Spraying system and method for integral alternating salt spray test

Abstract

The invention discloses a spraying system and method for an integral alternating salt spray test, and mainly solves the problems of poor spraying uniformity and low system reliability in the prior art. The device comprises a support (1), an air compressor (2), a brine tank (3), a plurality of saturators (4), a plurality of salt mist generating devices (5), a brine pipeline (6), an air pipeline (7) and a brine pump (8), the salt mist generating devices and the brine pipeline are installed on the support, and the saturators, the air compressor, the brine tank and the brine pump are all arranged outside a test room. One end of each salt mist generating device is connected with the corresponding saturator, and the other end of each salt mist generating device is connected with the brine tank through a brine pipeline and a brine pump. A gas channel, a liquid channel and a gas-liquid mixing channel are arranged on a spray head of each salt mist generating device; high-pressure saturated air and saline water are injected into the gas-liquid mixing cavity through the gas channel and the liquid channel respectively, a high-pressure gas-liquid mixture is formed, and salt mist is sprayed out through the gas-liquid mixing channel. The device is uniform in spraying and high in system reliability, and can be used for an integral alternating salt spray test.

Description

Technical Field

[0001] The present invention belongs to the technical field of equipment testing, and specifically relates to a spray system and method that can be used for whole-mount alternating salt spray testing. Background Art

[0002] With increasingly stringent requirements for equipment quality, salt spray testing methods based on samples and components are insufficient to assess the equipment's salt spray resistance, which can easily lead to under-testing. Therefore, it is urgent to conduct salt spray testing on the entire equipment. Since the salt spray test space used for equipment samples or components is relatively small, the test pieces are usually mounted on hanging or overhead test racks. The salt spray generator generally uses a tower spray, which is located in the middle of a small salt spray test chamber. During the spray phase, the test space is small, and the sedimentation is uniform and easy to control.

[0003] The whole-mounted salt spray test requires a large test space. The space for the whole-mounted salt spray test can reach 360m 3 During the spray phase of the alternating salt spray test, if tower spray is used, the limited space within each spray tower necessitates the use of numerous spray towers. This can lead to partial blockage or unstable air pressure during the spray phase of the complete salt spray test, resulting in reduced reliability and uneven salt spray deposition. This unevenness in the spray phase can also lead to poor repeatability in the salt spray test, resulting in inconsistent assessments of various parts of the equipment and causing partial over- or under-testing of the equipment's salt spray resistance, seriously impacting the assessment of test results.

[0004] Patent publication number CN 101551320 B discloses a "salt spray generating device for a salt spray test chamber." The device comprises a tower body, a tower cap, a gas nozzle, a gas pipeline, a liquid nozzle, a liquid pipeline, and a transmission device. The device utilizes a classic tower layout, which ensures uniform salt spray deposition and improves the accuracy and reproducibility of salt spray test results. However, due to its limited spray range, the device can only be used in small salt spray test chambers and is not suitable for the stable implementation of salt spray spray in large spaces such as large salt spray laboratories.

[0005] Patent publication number CN 101806704 B discloses a "Method for Assembling Atomization Units in a Large-Scale Salt Spray Environment Test System." This method utilizes small modular spray towers to assemble a spray unit for a large-scale salt spray test device for performing salt spray tests. Because this assembly unit utilizes a large number of small modular salt spray generators, the air and liquid supply channels are long, and pressure at each node is unstable. This results in poor unit stability, poor overall spatial spray uniformity, and low system reliability, making it impossible to achieve stable salt spray spraying over large areas. Summary of the Invention

[0006] The purpose of the present invention is to address the deficiencies of the above-mentioned prior art and provide a spray system and method for a self-contained alternating salt spray test, so as to improve the uniformity of the deposition amount in a large space and the reliability of the spray system, and effectively ensure the repeatability of the test results.

