difference threshold. Solidify the model parameters and upload the adjusted ignition source test mathematical model to the cloud for storage.

[0055] In some optional implementations of this application, a data processing terminal compares test data and simulation data. If the difference between the test data and simulation data is greater than a preset difference threshold (e.g., 2%), the model parameters are fine-tuned, and the ignition source test mathematical model is self-reflected and error correction is performed. The ignition source test mathematical model is then improved through multimodal self-learning, and the ignition source test simulation and ignition source verification tests are re-performed, and the data comparison is performed again until the difference between the two data is less than a preset difference threshold (e.g., 2%). In addition, through analysis of the ignition source test mathematical model, improvement suggestions are given for unqualified tested components.

[0056] In some optional implementations of the present application, if the difference between the test data and the simulation data is greater than a preset difference threshold, the model parameters are adjusted and the ignition source test mathematical model is reconstructed, and the ignition source verification test is repeatedly performed until the difference between the test data and the simulation data is less than the preset difference threshold, including: comparing the test data with the simulation data, if the difference between the test data and the simulation data is greater than the preset difference threshold, structuring the test data to obtain structured test data, based on the structured test data, constructing a time-space mapping relationship, verifying the constraints of the ignition source test mathematical model through IEC 60335-1 standard, IEC 60335-2-24 standard and refrigerant physical properties, capturing unmodeled factors, and identifying the uncertainty of the test data, adjusting the model parameters based on Bayesian optimization technology and reconstructing the ignition source test mathematical model, and repeatedly performing the ignition source verification test until the difference between the test data and the simulation data is less than the preset difference threshold.

[0057] In some optional implementations of the present application, the specific implementation process of the equivalent concentration verification of the flammable refrigerant is as follows: (1) input the code of the refrigerant to be tested on the data processing terminal, and use its built-in Refprop database to query the composition of the refrigerant; (2) write the chemical reaction formula of its combustion based on the queried refrigerant composition; (3) use ANSYS Chemkin and MATLAB simulation modeling software in the data processing terminal to simulate the combustion reaction, verify the chemical reaction formula of the above step (2), and calculate the theoretical chemical equivalent concentration C1 of the refrigerant to be tested; (4) fix the discharge electrode to the center position of the test chamber, arrange the pH sensor, temperature sensor, pressure sensor, video sensor, gas concentration tester, and connect the gas distribution module, discharge electrode and adjustable power supply; (5) set the voltage, current and discharge time of the discharge electrode (such as 15kV, 30mA, 0.3s), conduct a discharge test, verify the voltage, current and discharge time of the discharge electrode through an oscilloscope, and then seal the test chamber; (6) Set the test chamber temperature to the target temperature, target humidity and target pressure (such as 25℃, 50%RH, 101kPa, 25℃, 50%RH, 95kPa), turn on the gas concentration analysis device and the standard refrigerant cylinder according to the refrigerant to be tested, set the refrigerant concentration to be configured according to the theoretical equivalent concentration, and configure the refrigerant and air mixture with equivalent concentration; (7) Turn on the temperature sensor, pressure sensor, pH sensor, video sensor and other detection modules to detect the temperature, pressure, pH value, image and other parameters inside the tested component and the temperature, pressure, pH value, image, gas concentration and other parameters inside the test chamber; (8) Conduct an ignition source verification test; (9) According to the temperature, pressure, pH value changes, reaction material composition, image and other data inside the test chamber, determine whether the refrigerant is ignited; (10) If the refrigerant is burning, determine whether the tested refrigerant has completely undergone oxidation reaction based on the type and content of the collected reaction materials to verify the theoretical chemical equivalent concentration C1; (11) Turn on the air unit to output the reaction gas in the test chamber to the reaction product processing module and replace it with impurity-free air after filtering and drying; (12) Compare the test data and simulation data through the data processing terminal. If the difference between the test data and the simulation data is greater than the preset difference threshold (such as 2%), the test data is structured to obtain structured test data. Based on the structured test data, a time-space mapping relationship is constructed, and the discharge energy of the electrode is verified using the finite element model. The constraints of the mathematical model of the ignition source test are verified based on the relevant test requirements of IEC 60335-1 and IEC 60335-2-24 standards and the physical properties of refrigerants (such as environmental conditions, mass fraction, tangential strain rate, displacement velocity, energy transfer, etc.), capturing unmodeled factors (such as electrode surface oxide layer, friction loss, arc stability, etc.), and identifying the uncertainty of the test data (such as personnel, methods, environment, equipment, etc.). Based on the Bayesian optimization technology, the model parameters such as thermal conductivity and combustion velocity are updated and the mathematical model of the ignition source test is reconstructed. The ignition source verification test is repeated and the data is compared again until the difference between the test data and the simulation data is less than the preset difference threshold. The model parameters are solidified and the adjusted mathematical model of the ignition source test is uploaded to the cloud for storage; (13) If the tested component is found to be unqualified, the ignition source test mathematical model is analyzed and improvement suggestions are given for the unqualified tested component, and verification is performed.

