Production quality detection method of water pump controller

Abstract

The invention relates to the technical field of water pump controller production, and particularly discloses a production quality detection method of a water pump controller. The method comprises the steps that S1, the water pump controller is preliminarily inspected, and it is ensured that the water pump controller to be detected is a product which is preliminarily inspected to be qualified; s2, fixing the water pump controller which is preliminarily inspected to be qualified on a vibration table in an environment test box by adopting a clamp, and ensuring that the clamp is attached to a shell of the water pump controller; s3, performing multi-environment coupling detection on the water pump controller by adopting random parameter coupling detection or specific parameter coupling detection; multi-environment coupling detection is carried out on the water pump controller by setting multiple detection modes of random parameter coupling detection or specific parameter coupling detection, complex environment conditions of the water pump controller in the transportation, installation, operation and maintenance processes can be simulated more truly, and through combined testing of different environment conditions, the detection accuracy of the water pump controller is improved. And the full-life-cycle environmental influence of the product from production to scrapping is simulated.

Description

TECHNICAL FIELD

[0001] The application relates to the production technology field of a water pump controller and discloses a production quality detection method for a water pump controller. BACKGROUND

[0002] As a core electric control unit in a water pump system, the water pump controller is not only affected by vibration during transportation, but also subjected to different forms of impact or collision during installation, operation and maintenance.

[0003] For example, during transportation, the water pump controller is often subjected to instantaneous impact due to improper loading and unloading, vehicle bumping or falling; during installation and maintenance, the device may be subjected to a large mechanical impact due to external collision or accidental falling; and during normal operation, the water pump controller is subjected to periodic or irregular impact load due to water pump start-stop, pipeline water hammer effect and ground mechanical vibration. These factors may cause the internal electronic components of the water pump controller to loosen, the welding points to break, the shell structure to be damaged or the function to be abnormal, thereby affecting the reliability and service life of the whole machine.

[0004] However, the existing water pump controller detection methods mainly focus on direct electrical performance detection and button performance detection in an indoor environment, and it is difficult to truly reproduce the random impact, combined vibration and transient stress change that the product is subjected to during actual transportation and use; therefore, the detection result cannot comprehensively reflect the reliability of the water pump controller in the actual environment.

[0005] Therefore, it is necessary to provide a new technical solution to overcome the above defects. SUMMARY

[0006] The application aims to provide a production quality detection method for a water pump controller which can effectively solve the above technical problems.

[0007] To achieve the purpose of the application, the following technical solutions are adopted: A production quality detection method for a water pump controller, comprising the following steps: S1, performing preliminary inspection on the water pump controller to ensure that the water pump controller to be detected is a product that has passed the preliminary inspection; S2, fixing the water pump controller that has passed the preliminary inspection on a vibration table in an environmental test box by using a clamp to ensure that the clamp is attached to the shell of the water pump controller; S3, performing multi-environment coupling detection on the water pump controller by using random parameter coupling detection or specific parameter coupling detection; S3.1, the random parameter coupling detection comprises assigning random environmental parameters, a random vibration frequency f1 and a random impact force N; the random environmental parameters comprise assigning a random temperature T1 and a random air humidity φ1; S3.1.1, assign the duration of the random temperature t1, the duration of the random air humidity t2, the duration of the random vibration frequency t3, the random impact force N1; S3.1.2, until t1, t2 or t2 ends, switch the value or duration of the random environmental parameter; wherein the change speed of the switched value: temperature change 3-10 ℃ / min, humidity change 5-15%RH / h; In the random parameter coupling detection, the temperature range is-25 ℃-80 ℃, the temperature rising / slowing rate is 3-10 ℃ / min, the humidity range is 10%RH-95%RH, the vibration frequency range is 10-2000 Hz, 0.1 g-50 g; the impact force range is 100 g-1000 g; S3.2, the specific parameter coupling detection is used to verify the durability of the water pump controller under the conditions of cold and hot cycles, wet and hot vibration, and impact by combining multiple extreme environments; The specific parameter coupling detection comprises: Low-temperature and high-humidity vibration coupling detection: control the environmental test chamber to reduce the temperature to-20 ℃ to-25 ℃ and increase the relative humidity to 85%RH to 95%RH, and after the temperature and humidity are stable for 30 min±5 min, start the vibration table to run at a frequency of 10 Hz to 500 Hz and an acceleration of 1 g to 3 g for 2 h to 4 h, and record the function state through the external monitoring equipment during the running; High-temperature and high-humidity vibration coupling detection: keep the humidity unchanged, increase the temperature to 60 ℃ to 80 ℃, and after the temperature is stable for 30 min±5 min, run according to the vibration table parameters of the low-temperature and high-humidity vibration coupling detection for 2 h to 4 h, and continuously record the function state; Normal-temperature and normal-humidity impact coupling detection: restore the temperature and humidity to 25 ℃±2 ℃ and 50%RH±5%RH, and after the temperature and humidity are stable for 30 min±5 min, start the impact simulation table to apply impact 2 to 4 times at an acceleration of 50 g to 150 g and a duration of 8 ms to 12 ms, and record whether the function is interrupted; Specifically, the impact acceleration is 100 g, the duration is 10 ms, and the impact times are 3 times; The specific parameter coupling detection is at least 1 time.

