High pressure sensor seal test system and dynamic verification method thereof

Abstract

This invention belongs to the field of high-pressure sensor testing technology, specifically a high-pressure sensor sealing test system and its dynamic verification method, including: a pressure input adjustment system, a pressure transmission sealing mechanism, a pressure monitoring sensor, a sealing test platform, and data acquisition and analysis equipment. The pressure transmission sealing mechanism includes a three-way transmission block, a first interface connecting pipe, and a second interface connecting pipe; the pressure monitoring sensor is installed at the sensor assembly port on the upper part of the three-way transmission block at the plug; the sealing test platform is equipped with cross pressure transmission channels and multiple vertical pressure transmission output interface components connected to them. This invention provides ideal sealing effect, high testing efficiency, strong stability, and accurate precision.

Description

Technical Field

[0001] This invention belongs to the field of high-pressure sensor testing technology, specifically a high-pressure sensor sealing test system and its dynamic verification method. This system is applicable to liquid media with pressures above 60 MPa and can solve the problems of high-pressure seal failure and insufficient testing accuracy. Background Technology

[0002] Most current pressure testing systems are designed for testing environments with pressure sensors below 40MPa. However, liquid pressure sensor testing systems above 60MPa frequently experience leakage problems in practical applications, leading to limited high-pressure testing applications and making implementation difficult. Leakage is a major failure during testing, with many causes, especially for high-pressure liquids. Liquid leaks not only damage equipment and affect its use but also prevent normal testing, impacting work progress. Currently, most systems use rubber ring seals. However, under prolonged and repeated pressure from high-pressure liquids, the rubber ring seal structure cannot meet normal sealing pressure testing requirements, especially when external conditions do not allow for frequent replacement. Under high pressure, the rubber ring may tear, causing test termination. Simultaneously, the testing device must be easy to install, with easily removable vulnerable parts, and avoid the time and equipment costs associated with repeatedly replacing sealing components. Furthermore, high-precision pressure sensor testing has relatively high requirements, with minimal pressure loss during pressure transmission, necessitating an accurate and stable pressure testing environment. Existing testing environments exhibit large pressure fluctuations, with pressure oscillations exceeding 1% during stepped loading. Summary of the Invention

[0003] The present invention aims to overcome the shortcomings of the prior art by providing a high-pressure sensor sealing test system and its dynamic verification method. The main purpose is to solve the problems of unsatisfactory sealing effect, low test efficiency, poor stability and poor accuracy of the prior art.

[0004] To solve the above-mentioned technical problems, the present invention is implemented as follows:

[0005] A high-voltage sensor sealing test system includes:

[0006] Pressure input regulation system: used to provide stable liquid pressure above 60MPa;

[0007] Pressure transmission sealing mechanism: includes a three-way transmission block, a first interface connecting pipe, and a second interface connecting pipe; one port of the first interface connecting pipe is connected to the pressure transmission outlet of the pressure input regulating system, and the other port is connected to the pressure transmission inlet of the three-way transmission block; one port of the second interface connecting pipe is connected to the pressure transmission outlet of the three-way transmission block, and the other end is connected to the sealing test platform;

[0008] Pressure monitoring sensor: The sensor assembly port, installed on the upper part of the tee transmission block at the plug, monitors pressure changes in real time and feeds them back to the control system;

[0009] Sealing test platform: It is equipped with a cross pressure transmission channel and a multi-channel vertical pressure transmission output interface assembly connected to it; the pressure sensor under test is connected to the vertical pressure transmission output interface assembly through a pressure interface; the inlet of the cross pressure transmission channel is connected to the other port of the second interface connecting pipe;

[0010] Data acquisition and analysis equipment: Sensor performance indicators are calculated using data acquisition cards and least squares analysis software.

[0011] Furthermore, the pressure input regulation system includes a piston pressure gauge, a booster, and a weight block device; the data drive port of the piston pressure gauge is connected to the data transmission port of the weight block device; the hydraulic medium transmission port of the weight block device is connected to the second hydraulic medium port of the three-way block in the booster via a second pipeline; the data detection port of the piston pressure gauge is connected to the data transmission port of the manual drive cylinder in the booster; the hydraulic medium transmission port of the manual drive cylinder in the booster is connected to the first hydraulic medium port of the three-way block in the booster via a first pipeline; and the third hydraulic medium port of the three-way block outputs standard pressure.

[0012] Furthermore, the ends of both the first and second interface connecting pipes are tapered; the pressure transmission inlet and outlet of the three-way conductive block are also tapered at the ends of the first and second interface connecting pipes to achieve bidirectional tapered sealing of the hydraulic medium at the connection point.

[0013] Furthermore, the other port of the first interface connecting pipe is connected to the pressure transmission inlet of the tee block via a pressure cap and a reverse fixing ring in sequence; one port of the second interface connecting pipe is connected to the pressure transmission outlet of the tee block via a pressure cap and a reverse fixing ring in sequence.

