A method and system for diaphragm body assembly correction and testing of a diaphragm energy store

Abstract

The present application relates to the field of diaphragm energy storage, in particular to a diaphragm body assembly correction and testing method and system for diaphragm energy storage, modeling analysis is used to obtain deformation data of the diaphragm body under basic assembly conditions, so as to obtain stress fatigue area, and thus determine the contact unstable point between the diaphragm body and the shell; according to the distribution of the contact unstable point, the joint unstable area between the diaphragm body and the shell is determined, so as to correct the basic assembly condition to the actual assembly condition; the diaphragm energy storage formed according to the actual assembly condition is tested, the welding structure characteristics between the diaphragm body and the shell are obtained, and thus the actual assembly operation is adjusted. The present application can comprehensively determine the separation trend of the diaphragm body and the shell under different energy storage working conditions, accurately form the partition assembly operation of the diaphragm body and the shell, ensure the assembly reliability and stability of the diaphragm body, and improve the working performance of the energy storage.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of diaphragm accumulators, in particular to a diaphragm body assembly correction and testing method and system for diaphragm accumulators. BACKGROUND

[0002] An accumulator is a pressure energy storage and release switching power device for a hydraulic system. The accumulator separates gas and liquid through a specific structure, and uses the compressibility of the gas to realize the mutual conversion of pressure energy between the liquid and the gas. According to the working mode, the accumulator can be divided into three types: piston type, bladder type and diaphragm type. The diaphragm accumulator has the characteristics of small volume, fast response speed, high efficiency of pressure energy storage and release, and is widely used in mechanical power scenes such as automobile suspension.

[0003] The diaphragm accumulator mainly includes a shell and a diaphragm body arranged in the inner cavity of the shell. The diaphragm body divides the inner cavity of the shell into a gas cavity and a liquid cavity. During the operation of the diaphragm accumulator, the diaphragm body also deforms synchronously with the repeated compression and expansion of the gas in the gas cavity. Considering that the diaphragm body is made of rubber material and is usually bonded to the inner cavity of the shell by electron beam welding technology, as the diaphragm body deforms repeatedly, the diaphragm body inevitably experiences strain fatigue, and the bonding part of the diaphragm body and the inner cavity of the shell also experiences welding relaxation, which causes the diaphragm body and the inner cavity of the shell to separate, reduces the working stability and working life of the diaphragm accumulator. The existing technology is to weld the diaphragm body in the inner cavity of the shell in a standardized mode, and does not predict the possible separation of the diaphragm body and the inner cavity of the shell according to the dynamic load and stress response of the diaphragm body during the operation of the accumulator. It cannot take targeted assembly operation according to the working state of different diaphragm accumulators, reduces the assembly reliability and stability of the diaphragm body, and cannot prolong the working life of the accumulator. SUMMARY

[0004] Considering that the diaphragm accumulator forms a complex and variable situation of dynamic load and stress response to the diaphragm body under different working modes, the diaphragm body and the inner cavity of the shell cannot effectively adapt to the above complex and variable situation under conventional assembly conditions, which easily causes the diaphragm body and the inner cavity of the shell to separate, reduces the assembly reliability and stability of the diaphragm body, and affects the working performance of the accumulator. The present application provides a diaphragm body assembly correction and testing method for a diaphragm accumulator, which comprises the following steps:

[0005] S100: modeling and analyzing the diaphragm accumulator to obtain deformation data of the diaphragm body under basic assembly conditions; and determining a stress fatigue area of the diaphragm body according to the deformation data;

[0006] S200: determining a contact unstable point between the diaphragm body and the shell of the accumulator according to the physical state of the stress fatigue area;

[0007] S300: According to the distribution of the contact unstable points, determine the unstable joint area between the diaphragm body and the shell under the basic assembly condition, and change and correct the basic assembly condition to obtain the actual assembly condition.

[0008] S400: Test the diaphragm energy storage device formed according to the actual assembly condition to obtain the welding structure characteristics between the diaphragm body and the shell; and adjust the actual assembly operation according to the welding structure characteristics.

[0009] Preferably, in S100, the diaphragm energy storage device is analyzed by modeling to obtain deformation data of the diaphragm body under the basic assembly condition; and according to the deformation data, the stress fatigue area of the diaphragm body is determined, specifically:

[0010] Obtain the diaphragm body structure data and the shell inner cavity structure data of the diaphragm energy storage device, and perform finite element modeling analysis on the diaphragm energy storage device to obtain deformation data of the diaphragm body under the basic assembly condition corresponding to different compression ratio working states of the diaphragm energy storage device; wherein the basic assembly condition refers to the reference welding parameter condition of the diaphragm body joint in the shell inner cavity.

[0011] From the deformation data, extract the deformation position data and deformation amplitude data of the diaphragm body corresponding to different compression ratio working states, and perform stress response analysis on the diaphragm body according to the deformation position data and the deformation amplitude data to obtain stress response time evolution characteristics of all grid areas of the diaphragm body, so as to identify whether the grid area is a stress fatigue area.

[0012] Preferably, in S200, according to the physical state of the stress fatigue area, determine the contact abnormal point between the diaphragm body and the shell of the energy storage device, specifically:

[0013] Obtain the spatial distribution position and range of all stress fatigue areas in the diaphragm body, and estimate the stress concentration area of the diaphragm body according to the spatial distribution position and range.

