A new energy vehicle electric control box cover plate air tightness detection device and a detection method thereof

Abstract

The application relates to the technical field of air tightness detection, in particular to a new energy automobile electric control box cover plate air tightness detection device and a detection method thereof. The device comprises a base, a detection structure is bolted at the top of the base, a frame plate is arranged at the top of the detection structure, two hydraulic cylinders are bolted at the top of the frame plate, the output ends of the hydraulic cylinders penetrate through the frame plate and are bolted with the detection structure, and a cover plate body is arranged at the top of the detection structure. The detection structure comprises a detection cavity which is bolted at the top of the base, a peripheral leak point detection mechanism is arranged in a rectangular shape at the top of the detection cavity, the top of the peripheral leak point detection mechanism is in contact with the cover plate body, and a top leak point detection mechanism is in contact with the top of the cover plate body. The application provides a new energy automobile electric control box cover plate air tightness detection device and a detection method thereof, and has the advantages of realizing an integrated air tightness detection system of precise air tightness detection and intelligent positioning.

Description

Technical Field

[0001] This invention relates to the field of airtightness testing technology, specifically to an airtightness testing device and testing method for the cover plate of the electronic control box of a new energy vehicle. Background Technology

[0002] As we all know, with the rapid development of the global new energy vehicle industry, the electrical control box, as the core hub of the vehicle's power system, undertakes the key functions of power distribution, conversion and control. It integrates precision electronic components such as battery management system and motor controller. These components have extremely high requirements for the airtightness of the working environment. Once the cover of the electrical control box has an airtightness problem, rainwater, dust, moisture and corrosive gases from the outside can easily enter the box, which may cause short circuits, oxidation and corrosion of electronic components, thereby causing vehicle power system failures and even threatening the lives of drivers and passengers.

[0003] Air tightness testing of the cover of the power control box in new energy vehicles has become an important part of ensuring the safe and reliable operation of vehicles. However, the existing air tightness testing technology for the cover of the power control box has the following problems: during the production, assembly and fastening and long-term use, the top surface of the cover of the power control box is prone to develop micro cracks due to mechanical stress concentration. Under static conditions, the cover may temporarily close due to the micro-elastic deformation of the cover material. However, traditional static testing only observes macroscopic pressure changes and is difficult to locate such hidden leakage points. Furthermore, even if an airtightness problem is detected in the cover, existing technologies cannot quickly and accurately locate the leak. Some detection devices can only determine whether there is a leak, but cannot provide specific information about the leak point. Maintenance personnel need to spend a lot of time and effort to manually check each point to find the leak point, which is extremely inefficient. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a device and method for testing the airtightness of the cover plate of the electronic control box of a new energy vehicle, which has the advantages of an integrated airtightness testing system that achieves accurate airtightness testing and intelligent positioning.

[0005] The above-mentioned technical objective of the present invention is achieved through the following technical solution: a new energy vehicle electrical control box cover air tightness testing device, including a base, a testing structure bolted to the top of the base, a frame plate provided on the top of the testing structure, two hydraulic cylinders bolted to the top of the frame plate, and the output end of the hydraulic cylinders passing through the frame plate and bolted to the testing structure, and a cover plate body provided on the top of the testing structure. The detection structure includes a detection chamber bolted to the top of the base. The top of the detection chamber is rectangularly equipped with a peripheral leak detection mechanism. The top of the peripheral leak detection mechanism contacts the cover plate body. The top of the cover plate body contacts a top leak detection mechanism. A pressure plate is bolted to the bottom of the hydraulic cylinder, and several pressing mechanisms are bolted to the bottom of the pressure plate. The bottom of the pressing mechanisms is bolted to the top leak detection mechanism. The detection chamber, the peripheral leak detection mechanism, and the top leak detection mechanism are all connected to an external air source through pipelines.

[0006] By adopting the above technical solution, and through the combination of the top leak detection mechanism and the peripheral leak detection mechanism, accurate airtightness detection of the entire control box cover is achieved. The top leak detection mechanism, through its high-density sensor array layout, eliminates traditional blind spots and accurately determines the center coordinates of the leak. Meanwhile, the peripheral leak detection mechanism, through its segmented sealing structure and dynamic positioning components, achieves accurate positioning of the edge leakage area. The detection structure solves the technical problem that traditional detection methods cannot achieve both full coverage and accurate positioning, thus improving detection efficiency and reliability.

[0007] The invention is further configured such that: the top leakage detection mechanism includes an upper fixing plate and a flexible bonding plate; the upper fixing plate is bolted to the bottom of the pressing mechanism; a baffle is bolted to the rectangular edge of the bottom of the upper fixing plate, and the baffle is adapted to the shape of the cover plate body; a folded sealing edge is bolted between the edge of the flexible bonding plate and the upper fixing plate; both the flexible bonding plate and the folded sealing edge are located inside the baffle; several protrusions are provided inside the flexible bonding plate; an airflow sensor and a pressure sensor are respectively provided inside the protrusions, and the airflow sensor is located below the pressure sensor; a micro spring is bolted between the flexible bonding plate and the upper fixing plate, and the micro springs are distributed in an array.

