A performance testing system and method for side-plate heat exchangers

Abstract

This application discloses a performance testing system and method for side-plate heat exchangers, relating to the field of heat exchanger testing technology. The system includes: a computer for constructing a digital twin model, generating multiple sets of dynamic operating condition data, inputting the dynamic operating condition data into the digital twin model to obtain dynamic performance data, and filtering sensitive operating condition data based on the sensitivity coefficient of each dynamic performance data point; testing equipment for executing the sensitive operating condition data and collecting measured state data of the side-plate heat exchanger; and the computer determining whether the performance of the side-plate heat exchanger meets design requirements based on the measured state data. This application uses a digital twin approach to physically model the heat exchanger and simulate its heat exchange, thereby removing invalid test conditions from the parameter set and retaining only sensitive conditions, significantly saving time, manpower, and energy costs required for testing.

Description

Technical Field

[0001] This application relates to the field of heat exchanger testing technology, and in particular to a side-plate heat exchanger performance testing system and testing method. Background Technology

[0002] Side plate heat exchangers are one of the most commonly used heat exchangers. They consist of multiple plate-shaped cores stacked together, with the hot and cold media flowing in opposite directions between adjacent cores. This achieves efficient heat exchange through a large contact area. Moreover, this type of heat exchanger is relatively small in size, which is why it has been widely used in industry.

[0003] In the design process of side-plate heat exchangers, it is necessary to collect data on the usage scenario beforehand, such as the flow rate, temperature, and pressure of the hot and cold media, and then select key parameters such as the core size and number of layers accordingly. After the design is completed and a prototype is manufactured, the heat exchanger needs to be tested to determine whether the sample meets the actual usage requirements. During the testing process, the heat exchanger needs to be injected with the hot and cold media to simulate the actual usage environment, and the flow rate, temperature, and pressure of the media need to be controlled according to the design requirements. In most operating conditions, the parameters of the media are in a steady state, but under certain circumstances, these parameters will change. It is these changing operating conditions that are key to verifying the performance of the heat exchanger. If the heat exchanger can withstand all the changing operating conditions and achieve the required performance, then such a heat exchanger is qualified.

[0004] However, current testing processes for varying operating conditions involve pre-determining parameters for each condition and then implementing the tests on the heat exchanger. When there are many parameters to be tested, this process is time-consuming and results in high costs. Summary of the Invention

[0005] This application provides a side-plate heat exchanger performance testing system and method to solve the problem of high testing costs caused by the heat exchanger performing all test parameters in the prior art.

[0006] On one hand, embodiments of this application provide a performance testing system for a side-plate heat exchanger, including:

[0007] A computer is used to construct a digital twin model using physical data collected from a side-plate heat exchanger. Multiple sets of dynamic operating condition data are generated within a set operating condition range. The multiple sets of dynamic operating condition data are input into the digital twin model in simulation software to obtain the dynamic performance data of the digital twin model under each set of dynamic operating condition data. The sensitivity coefficient of each dynamic performance data is calculated. The dynamic operating condition data is filtered according to the sensitivity coefficient to obtain sensitive operating condition data.

[0008] The testing equipment is connected to the hot-side inlet and outlet and the cold-side inlet and outlet of the side plate heat exchanger. The testing equipment inputs the hot-side medium and the cold-side medium into the side plate heat exchanger according to the sensitive operating condition data, and collects the measured status data of the side plate heat exchanger at the hot-side inlet and outlet and the cold-side inlet and outlet.

[0009] The computer determines whether the performance of the side plate heat exchanger meets the design requirements based on the measured status data.

[0010] On the other hand, embodiments of this application also provide a method for testing the performance of a side-plate heat exchanger, including:

[0011] A digital twin model is constructed using physical data collected from a side-plate heat exchanger;

[0012] Multiple sets of dynamic operating condition data are generated within a set operating condition range. The multiple sets of dynamic operating condition data are then input into the digital twin model in the simulation software to obtain the dynamic performance data of the digital twin model under each set of dynamic operating condition data.

