Brake hose airtightness comprehensive testing device

Abstract

The invention discloses a brake hose airtightness comprehensive test device, and relates to the technical field of performance test equipment, the brake hose airtightness comprehensive test device comprises a machine body, a compressed air supply mechanism and a test unit cluster, the compressed air supply mechanism is fixedly installed on the side surface of the outer wall of the machine body, and the test unit cluster is fixedly installed on the side surface of the inner wall of the machine body. Through the test unit cluster, multi-channel parallel test of the airtight performance of the brake hose is achieved, the problems that a single-channel test device is low in efficiency and tedious in test process are solved, the test efficiency is greatly improved, and the test period is shortened.

Description

Technical Field

[0001] The invention relates to the technical field of performance testing equipment, in particular to a comprehensive airtightness testing device for a brake hose. Background Art

[0002] In automotive braking systems, the airtightness of brake hoses is directly related to driving safety and is a core indicator of vehicle reliability testing. With the large-scale development of the automotive industry, brake hose production testing has placed higher demands on equipment automation, testing efficiency, and accuracy. Existing brake hose airtightness testing equipment generally suffers from multiple technical bottlenecks: First, the single test channel is difficult to meet the efficient testing requirements of mass production. The single-channel sequential testing mode results in lengthy testing cycles, which is inconsistent with the pace of modern production lines. Second, the layout of the air and water systems is mixed, lacking a reasonable layered isolation design. This not only increases the difficulty of pipeline maintenance but also easily causes test data deviations due to media interference. Third, the height adjustment of the fixture is difficult, requiring frequent bending or raising the clamp during manual operation. This lacks ergonomic design, leads to operator fatigue, and poses safety risks. Fourth, the signal acquisition system has weak anti-interference capabilities and is susceptible to electromagnetic noise in complex industrial environments, causing pressure data fluctuations and hindering high-precision leakage detection.

[0003] Patent CN115356050B discloses a pipeline air tightness testing device. The above patent realizes that when the interior of the pipeline body is under negative pressure, the gas can move to the second air pipe through the fourth air pipe. When the pipeline body is under negative pressure, the second control valve is closed, and the third control valve and the first control valve are opened. When there is a problem with the sealing of the pipeline body, the gas moves from the second air pipe to the inside of the water collecting tank, that is, bubbles will be generated in the water inside the water collecting tank.

[0004] The above patent allows for rapid judgment of the sealing of the pipeline body. The multi-pipe linkage control structure adopted can complete leak detection by switching valves under negative pressure. It has the characteristics of simple operation process and visual detection phenomenon. However, with the increasing demand for efficiency and versatility in industrial detection scenarios, the single negative pressure bubble detection mode will have some limitations when dealing with scenarios such as brake hoses that require dual performance testing of airtightness and pressure resistance, as well as batch testing of multiple specifications.

[0005] To this end, this application proposes a brake hose airtightness comprehensive testing device that can realize multi-channel parallel testing through a systematic architecture, accurately control water and gas dual media, and intelligently monitor pressure and safety protection to meet the complex needs of high-performance testing of modern brake hoses. Summary of the Invention

[0006] The purpose of the present invention is to provide a brake hose airtightness comprehensive testing device to solve the technical problems raised in the above background technology, such as a single test channel, mixed layout of air and water system, and inconvenient clamp height adjustment.

[0007] To achieve the above objectives, the present invention provides the following technical solutions: a brake hose airtightness comprehensive testing device, comprising a body, a compressed air supply mechanism, and a test unit cluster, wherein the compressed air supply mechanism is fixedly mounted on the side surface of the outer wall of the body, and the test unit cluster is fixedly mounted on the side surface of the inner wall of the body;

[0008] The test unit cluster includes 8 groups of test paths, which are arranged horizontally along the inner wall and side wall of the machine body. A clamp is set at the end of the test path, and a dual-medium interface is set on the side of the outer wall of the clamp. A hose limiter is fixedly installed between the clamp and the dual-medium interface. The dual-medium interface is respectively connected to the output ends of the air control valve and the water control valve through a three-way valve.

[0009] Preferably, the compressed air supply mechanism includes an air boost valve, an air control valve and an air pipeline, the air boost valve is fixedly mounted on the left side of the inner wall of the control cabinet, and the air control valve is horizontally arranged on the outer wall of the air circuit board in the middle of the control cabinet;

[0010] The air outlet of the air booster valve is connected to the external air source through one end of the air pipeline, and the air outlet is divided into 8 branches through the other end of the air pipeline and then connected to the air control valves corresponding to the 8 groups of test paths respectively.

[0011] Preferably, the body is welded by the water tank and the control cabinet to form a right-angle structure. The interior of the control cabinet is horizontally divided into two layers, the upper layer is provided with an air system, and the lower layer is provided with a water system. The water system is connected to the test unit cluster through a pipe running through the top of the control cabinet. A clamp is fixedly installed on the side of the inner wall of the water tank. The fixing seat of the clamp is fixedly installed on the side of the inner wall of the water tank by bolts. The movable chuck is slidably connected to the fixing seat through a slide rail. The side of the movable chuck close to the dual-medium interface is provided with an arc-shaped clamping groove that fits with the outer wall of the hose.

[0012] The water system includes a booster pump unit, a water control valve and a high-pressure water pipe. One end of the high-pressure water pipe is connected to the external water source interface and extends to the lower layer of the control cabinet, and the other end is connected to the water control valve through the booster pump unit. The water control valve is fixedly installed on the inner wall of the control cabinet. The water control valve is connected to the water interface of 8 groups of test interfaces through 8 branch water pipes. A one-way stop valve is connected in series on the outer wall of the branch water pipe, and a pressure buffer tank is set at the connection between the main water pipe and the branch water pipe.

