A kind of alcohol sprayer flow test test bench and test method

Abstract

The application discloses a kind of alcohol sprayer flow test test bench and test method, it is related to alcohol sprayer test field, including methanol tank, methanol tank is connected to alcohol rail by methanol pump unit, the outlet of alcohol rail is used to connect the import of alcohol sprayer by valve;Flow test station can install alcohol sprayer, the import of mass flowmeter is used to be communicated with the outlet of alcohol sprayer located on flow test station, the outlet of mass flowmeter is communicated with the backflow port of methanol tank;Dynamic sealing test station includes sealing cover, sealing cover has the installation port of alcohol sprayer, installation port is sealed by sealing ring on alcohol sprayer, the outlet of alcohol sprayer is located in sealing cover, sealing cover is communicated with methanol tank by pneumatic ball valve in;Sealing cover is provided with at least pressure sensor, temperature sensor.The application is realized from methanol supply, temperature control, cycle filtration to data record full-process automation by the design of automatic test procedure, greatly shorten test cycle, reduce manpower cost.

Description

Technical Field

[0001] This invention relates to the field of alcohol sprayer testing, and in particular to an alcohol sprayer flow rate testing bench and testing method. Background Technology

[0002] With increasing environmental awareness and adjustments to the energy structure, methanol fuel, as a clean and renewable energy source, has seen continuous growth in market demand. As the core component of the methanol fuel engine, the performance of the methanol injector directly affects the accuracy and uniformity of fuel injection, as well as the overall engine efficiency and emission characteristics. Therefore, the technical specifications of methanol fuel injection systems, such as the methanol injector, also need to meet market and environmental requirements.

[0003] Existing methods for testing the performance of methanol injectors mostly rely on simple flow measurement devices, which often fail to comprehensively and accurately reflect the actual performance of methanol injectors under different operating conditions. Furthermore, the testing process is often time-consuming and involves a large amount of manual intervention. Therefore, a digital methanol injector testing technology and system is needed to support the technological development of methanol injectors in the methanol engine industry. Summary of the Invention

[0004] The purpose of this invention is to address the aforementioned problems by providing a methanol sprayer flow test bench and test method. Through the design of an automated test process, the entire process from methanol supply, temperature control, circulation filtration to data recording is automated, significantly shortening the test cycle and reducing labor costs.

[0005] The technical solution adopted in this invention is as follows: a methanol sprayer flow test bench, including a methanol tank, a flow test station and a dynamic sealing test station, wherein the outlet of the methanol tank is connected to the inlet of the methanol rail through a methanol pump unit, and the outlet of the methanol rail is connected to the inlet of the methanol sprayer through a valve.

[0006] The flow test station is used to install the alcohol sprayer and also includes a mass flow meter. The inlet of the mass flow meter is connected to the outlet of the alcohol sprayer located at the flow test station, and the outlet of the mass flow meter is connected to the reflux port of the methanol tank.

[0007] The dynamic sealing test station includes a sealing cover with an installation port for the alcohol injector. The installation port is sealed by a sealing ring on the alcohol injector. The outlet of the alcohol injector is located inside the sealing cover, and the inside of the sealing cover is connected to the methanol tank through a pneumatic ball valve. The sealing cover is equipped with at least a pressure sensor and a temperature sensor to obtain the pressure inside the sealing cover.

[0008] A proportional regulating valve is installed between the methanol pump unit and the methanol rail; the inlet of the accumulator is connected to the methanol rail through a shut-off valve, and the outlet of the accumulator is connected to the methanol tank through a safety valve.

[0009] Furthermore, the outlet of the methanol pump unit is connected in parallel with a pressure relief branch, which is connected to the interior of the methanol tank through a safety valve.

[0010] Furthermore, it also includes a water bath heat conduction system, which includes a water tank, a heater located in the water tank, and a heat exchange tube located in the methanol tank. The outlet of the water tank is connected to the inlet of the heat exchange tube via a heating water pump, and the outlet of the heat exchange tube is connected to the interior of the water tank. A first temperature sensor is installed in the methanol tank, and a second temperature sensor is installed in the water tank. Both the first and second temperature sensors are connected to the input terminal of a first sub-controller, and the output terminal of the first sub-controller is connected to the heater.

[0011] Furthermore, it also includes a flushing system, which includes a flushing tank; the outlet of the flushing tank is connected to the inlet of the methanol pump unit through a pneumatic ball valve, and flushing return branches are provided at the methanol rail, the inlet of the pneumatic ball valve between the sealing cover and the methanol tank, and the inlet of the pneumatic ball valve between the mass flow meter and the methanol tank. The outlet of the flushing return branch is connected to the inside of the flushing tank; the waste outlet of the flushing tank is connected to the wastewater pool through a flushing water pump.

[0012] Furthermore, it also includes a circulating filtration system, which includes a circulating pump, the inlet of which is connected to the inside of a new alcohol tank and / or a methanol tank, the outlet of which is connected to a waste alcohol tank and / or a methanol tank, and a filter assembly is provided at the outlet of the circulating pump.

