A comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices

Abstract

This invention relates to the field of gas pressure regulating device testing and discloses a comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices. Compared to current technologies that only study the evolution of quality defects in gas pressure regulating devices from a single perspective, resulting in incomplete research, this application uses vibration and fatigue simulation devices to transmit vibration and mechanical loads to the gas pressure regulating device. A gas source drives solid particles injected by an erosion simulation device and corrosive media injected by a corrosion simulation device. The gas pressure regulating device is repeatedly eroded through a loop pipeline, replicating the process where vibration during production accelerates the shedding of corrosion products and surface hardened layers, exposing fresh metal surfaces and intensifying corrosion. Simultaneously, the detached particles become new abrasive materials, further exacerbating material loss—a vicious cycle. By collecting relevant data during the experiment, a comprehensive experimental study of the evolution of quality defects in gas pressure regulating devices is achieved.

Description

Technical Field

[0001] This invention relates to the field of gas pressure regulating device testing, and in particular to a comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices. Background Technology

[0002] Gas pressure regulators are pressure-reducing devices used in gas transmission and distribution systems to regulate the gas supply pressure. Their basic task is to adjust the higher inlet pressure upstream to the pressure required downstream. As an important device for regulating gas supply pressure, gas pressure regulators ensure that gas is used safely, economically, and efficiently. Their safety and reliability directly affect the stability of gas supply and public safety.

[0003] However, during long-term service, gas pressure regulating devices are prone to quality defects such as cracks and wear due to airflow impact and corrosion, leading to problems such as internal leakage, malfunction, and blockage, seriously threatening the safe operation of the system. Current technology typically uses simulated stress conditions on gas pressure regulating devices, applying corrosive or mechanical loads to conduct experimental studies on the evolution of quality defects. However, this method has a limited perspective, and the operating conditions of gas pressure regulating devices are complex, with multiple factors interacting to exacerbate the damage.

[0004] Therefore, how to conduct experimental research on the evolution of quality defects in gas pressure regulating devices from multiple angles, more comprehensively and accurately is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to address the problem that current technologies, which only study the evolution of quality defects in gas pressure regulating devices from a single perspective, have incomplete research angles and cannot replicate the complex environment in which the gas pressure regulating device operates, resulting in inaccurate experimental data. Therefore, this invention provides a comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices, which can conduct experimental research on the evolution of quality defects in gas pressure regulating devices from multiple angles, in a more comprehensive and accurate manner.

[0006] To address the aforementioned technical problems, this invention provides a comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices, comprising:

[0007] Erosion simulation device, corrosion simulation device, vibration simulation device, fatigue simulation device, and data acquisition device;

[0008] The gas source flows through a loop pipe to the gas pressure regulating device, and the two ends of the loop pipe are respectively connected to the gas inlet and the gas outlet of the gas pressure regulating device;

[0009] The erosion simulation device and the corrosion simulation device are respectively connected to the loop pipeline and inject solid particles and corrosive media into the loop pipeline respectively;

[0010] The vibration simulation device and the fatigue simulation device are respectively connected to the gas pressure regulating device and are used to transmit vibration load and mechanical load to the gas pressure regulating device;

[0011] The erosion simulation device, the corrosion simulation device, the vibration simulation device, and the fatigue simulation device enable the gas pressure regulating device to generate data for experimental research on the evolution of quality defects.

[0012] Preferably, it also includes: a test chamber; the test chamber includes an inner liner, an outer shell, and an insulation layer located between the two;

[0013] The gas pressure regulating device is installed inside the inner liner, and the corrosion simulation device is also connected to the inner liner and injects a corrosive medium into the inner liner along with the gas source.

[0014] Preferably, the corrosion simulation device includes: a corrosion liquid storage tank and an atomizer;

[0015] The corrosive liquid storage tank is used to store a corrosive acidic solution, and the atomizer is used to atomize the acidic solution into micron-sized droplets and then inject it into the loop pipeline.

[0016] Preferably, the erosion simulation device includes: a particle storage tank, a feeder, and a mixing chamber;

[0017] The particle storage tank is used to store solid particles of a preset particle size; the feeder is used to control the number of solid particles injected into the mixing chamber; the solid particles and corrosive media can be mixed in the mixing chamber and then injected into the loop pipeline.

[0018] Preferably, the vibration simulation device includes: a piezoelectric ceramic actuator, a horizontal clamping arm, and a shock-absorbing suspension component;

[0019] The horizontal clamping arm is used to clamp the gas pressure regulating device, and the piezoelectric ceramic actuator applies vibration to the gas pressure regulating device through the shock-absorbing suspension.

[0020] Preferably, the fatigue simulation device includes: a heater, a hydraulic power unit, a hydraulic cylinder, a hydraulic arm, a clamping arm, and a clamping head;

[0021] The clamp head is used to fix the gas pressure regulating device, and the hydraulic power unit is used to drive the hydraulic cylinder, so that the hydraulic cylinder can apply alternating mechanical load to the gas pressure regulating device through the hydraulic arm and the clamp arm;

[0022] The heater is used to regulate the temperature inside the test chamber.