[0014] Furthermore, the vertical pressure transmission output interface assembly sequentially includes an output pressure cap, an output conduit, a connecting nut, a fixing block, and a sealing copper ring; a grooved O-ring is provided between the pressure interface of the pressure sensor under test and the upper end of the output conduit, and the output pressure cap enables the pressure sensor under test and the upper end of the output conduit to be fixedly connected; the fixing block is sleeved on the lower end of the output conduit, and the connecting nut and the sealing copper ring enable the output conduit to be fixedly connected to the test platform.

[0015] Furthermore, the ends of the first interface connecting pipe and the second interface connecting pipe both adopt a 74° conical structure, forming a contact length greater than 3 mm with the three-way conduction block, and the three-way conduction block, the first interface connecting pipe and the second interface connecting pipe are made of stainless steel with different hardnesses; the surface roughness Ra ≥ 1.6 μm; the reverse fixing retaining ring adopts a left-handed thread structure; the outer diameter of the grooved O-ring is 0.5 mm larger than the outer diameter of the corresponding output conduit with a groove.

[0016] Furthermore, the measured pressure sensor includes a pressure interface, an insulating pad, a circuit board, an outgoing line, a connector and a pressure core body; the circuit board is fixedly connected to the pressure interface through the insulating pad; the pressure core body is fixedly arranged in the cavity of the pressure interface; the data transmission interface of the circuit board is connected to the data transmission interface of the connector through the outgoing line.

[0017] The dynamic verification method of the above high-pressure sensor sealing test system includes the following steps:

[0018] Step S1: Pressure分级加载

[0019] a. When the target pressure ≤ 60 MPa, close the first pipeline, and the piston pressure gauge drives the weight block device to output pressure;

[0020] b. When the target pressure > 60 MPa, open the first pipeline, manually drive the oil cylinder to supplement pressure, and make the three-way block output the standard pressure;

[0021] c. Step up the pressure in steps of 10% of the range to the target pressure, and keep the pressure for 30 seconds at each level;

[0022] Step S2: Real-time verification of sealing performance

[0023] a. Keep the pressure for 5 minutes at the target pressure, and record the pressure output value fluctuation Δp through the pressure monitoring sensor and the measured pressure sensor;

[0024] b. If Δp / target pressure ≤ 0.05%, determine that the seal is qualified;

[0025] Step S3: Calculation of performance parameters

[0026] a. Collect the output voltage V of the measured pressure sensor, and fit the quadratic curve V = a0 + a1P + a2P² by the least squares method; where, P is the input pressure of the measured pressure sensor; a0, a1 and a2 are the coefficients to be determined; V is the output voltage of the measured pressure sensor; ΔV is the change in the output voltage of the measured pressure sensor; ΔP is the change value of the input pressure of the measured pressure sensor;

[0027] b. Calculate the sensitivity S = ΔV / ΔP, and the linearity L = max|V - a1P| / full range × 100%.

[0028] It should be noted that there is an incorrect expression "压力分级加载" in the original text, which is translated as "Pressure分级加载" here. It may need to be corrected in the original text for a more accurate translation.Further, in step S2b, a dual-channel comparison is used: Channel A: the pressure value p1 output by the pressure sensor under test; Channel B: the pressure value p2 output by the pressure monitoring sensor; if |p1-p2| continues to increase and the rate of change is >0.1MPa / s, the seal is determined to be faulty.

[0029] This invention effectively tests pressure sensors under pressures exceeding 60 MPa in liquid media. Through the pressure supply of the device system, the effective transmission of pressure through the pressure conduction system, the output of the test platform, and the structural design of the sensor, it prevents leakage, reduces pressure loss, ensures the sealing effect of the testing device under high pressure, provides relatively accurate pressure input, improves pressure transmission accuracy, and guarantees the accuracy of the testing system, providing accurate support for high-precision pressure testing. The sealing test platform is equipped with cross-channel pressure conduction and multi-channel vertical pressure conduction output interface components connected to it. It adopts a fixed seal with a sealing copper ring and a removable, better grooved O-ring to achieve double sealing. The pressure sensor under test includes a pressure core, a double-layer threaded cap structure, and an electron beam welded seal, capable of withstanding high pressures exceeding 60 MPa.

[0030] Attached Figure Description

[0031] The present invention will now be described in detail through specific embodiments. These embodiments are provided to enable a more thorough understanding of the invention and to fully convey the scope of the invention to those skilled in the art. As used throughout the specification and claims, the terms "comprising" or "including" are open-ended and are interpreted as "comprising but not limited to". The following description is a preferred embodiment for carrying out the invention; however, this description is intended to illustrate the general principles of the specification and is not intended to limit the scope of the invention. The scope of protection of the present invention is determined by the appended claims.