[0008] Using the above technical solution, a top leak detection mechanism is set up and connected to the pressure-blocking mechanism via an upper fixing plate. This mechanism moves downwards synchronously with the pressure-blocking mechanism, allowing the top leak detection mechanism to cover the upper surface of the cover body. During the movement of the upper fixing plate, the baffle first contacts the edge of the cover body, limiting the position of the flexible bonding plate. After inflation, the flexible bonding plate adheres to the top surface of the cover body. Simultaneously, the array of protrusions at the bottom of the flexible bonding plate covers the top surface of the cover. Airflow and pressure sensors within the protrusions monitor the leak in real time: if a leak is detected, the leaking airflow first triggers a signal fluctuation in the airflow sensor, while the pressure sensor simultaneously captures the local pressure change. The signals from both sensors are transmitted to the control system in tandem. The location of the leak is determined by the coordinates of the raised array. The flexible bonding plate and micro-spring work together to adapt to the slight curvature changes on the top surface of the cover, ensuring close contact between the sensor and the cover and eliminating blind spots. Furthermore, the dual-layer detection design of the airflow sensor and pressure sensor allows for rapid identification of the leak first, followed by precise location by the pressure sensor, avoiding misjudgments from a single sensor. The distribution of the airflow sensor and pressure sensor arrays achieves full coverage of the top of the cover, overcoming the blind spots inherent in existing discrete sensing units and significantly improving the comprehensiveness and accuracy of leak detection.

[0009] The present invention is further configured such that the protrusions are arranged in a honeycomb-like regular hexagonal pattern, and the distance between adjacent protrusions is ≤8mm.

[0010] By adopting the above technical solution, the honeycomb hexagonal arrangement can maximize the use of the space on the top surface of the cover plate, and achieve high-density, dead-angle-free coverage of the sensor. This arrangement method greatly improves the accuracy of leak point location.

[0011] The present invention is further configured such that: a protrusion is provided on the inner side of the baffle, the protrusion is located on the upper part of the edge of the cover plate body, the baffle and the protrusion together form a stepped structure, and a telescopic finger is slidably provided inside the protrusion, the bottom end of the telescopic finger is spherical and contacts the surface of the cover plate body, and a displacement sensor is provided on the top of the telescopic finger, and the displacement sensor is used in conjunction with the telescopic finger.

[0012] By adopting the above technical solution, the deformation area of ​​the cover plate edge can be marked in advance by using a telescopic finger in conjunction with a displacement sensor, providing a key direction for subsequent leak detection and improving detection efficiency; through the correlation analysis of deformation data and leakage signals, it is possible to quickly determine whether the leak is caused by deformation, providing a targeted basis for maintenance.

[0013] The present invention is further configured such that: guide rods are bolted to both sides of the top of the base, and the other end of the guide rods is bolted to the frame plate; guide plates are welded to both sides of the pressure plate, and the guide plates are slidably sleeved on the surface of the guide rods.

[0014] By adopting the above technical solution, guide rods and guide plates are set to provide precise guidance for the lifting and lowering of the pressure plate, ensuring the relative position stability between the detection mechanism and the main body of the cover plate, and eliminating poor sealing or detection deviation caused by the tilting of the pressure plate.

[0015] The invention is further configured such that: the peripheral leak detection mechanism includes several sealing strips, the bottom of the sealing strips is connected to the detection cavity, a partition is connected between adjacent sealing strips, and a dynamic positioning component is provided on the top of the sealing strips. The sealing strips are in close contact with the cover plate body through dynamic positioning. A hollow cavity is provided inside the sealing strip, and an inner air bladder is provided inside the hollow cavity. Several partition plates are provided inside the inner air bladder. Several elastic skeletons are provided at the bottom of the sealing strip. A fixed frame is provided on the inner side of the sealing strip. A pressure sensing diaphragm and a piezoresistive sensing element are respectively rectangularly arranged inside the fixed frame. A pressure block is movably arranged between the opposite sides of the pressure sensing diaphragm and the piezoresistive sensing element, and a wave plate is arranged between the pressure block and the opposite side of the pressure sensing diaphragm.

[0016] By adopting the above technical solution, a peripheral leak detection mechanism is set up. After the inner airbag is inflated, the partition plate divides the airbag into multiple independent air chambers, uniformly transmitting the expansion pressure. The elastic skeleton restricts the expansion direction of the inner airbag, causing it to expand the top of the sealing strip, ensuring tight contact with the cover plate body. This improves the sealing strip's adaptability to irregular cover plate edges. Furthermore, the use of partitions to form a segmented sealing strip design allows for zoned edge detection, avoiding the problem of traditional continuous sealing failing to locate specific leaks. When a leak exists at the edge of the cover plate body, the leaking airflow generates additional pressure fluctuations on the pressure-sensing diaphragm. The pressure-sensing diaphragm amplifies the pressure fluctuation signal through a wave plate and a pressure block, transmitting the pressure fluctuations of the leaking airflow to the piezoresistive sensing element. The piezoresistive sensing element converts the pressure fluctuations into electrical signals. By collecting the electrical signals from each piezoresistive sensing element, a pressure distribution image is generated. By analyzing the pressure distribution image and comparing it with normal pressure distribution, abnormal pressure areas can be clearly identified. Simultaneously, a dynamic positioning component detects the minute airflow pressure at the contact point with the cover plate body. With the combined detection of both, the leak location is accurately pinpointed.

[0017] The present invention is further configured such that: the dynamic positioning component includes an elastic sealing lip, and the opening of the elastic sealing lip faces the edge of the cover plate body; the interior of the elastic sealing lip is provided with a micro air cavity, and the micro air cavity is connected to the inner air bladder through a pipeline; the interior of the micro air cavity is provided with a plurality of elastic sheets along the length direction, and the top of the elastic sheets is provided with a pressure probe.