[0007] To achieve the above objectives, the technical solutions of the present invention include:

[0008] 1. A spray system for a self-contained alternating salt spray test, comprising a bracket, an air compressor, a brine tank, a saturator, a salt spray generating device, a brine pipeline, an air pipeline and a brine pump, wherein the salt spray generating device and the brine pipeline are mounted on the bracket, one end of the salt spray generating device is connected to the saturator, and the other end is connected to the brine tank via the brine pipeline and the brine pump, characterized in that the salt spray generating device comprises a nozzle, a saturated gas pipeline, a liquid level gauge, a brine tank and a liquid pipe, one end of the nozzle is connected to the saturator via the saturated gas pipeline, and the other end is connected to the upper end of the liquid pipe, and the lower end of the liquid pipe and the liquid level gauge are both fixed in the brine tank.

[0009] Furthermore, the nozzle includes a protective ring, a liquid cap, an air cap, a sealing gasket, and a connecting block. The liquid cap is connected to the protective ring and fixed at one end of the air cap, and is buckled with the air cap to form a cavity gas-liquid mixing chamber; the other end of the air cap is connected to the sealing gasket and fixed at one end of the connecting block; a thimble is fixed to the other end of the connecting block.

[0010] Furthermore, the brine tank is a trapezoidal tank body, the upper end of which is covered with a protective cover with two through holes. The liquid pipe and the liquid level meter are installed in the brine tank through the through holes, and the lower end of the brine tank is connected to the brine pipeline.

[0011] 2. A method for spraying using a spray system for a self-contained alternating salt spray test, characterized by comprising:

[0012] The high-pressure gas generated by the air compressor is injected into the saturator through the air pipe to form high-pressure saturated air, and the high-pressure saturated air is injected into the gas-liquid mixing chamber through the first gas channel, the second gas channel, and the third gas channel in the nozzle in sequence;

[0013] The brine in the brine tank is injected into the brine pipe and the brine tank in sequence through the brine pump. Under the action of negative pressure, the brine in the brine tank passes through the liquid pipe, the first liquid channel and the second liquid channel in the nozzle in sequence and is injected into the gas-liquid mixing chamber.

[0014] The brine level injected into the gas-liquid mixing chamber forms a high-pressure gas-liquid mixture with the high-pressure saturated air under the real-time control of the liquid level meter, and salt mist is continuously sprayed out through the gas-liquid mixture channel.

[0015] Compared with the prior art, the present invention has the following advantages:

[0016] Firstly, the present invention adopts a compact nozzle structure and is deployed horizontally, so a small number of nozzles and saturators can be used to achieve salt mist deposition in a large space, thereby improving the uniformity of the salt mist formed by the spray system.

[0017] Secondly, the present invention injects the high-pressure gas generated by the air compressor into the saturator through the air pipe to form high-pressure saturated air, which no longer absorbs moisture from the brine during spraying, thereby avoiding the crystallization of the brine to block the nozzle and improving the reliability of the spray system.

[0018] Thirdly, the present invention controls the liquid level of the brine tank in real time, so that the brine tank can always maintain sufficient brine supply during spraying, ensuring the continuity of spraying and effectively ensuring the repeatability of test results. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a structural diagram of the spray system of the present invention;

[0020] Figure 2 This is a structural diagram of the salt mist generating device in the system of the present invention;

[0021] Figure 3 FIG. 1 is a structural diagram of a nozzle in a salt mist generating device in the system of the present invention;

[0022] Figure 4 for Figure 3 Exploded diagram;

[0023] Figure 5 It is a flow chart for realizing the spraying method of the present invention. DETAILED DESCRIPTION

[0024] The embodiments of the present invention are described in further detail below with reference to the accompanying drawings.

[0025] The present invention is used for the scenario of whole-mount alternating salt spray test. The object of whole-mount salt spray test is the whole armored vehicle equipment. The space required for salt spray test is 360m 3 The alternating salt spray test is implemented as a 24-hour spraying and 24-hour drying cycle, and multiple cycles can be carried out as needed. To avoid under-testing and over-testing, the whole-mount alternating salt spray test needs to ensure the uniformity of salt spray in a large space and the reliability and continuity of long-term spraying.