[0013] Furthermore, in the circulating filtration system, a cooler is installed downstream of the filter assembly.

[0014] Furthermore, it also includes an air system, which includes an air source connected to the inlet of a pneumatic switch. The outlet of the pneumatic switch is connected to an alcohol sprayer inside a sealed cover via a shut-off valve and a pneumatic ball valve. The pneumatic switch is connected to all pneumatic ball valves via a solenoid valve.

[0015] Furthermore, it also includes a methanol gas-liquid converter, the inlet of which is connected to the interior of the methanol tank, and the outlet of which is equipped with an explosion-proof flame arrester; and the installation space of the methanol gas-liquid converter is higher than that of the methanol tank.

[0016] Furthermore, the methanol gas-liquid converter is a heat exchanger, and the heat exchanger is connected to an external cold source.

[0017] Furthermore, a filter group is provided in the direction of methanol flow, and all filter groups include at least two filters connected in series, with the filter precision gradually increasing along the direction of methanol flow.

[0018] A method for testing the flow rate of an alcohol injector, using the aforementioned alcohol injector flow rate testing test bench, includes a flow rate test and a dynamic sealing test, wherein:

[0019] S1: The flow test includes steps S11-S14;

[0020] S11: Install an alcohol sprayer at the flow test station. The inlet of the alcohol sprayer is connected to the alcohol track, and the outlet of the alcohol sprayer is connected to the mass flow meter.

[0021] S12: Start the methanol pump unit. The methanol pump unit draws methanol from the methanol tank and delivers the methanol to the methanol rail. In this step, the methanol pressure in the methanol rail is adjusted by the proportional regulating valve and stabilized by the accumulator.

[0022] S13: Methanol in the methanol track enters the methanol injector, and the methanol injected by the methanol injector enters the mass flow meter. The mass flow meter obtains the mass of methanol injected by the corresponding methanol injector per unit time.

[0023] S14: Methanol passing through the mass flow meter flows back into the methanol tank through the return port on the methanol tank.

[0024] S2: Dynamic sealing test includes steps S21-S26;

[0025] S21: Install a methanol injector at the dynamic sealing test station. The inlet of the methanol injector is connected to the methanol rail, and the outlet of the methanol injector is located inside the sealing cover. Close the pneumatic ball valve between the sealing cover and the methanol tank.

[0026] S22: Start the methanol pump unit, which draws methanol from the methanol tank and delivers it to the methanol rail; in this step, the methanol pressure in the methanol rail is adjusted by the proportional control valve and stabilized by the accumulator; or the methanol in the methanol rail from step S12 is used.

[0027] S23: Methanol in the alcohol track enters the alcohol injector, and the methanol sprayed out by the alcohol injector enters the sealing cover until the pressure inside the sealing cover reaches the preset pressure value.

[0028] S24: Block the flow of methanol between the methanol track and the methanol injector;

[0029] S25: Observe whether the pressure value of the pressure sensor installed on the sealing cover changes. If it does not change, the dynamic sealing performance is qualified; if it changes, the dynamic sealing performance is unqualified.

[0030] S26: Open the pneumatic ball valve between the sealing cover and the methanol tank, and the methanol in the sealing cover will flow back into the methanol tank through the pneumatic ball valve.

[0031] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0032] This invention achieves full automation from methanol supply, temperature control, circulation filtration to data recording by conducting systematic tests on the methanol injection flow rate and sealing performance of the methanol injector, which significantly shortens the testing cycle and reduces labor costs. Attached Figure Description

[0033] The present invention will be described by way of example and with reference to the accompanying drawings, wherein:

[0034] Figure 1 This is a partial schematic diagram of the test bench disclosed in this invention;

[0035] Figure 2 This is another part of the schematic diagram of the test bench disclosed in this invention;

[0036] Figure 3 This is a schematic diagram of an air system.

[0037] Figure 4 A schematic diagram of a structure for mounting an alcohol sprayer on a sealing cover;

[0038] The diagram shows the following markings: 1-Methanol tank; 2-Methanol pump unit; 3-Accumulator; 4-Filter; 5-Proportional control valve; 6-Pneumatic ball valve; 7-Methanol rail; 8-Stop valve; 9-Flow test station; 10-Mass flow meter; 11-Dynamic seal test station; 12-Safety valve; 13-Level sensor; 14-Water tank; 15-Heater; 16-Heating water pump; 17-Cooler; 18-Heat exchange tube; 19-Circulation pump; 20-Methanol-water concentration detector; 21-Rinsing tank; 22-Rinsing water pump; 23-Methanol gas-liquid converter; 24-Explosion-proof flame arrester; 25-Pneumatic switch; 26-Sealing ring; 27-Sealing cover. Detailed Implementation

[0039] In the description of this specification, it should be noted that if terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," or "outer" appear to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product is in use, they are only for the convenience of describing this specification and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this specification.