[0018] By adopting the above technical solution, the dynamic positioning component is set up, and the elastic sealing lip cooperates with the micro air cavity to greatly improve the adaptability to the deformation of the cover edge, eliminate the sealing gap caused by deformation, and the pressure probe monitors the small airflow pressure at the contact part with the cover body in real time, which can enhance the sensitivity of leakage signal capture. Combined with the segmented design, the edge leakage point can be accurately located, avoiding missed detection and misjudgment.

[0019] The present invention is further configured such that: the pressing mechanism includes a fixed cylinder, the top of the fixed cylinder is bolted to a pressure plate, a pressing column is slidably disposed inside the fixed cylinder, and a pressing seat is bolted to the bottom of the pressing column, a contact plate is rotatably connected to the surface of the pressing seat in an annular shape, a movable sleeve is slidably sleeved on the surface of the pressing column, and a connecting rod is rotatably connected to the inside of the movable sleeve in an annular shape, the other end of the connecting rod is rotatably connected to the contact plate, a fixed sleeve is sleeved on the top of the surface of the pressing column, and an electric push rod is bolted to the bottom of the fixed sleeve, the bottom of the electric push rod is bolted to the movable sleeve.

[0020] By adopting the above technical solution, a pressure-blocking mechanism is set up. The pressure plate is pushed down by a hydraulic cylinder, which moves the fixed cylinder and the pressure-blocking column until the pressure-blocking seat is in close contact with the cover plate body. Then, the movable sleeve on the surface of the pressure-blocking column is moved by an electric push rod, and the contact plate is moved by a connecting rod. The contact plate rotates around the connection point with the pressure-blocking seat until it contacts the cover plate body. At the same time, the pressure sensor built into the contact plate detects the pressure-blocking pressure, which can adjust the fixing pressure on the top leakage detection mechanism to avoid damage to it, while ensuring that the contact pressure between the top leakage detection mechanism and the cover plate body is uniform.

[0021] The present invention is further configured such that: a pressure spring is provided at the top of the pressure column, and the top of the pressure spring is connected to the inner wall of the fixed cylinder; a limit block is provided in an annular shape at the top of the surface of the pressure column; and an adapter groove is provided inside the fixed cylinder to cooperate with the limit block.

[0022] Using the above technical solution, when the pressure column rises, the limiting block and the adapter groove cooperate to prevent the pressure column from detaching from the fixed cylinder; while the pressure spring provides buffering force to ensure that the pressure seat and the top leak detection mechanism make flexible contact, avoiding damage caused by rigid compression.

[0023] A testing method for the airtightness testing device of the cover plate of the power control box of a new energy vehicle includes the following steps: S1. Place the cover plate body to be tested at the top of the testing chamber, start the hydraulic cylinder to push the pressure plate down, and make the top leakage detection mechanism fully contact the upper surface of the cover plate body through the pressing mechanism, while the peripheral leakage detection mechanism forms a sealed contact with the edge of the cover plate body; S2. Compressed air is simultaneously injected into the detection chamber, the peripheral leak detection mechanism and the top leak detection mechanism through the pipeline, so that the inner airbag expands and pushes the sealing strip to fit tightly against the edge of the cover plate body. The flexible bonding plate maintains uniform contact pressure with the surface of the cover plate body under the action of air pressure and micro spring. S3. During the pressure holding process, the top leak detection mechanism monitors the pressure field distribution on the surface of the cover plate in real time through a honeycomb-shaped airflow sensor and pressure sensor array, while the peripheral leak detection mechanism monitors the edge sealing status through a pressure probe and a piezoresistive sensing element. S4. When a leakage signal is detected, the system analyzes the signal strength distribution of the top sensor array, uses a weighted centroid algorithm to calculate the center coordinates of the leak point, and accurately locates the edge leakage section through the independent signal output of the surrounding segmented detection units; S5. The control system combines the deformation area data marked by the displacement sensor with the signals from each detection element to accurately locate the leak point and output the pressure change curve and leakage data.

[0024] Compared with the prior art, the present invention provides a device and method for testing the airtightness of the cover plate of the electronic control box of a new energy vehicle, which has the following beneficial effects: This airtightness testing device and method for the cover of the electrical control box of a new energy vehicle achieves accurate airtightness testing covering the entire area of ​​the cover by setting up a testing structure and using a combination of top and peripheral leak detection mechanisms. The top leak detection mechanism, through a high-density sensor array layout, eliminates traditional blind spots and accurately determines the center coordinates of leaks. Meanwhile, the peripheral leak detection mechanisms, through a segmented sealing structure and dynamic positioning components, achieve precise positioning of edge leakage areas. The testing structure solves the technical problem that traditional testing methods cannot achieve both full coverage and precise positioning, thus improving testing efficiency and reliability. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the detection structure in this invention; Figure 3 This is a schematic diagram showing the connection between the top leak detection mechanism and the cover plate body in this invention; Figure 4 This is a schematic diagram of the top leak detection mechanism structure in this invention; Figure 5 This is a cross-sectional schematic diagram of the peripheral leak detection mechanism, the cover plate body, and the detection cavity in this invention; Figure 6 This is a schematic diagram showing the connection between the cover plate body and the surrounding leak detection mechanism in this invention; Figure 7This is a schematic diagram of the dynamic positioning component structure in this invention; Figure 8 This is a schematic diagram showing the connection between the upper fixing plate and the pressing mechanism in this invention; Figure 9 This is a schematic flowchart of the detection method for the airtightness testing device for the cover plate of the new energy vehicle's electrical control box in this invention.