[0008] Further, S4, during the process of S3, continuously record the temperature and humidity of the environmental test chamber, the frequency and acceleration of the vibration table, the acceleration and duration of the impact simulation table; S5, after the detection is completed, unlock the clamp, take out the water pump controller, and place it in the temporary storage area for 2 hours; S6, perform appearance detection on the shell of the water pump controller to form a first result record; S7, wiring the water pump controller on the detection device, and performing function detection on the water pump controller to form a second result record; S8, based on the first result record and the second result record, outputting a detection result as qualified or unqualified.

[0009] Further, in S8, the following conditions are met to determine qualified: ① No cracking, deformation, corrosion and component shedding; ② No jamming and failure in the whole process, the start-stop control accuracy error is ≤±5%, and the time from fault simulation signal input to alarm signal output is ≤1 second; ③ No environmental parameter exceeds the limit during multi-environment coupling detection.

[0010] Further, S9, save the first result record, the second result record and the output result, and perform quality analysis on the water pump controller based on the first result record, the second result record and the output result.

[0011] Further, S9 includes: ① Defect statistical analysis: statistics of the occurrence frequency of various appearance and function defects, analysis of the distribution law and trend of defects; ② Failure mode analysis: establish failure mode and effect analysis database; analyze the main failure modes under different environmental conditions; ③ Process improvement guidance: improve production process according to appearance defect analysis; optimize design parameters based on function failure data; develop targeted quality control measures; ④ Quality trend monitoring: track the quality change trend of different batches of products; establish quality early warning mechanism; realize continuous improvement of quality.

[0012] Further, the environmental test chamber comprises a bottom box and an upper box; the bottom box is provided with a temperature adjusting system, a humidity adjusting system, a sealed wiring device and a vibration table; the upper box forms a test chamber inside.

[0013] Further, the vibration table comprises: a base fixedly installed in the bottom box, a spring installed on the top of the base, a top plate installed on the top of the spring, and a vibration motor installed on the bottom of the top plate; the top plate is used to install a clamp; the vibration motor is symmetrically arranged on both sides of the bottom of the top plate along the length direction of the top plate; the clamp comprises: a fixed part fixedly installed on the top of the top plate, and a sliding part slidably installed on the top of the top plate and arranged opposite to the fixed part; the sliding part is slidably connected with a guide part, and the guide part is fixedly installed on the top of the top plate; one end of the sliding part away from the fixed part is rotatably connected with a threaded rod, the other end of the threaded rod is fixedly connected with a hand wheel, and the hand wheel is threadedly connected with a limiting block, and the limiting block is fixedly installed on the top of the top plate.

[0014] Further, the impact simulation table comprises: a motor mounting seat fixedly installed on the rear sidewall of the upper box body, a motor fixedly installed on the motor mounting seat; an installation plate in transmission connection with the output end of the motor; a guide groove is arranged on the installation plate, a walking wheel set is slidably installed in the guide groove and can move along the guide groove, a linear direct electromagnetic iron is installed at the end of the walking wheel set away from the guide groove, and the output end of the linear direct electromagnetic iron is in transmission connection with an impact simulation piece.