[0023] Preferably, the data acquisition device includes: a force sensor for monitoring mechanical loads; an accelerometer for monitoring vibration loads; a strain gauge for measuring stress; an electrochemical monitoring probe for monitoring corrosion electrochemical signals; a pressure gauge for monitoring the internal pressure of the loop pipeline and the internal pressure of the test chamber; a thermometer for monitoring the internal temperature of the test chamber; and a flow meter for monitoring gas flow.

[0024] Preferably, it also includes: a recycling and processing device;

[0025] The recycling and processing device is used to connect the test chamber and the loop pipe to the external space.

[0026] Preferably, the air source includes a compressed air tank and a circulation pump;

[0027] The compressed gas tank is connected to the loop pipeline, and the circulation pump is used to drive the gas flow in the loop pipeline;

[0028] The circuit pipe is connected to the inlet and outlet of the gas pressure regulating device via a simulated flange.

[0029] Preferably, it further includes: a processing unit; the processing unit is connected to the data acquisition device and is used to conduct quality defect evolution experiments on the gas pressure regulating device based on the received data, and to compare and correlate with the microscopic dissection analysis results of the components of the gas pressure regulating device.

[0030] This invention provides a comprehensive experimental system for the evolution of quality defects in urban gas pressure regulators. Compared to current technologies that only study the evolution of quality defects in gas pressure regulators from a single perspective, resulting in incomplete research and inaccurate experimental data due to the inability to replicate the complex environment in which the gas pressure regulator operates, this application uses vibration and fatigue simulation devices to transmit vibration and mechanical loads to the gas pressure regulator. A gas source drives solid particles injected by an erosion simulation device and corrosive media injected by a corrosion simulation device, repeatedly scouring the gas pressure regulator through a loop pipeline. By simulating erosion, corrosion, vibration, and fatigue processes, this application replicates the vicious cycle in which vibration during the production process accelerates the shedding of corrosion products and surface hardened layers, exposing fresh metal surfaces and intensifying corrosion. Simultaneously, the detached particles become new abrasive materials, further exacerbating material loss. A data acquisition device collects relevant data during the experiment, enabling experimental research on the evolution of quality defects in the gas pressure regulator. Attached Figure Description

[0031] To more clearly illustrate the embodiments of this application, the accompanying drawings used in the embodiments 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.

[0032] Figure 1 This is a structural diagram of a comprehensive experimental system for the evolution of quality defects in a town gas pressure regulating device, provided in an embodiment of the present invention.

[0033] Figure 2 This is a structural diagram of a test chamber provided in an embodiment of the present invention;

[0034] The attached figures are labeled as follows: 1 is the erosion simulation device, 2 is the corrosion simulation device, 3 is the fatigue simulation device, 4 is the loop pipeline, 5 is the compressed air tank, 6 is the circulating pump, 7 is the heater, 8 is the recycling and processing device, 9 is the imitation flange, 10 is the test chamber, 11 is the sealing door cover, 12 is the vertical support rod, 13 is the hydraulic cylinder, 14 is the hydraulic power unit, 15 is the hydraulic arm, 16 is the clamp arm, 17 is the clamp head, 18 is the fastening bolt, 19 is the height adjustment mechanism, 20 is the horizontal clamp arm, 21 is the shock-absorbing suspension component, 22 is the piezoelectric ceramic actuator, 23 is the inner liner, 24 is the insulation layer, and 25 is the outer shell. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present invention.

[0036] The core of this invention is to provide a comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices, which can be used to conduct experimental research on the evolution of quality defects in gas pressure regulating devices from multiple perspectives, in a more comprehensive and accurate manner.

[0037] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0038] Figure 1 A structural diagram of a comprehensive experimental system for the evolution of quality defects in a town gas pressure regulating device, provided in an embodiment of the present invention, is shown below. Figure 1 As shown, the system includes:

[0039] Erosion simulation device 1, corrosion simulation device 2, vibration simulation device, fatigue simulation device 3, and data acquisition device;

[0040] The gas source flows through the gas pressure regulating device via the loop pipe 4, and the two ends of the loop pipe 4 are connected to the gas inlet and the gas outlet of the gas pressure regulating device, respectively.

[0041] Erosion simulation device 1 and corrosion simulation device 2 are respectively connected to loop pipe 4, and solid particles and corrosive media are respectively injected into loop pipe 4;

[0042] Vibration simulation device and fatigue simulation device 3 are respectively connected to gas pressure regulating device to transmit vibration load and mechanical load to gas pressure regulating device;

[0043] The erosion simulation device 1, corrosion simulation device 2, vibration simulation device, and fatigue simulation device 3 enable the gas pressure regulating device to generate data for experimental research on the evolution of quality defects.