[0058] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered by the scope of protection of the claims of the present invention.

Claims

1. A component ignition source test device for refrigeration appliances using flammable refrigerants, characterized in that: include: The dimension measurement module is used to obtain the six-sided scanning data of the measured component and import it into the data processing terminal for image processing to obtain the dimension data of the measured component; Test module, used to perform ignition source verification test on the components under test; a data processing terminal for receiving dimensional data of components under test, calling refrigerant physical property parameters in the Refprop database, constructing an ignition source test mathematical model using simulation modeling software, and conducting an ignition source test simulation test to obtain simulation data; and conducting an ignition source verification test through a test module to obtain test data, comparing the test data with the simulation data; and if the difference between the test data and the simulation data is greater than a preset difference threshold, adjusting the model parameters and reconstructing the ignition source test mathematical model; and repeating the ignition source verification test until the difference between the test data and the simulation data is less than the preset difference threshold; and then solidifying the model parameters and uploading the adjusted ignition source test mathematical model to the cloud for storage; The test module includes a protective shell that has both a pressure relief function and a function of generating heat when the refrigerant in the diffusion test chamber explodes, a test chamber arranged inside the protective shell and used to provide target test conditions for the components under test and perform an ignition source test, a gas distribution module connected to the interior of the test chamber and used to provide the test chamber with target gas and pressure, a detection module, a temperature, humidity and pressure control module for regulating the target test conditions in the test chamber, a reaction product processing module connected to the interior of the protective shell and used for exhaust gas treatment, and a control cabinet.

2. The component ignition source testing device for refrigeration appliances using flammable refrigerants according to claim 1, characterized in that: The dimension measurement module includes a test bench, a mounting frame and a laser 3D scanner. The mounting frame is fixedly installed on the test bench, and the laser 3D scanner is fixedly installed on the mounting frame. The laser 3D scanner is connected to the data processing terminal to obtain six-sided scanning data of the measured component and import it into the data processing terminal for image processing to obtain the dimension data of the measured component.

3. The component ignition source testing device for refrigeration appliances using flammable refrigerants according to claim 1, characterized in that: The protective shell includes a shell, a cavity is provided between the shell and the test box, the cavity is provided with a water inlet and a water outlet for diffusing the heat generated when the refrigerant in the test box explodes, a first opening and closing door is provided at the front end of the shell, an observation window is provided on the first opening and closing door, a pressure release device is provided on the top of the shell, a pressure detection unit is provided on the inner side of the wall of the shell, which is used to obtain the real-time pressure in the shell and start the pressure release device when the real-time pressure exceeds a preset pressure threshold, and the shell is connected to a liquid nitrogen fire extinguishing device and a vacuum pump.

4. The component ignition source testing device for refrigeration appliances using flammable refrigerants according to claim 3, characterized in that: The test box includes a box body, the bottom of which is fixedly installed in the shell through a first bracket, and a second opening and closing door is provided at the front end of the box body. The position of the second opening and closing door corresponds to the position of the first opening and closing door, so as to facilitate the placement of the components under test inside the box body. A second bracket is provided inside the box body for fixing the components under test and the discharge electrode.