[0014] According to the stress concentration area, estimate the abnormal contact and collision position between the diaphragm body and the shell inner cavity, so as to determine the contact unstable point between the diaphragm body and the shell inner cavity.

[0015] Preferably, in S300, according to the distribution of the contact unstable points, determine the unstable joint area between the diaphragm body and the shell under the basic assembly condition, and change and correct the basic assembly condition to obtain the actual assembly condition, specifically:

[0016] determine a joint unstable region between the diaphragm body and the shell inner cavity under the basic assembly condition according to distribution aggregation characteristics of all contact unstable points in a joint region of the diaphragm body and the shell inner cavity;

[0017] According to the cross-sectional size of the diaphragm body corresponding to the joint unstable region and the welding interval size of the diaphragm body and the shell inner cavity, the welding strength of the joint unstable region under the basic assembly condition is corrected to obtain an actual assembly condition.

[0018] Preferably, in S400, the diaphragm energy storage device formed according to the actual assembly condition is tested to obtain the welding structure characteristics between the diaphragm body and the shell; and according to the welding structure characteristics, the actual assembly operation is adjusted, specifically:

[0019] The diaphragm energy storage device formed according to the actual assembly condition is subjected to ultrasonic testing to obtain the welding gap structure characteristics between the diaphragm body and the shell inner cavity; wherein the welding gap structure characteristics include welding gap structure size and quantity distribution between the diaphragm body and the shell inner cavity.

[0020] According to the welding gap structure characteristics, the welding defect position between the diaphragm body and the shell is calibrated, and the welding operation parameters of the actual assembly operation on the welding defect position are adjusted.

[0021] On the other hand, the present application provides a diaphragm body assembly correction and testing system for a diaphragm energy storage device, which comprises the following modules:

[0022] A modeling analysis module is used to model and analyze the diaphragm energy storage device to obtain deformation data of the diaphragm body under a basic assembly condition.

[0023] A fatigue region identification module is used to determine a stress fatigue region of the diaphragm body according to the deformation data.

[0024] A contact unstable calibration module is used to determine a contact unstable point between the diaphragm body and the shell of the energy storage device according to the physical state of the stress fatigue region.

[0025] An assembly change correction module is used to determine a joint unstable region between the diaphragm body and the shell under the basic assembly condition according to the distribution of the contact unstable points, so as to change and correct the basic assembly condition to obtain an actual assembly condition.

[0026] A testing module is used to test the diaphragm energy storage device formed according to the actual assembly condition to obtain the welding structure characteristics between the diaphragm body and the shell.

[0027] An assembly adjustment module is configured to adjust an actual assembly operation according to the welding structure feature.

[0028] Preferably, the modeling analysis module is configured to model and analyze the diaphragm accumulator to obtain deformation data of the diaphragm body under a basic assembly condition, in particular:

[0029] The diaphragm body structure data and the inner cavity structure data of the shell of the diaphragm accumulator are obtained to perform finite element modeling analysis on the diaphragm accumulator to obtain deformation data of the diaphragm body under a basic assembly condition corresponding to different compression ratio working states of the diaphragm accumulator; wherein the basic assembly condition refers to a reference welding parameter condition in which the diaphragm body is joined to the inner cavity of the shell.

[0030] The fatigue region identification module is configured to determine a stress fatigue region of the diaphragm body according to the deformation data, in particular:

[0031] The deformation position data and the deformation amplitude data of the diaphragm body corresponding to different compression ratio working states are extracted from the deformation data, and stress response analysis is performed on the diaphragm body according to the deformation position data and the deformation amplitude data to obtain stress response time evolution characteristics of all grid regions of the diaphragm body to identify whether the grid regions are stress fatigue regions.

[0032] Preferably, the contact instability calibration module is configured to determine a contact instability point between the diaphragm body and the shell of the accumulator according to the physical state of the stress fatigue region, in particular:

[0033] The spatial distribution position and range of all stress fatigue regions in the diaphragm body are obtained, and the stress concentration action region of the diaphragm body is estimated according to the spatial distribution position and range.

[0034] The abnormal contact and collision position between the diaphragm body and the inner cavity of the shell is estimated according to the stress concentration action region to determine the contact instability point between the diaphragm body and the inner cavity of the shell.

[0035] Preferably, the assembly change correction module is configured to determine a joint instability region between the diaphragm body and the shell under the basic assembly condition according to the distribution of the contact instability point to change and correct the basic assembly condition to obtain an actual assembly condition, in particular:

[0036] The joint instability region between the diaphragm body and the inner cavity of the shell under the basic assembly condition is determined according to the distribution and aggregation characteristics of all contact instability points in the joint region of the diaphragm body and the inner cavity of the shell.

[0037] According to the cross-sectional size of the diaphragm body corresponding to the unstable joint area and the welding interval size of the diaphragm body and the inner cavity of the shell, the welding strength of the unstable joint area under the basic assembly condition is changed and corrected to obtain an actual assembly condition.

[0038] Preferably, the test module is used to test the diaphragm energy accumulator formed according to the actual assembly condition to obtain the welding structure feature between the diaphragm body and the shell, in particular:

[0039] The diaphragm energy accumulator formed according to the actual assembly condition is subjected to ultrasonic testing to obtain the welding gap structure feature between the diaphragm body and the inner cavity of the shell; wherein the welding gap structure feature includes the welding gap structure size and quantity distribution between the diaphragm body and the inner cavity of the shell.