[0044] The comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices provided in this application is used to conduct experimental research on the evolution of quality defects in gas pressure regulating devices, thereby further realizing reliability testing and life prediction. It is mainly applied to gas pressure regulating devices used in urban areas. As an important device for regulating the pressure of gas supply, the gas pressure regulating device can ensure that gas is used under safe, economical and efficient conditions. In urban applications, gas pressure regulating devices (such as pressure regulating valves and safety shut-off valves) are exposed to gas environments containing impurities and corrosive media for extended periods. Their failure mechanisms exhibit multi-factor coupling characteristics. First, there is erosion damage, where high-speed gas flow carrying solid particles causes mechanical wear on the valve port and seat. Especially when the valve opening is less than 30%, the local flow velocity can reach over 200 m / s, leading to blunting of the valve port's sharp angle. Second, there is electrochemical corrosion, where trace amounts of moisture in the gas react with H2S / CO2 to form an acidic electrolyte, causing corrosion and perforation of the valve body and diaphragm. Experiments have shown that the corrosion rate increases threefold when the H2S concentration is >50 ppm. Third, there is vibration and alternating stress. Pressure fluctuations (0.2~4.0 MPa) and gas flow pulsations induce high-frequency vibrations in the typical frequency range of 20~500 Hz, leading to fatigue cracks in parts such as the valve stem and support. Erosion forms pitting or directional erosion marks, destroys the passivation film on the material surface and accelerates corrosion, while the shedding of corrosion products exacerbates particle erosion. Vibration promotes crack propagation and the penetration of corrosive media. Under alternating stress, the crack tip undergoes plastic deformation. The combined effect of multiple factors multiplies the damage rate.

[0045] To accurately simulate the working environment of gas pressure regulators, this application provides various simulation devices capable of simulating the potential quality defects such as cracks and wear that may occur in gas pressure regulators during long-term service under the coupled effects of multiple factors including vibration, pressure fluctuations, fluid erosion, and corrosion, leading to problems such as internal leakage, malfunction, and blockage. Finally, by collecting relevant data, the performance degradation patterns and failure mechanisms of gas pressure regulators during long-term operation are analyzed, providing experimental basis for the safe operation and lifespan optimization of gas systems.

[0046] This embodiment provides a specific gas source structure, including a compressed gas tank 5 and a circulating pump 6. The compressed gas tank 5 is connected to a loop pipeline 4, and the circulating pump 6 is used to drive the gas flow in the loop pipeline 4. The loop pipeline 4 is connected to the inlet and outlet of a gas pressure regulating device via a simulated flange 9. The compressed gas tank 5 can generate a high-speed airflow, which, through connection with the gas pressure regulating device, simulates the impact of the airflow. Furthermore, by injecting corrosive media and solid particles, it simulates the erosion and corrosion of the gas pressure regulating device. In this embodiment, the compressed gas tank 5 is connected to the inlet and outlet of the gas pressure regulating device through the loop pipeline 4, and the gas can conduct multiple and repeated scouring experiments on the gas pressure regulating device through the loop pipeline 4. It can be understood that the function of the compressed gas tank 5 is to generate an impact airflow, thereby driving corrosive media and solid particles to simulate the scouring of the gas pressure regulating device. The gas generated by the compressed gas tank 5 can be air. Of course, to more accurately verify the impact of corrosive media and solid particles on the gas pressure regulating device, the gas generated by the compressed gas tank 5 can be an inert gas, which can improve the safety of the experimental process while ensuring accurate experimental data. Furthermore, in order to ensure the tightness of the connection between the loop pipe 4 and the gas pressure regulating device and to avoid the impact of leakage on the environment and experimental equipment, the loop pipe 4 can be connected to the gas inlet and outlet of the gas pressure regulating device through the imitation flange 9. During installation, the standard flange sealing procedure is used to ensure that the connection is absolutely sealed.

[0047] The erosion simulation device 1 in this application is used to simulate the particulate erosion effects that a gas pressure regulating device may receive during actual production. These particles are mainly solid particles. Therefore, in this embodiment, the erosion simulation device 1 is used to inject solid particles into the airflow of the loop pipe 4. During the experiment, the solid particles can be sand, dust, metal particles, etc. It should be noted that, since the particulate erosion conditions experienced by gas pressure regulating devices vary in different regions and under different working environments, in order to improve the accuracy of the experiment, the diameter of the solid particles and their concentration after injection into the airflow can be adjusted accordingly.

[0048] This embodiment provides a specific erosion simulation device 1, which includes a particle storage tank, a feeder, and a mixing chamber. The particle storage tank stores solid particles of a preset size, such as quartz sand (50-200 μm) or alumina powder (5-50 μm). The feeder controls the amount of solid particles injected into the mixing chamber, thereby controlling the concentration of the injected gas flow. The solid particles and the corrosive medium in the loop pipe 4 are mixed in the mixing chamber, ensuring uniform injection of particles into the loop pipe 4.