[0013] Calculate the sensitivity coefficient for each dynamic performance data point, and filter the dynamic operating condition data based on the sensitivity coefficient to obtain the sensitive operating condition data;

[0014] The testing equipment inputs hot and cold media into the side plate heat exchanger according to sensitive operating condition data, and collects measured status data of the side plate heat exchanger at the hot and cold inlet and outlet.

[0015] Determine whether the performance of the side plate heat exchanger meets the design requirements based on the measured data.

[0016] The side-plate heat exchanger performance testing system and method disclosed in this application have the following advantages:

[0017] By using digital twins to physically model the heat exchanger and simulating its heat exchange under various dynamic parameters in simulation software, invalid test conditions are removed from the parameter set, leaving only sensitive conditions. This not only greatly saves the time, manpower, and energy costs required for testing, but also allows for targeted testing of the heat exchanger within a limited time, maximizing the exploration of the heat exchanger's performance under conditions that could lead to failure. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1This is a schematic diagram of the composition of a side-plate heat exchanger performance testing system provided in an embodiment of this application.

[0020] Figure 2 A flowchart illustrating a performance testing method for a side-plate heat exchanger provided in this application embodiment.

[0021] Reference numerals: 100, Computer; 201, Hot-side oil temperature controller; 202, Hot-side valve; 203, Hot-side flow meter; 204, Hot-side inlet thermometer; 205, Hot-side inlet pressure gauge; 206, Hot-side outlet thermometer; 207, Hot-side outlet pressure gauge; 210, Cold-side oil temperature controller; 211, Cold-side valve; 212, Cold-side flow meter; 213, Cold-side inlet thermometer; 214, Cold-side inlet pressure gauge; 215, Cold-side outlet thermometer; 216, Cold-side outlet pressure gauge; 220, Auxiliary heat exchanger; 221, Auxiliary valve; 222, Auxiliary water chiller; 300, Side-plate heat exchanger. Detailed Implementation

[0022] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0023] Figure 1 This is a schematic diagram illustrating the composition of a side-plate heat exchanger performance testing system provided in an embodiment of this application. This application provides a side-plate heat exchanger performance testing system, comprising:

[0024] Computer 100 is used to construct a digital twin model using physical data collected from the side plate heat exchanger 300, generate multiple sets of dynamic operating condition data within a set operating condition range, input the multiple sets of dynamic operating condition data into the digital twin model in simulation software, obtain the dynamic performance data of the digital twin model under each set of dynamic operating condition data, calculate the sensitivity coefficient of each dynamic performance data, and filter the dynamic operating condition data according to the sensitivity coefficient to obtain sensitive operating condition data.

[0025] The testing equipment is connected to the hot side inlet and cold side inlet and outlet of the side plate heat exchanger 300. The testing equipment inputs the hot side medium and cold side medium into the side plate heat exchanger 300 according to the sensitive operating condition data, and collects the measured status data of the side plate heat exchanger 300 at the hot side inlet and cold side inlet and outlet.

[0026] Computer 100 determines whether the performance of the side plate heat exchanger 300 meets the design requirements based on the measured status data.

[0027] For example, before starting the test, it is necessary to first clarify the test objectives and parameter definitions. The test objectives may include covering the range of traffic fluctuations and the magnitude of temperature steps, while the parameters involved include the following:

[0028] Input medium operating data, including instantaneous cold-side input flow rate. q c ( t Instantaneous input flow rate on the hot side q h ( t ), hot side inlet temperature T hin ( t ), cold side inlet temperature T cin ( t ) and system pressure P ( t );

[0029] Operating data of the output medium, including transient heat transfer. Q ( t ), hot side outlet temperature T hout ( t ), cold side outlet temperature T cout ( t ), pressure drop Δ P ( t and core hot spot temperature T hot ( t );

[0030] Operating condition boundaries, including frequency fluctuation range f ∈[ f min , f max ], range d =Δ x / x 0∈[ d min , d max ],in, f min and f max These are the minimum and maximum values ​​of the frequency fluctuation, Δ. x For flow rate or temperature, x 0 represents the rated value for flow rate or temperature. d min and d max These are the minimum and maximum values ​​of the amplitude, respectively.