[0013] Preferably, vertical guide rails are symmetrically welded on both sides of the inner wall of the water tank, the bottom ends of the outer walls of the vertical guide rails are fixedly mounted on the body base, the vertical guide rails are slidably connected to the lifting platform through a slider, the lifting platform is hinged to the piston rod of the cylinder, and the cylinder is connected to the manual control valve fixedly mounted on the outer wall of the water tank through an air pipe;

[0014] A drain valve is provided at the bottom of the inner wall of the water tank, which is connected to the external drainage system through a pipe, and a water level observation window is provided on the side of the inner wall of the water tank.

[0015] Preferably, the air circuit system includes an air compressor, an air circuit control element and a first pipeline. The air compressor is horizontally fixedly installed on the left side of the upper layer of the control cabinet. The air inlet end of the air compressor is connected to the air outlet end of the air boost valve through the first pipeline. The air outlet end of the air compressor is connected to the air inlet end of the air circuit control element through the first pipeline. The air circuit control element is fixedly installed on the right side of the upper layer of the control cabinet.

[0016] A pressure reducing valve is provided on the outer wall of the first pipeline.

[0017] Preferably, the booster pump unit comprises a centrifugal pump, a high-pressure pump and a relief valve, the high-pressure pump is fixedly mounted on the right downstream of the outer wall of the centrifugal pump, and the relief valve is fixedly mounted on the top of the inner wall of the high-pressure pump outlet pipe;

[0018] The inlet end of the centrifugal pump is connected to the water source interface through a pipeline, the outlet end of the centrifugal pump is connected to the inlet end of the high-pressure pump through a pipeline, and the outlet end of the high-pressure pump is connected to the inlet end of the overflow valve through a pipeline.

[0019] Preferably, a terminal is provided at the bottom of the outer wall of the control cabinet, and the terminal is connected to the buried metal pipe through a copper wire, and the grounding resistance value is less than 4Ω. An operation panel is embedded in the top of the outer wall of the control cabinet, and 8 groups of channel control buttons are arranged horizontally on the operation panel. The channel control buttons include an air channel, a water channel and a pressure relief button. An operation box is provided on the left side of the operation panel, and an air pressurization button and a water pressurization button are provided on the top of the outer wall of the operation box. The air pressurization button is connected to the low-pressure air channel interface of the air control valve, and the water pressurization button is connected to the electric booster pump;

[0020] A high-pressure air button is set on the left side of the outer wall of the air pressurization button. The high-pressure air button is connected to the high-pressure air circuit interface of the air control valve. The air pressurization button and the high-pressure air button are connected by a U-shaped connecting rod. The two ends of the U-shaped connecting rod are respectively embedded in the side surfaces of the outer walls of the air pressurization button and the high-pressure air button. An inclined guide surface is set on the top of the outer walls of the air pressurization button and the high-pressure air button.

[0021] Preferably, an axial flow fan is fixedly installed on the top of the outer wall of the control cabinet, the air outlet of the axial flow fan faces the outside of the control cabinet, and a drawer-type air filter is provided at the air outlet of the axial flow fan, and the air filter is pulled out from the side of the cabinet for replacement;

[0022] A control system is set up inside the body. The control system includes an isolation driver board and a core control board. The core control board is fixedly installed horizontally above the isolation driver board. The isolation driver board is connected to the digital output board and the solenoid valve via a data line. A converter is fixedly installed on the top of the outer wall of the core control board. The input end of the core control board is connected to the pressure sensor via a wire. The pressure sensor is connected in parallel to the input end of the analog acquisition block. The output end of the analog acquisition block is connected to the industrial computer via a data line.

[0023] The isolation driver board and the core control board are connected to a dual-way switch via a data line.

[0024] Preferably, a total pressure relief valve is fixedly installed at the end of the gas pipeline, the total pressure relief valve is arranged at the bottom end of the inner wall of the control cabinet, the dual-media interface is connected to the sub-pressure relief valve, and a pressure releaser is arranged at the outlet end of the booster pump unit;

[0025] The eight groups of test paths of the test unit cluster are isolated from each other by partitions, which are fixedly installed on the side of the inner wall of the machine body.

[0026] Preferably, a zero-point calibration button and a full-scale calibration button are provided on the surface of the core control board, and the zero-point calibration button and the full-scale calibration button are respectively connected to the circuit of the core control board through resistors;

[0027] A signal isolator is welded on the left side of the outer wall of the core control board. A low-pass filter is connected in series at the output end of the signal isolator. The signal isolator is set at the signal transmission path between the pressure sensor and the analog acquisition block.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] 1. This invention uses a cluster of test units to achieve multi-channel parallel testing of brake hose airtightness, solving the problems of low efficiency and cumbersome testing procedures of single-channel testing devices, significantly improving testing efficiency and shortening testing cycles.

