A multi-parameter coupling control-based refrigerant valve endurance test system for vehicle

Abstract

The application relates to the technical field of vehicle component testing, and discloses a vehicle refrigerant valve endurance test system based on multi-parameter coupling control, which comprises a power supply and refrigerant medium supply module, a multi-parameter coupling environment simulation module, a refrigerant valve driving control module, a multi-parameter acquisition and coupling control module, a refrigerant valve special test tool module, an upper computer processing module and a safety protection module. The upper computer processing module is connected with all the modules as the hub, the power supply module provides power and refrigerant circulation, the environment simulation module provides coupled environment conditions, the driving control module outputs valve driving signals, the acquisition and coupling control module realizes parameter closed-loop control, the tool module is used for installing a refrigerant valve for testing, and the safety protection module monitors and responds to safety hazards. The system realizes the cooperative control of environment parameters, refrigerant parameters and valve actions, accurately simulates real vehicle working conditions, has the high-efficiency parallel test and safety protection capabilities, and improves the reliability and efficiency of vehicle refrigerant valve endurance test.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of vehicle component testing, in particular to a vehicle refrigerant valve durability test system based on multi-parameter coupling control. BACKGROUND

[0002] The vehicle refrigerant valve is the core electric control component of the automobile thermal management system, and its durability directly determines the long-term reliability and operation stability of the automobile air conditioning system. Therefore, carrying out durability testing of the vehicle refrigerant valve close to the actual vehicle working condition is a key link to ensure the performance of the automobile and the user experience.

[0003] The current vehicle refrigerant valve durability test technology has many deficiencies and cannot meet the needs of the industry in terms of test accuracy, efficiency and safety. First, the existing test system mostly uses single parameter control mode, which only adjusts and controls temperature or pressure and other single dimension parameters, and cannot simulate the complex working conditions of the multi-parameter synergistic effect of "temperature-pressure-refrigerant state" in the actual vehicle environment, resulting in a serious disconnection between the test working condition and the actual working scene of the refrigerant valve, and the test results have limited reference value for actual use. Second, the test time planning relies on manual calculation, lacks automatic time calculation logic based on test working condition characteristics, and cannot dynamically adjust the test duration according to the cycle requirements and parameter balance requirements of different working conditions, which is prone to time planning deviation, resulting in test progress delay or resource waste. Third, the existing test tooling lacks speciality, and is not designed to adapt to the sealing requirements and chemical properties of refrigerant medium, which is prone to refrigerant leakage during testing, affecting the continuity of testing and even causing safety risks. At the same time, the parallel test capability of the tooling is weak, and it is difficult to realize the synchronous test of multiple refrigerant valves, resulting in low test efficiency. In addition, the safety protection mechanism of the existing system is not perfect, and specific leakage monitoring, overpressure protection and other emergency modules are not set according to the physical and chemical properties of the refrigerant, which cannot respond to safety hazards in the test process in time, and there is a risk of equipment damage or personnel injury.

[0004] In summary, the current vehicle refrigerant valve durability test system has obvious defects in working condition simulation authenticity, time calculation accuracy, tooling speciality and safety protection capability, and an integrated test system that can solve the above problems is urgently needed. SUMMARY

[0005] The present application provides a vehicle refrigerant valve durability test system based on multi-parameter coupling control, which realizes the coordinated control of environmental parameters-refrigerant parameters-valve action, accurately simulates the actual vehicle working condition, and has efficient parallel test and safety protection capability.

[0006] The application provides a vehicle refrigerant valve endurance test system based on multi-parameter coupling control, which comprises a power supply and refrigerant medium supply module, a multi-parameter coupling environment simulation module, a refrigerant valve driving control module, a multi-parameter acquisition and coupling control module, a refrigerant valve special test tooling module, an upper computer processing module and a safety protection module.

[0007] The upper computer processing module is connected with the power supply and refrigerant medium supply module, the multi-parameter coupling environment simulation module, the refrigerant valve driving control module, the multi-parameter acquisition and coupling control module, the refrigerant valve special test tooling module and the safety protection module respectively, and the power supply and refrigerant medium supply module is also connected with the multi-parameter coupling environment simulation module, the refrigerant valve driving control module, the multi-parameter acquisition and coupling control module, the refrigerant valve special test tooling module and the safety protection module respectively, the multi-parameter coupling environment simulation module is also connected with the multi-parameter acquisition and coupling control module and the refrigerant valve special test tooling module respectively, the refrigerant valve driving control module is also connected with the multi-parameter acquisition and coupling control module and the refrigerant valve special test tooling module respectively, the multi-parameter acquisition and coupling control module is connected with the refrigerant valve special test tooling module, the refrigerant valve special test tooling module is connected with the safety protection module, and the safety protection module is connected with the multi-parameter coupling environment simulation module.

[0008] The power supply and refrigerant medium supply module is used for receiving sensor data of the multi-parameter acquisition and coupling control module, receiving work station state of the refrigerant valve special test tooling module and alarm information of the safety protection module, and issuing control instructions to the multi-parameter coupling environment simulation module, the refrigerant valve driving control module and the power supply and refrigerant medium supply module.

[0009] The power supply and refrigerant medium supply module is used for receiving power supply switching instructions of the upper computer processing module, providing power for the multi-parameter coupling environment simulation module, the refrigerant valve driving control module, the multi-parameter acquisition and coupling control module and the refrigerant valve special test tooling module, receiving pressure adjustment instructions of the multi-parameter acquisition and coupling control module, conveying refrigerant to the refrigerant valve special test tooling module and recycling, and feeding back pressure data to the safety protection module.

[0010] The multi-parameter coupling environment simulation module is used for receiving temperature and humidity and refrigerant temperature instructions of the upper computer processing module, providing coupling environment conditions for the refrigerant valve special test tooling module, feeding back real-time environment data to the upper computer processing module, receiving refrigerant temperature adjustment instructions of the multi-parameter acquisition and coupling control module and executing the instructions.