[0031] Next, the construction of the digital twin model will begin. Before modeling begins, various physical data of the side-plate heat exchanger 300 will be collected. Specifically, the physical data will be collected by a 3D scanning device, which is connected to the computer 100 via a data cable. The 3D scanning device uses laser scanning technology to collect the 3D point cloud of the side-plate heat exchanger, and the computer 100 will extract and analyze the 3D point cloud to obtain the physical data.

[0032] The aforementioned physical data includes the dimensions of the core, corrugations, and flow channels. During the acquisition of physical data, it is necessary to ensure that the difference between the acquired physical data and the actual data is small. In this embodiment of the application, the ratio of the difference between the physical data and the actual data to the actual data is required to be within 0.1% to ensure the accuracy of the constructed digital twin model.

[0033] Furthermore, after constructing the digital twin model, the computer 100 embeds dynamic physical laws into the digital twin model, including unsteady flow laws, heat transfer models, and structural mechanics models.

[0034] The unsteady flow behavior is described by the unsteady Navier-Stokes equations:

[0035]

[0036] In the above formula, r Let be the density of the medium, and u be the velocity vector of the medium. t Indicates time, For vector differential operators, p For pressure, m The dynamic viscosity of the medium, indicated by the superscript. T This indicates transpose, and f is the volume force.

[0037] The heat transfer model is expressed as:

[0038]

[0039] In the above formula, C The heat capacity of the side plate heat exchanger is 300. K ( t () represents the dynamic heat transfer coefficient. F For heat transfer area, Q loss This is due to heat loss. T h and T c These are collective terms for hot-side temperature and cold-side temperature, respectively. When calculating... T h If the inlet temperature on the heating side is taken, then Tc The cold side inlet temperature needs to be obtained, and if T h Take the outlet temperature on the hot side, then T c The cold side outlet temperature needs to be obtained.

[0040] The structural mechanics model is represented as follows:

[0041]

[0042] In the above formula, r s Core density, d ( t () represents the core deformation. s ( t ) is the stress tensor. This is a thermal stress load.

[0043] Furthermore, after constructing the digital twin model, the computer 100 establishes an input-output mapping model, which characterizes the mapping relationship between the input medium and the output medium in terms of temperature, pressure drop, and heat exchange in the digital twin model.

[0044] The input-output mapping model is represented as follows:

[0045]

[0046] In the above formula, f 1 and f 2 represents the temperature mapping function and the heat transfer mapping function, respectively. c h and c c These are the specific heat capacities of the hot-side medium and the cold-side medium, respectively.

[0047] Furthermore, after constructing the digital twin model, the computer 100 selects multiple sets of steady-state operating condition data. The testing equipment executes multiple sets of steady-state operating condition data on the side plate heat exchanger 300 and collects the corresponding steady-state performance data. Then, the computer 100 corrects the model parameters in the digital twin model based on the steady-state performance data.

[0048] Specifically, it can be pre-selected n Set up steady-state operating condition data, such as the steady-state flow rate of the hot-side medium. q h = k · q h0 , k =0.5,1.0,1.5, cold side medium q c = k · qc0 ,in q h0 and q c0 These are the rated values ​​for the steady-state flow rates of the hot-side and cold-side media, respectively. By inputting the hot-side and cold-side media into the side-plate heat exchanger 300 according to these steady-state operating conditions, measured state data of the side-plate heat exchanger 300 can be collected at the hot-side and cold-side outlets, respectively. Based on this measured state data, the measured performance data of the side-plate heat exchanger, i.e., the steady-state performance data, can then be calculated. Next, the steady-state operating conditions data can be compared with a digital twin model to obtain the corresponding predicted performance data. The root mean square error (RMSE) of the steady-state performance data and the corresponding predicted performance data is calculated. Based on this RMS error, the model coefficients of the digital twin model are adjusted, such as the correction coefficient in the empirical formula for the heat transfer coefficient and the friction coefficient of the seals, so that the RMS error ultimately reaches within 5%.