[0030] 2. The present invention uses a right-angle structure to achieve a layered and independent layout of the gas and water systems, solving the problem of traditional devices where the gas and water systems are easily interfering with each other, and the layout is chaotic and inconvenient for maintenance, making the operation of the gas and water systems more stable and reliable;

[0031] 3. The present invention uses a lifting platform to achieve the lifting and adjustment of the clamp, solving the problem of fixed clamp height and inconvenient operation, and improving the human-computer interaction and ease of use of the device;

[0032] 4. The present invention achieves high-precision acquisition and processing of test signals by isolating the driver board and the core control board, solves the problem that the signal in the device is easily interfered with and the test accuracy is low, and improves the accuracy and reliability of the test data. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a front view structural schematic diagram of the present invention;

[0034] Figure 2 It is a schematic diagram of the working principle of the device of the present invention;

[0035] Figure 3 This is a schematic diagram of the test unit cluster structure of the present invention;

[0036] Figure 4 It is a structural schematic diagram of the booster pump unit of the present invention;

[0037] Figure 5 This is a schematic diagram of the waterway system structure of the present invention;

[0038] Figure 6 This is a schematic diagram of the lifting platform structure of the present invention;

[0039] Figure 7 Schematic diagram of the control system structure of the present invention;

[0040] Figure 8 This is a schematic diagram of the internal structure of the control cabinet of the present invention;

[0041] Figure 9 It is a schematic diagram of the gas pipeline structure of the present invention.

[0042] Figure: 1. Machine body; 2. Compressed air supply mechanism; 3. Water system; 4. Test unit cluster; 5. Fixture; 6. Dual-medium interface; 7. Hose stopper; 8. Air control valve; 9. Water control valve; 10. Water tank; 11. Air boost valve; 12. Control cabinet; 13. Air system; 14. Vertical guide rail; 15. Lifting platform; 16. Low-pass filter; 17. Booster pump unit; 18. High-pressure water pipe; 19. Air control element; 20. First pipeline ; 21. Centrifugal pump; 22. High-pressure pump; 23. Overflow valve; 24. Terminal; 25. Operation panel; 26. Operation box; 27. Channel control button; 28. Air pressurization button; 29. Water pressurization button; 30. Air high-pressure button; 31. Axial fan; 32. Isolation drive board; 33. Core control board; 34. Analog acquisition block; 35. Main pressure relief valve; 36. Sub-pressure relief valve; 37. Pressure releaser; 38. Signal isolator; 39. Air pipeline. DETAILED DESCRIPTION

[0043] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0044] In the description of the present invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," "the other end," and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0045] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "provided with," "connected," etc., should be understood in a broad sense. For example, "connected" may refer to a fixed connection, a detachable connection, or an integral connection; a mechanical connection or an electrical connection; a direct connection or an indirect connection through an intermediate medium; or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0046] See also Figure 1 、 Figure 2 、 Figure 3 and Figure 5 The present invention provides an embodiment of a brake hose airtightness comprehensive test device, comprising a body 1, a compressed air supply mechanism 2, and a test unit cluster 4. The compressed air supply mechanism 2 is fixedly mounted on the outer wall side of the body 1, and the test unit cluster 4 is fixedly mounted on the inner wall side of the body 1. The test unit cluster 4 includes eight groups of test passages, which are arranged transversely along the inner wall side of the body 1. A clamp 5 is provided at the end of each test passage, and a dual-medium interface 6 is provided on the outer wall side of the clamp 5. A hose stopper 7 is fixedly mounted between the clamp 5 and the dual-medium interface 6. The dual-medium interface 6 is respectively connected to the output ends of an air control valve 8 and a water control valve 9 through a three-way valve.

[0047] The compressed air supply mechanism 2 includes an air booster valve 11, an air control valve 8, and an air pipeline 39. The air booster valve 11 is fixedly mounted on the left side of the inner wall of the control cabinet 12, and the air control valve 8 is horizontally mounted on the outer wall of the air manifold in the middle of the control cabinet 12. The air outlet of the air booster valve 11 is connected to an external air source through one end of the air pipeline 39. The air outlet is then split into eight branches through the other end of the air pipeline 39, and the branches are respectively connected to the air control valves 8 corresponding to the eight test paths.

[0048] Furthermore, first, 8 groups of test passages are arranged horizontally along the inner wall of the body 1, the fixing seat of the clamp 5 is vertically fixed to the inner wall of the water tank 10 by bolts, the movable clamp slides horizontally through the slide rail, and the arc-shaped clamp groove is adjusted to fit the outer wall of the hose. The hose limiter 7 is installed between the clamp 5 and the dual-medium interface 6. The hose limiter 7 is made of rubber and fixes the middle part of the hose by a spring buckle to prevent the hose from axial displacement due to pressure shock during the test. The dual-medium interface 6 is respectively connected to the air control valve 8 and the water control valve 9 through a three-way valve. The distance between the air and water interfaces is ≥50mm to avoid medium mixing; the 8 groups of passages are tested in parallel, and the efficiency is increased by 8 times compared with a single channel, and the failure of any one channel does not affect other passages. The air boost valve 11 is combined with the pressure reducing valve, and the air pressure fluctuation is ≤±1.5%FS, ensuring that the repeatability error of the test results is small;

[0049] Then, an air booster valve 11 is installed on the left side of the inner wall of the control cabinet 12, and 8 groups of air control valves 8 are fixed horizontally on the middle air circuit board. Each group of air control valves 8 is connected to the corresponding test path through a Φ8mm air pipeline 39. After the external air source is pressure-regulated by the air booster valve 11, it is divided into 8 branches through the main air pipeline 39. A pressure transmitter is installed in each branch. The pressure transmitter monitors the air pressure of each path in real time. Turn on the air source switch, adjust the air booster valve 11 to the test pressure, and control the opening and closing of the air control valve 8 through the air pressurization button 28 corresponding to the low pressure or the air high pressure button 30 corresponding to the high pressure on the operation panel 25;