[0015] Further, the impact simulation piece comprises: an simulation piece connecting rod in transmission connection with the output end of the linear direct electromagnetic iron, and a rubber impact head in detachable connection with the other end of the simulation piece connecting rod; the simulation piece connecting rod comprises: a telescopic rod body, a reset spring arranged in the telescopic rod body, the movable end of the telescopic rod body is in transmission connection with the output end of the linear direct electromagnetic iron, and the two ends of the reset spring are respectively connected with the fixed end and the movable end of the telescopic rod body, and the reset spring is arranged in dislocation with the output end of the linear direct electromagnetic iron.

[0016] Further, the rubber impact head is provided in multiple specifications, the multiple rubber impact heads are different in size, and a pressure sensor is arranged between the rubber impact head and the simulation piece connecting rod.

[0017] Compared with the prior art, the present application has the following beneficial effects: the present application can more truly simulate the complex environmental conditions of the water pump controller in the transportation, installation, operation and maintenance process through the multi-environment coupling detection of the water pump controller by respectively setting the multiple detection modes of random parameter coupling detection or specific parameter coupling detection, and the whole life cycle environmental influence of the product from production to scrap can be simulated through the combination test of different environmental conditions. BRIEF DESCRIPTION OF DRAWINGS

[0018] The accompanying drawings are included to provide a further understanding of the present application, and constitute a part of the specification, illustrate the present application together with the embodiments thereof, and explain the present application, but do not constitute a limitation of the present application.

[0019] Figure 1 It is a structural schematic view of the production quality detection method of the water pump controller; Figure 2 It is a schematic view of the production quality detection method of the water pump controller; Figure 3 It is a schematic view of the vibration table of the production quality detection method of the water pump controller; Figure 4 It is a schematic view of the installation plate of the production quality detection method of the water pump controller; Figure 5It is a schematic view of the impact simulation piece and the walking wheel group of the water pump controller production quality detection method of the application.

[0020] In the figure: 101, environmental test box; 102, control box; 103, control console; 104, upper box body; 105, test box door; 106, wiring port; 107, impact simulation table; 108, vibration table; 109, base; 110, spring; 111, vibration motor; 112, top plate; 113, clamp; 1131, fixed part; 1132, sliding part; 1133, guide part; 114, limit block; 115, hand wheel; 116, threaded rod; 117, impact simulation piece; 118, mounting plate; 119, guide groove; 120, driving motor; 121, simulation piece connecting rod; 122, walking wheel group; 123, rubber impact head; 124, linear direct acting electromagnet; 125, connecting seat; 126, reset spring. DETAILED DESCRIPTION

[0021] In order to make the purpose, technical scheme and advantages of the embodiments of the application more clear, the following will combine the technical scheme in the embodiments of the application to make a clear and complete description. Obviously, the described embodiments are part of the embodiments of the application, not all the embodiments.

[0022] In the description of the application, it should be understood that the terms "center", "transverse", "longitudinal", "front", "back", "left", "right", "up", "down", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the scope of protection of the application. When a component is referred to as "fixed to" another component, it can be directly on the other component or there can be a middle component. When a component is referred to as "connected to" another component, it can be directly connected to the other component or there can be a middle component. When a component is referred to as "provided on" another component, it can be directly provided on the other component or there can be a middle component. The terms "vertical", "horizontal", "left", "right" and the like used herein are only for the purpose of illustration.

[0023] As Figures 1 to 5 shown, the application relates to a water pump controller production quality detection method, comprising: The environmental test chamber 101 comprises a bottom chamber, an upper chamber 104; the bottom chamber is internally provided with a temperature adjusting system, a humidity adjusting system, a sealed wiring device, and a vibration table 108; the bottom chamber is made of stainless steel material, has good heat preservation and corrosion resistance; the front side of the bottom chamber is provided with a 103 for manual start-stop control operation.

[0024] The upper chamber 104 internally forms a test chamber for accommodating the water pump controller sample to be tested, and the top of the vibration table 108 is located at the bottom of the upper chamber 104.

[0025] The temperature adjusting system comprises a compressor refrigeration device and an electric heating device. The compressor refrigeration device is used for low-temperature refrigeration and can reduce the temperature to-25℃; the electric heating device is used for high-temperature heating and can raise the temperature to 80℃. The temperature adjusting system adopts a PID control mode, and the temperature control precision is ±2℃; the high and low temperature can be selected according to actual needs.