[0049] The corrosion simulation device 2 simulates the corrosion effects on the gas regulating device. Similar to the erosion simulation device 1, it simulates the erosion of the gas pressure regulating device by injecting a corrosive medium into the loop pipe 4 and allowing it to flow with the gas. It is understood that gas pressure regulating devices are often corroded by acidic substances in actual production operations. Therefore, the corrosive medium in the corrosion simulation device 2 can be configured as an acidic medium. This embodiment provides a specific corrosion simulation device 2, which includes a corrosive liquid storage tank and an atomizer. The corrosive liquid storage tank stores a corrosive acidic solution, such as a 0.1M HCl + 0.05M FeCl3 solution (simulating H2S corrosion equivalent), while the atomizer atomizes the acidic solution into micron-sized droplets before injecting it into the loop pipe 4.

[0050] The vibration simulation device and fatigue simulation device 3 simulate the working environment of the gas regulator from a stress perspective. The vibration simulation device transmits vibration loads to the gas regulator, while the fatigue simulation device 3 transmits mechanical loads. The data acquisition device collects stress conditions and environmental data of the gas regulator during the experiment to conduct experimental research on the evolution of quality defects in the gas pressure regulating device.

[0051] As can be seen, this application comprehensively studies the evolution of quality defects in gas pressure regulating devices through simulation of various operating conditions. Specifically, the erosion process simulation involves injecting particles of a certain size into the gas flow and conducting a circulating flow test through the gas pressure regulating device to simulate the erosive effect of impurities in the gas on the device. Furthermore, by controlling the airflow speed and particle size, the erosion conditions that the device may encounter in actual operation are accurately simulated. During data acquisition, laser scanners, stereomicroscopes, and electron microscopes can be used to analyze damage such as etching and pitting, and to measure wear. The corrosion process simulation involves creating corrosive media of different concentrations and temperatures to simulate the corrosion of the gas pressure regulating device under different operating environments. Data acquisition uses an electrochemical corrosion monitoring probe to measure the corrosion effect of the media on the surface of the gas pressure regulating device. The vibration process simulation involves applying vibration loads to study the development of microcracks, material deformation, and damage on the surface of the gas pressure regulating device. The fatigue process simulation involves applying periodic mechanical loads, and by adjusting the temperature, the fatigue life at high or low temperatures can be verified, detecting crack propagation, fracture, and failure of the gas pressure regulating device under repeated loading. This application integrates multiple operating conditions to achieve a comprehensive experimental study on the evolution of quality defects in gas pressure regulating devices under complex operating conditions.

[0052] The comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices provided in this application addresses the shortcomings of current technologies that only study the evolution of quality defects in gas pressure regulating devices from a single perspective, resulting in incomplete research and inaccurate experimental data due to the inability to replicate the complex environment in which the gas pressure regulating device operates. This application transmits vibration and mechanical loads to the gas pressure regulating device through vibration and fatigue simulation devices. A gas source drives solid particles injected by an erosion simulation device and corrosive media injected by a corrosion simulation device, repeatedly scouring the gas pressure regulating device through a loop pipeline. By simulating erosion, corrosion, vibration, and fatigue processes, this application replicates the vicious cycle in which vibration during the production process accelerates the shedding of corrosion products and surface hardened layers, exposing fresh metal surfaces and intensifying corrosion. Simultaneously, the detached particles become new abrasive materials, further exacerbating material loss. A data acquisition device collects relevant data during the experiment, enabling experimental research on the evolution of quality defects in the gas pressure regulating device.

[0053] As can be seen from the above embodiments, the particles and corrosive media generated by the erosion simulation device 1 and corrosion simulation device 2 scour the gas pressure regulating device with the gas flow, acting on the inner surface of the gas pressure regulating device, while the vibration simulation device and fatigue simulation device 3 act on the structure of the gas pressure regulating device. It is understandable that in addition to the scouring of the inner surface, the external structure of the gas pressure regulating device is also affected due to long-term exposure to an acidic environment during operation. In order to improve the comprehensiveness of the experiment, the comprehensive experimental system for the evolution of quality defects of urban gas pressure regulating devices in this embodiment also includes: a test chamber 10; the test chamber includes an inner liner 23, an outer shell 25, and an insulation layer 24 located between the two; specifically, the inner liner 23 can be made of corrosion-resistant stainless steel, and the outer shell 25 can be made of pressure-bearing carbon steel. Figure 2 This is a structural diagram of a test chamber provided in an embodiment of the present invention. A gas pressure regulating device is installed inside the inner liner 23. A corrosion simulation device 2 is also connected to the inner liner 23 and injects a corrosive medium into the inner liner 23 along with the gas source. The corrosion-resistant stainless steel inner liner 23 is in direct contact with the corrosive medium, ensuring that the chamber itself is not corroded. The insulation layer 24 is made of insulating aluminum silicate fiber, wrapping the inner liner 23 to maintain a stable internal temperature and reduce heat loss. The pressure-bearing carbon steel outer shell 25 provides the main structural strength and withstands the internal high pressure. The test chamber 10 should be equipped with a sealed door 11 for installing and removing samples.

[0054] In this embodiment, the atomized droplets from the corrosion simulation device 2 are injected into the inner liner 23 in addition to the compressed gas injection loop pipe 4, to simulate an acidic and humid environment and verify the corrosion status of the outer surface of the gas pressure regulating device.