[0050] Finally, connect the hose to be tested that is compatible with the DN25 / DN32 interface tightly to the dual-media interface 6 through the adapter, rotate the movable chuck of the fixture 5 to the locking position, ensure that the interface sealing ring is not twisted, click the channel control button 27 of the corresponding channel on the operation panel 25, open the air control valve 8, and the pressure will rise to the set value within 3 seconds. Maintain the pressure for 5 minutes, observe the pressure display instrument panel, and the pressure drop is ≤10kPa to be qualified; at the same time, apply soapy water to the hose joints, and the bubble diameter is ≤20mm within 10 seconds. After the test is completed, click the pressure relief button to open the sub-pressure relief valve 36, and remove the hose after the pressure drops to 0kPa. Record the test results and store them in the industrial computer database. The test results need to include the valve number, pressure curve, and leakage amount.

[0051] See also Figure 1 、 Figure 2 and Figure 3, the present invention provides an embodiment: a brake hose airtightness comprehensive test device, the body 1 is welded by a water tank 10 and a control cabinet 12 to form a right-angle structure, the control cabinet 12 is laterally divided into two layers, the upper layer is provided with an air system 13, the lower layer is provided with a water system 3, the water system 3 is connected to the test unit cluster 4 through a pipe running through the top of the control cabinet 12, the fixture 5 is fixedly installed on the side of the inner wall of the water tank 10, the fixing seat of the fixture 5 is fixedly installed on the side of the inner wall of the water tank 10 by bolts, the movable clamp is slidably connected to the fixing seat by a slide rail, and the movable An arc-shaped clamping groove that fits with the outer wall of the hose is provided on one side of the chuck close to the dual-medium interface 6; the water system 3 includes a booster pump unit 17, a water control valve 9 and a high-pressure water pipe 18. One end of the high-pressure water pipe 18 is connected to the external water source interface and extends to the lower layer of the control cabinet 12, and the other end is connected to the water control valve 9 through the booster pump unit 17. The water control valve 9 is fixedly mounted on the inner wall of the control cabinet 12. The water control valve 9 is connected to the water interface of 8 groups of test interfaces respectively through 8 branch water pipes. A one-way stop valve is connected in series on the outer wall of the branch water pipe, and a pressure buffer tank is provided at the connection between the main water pipe and the branch water pipe.

[0052] The vertical guide rails 14 are symmetrically welded on both sides of the inner wall of the water tank 10. The bottom end of the outer wall of the vertical guide rails 14 is fixedly mounted on the base of the body 1. The vertical guide rails 14 are slidably connected to the lifting platform 15 through a slider. The lifting platform 15 is hinged to the piston rod of the cylinder. The cylinder is connected to the manual control valve fixedly mounted on the outer wall of the water tank 10 through an air pipe. A drain valve is provided at the bottom end of the inner wall of the water tank 10. The drain valve is connected to the external drainage system through a pipeline. A water level observation window is provided on the side of the inner wall of the water tank 10.

[0053] Furthermore, first, the water tank 10 and the control cabinet 12 are welded into a right-angle structure using L-shaped angle steel, and the interior is filled with sound insulation cotton. The vertical guide rails 14 on both sides of the water tank 10 are spaced 1.2 meters apart. The lifting platform 15 is driven by a cylinder, and the manual control valve adjusts the lifting speed to ≤50mm / s. The fixture 5 fixing seat is installed on the inner wall of the water tank 10 using M12 bolts. The surface roughness of the movable clamp slide rail Ra ≤1.6μm, ensuring a sliding resistance of ≤5N. The arc-shaped clamp groove has a built-in pressure sensor to monitor the clamping force of the hose in real time; the pressure buffer tank is equipped with an overflow valve, and the water pressure fluctuation is ≤±2%FS, meeting the requirements of the blasting test; the terminal 24 is connected to the buried metal pipe, and the grounding resistance is <4Ω to prevent static electricity from causing electric sparks.

[0054] Then, the booster pump unit 17 is installed on the lower layer of the control cabinet 12. The centrifugal pump 21 draws in tap water, which is pressurized by the high-pressure pump 22 and then output through the overflow valve 23. The high-pressure pump 22 adopts a plunger type. The main line of the high-pressure water pipe 18 is connected to the pressure buffer tank. The pressure buffer tank reduces pulse fluctuations. The branch water pipe adopts a Φ10mm copper pipe and a one-way stop valve in series to ensure that the water pressure synchronization deviation of each channel is ≤2% and the reverse leakage of the one-way stop valve is ≤5ml / min. The water control valve 9 is connected to the water end of the dual-media interface 6. Before the test, the centrifugal pump 21 is pre-started through the water pressurization button 29 on the operation panel 25 to empty the air in the pipeline. The water control valve 9 includes a two-position two-way solenoid valve;

[0055] Finally, rotate the manual control valve to raise the lifting platform 15, immerse the hose vertically into the water tank 10, the water level of the water tank 10 is 50mm higher than the top of the hose, close the drain valve, click the channel control button 27 to open the water control valve 9, and the high-pressure pump 22 gradually increases the pressure to 1.5MPa, maintains the pressure for 3 minutes, observes that there is no bulge or rupture on the surface of the hose, and the pressure drop is ≤15kPa to be qualified. During the test, if the pressure drops by more than 50kPa, the system automatically triggers the overflow valve 23 to relieve the pressure, and the axial flow fan 31 starts to dissipate heat to prevent the motor from overloading; after the end, turn off the high-pressure pump 22 first, open the pressure releaser 37 to empty the remaining water in the pipeline, and then discharge the wastewater containing rust inhibitor from the water tank 10 through the drain valve, and filter it through the filter before recycling.