[0026] The humidity adjusting system comprises a humidity generator and a dehumidification module. The humidity generator adopts ultrasonic atomization humidification and can raise the relative humidity to 95%RH; the dehumidification module adopts condenser dehumidification and can reduce the relative humidity to 10%RH.

[0027] The sealed wiring device is arranged on the side wall of the chamber and comprises a plurality of cable sealed wall joints made of polytetrafluoroethylene material and having good sealing performance and temperature resistance. The power line, signal line and sensor lead can be led out through the cable sealed wall joint to ensure the sealing of the chamber and realize reliable signal transmission; all the sensor leads adopt shielded wires to shield the interference of high-frequency vibration or impact on the sensor signal and enable the signal line to communicate with the external monitoring equipment in real time.

[0028] The vibration table 108 is fixedly installed on one side of the bottom inside the environmental test chamber 101, and the vibration table 108 is staggered with the temperature adjusting system and the humidity adjusting system to provide a vibration environment for the water pump controller sample. The frequency range of the vibration table 108 is 10Hz-2000Hz, the acceleration range is 0.1g-50g, the frequency control precision is ±1Hz, and the acceleration control precision is ±0.1g.

[0029] The rear side of the upper chamber 104 is provided with an impact simulation table 107 for providing an impact environment for the water pump controller sample. The impact acceleration range of the impact simulation table 107 is 50g-150g, and the impact duration is 8ms to 12ms; the front side of the upper chamber 104 is provided with a test chamber door 105, and the test chamber door 105 is provided with an observation window for observing the internal working condition.

[0030] The control box 102 is provided on one side of the environmental test chamber 101, and an industrial computer is built in the control box 102. The industrial computer is in communication connection with the water pump controller through an RS485 bus, and the output signal of the water pump controller is collected and stored in real time. The control box 102 is also used for collecting the temperature and humidity of the environmental test chamber 101, the frequency and acceleration of the vibration table 108, the impact parameters of the impact simulation table 107 and the like in real time.

[0031] The vibration table 108 is provided with a clamp 113 on the top, and the clamp 113 is adapted to the shape of the water pump controller and is used for clamping and fixing the water pump controller.

[0032] In the embodiment, the water pump controller is tested by using the following S: S1, the water pump controller is preliminarily inspected to ensure that the water pump controller to be detected is a product that has passed the preliminary inspection; S2, the clamp 113 is used to fix the water pump controller that has passed the preliminary inspection on the vibration table 108 in the environmental test chamber 101, to ensure that the clamp 113 is attached to the shell of the water pump controller and is staggered with the wiring terminal to avoid affecting the wiring. The vibration table 108 comprises: a base 109 fixedly installed in the bottom box, a spring 110 installed on the top of the base 109, a top plate 112 installed on the top of the spring 110, and a vibration motor 111 installed on the bottom of the top plate 112; the top plate 112 is used for installing the clamp 113; wherein the base 109 is symmetrically provided as two groups along the length direction of the top plate 112, four corners of the top of each base 109 are respectively provided with a connecting seat 125, one spring 110 is respectively installed in each connecting seat 125, the top of the spring 110 is also connected with a connecting seat 125, and the connecting seat 125 is connected with the bottom of the top plate 112; the vibration motor 111 is symmetrically provided on both sides of the bottom of the top plate 112 along the length direction of the top plate 112, and is located between the two groups of connecting seats 125 on the top of the same base 109.

[0033] The clamp 113 comprises: a fixed portion 1131 fixedly installed on the top of the top plate 112, and a sliding portion 1132 oppositely arranged with the fixed portion 1131 and slidably installed on the top of the top plate 112; the sliding portion 1132 is slidably connected with a guide portion 1133 fixedly installed on the top of the top plate 112; one end of the sliding portion 1132 away from the fixed portion 1131 is rotatably connected with a threaded rod 116, the other end of the threaded rod 116 is fixedly connected with a hand wheel 115, the hand wheel 115 is threadedly connected with a limiting block 114, and the limiting block 114 is fixedly installed on the top of the top plate 112; when the hand wheel 115 is rotated, the sliding portion 1132 is driven to slide along the guide portion 1133 to clamp or release the water pump controller in cooperation with the fixed portion 1131; the material of the contact side of the fixed portion 1131 and the sliding portion 1132 can be selected as hard polyurethane, a silica gel buffer layer is arranged on the side of the clamp 113 abutting against the water pump controller shell for buffering, and the thickness of the silica gel buffer layer is set to 1mm to 2mm.