[0040] The assembly adjustment module is used to adjust the actual assembly operation according to the welding structure feature, in particular:

[0041] According to the welding gap structure feature, the welding defect position between the diaphragm body and the shell is calibrated to adjust the welding operation parameter of the actual assembly operation on the welding defect position.

[0042] Compared with the prior art, the present application has the following beneficial effects:

[0043] The diaphragm body assembly correction and test method of the diaphragm energy accumulator of the present application obtains the deformation data of the diaphragm body under the basic assembly condition through modeling analysis, thereby obtaining the stress fatigue area to determine the unstable contact point between the diaphragm body and the shell; according to the distribution of the unstable contact point, the unstable joint area between the diaphragm body and the shell is determined, so as to correct the basic assembly condition to the actual assembly condition to realize the localized reinforced welding of the diaphragm body and the shell; the diaphragm energy accumulator formed according to the actual assembly condition is tested to obtain the welding structure feature between the diaphragm body and the shell, so as to adjust the actual assembly operation. Through dynamic modeling analysis of the diaphragm energy accumulator, the separation trend of the diaphragm body and the shell under different energy accumulator working states is comprehensively determined, the partition assembly operation of the diaphragm body and the shell is accurately formed, the assembly reliability and stability of the diaphragm body are ensured, and the working performance of the energy accumulator is improved. BRIEF DESCRIPTION OF DRAWINGS

[0044] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can also be obtained by those skilled in the art without any creative effort. Among them:

[0045] Figure 1is a flow chart of a diaphragm body assembly correction and testing method of a diaphragm energy storage device provided by the present application.

[0046] Figure 2 is a structure of a diaphragm energy storage device.

[0047] Figure 3 is a deformation condition obtained by finite element modeling of a diaphragm body.

[0048] Figure 4 is a stress response time change curve of a diaphragm body.

[0049] Figure 5 is a stress concentration area distribution of a diaphragm body.

[0050] Figure 6 is a joint unstable area distribution of a diaphragm body and an inner cavity of a shell.

[0051] Figure 7 is an ultrasonic testing device for a diaphragm energy storage device.

[0052] Figure 8 is a structure diagram of a diaphragm body assembly correction and testing system of a diaphragm energy storage device provided by the present application. DETAILED DESCRIPTION

[0053] In order to make the above objectives, characteristics and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application will be described in detail below with reference to the drawings. It can be understood that the specific embodiments described herein are only used to explain the present application, but not to limit the present application. In addition, it should be noted that, in order to facilitate the description, only the parts related to the present application are shown in the drawings, but not all the structures. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0054] The terms "comprising" and "having" and any variations thereof in the present application are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device including a series of steps or units is not limited to the listed steps or units, but optionally further includes steps or units not listed, or optionally further includes other steps or units inherent to these processes, methods, products or devices.

[0055] In this document, the term "embodiment" means that the specific features, structures or characteristics described in connection with the embodiment can be included in at least one embodiment of the present application. The phrase appears at various places in the specification does not necessarily refer to the same embodiment, nor is it necessarily mutually exclusive or alternative to other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0056] Referring to Figure 1 As shown in the drawings, the present application provides a diaphragm body assembly correction and testing method for a diaphragm accumulator, which comprises the following steps:

[0057] S100: Model analysis of the diaphragm accumulator to obtain deformation data of the diaphragm body under the basic assembly condition; according to the deformation data, determine the stress fatigue area of the diaphragm body.

[0058] Further, in S100, model analysis of the diaphragm accumulator is performed to obtain deformation data of the diaphragm body under the basic assembly condition; according to the deformation data, the stress fatigue area of the diaphragm body is determined, specifically:

[0059] Obtain the structure data of the diaphragm body and the inner cavity structure data of the shell of the diaphragm accumulator, and perform finite element modeling analysis on the diaphragm accumulator to obtain deformation data of the diaphragm body under the basic assembly condition corresponding to different compression ratio working states of the diaphragm accumulator; wherein the basic assembly condition refers to the reference welding parameter condition of the diaphragm body jointed in the inner cavity of the shell;

[0060] From the deformation data, extract the deformation position data and deformation amplitude data of the diaphragm body corresponding to different compression ratio working states, and according to the deformation position data and the deformation amplitude data, perform stress response analysis on the diaphragm body to obtain the stress response time evolution characteristics of all grid areas subordinate to the diaphragm body, so as to identify whether the grid area is a stress fatigue area.

[0061] Referring to Figure 2 The shell of the diaphragm accumulator includes an upper shell and a lower shell that are assembled together; the upper shell is provided with an air inlet end for filling high-pressure nitrogen; the lower shell is provided with a liquid inlet end for injecting oil. The upper shell and the lower shell are assembled together to form a complete sealed shell, and the diaphragm body can be fixedly arranged in the inner cavity of the shell by electron beam welding technology. The diaphragm body can include a main body portion and an edge portion, wherein the main body portion and the edge portion can be integrally formed. The material of the diaphragm body can be preferably rubber. When the diaphragm body is installed in the inner cavity of the shell, the edge portion of the diaphragm body can be welded and fixed with the inner cavity wall surface of the shell by electron beam welding technology, wherein the area where the edge portion is in contact with the inner cavity wall surface of the shell becomes the joint area of the two. After the diaphragm body is installed in the inner cavity of the shell, the inner cavity is divided into two independent space areas, i.e. a gas cavity and a liquid cavity. The high-pressure nitrogen filled through the air inlet end is stored in the gas cavity, and the oil injected through the liquid inlet end is stored in the liquid cavity. During the operation of the diaphragm accumulator, the gas cavity interacts with the outside world to repeatedly absorb and release pressure energy, and correspondingly the high-pressure nitrogen in the gas cavity is repeatedly squeezed and expanded, at this time the diaphragm body will synchronously deform to change the volume of the gas cavity and the liquid cavity.