[0040] Furthermore, the use of terms such as "horizontal" or "vertical" in this specification does not imply that the component must be absolutely horizontal or suspended, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0041] In the description of this specification, it should also be noted that, unless otherwise expressly specified and limited, the terms “set up,” “install,” “connect,” and “link” should be interpreted broadly. For example, a link can be a fixed link, a detachable link, or an integral link; it can be a mechanical link or an electrical link; it can be a direct link or an indirect link through an intermediate medium; it can be a connection within two components.

[0042] It should be noted that, for the sake of clarity in the disclosed schematic diagram, the schematic diagram of this invention has been divided into... Figure 1 , Figure 2 ;exist Figures 1-2 middle, Figure 1 "Connection I port" and Figure 2 Connect "I port" in the diagram; similarly, connect "II port" to "II port"; connect "III port" to "III port".

[0043] Example 1

[0044] like Figures 1-4 As shown, a methanol sprayer flow test bench includes a methanol tank 1, a flow test station 9, and a dynamic sealing test station 11. The outlet of the methanol tank 1 is connected to the inlet of the methanol rail 7 via a methanol pump unit 2. The outlet of the methanol rail 7 is connected to the inlet of the methanol sprayer via a valve.

[0045] In this embodiment, the flow test station 9 has 6 stations, which can simultaneously test the flow of 6 alcohol injectors; the dynamic seal test station 11 has 1 station; the alcohol rail 7 is connected to the alcohol injector on the flow test station 9 through a shut-off valve 8, which can be a solenoid valve and can be opened and closed by the control assembly; the alcohol rail 7 is connected to the alcohol injector on the dynamic seal test station 11 through a pneumatic ball valve 6, which can be opened and closed by the air pressure provided by the subsequent air system.

[0046] In this embodiment, the methanol rail 7 can actually be made of seamless stainless steel tubing or a pressure vessel. Its pressure rating is 14 MPa, and its volume is 28 L. Combined with the outlet valves (stop valve 8 and pneumatic ball valve 6), it can effectively reduce methanol leakage and evaporation.

[0047] In this embodiment, the flow test station 9 is used to install the methanol injector and also includes a mass flow meter 10. The inlet of the mass flow meter 10 is connected to the outlet of the methanol injector located on the flow test station 9, and the outlet of the mass flow meter 10 is connected to the return port of the methanol tank 1 through a pneumatic ball valve 6. The mass flow meter 10 can be connected to the control assembly to obtain the flow rate of methanol injected by the methanol injector.

[0048] In this embodiment, a temperature sensor and a pressure sensor can be installed on the methanol rail 7 or at the inlet of the methanol rail 7 to obtain the temperature and pressure of the methanol entering the methanol rail 7.

[0049] In this embodiment, the dynamic sealing test station 11 includes a sealing cover 27. The sealing cover 27 has an installation port for the alcohol injector. The installation port is sealed by a sealing ring 26 on the alcohol injector. Specifically, a pressure plate can be installed on the outer surface of the sealing cover 27. One end of the pressure plate is connected to the surface of the sealing cover 27 by a screw, and the other end of the pressure plate presses against the alcohol injector to achieve a tight installation. The outlet of the alcohol injector is located inside the sealing cover 27, and the sealing cover 27 is connected to the methanol tank 1 via a pneumatic ball valve 6. The sealing cover 27 has a pressure sensor and a temperature sensor. The pressure sensor is used to obtain the pressure inside the sealing cover 27, and the temperature sensor is used to obtain the temperature of the methanol entering the sealing cover 27. By observing whether the pressure value of the pressure sensor on the sealing cover 27 changes, if the pressure value decreases, it indicates a leak, meaning the dynamic sealing performance of the alcohol injector is unqualified; conversely, if the pressure value increases, the dynamic sealing performance of the alcohol injector is qualified.

[0050] In this embodiment, a filter assembly and a proportional control valve 5 are connected in series between the methanol pump unit 2 and the methanol rail 7, along the flow direction of the methanol liquid; wherein:

[0051] The filter assembly includes two filters 4, one of which has a filtration accuracy of 10μm and the other has a filtration accuracy of 5μm. The filtration accuracy gradually increases, which can ensure the filtration accuracy while reducing the filtration intensity that the filter 4 has to bear.

[0052] The proportional control valve 5 is a pneumatically controlled pressure proportional control valve 5, which can form a pressure control closed loop with the pressure sensor in the alcohol rail 7. Therefore, the valve core of the proportional control valve 5 can be adaptively adjusted during the test to ensure that the pressure in the alcohol rail 7 tends to the set pressure value.