[0011] The refrigerant valve drive control module is configured to receive the basic action instruction of the host computer processing module and the parameter linkage instruction of the multi-parameter acquisition and coupling control module, output a drive signal to the refrigerant valve of the refrigerant valve special test tooling module, and feed back the valve opening degree data to the host computer processing module;

[0012] The multi-parameter acquisition and coupling control module is configured to acquire pressure, flow, temperature and valve position data from the refrigerant valve special test tooling module, send the data to the host computer processing module, output adjustment instructions to the refrigerant valve drive control module, the multi-parameter coupling environment simulation module and the power supply and refrigerant medium supply module, and realize parameter closed-loop control.

[0013] The refrigerant valve special test tooling module is configured to receive power and refrigerant from the power supply and refrigerant medium supply module and a drive signal from the refrigerant valve drive control module, install and test a refrigerant valve, output sensor data to the multi-parameter acquisition and coupling control module, output leakage data to the safety protection module, and feed back the station state to the host computer processing module.

[0014] The safety protection module is configured to acquire pressure and leakage safety data from the power supply and refrigerant medium supply module, the multi-parameter coupling environment simulation module and the refrigerant valve special test tooling module, send an alarm signal to the host computer processing module, and output an emergency stop or emergency control instruction to the power supply and refrigerant medium supply module, the multi-parameter coupling environment simulation module and the refrigerant valve special test tooling module.

[0015] Further, the multi-parameter coupling environment simulation module includes an environmental test box, a refrigerant temperature control assembly and a multi-parameter load spectrum configuration unit.

[0016] The environmental test box is a temperature and humidity test box, and an environmental temperature sensor and a humidity sensor are installed on the inner side wall of the environmental test box. Sensor signals are transmitted to the multi-parameter acquisition and coupling control module through signal lines.

[0017] The refrigerant temperature control assembly includes a constant temperature water tank and a refrigerant heat exchange coil. The heat exchange coil is laid in the environmental test box, and the inlet and outlet thereof are connected to the water outlet and return port of the constant temperature water tank through pipelines, respectively, to form a water circulation loop. The constant temperature water tank communicates with the host computer processing module through an RS485 bus, receives temperature adjustment instructions, and is used to control the temperature of the refrigerant in the refrigerant pipeline in the environmental test box.

[0018] The multi-parameter load spectrum configuration unit is integrated in the host computer processing module, and includes a parameter input interface and a logic control interface. The parameter input interface is used for configuring parameter groups of environmental temperature, environmental humidity, refrigerant temperature, refrigerant pressure and endurance cycle number, and can import a preset load spectrum table. The logic control interface is used for sending adjustment instructions to the environmental test chamber and the constant temperature water tank according to the configured parameters, so as to realize coupled control of the environmental temperature and the refrigerant temperature.

[0019] Further, the refrigerant valve driving control module includes a driving execution unit and a coupled driving logic unit.

[0020] The driving execution unit includes an electromagnetic valve controller, a signal input end of the electromagnetic valve controller is connected with the host computer processing module, a signal output end is connected with a coil of the measured refrigerant valve, and is used for outputting a PWM signal to control the opening degree of the measured refrigerant valve. The opening degree feedback signal of the measured refrigerant valve is transmitted back to the host computer processing module through a CAN bus, so as to realize action closed-loop control.

[0021] The coupled driving logic unit is integrated in the host computer processing module, and includes basic action configuration and parameter linkage. The basic action configuration is used for setting on-off frequency, opening degree retention time and action delay, and generating a cycle action instruction of the measured refrigerant valve. The parameter linkage is used for receiving real-time pressure and flow data transmitted by the multi-parameter acquisition and coupled control module. When the parameters exceed a first preset threshold, the driving instruction is automatically adjusted, so as to realize coupled control of parameters and actions.

[0022] Further, the refrigerant valve special test tool module includes a multi-station installation frame, a sealed connection assembly and a leakage detection unit.

[0023] The multi-station installation frame is provided with a plurality of independent test stations. The stations are adjusted in the interval of the fixing clamps of the measured refrigerant valves through slide rails. An electrical interface plate is arranged on the side surface, and a direct current power supply interface and a CAN communication interface are integrated in the electrical interface plate, which are used for electrical connection of the measured refrigerant valve.

[0024] The sealed connection assembly is provided with a refrigerant inlet / outlet quick connector for each independent test station. The quick connector is connected with a system main pipeline through a refrigerant-resistant hose. An annular groove is arranged on the connection surface of the connector and the measured refrigerant valve, and a butyronitrile rubber sealing ring is arranged in the annular groove.

[0025] The leakage detection unit includes a plurality of micro leak detectors and a signal transmission assembly. The leak detector probe is installed at the connection position of the measured refrigerant valve and the quick connector. The detection signal is transmitted to the host computer processing module through an RS232 bus. When the leakage amount is greater than a second preset threshold, a station test pause instruction is triggered.

[0026] Further, the power supply and refrigerant medium supply module includes a power supply unit and a refrigerant medium supply unit.

[0027] The power supply unit includes a 220V AC main power supply, a first DC power supply, a second DC power supply, and a plurality of fuses; the 220V AC main power supply respectively supplies power to the environmental test box and the refrigerant valve driving control module; the first DC power supply and the second DC power supply selectively supply power to the measured refrigerant valve through a switch, and each power supply circuit is connected in series with the fuse to prevent damage to the equipment caused by short circuit of the measured refrigerant valve;

[0028] The refrigerant medium supply unit includes a refrigerant storage tank, a booster pump, a refrigerant filter, a one-way valve, and a refrigerant recovery tank; the outlet of the refrigerant storage tank is connected in sequence through a pipeline to the filter, the booster pump, and the one-way valve, and then communicates with the inlet of the measured refrigerant valve through a quick connector; the outlet of the measured refrigerant valve is connected through a pipeline to the refrigerant recovery tank, forming a closed loop circulation; the booster pump is integrated with a pressure controller for receiving instructions from the host computer processing module to adjust the refrigerant pressure.

[0029] Further, the multi-parameter acquisition and coupling control module includes a sensing acquisition unit and a closed-loop coupling control unit.