[0026] Reference Figure 1This example is a spray system for a complete alternating salt spray test, comprising a bracket 1, an air compressor 2, a brine tank 3, multiple saturators 4, multiple salt spray generating devices 5, a brine pipe 6, an air pipe 7, and a brine pump 8. The number of salt spray generating devices 5 is twice the number of saturators 4; the bracket 1 is a rectangular frame that serves as a support; the air compressor 2, brine tank 3, brine pump 8, and multiple saturators 4 are arranged outside the test chamber, with all saturators arranged at equal intervals; the brine pipe 6 and multiple salt spray generating devices 5 are fixed to the bracket 1, with all salt spray generating devices 5 arranged at equal intervals. One end of each salt spray generating device 5 is connected to its corresponding saturator 4, and the other end is connected to the brine tank 3 via the brine pipe 6 and brine pump 8; the other end of each saturator 4 is connected to the air compressor 2 via the air pipe 7; and the brine pump 8 is installed at the lower end of the brine tank 3.

[0027] Hot water is stored in each saturator 4 arranged at equal intervals. The dry, room-temperature, high-pressure gas generated by the air compressor 2 is injected into the saturator 4 through the air pipe 7. After fully contacting with the hot water in the saturator 4, high-pressure saturated gas is formed and provided to the salt mist generating device 5 to avoid crystallization when it mixes with the brine, thereby ensuring the reliability of the spray.

[0028] Reference Figure 2 Each salt mist generating device 5 includes a nozzle 51, a saturated gas pipeline 52, a liquid level gauge 53, a brine tank 54, a liquid pipe 55 and a protective cover 56. The brine tank 54 is arranged below the nozzle 51 and is a trapezoidal tank body. The protective cover 56 covers the upper end of the brine tank 54 to prevent pollutants from falling and contaminating the brine or causing the nozzle to be blocked. The protective cover 56 has two through holes, and the liquid pipe 55 and the liquid level gauge 53 are installed in the brine tank 54 through the through holes. The brine tanks 54 in each salt mist generating device are connected in series and used independently. Multiple brine tanks 54 are connected to the brine pipeline 6 through the bottom to keep the brine water level of each individual brine tank consistent, so that the brine in the brine tank 54 remains in a flowing state, and the dynamic balance of the brine liquid level is guaranteed. The nozzle 51 is made of polytetrafluoroethylene, which has the advantages of high mechanical strength, not easy to deform and corrosion-resistant, and easy to disassemble and clean. One end of the nozzle is connected to the saturator 4 through the saturated gas pipeline 52, and the other end is connected to the upper end of the liquid pipe 55. The lower end of the liquid pipe 55 is fixed in the brine tank 54. The nozzle 51 absorbs the brine in the brine tank 54 below through the liquid pipe 55 through the negative pressure continuously formed during the spraying to achieve continuous spraying, which can realize large-area spraying. A small number of nozzles can be used to achieve large-space salt mist deposition.

[0029] Reference Figure 3 and Figure 4The nozzle 51 adopts a round nozzle structure and includes a retaining ring 511, a liquid cap 512, an air cap 513, a sealing gasket 514, a connecting block 515, and a ejector pin 516. The liquid cap 512 has a through hole serving as a gas-liquid mixture passage c. It is connected to the retaining ring 511 and fixed to one end of the air cap 513. It interlocks with the air cap 513 to form a gas-liquid mixing chamber 517. The air cap 513 has two through holes serving as a third gas passage a3 and a second liquid passage b2, respectively. The other end of the air cap 513 is connected to the sealing gasket 514. The sealing gasket 514 has a through hole serving as the second gas passage a2 and is fixed to one end of the connecting block 515. The connecting block 515 has two through holes serving as a first gas passage a1 and a first liquid passage b1, respectively. The ejector pin 516 is fixed to the other end of the connecting block 515.

[0030] Reference Figure 5 The method for spraying in a whole-mount alternating salt spray test using the above system includes the following steps:

[0031] The high-pressure gas generated by the air compressor 2 is injected into the saturator 4 through the air pipe 7 to form high-pressure saturated air. The high-pressure saturated air is then injected into the gas-liquid mixing chamber 517 through the first gas channel a1, the second gas channel a2, and the third gas channel a3 in the nozzle 51 in sequence.