[0026] In the diagram: 1. Base; 2. Detection structure; 3. Detection chamber; 4. Peripheral leak detection mechanism; 41. Sealing strip; 42. Inner airbag; 43. Partition plate; 44. Fixing frame; 45. Pressure sensing diaphragm; 46. Piezoresistive sensing element; 47. Pressure block; 48. Waveform sheet; 49. Dynamic positioning component; 491. Elastic sealing lip; 492. Miniature air chamber; 493. Elastic sheet; 494. Pressure probe; 410. Spacing plate; 5. Top leak detection mechanism; 51. Upper fixing plate; 52. Flexible 53. Adhesive plate; 54. Folded sealing edge; 55. Protrusion; 56. Airflow sensor; 57. Pressure sensor; 58. Miniature spring; 59. Baffle; 6. Pressure plate; 70. Pressing mechanism; 71. Fixed cylinder; 72. Pressing column; 73. Pressing seat; 74. Contact plate; 75. Movable sleeve; 76. Connecting rod; 77. Fixed sleeve; 78. Electric push rod; 8. Frame plate; 9. Cover plate body; 10. Telescopic touch finger; 11. Displacement sensor; 12. Guide rod; 13. Guide plate; 14. Pressing spring; 15. Hydraulic cylinder. Detailed Implementation

[0027] 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 skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Example 1 Please see Figure 1-7 A device for testing the air tightness of the cover of the electrical control box of a new energy vehicle includes a base 1, a testing structure 2 is bolted to the top of the base 1, a frame plate 8 is provided on the top of the testing structure 2, two hydraulic cylinders 15 are bolted to the top of the frame plate 8, and the output end of the hydraulic cylinders 15 passes through the frame plate 8 and is bolted to the testing structure 2. A cover plate body 9 is provided on the top of the testing structure 2. The detection structure 2 includes a detection chamber 3, which is bolted to the top of the base 1. A peripheral leak detection mechanism 4 is rectangularly arranged on the top of the detection chamber 3. The top of the peripheral leak detection mechanism 4 contacts the cover plate body 9, and the top of the cover plate body 9 contacts a top leak detection mechanism 5. A pressure plate 6 is bolted to the bottom of the hydraulic cylinder 15, and several pressing mechanisms 7 are bolted to the bottom of the pressure plate 6. The bottom of the pressing mechanisms 7 is bolted to the top leak detection mechanism 5. The detection chamber 3, the peripheral leak detection mechanism 4, and the top leak detection mechanism 5 are all connected to an external air source via pipelines. The detection structure... Structure 2, through the combined use of the top leak detection mechanism 5 and the peripheral leak detection mechanism 4, achieves accurate airtightness detection covering the entire area of ​​the electrical control box cover. The top leak detection mechanism 5, through the high-density sensor array layout, can eliminate the traditional detection blind spots and accurately determine the center coordinates of the leak. The peripheral leak detection mechanism 4, through the segmented sealing structure and dynamic positioning component 49, achieves accurate positioning of the edge leakage area. Detection structure 2 solves the technical problem that traditional detection methods cannot achieve both full coverage and accurate positioning, and improves detection efficiency and reliability.

[0029] The top leakage detection mechanism 5 includes an upper fixing plate 51 and a flexible bonding plate 52. The upper fixing plate 51 is bolted to the bottom of the pressing mechanism 7. A baffle 58 is bolted to the rectangular edge of the bottom of the upper fixing plate 51, and the baffle 58 is adapted to the shape of the cover plate body 9. A folded sealing edge 53 is bolted between the edge of the flexible bonding plate 52 and the upper fixing plate 51. Both the flexible bonding plate 52 and the folded sealing edge 53 are located inside the baffle 58. Several protrusions 54 are provided inside the flexible bonding plate 52, and each protrusion 54 is provided with a... An airflow sensor 55 and a pressure sensor 56 are provided, with the airflow sensor 55 positioned below the pressure sensor 56. Miniature springs 57 are bolted between the flexible bonding plate 52 and the upper fixing plate 51, and these springs are arranged in an array. A top leak detection mechanism 5 is provided, connected to the pressing mechanism 7 via the upper fixing plate 51. This mechanism can move downwards synchronously with the pressing mechanism 7, facilitating the top leak detection mechanism 5 to cover the upper surface of the cover plate body 9. During the movement of the upper fixing plate 51, a baffle 58 first contacts the edge of the cover plate body 9, thus restricting the flexible bonding... The flexible bonding plate 52 is used in a specific location. After inflation, the flexible bonding plate 52 adheres to the top surface of the cover body 9. At the same time, the array of protrusions 54 at the bottom of the flexible bonding plate 52 covers the top surface of the cover. The airflow sensor 55 and pressure sensor 56 within the protrusions 54 monitor in real time. If a leak is found, the leaking airflow first triggers a signal fluctuation in the airflow sensor 55, and the pressure sensor 56 simultaneously captures the local pressure change. The signals from both sensors are transmitted to the control system, and the location of the leak is determined by the coordinates of the array of protrusions 54. The flexible bonding plate 52, in conjunction with the micro spring 57, can adapt to the slight curvature changes of the top surface of the cover, ensuring close contact between the sensor and the cover, eliminating blind spots. Furthermore, the dual-layer detection design of the airflow sensor 55 and pressure sensor 56 allows for rapid identification of leaks by the airflow sensor 55 and precise location by the pressure sensor 56, avoiding misjudgments by a single sensor. The distribution of the array of airflow sensors 55 and pressure sensors 56 achieves full coverage of the top of the cover, solving the blind spot defect of existing discrete sensing units and significantly improving the comprehensiveness and positioning accuracy of leak detection.