[0056] See also Figure 1 、 Figure 2 、 Figure 4 and Figure 7 The present invention provides an embodiment of a brake hose airtightness comprehensive test device, wherein the air circuit system 13 includes an air compressor, an air circuit control element 19, and a first pipeline 20. The air compressor is horizontally fixedly installed on the upper left side of the control cabinet 12. The air inlet end of the air compressor is connected to the air outlet end of the air boost valve 11 through the first pipeline 20. The air outlet end of the air compressor is connected to the air inlet end of the air circuit control element 19 through the first pipeline 20. The air circuit control element 19 is fixedly installed on the upper right side of the control cabinet 12. A pressure reducing valve is provided on the outer wall of the first pipeline 20.

[0057] The booster pump unit 17 includes a centrifugal pump 21, a high-pressure pump 22 and a relief valve 23. The high-pressure pump 22 is fixedly installed on the right downstream side of the outer wall of the centrifugal pump 21, and the relief valve 23 is fixedly installed on the top of the inner wall of the outlet pipe of the high-pressure pump 22; the inlet end of the centrifugal pump 21 is connected to the water source interface through a pipe, the outlet end of the centrifugal pump 21 is connected to the inlet end of the high-pressure pump 22 through a pipe, and the outlet end of the high-pressure pump 22 is connected to the inlet end of the relief valve 23 through a pipe;

[0058] Furthermore, first, after the air compressor is started, compressed air is delivered through the first pipeline 20 and adjusted to a low pressure of 0.6 MPa or a high pressure of 1 MPa by the pressure reducing valve. The air path control element 19 realizes independent opening and closing of each path. The pressure sensor feeds back data to the core control board 33 in real time. If the displayed value deviates from the standard table by more than ±1.5 kPa, the proportional coefficient is adjusted through the "calibration / manual page" of the industrial computer;

[0059] Then, after the centrifugal pump 21 draws in water, the high-pressure pump 22 increases the water pressure to 1.5 MPa at a boost ratio of 10:1. The relief valve 23 automatically opens when the pressure exceeds 1.6 MPa to prevent the hose from being damaged by overpressure. After the air circuit test is completed, the industrial computer automatically switches to the water circuit test mode, closes all air control valves 8, opens the corresponding water control valves 9, and starts the high-pressure pump 22 by pressing the water pressure button 29. The pressure is increased within 20 seconds.

[0060] Finally, during the air circuit test, the software draws the pressure-time curve in real time and automatically calculates the leakage volume. The formula is: leakage volume = (initial pressure - end pressure) × pipeline volume / pressure holding time; during the water circuit test, the pressure buffer tank controls the water pressure fluctuation within ±3%FS, and the industrial computer records the peak pressure through the analog acquisition block 34 of the 12-bit A / D conversion. If the hose bursts, the system automatically marks it as "unqualified" and saves the burst instant curve. After the test, a PDF report containing the airtight leakage volume, pressure holding value, and test time is generated. It supports query by "test date" or "hose number" and can be output and archived through a printer.

[0061] See also Figure 1 、 Figure 6 、 Figure 8 and Figure 9 , an embodiment of the present invention provides: a brake hose airtightness comprehensive test device, the control cabinet 12 outer wall bottom is provided with a terminal 24, the terminal 24 is connected to the buried metal pipe through a copper wire, and the grounding resistance value is less than 4Ω, the control cabinet 12 outer wall top is embedded with an operation panel 25, the operation panel 25 is horizontally provided with 8 groups of channel control buttons 27, the channel control buttons 27 include air channel, water channel and pressure relief buttons, an operation box 26 is provided on the left side of the operation panel 25, and an air pressurization button 2 is provided on the outer wall top of the operation box 26. 8 and the water pressurization button 29, the air pressurization button 28 is connected to the low-pressure air circuit interface of the air control valve 8, and the water pressurization button 29 is connected to the electric booster pump; a high-pressure air button 30 is provided on the left side of the outer wall of the air pressurization button 28, and the high-pressure air button 30 is connected to the high-pressure air circuit interface of the air control valve 8. The air pressurization button 28 and the high-pressure air button 30 are connected by a U-shaped connecting rod, and the two ends of the U-shaped connecting rod are respectively embedded in the side surfaces of the outer walls of the air pressurization button 28 and the high-pressure air button 30, and the tops of the outer walls of the air pressurization button 28 and the high-pressure air button 30 are provided with inclined guide surfaces;

[0062] A total pressure relief valve 35 is fixedly installed at the end of the gas pipeline 39, and the total pressure relief valve 35 is arranged at the bottom end of the inner wall of the control cabinet 12. The dual-medium interface 6 is connected to the sub-pressure relief valve 36, and a pressure releaser 37 is provided at the outlet end of the booster pump unit 17. The eight groups of test passages of the test unit cluster 4 are isolated from each other by partitions, which are fixedly installed on the side of the inner wall of the body 1.

[0063] Furthermore, first, terminal 24 is connected to a metal pipe buried 1.5m deep using a 4mm² copper wire. A ground resistance tester is used to measure a resistance value of less than 4Ω. If the resistance value exceeds the standard, check the wire connection or replace the grounding electrode. After the operation panel 25 is powered on, the eight groups of channel control buttons 27 with LED indicators are initialized to display the "standby" state. The "gas pressurization" and "gas high pressure" buttons on the operation box 26 are linked by a U-shaped connecting rod to prevent simultaneous pressing and causing gas path conflicts.