[0062] In order to ensure the stability and sealing of the joint between the diaphragm body and the inner cavity wall of the shell, the edge portion of the diaphragm body is melted by using electron beam welding technology, and the edge portion is connected and combined with the inner cavity wall of the shell during the melting process. In general, the corresponding electron beam welding operation is performed on the diaphragm body and the inner cavity wall of the shell according to the basic assembly conditions, wherein the basic assembly conditions refer to that the same reference intensity of electron beam is uniformly projected on the entire edge portion of the diaphragm body during the electron beam welding operation, and the electron beam projection time of each section in the entire edge portion is the same, so that the entire edge portion is globally combined with the inner cavity wall of the shell at the same melting degree. According to the above basic assembly conditions, the joint strength between the diaphragm body and the inner cavity wall of the shell in the diaphragm energy storage device is uniform and consistent.

[0063] The diaphragm energy storage device can operate in different compression ratio working states. When the diaphragm energy storage device is in different compression ratios, the spatial distribution of the extrusion and expansion forces acting on the diaphragm body is different, resulting in different deformation positions and deformation amplitudes of the diaphragm body. Considering the particularity of the joint between the diaphragm body and the inner cavity wall of the shell and the arbitrary variability of the structure of the diaphragm body, the finite element modeling method is preferably used to analyze the dynamic deformation of the diaphragm body. Specifically, the shape and size data of the edge portion and the main body portion of the diaphragm body and the surface curvature and shape profile data of the inner cavity wall of the shell are obtained, and the edge portion and the main body portion of the diaphragm body are independently divided into finite element grids. The edge portion and the main body portion of the diaphragm body are divided into a plurality of finite element grid regions; wherein the finite element grid regions of the edge portion and the main body portion can have the same or different shapes and sizes. The extrusion force acting on the diaphragm body in the global range of the diaphragm body under different compression ratio working states (such as compression ratios of 4, 6, 8, etc.) is obtained, and the joint strength between the diaphragm body and the inner cavity wall of the shell formed according to the above basic assembly conditions is taken as the boundary condition. The diaphragm body is analyzed by finite element modeling to obtain the deformation amplitude value of the diaphragm body corresponding to different compression ratio working states.

[0064] Please refer to Figure 3 , (a), (b), (c) respectively correspond to the deformation displacement amount (i.e. deformation amplitude value) of the diaphragm body when the compression ratio is 4, 6, 8. From Figure 3It can be seen that when the diaphragm accumulator is in different compression ratio working states, the deformation amplitude values generated at different positions in the diaphragm body (especially the main body part of the diaphragm body) are different. Generally speaking, the deformation amplitude value of the diaphragm body gradually increases from the outer edge side to the center side. In addition, for the same position in the diaphragm body, the greater the compression ratio, the greater the deformation amplitude value at the corresponding position. Through the above finite element modeling analysis, the deformation position data and the deformation amplitude data of the diaphragm body corresponding to different compression ratio working states are obtained. During the operation of the diaphragm accumulator, the diaphragm body will be periodically subjected to extrusion and expansion, and accordingly the diaphragm body will periodically expand and contract. During the periodic expansion and contraction of the diaphragm body, the diaphragm body will also generate a periodic stress response. The stress response refers to the response change of the stress size of a certain finite element grid area in the diaphragm body during the periodic deformation of the diaphragm body. Please refer to Figure 4 For the stress response time change curve of a certain finite element grid area in the diaphragm body, the internal stress size of the finite element grid area also changes periodically during the initial time stage of the operation of the diaphragm accumulator as the diaphragm body periodically expands and contracts, but in the subsequent time stage of the operation, it cannot present a periodic change rule due to stress fatigue. Therefore, by analyzing the time evolution characteristics of the stress response time change curve of each finite element grid area, when the finite element grid area cannot continue to maintain the periodic change of the stress size, the finite element grid area can be determined as a stress fatigue area. In the above manner, the stress fatigue area can be located and identified in the global range of the diaphragm body, and a reliable basis is provided for subsequent determination of the contact stability state (i.e. the engagement stability state) between the diaphragm body and the inner cavity wall surface of the shell.

[0065] S200: According to the physical state of the stress fatigue area, determine the contact unstable point between the diaphragm body and the shell of the accumulator.

[0066] In S200, according to the physical state of the stress fatigue area, the contact abnormal point between the diaphragm body and the shell of the accumulator is determined, specifically:

[0067] Obtain the spatial distribution position and range of all stress fatigue areas in the diaphragm body, estimate the stress concentration area of the diaphragm body according to the spatial distribution position and range;

[0068] According to the stress concentration area, estimate the abnormal contact and collision position between the diaphragm body and the inner cavity of the shell, so as to determine the contact unstable point between the diaphragm body and the inner cavity of the shell.