[0030] Among them, the protrusions 54 adopt a honeycomb-shaped regular hexagonal arrangement, and the distance between adjacent protrusions 54 is ≤8mm. The honeycomb-shaped regular hexagonal arrangement can maximize the use of the top surface space of the cover plate, realize high-density and no dead-angle coverage of the sensor, and this arrangement greatly improves the leakage point positioning accuracy.

[0031] The inner side of the baffle 58 is provided with a protrusion, which is located on the upper part of the edge of the cover body 9. The baffle 58 and the protrusion together form a stepped structure. A telescopic finger 10 is slidably arranged inside the protrusion. The bottom end of the telescopic finger 10 is spherical and contacts the surface of the cover body 9. A displacement sensor 11 is provided on the top of the telescopic finger 10. The displacement sensor 11 works in conjunction with the telescopic finger 10. By working together, the deformation area of ​​the cover edge can be marked in advance, providing a key direction for subsequent leak detection and improving detection efficiency. Through the correlation analysis of deformation data and leakage signals, it is possible to quickly determine whether the leakage is caused by deformation, providing a targeted basis for maintenance.

[0032] Guide rods 12 are bolted to both sides of the top of the base 1, and the other end of the guide rods 12 is bolted to the frame plate 8. Guide plates 13 are welded to both sides of the pressure plate 6, and the guide plates 13 are slidably sleeved on the surface of the guide rods 12. By setting the guide rods 12 and the guide plates 13, precise guidance is provided for the lifting and lowering of the pressure plate 6, ensuring the relative position stability between the detection mechanism and the cover plate body 9, and eliminating poor sealing or detection deviation caused by the tilt of the pressure plate 6.

[0033] The peripheral leak detection mechanism 4 includes several sealing strips 41. The bottom of the sealing strips 41 is connected to the detection chamber 3. A spacer 410 connects adjacent sealing strips 41, and a dynamic positioning component 49 is provided on the top of the sealing strips 41. The sealing strips 41 are in close contact with the cover plate body 9 through dynamic positioning. The interior of the sealing strips 41 is provided with a hollow cavity, and an inner airbag 42 is provided inside the hollow cavity. Several partition plates 43 are provided inside the inner airbag 42. Several springs are provided at the bottom of the interior of the sealing strips 41. The inner side of the sealing strip 41 is provided with a fixed frame 44. Inside the fixed frame 44, a pressure-sensing diaphragm 45 and a piezoresistive sensing element 46 are rectangularly arranged. A pressure block 47 is movably arranged between the opposing sides of the pressure-sensing diaphragm 45 and the piezoresistive sensing element 46. A corrugated sheet 48 is arranged between the pressure block 47 and the opposing side of the pressure-sensing diaphragm 45. Through the peripheral leak detection mechanism 4, after the inner airbag 42 is inflated, the partition plate 43 divides the airbag into multiple independent air chambers, evenly transmitting the expansion pressure. The expansion direction of the inner airbag 42 is restricted by the elastic skeleton, allowing the inner airbag 42 to expand the top of the sealing strip 41, making it in close contact with the cover body 9. This improves the adaptability of the sealing strip 41 to irregular cover edges. Furthermore, the use of spacers 410 to form a segmented sealing strip 41 design allows for zoned edge detection, avoiding the problem of traditional continuous sealing failing to locate specific leak points. When there is a leak at the edge of the cover body 9, the leaking airflow will generate additional pressure fluctuations on the pressure sensing diaphragm 45. The pressure sensing diaphragm 45 amplifies the pressure fluctuation signal through the wave plate 48 and the pressure block 47, transmitting the pressure fluctuations of the leaking airflow to the piezoresistive sensing element 46. The piezoresistive sensing element 46 converts the pressure fluctuations into electrical signals. By collecting the electrical signals of each piezoresistive sensing element 46, a pressure distribution image is generated. By analyzing the pressure distribution image and comparing it with the normal pressure distribution, abnormal pressure areas can be clearly identified. At the same time, the dynamic positioning component 49 detects the minute airflow pressure at the contact point with the cover body 9. With the combined detection of both, the leak point is accurately located.

[0034] The dynamic positioning component 49 includes an elastic sealing lip 491 with its opening facing the edge of the cover body 9. The elastic sealing lip 491 has a micro-air cavity 492 inside, which is connected to the inner air bladder 42 via a pipe. Several elastic plates 493 are arranged along the length of the micro-air cavity 492, and a pressure probe 494 is located on the top of each elastic plate 493. By setting up the dynamic positioning component 49, the elastic sealing lip 491 and the micro-air cavity 492 work together to significantly improve the adaptability to edge deformation of the cover, eliminating sealing gaps caused by deformation. Furthermore, the pressure probe 494 monitors the pressure of minute airflows at the contact point with the cover body 9 in real time, enhancing the sensitivity of leak signal capture. Combined with the segmented design, it achieves accurate positioning of edge leaks, avoiding missed detections and misjudgments.