[0053] In this embodiment, pressure fluctuations will occur in the methanol rail 7 and pipeline during the methanol injector test. These pressure fluctuations mainly originate from the flow pulsation of the methanol pump unit 2, the valve core control of the proportional regulating valve 5, and the opening and closing of the valve core during methanol injection. The pressure fluctuations caused by these factors will affect the normal methanol injection of the injector, resulting in inaccurate measurement of the methanol injection volume. Therefore, it is necessary to effectively control the pressure fluctuations. Specific control schemes include at least the following:

[0054] 1. Methanol pump unit 2 adopts a high-speed, small-displacement plunger high-pressure oil pump, which not only has excellent adaptability to methanol and water media, but also has a unique plunger and valve body structure and processing technology that enables it to reach a rated speed of 1740 rpm. Under the premise of meeting the working conditions, it can minimize the pressure fluctuation interference caused by the pulsation of the pump source flow.

[0055] 2. A pressure relief branch is connected in parallel at the outlet of the methanol pump unit 2. This pressure relief branch is connected to the interior of the methanol tank 1 through a safety valve 12 to release excessive pressure fluctuations and excess methanol pumped by the methanol pump unit 2. This transforms the large pressure fluctuations in the methanol rail 7 and pipeline into smaller pressure fluctuations caused by valve core vibration when the safety valve 12 reaches its critical value on the pressure relief branch. The following measures can be taken to address the pressure fluctuations caused by the safety valve 12: The safety valve 12 should be a valve core structure product with a lead design, which can improve the stability of the safety valve 12 pressure setting and prevent valve core eccentricity from causing system malfunctions. The pressure setting of the safety valve 12 should be slightly higher than the methanol pressure inside the methanol rail 7 required for normal methanol injection by the injector (20 bar). A pressure sensor can be installed at the inlet of the safety valve 12 to monitor the pressure value.

[0056] Third, an accumulator 3 is installed on the methanol rail 7. Specifically, the inlet of the accumulator 3 is connected to the methanol rail 7 through a shut-off valve 8, and the outlet of the accumulator 3 is connected to the inside of the methanol tank 1 through a safety valve 12. The pressure fluctuation is eliminated by the energy absorption and release of the accumulator 3 and the volume elasticity of the liquid in the methanol rail 7.

[0057] In summary, these three pressure fluctuation control schemes comprehensively stabilize the pressure fluctuations generated during the alcohol sprayer flow test, achieving pressure fluctuation control within ±0.03MPa at a pressure of 1MPa, within ±0.1MPa at a pressure of 5MPa, and within ±0.15MPa at a pressure of 10MPa.

[0058] In this embodiment, all the pressure and temperature sensors mentioned above can be connected to the control assembly to obtain the temperature and pressure at the corresponding locations, thereby achieving automated testing and data acquisition. All the shut-off valves 8 mentioned above can be solenoid valves, and electrically powered devices such as methanol pump unit 2 can be used as actuators and connected to the output of the control assembly to achieve automated control.

[0059] Specifically, the flow test bench for this alcohol sprayer is preferably connected to the control assembly to avoid manual operation and thus prevent alcohol poisoning incidents. After the control assembly is connected, the control assembly controls the opening of the proportional regulating valve 5 based on the pressure data obtained by the pressure sensor on the alcohol rail 7, thereby controlling the pressure of the alcohol liquid in the alcohol rail 7.

[0060] Example 2

[0061] Based on Example 1, further feasible implementation methods are proposed.

[0062] One feasible implementation further includes a water bath heat conduction system, which includes a water tank 14, a heater 15 located within the water tank 14, and a heat exchange tube 18 located within a methanol tank 1. The outlet of the water tank 14 is connected to the inlet of the heat exchange tube 18 via a heating water pump 16, and the outlet of the heat exchange tube 18 communicates with the interior of the water tank 14. A first temperature sensor is installed inside the methanol tank 1, and a second temperature sensor is installed inside the water tank 14. Both the first and second temperature sensors are connected to the input terminal of a first sub-controller, and the output terminal of the first sub-controller is connected to the heater 15. 5. The water in the water tank 14 is heated, and the heated water is then pumped by the heating water pump 16 to the heat exchange tube 18 to exchange heat with the methanol in the methanol tank 1 to maintain the temperature of the methanol. This temperature maintenance is achieved by two temperature sensors: a first temperature sensor located in the methanol tank 1 and a second temperature sensor located in the water tank 14. They work together to ensure that the water temperature is sufficient to maintain the methanol temperature. The water temperature is also controlled by adjusting the power of the heater 15 according to the methanol temperature, thereby improving the stability of the methanol temperature and regulating the reaction rate. This allows for a temperature rise range of 2℃ to 60℃ in the methanol tank 1, and ensures a temperature holding capability of ±2℃.

[0063] It should be noted that the water bath heat conduction system is mainly used to heat the methanol liquid in methanol tank 1. Due to the physical characteristics of methanol, it is specially designed with an external heat source and circulating heat conduction to effectively prevent dangerous sources such as static electricity, strong current and local high temperature from igniting the methanol in methanol tank 1, thus avoiding safety hazards to the test bench and personnel.

[0064] Of course, the inlet of the water tank 14 can be connected to an external water source, and a Y-type filter 4 is installed at the inlet to filter impurities in the water; a pressure sensor can be installed at the outlet of the heating water pump 16, and the pressure sensor is connected to the first sub-controller to detect the water pressure and prevent excessive pressure from causing a physical explosion.