[0032] Figure 1 This is a schematic diagram of the overall system structure of the present invention;

[0033] Figure 2 For the present invention Figure 1 Top view;

[0034] Figure 3 This is a schematic diagram of the pressure transmission sealing mechanism of the present invention;

[0035] Figure 4 This is a schematic diagram of the sealing test platform structure of the present invention;

[0036] Figure 5 This is a schematic diagram of the structure of the pressure sensor to be measured in this invention;

[0037] Figure 6 This describes the working principle of the pressure input regulation subsystem of the present invention.

[0038] Figure 7 This is a flowchart of the dynamic verification method of the present invention.

[0039] In the diagram: 1. Pressure input regulation system; 101. Piston pressure gauge; 102. Weight block device; 103. Intensifier; 4. Pressure transmission sealing mechanism; 5. Pressure monitoring sensor; 6. Sealing test platform; 7. Test pressure sensor; 801. First interface connecting pipe; 802. Second interface connecting pipe; 9. Pressure cap; 10. Reverse fixing ring; 11. Plug; 12. T-junction transmission block; 13. Test platform; 1301. Cross pressure transmission... 1302. Vertical pressure transmission output interface assembly; 14. Sealing copper ring; 15. Fixing block; 16. Connecting nut; 17. Output conduit; 18. Output pressure cap; 19. Groove O-ring; 20. Sealing plug; 21. Sealing plug head; 22. Pressure interface; 23. Screw; 24. Threaded pressure cap; 25. Insulating gasket; 26. Circuit board; 27. Outlet cable; 28. Connector; 29. ​​Potting compound; 30. Pressure core; 31. Housing. Detailed Implementation

[0040] like Figure 1 , 2 As shown, the high-voltage sensor sealing test system includes:

[0041] Pressure input regulation system 1: Used to provide a stable liquid pressure of 60MPa or higher;

[0042] Pressure transmission sealing mechanism 4: includes a three-way transmission block 12, a first interface connecting pipe 801, and a second interface connecting pipe 802; one port of the first interface connecting pipe 801 is connected to the pressure transmission outlet of the pressure input regulating system 1, and the other port is connected to the pressure transmission inlet of the three-way transmission block 12; one port of the second interface connecting pipe 802 is connected to the pressure transmission outlet of the three-way transmission block 12.

[0043] Pressure monitoring sensor 5: Installed at the sensor assembly port on the upper part of the tee conduction block 12 through the plug 11 to monitor pressure changes in real time and feed them back to the control system;

[0044] Sealing test platform 6: It is equipped with a cross pressure transmission channel 1301 and a multi-channel vertical pressure transmission output interface component 1302 connected to it; the pressure sensor under test 7 is connected to the vertical pressure transmission output interface component 1302 through the pressure interface 22; the inlet of the cross pressure transmission channel 1301 is connected to the other port of the second interface connecting pipe 802;

[0045] Data acquisition and analysis equipment: Sensor performance indicators are calculated using data acquisition cards and least squares analysis software.

[0046] See Figure 1 , 2 As shown in Figure 6, the pressure input regulating system 1 includes a piston pressure gauge 101, a booster 103, and a weight block device 102; the data drive port of the piston pressure gauge 101 is connected to the data transmission port of the weight block device 102; the hydraulic medium transmission port of the weight block device 102 is connected to the second hydraulic medium port of the three-way block in the booster 103 via a second pipeline; the data detection port of the piston pressure gauge 101 is connected to the data transmission port of the manual drive cylinder in the booster 103; the hydraulic medium transmission port of the manual drive cylinder in the booster 103 is connected to the first hydraulic medium port of the three-way block in the booster 103 via a first pipeline; the third hydraulic medium port of the three-way block outputs standard pressure.

[0047] See Figure 3 As shown, the ends of the first interface connecting pipe 801 and the second interface connecting pipe 802 are both tapered; the pressure transmission inlet and pressure transmission outlet of the three-way transmission block 12 are both tapered at the end positions of the first interface connecting pipe 801 and the second interface connecting pipe 802, so as to achieve bidirectional tapered sealing of the hydraulic medium at the connection part.

[0048] See Figure 3 As shown, the other port of the first interface connecting pipe 801 is connected to the pressure transmission inlet of the tee transmission block 12 via the pressure cap 9 and the reverse fixing ring 10 in sequence; one port of the second interface connecting pipe 802 is connected to the pressure transmission outlet of the tee transmission block 12 via the pressure cap 9 and the reverse fixing ring 10 in sequence.

[0049] See Figure 2 , 4 As shown, the vertical pressure transmission output interface assembly 1302 sequentially includes an output pressure cap 18, an output conduit 17, a connecting nut 16, a fixing block 15, and a sealing copper ring 14; a grooved O-ring 19 is provided between the pressure interface 22 of the pressure sensor under test 7 and the upper end of the output conduit 17, and the pressure sensor under test 7 and the upper end of the output conduit 17 are fixedly connected to each other through the output pressure cap 18; the fixing block 15 and the sealing copper ring 14 are respectively sleeved on the lower end of the output conduit 17, and the output conduit 17 is fixedly connected to the test platform 13 through the connecting nut 16.