[0069] It can be known from the above analysis that the stress fatigue area in the diaphragm body is a finite element grid area that cannot respond to the change in stress size synchronously according to the periodic expansion and contraction deformation of the diaphragm body. These stress fatigue areas will experience stress relaxation, causing the internal stress of the diaphragm body to be unable to be uniformly distributed in the entire diaphragm body range during the periodic expansion and contraction deformation of the diaphragm body, so that the local stress of the diaphragm body is too large, thereby forming a stress concentration area. Specifically, according to the spatial distribution position and range size of all stress fatigue areas in the diaphragm body, the stress load distribution modeling analysis is performed on the diaphragm body, so as to estimate all stress concentration areas in the diaphragm body. Please refer to Figure 5 , the stress action distribution model of the diaphragm body is obtained by stress load distribution modeling analysis, Figure 5 , the stress concentration area of the diaphragm body is a red area.

[0070] When the stress concentration area exists in the diaphragm body, the expansion and contraction deformation of the diaphragm body will be irregularly dithered by the stress concentration area during the expansion and contraction deformation of the diaphragm body, and these irregular dithers will drive the diaphragm body and the inner cavity of the shell to avoid abnormal contact and collision, thereby forming a separation trend of the diaphragm body relative to the surface of the inner cavity of the shell. Thus, the joint area of the diaphragm body and the inner cavity of the shell cannot continue to maintain the original stable joint state under the influence of the separation trend, thereby forming a contact unstable point of the diaphragm body and the inner cavity of the shell. The contact unstable point can be understood as a contact position point at which the separation force of the diaphragm body and the inner cavity wall of the shell in the joint area is likely to exceed the joint force between the diaphragm body and the inner cavity wall of the shell. Through the above process, the contact unstable point between the diaphragm body and the inner cavity wall of the shell due to the stress fatigue of the diaphragm body itself can be accurately identified in a full range, the potential separation position point between the diaphragm body and the inner cavity wall of the shell is accurately positioned, and reliable basis is provided for subsequent correction of the basic assembly condition.

[0071] S300: According to the distribution of the contact unstable point, the joint unstable area between the diaphragm body and the shell under the basic assembly condition is determined, so as to change and correct the basic assembly condition to obtain the actual assembly condition.

[0072] In S300, according to the distribution of the contact unstable point, the joint unstable area between the diaphragm body and the shell under the basic assembly condition is determined, so as to change and correct the basic assembly condition to obtain the actual assembly condition, specifically:

[0073] According to the distribution and aggregation characteristics of all contact unstable points in the joint area between the diaphragm body and the inner cavity of the shell, the joint unstable area between the diaphragm body and the inner cavity of the shell under the basic assembly condition is determined;

[0074] According to the cross-sectional size of the diaphragm body corresponding to the unstable bonding area and the welding interval size of the diaphragm body and the inner cavity of the shell, the welding strength of the unstable bonding area is changed by changing the correction basic assembly condition to obtain the actual assembly condition.

[0075] As can be known from the foregoing, the unstable contact points between the diaphragm body and the inner cavity wall of the shell are potential separation points between the diaphragm body and the inner cavity wall of the shell. The more intensive the distribution of these unstable contact points, the greater the total separation force formed by the unstable contact points in the area, and the more likely the diaphragm body and the inner cavity wall of the shell to separate in the area. Conversely, the sparser the distribution of these unstable contact points, the smaller the total separation force formed by the unstable contact points in the area, and the less likely the diaphragm body and the inner cavity wall of the shell to separate in the area. As can be known from the above analysis, the distribution density of the unstable contact points directly affects the bonding stability between the diaphragm body and the inner cavity wall of the shell. Therefore, the spatial distribution aggregation degree of the unstable contact points on the corresponding bonding area between the diaphragm body and the inner cavity wall of the shell is analyzed first to obtain the distribution density of all unstable contact points in the above bonding area. If the distribution density of the unstable contact points in a certain range in the above bonding area is greater than a preset density threshold, the above range is determined as an unstable bonding area. Otherwise, the above range is not determined as an unstable bonding area, which provides a reliable basis for determining the weak welding bonding area between the diaphragm body and the inner cavity wall of the shell of the diaphragm energy storage device assembled under the above basic assembly condition. Please refer to Figure 6 The spatial distribution of all unstable bonding areas between the diaphragm body (the edge area of the diaphragm body) and the inner cavity wall of the shell.

[0076] According to the foregoing, the diaphragm body is assembled into the inner cavity of the shell by using electron beam welding technology to project an electron beam to the edge part of the diaphragm body. The edge part will melt under the action of the electron beam, and the edge part and the inner cavity wall of the shell are bonded during the melting process. The melting degree of the edge part determines the volume of the rubber material of the edge part melted into the hot glue material. The higher the melting degree, the greater the volume of the generated hot glue material, and the higher the stability of the joint between the edge part and the inner cavity wall of the shell. Through the above analysis, it is known that the unstable joint area is prone to separation between the diaphragm body (especially the edge part of the diaphragm body) and the inner cavity wall of the shell. In order to reduce the separation occurrence, it is necessary to further increase the volume of the hot glue material in the above unstable joint area on the basis of the original assembly condition. However, as the volume of the hot glue material in the unstable joint area increases, the thickness of the edge part of the diaphragm body in the above unstable joint area will decrease, which is easy to cause the edge part to be perforated or cracked in the above unstable joint area. In order to balance the generation of sufficient volume of hot glue material in the above unstable joint area and the joint with the inner cavity wall of the shell, and avoid the above unstable joint area from being thinned and cracked due to excessive generation of hot glue material, it is necessary to change the cross-sectional thickness of the edge part of the diaphragm body corresponding to the unstable joint area and the welding interval range size of the diaphragm body and the inner cavity of the shell. The welding strength (such as electron beam projection strength and / or projection duration) of the original basis assembly condition on the above unstable joint area is corrected, the basis assembly condition uniformly projects the same reference strength of the electron beam on the entire edge part of the diaphragm body during the electron beam welding operation, and the electron beam projection time of each section in the entire edge part is the same. The electron beam welding strength of the edge part corresponding to the unstable joint area is enhanced, and the spatial differentiation electron beam welding of the edge part is realized.