[0034] The impact simulation table 107 comprises: a motor mounting seat fixedly installed on the rear side wall of the upper box body 104, and a motor fixedly installed on the motor mounting seat; an installation plate 118 in transmission connection with the output end of the motor and driven to rotate by the motor; the installation plate 118 is provided with a guide groove 119, and a walking wheel set 122 movably installed in the guide groove 119 is slidably arranged in the guide groove 119; one end of the walking wheel set 122 away from the guide groove 119 is provided with a linear direct electromagnetic iron 124, the linear direct electromagnetic iron 124 can adjust the force by changing the driving voltage of the coil, has fast response and compact structure; the output end of the linear direct electromagnetic iron 124 is in transmission connection with an impact simulation piece 117; the walking wheel set 122 mainly comprises a common guide wheel and a driving motor 120 driving the guide wheel to rotate.

[0035] The impact simulation piece 117 comprises: a simulation piece connecting rod 121 in transmission connection with the output end of the linear direct electromagnetic iron 124, one end of the simulation piece connecting rod 121 fixedly installed on the walking wheel set 122 close to the linear direct electromagnetic iron 124, and a rubber impact head 123 detachably connected to the other end of the simulation piece connecting rod 121; wherein the simulation piece connecting rod 121 comprises: a telescopic rod body, a reset spring 126 arranged in the telescopic rod body, the movable end of the telescopic rod body in transmission connection with the output end of the linear direct electromagnetic iron 124, and the two ends of the reset spring 126 in connection with the fixed end and the movable end of the telescopic rod body, respectively, and the reset spring 126 is arranged in dislocation with the output end of the linear direct electromagnetic iron 124; the rubber impact head 123 is provided in multiple specifications, the multiple rubber impact heads 123 are different in size, a pressure sensor is arranged between the rubber impact head 123 and the simulation piece connecting rod 121 for pressure detection, so as to confirm the touch event and detect the touch pressure, and avoid error caused by single recording of the output force of the linear direct electromagnetic iron 124.

[0036] The impact simulation table 107 is used to simulate different degrees of impact test on the water pump controller to simulate the vibration and impact during transportation or installation process, and the structure is not damaged and the function is normal after the test. Close the door of the environmental test chamber 101, set the initial environmental parameters, wherein the preset initial temperature is T0 and the initial humidity is φ0; for example, the preset initial temperature is 25°C and the relative humidity is 50%RH±5%RH, and the water pump controller is balanced with the environmental temperature for one hour; S3: using random parameter coupling detection or specific parameter coupling detection to perform multi-environment coupling detection on the water pump controller; S3.1, the random parameter coupling detection specifically includes: assigning random environmental parameters, random vibration frequency f1, and random impact force N; the random environmental parameters include assigning random temperature T1 and random air humidity φ1; S3.1.1, the duration of assigning random temperature t1, the duration of random air humidity t2, the duration of random vibration frequency t3, and the random impact force N1; t1≥0; t2≥0; t3≥0; N1≥0.