[0050] See Figure 3 As shown, the ends of both the first interface connecting pipe 801 and the second interface connecting pipe 802 adopt a 74° tapered structure, forming a contact length greater than 3mm with the tee conductive block 12; the surface roughness Ra≤1.6μm; the reverse fixing retaining ring 10 adopts a left-hand thread structure; the outer diameter of the grooved O-ring is 0.5mm larger than the outer diameter of the corresponding slotted output conduit 17. Figure 4 As shown, the sealed copper ring 14 is micro-deformed and sealed by pressing with the connecting nut 16; after the sealed copper ring 14 is installed and sealed, it is fixed and not disassembled, and the grooved O-ring 19 and the connected pressure sensor 7 to be measured are detachable and replaceable.

[0051] See Figure 5 As shown, the pressure sensor 7 to be measured includes a pressure interface 22, an insulating pad 25, a circuit board 26, an outgoing line 27, a connector 28 and a pressure core 30; the circuit board 26 is fixedly connected to the pressure interface 22 through the insulating pad 25; the pressure core 30 is fixedly arranged in the cavity of the pressure interface 22; the data transmission interface of the circuit board 26 is connected to the data transmission interface of the connector 28 through the outgoing line 27.

[0052] See Figure 7 As shown, the dynamic verification method of the above high-pressure sensor sealing test system includes the following steps:

[0053] Step S1: Pressure grading and loading

[0054] a. When the target pressure ≤ 60 MPa, close the first pipeline, and the piston pressure gauge 101 drives the weight block device 102 to output pressure;

[0055] b. When the target pressure > 60 MPa, open the first pipeline, manually drive the oil cylinder to supplement pressure, and make the three-way block output the standard pressure;

[0056] c. Step up the pressure step by step to the target pressure in steps of 10% of the range, and keep the pressure for 30 seconds at each level;

[0057] Step S2: Real-time verification of sealing performance

[0058] a. Keep the pressure for 5 minutes at the target pressure, and record the pressure output value fluctuation Δp through the pressure monitoring sensor 5 and the pressure sensor 7 to be measured;

[0059] b. If Δp / target pressure ≤ 0.05%, determine that the seal is qualified;

[0060] Step S3: Calculation of performance parameters

[0061] a. Collect the output voltage V of the pressure sensor 7 to be measured, and fit the quadratic curve V = a0 + a1P + a2P² by the least squares method; where, P is the input pressure of the pressure sensor 7 to be measured; a0, a1 and a2 are the coefficients to be determined; V is the output voltage of the pressure sensor 7 to be measured; ΔV is the change in the output voltage of the pressure sensor 7 to be measured; ΔP is the change value of the input pressure of the pressure sensor 7 to be measured;

[0062] b. Calculate the sensitivity S = ΔV / ΔP, and the linearity L = max|V - a1P| / full range × 100%.

[0063] The high-pressure sensor sealing test system of the present invention comprises: a pressure input adjustment system 1, a pressure transmission sealing mechanism 4, a sealing test platform 6, a pressure sensor under test 7, and data acquisition and analysis equipment.

[0064] The pressure input regulation system 1 includes a piston pressure gauge 101, a booster 103, and a weight block device 102, mainly providing a stable and reliable test pressure for the high-pressure sensor sealing test system of this invention. This invention utilizes the piston pressure gauge 101 to automatically drive the weight block device 102 for balance, thereby forming a stable hydraulic pressure. The maximum pressure of the piston pressure gauge 101 is 60 MPa. When the pressure exceeds 60 MPa, the booster 103 provides a large pressure output to the pipeline cavity, ensuring the system can provide a test pressure output greater than 60 MPa. The outlet of the piston pressure gauge 101 is connected to the booster 103, and the booster 103 is connected to the weight block device 102. The standard test pressure is output from the upper outlet of the booster 103 via a pipeline converging at the T-junction of the booster 103. See also... Figure 6 As shown, the booster 103 is equipped with a brake handle and a valve. A hydraulic cylinder is installed inside the booster 103. The brake handle drives the hydraulic cylinder to move, providing boosting capacity to the booster 103. The valve is located at the outlet of the manually driven hydraulic cylinder. When the pressure is less than 60MPa, it is in a closed state, and when the pressure is greater than 60MPa, it is turned on.