[0030] The sensing acquisition unit includes a refrigerant pressure sensor, a refrigerant flow sensor, a refrigerant temperature sensor, a valve position sensor, and a data acquisition card; the refrigerant pressure sensor, the refrigerant flow sensor, and the refrigerant temperature sensor are installed at the test points of the inlet / outlet pipelines of the measured refrigerant valve, and the valve position sensor is fixed to the valve stem of the measured refrigerant valve; the signals of each sensor are transmitted to the data acquisition card, and then uploaded to the host computer processing module through a USB interface;

[0031] The closed-loop coupling control unit includes data processing and PID control; the data processing filters, converts, and stores the acquired parameters; the PID control takes the preset target parameters as input and the real-time acquisition values as feedback, and outputs adjustment instructions to the booster pump, the constant-temperature water tank, or the refrigerant valve driving control module.

[0032] Further, the host computer processing module includes a parameter configuration unit, a test time automatic calculation unit, a real-time monitoring unit, a data recording unit, and a failure analysis unit.

[0033] The parameter configuration unit provides a visual interface for configuring environmental parameters, refrigerant parameters, driving parameters, coupling logic parameters, and saving / importing configuration files, and receives user input of total endurance cycle number, coupling condition proportion, single cycle time, and condition temperature-pressure balance time; wherein the coupling logic parameters include parameter correlation formula, PID control parameters, and failure judgment threshold.

[0034] The test time calculation unit calculates the test time and total time of each working condition according to the total endurance cycle number, the proportion of each coupled working condition, the single cycle time and the temperature and pressure balance time of each working condition, so as to support the test plan formulation and progress monitoring.

[0035] The real-time monitoring unit is used for displaying the environmental parameters, refrigerant parameters, valve state and leakage amount of the independent test station in a region, and presents by using a dashboard, a trend curve and a state indicator light.

[0036] The data recording unit is used for creating a folder according to the test date and station number, storing the multi-parameter original data, abnormal event log and test configuration file, and uploading remotely through Ethernet and a server.

[0037] The failure analysis unit is used for generating a PDF format report after the test is completed, including the cumulative cycle number, parameter fluctuation range, failure number and type, failure time distribution, and performing parameter trend curve export and data statistical analysis.

[0038] Further, the calculation process of the test time calculation unit is as follows: (1) receiving the total endurance cycle number, the proportion of each coupled working condition, the single cycle time and the temperature and pressure balance time of each working condition input by a user.

[0039] (2) calculating the target cycle number of each "pressure-temperature-flow" coupled working condition, and the calculation formula is as follows:

[0040]

[0041] wherein, is the total cycle number under the i th "pressure-temperature" coupled working condition; is the total endurance cycle number of the refrigerant valve; is the cycle number proportion of the working condition;

[0042] (3) calculating the single working condition time according to the target cycle number, the single cycle time and the temperature and pressure balance time of each working condition, and the calculation formula is as follows:

[0043]

[0044] wherein, is the test duration of the i th coupled working condition; is the single opening and closing cycle time of the refrigerant valve; is the temperature and pressure balance time of the working condition;

[0045] ​​​​​​​​(4) Accumulate all working condition time to generate total test time, the formula is:

[0046]

[0047] Wherein, Total test time of whole process, m is total number of coupling working conditions.

[0048] Further, the real-time monitoring unit collects the number of completed cycles of the current working condition in real time ;

[0049] According to Progress is calculated, and the formula is: current working condition progress = ;

[0050] According to The remaining time is calculated and dynamically updated, and the formula is: current working condition remaining time = ;

[0051] According to The total remaining time is calculated and displayed in real time, and the formula is: total progress = sum of completed working condition time / ×100%.

[0052] Further, the safety protection module includes a hardware safety component and a software safety unit.

[0053] The hardware safety component includes: a safety valve and a bursting disc are arranged in series at the outlet of the booster pump in the refrigerant main pipeline; a refrigerant leakage sensor is installed in the environmental test box, and the box door is provided with an electromagnetic lock; an explosion-proof exhaust device is arranged outside the environmental test box; a plurality of emergency stop buttons are arranged, and after being pressed, all device power sources except the exhaust device are cut off, and the refrigerant storage tank outlet valve is closed.

[0054] The software safety unit includes: two levels of permissions, administrator and operator, are set, the administrator is used for configuring safety threshold and operation permission, and the operator is used for executing the normal operation of test starting / pausing; when overpressure, excessive leakage and temperature anomaly are detected, sound and light alarms are triggered, emergency treatment instructions are displayed on the interface, and alarm logs are recorded synchronously.

[0055] The beneficial effects of the application are:

[0056] This invention achieves coordinated control of multiple parameters such as temperature, pressure, and refrigerant state through a multi-parameter coupled environmental simulation and closed-loop control module. This accurately replicates the complex operating conditions of real vehicles, significantly improving the consistency between test conditions and actual usage scenarios, and ensuring the reliability and reference value of test results. Through integrated automatic calculation logic for durability test time, combined with real-time parameter feedback to dynamically correct test duration, it replaces manual calculation, effectively avoiding time planning deviations and improving the accuracy and execution efficiency of test plans. The sealed design and multi-station layout of the dedicated test fixture adapts to the characteristics of the refrigerant to reduce leakage risks, while supporting parallel testing of multiple refrigerant valves, balancing test stability and efficiency. Through a hardware and software collaborative safety protection module, targeted leakage monitoring and overpressure protection mechanisms are set up for the refrigerant characteristics, significantly improving the safety of the testing process and reducing equipment maintenance costs. Overall, it achieves precision, automation, and safety in the durability testing of automotive refrigerant valves. Attached Figure Description

[0057] Figure 1 This is a schematic diagram of the durability testing system for automotive refrigerant valves based on multi-parameter coupling control, as described in this invention.

[0058] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0059] It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0060] like Figure 1 As shown, the present invention provides a durability testing system for automotive refrigerant valves based on multi-parameter coupling control, including a power supply and refrigerant supply module, a multi-parameter coupling environment simulation module, a refrigerant valve drive control module, a multi-parameter acquisition and coupling control module, a refrigerant valve dedicated test fixture module, a host computer processing module, and a safety protection module;

[0061] The upper computer processing module is connected with the power supply and refrigerant medium supply module, the multi-parameter coupled environment simulation module, the refrigerant valve driving control module, the multi-parameter acquisition and coupling control module, the refrigerant valve special test tooling module and the safety protection module respectively.