[0065] Furthermore, in this embodiment, the first sub-controller is used to control the temperature of the alcohol liquid in the methanol tank 1; when a control assembly is connected, the first sub-controller is also integrated into the control assembly. The control assembly obtains the temperature of the alcohol liquid in the sealing cover 27 and the alcohol rail 7, and feeds back to control the first sub-controller to adjust the temperature of the alcohol liquid in the methanol tank 1 to ensure that the temperature of the alcohol liquid in the sealing cover 27 and the alcohol rail 7 meets the test requirements.

[0066] Example 3

[0067] Based on Examples 1-2, further feasible implementation methods are proposed.

[0068] One feasible implementation further includes a flushing system comprising a flushing tank 21; the outlet of the flushing tank 21 is connected to the inlet of the methanol pump unit 2 via a pneumatic ball valve 6, and flushing return branches are provided at the methanol rail 7, the inlet of the pneumatic ball valve 6 between the sealing cover 27 and the methanol tank 1, and the inlet of the pneumatic ball valve 6 between the mass flow meter 10 and the methanol tank 1, the outlet of which is connected to the interior of the flushing tank 21; the waste outlet of the flushing tank 21 is connected to the wastewater pool via a flushing water pump 22.

[0069] It should be noted that methanol tank 1 and methanol pump unit 2 are connected via pneumatic ball valve 6, and the flushing tank 21 is connected to methanol pump unit 2 between pneumatic ball valve 6 and methanol pump unit 2. When using this flushing system to flush the methanol in the pipeline and methanol rail 7, pneumatic ball valve 6 needs to be closed to avoid contaminating the methanol in methanol tank 1. At the same time, the valves on the pipeline returning to methanol tank 1, such as pneumatic ball valve 6 between methanol tank 1 and mass flow meter 10, and pneumatic ball valve 6 between methanol tank 1 and sealing cover 27, should also be closed. Open pneumatic ball valve 6 or shut-off valve 8 on the flushing return branch, and use methanol pump unit 2 to deliver flushing water from flushing tank 21. This flushing water passes through the filter group, proportional regulating valve 5, methanol rail 7, methanol injector, mass flow meter 10, and sealing cover 27 before returning to flushing tank 21. After flushing, the wastewater in flushing tank 21 can be discharged into the wastewater pool through flushing water pump 22. This flushing system achieves the flushing of residual methanol.

[0070] Preferably, to avoid cavitation damage to components caused by water under high pressure, it is recommended that the flushing pressure not exceed 1 MPa.

[0071] Of course, the rinsing tank 21 also contains a temperature sensor and a liquid level sensor 13 to obtain the temperature and liquid level of the rinsing water in the rinsing tank 21; similarly, the liquid inlet of the rinsing tank 21 can also be connected to an external water source, and a filter 4 needs to be installed at the liquid inlet.

[0072] Furthermore, in this embodiment, the temperature sensor and the liquid level sensor 13 can also be directly integrated into the control assembly, or integrated into the control assembly through the second sub-controller; the temperature and liquid level of the water in the rinsing tank are controlled by the control assembly and / or the second sub-controller.

[0073] Furthermore, in this embodiment, the shut-off valve 8 and / or the pneumatic ball valve 6 are directly or indirectly connected to the control assembly. As needed, the operator can operate the required valves to open or close from outside the test bench, thereby avoiding the need for the operator to enter the test bench and reducing the risk of alcohol poisoning.

[0074] Example 4

[0075] Based on Examples 1-3, further feasible implementation methods are proposed.

[0076] One feasible implementation also includes a circulating filtration system, which includes a circulating pump 19. The inlet of the circulating pump 19 is connected to the interior of the new methanol tank and / or methanol tank 1, and the outlet of the circulating pump 19 is connected to the waste methanol tank and / or methanol tank 1. A filter assembly is installed at the outlet of the circulating pump 19. The circulating system mainly maintains the cleanliness of the methanol liquid in the methanol tank 1. The filter assembly still has two filters 4, which are still along the flow direction of methanol. The precision of the filters 4 is gradually increased, namely 10μm precision and 5μm precision, which also effectively reduces the filtration intensity of the filters 4, improves the service life of the filters 4 and the adaptability of the methanol medium.

[0077] It should be noted that when the inlet of the circulating pump 19 is connected to both the new methanol tank and the methanol tank 1, or / and the outlet of the circulating pump 19 is connected to both the waste methanol tank and the methanol tank 1, a three-way ball valve can be used for connection to realize the oil filling and draining functions of the methanol tank 1, thereby reducing the probability of personnel directly contacting methanol.

[0078] Furthermore, in the circulating filtration system, a cooler 17 is installed downstream of the filter group to cool the methanol in the methanol tank 1. In conjunction with the water bath heat conduction system, the temperature of the methanol liquid in the methanol tank 1 is further maintained. The medium of the cooler 17 can be cold air or cooling water.