[0065] The pressure transmission sealing mechanism 4 includes a three-way transmission block 12, an interface connecting pipe, a pressure cap 9, a reverse fixing ring 10, and a plug 11. The pressure transmission sealing mechanism 4 is the connecting device for the pressure output from the booster 103 into the sealing test platform 6. Due to the long distance between the connecting devices, an intermediate connecting three-way transmission block 12 is required for transfer. The sealing structure adopts a metal conical surface for tight compression, forming a high-pressure seal in the connecting pipeline to ensure effective hydraulic pressure output. To ensure the tightness of the conical surface, a reverse fixing ring 10 is installed in the pipeline connection line. The integrity and fixation of the sealing structure are achieved through the locking of the reverse fixing ring 10 and the tightening of the pressure cap 9, thus realizing its high-pressure sealing performance.

[0066] Pressure monitoring sensor 5 is a high-precision pressure sensor that can monitor pressure changes within the test chamber in real time and transmit the data to the control system for timely data analysis and pressure adjustment. The measurement range and accuracy of pressure monitoring sensor 5 should be appropriately selected based on the testing requirements.

[0067] See Figure 2 , 4As shown, the sealing test platform 6 includes a test platform 13, an output conduit 17, a connecting nut 16, a sealing copper ring 14, a fixing block 15, an output pressure cap 18, a grooved O-ring 19, a sealing plug 20, and a sealing end 21. The sealing test platform 6 is connected to the pressure transmission sealing mechanism 4, introducing pressure into the test platform 13. Through structural design, the test platform 13 forms nine vertical pipeline interfaces to output pressure, which are then connected to the pressure sensor 7 under test for testing. The sealing part is divided into three parts: the pressure interface inlet seal uses a conical sealing surface for compression; the nine vertical outlet sections use a reverse compression method with the sealing copper ring 14 for a fixed seal; the test connection of the pressure sensor 7 under test uses a replaceable high-hardness grooved O-ring seal; and the platform process holes use threaded tightening followed by welding to ensure high-pressure sealing and strength.

[0068] The pressure sensor 7 under test comprises several parts, including a pressure interface 22, a screw 23, a threaded cap 24, an insulating pad 25, a circuit board 26, a lead wire 27, a connector 28, potting compound 29, a pressure core 30, and a housing 31. The pressure sensor 7 measures pressure values ​​exceeding 60 MPa. The pressure core 30 senses the chamber pressure, acquires the pressure signal, and converts the acquired pressure signal into the required output signal through external circuitry. Structurally, the pressure core 30 and the threaded cap 24, tightened by two layers of threads, ensure the structural strength and stability of the ultra-high pressure liquid transmission process. The pressure core 30 is welded to ensure the sealing of the high-pressure liquid, and the double-layer threads work together to increase the overall structural strength. The pressure interface 22 is connected to the sealing test platform 6 to introduce the cavity pressure into the pressure core 30. The output line 27 is partially connected to the circuit board 26. Through compensation circuit, analog-to-digital conversion, and amplification circuit, the weak electrical signal output by the pressure core 30 is processed and converted into a voltage value suitable for reading and analysis by the test instrument. The signal is then output through the output line 27 and connector 28. The insulating pad 25 isolates the threaded cap 24 and the circuit board 26, providing insulation. The double-layer circuit board 26 is connected and fixed to the pressure interface 22 by screws 23.

[0069] The data acquisition and analysis equipment employs a high-precision data acquisition card and data analysis software to collect sensor output signals and parameters during the testing process in real time. It then analyzes and processes these signals to calculate various sensor performance indicators, such as sensitivity, accuracy, and linearity. The data analysis software features data storage, graphing, and report generation functions, facilitating the recording and analysis of test results by operators.

[0070] In its specific design, the high-pressure sensor sealing test system of this invention includes: a pressure input regulation system 1, a pressure transmission sealing mechanism 4, a pressure monitoring sensor 5, a sealing test platform 6, a pressure sensor under test 7, and data acquisition and analysis equipment.

[0071] The piston pressure gauge 101 and the weight block device 102 can provide a test pressure below 60MPa; when the pressure exceeds 60MPa, the booster 103 needs to be activated; the first pipeline of the booster 103 is connected to the piston pressure gauge 101 to provide pressurized oil to the cylinder of the booster 103, and the second pipeline of the booster 103 is connected to the three-way block of the booster 103 to provide a pressure below 60MPa. The two hydraulic pipelines converge in the three-way block of the booster 103 and output the standard test pressure from the upper outlet of the booster 103. The piston pressure gauge 101 and the weight block device 102 are connected via a data cable. When the set pressure is less than 60 MPa, the first pipeline at the booster 103 is closed, and the piston pressure gauge 101 directly drives the weight block device 102 to provide test pressure fluid. This fluid, through a three-way valve, outputs the standard test pressure from the upper outlet of the booster 103. When the set pressure is greater than 60 MPa, exceeding the pressure range provided by the piston pressure gauge 101, the first pipeline of the booster 103 opens via a valve. The brake handle is manually activated, driving the manual cylinder to provide pressurized fluid. This, together with the second pipeline, drives the weight block device 102 to balance the pressure. The combined pressure exceeding 60 MPa is then output as standard test pressure fluid from the upper outlet of the booster 103. The connection between the first and second pipelines uses a conical surface seal, achieved by tightening a pressure cap.