[0062] (1) Upper computer processing module

[0063] The upper computer processing module is used for receiving sensor data of the multi-parameter acquisition and coupling control module, receiving work station state of the refrigerant valve special test tooling module and alarm information of the safety protection module, and issuing control instructions to the multi-parameter coupled environment simulation module, the refrigerant valve driving control module and the power supply and refrigerant medium supply module.

[0064] The upper computer processing module comprises a parameter configuration unit, a test time automatic calculation unit, a real-time monitoring unit, a data recording unit and a failure analysis unit, is used for realizing digital control of the whole process of the system, providing parameter configuration, real-time monitoring, data storage and failure analysis integrated functions, and supporting test process tracing and result evaluation.

[0065] The parameter configuration unit provides a visual interface, is used for configuring environment parameters, refrigerant parameters, driving parameters and coupling logic parameters, saving / importing configuration files, receiving total endurance cycle number, coupling condition proportion, single cycle time and condition temperature-pressure balance time input by a user, and the coupling logic parameters comprise parameter correlation formula (such as temperature-pressure linkage curve), PID control parameter (proportion coefficient, integral time and differential time) and failure determination threshold (such as response delay> 500 ms).

[0066] The data recording unit is used for creating a folder according to test date-work station number, storing multi-parameter original data, abnormal event log (containing time, parameter value and processing measures) and test configuration file, and uploading remotely to a server through Ethernet.

[0067] The failure analysis unit is used to generate a PDF format report after the test ends, including cumulative cycle number, parameter fluctuation range, failure number and type (such as leakage failure, response failure), failure time distribution, and parameter trend curve derivation and data statistical analysis (such as average cycle number before failure).

[0068] The test time calculation unit calculates the test time and total time of each working condition according to the total endurance cycle number, the proportion of each coupled working condition, the single cycle time, and the temperature and pressure balance time of each working condition, to support test plan formulation and progress monitoring.

[0069] The calculation process of the test time calculation unit is as follows: (1) receiving user input of total endurance cycle number , the proportion of each coupled working condition , single cycle time , and temperature and pressure balance time of each working condition .

[0070] (2) Calculate the target cycle number of each "pressure-temperature-flow" coupled working condition , the calculation formula is:

[0071]

[0072] Wherein, is the total cycle number under the i-th "pressure-temperature" coupled working condition; is the total endurance cycle number of the refrigerant valve (such as 100,000 times); is the cycle number proportion of the working condition (such as 20%);

[0073] (3) Calculate the single working condition time according to the target cycle number , single cycle time , and temperature and pressure balance time of each working condition , the calculation formula is:

[0074]

[0075] Wherein, is the test duration of the i-th coupled working condition; is the single on-off cycle time of the refrigerant valve (such as 10 seconds / time); is the temperature and pressure balance time of the working condition (such as temperature change + stabilization time from -40℃ to 50℃, 30 minutes);

[0076] (4) Add up all working condition times to generate total test time, and finally display the working condition detail time list and total test time on the interface. The total test time calculation formula is:

[0077]

[0078] in, The total test time is denoted by m, where m represents the total number of coupled operating conditions (e.g., 5).

[0079] The real-time monitoring unit is used to display environmental parameters, refrigerant parameters, valve status, and leakage at independent test stations in different areas, using dashboards, trend curves, and status indicator lights; it also supports viewing detailed parameters for each station (triggered by station number association).

[0080] The real-time monitoring unit collects the number of cycles completed under the current operating condition in real time. ;

[0081] (1) According to The progress is calculated using the following formula: Current progress = ;

[0082] (2) According to Calculate the remaining time and update it dynamically. The calculation formula is: Remaining time under current operating conditions = ;

[0083] (3) According to The total remaining time is calculated and displayed in real time. The calculation formula is: Total progress = Sum of completed time / ×100%.

[0084] In addition, the multi-parameter coupled environment simulation module will simulate the actual temperature and pressure equilibrium time. Feedback is sent to the host computer processing module, which then processes the data. The calculation process (3) of updating the test time calculation unit To ensure the accuracy of single-condition time calculation (e.g., the original plan of 93 hours is revised to 93 hours + 5 minutes).

[0085] The drive control module will control the actual single cycle time of the refrigerant valve. Feedback is sent to the host computer processing module, which then processes the data. The calculation process (3) of updating the test time calculation unit The remaining time calculation is dynamically adjusted (e.g., the original remaining 5 hours are corrected to 6 hours).

[0086] The multi-parameter acquisition and coupling control module uploads the current operating conditions' pressure and temperature stability status in real time (e.g., the target pressure of 1.5 MPa has been reached and stabilized for 5 minutes), triggering the upper computer processing module to make a judgment. When the timing ends, the calculation process of the test time calculation unit starts (3) and the number of loops in the formula is counted. ).

[0087] The formula automatically calculates the time, replacing manual calculation, reducing calculation errors caused by complex parameters (multiple pressures, multiple temperature couplings); combined with real-time feedback and correction time, ensuring the accuracy of progress monitoring (error <5%); the formula calculation process and parameters (such as 、 ) are automatically recorded to the data log for subsequent tracing of the impact of different working conditions on the total time. Ultimately, the full-process automation of parameter input-automatic calculation-real-time correction-progress monitoring is achieved, significantly improving the accuracy and executability of test plans in multiple parameter coupling scenarios.

[0088] (2) Power supply and refrigerant medium supply module

[0089] The power supply and refrigerant medium supply module is used to receive the power supply switching instructions of the host computer processing module, provide power to the multi-parameter coupling environment simulation module, refrigerant valve drive control module, multi-parameter acquisition and coupling control module, and refrigerant valve dedicated test tooling module; receive the pressure adjustment instructions of the multi-parameter acquisition and coupling control module, deliver refrigerant to the refrigerant valve dedicated test tooling module and recycle, and feed back the pressure data to the safety protection module.