[0079] Furthermore, in this embodiment, the circulating pump and the three-way ball valve can be directly integrated into the control assembly, or they can be integrated into the control assembly through a third sub-controller; so that the opening and closing of the circulating pump or the three-way ball valve can be controlled by the control assembly, thereby reducing the risk of operators being exposed to methanol.

[0080] Example 5

[0081] Based on Examples 1-4, further feasible implementation methods are proposed.

[0082] One feasible implementation also includes an air system. The air system includes an air source connected to the inlet of a pneumatic switch 25. The outlet of the pneumatic switch 25 is connected to the methanol injector inside the sealing cover 27 via a shut-off valve 8 and a pneumatic ball valve 6. The pneumatic switch 25 is connected to all pneumatic ball valves 6 via a solenoid valve. The air source can be provided by a compressor, a compressed gas tank, or compressed air generated by other equipment within the plant, with the pressure controlled between 0.5 MPa and 0.8 MPa. This air system is primarily used for purging during dynamic sealing tests and to power the pneumatic control components of the entire test bench. Purging using the air system mainly involves purging the methanol gas (from the evaporation of liquid methanol) inside the sealing cover 27. More specifically, the entry of compressed air and methanol into the sealing cover 27 is achieved by changing the opening and closing of the pneumatic ball valve 6 between the methanol injector and the pneumatic switch 25, and between the methanol injector and the methanol rail 7.

[0083] Furthermore, in this embodiment, all the shut-off valves 8, pneumatic ball valves and air switches can be directly integrated into the control assembly, or they can be integrated into the control assembly through the fourth sub-controller, so that the flow direction of compressed air can be controlled by the control assembly to control whether to perform purging work, as well as the opening and closing of the specific pneumatic ball valve 6.

[0084] It should be noted that the pneumatic ball valve 6 is mainly selected for the valves in the test bench in this article. The pneumatic ball valve 6 can effectively reduce the application of electrical components, thereby reducing the risk of methanol combustion caused by static electricity.

[0085] Example 6

[0086] Based on Examples 1-5, further feasible implementation methods are proposed.

[0087] One feasible implementation also includes a methanol gas-liquid converter 23. The inlet of the methanol gas-liquid converter 23 is connected to the interior of the methanol tank 1, and the outlet of the methanol gas-liquid converter 23 is equipped with an explosion-proof flame arrester 24. The methanol gas-liquid converter 23 is installed higher than the methanol tank 1. The methanol gas-liquid converter 23 is used to cool the volatilized methanol gas into methanol liquid, and the formed methanol liquid flows back into the methanol tank 1 under gravity. Through this design, external fire sources are prevented from entering the methanol tank 1 and causing deflagration or explosion, and the external emission of methanol volatilized gas is reduced, effectively increasing the safety of equipment and personnel on the methanol sprayer flow test bench.

[0088] This configuration indicates that the methanol tank 1 employs an open design, effectively achieving explosion-proof functionality. In the event of high pressure within the methanol tank 1 (excessive methanol gas evaporation or accidental combustion), the open design allows for rapid pressure release, preventing an explosion. Furthermore, for added safety, as mentioned above, the methanol tank 1 contains no electrical components; all electrical components are externally mounted. This effectively prevents static electricity, short circuits, localized high temperatures, and other ignition sources from contacting the methanol medium inside the tank, enhancing equipment and personnel safety. Additionally, the methanol tank 1 is equipped with a methanol-water concentration detector 20, which can monitor the water content of the methanol within the tank in real time.

[0089] Furthermore, the methanol gas-liquid converter 23 is a heat exchanger connected to an external cold source. The cold source provides refrigerant to cool the methanol gas, thereby converting the methanol gas into methanol liquid.

[0090] In this embodiment, all the shut-off valves 8 can be solenoid valves, which can be connected to the output of the control assembly as actuators to realize the opening and closing of the shut-off valves 8 through the control assembly; of course, other electrical equipment, such as pumps, motors, proportional regulating valves 5, safety valves 12, etc., can also be connected to the output of the control assembly as actuators to realize the operation opening and closing control through the control assembly; all the sensors and the first sub-controller are connected to the input of the control assembly to realize the control assembly to acquire all data of the test process.

[0091] In this embodiment, a housing is also included, in which all components except the water bath heat conduction system can be located, achieving the purpose of explosion protection and reducing methanol leakage.

[0092] Example 7

[0093] A method for testing the flow rate of an alcohol injector, using the alcohol injector flow rate testing test bench described in Examples 1-6, includes a flow rate test and a dynamic sealing test, wherein:

[0094] S1: The flow test includes steps S11-S14;

[0095] S11: Install an alcohol sprayer on the flow test station 9. The inlet of the alcohol sprayer is connected to the alcohol track 7, and the outlet of the alcohol sprayer is connected to the mass flow meter 10.