[0037] S3.1.2, after t1, t2 or t2 ends, the value or duration of the random environmental parameters is switched; wherein the change speed of the switching value: temperature change 3-10°C / min, humidity change 5-15%RH / h; In the random parameter coupling detection, the temperature range is -25°C-80°C, the temperature rising / slowing rate is 3-10°C / min, and the extreme high and low temperatures that the product may face, such as northern winter low temperature and equipment operation high temperature, are covered; the humidity range is 10%RH-95%RH, the high humidity in rainy season, the low humidity in desert, or the diurnal humidity fluctuation is simulated; the vibration frequency range is 10-2000Hz, 0.1g-50g; the amplitude / acceleration, impact force range is 100g-1000g, which simulates corresponding transportation bumps (low frequency vibration), equipment operation vibration (high frequency), accidental falling (impact) and the like; S3.2, the specific parameter coupling detection is used to verify the durability of the water pump controller under cold-heat cycle, wet-heat vibration and impact conditions by combining multiple extreme environments; S3.2.1, the specific parameter coupling detection includes: The first mode: low-temperature and high-humidity vibration coupling detection: control the environmental test chamber 101 to reduce the temperature to -20°C to -25°C and increase the relative humidity to 85%RH to 95%RH, and after the temperature and humidity are stable for 30min±5min, start the vibration table 108 to operate at a frequency of 10Hz to 500Hz and an acceleration of 1g to 3g for 2h to 4h, and record the function state through the external monitoring device during the operation; Specifically, the low temperature setting value is-25℃, the relative humidity setting value is 90%RH, the frequency of the vibration table 108 is 50Hz to 300Hz, the acceleration is 2g, and the running time is 3h; S3.2.2, the second mode: high temperature and high humidity vibration coupling detection: keeping the humidity unchanged, the temperature is increased to 60℃ to 80℃, after the temperature is stable for 30min±5min, the vibration table 108 is operated according to the parameters in the first mode of S3.2.1 for 2h to 4h, and the function state is continuously recorded; Specifically, the high temperature setting value is 70℃, the relative humidity setting value is consistent with the first mode, and the vibration table 108 operating parameters are consistent with the first mode; S3.2.3, the third mode: normal temperature and normal humidity impact coupling detection: the temperature and humidity are restored to 25℃±2℃ and 50%RH±5%RH, and after being stable for 30min±5min, the impact simulation table 107 is started to apply impact 2 to 4 times at an acceleration of 50g to 150g and a duration of 8ms to 12ms, and whether the function is interrupted is recorded; Specifically, the impact acceleration is 100g, the duration is 10ms, and the impact times are 3 times; S3.2.4, the cycle number of the first, second and third modes is at least 1 time; the present application can more truly simulate the complex environmental conditions of the water pump controller in the transportation, installation, operation and maintenance process by respectively setting the multi-detection mode of random parameter coupling detection or specific parameter coupling detection for the water pump controller, and can simulate the whole life cycle environmental influence of the product from production to scrap through the combination test of different environmental conditions; S4, during the execution of S3, the temperature and humidity of the environmental test chamber 101, the frequency and acceleration of the vibration table 108, and the acceleration and duration of the impact simulation table 107 are continuously recorded; Wherein, the parameter deviation needs to meet: temperature±2℃, relative humidity±5%RH, vibration frequency±1Hz, vibration acceleration±0.1g, impact acceleration±5g, impact duration±1ms, forming an environmental parameter monitoring record; S5, after the detection is completed, the fixture 113 is unlocked, and the water pump controller is taken out and placed in the temporary storage area for 2 hours; S6, the appearance of the water pump controller is detected, including: cracking, deformation; the corrosion of the wiring terminal, the falling off / loosening of the components are detected, and the first result record is formed; S7, the water pump controller is connected to the detection device, and the water pump controller is continuously operated for 2h to 4h, and the function of the water pump controller is detected, including: testing the start-stop control accuracy, the pressure regulation range, and the fault alarm response speed, recording the function jam / failure and parameter out-of-tolerance, and forming the second result record; S8, the output result is qualified or unqualified; Specifically, the following conditions are met to determine the pass: ① No cracking, deformation, corrosion and component shedding; ② No jamming and failure in the whole process, the start-stop control accuracy error is less than or equal to ± 5%, the pressure regulation range meets the design requirements, and the time from the fault simulation signal input to the alarm signal output is less than or equal to 1 second, wherein the fault alarm test includes overload alarm, undervoltage alarm and water leakage alarm; ③ No environmental parameter exceeds the standard during the multi-environment coupling detection.

[0038] Wherein, the water pump controller that passes the preliminary inspection can also be inspected in the above-mentioned manner, and is confirmed as passing the preliminary inspection after passing the inspection; or can be preliminarily inspected according to the following items: appearance inspection (such as no obvious scratches, deformation, cracks on the surface of the shell, and firm installation of components); size inspection (such as the shape size and mounting hole position meet the design requirements); electrical performance test; basic function test (such as power indication, manual-automatic switching and start-stop control function are normal); all test items meet the requirements of relevant standards, no fatal defects, and no more than 2 minor defects, then the preliminary inspection is qualified.