[0090] The power supply and refrigerant medium supply module includes a power supply unit and a refrigerant medium supply unit, which work cooperatively through electrical connection lines and pipeline interfaces; it is used to provide stable power supply for each module of the system and provide refrigerant medium meeting the pressure requirements for the test process, realizing medium recycling.

[0091] The power supply unit includes a 220V AC main power supply, a first DC power supply, a second DC power supply, and a multi-way fuse; the 220V AC main power supply supplies power to the environmental test chamber and the refrigerant valve drive control module; the first DC power supply and the second DC power supply selectively supply power to the measured refrigerant valve through a switch, and each power supply circuit is connected in series with the fuse to prevent equipment damage caused by short circuit of the measured refrigerant valve;

[0092] The refrigerant medium supply unit includes a refrigerant storage tank, a booster pump, a refrigerant filter, a one-way valve, and a refrigerant recovery tank; the outlet of the refrigerant storage tank is connected in sequence through a pipeline to the filter, the booster pump, and the one-way valve, and then communicates with the inlet of the measured refrigerant valve through a quick connector; the outlet of the measured refrigerant valve is connected through a pipeline to the refrigerant recovery tank, forming a closed loop circulation; the booster pump integrates a pressure controller for receiving instructions from the host computer processing module to adjust the refrigerant pressure.

[0093] (3) Multi-parameter coupling environment simulation module

[0094] The multi-parameter coupled environment simulation module is configured to receive the temperature and humidity and refrigerant temperature instructions from the host computer processing module, provide coupled environment conditions to the refrigerant valve dedicated test tool module, feed back real-time environment data to the host computer processing module, receive refrigerant temperature adjustment instructions from the multi-parameter acquisition and coupled control module and execute the instructions.

[0095] The multi-parameter coupled environment simulation module includes an environmental test chamber, a refrigerant temperature control assembly, and a multi-parameter load spectrum configuration unit, and is configured to simulate complex real vehicle environment conditions, realize coordinated control of environmental temperature and humidity and refrigerant temperature, and provide basic environment conditions for durability testing.

[0096] The environmental test chamber is a temperature and humidity test chamber, the temperature control range is -40-180°C, the humidity control range is 10%-98% RH, an environmental temperature sensor and a humidity sensor are installed on the inner side wall of the environmental test chamber, and the sensor signals are transmitted to the multi-parameter acquisition and coupled control module through signal lines.

[0097] The refrigerant temperature control assembly includes a constant temperature water tank (temperature control range -20-80°C, accuracy ±0.5°C) and a refrigerant heat exchange coil, the heat exchange coil is laid in the environmental test chamber, the inlet and outlet of the heat exchange coil are connected to the water outlet and the return water outlet of the constant temperature water tank through pipelines respectively to form a water circulation loop, and the constant temperature water tank communicates with the host computer processing module through an RS485 bus, receives temperature adjustment instructions, and is configured to control the temperature of the refrigerant in the refrigerant pipeline in the environmental test chamber.

[0098] The multi-parameter load spectrum configuration unit is integrated in the host computer processing module and includes a parameter input interface and a logic control interface, the parameter input interface is configured to configure parameter groups of environmental temperature, environmental humidity, refrigerant temperature, refrigerant pressure, and durability cycle number, and can import a preset load spectrum table, and the logic control interface is configured to send adjustment instructions to the environmental test chamber and the constant temperature water tank according to the configured parameters, realize coupled control of environmental temperature and refrigerant temperature, and support setting of parameter switching balance time.

[0099] (4) Refrigerant valve drive control module

[0100] The refrigerant valve drive control module is configured to receive basic action instructions from the host computer processing module and parameter linkage instructions from the multi-parameter acquisition and coupled control module, output drive signals to the refrigerant valve of the refrigerant valve dedicated test tool module, and feed back valve opening data to the host computer processing module.

[0101] The refrigerant valve drive control module includes a drive execution unit and a coupled drive logic unit, and is configured to accurately control the opening and closing action or proportional opening of the refrigerant valve, dynamically adjust the action logic according to real-time parameters, and simulate the response characteristics of the refrigerant valve in the real vehicle.

[0102] The drive execution unit comprises an electromagnetic valve controller (outputting a PWM signal, control precision ±1% opening degree), a signal input end of the electromagnetic valve controller being connected with the host computer processing module, a signal output end being connected with a coil of the measured refrigerant valve, and being used for outputting a PWM signal to control an opening degree (0%~100% continuously adjustable) of the measured refrigerant valve; an opening degree feedback signal of the measured refrigerant valve is returned to the host computer processing module through a CAN bus, so as to realize action closed-loop control.

[0103] The coupling drive logic unit is integrated in the host computer processing module, comprising basic action configuration and parameter linkage, the basic action configuration is used for setting start-stop frequency, opening degree holding time and action delay, and generating a cycle action instruction of the measured refrigerant valve; the parameter linkage is used for receiving real-time pressure and flow data transmitted by the multi-parameter acquisition and coupling control module, and automatically adjusting a drive instruction (such as increasing the opening degree to 80%) when the parameter exceeds a first preset threshold value (such as pressure > 2.0 MPa), so as to realize parameter-action coupling control.

[0104] (5) Multi-parameter acquisition and coupling control module

[0105] The multi-parameter acquisition and coupling control module is used for acquiring pressure, flow, temperature and valve position data from a refrigerant valve special test tool module, sending to the host computer processing module, and outputting adjustment instructions to the refrigerant valve drive control module, the multi-parameter coupling environment simulation module and the power supply and refrigerant medium supply module, so as to realize parameter closed-loop control.

[0106] The multi-parameter acquisition and coupling control module comprises a sensing acquisition unit and a closed-loop coupling control unit, and is used for real-time acquisition of multi-dimensional test parameters, dynamic coupling between parameters through a closed-loop control algorithm, and ensuring that a test working condition is stable in a preset range.