[0035] The working principle of this embodiment is as follows: The cover plate body 9 is placed on top of the detection chamber 3, ensuring that the edge of the cover plate body 9 is aligned with the sealing strip 41 of the surrounding leak detection mechanism 4. Then, the pressure plate 6 is driven to move down by the hydraulic cylinder 15, which drives the top leak detection mechanism 5 to descend synchronously. The baffle 58 of the top leak detection mechanism 5 first contacts the edge of the cover plate body 9. The protrusions on the inner side of the baffle 58 form a step-like positioning, which restricts the horizontal displacement of the cover plate body 9. At the same time, the telescopic finger 10 inside the baffle 58 will fit against the surface of the cover plate body 9. The displacement sensor 11 captures the telescopic finger extension and contraction in real time. If there is stress deformation on the top surface of the cover plate (such as local protrusions or depressions), the telescopic finger 10 at the corresponding position will produce differentiated extension and contraction. (The compression amount increases at the deformed protrusions and decreases at the recesses). Displacement sensor 11 transmits this difference signal to the control system, generating a "cover deformation distribution map" on the display screen, completing the pre-marking of the deformation area, and providing a targeted direction for subsequent leak detection. Then, an external air source supplies air to the detection chamber 3, the inner airbag 42 of the peripheral leak detection mechanism 4, and the top leak detection mechanism 5 through pipelines. The detection chamber 3 is inflated to form a reference pressure environment. In the peripheral leak detection mechanism 4, the inner airbag 42 expands and transmits pressure evenly through the partition plate 43, which, together with the elastic skeleton, pushes the sealing strip 41 to fit the edge of the cover plate. The micro air chamber 492 of the dynamic positioning component 49 is simultaneously replenished with air, making... The elastic sealing lip 491 expands and adapts to edge deformation under the support of the elastic sheet 493, achieving a tight seal. The flexible bonding plate 52 of the top leak detection mechanism 5 adheres to the top surface of the cover plate under the action of the micro spring 57 and air pressure, and the array of protrusions 54 completely covers the detection area. The preset pressure is maintained by the detection chamber 3, and the control system receives signals from each sensor in real time. If there is a tiny crack on the top surface of the cover plate, the leaking airflow will first overflow through the crack, triggering the airflow sensor 55 in the corresponding protrusion. After the airflow sensor 55 probe captures the airflow fluctuation, it quickly outputs a preliminary signal of "leakage exists". At the same time, the leaking airflow pushes the air on the surface of the cover plate to form a local pressure difference, and the pressure sensor 56 simultaneously captures this pressure. The control system combines the signal time difference (airflow sensor 55 responds first, pressure sensor 56 responds later) and intensity of the two sensors, and refers to the previous deformation distribution map to accurately locate the crack. Because the protrusions 54 are densely distributed in a honeycomb pattern, even if the crack width is extremely small, the leak point can be locked by comparing the sensor signals of adjacent protrusions 54, avoiding detection blind spots. If there is a leak point at the edge of the cover plate, the leaking airflow impacts the pressure sensing film 45, and the signal is amplified by the waveform sheet 48 and the pressure block 47 and transmitted to the piezoresistive sensing element 46. At the same time, the pressure probe 494 of the dynamic positioning component 49 captures the small pressure at the contact point. The two cross-verify and refer to the previous deformation distribution map to realize the edge leak point location.

[0036] Example 2: refer to Figure 8A device for testing the airtightness of a new energy vehicle electrical control box cover also includes a pressing mechanism 7. The pressing mechanism 7 includes a fixed cylinder 71, the top of which is bolted to a pressure plate 6. A pressing column 72 is slidably disposed inside the fixed cylinder 71, and a pressing seat 73 is bolted to the bottom of the pressing column 72. A contact plate 74 is rotatably connected to the surface of the pressing seat 73 in an annular shape. A movable sleeve 75 is slidably sleeved on the surface of the pressing column 72, and a connecting rod 76 is rotatably connected to the inside of the movable sleeve 75 in an annular shape. The other end of the connecting rod 76 is rotatably connected to the contact plate 74. A fixed sleeve 77 is sleeved on the top of the surface of the pressing column 72, and an electric push rod 78 is bolted to the bottom of the fixed sleeve 77. The bottom of the electric push rod 78 is connected to the movable sleeve 75. The bolted connection is achieved by setting a pressure-retaining mechanism 7, which pushes the pressure plate 6 downward via the hydraulic cylinder 15. This causes the fixed cylinder 71 and the pressure-retaining column 72 to move accordingly until the pressure-retaining seat 73 is in close contact with the cover plate body 9. Then, the electric push rod 78 pushes the movable sleeve 75 to move on the surface of the pressure-retaining column 72, and the connecting rod 76 pushes the contact plate 74 to move. The contact plate 74 rotates around the connection point with the pressure-retaining seat 73 until it contacts the cover plate body 9. At the same time, the pressure sensor built into the contact plate 74 detects the pressure-retaining pressure, which can adjust the fixing pressure on the top leakage detection mechanism 5 to avoid damage to it, while ensuring that the contact pressure between the top leakage detection mechanism 5 and the cover plate body 9 is uniform.

[0037] The top of the pressure column 72 is provided with a pressure spring 14, and the top of the pressure spring 14 is connected to the inner wall of the fixed cylinder 71. The top of the surface of the pressure column 72 is provided with a limit block in an annular shape, and the inside of the fixed cylinder 71 is provided with an adapter groove that works with the limit block. When the pressure column 72 rises, the limit block and the adapter groove work together to prevent the pressure column 72 from falling off the fixed cylinder 71. The pressure spring 14 provides a buffer force to ensure that the pressure seat 73 and the top leakage detection mechanism 5 make flexible contact and avoid damage caused by rigid compression.