[0032] The brine in the brine tank 3 is sequentially injected into the brine pipe 6 and the brine tank 54 through the brine pump 8. When the brine in the brine tank 54 reaches 2 / 3 of the tank body height, the brine pump 8 is stopped. Under the action of negative pressure, the brine in the brine tank 54 sequentially passes through the liquid pipe 55, the first liquid channel b1 and the second liquid channel b2 in the nozzle 51, and is injected into the gas-liquid mixing chamber 517.

[0033] The brine injected into the gas-liquid mixing chamber 517 is fully mixed with the high-pressure saturated air to form a high-pressure gas-liquid mixture, which is continuously sprayed out through the gas-liquid mixture channel c. The negative pressure is the pressure below atmospheric pressure formed in the gas-liquid mixing chamber 517 when spraying the salt mist, which provides power for the nozzle 51 to absorb the brine from the brine tank 54 below through the liquid pipe 55.

[0034] As the spraying proceeds, when the brine level drops to 1 / 3 of the depth of the brine tank 54, the brine pump 8 is turned on again to inject brine to 2 / 3 of the height of the brine tank 54;

[0035] The process of starting and stopping the salt water pump 8 is circulated in this way to ensure sufficient supply of salt water during the spraying stage and to achieve continuous spraying.

[0036] The effect of the present invention can be further illustrated by the following test experiments:

[0037] 1. Test conditions

[0038] The space of the fully equipped salt spray test chamber is 13.5m long, 6m wide and 5m high. It is equipped with 24 salt spray generators and 12 saturators, that is, one saturator corresponds to two salt spray generators. During spraying, the hot water temperature of the saturator is 55℃ and the high-pressure air pressure is 2.2kpa.

[0039] 2. Test content

[0040] Under the above test conditions, the spray was continuously applied for 24 hours and the precipitation in the salt spray test chamber was monitored. The results are as follows:

[0041] The maximum value is 2.51 ml / (80cm 2 •h), with a minimum value of 2.15 ml / (80cm 2 •h),

[0042] The average sedimentation volume was 2.21 ml / (80cm 2 •h), and spray continuously without interruption.

[0043] The test results meet the requirements of the laboratory environmental test standards for salt spray deposition, indicating that the present invention can well solve the problems of spray uniformity and reliability in the whole-pack alternating salt spray test.

[0044] The above description is only a specific example of the present invention and does not constitute any limitation to the present invention. Obviously, for professionals in this field, after understanding the content and principles of the present invention, it is possible to make various modifications and changes in form and details without departing from the principles and structure of the present invention. For example, the nozzle of this example adopts a round nozzle structure, which can also be designed as an elliptical structure, a square structure or a rectangular structure; the bracket is a rectangular frame, which can be designed as a circular frame or a square frame rectangular structure; however, these modifications and changes based on the ideas of the present invention are still within the scope of protection of the claims of the present invention.

Claims

1. A spray system for a complete alternating salt spray test, comprising a bracket (1), an air compressor (2), a salt water tank (3), a saturator (4), a salt spray generator (5), a salt water pipeline (6), an air pipeline (7) and a salt water pump (8), wherein the salt spray generator (5) and the salt water pipeline (6) are mounted on the bracket (1), and characterized in that: The saturators (4) and the salt mist generating devices (5) are both provided in a plurality, and the plurality of saturators (4) are connected to the air compressor (2) via an air pipe (7). Each salt mist generating device (5) comprises a nozzle (51), a saturated gas pipe (52), a liquid level gauge (53), a brine tank (54), a liquid pipe (55) and a protective cover (56). One end of the nozzle (51) is connected to a corresponding saturator (4) via a saturated gas pipe (52), and the other end is connected to the upper end of the liquid pipe (55). The lower end of the liquid pipe (55) and the liquid level gauge (53) are both fixed in the brine tank (54). The brine tank (54) is connected to the brine tank (3) via a brine pipe (6) and a brine pump (8).