[0072] The pressure transmission sealing mechanism 4 includes a three-way transmission block 12 and an interface connection pipe (see...). Figure 3The system includes a first interface connecting pipe 801, a second interface connecting pipe 802, a pressure cap 9, a reverse fixing retaining ring 10, and a plug 11. The three-way conductive block 12 is used when the liquid pressure transmission distance exceeds 500mm. The three-way conductive block 12 has holes at both horizontal ends, which are connected, serving as the inlet and outlet respectively. The inlet and outlet are sealed with 74° conical seals, requiring a surface roughness greater than 1.6μm. The three-way conductive block 12 has a hole at its upper vertical direction for placing a pressure monitoring sensor 5. On the three-way conductive block 12 without the pressure monitoring sensor 5, a plug 11 is screwed in for sealing. The three conical holes in the horizontal and vertical directions of the three-way conductive block 12 are all provided with internal threads for tightening the pressure cap 9. The interface connecting pipe is a slender steel pipe with 74° conical structures at both ends, and both ends are provided with left-hand threads to place the reverse fixing retaining ring 10. When the pressure cap 9 is tightened... The three-way conductive block 12 has a tapered length less than that of the interface connecting pipe, ensuring a tapered contact length greater than 3mm. The pressure cap 9 is threaded, with an inner hole at the threaded end. The hole diameter is larger than the outer diameter of the fixing retaining ring 10, and it has a shoulder to lock the fixing retaining block 10. The fixing retaining ring 10 adopts a left-hand thread design and is fixed to the interface connecting pipe. The pressure cap 9 passes through the reverse fixing retaining ring 10 and is locked at the shoulder, pressing it tightly against the three-way conductive block 12. This left-hand thread design effectively prevents the reverse fixing retaining ring 10 from loosening after the pressure cap 9 is tightened, ensuring a tight fit of the tapered opening and achieving a sealing effect. The plug 11 is connected to the upper end of the three-way conductive block 12. When the pressure monitoring sensor 5 is not installed, the plug 11 is used to block the upper end of the three-way conductive block 12 to ensure a seal. The interface connecting pipe and the three-way conductive block 12 are made of two different hardness stainless steel materials to ensure the reliability of the hard seal.

[0073] A standard high-precision pressure monitoring sensor 5 is installed at the output end of the pressure transmission sealing mechanism 4, before connecting to the sealing test platform 6. This sensor monitors changes in liquid pressure within the pipeline chamber and transmits the data to the control system for timely data analysis and adjustment. The measurement range and accuracy of the pressure monitoring sensor 5 should be appropriately selected based on different test pressures.

[0074] The sealing test platform 6 includes a test platform 13, an output conduit 17, a connecting nut 16, a sealing copper ring 14, a fixing block 15, an output pressure cap 18, a support, and bolt plugs. The sealing test platform 6 is a 260mm x 260mm square platform with four intersecting channels inside and nine liquid pressure outlets in the vertical direction for connecting to the pressure sensor 7 under test. The pressure inlet end uses a conical compression sealing structure of the pressure transmission sealing connection mechanism 4. The four channels are interconnected inside the platform, and the ends are sealed by argon arc welding after tightening with sealing plugs 21, using the same material as the platform. The nine outlets in the vertical direction use a hard seal. The bottom plane of the platform's inner bore is grooved, and a sealing copper ring 14 is installed, with the groove depth less than the copper ring wire diameter. One end of the output conduit 17 connects to the square platform, and the other end connects to the pressure sensor 7 under test. The diameters of the output pressure cap 18 and the connecting nut 16 are both larger than the outer diameter of the output conduit 17. After the output cap 18 and connecting nut 16 are successively fitted onto the output conduit 17, the fixing block 15 is threadedly connected to the output conduit 17 for locking. The sealing copper ring 14 is pressed between the connecting nut 16 and the inner hole of the square platform to achieve sealing and transfer of the nine outlets. The test end of the interface with the pressure sensor 7 under test uses a slotted O-ring 19 made of nitrile material with a hardness greater than 90 and a wire diameter of 3mm. The slot depth of the slotted O-ring 19 in the output conduit 17 is 2.5mm, and the outer diameter of the slot is 0.5mm smaller than the outer diameter of the slotted O-ring 19. The output cap 18 is pressed tightly with the pressure sensor 7 under test to achieve sealing. The slotted O-ring 19 seal here can ensure high-pressure test use and has easy disassembly and replaceability. The nine output interfaces of the sealing test platform of this invention employ layered sealing. The first layer consists of a sealing copper ring 14, which is tightened by a connecting nut to create a micro-deformation seal. The second layer consists of a sealing ring (nitrile O-ring) with a hardness >90, embedded in a matching groove with a depth of 2.5mm, and tightened by an output cap 18. Specifically, for the first seal, pressure is introduced through the output conduit 17, tightened by the connecting nut 16, and blocked by the fixing block 15, pressing the sealing copper ring 14 against the bottom plane of the nine holes of the test platform 13. The deformation of the sealing copper ring 14 achieves a seal. For the second seal, a grooved O-ring 19 is placed on the upper plane of the output conduit 17, connected to the pressure interface 22 of the pressure sensor 7 under test via the output cap 18, forming an output seal. Finally, pressurized liquid is introduced into the pressure sensor 7 under test for testing.