[0038] The working principle of this embodiment is as follows: In the initial state, the pressure column 72 is located at the bottom of the fixed cylinder 71 under the support of the pressure spring 14. The limiting block is in contact with the bottom of the adapter groove inside the fixed cylinder 71, the movable sleeve 75 is located at the top of the pressure column 72, and the contact plate 74 is in a retracted state. When the hydraulic cylinder 15 pushes the pressure plate 6 down, the fixed cylinder 71 descends synchronously with the pressure plate 6. The pressure seat 73 at the bottom of the pressure column 72 first contacts the upper fixed plate 51 of the top leakage detection mechanism 5. As the pressure plate 6 continues to move down, the pressure column 72 slides upward relative to the fixed cylinder 71, compressing the top pressure spring 14. The spring generates a reverse elastic force to form a buffer, avoiding rigid impact damage to the detection mechanism or the cover plate body 9. At this time, the electric push rod 78 is activated, pushing the movable sleeve 75 to the top of the pressure column 72. The movable sleeve 75 slides downward along the pressure column 72. The movable sleeve 75 drives the contact plate 74 to rotate around the pressure seat 73 through the ring-shaped connecting rod 76, so that the contact plate 74 gradually unfolds and fits against the surface of the upper fixed plate 51, forming a multi-point uniform pressure. During the detection process, the pressure spring 14 continuously provides stable elastic force to compensate for pressure fluctuations caused by vibration or slight deformation of the cover plate, ensuring that the contact pressure between the top leak detection mechanism 5 and the cover plate body 9 is constant. After the detection is completed, the electric push rod 78 retracts and drives the movable sleeve 75 to move upward. The contact plate 74 is reset and retracted under the pull of the connecting rod 76. The hydraulic cylinder 15 drives the pressure plate 6 to rise. The pressure spring 14 pushes the pressure column 72 to reset. The limit block returns to the initial position, waiting for the next detection cycle.

[0039] Example 3: refer to Figure 9 The present invention also provides a testing method for the airtightness testing device of the cover plate of the power control box of a new energy vehicle, comprising the following steps: S1. Place the cover plate body 9 to be tested on top of the detection chamber 3, start the hydraulic cylinder 15 to push the pressure plate 6 down, and make the top leakage detection mechanism 5 fully contact the upper surface of the cover plate body 9 through the pressing mechanism 7, while the peripheral leakage detection mechanism 4 forms a sealed contact with the edge of the cover plate body 9. S2. Compressed air is simultaneously injected into the detection chamber 3, the peripheral leak detection mechanism 4 and the top leak detection mechanism 5 through the pipeline, causing the inner airbag 42 to expand and push the sealing strip 41 to fit tightly against the edge of the cover plate body 9. The flexible bonding plate 52 maintains uniform contact pressure with the surface of the cover plate body 9 under the action of air pressure and micro spring 57. S3. During the pressure holding process, the top leak detection mechanism 5 monitors the pressure field distribution on the surface of the cover plate body 9 in real time through the honeycomb-arranged airflow sensor 55 and pressure sensor 56 array, while the peripheral leak detection mechanism 4 monitors the edge sealing status through the pressure probe 494 and piezoresistive sensing element 46. S4. When a leakage signal is detected, the system analyzes the signal strength distribution of the top sensor array, uses a weighted centroid algorithm to calculate the center coordinates of the leak point, and accurately locates the edge leakage section through the independent signal output of the surrounding segmented detection units; S5. The control system combines the deformation area data marked by displacement sensor 11 with the signals from each detection element to accurately locate the leak point and output the pressure change curve and leakage data.

[0040] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. Those skilled in the art can make modifications to this embodiment without contributing any inventive step after reading this specification. Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A device for testing the airtightness of the cover of a new energy vehicle's electrical control box, comprising a base (1), characterized in that: The top of the base (1) is bolted with a detection structure (2), the top of the detection structure (2) is provided with a frame plate (8), the top of the frame plate (8) is bolted with two hydraulic cylinders (15), and the output end of the hydraulic cylinders (15) passes through the frame plate (8) and is bolted to the detection structure (2). The top of the detection structure (2) is provided with a cover plate body (9). The detection structure (2) includes a detection chamber (3), which is bolted to the top of the base (1). The top of the detection chamber (3) is rectangularly provided with a peripheral leak detection mechanism (4). The top of the peripheral leak detection mechanism (4) is in contact with the cover plate body (9). The top of the cover plate body (9) is in contact with a top leak detection mechanism (5). The bottom of the hydraulic cylinder (15) is bolted with a pressure plate (6), and the bottom of the pressure plate (6) is bolted with several pressure-blocking mechanisms (7). The bottom of the pressure-blocking mechanism (7) is bolted to the top leak detection mechanism (5). The detection chamber (3), the peripheral leak detection mechanism (4), and the top leak detection mechanism (5) are all connected to an external air source through pipelines. The top leak detection mechanism (5) includes an upper fixing plate (51) and a flexible bonding plate (52). The upper fixing plate (51) is bolted to the bottom of the pressing mechanism (7). A baffle (58) is bolted to the bottom edge of the upper fixing plate (51) in a rectangular shape, and the baffle (58) is adapted to the shape of the cover body (9). A folded sealing edge (53) is bolted between the edge of the flexible bonding plate (52) and the upper fixing plate (51). The folded sealing edge (53) is located inside the baffle (58). The flexible bonding plate (52) has several protrusions (54) inside. The protrusions (54) are respectively equipped with an airflow sensor (55) and a pressure sensor (56), and the airflow sensor (55) is located below the pressure sensor (56). The flexible bonding plate (52) and the upper fixing plate (51) are connected by a miniature spring (57), and the miniature springs (57) are distributed in an array. The inner side of the baffle (58) is provided with a protrusion, which is located at the upper part of the edge of the cover body (9). The baffle (58) and the protrusion together form a stepped structure, and a telescopic finger (10) is slidably provided inside the protrusion. The bottom end of the telescopic finger (10) is spherical and contacts the surface of the cover body (9). A displacement sensor (11) is provided on the top of the telescopic finger (10), and the displacement sensor (11) is used in conjunction with the telescopic finger (10). The peripheral leak detection mechanism (4) includes several sealing strips (41). The bottom of the sealing strip (41) is connected to the detection chamber (3). A spacer (410) is connected between adjacent sealing strips (41). A dynamic positioning component (49) is provided on the top of the sealing strip (41). The sealing strip (41) is in close contact with the cover plate body (9) through the dynamic positioning component (49). A hollow cavity is provided inside the sealing strip (41), and an inner airbag (42) is provided inside the hollow cavity. The inner airbag (42) is provided with... There are several partition plates (43), and several elastic skeletons are provided at the bottom of the sealing strip (41). A fixed frame (44) is provided on the inner side of the sealing strip (41). The fixed frame (44) is provided with a pressure sensing film (45) and a piezoresistive sensing element (46) in a rectangular shape. A pressure block (47) is movably provided between the opposite sides of the pressure sensing film (45) and the piezoresistive sensing element (46), and a wave plate (48) is provided between the pressure block (47) and the opposite side of the pressure sensing film (45). The dynamic positioning component (49) includes an elastic sealing lip (491), with the opening of the elastic sealing lip (491) facing the edge of the cover body (9). The interior of the elastic sealing lip (491) is provided with a micro air chamber (492), and the micro air chamber (492) is connected to the inner air bladder (42) through a pipeline. The interior of the micro air chamber (492) is provided with a plurality of elastic sheets (493) along the length direction, and the top of the elastic sheet (493) is provided with a pressure probe (494).