[0049] In addition to using steady-state operating condition data to correct the digital twin model, dynamic operating condition data can also be used to correct inertial parameters in the model, such as the residence time of fluid in the flow channel and the specific heat capacity of the core. The specific correction method is the same as the correction process based on steady-state operating condition data, and will not be repeated here.

[0050] After refining the digital twin model, it achieved high accuracy and can be used to filter dynamic operating condition data. Before starting the filtering process, the frequency fluctuation range can be considered. f and amplitude range d The system generates m sets of dynamic operating condition data. After inputting each set of dynamic operating condition data into the digital twin model, a corresponding set of dynamic performance data can be obtained. These m sets of dynamic performance data can form a dynamic performance matrix. Y The elements in this matrix, i.e., each dynamic performance data point, are represented by... y express.

[0051] Then calculate the sensitivity coefficient according to the following formula. S :

[0052]

[0053] In the above formula, Δ y The change in dynamic performance data, i.e., the current dynamic performance data. y Compared with the average The difference, Δ x’ The change in dynamic operating condition data, i.e., the current dynamic operating condition data. x’ Compared with the average The difference.

[0054] After obtaining the sensitivity coefficient for each set of dynamic operating condition data, it can be compared with the sensitivity threshold.S A comparison is made between 0 and 1, retaining only dynamic operating condition data with a sensitivity coefficient greater than the sensitivity threshold, while also retaining boundary conditions, such as... d = d max and f = f max The remaining dynamic operating condition data are considered invalid and must be removed.

[0055] In the embodiments of this application, in addition to retaining sensitive operating conditions and boundary operating conditions, typical application operating conditions in actual application scenarios can also be retained, such as the day and night load fluctuation curve of the vehicle heat pump, the flow rate change of the vehicle heat exchanger during rapid acceleration / deceleration, etc., to ensure that the retained dynamic operating condition data matches the actual application scenario.

[0056] After obtaining the sensitive operating condition data, the testing equipment can execute these data, and then the acquisition equipment in the testing equipment can collect the measured status data of the side plate heat exchanger 300, such as using a fiber optic sensor to collect temperature and using a high-frequency flow meter to collect flow.

[0057] Furthermore, after the test equipment executes sensitive operating condition data and collects measured state data, the computer 100 predicts the predicted state data corresponding to the sensitive operating condition data based on the digital twin model, and corrects the dynamic parameters of the digital twin model according to the difference between the measured state data and the predicted state data.

[0058] Specifically, after obtaining the predicted state data and the measured state data, the ratio of the difference between the predicted state data and the measured state data to the measured state data can be used as the dynamic response error. e Then, machine learning algorithms, such as random forests, are used to analyze the dynamic parameters of the digital twin model, such as the inertia coefficient. t Adjustments are made to reduce the dynamic response error of the dynamic parameters. e Reduced to below 3%.

[0059] Furthermore, after correcting the digital twin model, the computer 100 uses the corrected digital twin model to predict the predicted performance data corresponding to the untested operating condition data (excluding sensitive operating condition data) in multiple sets of dynamic operating condition data, and combines the predicted performance data and the measured performance data corresponding to the measured state data to form a complete performance database.

[0060] Based on a complete performance database, a dynamic performance report can be output, which includes transient curves under sensitive operating conditions and performance limit values ​​under boundary conditions. With this data, it is easy to determine whether the actual performance of the designed side-plate heat exchanger 300 meets the design requirements.

[0061] By adopting the system composition and process of this application, the actual test conditions required for the side plate heat exchanger 300 can be reduced by 60%-70%, and the total test cost can be reduced by more than 50%.

[0062] Furthermore, the testing equipment includes a hot-side circulation branch and a cold-side circulation branch. The hot-side circulation branch includes a hot-side oil temperature controller 201, a hot-side valve 202, and a hot-side flow meter 203. The hot-side inlet of the side-plate heat exchanger 300 is connected to a hot-side inlet thermometer 204 and a hot-side inlet pressure gauge 205. The hot-side outlet of the side-plate heat exchanger 300 is connected to a hot-side outlet thermometer 206 and a hot-side outlet pressure gauge 207. The cold-side circulation branch includes a cold-side oil temperature controller 210, a cold-side valve 211, and a cold-side flow meter 212. The cold-side inlet of the side-plate heat exchanger 300 is connected to a cold-side inlet thermometer 213 and a cold-side inlet pressure gauge 214. The cold-side outlet of the side-plate heat exchanger 300 is connected to a cold-side outlet thermometer 215 and a cold-side outlet pressure gauge 216.