[0107] The sensing acquisition unit comprises a refrigerant pressure sensor, a refrigerant flow sensor, a refrigerant temperature sensor, a valve position sensor and a data acquisition card; the refrigerant pressure sensor, the refrigerant flow sensor and the refrigerant temperature sensor are installed at test points of inlet / outlet pipelines of the measured refrigerant valve, and the valve position sensor is fixed at a valve rod of the measured refrigerant valve; signals of the sensors are transmitted to the data acquisition card, and then uploaded to the host computer processing module through a USB interface;

[0108] The closed-loop coupling control unit comprises data processing and PID control, the data processing filters, converts and stores the collected parameters; the PID control takes preset target parameters (such as pressure 1.5 MPa, flow 5 L / min) as input, takes real-time collected values as feedback, and outputs adjustment instructions to the booster pump (adjusts pressure), the constant-temperature water tank (adjusts coolant temperature) or the coolant valve driving control module (adjusts valve opening). The control precision meets: pressure ±0.05 MPa, flow ±0.2 L / min, temperature ±0.5℃.

[0109] (6) Special test tooling module for coolant valve

[0110] The special test tooling module for coolant valve is used for receiving power and coolant from the power and coolant medium supply module, receiving driving signals from the coolant valve driving control module, installing and testing the coolant valve, outputting sensor data to the multi-parameter acquisition and coupling control module, outputting leakage data to the safety protection module, and feeding back the station state to the upper computer processing module.

[0111] The special test tooling module for coolant valve comprises a multi-station installation frame, a sealed connection assembly and a leakage detection unit, and is used for realizing parallel installation, sealed connection and independent testing of multiple coolant valves, and simultaneously realizing real-time monitoring of coolant leakage state and guaranteeing testing reliability.

[0112] The multi-station installation frame is provided with multiple independent testing stations, each station adjusts the spacing of the fixing clamps of the measured coolant valve through a slide rail, and an electrical interface plate is arranged on the side surface, integrating a DC power supply interface and a CAN communication interface, which are used for electrical connection of the measured coolant valve.

[0113] The sealed connection assembly is provided with a coolant inlet / outlet quick connector for each independent testing station, the quick connector is connected with the system main pipeline through a coolant-resistant hose, and an annular groove is arranged on the connection surface of the connector and the measured coolant valve, and a butyronitrile rubber sealing ring is arranged in the groove, so that the static leakage rate is less than 0.1 g / h.

[0114] The leakage detection unit comprises multiple micro leak detectors and signal transmission assemblies; the probe of the leak detector is installed at the connection between the measured coolant valve and the quick connector, the detection signal is transmitted to the upper computer processing module through an RS232 bus, and when the leakage amount is greater than a second preset threshold (such as >0.5 g / h), a station testing pause instruction is triggered.

[0115] (7) Safety protection module

[0116] The safety protection module is used for collecting safety data of pressure and leakage from the power supply and refrigerant medium supply module, the multi-parameter coupled environment simulation module and the refrigerant valve special test tooling module, sending an alarm signal to an upper computer processing module, and outputting an emergency shutdown or emergency control instruction to the power supply and refrigerant medium supply module, the multi-parameter coupled environment simulation module and the refrigerant valve special test tooling module.

[0117] The safety protection module includes a hardware safety component and a software safety unit, and is used for protecting against risks such as refrigerant leakage and overpressure through hardware and software cooperation to ensure the safety of personnel and equipment during the test process.

[0118] ① Hardware safety component

[0119] Pressure protection: A safety valve and a bursting disc are arranged in series at the outlet of the booster pump in the main refrigerant pipeline;

[0120] Leakage protection: A refrigerant leakage sensor is arranged in the environmental test box, and the box door is provided with an electromagnetic lock, and an explosion-proof exhaust device is arranged outside the environmental test box;

[0121] Emergency shutdown: Multiple emergency shutdown buttons (next to the upper computer, next to the test box and at the control console) are arranged, and after being pressed, all device power sources except the exhaust device are cut off, and the refrigerant storage tank outlet valve is closed;

[0122] ② Software safety unit

[0123] Authority management: Two levels of authority, i.e., administrator and operator, are set, the administrator is used for configuring safety thresholds and operation authority, and the operator is used for performing normal operations such as test start / pause;

[0124] Safety alarm: When overpressure, excessive leakage or abnormal temperature is detected, an audible and visual alarm is triggered, emergency treatment instructions are displayed on the interface, and alarm logs (including time, triggering conditions and treatment results) are recorded synchronously.

[0125] The application realizes the coordinated regulation of multiple parameters such as temperature, pressure and refrigerant state through the multi-parameter coupling environment simulation and closed-loop control module, accurately reproduces the complex working conditions of the actual vehicle, significantly improves the consistency of the test working conditions and the actual use scene, and ensures the reliability and reference value of the test results; through the integrated durability test time automatic calculation logic, combined with real-time parameter feedback dynamic correction test time, replacing manual calculation, effectively avoiding time planning deviation, improving the accuracy and execution efficiency of the test plan; through the sealing design and multi-station layout of the special test tooling, adapting to the characteristics of the refrigerant medium to reduce the risk of leakage, while supporting parallel testing of multiple refrigerant valves, balancing the test stability and efficiency; through the safety protection module of hardware and software cooperation, setting specific leakage monitoring, overpressure protection and other mechanisms for refrigerant characteristics, significantly improving the safety of the test process, reducing the equipment maintenance cost, and overall realizing the precision, automation and safety of the durability test of the vehicle refrigerant valve.

[0126] It should be noted that in this paper, the term "includes", "contains" or any other variant thereof is intended to cover non-exclusive inclusion, so that the process, device, article or method including a series of elements not only includes those elements, but also includes other elements not explicitly listed, or includes elements inherent to such process, device, article or method. Without more limitations, the element defined by the statement "includes a" does not exclude the presence of other identical elements in the process, device, article or method including the element.

[0127] The above is only the preferred embodiment of the application, and does not limit the patent scope of the application, and any equivalent structure or equivalent process transformation using the content of the application specification and drawings, or direct or indirect application in other related technical fields, are also included in the patent protection scope of the application.