2. The airtightness testing device for the cover plate of the electrical control box of a new energy vehicle according to claim 1, characterized in that: The protrusions (54) are arranged in a honeycomb-like regular hexagonal pattern, and the distance between adjacent protrusions (54) is ≤8mm.

3. The airtightness testing device for the cover plate of the electrical control box of a new energy vehicle according to claim 1, characterized in that: Guide rods (12) are bolted to both sides of the top of the base (1), and the other end of the guide rods (12) is bolted to the frame plate (8). Guide plates (13) are welded to both sides of the pressure plate (6), and the guide plates (13) are slidably sleeved on the surface of the guide rods (12).

4. The airtightness testing device for the cover plate of the electronic control box of a new energy vehicle according to claim 1, characterized in that: The pressing mechanism (7) includes a fixed cylinder (71), the top of which is bolted to the pressure plate (6). A pressing column (72) is slidably disposed inside the fixed cylinder (71), and a pressing seat (73) is bolted to the bottom of the pressing column (72). A contact plate (74) is rotatably connected to the surface of the pressing seat (73) in an annular shape. A movable sleeve (75) is slidably sleeved on the surface of the pressing column (72), and a connecting rod (76) is rotatably connected inside the movable sleeve (75) in an annular shape. The other end of the connecting rod (76) is rotatably connected to the contact plate (74). A fixed sleeve (77) is sleeved on the top of the surface of the pressing column (72), and an electric push rod (78) is bolted to the bottom of the fixed sleeve (77). The bottom of the electric push rod (78) is bolted to the movable sleeve (75).

5. The airtightness testing device for the cover plate of the electronic control box of a new energy vehicle according to claim 4, characterized in that: The top of the pressure column (72) is provided with a pressure spring (14), and the top of the pressure spring (14) is connected to the inner wall of the fixed cylinder (71). The top of the surface of the pressure column (72) is provided with a limit block in an annular shape, and the inside of the fixed cylinder (71) is provided with an adapter groove that works with the limit block.

6. The testing method for the airtightness testing device of the electrical control box cover of a new energy vehicle as described in any one of claims 1-5, characterized in that: Includes the following steps: S1. Place the cover body (9) to be tested on top of the test chamber (3), start the hydraulic cylinder (15) to push the pressure plate (6) down, and make the top leakage detection mechanism (5) fully contact the upper surface of the cover body (9) through the pressing mechanism (7), while the peripheral leakage detection mechanism (4) forms a sealed contact with the edge of the cover body (9); S2. Compressed air is simultaneously injected into the detection chamber (3), the peripheral leak detection mechanism (4) and the top leak detection mechanism (5) through the pipeline, so that the inner airbag (42) expands and pushes the sealing strip (41) to fit tightly against the edge of the cover plate body (9). The flexible bonding plate (52) maintains uniform contact pressure with the surface of the cover plate body (9) under the action of air pressure and micro spring (57). S3. During the pressure holding process, the top leak detection mechanism (5) monitors the pressure field distribution on the surface of the cover body (9) in real time through the honeycomb-shaped airflow sensor (55) and pressure sensor (56) array, and the peripheral leak detection mechanism (4) monitors the edge sealing status through the pressure probe (494) and piezoresistive sensing element (46). S4. When a leakage signal is detected, the system analyzes the signal strength distribution of the top sensor array, uses a weighted centroid algorithm to calculate the center coordinates of the leak point, and accurately locates the edge leakage section through the independent signal output of the surrounding segmented detection units; S5. The control system combines the deformation area data marked by the displacement sensor (11) and the signals of each detection element to accurately locate the leak point and output the pressure change curve and leakage data.

Images