[0055] Based on the above embodiments, this embodiment also provides a specific structure of the vibration simulation device, including a piezoelectric ceramic actuator 22, a horizontal clamping arm 20, and a vibration-damping suspension 21. The horizontal clamping arm 20 is used to clamp the gas pressure regulating device, and the piezoelectric ceramic actuator 22 applies vibration to the gas pressure regulating device through the vibration-damping suspension 21. The vibration center of the piezoelectric ceramic actuator 22 is aligned with the central axis of the gas pressure regulating device to ensure the accuracy of load application. The vibration load applied by the piezoelectric ceramic actuator 22 is transmitted to the gas pressure regulating device through the horizontal clamping arm 20 and the vibration-damping suspension 21. The horizontal clamping arm 20 supports the piezoelectric ceramic actuator 22 and the vibration-damping suspension 21, and the vibration-damping suspension 21 is used to mitigate the effect of the vibration load on the horizontal clamping arm 20. In specific implementation, the vibration simulation device can be installed on the vertical support rod 12, and the horizontal clamp arm 20 can be supported and connected by the height adjustment mechanism 19 using a pin. The vibration damping suspension 21 and the piezoelectric ceramic actuator 22 that realizes the vibration effect are installed on the horizontal clamp arm 20. In application, the same structure can be installed on the left and right sides of the gas pressure regulating device to apply the vibration load.

[0056] The vibration simulation device applies a vibration load to the gas pressure regulating device from a horizontal direction (20°). In this embodiment, the fatigue simulation device 3 applies a mechanical load to the gas pressure regulating device from a vertical direction. The fatigue simulation device 3 includes: a heater 7, a hydraulic power unit 14, a hydraulic cylinder 13, a hydraulic arm 15, a clamping arm 16, and a clamping head 17. The hydraulic arm 15 is used to transmit the mechanical load in the vertical direction and ensure the stability of the loading direction. The clamping arm 16 is used to clamp the sample and transmit the mechanical load in the vertical direction. The hydraulic cylinder 13 is used to generate a large-amplitude, low-frequency reciprocating motion to apply alternating stress. The hydraulic power unit 14 includes a motor, oil pump, oil tank, cooler, etc., to provide power to the hydraulic cylinder 13. The clamping head 17 is used to clamp the gas pressure regulating device. Similarly, this structure can also be in two sets, respectively set at the upper and lower parts of the gas pressure regulating device. The hydraulic power unit 14 and the hydraulic cylinder 13 can be installed at the top and bottom of the test chamber 10.

[0057] In specific implementation, the gas pressure regulating device is fixed to the clamp head 17, the hydraulic power unit 14 drives the hydraulic cylinder 13, and applies alternating mechanical load to the gas pressure regulating device through the hydraulic arm 15 and the clamp arm 16; the heater 7 can be set inside the test chamber 10 to regulate the temperature inside the test chamber 10 and realize the simulation verification of the stress state under different temperature environments.

[0058] This application conducts experimental research on the quality defect evolution of a gas pressure regulating device from multiple perspectives, including erosion, corrosion, vibration, and fatigue. Data collection also requires analysis from multiple angles. Based on data type, this application divides the data acquisition device into three parts: a mechanical response sensor, an electrochemical monitoring sensor, and a process parameter sensor. The mechanical response sensor includes a strain gauge, mounted on the sensitive area of ​​the gas pressure regulating device, for measuring stress; an accelerometer, located at the horizontal clamp arm 20, for monitoring vibration loads; and a force sensor, located at the vertical clamp head, for monitoring mechanical loads. The electrochemical monitoring sensor is an electrochemical monitoring probe, located at the gas pressure regulating device, for monitoring corrosion electrochemical signals and calculating instantaneous corrosion rates. The process parameter sensor includes a pressure gauge, installed upstream or downstream of the gas pressure regulating device and inside the test chamber 10, for monitoring the internal pressure of the loop pipe 4 and the test chamber 10; a thermometer, located inside the test chamber 10, for monitoring the internal temperature of the test chamber 10; and a flow meter, installed inside the loop pipe 4, for monitoring gas flow.

[0059] In practical implementation, the comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices should also include a central control system that provides a user interface for setting all experimental parameters and monitoring the entire process; it should also include a programmable logic controller and driver that receive computer instructions and directly control the actions of each actuator (pump, valve, heater, hydraulic servo valve, etc.).

[0060] To ensure the safety of the experiment, the comprehensive experimental system for the evolution of quality defects in urban gas pressure regulators should also include a safety protection system. Specifically, this may include a safety interlock device to automatically cut off the power source when pressure or temperature exceeds limits; an emergency stop button for manual quick shutdown in emergencies; and an automatic purging system to purge the circuit with compressed gas at the end of the experiment or in abnormal situations to remove corrosive media. For the treatment of exhaust gas after the experiment, the comprehensive experimental system for the evolution of quality defects in urban gas pressure regulators may also include a recovery and treatment device 8. The recovery and treatment device 8 is connected to the test chamber 10 and the circuit pipeline 4, and is used to treat the gas until it is harmless before discharge; it also filters particles from the gas.