[0039] S9, save the first result record, the second result record and the output result, and perform quality analysis on the water pump controller based on the first result record, the second result record and the output result, specifically including the following dimensions: ① Defect statistical analysis: statistics the occurrence frequency of various appearance and function defects, and analyzes the distribution law and trend of the defects; ② Failure mode analysis: establish a failure mode and effect analysis database; analyze the main failure modes under different environmental conditions; ③ Process improvement guidance: improve the production process according to the appearance defect analysis; optimize the design parameters based on the function failure data; develop targeted quality control measures; ④ Quality trend monitoring: track the quality trend of different batches of products; establish a quality early warning mechanism; realize continuous improvement of quality; identify the main quality problem points by identifying the weak links of the product, and provide accurate data support for the direction of quality improvement, so as to realize the continuous improvement of product quality and reduce the after-sales failure rate of the product.

[0040] The standard parts used in the application can be purchased from the market, and the special-shaped parts can be ordered according to the description and the drawings. The specific connection mode of each part adopts the conventional means such as bolts, rivets and welding in the prior art. The mechanical parts and equipment adopt conventional models in the prior art, and the circuit connection adopts conventional connection mode in the prior art, which will not be described in detail. The contents not described in detail in the specification belong to the prior art known to those skilled in the art.

[0041] It should be understood that those skilled in the art can make improvements or changes according to the above description, and all these improvements and changes shall fall within the protection scope of the appended claims of the application.

Claims

1. A method of detecting production quality of a water pump controller, characterized by, The method comprises the following steps: S1, preliminary inspection of the water pump controller is carried out to ensure that the water pump controller to be detected is a product that has passed the preliminary inspection; S2, a jig is used to fix the water pump controller that has passed the preliminary inspection on a vibration table in an environmental test chamber, and the jig is ensured to be attached to the shell of the water pump controller; S3, random parameter coupling detection or specific parameter coupling detection is used to carry out multi-environment coupling detection on the water pump controller; S3.1, the random parameter coupling detection comprises: assigning random environmental parameters, random vibration frequency f1, and random impact force N; the random environmental parameters comprise assigned random temperature T1 and random air humidity φ1; S3.1.1, the duration of the assigned random temperature t1, the duration of the random air humidity t2, the duration of the random vibration frequency t3, and the random impact force N1; S3.1.2, after t1, t2 or t2 ends, the value or duration of the random environmental parameters is switched; wherein the change speed of the switching value is: temperature change 3-10 ℃ / min, humidity change 5-15% RH / h; In the random parameter coupling detection, the temperature range is -25-80 ℃, the temperature rise / fall rate is 3-10 ℃ / min, the humidity range is 10-95% RH, the vibration frequency range is 10-2000 Hz, 0.1-50 g, and the impact force range is 100-1000 g; S3.2, the specific parameter coupling detection is used to verify the durability of the water pump controller under cold-heat cycling, wet-heat vibration, and impact conditions through a plurality of extreme environment combinations; The specific parameter coupling detection comprises: Low-temperature and high-humidity vibration coupling detection: the environmental test chamber is controlled to reduce the temperature to -20-25 ℃ and increase the relative humidity to 85-95% RH, and after the temperature and humidity are stabilized for 30 min±5 min, the vibration table is started to operate at a frequency of 10-500 Hz and an acceleration of 1-3 g for 2-4 h, during which the functional status is recorded by an external monitoring device; High-temperature and high-humidity vibration coupling detection: the humidity is kept unchanged, the temperature is increased to 60-80 ℃, and after the temperature is stabilized for 30 min±5 min, the vibration table is operated according to the parameters of the low-temperature and high-humidity vibration coupling detection for 2-4 h, and the functional status is continuously recorded; Normal-temperature and normal-humidity impact coupling detection: the temperature and humidity are restored to 25±2 ℃ and 50% RH±5% RH, and after being stabilized for 30 min±5 min, the impact simulation table is started to apply impact 2-4 times at an acceleration of 50-150 g and a duration of 8-12 ms, and whether the function is interrupted is recorded; Specifically, the impact acceleration is 100 g, the duration is 10 ms, and the impact frequency is 3 times; The specific parameter coupling detection is repeated at least once.

2. The method of claim 1, wherein S4, during the execution of S3, the temperature and humidity of the environmental test chamber, the frequency and acceleration of the vibration table, and the acceleration and duration of the impact simulation table are continuously recorded; S5, after the detection is completed, the jig is unlocked, the water pump controller is taken out, and placed in a temporary storage area for 2 hours; S6, appearance detection is performed on the shell of the water pump controller to form a first result record; S7, wiring the water pump controller on the detection device, and performing function detection on the water pump controller to form a second result record; S8, based on the first result record and the second result record, outputting a detection result as qualified or unqualified.