[0063] In the embodiments of this application, the cold side outlet of the side plate heat exchanger 300 is also connected to an auxiliary circulation branch, which includes an auxiliary heat exchanger 220, an auxiliary valve 221, and an auxiliary water chiller 222.

[0064] Specifically, the hot-side oil temperature controller 201 is used to heat the hot-side medium to the required temperature, while the cold-side oil temperature controller 210 is used to heat the cold-side medium. Since the temperature of the cold-side medium is not easy to control during the cooling process by the auxiliary water chiller 222, the auxiliary heat exchanger 220 is generally used to cool the cold-side medium to below the required temperature, and then the cold-side oil temperature controller 210 is used to heat the cold-side medium to the required temperature to ensure the accuracy of the cold-side medium temperature.

[0065] This application also provides a method for testing the performance of a side-plate heat exchanger, including:

[0066] A digital twin model was constructed using physical data collected from the side plate heat exchanger 300;

[0067] Multiple sets of dynamic operating condition data are generated within a set operating condition range. The multiple sets of dynamic operating condition data are then input into the digital twin model in the simulation software to obtain the dynamic performance data of the digital twin model under each set of dynamic operating condition data.

[0068] Calculate the sensitivity coefficient for each dynamic performance data point, and filter the dynamic operating condition data based on the sensitivity coefficient to obtain the sensitive operating condition data;

[0069] The test equipment inputs hot and cold media into the side plate heat exchanger 300 according to sensitive operating condition data, and collects measured status data of the side plate heat exchanger 300 at the hot and cold inlet and outlet.

[0070] Determine whether the performance of the side plate heat exchanger 300 meets the design requirements based on the measured data.

[0071] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0072] Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application. Therefore, if such modifications and variations fall within the scope of the claims of this application and their equivalents, this application also intends to include such modifications and variations.

Claims

1. A side plate heat exchanger performance test system, characterized by, The application relates to a method for testing the performance of a side plate heat exchanger (300), which comprises the following steps: a computer (100) is used to construct a digital twin model by using physical data collected from the side plate heat exchanger (300), to generate a plurality of groups of dynamic working condition data within a set working condition range, to input the plurality of groups of dynamic working condition data into the digital twin model in simulation software, to obtain dynamic performance data of the digital twin model under each group of dynamic working condition data, to calculate a sensitive coefficient of each dynamic performance data, to screen the dynamic working condition data according to the sensitive coefficient, and to obtain sensitive working condition data; a test device is connected to the hot side inlet and outlet and the cold side inlet and outlet of the side plate heat exchanger (300), the test device inputs hot side medium and cold side medium into the side plate heat exchanger (300) according to the sensitive working condition data, and collects measured state data of the side plate heat exchanger (300) at the hot side inlet and outlet and the cold side inlet and outlet; the computer (100) judges whether the performance of the side plate heat exchanger (300) meets the design requirements according to the measured state data; the physical data is collected by a three-dimensional scanning device, the three-dimensional scanning device is connected to the computer (100) through a data cable, the three-dimensional scanning device collects three-dimensional point clouds of the side plate heat exchanger by using a laser scanning technology, and the computer (100) extracts and analyzes the three-dimensional point clouds to obtain the physical data; after the digital twin model is constructed, the computer (100) implants dynamic physical laws in the digital twin model, the dynamic physical laws include non-steady flow laws, heat transfer models and structural mechanics models; after the digital twin model is constructed, the computer (100) establishes an input-output mapping model, the input-output mapping model represents the mapping relationship between input medium and output medium in terms of temperature, pressure drop and heat exchange capacity in the digital twin model; after the digital twin model is constructed, the computer (100) selects a plurality of groups of steady working condition data, after the test device executes the plurality of groups of steady working condition data on the side plate heat exchanger (300) and collects corresponding steady performance data, the computer (100) corrects model parameters in the digital twin model according to the steady performance data; after the test device executes the sensitive working condition data and collects the measured state data, the computer (100) predicts predicted state data corresponding to the sensitive working condition data based on the digital twin model, and corrects dynamic parameters of the digital twin model according to the difference between the measured state data and the predicted state data; after the digital twin model is corrected, the computer (100) predicts predicted performance data corresponding to untested working condition data except the sensitive working condition data in the plurality of groups of dynamic working condition data by using the corrected digital twin model, and the predicted performance data and measured performance data corresponding to the measured state data form a complete performance database. ​ ​ ​ wherein said sensitivity coefficient is calculated according to the following formula S : In the above formula, Δ y is the change amount of the dynamic performance data, i.e., the current dynamic performance data y minus the average value ; Δ x’ is the change amount of the dynamic working condition data, i.e., the current dynamic working condition data x’ minus the average value ; and the average value is the average value of the dynamic performance data or the dynamic working condition data in the past time period. The method for filtering the dynamic operating condition data is as follows: The sensitivity coefficient and sensitivity threshold of each group of dynamic operating condition data are compared. S The data is compared with 0, and only the dynamic operating condition data whose sensitivity coefficient is greater than the sensitivity threshold are retained.