Claims

1. A multi-parameter coupling control-based refrigerant valve durability test system for vehicles, characterized by, The power supply and refrigerant medium supply module, the multi-parameter coupled environment simulation module, the refrigerant valve driving control module, the multi-parameter acquisition and coupled control module, the refrigerant valve special test tooling module, the upper computer processing module and the safety protection module are connected respectively. The power supply and refrigerant medium supply module, the multi-parameter coupled environment simulation module, the refrigerant valve driving control module, the multi-parameter acquisition and coupled control module, the refrigerant valve special test tooling module, the upper computer processing module and the safety protection module are connected respectively. The multi-parameter coupled environment simulation module is used for receiving the temperature and humidity and refrigerant temperature instructions of the upper computer processing module, providing the coupled environment conditions for the refrigerant valve special test tooling module, feeding back the real-time environment data to the upper computer processing module, receiving the refrigerant temperature adjustment instructions of the multi-parameter acquisition and coupled control module and executing. The multi-parameter coupled environment simulation module comprises an environment test box, a refrigerant temperature control assembly and a multi-parameter load spectrum configuration unit. The environment test box adopts a temperature and humidity test box, and environment temperature sensors and humidity sensors are mounted on the inner side wall of the environment test box. The refrigerant temperature control assembly comprises a constant-temperature water tank and a refrigerant heat exchange coil, the heat exchange coil is laid in the environment test box, and the inlet and outlet of the heat exchange coil are connected to the water outlet and the backwater outlet of the constant-temperature water tank through pipelines respectively to form a water circulation loop. The multi-parameter load spectrum configuration unit is integrated in the upper computer processing module and comprises a parameter input interface and a logic control interface. The logic control interface is used for sending adjustment instructions to the environment test box and the constant-temperature water tank according to the configuration parameters to realize coupled control of the environment temperature and the refrigerant temperature. The refrigerant valve driving control module is used for receiving the basic action instructions of the upper computer processing module and the parameter linkage instructions of the multi-parameter acquisition and coupled control module, outputting driving signals to the refrigerant valve of the refrigerant valve special test tooling module and feeding back the valve opening degree data to the upper computer processing module.

2. The multi-parameter coupled control based refrigerant valve durability test system for vehicle of claim 1, wherein, The refrigerant valve drive control module comprises a drive execution unit and a coupling drive logic unit; The drive execution unit comprises an electromagnetic valve controller, a signal input end of the electromagnetic valve controller being connected with the host computer processing module, a signal output end being connected with a coil of the measured refrigerant valve, and being used for outputting a PWM signal to control the opening of the measured refrigerant valve; the opening feedback signal of the measured refrigerant valve is transmitted back to the host computer processing module through a CAN bus, so as to realize action closed-loop control; The coupling drive logic unit is integrated in the host computer processing module, and comprises basic action configuration and parameter linkage; the basic action configuration is used for setting on-off frequency, opening retention time and action delay, and generating a cycle action instruction of the measured refrigerant valve; the parameter linkage is used for receiving real-time pressure and flow data transmitted by the multi-parameter acquisition and coupling control module, and automatically adjusting the drive instruction when the parameter exceeds a first preset threshold, so as to realize parameter-action coupling control.

3. The multi-parameter coupled control based refrigerant valve durability test system for vehicle of claim 2, wherein, The refrigerant valve special test tool module is used for receiving power and refrigerant from the power supply and refrigerant medium supply module, receiving the drive signal of the refrigerant valve drive control module, installing and testing the refrigerant valve, outputting sensor data to the multi-parameter acquisition and coupling control module, outputting leakage data to the safety protection module, and feeding back the station state to the host computer processing module; the refrigerant valve special test tool module comprises a multi-station installation frame, a sealed connection assembly and a leakage detection unit; The multi-station installation frame is provided with a plurality of independent test stations, each station adjusts the spacing of the fixing clamp of the measured refrigerant valve through a slide rail, and an electrical interface plate is arranged on the side surface, and a DC power supply interface and a CAN communication interface are integrated, which are used for electrical connection of the measured refrigerant valve; The sealed connection assembly is provided with a refrigerant inlet / outlet quick connector for each independent test station, the quick connector is connected with a system main pipeline through a refrigerant-resistant hose, and an annular groove is arranged on the connecting surface of the quick connector and the measured refrigerant valve, and a butyronitrile rubber sealing ring is arranged in the groove; The leakage detection unit comprises a plurality of micro leak detectors and a signal transmission assembly; the leak detector probe is installed at the connection between the measured refrigerant valve and the quick connector, and the detection signal is transmitted to the host computer processing module through an RS232 bus; when the leakage amount is greater than a second preset threshold, a station test pause instruction is triggered.

4. The multi-parameter coupled control based refrigerant valve durability test system for vehicle of claim 3, wherein, The power supply and refrigerant medium supply module is used for receiving a power switching instruction of the host computer processing module, providing power for the multi-parameter coupling environment simulation module, the refrigerant valve drive control module, the multi-parameter acquisition and coupling control module and the refrigerant valve special test tool module; receiving a pressure adjustment instruction of the multi-parameter acquisition and coupling control module, conveying refrigerant to the refrigerant valve special test tool module and recycling the refrigerant, and feeding back pressure data to the safety protection module; the power supply and refrigerant medium supply module comprises a power supply unit and a refrigerant medium supply unit. The power supply unit includes a 220V alternating current main power supply, a first direct current power supply, a second direct current power supply, and a plurality of fuses; the 220V alternating current main power supply respectively supplies power to the environmental test box and the refrigerant valve driving control module; the first direct current power supply and the second direct current power supply selectively supply power to the measured refrigerant valve through a switch, and each power supply circuit is connected in series with the fuse, for preventing damage to the equipment caused by short circuit of the measured refrigerant valve; The refrigerant medium supply unit includes a refrigerant storage tank, a booster pump, a refrigerant filter, a one-way valve, and a refrigerant recovery tank; the outlet of the refrigerant storage tank is connected in sequence with the filter, the booster pump, and the one-way valve through a pipeline, and then is communicated with the inlet of the measured refrigerant valve through a quick connector; the outlet of the measured refrigerant valve is connected to the refrigerant recovery tank through a pipeline, forming a closed loop circulation; the booster pump is integrated with a pressure controller, for receiving instructions from the host computer processing module to adjust the refrigerant pressure.