[0096] S12: Start methanol pump unit 2. Methanol pump unit 2 draws methanol from methanol tank 1 and delivers methanol to methanol rail 7. In this step, the methanol pressure in methanol rail 7 is adjusted by proportional regulating valve 5 and the methanol pressure in methanol rail 7 is stabilized by accumulator 3.

[0097] S13: Open the shut-off valve 8 between the alcohol track 7 and the alcohol injector. Methanol in the alcohol track 7 enters the alcohol injector. Methanol sprayed out by the alcohol injector enters the mass flow meter 10. The mass flow meter 10 obtains the mass of methanol sprayed out by the corresponding alcohol injector per unit time.

[0098] S14: Methanol passing through mass flow meter 10 flows back into methanol tank 1 through the reflux port on methanol tank 1.

[0099] S2: Dynamic sealing test includes steps S21-S26;

[0100] S21: Install an alcohol injector on the dynamic sealing test station 11. The inlet of the alcohol injector is connected to the alcohol track 7, and the outlet of the alcohol injector is located inside the sealing cover 27. Close the pneumatic ball valve 6 between the sealing cover 27 and the methanol tank 1.

[0101] S22: Start methanol pump unit 2. Methanol pump unit 2 draws methanol from methanol tank 1 and delivers methanol to methanol rail 7. In this step, the methanol pressure in methanol rail 7 is adjusted by proportional regulating valve 5 and the methanol pressure in methanol rail 7 is stabilized by accumulator 3. Alternatively, the methanol in methanol rail 7 from step S12 can be used.

[0102] S23: Methanol in methanol track 7 enters the methanol injector, and methanol sprayed out by the methanol injector enters the sealing cover 27 until the pressure in the sealing cover 27 reaches the preset pressure value.

[0103] S24: Block the flow of methanol between methanol track 7 and the methanol injector;

[0104] S25: Observe whether the pressure value of the pressure sensor installed on the sealing cover 27 changes. If it does not change, the dynamic sealing performance is qualified; if it changes, the dynamic sealing performance is unqualified.

[0105] S26: Open the pneumatic ball valve 6 between the sealing cover 27 and the methanol tank 1, and the methanol in the sealing cover 27 flows back to the methanol tank 1 through the pneumatic ball valve 6.

[0106] Of course, the above steps are only the basic steps of the experiment. There are other processes, such as maintaining the methanol temperature in methanol tank 1 using a water bath heat conduction system, rinsing residual methanol in components such as methanol rail 7, sealing cover 27 and pipelines using a rinsing system, maintaining the cleanliness of methanol in methanol tank 1 using a circulating filtration system, blowing methanol gas in sealing cover 27 using an air system, controlling the opening and closing of pneumatic ball valve 6, and recovering volatilized methanol gas using methanol gas-liquid converter 23. The steps of these processes can be obtained without any objection in Examples 1-6, so they will not be described in detail in this example.

[0107] This invention is not limited to the specific embodiments described above. The invention extends to any new feature or combination disclosed in this specification, as well as any new method or process step or combination disclosed herein.

Claims

1. A test bench for testing the flow rate of an alcohol sprayer, characterized in that: It includes a methanol tank (1), a flow test station (9) and a dynamic sealing test station (11). The outlet of the methanol tank (1) is connected to the inlet of the methanol rail (7) through a methanol pump unit (2). The outlet of the methanol rail (7) is connected to the inlet of the methanol injector through a valve. The flow test station (9) is used to install the alcohol sprayer and also includes a mass flow meter (10). The inlet of the mass flow meter (10) is connected to the outlet of the alcohol sprayer located on the flow test station (9), and the outlet of the mass flow meter (10) is connected to the reflux port of the methanol tank (1). The dynamic sealing test station (11) includes a sealing cover (27), which has an installation port for the alcohol injector. The installation port is sealed by a sealing ring (26) on the alcohol injector. The outlet of the alcohol injector is located inside the sealing cover (27). The sealing cover (27) is connected to the methanol tank (1) through a pneumatic ball valve (6). At least one pressure sensor is provided on the sealing cover (27) to obtain the pressure inside the sealing cover (27). A proportional regulating valve (5) is provided between the methanol pump unit (2) and the methanol rail (7); the inlet of the accumulator (3) is connected to the methanol rail (7) through a shut-off valve (8), and the outlet of the accumulator (3) is connected to the inside of the methanol tank (1) through a safety valve (12). It also includes a flushing system, which includes a flushing tank (21); the outlet of the flushing tank (21) is connected to the inlet of the methanol pump unit (2) through a pneumatic ball valve (6), and flushing return branches are provided at the methanol rail (7), the inlet of the pneumatic ball valve (6) between the sealing cover (27) and the methanol tank (1), and the inlet of the pneumatic ball valve (6) between the mass flow meter (10) and the methanol tank (1). The outlet of the flushing return branch is connected to the inside of the flushing tank (21); the waste outlet of the flushing tank (21) is connected to the wastewater pool through a flushing water pump (22).

2. The alcohol sprayer flow test bench according to claim 1, characterized in that: The outlet of the methanol pump unit (2) is connected in parallel with a pressure relief branch, which is connected to the interior of the methanol tank (1) through a safety valve (12).