[0075] The pressure sensor under test 7 includes a pressure interface 22, a pressure core 30, a threaded cap 24, an insulating pad 25, a circuit board 26, a housing 31, a connector 28, and potting compound 29. The pressure core 30 for high-pressure testing in the pressure sensor 7 is selected according to performance indicators. The outer diameter of the pressure core 30 adopts a partially coarse-threaded structure, which is threaded to the pressure interface 22. The top surface of the pressure core 30 is flush with the threaded contact surface of the pressure interface 22. Electron beam welding is used to ensure sealing and meet high-pressure requirements. The inner diameter of the threaded cap 24 is smaller than the outer diameter of the pressure core 30. The threaded cap 24 is screwed into the pressure interface to compress the pressure core 30, increasing the strength of the high-pressure structure. The insulating pad 25 is installed between the circuit board 26 and the threaded cap 24, and has a certain height to provide insulation. The inner ring of the threaded cap 24 has holes for easy wire exit; the pressure interface 22 has three small threaded holes around its perimeter, and the circuit board 26 is tightened to the pressure interface 22 with insulated PTFE screws to fix the circuit board 26 onto the pressure interface 22; the circuit board 26 is equipped with a compensation resistor, an analog-to-digital conversion module, and an amplifier circuit to process the electrical signal output from the pressure core 30, convert it into the voltage value required for reading and analysis by the testing instrument, and lead it out through transmission lines and connectors; the housing 31 is screwed into the pressure interface 22, and colloid 29 is injected from the connector 28 port to provide insulation; the connector 28 is connected to the housing 31 by screws.

[0076] Data acquisition and analysis equipment employs high-precision data acquisition cards and data analysis software to collect sensor output signals and parameters during the testing process in real time. It typically uses the least squares method to analyze and process the acquired pressure signal data, calculating various sensor performance indicators such as sensitivity, accuracy, and linearity. The data analysis software should have functions such as data storage, graphing, and report generation to facilitate operators in recording and analyzing test results.

[0077] Data acquisition involved testing three 70MPa pressure transmitters powered by 24V and accessed via a 485 bus. A least-squares table was used. The test temperature for each pressure transmitter was 25℃ (indoor air conditioning). A high-pressure sensor sealing test system was employed at atmospheric pressure (102.677 kPa), and three rounds of forward and reverse stroke tests were performed. The static characteristic calculation results from the floating-point tests are as follows:

[0078]

[0079]

[0080]

[0081] measured data

[0082]

[0083] The content of this invention is not limited to the embodiments listed. Any equivalent modifications made by those skilled in the art to the technical solutions of this invention by reading this specification are covered by the claims of this invention.

Claims

1. A high-pressure sensor sealing test system, characterized in that, include: Pressure input regulation system (1): used to provide a stable liquid pressure of 60MPa or higher; Pressure transmission sealing mechanism (4): includes a three-way transmission block (12), a first interface connecting pipe (801), and a second interface connecting pipe (802); one port of the first interface connecting pipe (801) is connected to the pressure transmission outlet of the pressure input regulating system (1), and the other port is connected to the pressure transmission inlet of the three-way transmission block (12); one port of the second interface connecting pipe (802) is connected to the pressure transmission outlet of the three-way transmission block (12); Pressure monitoring sensor (5): The sensor assembly port installed on the upper part of the tee conduction block (12) at the plug (11) is used to monitor pressure changes in real time and feed them back to the control system. Sealing test platform (6): It is equipped with a cross pressure transmission channel (1301) and a multi-channel vertical pressure transmission output interface assembly (1302) connected to it; the pressure sensor under test (7) is connected to the vertical pressure transmission output interface assembly (1302) through the pressure interface (22); the inlet of the cross pressure transmission channel (1301) is connected to the other port of the second interface connecting pipe (802); Data acquisition and analysis equipment: Sensor performance indicators are calculated using data acquisition cards and least squares analysis software.

2. The high-voltage sensor sealing test system according to claim 1, characterized in that: The pressure input regulation system (1) includes a piston pressure gauge (101), a booster (103), and a weight block device (102); the data drive port of the piston pressure gauge (101) is connected to the data transmission port of the weight block device (102); the hydraulic medium transmission port of the weight block device (102) is connected to the second hydraulic medium port of the three-way block in the booster (103) via a second pipeline; the data detection port of the piston pressure gauge (101) is connected to the data transmission port of the manual drive cylinder in the booster (103); the hydraulic medium transmission port of the manual drive cylinder in the booster (103) is connected to the first hydraulic medium port of the three-way block in the booster (103) via a first pipeline; the third hydraulic medium port of the three-way block outputs standard pressure.