5. The multi-parameter coupled control based refrigerant valve durability test system for vehicle of claim 4, wherein, The multi-parameter acquisition and coupling control module is used to acquire pressure, flow, temperature, and valve position data from the refrigerant valve dedicated test tool module, and send the data to the host computer processing module, while outputting adjustment instructions to the refrigerant valve driving control module, the multi-parameter coupling environment simulation module, the power supply and refrigerant medium supply module, to realize closed loop control of parameters; the multi-parameter acquisition and coupling control module includes a sensing acquisition unit and a closed loop coupling control unit; The sensing acquisition unit includes a refrigerant pressure sensor, a refrigerant flow sensor, a refrigerant temperature sensor, a valve position sensor, and a data acquisition card; the refrigerant pressure sensor, the refrigerant flow sensor, and the refrigerant temperature sensor are installed at test points of the inlet / outlet pipeline of the measured refrigerant valve, and the valve position sensor is fixed at the valve stem of the measured refrigerant valve; the signals of each sensor are transmitted to the data acquisition card, and then uploaded to the host computer processing module through a USB interface; The closed loop coupling control unit includes data processing and PID control; the data processing filters, converts, and stores the acquired parameters; the PID control takes preset target parameters as input, and real-time acquisition values as feedback, and outputs adjustment instructions to the booster pump, the constant temperature water tank, or the refrigerant valve driving control module.

6. The multi-parameter coupled control based refrigerant valve durability test system for vehicle of claim 5, wherein, The host computer processing module is used to receive sensor data from the multi-parameter acquisition and coupling control module, and to receive work station state and alarm information from the safety protection module of the refrigerant valve dedicated test tool module, and to issue control instructions to the multi-parameter coupling environment simulation module, the refrigerant valve driving control module, and the power supply and refrigerant medium supply module; the host computer processing module includes a parameter configuration unit, a test time automatic calculation unit, a real-time monitoring unit, a data recording unit, and a failure analysis unit; The parameter configuration unit provides a visual interface for configuring environmental parameters, refrigerant parameters, driving parameters, and coupling logic parameters, and saving / importing configuration files, and receiving user input of total endurance cycle number, coupling condition proportion, single cycle time, and each condition temperature and pressure balance time; wherein, the coupling logic parameters include parameter correlation formula, PID control parameters, and failure determination threshold value. The test time automatic calculation unit calculates the test time of each working condition and the total time according to the total durability cycle number, the proportion of each coupling working condition, the single cycle time and the temperature and pressure balance time of each working condition, so as to support the test plan formulation and progress monitoring; The real-time monitoring unit is used for displaying the environmental parameters, refrigerant parameters, valve state and leakage amount of the independent test station in a region, and presents by using the instrument panel, trend curve and state indicator light; The data recording unit is used for creating a folder according to the test date and station number, storing the multi-parameter original data, abnormal event log and test configuration file, and uploading remotely through the Ethernet and the server; The failure analysis unit is used for generating a PDF format report after the test is completed, including the cumulative cycle number, parameter fluctuation range, failure number and type, failure time distribution, and performing the parameter trend curve export and data statistical analysis.

7. The multi-parameter coupled control based refrigerant valve durability test system for vehicle of claim 6, wherein, The calculation process of the test time automatic calculation unit is as follows: (1) total endurance cycle number input by user , coupling condition proportion of each condition , single cycle time , temperature and pressure balance time of each condition ; (2) Calculate the target cycle number for each "pressure-temperature-flow" coupling condition , the calculation formula is: ​ wherein, is the total number of cycles for the i-th "pressure-temperature" coupling condition; is the total number of durability cycles of the refrigerant valve; is the cycle number ratio of the condition; (3) According to the target cycle number With single cycle time , each operating temperature and pressure equilibrium time Single operating time is calculated, and the calculation formula is: ; wherein, is the test duration for the i-th coupling condition; is the single opening and closing cycle time of the refrigerant valve; is the temperature and pressure balance time for the condition; (4) Accumulate all the working condition time to generate the total test time, whose formula is: ​ wherein is the total test time for the whole process, m is the total number of coupled operating conditions.

8. The multi-parameter coupled control based refrigerant valve durability test system for vehicle of claim 7, wherein, The real-time monitoring unit collects the completed cycle number of the current working condition in real time ; according to The calculation formula is: current working condition progress = (current working condition cycle number - initial working condition cycle number) / (target working condition cycle number - initial working condition cycle number) ; According to The remaining duration is calculated and dynamically updated, and the calculation formula is: the remaining time of the current working condition = ; according to The total remaining time is calculated and displayed in real time, and the calculation formula is: total progress = sum of completed working condition time / × 100%.

9. The multi-parameter coupled control based refrigerant valve durability test system for vehicle of claim 8, wherein, The safety protection module is used for collecting the safety data of pressure and leakage from the power supply and refrigerant medium supply module, the multi-parameter coupled environment simulation module and the refrigerant valve special test tooling module, sending an alarm signal to the upper computer processing module, and outputting an emergency stop or emergency control instruction to the power supply and refrigerant medium supply module, the multi-parameter coupled environment simulation module and the refrigerant valve special test tooling module; the safety protection module comprises a hardware safety component and a software safety unit; The hardware safety component comprises a safety valve and a bursting disc installed in series at the outlet of the booster pump in the refrigerant main pipeline, a refrigerant leakage sensor installed in the environmental test box, an electromagnetic lock provided on the box door, an explosion-proof exhaust device provided outside the environmental test box, and multiple emergency stop buttons which are pressed to cut off the power supply of all devices except the exhaust device and close the outlet valve of the refrigerant storage tank; The software safety unit comprises an administrator-operator two-level permission, an administrator for configuring safety threshold and operation permission, and an operator for performing the normal operation of test start / pause; when overpressure, excessive leakage and temperature anomaly are detected, an audible and light alarm is triggered, emergency treatment instructions are displayed on the interface, and alarm logs are recorded synchronously.

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