[0061] The above embodiments provide a detailed description of the comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices provided in this application. This embodiment further illustrates the system in conjunction with the actual experimental process.

[0062] In this embodiment, the experimental process mainly includes three stages: sample installation and system configuration, system environment establishment and load loading, and test monitoring and post-processing.

[0063] During the sample installation and system configuration phase, the gas pressure regulator is placed on the clamp head 17 by loosening the fastening device on the sealing door 11 of the test chamber 10 and opening the door. The position is then roughly adjusted using the height adjustment mechanism 19 and the vertical clamp arm 16. The operator needs to adjust the clamp head 17 according to the specific shape and size of the gas pressure regulator and use the fastening bolts 18 for initial fixation. Then, the spatial orientation of the gas pressure regulator is finely adjusted to ensure that its central axis is strictly aligned with the center of the conformal flange interface and the vibration center of the piezoelectric ceramic actuator 22 to ensure accurate load application. Strain gauges are attached to key mechanically sensitive parts of the gas pressure regulator, such as the valve stem, valve cover, and thin-walled areas, and accelerometers are connected. High-frequency response pressure gauge probes are installed at appropriate upstream and downstream positions of the gas pressure regulator. The inlet and outlet of the gas pressure regulator are securely connected to the loop pipeline 4 through a dedicated conformal flange interface, and a standard flange sealing procedure is used to ensure an absolute seal at the connection. After confirming proper alignment, tighten all fastening bolts 18 to ensure that the gas pressure regulator only deforms or moves at the predetermined position during subsequent vibration and alternating stress loading, without any risk of loosening. Operate the central control system to reset all fatigue and vibration simulation units to their initial zero or safe positions. Install the electrochemical monitoring probe, inserting it into the test chamber 10 close to the surface of the gas pressure regulator to monitor corrosion electrochemical signals. Close the sealing door 11 and confirm it is securely locked. After installation, thoroughly check the uniformity and reliability of the clamping.

[0064] During the system environment setup and load loading phase, the first step is to perform an airtightness check and establish an inert environment, ensuring that the inlet valves of the precision feeder and atomizer of the erosion simulation device 1 are closed. Open the inflation valve of the compressed air tank 5 and fill the system with air to a low pressure (e.g., 0.5 times the experimental pressure). Use leak detection fluid or the system's built-in pressure gauge to monitor the pressure drop and perform an airtightness check on the entire loop. After confirming a good seal, turn on the circulation pump 6 to briefly circulate the inert gas in the loop, purging the air from the system.

[0065] Following the establishment of a high-temperature, high-pressure corrosive environment, after the airtightness test is completed, the circulation pump 6 is stopped, and the heater 7 is started to heat the test chamber 10, slowly and uniformly raising its inner wall and internal gas to the preset experimental temperature (e.g., 80°C), which is monitored in real time using a thermometer. After the temperature stabilizes, the valve of the compressed gas tank 5 is slowly reopened to pressurize the system, while the circulation pump 6 is restarted to ensure uniform gas distribution until the pressure inside the chamber reaches the preset value. The atomizer is then activated to atomize the corrosive solution from the corrosive liquid storage tank into micron-sized droplets, which are continuously injected into the gas flow, establishing a stable high-temperature, high-pressure, corrosive gas environment within the test chamber 10. During this stage, the environmental corrosivity can be initially observed using an electrochemical monitoring probe.

[0066] Multi-field coupled load application: Corrosion load: In the above environment, the corrosion load has been continuously applied by atomized acidic droplets.

[0067] Erosion Load: After the environment stabilizes, the gas circuit is completely sealed. Then, the erosion simulation device 1 is started, and the precision feeder begins to inject solid particles of a specific size and concentration stored in the particle storage tank into the gas flow at a preset precise rate. After the particles are fully mixed with the corrosive gas in the mixing chamber, they are driven by the circulating pump 6 to form an erosion medium that continuously flows over the surface of the gas pressure regulating device.

[0068] Vibration loading: The piezoelectric ceramic actuator 22 is activated to apply a horizontal vibration load with a preset frequency and amplitude in the 20 direction. The vibration is transmitted to the gas pressure regulating device through the horizontal clamp arm 20 and the shock-absorbing suspension 21. The accelerometer provides real-time feedback of the vibration signal to ensure accurate loading.

[0069] Alternating stress loading: The top and bottom hydraulic power units 14 are activated, driving the top and bottom hydraulic cylinders 13. Through the vertical hydraulic arm 15 and the vertical clamping arm 16, large-amplitude, low-frequency alternating fatigue stress is applied to the gas pressure regulating device. A force sensor integrated into the clamping head 17 monitors the load magnitude in real time. Once all loads have stabilized and reached the preset parameters, the coupling experiment officially begins.