3. The method of claim 2, wherein the step of detecting the production quality of the water pump controller is performed by a quality inspection device. In S8, the following conditions are met to determine qualified: ① No cracking, deformation, corrosion and component shedding on the appearance; ② No jamming and failure in the whole process, the start-stop control precision error is ≤±5%, and the time from the fault simulation signal input to the alarm signal output is ≤1 second; ③ No environmental parameter out-of-tolerance record in the multi-environment coupling detection process.

4. The method of claim 3, wherein the step of detecting the production quality of the water pump controller is performed by a quality inspection device. S9, saving the first result record, the second result record and the output result, and performing quality analysis on the water pump controller based on the first result record, the second result record and the output result.

5. The method of claim 4, wherein S9 includes: ① Defect statistical analysis: statistics of the occurrence frequency of various appearance and function defects, analysis of the distribution law and trend of defects; ② Failure mode analysis: establish failure mode and effect analysis database; analyze the main failure modes under different environmental conditions; ③ Process improvement guidance: improve production process according to appearance defect analysis; optimize design parameters based on function failure data; develop targeted quality control measures; ④ Quality trend monitoring: track the quality change trend of different batches of products; establish quality early warning mechanism; realize the continuous improvement of quality.

6. The method of claim 5, wherein the step of detecting the quality of the water pump controller is performed by a quality inspection device. The environmental test chamber comprises a bottom box body and an upper box body; a temperature adjusting system, a humidity adjusting system, a sealed wiring device and a vibration table are arranged in the bottom box body; a test chamber is formed in the upper box body.

7. The method of claim 6, wherein the step of detecting the quality of the water pump controller is performed by a quality inspection device. The vibration table comprises: a base fixedly installed in the bottom box body, a spring installed on the top of the base, a top plate installed on the top of the spring, and a vibration motor installed on the bottom of the top plate; the top plate is used for installing a clamp; the vibration motor is symmetrically arranged on both sides of the bottom of the top plate along the length direction of the top plate; the clamp comprises: a fixed part fixedly installed on the top of the top plate, and a sliding part slidably installed on the top of the top plate and arranged opposite to the fixed part; the sliding part is slidably connected with a guide part, and the guide part is fixedly installed on the top of the top plate; one end of the sliding part away from the fixed part is rotatably connected with a threaded rod, the other end of the threaded rod is fixedly connected with a hand wheel, and the hand wheel is threadedly connected with a limiting block, and the limiting block is fixedly installed on the top of the top plate.

8. The method of claim 7, wherein the step of detecting the quality of the water pump controller is performed by a quality inspection device. The impact simulation table comprises: a motor mounting seat fixedly installed on the rear side wall of the upper box body, and a motor fixedly installed on the motor mounting seat; an installation plate in transmission connection with the output end of the motor; the installation plate is provided with a guide groove, a walking wheel set slidably installed in the guide groove and movable along the guide groove is slidably installed in the guide groove, and a linear direct electromagnetic iron is installed on one end of the walking wheel set away from the guide groove; the output end of the linear direct electromagnetic iron is in transmission connection with an impact simulation piece.

9. The method of claim 8, wherein the step of detecting the quality of the water pump controller is performed by a quality inspection device. The impact simulation piece comprises a simulation piece connecting rod in transmission connection with the output end of the linear direct electromagnetic iron, and a rubber impact head in detachable connection with the other end of the simulation piece connecting rod; the simulation piece connecting rod comprises a telescopic rod body, and a reset spring arranged inside the telescopic rod body; the movable end of the telescopic rod body is in transmission connection with the output end of the linear direct electromagnetic iron; the two ends of the reset spring are respectively connected with the fixed end and the movable end of the telescopic rod body; and the reset spring is arranged in dislocation with the output end of the linear direct electromagnetic iron.

10. The method of claim 9, wherein the water pump controller is a water pump controller for a vehicle. The rubber impact head is provided in multiple specifications, and the multiple rubber impact heads are different in size; and a pressure sensor is arranged between the rubber impact head and the simulation piece connecting rod.

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