[0064] Then, before the test, manually pull the handle of the main pressure relief valve 35. The sub-pressure relief valve 36 with a built-in spring return mechanism is in the closed state when there is no air pressure. The bursting disc pressure releaser 37 is calibrated every 6 months; "Dummy load" test: without installing the hose, select any channel and click "Air Pressurization". After the pressure rises to 0.6MPa, press the "Pressure Relief" button and observe the pressure display panel. The pressure should drop to 0kPa within 5s. Otherwise, check whether the valve core of the air control valve 8 is stuck;

[0065] Finally, in automatic mode, select "Air Tightness Test" and enter the hose number, and the system will automatically complete the pressurization-pressure maintenance-pressure relief process; in manual mode, click the "Channel 1 Open" and "Air Pressurization" buttons one by one through the operation box 26, which is suitable for single-channel troubleshooting. If the hose bursts during the test, immediately press the "Emergency Stop Button", the total pressure relief valve 35 will open in conjunction, and at the same time the air circuit control element 19 will cut off the air source, and the axial flow fan 31 will accelerate the discharge of water mist to prevent the electrical components from getting damp. After pressure relief, rotate the manual valve on the side of the water tank 10 to lower the lifting platform 15, take out the broken hose, mark "Burst Failure" on the "Data Query" page, and record the bursting pressure value.

[0066] See also Figure 1 、 Figure 3 and Figure 5, an embodiment provided by the present invention: a brake hose air tightness comprehensive test device, the top of the outer wall of the control cabinet 12 is fixedly installed with an axial flow fan 31, the air outlet of the axial flow fan 31 faces the outside of the control cabinet 12, and a drawer-type air filter is provided at the air outlet of the axial flow fan 31, and the air filter is pulled out and replaced from the side of the cabinet; a control system is provided inside the body 1, the control system includes an isolation drive board 32 and a core control board 33, the core control board 33 is fixedly installed horizontally above the isolation drive board 32, the isolation drive board 32 is connected to the digital output board and the solenoid valve through a data line, a converter is fixedly installed on the top of the outer wall of the core control board 33, the input end of the core control board 33 is connected to the pressure sensor through a wire, the pressure sensor is connected in parallel to the input end of the analog acquisition block 34, and the output end of the analog acquisition block 34 is connected to the industrial computer through a data line; the isolation drive board 32 and the core control board 33 are connected to a two-way switch through a data line;

[0067] The core control board 33 is provided with a zero-point calibration button and a full-scale calibration button, which are respectively connected to the circuit of the core control board 33 through resistors; a signal isolator 38 is welded on the left side of the outer wall of the core control board 33, and a low-pass filter 16 is connected in series to the output end of the signal isolator 38. The signal isolator 38 is provided in the signal transmission path between the pressure sensor and the analog acquisition block 34;

[0068] Furthermore, first, the axial fan 31 is installed on the top of the control cabinet 12, and the air filter at the air outlet is cleaned once a quarter to ensure that the internal temperature is ≤40°C. The core control board 33 is fixed above the isolation driver board 32 by four M3 copper pillars, with a spacing of 20mm for heat dissipation. The data cable uses a twisted pair shielded cable to reduce electromagnetic interference;

[0069] Then, for zero-point calibration, close all gas / water circuits, open the "Calibration / Manual Page" on the operation panel 25, click the "Zero-point Calibration" button, and the core control board 33 collects the 4mA signal output by the pressure sensor. If the measured value deviates from ±0.5kPa, adjust the value through the "Zero Point" input box until the displayed value is 0.0kPa; for full-scale calibration, connect a standard pressure source, pressurize the gas circuit to 1MPa or the water circuit to 1.5MPa, click the "Full-scale Calibration" button, and the core control board 33 calculates the pressure value corresponding to the 20mA signal output by the sensor. If the error is greater than ±1%, adjust the "Coefficient" parameter until the displayed value is consistent with the standard value;

[0070] Finally, the analog acquisition block 34 collects 8-channel pressure data in real time, removes high-frequency noise through the low-pass filter 16, and transmits it to the industrial computer for display. The simulated electromagnetic interference source is started near the power tool, and the pressure curve fluctuation is observed to be ≤±1.2kPa. The anti-interference effect of the signal isolator 38 and the shielded wire is verified. The calibration data is printed regularly through the "calibration record" page, including the calibration time, channel number, zero point / coefficient value, and traceable data.

[0071] Working principle: First, arrange 8 groups of test paths horizontally along the inner wall of the machine body 1, and vertically install the fixture 5 fixing seat on the inner wall of the water tank 10 by bolts. The movable clamp adjusts the arc clamp groove to fit the outer wall of the hose through the slide rail. The built-in pressure sensor monitors the clamping force. Install a rubber hose limiter 7 between the clamp 5 and the dual-media interface 6. Fix the middle of the hose with a spring buckle to prevent the axial displacement from exceeding 2mm during the test. The dual-media interface 6 is connected to the air control valve 8 and the water control valve 9 respectively through a three-way valve. The distance between the air and water interfaces is ≥50mm to avoid media mixing; on the left side of the inner wall of the control cabinet 12 Install the air booster valve 11, and fix 8 groups of air control valves 8 on the middle air circuit board. Each group is connected to the test passage through a Φ8mm air circuit pipe 39. After the external air source is pressure-regulated by the air booster valve 11, it is divided into 8 branches through the main air circuit pipe 39. Each branch is installed with a pressure transmitter to monitor the air pressure in real time. Install the booster pump unit 17 on the lower layer of the control cabinet 12. The main high-pressure water pipe 18 is connected to the pressure buffer tank. The branch water pipes use Φ10mm copper pipes and are connected in series with a one-way stop valve. The water control valve 9 is connected to the water interface of the test passage through 8 branch water pipes. Before testing, pre-start the centrifugal pump 21 to empty the air in the pipeline.