2. The performance test system of a side plate heat exchanger according to claim 1, characterized in that, ​ 3. The performance test system of a side plate heat exchanger according to claim 1, characterized in that, ​ 4. The performance test system of a side plate heat exchanger according to claim 1, characterized in that, ​ 5. The performance test system of a side plate heat exchanger according to claim 1, wherein ​ 6. The performance test system of a side plate heat exchanger according to claim 1, wherein ​ 7. The performance test system of a side plate heat exchanger according to claim 6, characterized in that, ​ 8. The performance test system of a side plate heat exchanger according to claim 1, characterized in that, The test device comprises a hot side circulation branch and a cold side circulation branch, the hot side circulation branch comprises a hot side oil temperature machine (201), a hot side valve (202) and a hot side flow meter (203), a hot side inlet temperature meter (204) and a hot side inlet pressure meter (205) are connected to a hot side inlet of the side plate heat exchanger (300), a hot side outlet temperature meter (206) and a hot side outlet pressure meter (207) are connected to a hot side outlet of the side plate heat exchanger (300), the cold side circulation branch comprises a cold side oil temperature machine (210), a cold side valve (211) and a cold side flow meter (212), a cold side inlet temperature meter (213) and a cold side inlet pressure meter (214) are connected to a cold side inlet of the side plate heat exchanger (300), and a cold side outlet temperature meter (215) and a cold side outlet pressure meter (216) are connected to a cold side outlet of the side plate heat exchanger (300).

9. The performance test system of a side plate heat exchanger according to claim 8, characterized in that, The cold side outlet of the side plate heat exchanger (300) is further connected to an auxiliary circulation branch, and the auxiliary circulation branch comprises an auxiliary heat exchanger (220), an auxiliary valve (221) and an auxiliary water cooler (222).

10. A method applied to the performance test system of any one of claims 1-9, characterized in that, The method comprises the following steps: constructing a digital twin model by using physical data collected from the side plate heat exchanger (300); generating a plurality of groups of dynamic working condition data within a set working condition range, inputting the plurality of groups of dynamic working condition data into the digital twin model in simulation software, and obtaining dynamic performance data of the digital twin model under each group of dynamic working condition data; calculating a sensitive coefficient of each dynamic performance data, screening the dynamic working condition data according to the sensitive coefficient, and obtaining sensitive working condition data; inputting hot side medium and cold side medium into the side plate heat exchanger (300) according to the sensitive working condition data by using the test device, and collecting measured state data of the side plate heat exchanger (300) at hot side inlets and outlets and cold side inlets and outlets; judging whether the performance of the side plate heat exchanger (300) meets the design requirements according to the measured state data.

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