[0077] S400: Test the diaphragm energy storage formed according to the actual assembly condition to obtain the welding structure characteristics between the diaphragm body and the shell; adjust the actual assembly operation according to the welding structure characteristics.

[0078] In S400, the diaphragm energy storage formed according to the actual assembly condition is tested to obtain the welding structure characteristics between the diaphragm body and the shell; the actual assembly operation is adjusted according to the welding structure characteristics, specifically:

[0079] The diaphragm energy storage formed according to the actual assembly condition is tested by ultrasonic wave to obtain the welding gap structure characteristics between the diaphragm body and the inner cavity of the shell; wherein the welding gap structure characteristics include the welding gap structure size and quantity distribution between the diaphragm body and the inner cavity of the shell;

[0080] According to the welding gap structure characteristics, the welding defect position between the diaphragm body and the shell is calibrated, and the welding operation parameter of the actual assembly operation on the welding defect position is adjusted.

[0081] Please refer toFigure 7 The diaphragm accumulator can be placed on a rotating support (not shown in the figure) to rotate the diaphragm accumulator as a whole. During the rotation of the diaphragm accumulator, an ultrasonic detector (not shown in the figure) is used to detect the space where the joint area between the edge of the diaphragm body and the wall surface of the inner cavity of the shell is located during the implementation of the above actual assembly condition, and the welding gap structure characteristics between the edge of the diaphragm body and the wall surface of the inner cavity of the shell are obtained. The welding gap structure characteristics refer to the size and number distribution of the gap structure inside the hot glue material formed by the melting of the rubber material of the edge under the action of the electron beam. The size and number of the gap structure determine the joint tightness between the edge and the wall surface of the inner cavity of the shell. The smaller the size and / or the fewer the number, the higher the joint tightness between the edge and the wall surface of the inner cavity of the shell. Conversely, the smaller the size and / or the fewer the number, the lower the joint tightness between the edge and the wall surface of the inner cavity of the shell. According to the above gap structure size and number, the welding defect position between the edge of the diaphragm body and the wall surface of the inner cavity of the shell is calibrated, such as determining the position where the gap structure size is greater than the preset size threshold and / or the gap structure number is greater than the preset number threshold as the welding defect position, so as to adjust the electron beam emission intensity of the electron beam emitter to implement the actual assembly operation (such as electron beam emission operation) on the above welding defect position, thereby increasing the melting efficiency of the rubber material at the above welding defect position, making the melted hot glue fill the above gap to the maximum extent, improving the joint tightness between the edge and the wall surface of the inner cavity of the shell, and improving the assembly reliability and stability of the diaphragm body.

[0082] Referring to Figure 8 As shown in the figure, the present application provides a diaphragm body assembly correction and testing system for a diaphragm accumulator, which comprises the following modules:

[0083] A modeling analysis module is used to model and analyze the diaphragm accumulator to obtain deformation data of the diaphragm body under the basic assembly condition.

[0084] A fatigue area identification module is used to determine the stress fatigue area of the diaphragm body according to the deformation data.

[0085] A contact instability calibration module is used to determine the contact instability point between the diaphragm body and the shell of the accumulator according to the physical state of the stress fatigue area.

[0086] An assembly change correction module is used to determine the joint instability area between the diaphragm body and the shell under the basic assembly condition according to the distribution of the contact instability point, so as to change and correct the basic assembly condition to obtain the actual assembly condition.

[0087] A testing module is used to test the diaphragm accumulator formed according to the actual assembly condition to obtain the welding structure characteristics between the diaphragm body and the shell.

[0088] An assembly adjustment module is configured to adjust an actual assembly operation according to the welding structure characteristics.

[0089] Further, the modeling analysis module is configured to model and analyze the diaphragm accumulator to obtain deformation data of the diaphragm body under a basic assembly condition, specifically as follows:

[0090] The diaphragm body structure data and the inner cavity structure data of the shell of the diaphragm accumulator are obtained, and finite element modeling analysis is performed on the diaphragm accumulator based on the data to obtain deformation data of the diaphragm body under the basic assembly condition corresponding to different compression ratio working states of the diaphragm accumulator; wherein the basic assembly condition refers to the reference welding parameter condition under which the diaphragm body is joined to the inner cavity of the shell.

[0091] The fatigue region identification module is configured to determine the stress fatigue region of the diaphragm body according to the deformation data, specifically as follows:

[0092] The deformation position data and the deformation amplitude data of the diaphragm body corresponding to different compression ratio working states are extracted from the deformation data, and stress response analysis is performed on the diaphragm body based on the deformation position data and the deformation amplitude data to obtain stress response time evolution characteristics of all grid regions of the diaphragm body, so as to identify whether the grid region is a stress fatigue region.