[0072] Then, select "low pressure" or "high pressure" mode through the operation panel 25, click the "air pressurization" or "air high pressure" button, the air boost valve 11 adjusts the output pressure, the air control valve 8 opens, the pressure rises to the set value within 3 seconds, and the pressure is maintained for 5 minutes. The software draws a pressure-time curve in real time and automatically calculates the leakage amount; rotate the manual control valve to raise the lifting platform 15, immerse the hose vertically in the water tank 10, close the drain valve, click the "water pressurization" button, and the high-pressure pump 22 increases the water pressure to 1.5MPa with a 10:1 pressure ratio, maintains the pressure for 3 minutes, and the pressure buffer tank controls the fluctuation within ±2%FS; observe that there is no bulge or rupture on the surface of the hose, and the pressure drop is ≤15kPa for passing; if the pressure drop exceeds 50kPa, the relief valve 23 automatically relieves the pressure, and the axial flow fan 31 starts to dissipate heat. After the test, first turn off the high-pressure pump 22, open the pressure release 37 to empty the remaining water in the pipeline, and then discharge the wastewater containing rust inhibitor through the drain valve;

[0073] Finally, close all air / water lines, enter the "Calibration / Manual Page" through the operation panel 25, click "Zero Point Calibration", the core control board 33 collects the 4mA signal of the pressure sensor, and adjusts the "Zero Point" parameter until the displayed value is 0.0kPa; connect the standard pressure source, pressurize the air line to 1MPa or the water line to 1.5MPa, click "Full Scale Calibration", and adjust the "Coefficient" parameter to make the displayed value consistent with the standard value; the analog acquisition block 34 collects 8-channel pressure data in real time, removes interference through the signal isolator 38 and the low-pass filter 16, and transmits it to the industrial computer. The adjacent power tools simulate electromagnetic interference to verify the anti-interference ability. In automatic mode, the system performs the test according to the "pressurization → pressure maintenance → pressure relief" process. The manual mode supports single-channel independent control. After the test, a PDF report is generated, including airtight leakage, pressure resistance and pressure maintenance value, test time, etc. It supports query by "test date" or "hose number" and outputs it to the printer for archiving.

[0074] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. A brake hose airtightness comprehensive testing device, characterized by: It comprises a machine body (1), a compressed air supply mechanism (2) and a test unit cluster (4), wherein the compressed air supply mechanism (2) is fixedly mounted on the side surface of the outer wall of the machine body (1), and the test unit cluster (4) is fixedly mounted on the side surface of the inner wall of the machine body (1); The test unit cluster (4) includes 8 groups of test passages, which are arranged transversely along the inner wall side wall of the body (1), a clamp (5) is provided at the end of the test passage, a dual-medium interface (6) is provided on the side of the outer wall of the clamp (5), a hose limiter (7) is fixedly installed between the clamp (5) and the dual-medium interface (6), and the dual-medium interface (6) is respectively connected to the output end of the air control valve (8) and the water control valve (9) through a three-way valve.

2. A brake hose airtightness comprehensive testing device according to claim 1, characterized in that: The compressed air supply mechanism (2) includes an air boost valve (11), an air control valve (8) and an air pipeline (39), wherein the air boost valve (11) is fixedly mounted on the left side of the inner wall of the control cabinet (12), and the air control valve (8) is horizontally arranged on the outer wall of the air circuit board in the middle of the control cabinet (12); The air outlet of the air boost valve (11) is connected to an external air source through one end of the air pipeline (39), and the air outlet is divided into 8 branches through the other end of the air pipeline (39) and then connected to the air control valves (8) corresponding to the 8 groups of test paths respectively.

3. The brake hose airtightness comprehensive testing device according to claim 1, characterized in that: The body (1) is welded to form a right-angle structure by welding a water tank (10) and a control cabinet (12). The interior of the control cabinet (12) is laterally divided into two layers, an upper layer is provided with an air system (13), and a lower layer is provided with a water system (3). The water system (3) is connected to the test unit cluster (4) through a pipeline penetrating the top of the control cabinet (12). A fixture (5) is fixedly installed on the side of the inner wall of the water tank (10). The fixing seat of the fixture (5) is fixedly installed on the side of the inner wall of the water tank (10) by bolts. The movable clamp is slidably connected to the fixing seat through a slide rail. An arc-shaped clamp groove that fits the outer wall of the hose is provided on the side of the movable clamp close to the dual-medium interface (6). The water system (3) includes a booster pump unit (17), a water control valve (9) and a high-pressure water pipe (18). One end of the high-pressure water pipe (18) is connected to the external water source interface and extends to the lower layer of the control cabinet (12). The other end is connected to the water control valve (9) through the booster pump unit (17). The water control valve (9) is fixedly installed on the inner wall of the control cabinet (12). The water control valve (9) is connected to the water interface of 8 groups of test interfaces through 8 branch water pipes. The outer wall of the branch water pipe is connected in series with a one-way stop valve. A pressure buffer tank is set at the connection between the main water pipe and the branch water pipe.