3. The alcohol sprayer flow test bench according to claim 1, characterized in that: It also includes a water bath heat conduction system, which includes a water tank (14), a heater (15) located in the water tank (14), and a heat exchange tube (18) located in the methanol tank (1). The outlet of the water tank (14) is connected to the inlet of the heat exchange tube (18) through a heating water pump (16), and the outlet of the heat exchange tube (18) is connected to the inside of the water tank (14). A first temperature sensor is installed in the methanol tank (1), and a second temperature sensor is installed in the water tank (14). The first temperature sensor and the second temperature sensor are both connected to the input terminal of the first sub-controller, and the output terminal of the first sub-controller is connected to the heater (15).

4. The alcohol sprayer flow test bench according to claim 1, characterized in that: It also includes a circulating filtration system, which includes a circulating pump (19), the inlet of which is connected to the interior of a new alcohol tank and / or a methanol tank (1), the outlet of which is connected to a waste alcohol tank and / or a methanol tank (1), and a filter assembly is provided at the outlet of the circulating pump (19).

5. The alcohol sprayer flow test bench according to claim 4, characterized in that: In the circulating filtration system, a cooler (17) is installed downstream of the filter group.

6. The alcohol sprayer flow test bench according to claim 1, characterized in that: It also includes an air system, which includes an air source connected to the inlet of a pneumatic switch (25). The outlet of the pneumatic switch (25) is connected to the alcohol sprayer inside the sealing cover (27) via a shut-off valve (8) and a pneumatic ball valve (6). The pneumatic switch (25) is connected to all the pneumatic ball valves (6) via a solenoid valve.

7. The alcohol sprayer flow test bench according to claim 1, characterized in that: It also includes a methanol gas-liquid converter (23), the inlet of which is connected to the interior of the methanol tank (1), and the outlet of the methanol gas-liquid converter (23) is equipped with an explosion-proof flame arrester (24); and the installation space of the methanol gas-liquid converter (23) is higher than that of the methanol tank (1).

8. The alcohol sprayer flow test bench according to claim 7, characterized in that: The methanol gas-liquid converter (23) is a heat exchanger, and the heat exchanger is connected to an external cold source.

9. The alcohol sprayer flow test bench according to any one of claims 1-8, characterized in that: A filter group is set up along the flow path of the alcohol liquid. All filter groups include at least two filters connected in series (4), and the accuracy of the filter (4) gradually increases along the flow direction of methanol.

10. A method for testing the flow rate of an alcohol injector, using the alcohol injector flow rate testing bench according to any one of claims 1-9, characterized in that: This method includes flow testing and dynamic sealing testing, wherein: S1: The flow test includes steps S11-S14; S11: Install an alcohol sprayer on the flow test station (9). The inlet of the alcohol sprayer is connected to the alcohol track (7), and the outlet of the alcohol sprayer is connected to the mass flow meter (10). S12: Start the methanol pump unit (2), the methanol pump unit (2) draws methanol from the methanol tank (1) and delivers the methanol to the methanol rail (7); in this step, the methanol pressure in the methanol rail (7) is adjusted by the proportional regulating valve (5), and the methanol pressure in the methanol rail (7) is stabilized by the accumulator (3); S13: Methanol in the alcohol track (7) enters the alcohol injector, and the methanol sprayed out by the alcohol injector enters the mass flow meter (10). The mass flow meter (10) obtains the mass of methanol sprayed out by the corresponding alcohol injector per unit time. S14: Methanol passing through the mass flow meter (10) flows back into the methanol tank (1) through the return port on the methanol tank (1); S2: Dynamic sealing test includes steps S21-S26; S21: Install an alcohol injector on the dynamic sealing test station (11). The inlet of the alcohol injector is connected to the alcohol track (7), and the outlet of the alcohol injector is located inside the sealing cover (27). Close the pneumatic ball valve (6) between the sealing cover (27) and the methanol tank (1). S22: Start the methanol pump unit (2), the methanol pump unit (2) draws methanol from the methanol tank (1) and delivers the methanol to the methanol rail (7); in this step, the methanol pressure in the methanol rail (7) is adjusted by the proportional regulating valve (5), and the methanol pressure in the methanol rail (7) is stabilized by the accumulator (3); S23: Methanol in the alcohol track (7) enters the alcohol injector, and the methanol sprayed out by the alcohol injector enters the sealing cover (27) until the pressure in the sealing cover (27) reaches the preset pressure value. S24: Block the flow of methanol between the methanol track (7) and the methanol injector; S25: Observe whether the pressure value of the pressure sensor installed on the sealing cover (27) changes. If it does not change, the dynamic sealing performance is qualified; if it changes, the dynamic sealing performance is unqualified. S26: Open the pneumatic ball valve (6) between the sealing cover (27) and the methanol tank (1), and the methanol in the sealing cover (27) flows back to the methanol tank (1) through the pneumatic ball valve (6).

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