5. The component ignition source testing device for refrigeration appliances using flammable refrigerants according to claim 4, characterized in that: The detection module includes a test box environment detection unit, a pH detection unit, a gas composition detection unit, a discharge device detection unit and a test process detection unit.

6. The component ignition source testing device for refrigeration appliances using flammable refrigerants according to claim 4, characterized in that: The air distribution module includes an air unit and a refrigerant unit. The air unit includes an air compressor, an air storage tank and a filter structure connected in sequence. The output end of the filter structure is connected to the interior of the test box. The refrigerant unit includes a standard refrigerant cylinder and a gas concentration analysis device. The output pipe of the standard refrigerant cylinder is connected to the interior of the test box. A pressure reducing valve and an electric regulating valve are provided on the output pipe of the standard refrigerant cylinder. The detection end of the gas concentration analysis device is connected to the interior of the test box for real-time detection of the refrigerant concentration inside the test box and feedback of the refrigerant concentration to the control cabinet. By adjusting the on-off state of the electric regulating valve, the refrigerant filling amount is controlled to reach the target concentration.

7. The component ignition source testing device for refrigeration appliances using flammable refrigerants according to claim 4, characterized in that: The control cabinet includes a display touch screen, a PLC control module, an AD conversion module and an adjustable power supply. The PLC control module is respectively connected to the display touch screen, the AD conversion module and the adjustable power supply. The PLC control module is respectively connected to the protective shell, the test chamber, the gas distribution module, the detection module, the temperature, humidity and pressure control module, and the reaction product processing module through the AD conversion module. It is used to execute control of the protective shell, the test chamber, the gas distribution module, the detection module, the temperature, humidity and pressure control module, and the reaction product processing module, and is connected to the data processing terminal via a wired or wireless network. The adjustable power supply is connected to the discharge electrode and is used to regulate the voltage, discharge current, discharge energy and discharge time of the discharge electrode.

8. A component ignition source testing method for refrigeration appliances using flammable refrigerants, applied to a component ignition source testing device for refrigeration appliances using flammable refrigerants as claimed in any one of claims 1 to 7, characterized in that: include: The six-sided scanning data of the measured component is obtained through the dimension measurement module and imported into the data processing terminal for image processing to obtain the dimension data of the measured component; The dimensional data of the component under test is compared with the preset opening effective size threshold. If the dimensional data of the component under test meets the preset opening effective size threshold, the ignition source test mathematical model is constructed using simulation modeling software. According to the refrigerant type applicable to the component under test, the refrigerant physical property parameters in the Refprop database are called, and the ignition source test simulation test is performed on the component under test using the constructed ignition source test mathematical model to obtain simulation data; Perform ignition source verification test through the test module to obtain test data; The test data is compared with the simulation data. If the difference between the test data and the simulation data is greater than the preset difference threshold, the model parameters are adjusted and the ignition source test mathematical model is rebuilt. The ignition source verification test is repeated until the difference between the test data and the simulation data is less than the preset difference threshold. The model parameters are solidified and the adjusted ignition source test mathematical model is uploaded to the cloud for storage.

9. The component ignition source testing method for refrigeration appliances using flammable refrigerants according to claim 8, characterized in that: If the difference between the test data and the simulation data is greater than a preset difference threshold, the model parameters are adjusted and the ignition source test mathematical model is rebuilt, and the ignition source verification test is repeatedly performed until the difference between the test data and the simulation data is less than the preset difference threshold, including: The test data is compared with the simulation data. If the difference between the test data and the simulation data is greater than the preset difference threshold, the test data is structured to obtain structured test data. Based on the structured test data, a time-space mapping relationship is constructed. The constraints of the ignition source test mathematical model are verified through the IEC 60335-1 standard, IEC 60335-2-24 standard and refrigerant physical properties, the unmodeled factors are captured, and the uncertainty of the test data is identified. The model parameters are adjusted based on the Bayesian optimization technology and the ignition source test mathematical model is reconstructed. The ignition source verification test is repeated until the difference between the test data and the simulation data is less than the preset difference threshold.

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