4. A brake hose airtightness comprehensive testing device according to claim 3, characterized in that: Vertical guide rails (14) are symmetrically welded on both sides of the inner wall of the water tank (10), and the bottom end of the outer wall of the vertical guide rail (14) is fixedly mounted on the base of the machine body (1). The vertical guide rail (14) is slidably connected to the lifting platform (15) through a slider. The lifting platform (15) is hinged to the piston rod of the cylinder, and the cylinder is connected to the manual control valve fixedly mounted on the outer wall of the water tank (10) through an air pipe. A drain valve is provided at the bottom end of the inner wall of the water tank (10), and the drain valve is connected to an external drainage system through a pipeline. A water level observation window is provided on the side of the inner wall of the water tank (10).

5. The brake hose airtightness comprehensive testing device according to claim 3, characterized in that: The air circuit system (13) includes an air compressor, an air circuit control element (19) and a first pipeline (20), wherein the air compressor is fixedly mounted horizontally on the left side of the upper layer of the control cabinet (12), the air inlet end of the air compressor is connected to the air outlet end of the air boost valve (11) through the first pipeline (20), and the air outlet end of the air compressor is connected to the air inlet end of the air circuit control element (19) through the first pipeline (20), and the air circuit control element (19) is fixedly mounted on the right side of the upper layer of the control cabinet (12); A pressure reducing valve is provided on the outer wall of the first pipeline (20).

6. The brake hose airtightness comprehensive testing device according to claim 3, characterized in that: The booster pump unit (17) comprises a centrifugal pump (21), a high-pressure pump (22) and a relief valve (23), wherein the high-pressure pump (22) is fixedly mounted on the right downstream side of the outer wall of the centrifugal pump (21), and the relief valve (23) is fixedly mounted on the top of the inner wall of the outlet pipe of the high-pressure pump (22); The inlet end of the centrifugal pump (21) is connected to the water source interface through a pipeline, the outlet end of the centrifugal pump (21) is connected to the inlet end of the high-pressure pump (22) through a pipeline, and the outlet end of the high-pressure pump (22) is connected to the inlet end of the overflow valve (23) through a pipeline.

7. The brake hose airtightness comprehensive testing device according to claim 2, characterized in that: The control cabinet (12) is provided with a terminal (24) at the bottom of the outer wall, and the terminal (24) is connected to the buried metal pipe through a copper wire, and the grounding resistance value is less than 4Ω. The top of the outer wall of the control cabinet (12) is embedded with an operation panel (25), and 8 groups of channel control buttons (27) are arranged horizontally on the operation panel (25). The channel control buttons (27) include air path opening, water path opening and pressure relief buttons. An operation box (26) is provided on the left side of the operation panel (25), and an air pressurization button (28) and a water pressurization button (29) are provided on the top of the outer wall of the operation box (26). The air pressurization button (28) is connected to the low-pressure air path interface of the air control valve (8), and the water pressurization button (29) is connected to the electric booster pump. A high-pressure gas button (30) is provided on the left side of the outer wall of the gas pressurization button (28). The high-pressure gas button (30) is connected to the high-pressure gas circuit interface of the gas control valve (8). The gas pressurization button (28) and the high-pressure gas button (30) are connected by a U-shaped connecting rod. The two ends of the U-shaped connecting rod are respectively embedded in the side surfaces of the outer walls of the gas pressurization button (28) and the high-pressure gas button (30). An inclined guide surface is provided on the top of the outer walls of the gas pressurization button (28) and the high-pressure gas button (30).

8. The brake hose airtightness comprehensive testing device according to claim 2, characterized in that: An axial flow fan (31) is fixedly installed on the top of the outer wall of the control cabinet (12), and the air outlet of the axial flow fan (31) faces the outside of the control cabinet (12). A drawer-type air filter is provided at the air outlet of the axial flow fan (31), and the air filter is pulled out from the side of the cabinet for replacement; A control system is provided inside the body (1), and the control system includes an isolation drive board (32) and a core control board (33). The core control board (33) is fixedly installed horizontally above the isolation drive board (32). The isolation drive board (32) is connected to a digital output board and a solenoid valve via a data line. A converter is fixedly installed on the top of the outer wall of the core control board (33). The input end of the core control board (33) is connected to a pressure sensor via a wire. The pressure sensor is connected in parallel to the input end of an analog acquisition block (34). The output end of the analog acquisition block (34) is connected to an industrial computer via a data line. The isolation drive board (32) and the core control board (33) are connected to a dual-way switch via a data line.

9. The brake hose airtightness comprehensive testing device according to claim 2, characterized in that: A total pressure relief valve (35) is fixedly installed at the end of the gas line (39), the total pressure relief valve (35) is arranged at the bottom end of the inner wall of the control cabinet (12), the dual medium interface (6) is connected to the sub-pressure relief valve (36), and a pressure releaser (37) is arranged at the outlet end of the booster pump unit (17); The eight test paths of the test unit cluster (4) are isolated from each other by partitions, and the partitions are fixedly mounted on the inner wall side of the body (1).

10. The brake hose airtightness comprehensive testing device according to claim 8, characterized in that: A zero-point calibration button and a full-scale calibration button are provided on the surface of the core control board (33), and the zero-point calibration button and the full-scale calibration button are respectively connected to the circuit of the core control board (33) via resistors; A signal isolator (38) is welded to the left side of the outer wall of the core control board (33), a low-pass filter (16) is connected in series to the output end of the signal isolator (38), and the signal isolator (38) is arranged at the signal transmission path between the pressure sensor and the analog acquisition block (34).

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