3. The high-voltage sensor sealing test system according to claim 1, characterized in that: The ends of the first interface connecting pipe (801) and the second interface connecting pipe (802) are both tapered; the pressure transmission inlet and pressure transmission outlet of the three-way transmission block (12) are both tapered at the end positions of the first interface connecting pipe (801) and the second interface connecting pipe (802) to achieve bidirectional cone angle hard seal of the hydraulic medium at the connection part.

4. The high-voltage sensor sealing test system according to claim 2, characterized in that: The other port of the first interface connecting pipe (801) is connected to the pressure transmission inlet of the three-way transmission block (12) through the pressure cap (9) and the reverse fixing ring (10) in sequence; the other port of the second interface connecting pipe (802) is connected to the pressure transmission outlet of the three-way transmission block (12) through the pressure cap (9) and the reverse fixing ring (10) in sequence.

5. The high-voltage sensor sealing test system according to claim 4, characterized in that: The vertical pressure conduction output interface component (1302) sequentially includes an output pressure cap (18), an output conduit (17), a connecting nut (16), a fixed stop block (15), and a sealing copper ring (14); a grooved O-ring (19) is provided between the pressure interface (22) of the pressure sensor under test (7) and the upper end of the output conduit (17), and the pressure sensor under test (7) and the upper end of the output conduit (17) are fixedly docked with each other through the output pressure cap (18); the fixed stop block (15) is sleeved on the lower end of the output conduit (17), and the output conduit (17) is fixedly connected to the test platform (13) through the connecting nut (16) and the sealing copper ring (14).

6. The high-voltage sensor sealing test system according to claim 5, characterized in that: The ends of the first interface connecting pipe (801) and the second interface connecting pipe (802) both adopt a 74° conical structure, forming a contact length greater than 3 mm with the three-way conduction block (12), and the three-way conduction block (12), the first interface connecting pipe (801), and the second interface connecting pipe (802) are made of stainless steel with different hardnesses; the surface roughness Ra≥1.6 μm; the reverse fixed retaining ring (10) adopts a left-handed thread structure; the outer diameter of the grooved O-ring (19) is 0.5 mm larger than the outer diameter of the corresponding output conduit (17) with a groove.

7. The high-voltage sensor sealing test system according to claim 6, characterized in that: The pressure sensor under test (7) includes a pressure interface (22), an insulating pad (25), a circuit board (26), an outgoing line (27), a connector (28), and a pressure core body (30); the circuit board (26) is fixedly connected to the pressure interface (22) through the insulating pad (25); the pressure core body (30) is fixedly arranged in the cavity of the pressure interface (22); the data transmission interface of the circuit board (26) is connected to the data transmission interface of the connector (28) through the outgoing line (27).

8. A dynamic verification method using the high-voltage sensor sealing test system as described in any one of claims 1 to 7, characterized in that, It includes the following steps: Step S1: Pressure分级加载 a. When the target pressure ≤ 60 MPa, close the first pipeline, and the piston pressure gauge (101) drives the weight block device (102) to output pressure; b. When the target pressure > 60 MPa, open the first pipeline, manually drive the oil cylinder to supplement pressure, and make the three-way block output the standard pressure; c. Step up the pressure step by step to the target pressure in steps of 10% of the range, and keep the pressure for 30 seconds at each level; Step S2: Real-time verification of sealing performance a. Keep the pressure for 5 minutes at the target pressure, and record the pressure output value fluctuation Δp through the pressure monitoring sensor (5) and the pressure sensor under test (7); b. If Δp / target pressure ≤ 0.05%, it is determined that the seal is qualified; Step S3: Calculation of performance parameters a. Collect the output voltage V of the pressure sensor under test (7), and fit the quadratic curve V = a0 + a1P + a2P² by the least squares method; where, P is the input pressure of the pressure sensor under test (7); a0, a1, and a2 are the coefficients to be determined; V is the output voltage of the pressure sensor under test (7); ΔV is the change in the output voltage of the pressure sensor under test (7); ΔP is the change value of the input pressure of the pressure sensor under test (7); b. Calculate the sensitivity S = ΔV / ΔP, and the linearity L = max|V - a1P| / full range × 100%.

9. The dynamic verification method for the high-voltage sensor sealing test system according to claim 8, characterized in that: In step S2, step b, a dual-channel comparison is used. Channel A: the pressure value p1 output by the pressure sensor (7) under test; Channel B: the pressure value p2 output by the pressure monitoring sensor (5). If |p1-p2| continues to increase and the rate of change is >0.1MPa / s, the seal is determined to be faulty.

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