[0093] Further, the contact instability calibration module is configured to determine the contact instability point between the diaphragm body and the shell of the accumulator according to the physical state of the stress fatigue region, specifically as follows:

[0094] The spatial distribution position and range of all stress fatigue regions in the diaphragm body are obtained, and the stress concentration region of the diaphragm body is estimated based on the spatial distribution position and range.

[0095] The abnormal contact and collision position between the diaphragm body and the inner cavity of the shell is estimated based on the stress concentration region, so as to determine the contact instability point between the diaphragm body and the inner cavity of the shell.

[0096] Further, the assembly change correction module is configured to determine the unstable joint region between the diaphragm body and the shell under the basic assembly condition according to the distribution of the contact instability point, so as to change and correct the basic assembly condition to obtain an actual assembly condition, specifically as follows:

[0097] The unstable joint region between the diaphragm body and the inner cavity of the shell under the basic assembly condition is determined based on the distribution and aggregation characteristics of all contact instability points in the joint region of the diaphragm body and the inner cavity of the shell.

[0098] The welding strength of the unstable joint region by the basic assembly condition is changed and corrected according to the cross-sectional size of the diaphragm body corresponding to the unstable joint region and the welding interval size of the diaphragm body and the inner cavity of the shell, so as to obtain the actual assembly condition.

[0099] Further, the test module is used for testing the diaphragm energy accumulator formed according to the actual assembly condition, to obtain the welding structure characteristics between the diaphragm body and the shell, specifically:

[0100] The diaphragm energy accumulator formed according to the actual assembly condition is subjected to ultrasonic testing, to obtain the welding gap structure characteristics between the diaphragm body and the inner cavity of the shell; wherein the welding gap structure characteristics include the welding gap structure size and quantity distribution between the diaphragm body and the inner cavity of the shell.

[0101] The assembly adjustment module is used for adjusting the actual assembly operation according to the welding structure characteristics, specifically:

[0102] According to the welding gap structure characteristics, the welding defect position between the diaphragm body and the shell is calibrated, so as to adjust the welding operation parameters of the actual assembly operation on the welding defect position.

[0103] The diaphragm body assembly correction and test system of the diaphragm energy accumulator is corresponding to the operation and effect of the diaphragm body assembly correction and test method of the diaphragm energy accumulator, and the diaphragm body assembly correction and test system of the diaphragm energy accumulator will not be repeated here.

[0104] Through the description of the above embodiments, those skilled in the art can clearly understand that each embodiment can be realized by means of a general hardware platform as necessary, and of course can also be realized by means of combination of hardware and software. Based on such understanding, the above technical solutions can be embodied in the form of computer program products, and the present application can be embodied in the form of computer program products implemented on one or more computer usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer usable program code.

[0105] Finally, it should be pointed out that: the above examples are only used to illustrate the technical solutions of the present application, and are not limited thereto, and other embodiments can also be used; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that they can still modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for part of the technical features; and these modifications or replacements do not make the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A method for assembling, calibrating, and testing the diaphragm body of a diaphragm energy storage device, characterized in that, The method includes the following steps: S100: Model and analyze the diaphragm energy storage device to obtain deformation data of the diaphragm body under basic assembly conditions; based on the deformation data, determine the stress fatigue region of the diaphragm body, specifically: The diaphragm structure data and the shell cavity structure data of the diaphragm energy storage device are obtained, and finite element modeling analysis is performed on the diaphragm energy storage device to obtain the deformation data of the diaphragm body under basic assembly conditions corresponding to the working state of the diaphragm energy storage device under different compression ratios; wherein, the basic assembly conditions refer to the reference welding parameter conditions for the diaphragm body to be joined to the shell cavity. The deformation location data and deformation amplitude data of the diaphragm body corresponding to different compression ratio working states are extracted from the deformation data. Based on the deformation location data and the deformation amplitude data, stress response analysis is performed on the diaphragm body to obtain the stress response time evolution characteristics of all grid regions under the diaphragm body, thereby identifying whether the grid region is a stress fatigue region. S200: Based on the physical state of the stress fatigue region, determine the contact instability point between the diaphragm and the energy storage device housing, specifically: Obtain the spatial distribution location and range of all stress fatigue regions within the diaphragm body, and estimate the stress concentration area of ​​the diaphragm body based on the spatial distribution location and range. Based on the stress concentration area, the location of abnormal contact and collision between the diaphragm and the inner cavity of the shell is estimated, thereby determining the contact instability point between the diaphragm and the inner cavity of the shell; wherein, the contact instability point refers to the contact location point in the joint area between the diaphragm and the inner cavity wall surface where the separation force between the diaphragm and the inner cavity wall surface exceeds the joint force between the diaphragm and the inner cavity wall surface of the shell; the separation force refers to the separation force of the diaphragm relative to the inner cavity wall surface of the shell surface formed during the expansion and contraction deformation of the diaphragm. S300: Based on the distribution of the unstable contact points, determine the unstable bonding region between the diaphragm and the shell under the basic assembly conditions, and thereby change and correct the basic assembly conditions to obtain the actual assembly conditions; S400: Test the diaphragm energy storage device formed according to the actual assembly conditions to obtain the welding structure characteristics between the diaphragm body and the shell; adjust the actual assembly operation according to the welding structure characteristics.