2. The system according to claim 1, wherein: The multiple saturators (4) and the multiple salt mist generating devices (5) are all distributed at equal intervals, and the number of the salt mist generating devices (5) is twice the number of the saturators (4).

3. The system according to claim 1, wherein: The nozzle (51) comprises a retaining ring (511), a liquid cap (512), an air cap (513), a sealing gasket (514), a connecting block (515) and a thimble (516). The liquid cap (512) is connected to the retaining ring (511) and fixed to one end of the air cap (513), and is interlocked with the air cap (513) to form a cavity gas-liquid mixing chamber (517); the other end of the air cap (513) is connected to the sealing gasket (514) and fixed to one end of the connecting block (515); and the thimble (516) is fixed to the other end of the connecting block (515).

4. The system according to claim 1, wherein: The brine tank (54) is a trapezoidal tank body, the upper end of which is covered with a protective cover (56). The protective cover has two through holes, through which the liquid pipe (55) and the liquid level meter (53) are installed in the brine tank. The lower end of the brine tank (54) is connected to the brine pipeline (6).

5. The system according to claim 1, wherein: The bracket (1) is a rectangular frame that plays a supporting role. The salt mist generating device (5) and the brine pipeline (6) are installed on the bracket (1).

6. The system according to claim 1, wherein: The air compressor (2), the brine tank (3), the brine pump (8) and the saturator (4) are installed outside the complete salt spray test chamber. The air compressor (2) is connected to the saturator (4) through an air pipe (7), and the brine pump (8) is installed at the lower end of the brine tank (3).

7. The system according to claim 3, characterized in that: The connecting block (515) has two through holes formed thereon, serving as a first passage (a1) for gas and a first passage (b1) for liquid respectively; The sealing gasket (514) has a through hole formed thereon, serving as a second gas passage (a2); The air cap (513) is provided with two through holes, which are used as a third channel (a3) ​​for gas and a second channel (b2) for liquid, respectively. The liquid cap (512) is provided with a through hole thereon, serving as a gas-liquid mixture passage (c).

8. A method for spraying using a spray system for a self-contained alternating salt spray test, characterized in that: include: The high-pressure gas generated by the air compressor (2) is injected into the saturator (4) through the air pipe (7) to form high-pressure saturated air, and the high-pressure saturated air is injected into the gas-liquid mixing chamber (517) through the first gas channel (a1), the second gas channel (a2), and the third gas channel (a3) ​​in the nozzle (51) in sequence; The brine in the brine tank (3) is sequentially injected into the brine pipe (6) and the brine tank (54) through the brine pump (8); the brine in the brine tank (54) is sequentially injected into the gas-liquid mixing chamber (517) through the liquid pipe (55), the first liquid channel (b1), and the second liquid channel (b2) in the nozzle (51) under the action of negative pressure; The brine level injected into the gas-liquid mixing chamber (517) forms a high-pressure gas-liquid mixture with the high-pressure saturated air under the real-time control of the liquid level meter (53), and salt mist is continuously sprayed out through the gas-liquid mixture channel (c).

9. The method according to claim 7, wherein: The brine level injected into the gas-liquid mixing chamber (517) forms a high-pressure gas-liquid mixture with the high-pressure saturated air under the real-time control of the level meter (53), which is achieved as follows: When the brine is injected into the brine tank (54) to 2 / 3 of its height by the brine pump (8), the brine pump (8) is suspended, and the brine and the high-pressure saturated air form a high-pressure gas-liquid mixture to spray out salt mist; As the spraying proceeds, when the brine level drops to 1 / 3 of the height of the brine tank (54), the brine pump (8) is turned on again to inject brine to 2 / 3 of the height of the brine tank (54); this cycle is repeated to ensure sufficient brine supply during the spraying stage and to achieve continuous spraying.

10. The system according to claim 7, wherein: The negative pressure is the pressure formed in the gas-liquid mixing chamber (517) when the salt mist is sprayed through the gas-liquid mixture channel (c) of the nozzle (51), and its value is lower than the atmospheric pressure.

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