[0070] During the testing, monitoring, and post-processing phases, the entire process is monitored and data is acquired: the central control system acquires all sensor signals at high speed and synchronously via a data acquisition instrument: strain gauges measure strain and calculate stress; accelerometers monitor vibration; force sensors monitor axial load. Electrochemical monitoring probes monitor corrosion current and potential in real time and calculate the instantaneous corrosion rate. Pressure gauges, thermometers, and flow meters continuously monitor ambient pressure, temperature, and medium flow rate. The control software loaded into the central control system sets alarm thresholds for various parameters. The system also monitors for signs of performance degradation in the gas pressure regulating device (such as inferring seal failure or regulation malfunction through pressure and flow data).

[0071] During post-processing, the experiment will automatically terminate when the preset test time or number of cycles is reached, or when the gas pressure regulating device fails or parameters exceed limits, triggering the safety interlock device. Alternatively, the emergency stop button can be pressed manually for an emergency stop. The termination sequence is as follows: first, stop the piezoelectric ceramic drive and hydraulic power unit 14; then, turn off the precision feeder and atomizer; finally, stop the heater 7.

[0072] The automatic purging system is activated, and a large amount of inert or compressed gas is introduced to drive the circulating pump 6 to thoroughly purge the entire loop pipeline 4 and test chamber 10, removing residual corrosive media and solid particles. After purging, the system is depressurized to atmospheric pressure and allowed to cool naturally or by forced cooling to room temperature.

[0073] Gas pressure regulator disassembly and subsequent analysis: Open the sealed door cover 11, disconnect the sensor connector and the circuit pipe 4, loosen the fastening bolts 18, and take out the gas pressure regulator after the experiment.

[0074] Perform a macroscopic inspection of the gas pressure regulating device and record the overall corrosion, erosion and wear conditions.

[0075] Disassemble key components of the gas pressure regulating device and use equipment such as stereomicroscopes, laser scanners, and scanning electron microscopes for microscopic analysis to observe damage morphology (such as pitting, wear marks, and cracks), measure wear amount, and analyze the composition of corrosion products.

[0076] Subsequently, data collected by the data acquisition device can be used to conduct experimental research on the evolution of quality defects in the gas pressure regulating device, and the results can be compared and correlated with the microscopic dissection analysis results of the components of the gas pressure regulating device. This process can be performed by a separate processing unit or by the central control system. By comparing and correlating the collected full-process data (such as corrosion rate curves, stress-cycle number curves, and performance degradation data) with the microscopic dissection analysis results, a comprehensive analysis of the performance degradation degree and failure mechanism of the gas pressure regulating device can be conducted.

[0077] The above describes the experimental process of the gas pressure regulating device in detail. This embodiment also provides the connection details of each hardware component during the experiment. The central control system mainly establishes physical connections with the components in the following ways:

[0078] All sensors are connected to the analog / digital input module of the data acquisition instrument or PLC via signal cables, continuously converting physical quantities (such as pressure, temperature, force, and voltage) into standard electrical signals (4-20mA current signal, 0-10V voltage signal) and transmitting them to the control system to achieve data acquisition;

[0079] Connection to actuator control output: Digital / analog control: For equipment requiring precise adjustment, such as piezoelectric ceramic actuator 22, precision feeder, atomizer, circulating pump 6, heater 7, etc., control signals are sent through the analog output module of the PLC or a dedicated controller;

[0080] Hydraulic servo control: The control connection for the core hydraulic cylinder 13 is more complex. The electro-hydraulic servo valve in the hydraulic power unit 14 receives analog command signals from the PLC or a dedicated motion control card via a dedicated cable. These signals precisely control the opening size and direction of the servo valve, thereby controlling the oil flow direction and flow rate, and ultimately driving the hydraulic cylinder 13 to achieve high-precision reciprocating motion.

[0081] Connection to the safety system (emergency input / output): As a software-independent safety feature, once triggered, it will immediately cut off the power supply (such as the power supply of the hydraulic pump and heater) to ensure system safety, and at the same time send an emergency interrupt signal to the PLC.

[0082] Safety interlock devices and emergency stop buttons are directly connected to the PLC's safety input module or external safety relay with the highest priority via hard wiring.

[0083] Logic control and workflow (software-level connection): This involves using control software to achieve logical-level connections within the system.

[0084] Set all experimental parameters (target temperature, pressure, vibration frequency and amplitude, fatigue load spectrum, particle injection rate, total experimental time, etc.) on the user interface of the control software.

[0085] The central control system converts user-defined values ​​into control commands and sends them to the programmable logic controller (PLC) and drivers; the PLC performs the following operations based on its internally written logic program:

[0086] A signal is sent to heater 7 for PID control to ensure that the actual temperature accurately follows the set temperature; the circulating pump 6 is started; a set rate command is sent to the controller of the precision feeder; waveform parameters (frequency and amplitude) are sent to the power amplifier of the piezoelectric ceramic driver 22; and a complex analog signal is sent to the hydraulic servo valve according to the set load spectrum to control the movement of the hydraulic cylinder 13.

[0087] Meanwhile, the PLC continuously reads signals from all sensors, and this real-time data is fed back to the central control system for display, recording (forming a data file), and judgment. The system compares the sensor readings (process value PV) with the user-set values ​​(setpoint SP) and adjusts the output signals in real time (e.g., adjusting the intake valve opening according to the actual pressure) to ensure that the entire system operates stably under the preset experimental conditions and achieves closed-loop control.