2. The method according to claim 1, characterized in that, In S300, based on the distribution of the contact instability points, the unstable bonding region between the diaphragm and the housing under the basic assembly conditions is determined, and the basic assembly conditions are modified and corrected accordingly to obtain the actual assembly conditions, specifically: Based on the distribution and aggregation characteristics of all contact instabilities in the junction area between the diaphragm and the inner cavity of the housing, the junction instability area between the diaphragm and the inner cavity of the housing under the basic assembly conditions is determined. Based on the cross-sectional dimensions of the diaphragm corresponding to the unstable bonding region and the welding interval dimensions between the diaphragm and the inner cavity of the housing, the welding strength of the basic assembly conditions for the unstable bonding region is modified and corrected to obtain the actual assembly conditions.

3. The method according to claim 1, characterized in that, In S400, the diaphragm energy storage device formed according to the actual assembly conditions is tested to obtain the welding structure characteristics between the diaphragm body and the housing; based on the welding structure characteristics, the actual assembly operation is adjusted, specifically as follows: An ultrasonic test was performed on the diaphragm energy storage device formed according to the actual assembly conditions to obtain the structural characteristics of the welding gap between the diaphragm body and the inner cavity of the shell; wherein, the structural characteristics of the welding gap include the size and number distribution of the welding gap structure between the diaphragm body and the inner cavity of the shell; Based on the structural characteristics of the weld gap, the location of the weld defect between the diaphragm and the shell is determined, and the welding operation parameters for the location of the weld defect are adjusted accordingly during the actual assembly operation.

4. A diaphragm assembly calibration and testing system for a diaphragm energy storage device, characterized in that, The system includes the following modules: The modeling and analysis module is used to model and analyze the diaphragm energy storage device, obtaining deformation data of the diaphragm body under basic assembly conditions, specifically: The diaphragm structure data and the shell cavity structure data of the diaphragm energy storage device are obtained, and finite element modeling analysis is performed on the diaphragm energy storage device to obtain the deformation data of the diaphragm body under basic assembly conditions corresponding to the working state of the diaphragm energy storage device under different compression ratios; wherein, the basic assembly conditions refer to the reference welding parameter conditions for the diaphragm body to be joined to the shell cavity. The fatigue region identification module is used to determine the stress fatigue region of the diaphragm body based on the deformation data, specifically: The deformation location data and deformation amplitude data of the diaphragm body corresponding to different compression ratio working states are extracted from the deformation data. Based on the deformation location data and the deformation amplitude data, stress response analysis is performed on the diaphragm body to obtain the stress response time evolution characteristics of all grid regions under the diaphragm body, thereby identifying whether the grid region is a stress fatigue region. The contact instability calibration module is used to determine the contact instability point between the diaphragm and the energy storage device housing based on the physical state of the stress fatigue region, specifically: Obtain the spatial distribution location and range of all stress fatigue regions within the diaphragm body, and estimate the stress concentration area of ​​the diaphragm body based on the spatial distribution location and range. Based on the stress concentration area, the location of abnormal contact and collision between the diaphragm and the inner cavity of the shell is estimated, thereby determining the contact instability point between the diaphragm and the inner cavity of the shell; wherein, the contact instability point refers to the contact location point in the joint area between the diaphragm and the inner cavity wall surface where the separation force between the diaphragm and the inner cavity wall surface exceeds the joint force between the diaphragm and the inner cavity wall surface of the shell; the separation force refers to the separation force of the diaphragm relative to the inner cavity wall surface of the shell surface formed during the expansion and contraction deformation of the diaphragm. The assembly change correction module is used to determine the unstable bonding area between the diaphragm and the shell under the basic assembly conditions based on the distribution of the unstable contact points, and thereby change and correct the basic assembly conditions to obtain the actual assembly conditions. The testing module is used to test the diaphragm energy storage device formed according to the actual assembly conditions, and to obtain the welding structure characteristics between the diaphragm body and the shell. The assembly adjustment module is used to adjust the actual assembly operation according to the characteristics of the welding structure.

5. The system according to claim 4, characterized in that, The assembly change correction module is used to determine the unstable bonding region between the diaphragm and the shell under the basic assembly conditions based on the distribution of the unstable contact points, and thereby change and correct the basic assembly conditions to obtain the actual assembly conditions, specifically: Based on the distribution and aggregation characteristics of all contact instabilities in the junction area between the diaphragm and the inner cavity of the housing, the junction instability area between the diaphragm and the inner cavity of the housing under the basic assembly conditions is determined. Based on the cross-sectional dimensions of the diaphragm corresponding to the unstable bonding region and the welding interval dimensions between the diaphragm and the inner cavity of the housing, the welding strength of the basic assembly conditions for the unstable bonding region is modified and corrected to obtain the actual assembly conditions.

6. The system according to claim 4, characterized in that, The testing module is used to test the diaphragm energy storage device formed according to the actual assembly conditions, and to obtain the welding structure characteristics between the diaphragm body and the shell, specifically: An ultrasonic test was performed on the diaphragm energy storage device formed according to the actual assembly conditions to obtain the structural characteristics of the welding gap between the diaphragm body and the inner cavity of the shell; wherein, the structural characteristics of the welding gap include the size and number distribution of the welding gap structure between the diaphragm body and the inner cavity of the shell; The assembly adjustment module is used to adjust the actual assembly operation according to the welding structure characteristics, specifically: Based on the structural characteristics of the weld gap, the location of the weld defect between the diaphragm and the shell is determined, and the welding operation parameters for the location of the weld defect are adjusted accordingly during the actual assembly operation.

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