[0088] The PLC's internal program has strict safety interlocks and sequential control logic. For example, if the pressure gauge detects that the pressure exceeds the limit, the PLC will immediately close the air inlet valve and stop heating; the pressurization and heating process can only be started after the "sealed door cover is closed" signal is detected; pressing the emergency stop button will trigger the pre-programmed emergency stop sequence, stopping all equipment in a safe order.

[0089] The above provides a detailed description of the comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices provided by this invention. The various embodiments in the specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. It should be noted that those skilled in the art can make various improvements and modifications to this invention without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this invention.

Claims

1. A comprehensive experimental system for quality defect evolution of urban gas pressure regulating device, characterized in that, include: Erosion simulation device (1), corrosion simulation device (2), vibration simulation device, fatigue simulation device (3) and data acquisition device; The gas source flows through the gas pressure regulating device via the loop pipe (4), and the two ends of the loop pipe (4) are respectively connected to the gas inlet and the gas outlet of the gas pressure regulating device; The erosion simulation device (1) and the corrosion simulation device (2) are respectively connected to the loop pipe (4) and inject solid particles and corrosive media into the loop pipe (4) respectively; The vibration simulation device and the fatigue simulation device (3) are respectively connected to the gas pressure regulating device and are used to transmit vibration load and mechanical load to the gas pressure regulating device; The erosion simulation device (1), the corrosion simulation device (2), the vibration simulation device and the fatigue simulation device (3) enable the gas pressure regulating device to generate data for experimental research on the evolution of quality defects; It also includes: a test chamber (10); the test chamber (10) includes an inner liner (23), an outer shell (25) and an insulation layer (24) located between the two; The gas pressure regulating device is installed inside the inner liner (23), and the corrosion simulation device (2) is also connected to the inner liner (23) and injects a corrosive medium into the inner liner (23) along with the gas source; The corrosion simulation device (2) includes: a corrosion liquid storage tank and an atomizer; The corrosive liquid storage tank is used to store a corrosive acidic solution, and the atomizer is used to atomize the acidic solution into micron-sized droplets and then inject it into the loop pipe (4). The erosion simulation device (1) includes: a particle storage tank, a feeder, and a mixing chamber; The particle storage tank is used to store solid particles of a preset particle size; the feeder is used to control the number of solid particles injected into the mixing chamber; the solid particles and corrosive media can be mixed in the mixing chamber and then injected into the loop pipeline (4). It also includes: a processing unit; the processing unit is connected to the data acquisition device and is used to conduct quality defect evolution experiments on the gas pressure regulating device based on the received data, and to compare and correlate with the microscopic dissection analysis results of the components of the gas pressure regulating device.

2. The urban gas pressure regulating device quality defect evolution comprehensive experimental system according to claim 1, characterized in that, The vibration simulation device includes: a piezoelectric ceramic actuator (22), a horizontal clamp arm (20), and a shock-absorbing suspension (21). The horizontal clamp arm (20) is used to clamp the gas pressure regulating device, and the piezoelectric ceramic actuator (22) applies vibration to the gas pressure regulating device through the shock-absorbing suspension (21).

3. The urban gas pressure regulating device quality defect evolution comprehensive experimental system according to claim 2, characterized in that, The fatigue simulation device (3) includes: heater (7), hydraulic power unit (14), hydraulic cylinder (13), hydraulic arm (15), clamp arm (16) and clamp head (17). The clamp head (17) is used to fix the gas pressure regulating device, and the hydraulic power unit (14) is used to drive the hydraulic cylinder (13), so that the hydraulic cylinder (13) can apply alternating mechanical load to the gas pressure regulating device through the hydraulic arm (15) and the clamp arm (16); The heater (7) is used to regulate the temperature inside the test chamber (10).

4. The urban gas pressure regulating device quality defect evolution comprehensive experimental system according to claim 3, characterized in that, The data acquisition device includes: a force sensor for monitoring mechanical loads; an accelerometer for monitoring vibration loads; a strain gauge for measuring stress; an electrochemical monitoring probe for monitoring corrosion electrochemical signals; a pressure gauge for monitoring the internal pressure of the loop pipe (4) and the internal pressure of the test chamber (10); a thermometer for monitoring the internal temperature of the test chamber (10); and a flow meter for monitoring gas flow.

5. The comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices according to any one of claims 1 to 4, characterized in that, Also includes: Recycling and processing device (8); The recycling device (8) is used to connect the test chamber (10) and the loop pipe (4) to the external space.

6. The comprehensive experimental system for the evolution of quality defects in urban gas pressure regulating devices according to any one of claims 1 to 4, characterized in that, The gas source includes a compressed air tank (5) and a circulation pump (6); The compressed gas tank (5) is connected to the loop pipe (4), and the circulation pump (6) is used to drive the gas flow in the loop pipe (4); The circuit pipe (4) is connected to the gas inlet and outlet of the gas pressure regulating device via a simulated flange (9).

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