Method for testing back pressure of manufactured component

Abstract

In accordance with various aspects of the present disclosure, there is provided a method of backpressure testing a manufactured component, the method comprising obtaining one or more reference components and, when or if tested on a reference test unit, providing a backpressure test on one or more reference components. Determining, for each reference component, a reference back pressure measurement indicative of a back pressure of the reference component; calibrating one or more test positions of the backpressure test unit using one or more reference components; setting a back pressure upper limit and a back pressure lower limit for each of the one or more test positions; and thereafter, the backpressure of the one or more manufactured components is evaluated using the one or more test locations.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the field of back pressure testing of manufactured components, such as flow-through monoliths and filters. BACKGROUND

[0002] Exhaust gas is a waste product produced by the combustion of fuel, such as the combustion of gasoline in an internal combustion engine. Exhaust gas can include a mixture of components such as air, carbon dioxide, carbon monoxide, nitrous oxide, sulfur dioxide, hydrocarbons, benzene, and / or particulates. The components of exhaust gas can vary depending on the fuel that is combusted. Exhaust gas can be harmful to a user and / or harmful to the environment.

[0003] An exhaust system can be used to transport exhaust gas from one location to another location using a pipe. For example, a vehicle exhaust system can transport exhaust gas from an internal combustion engine to the outside of the vehicle using a pipe. This can avoid a user inhaling exhaust gas.

[0004] In many cases, it is desirable to remove a component from exhaust gas. Therefore, flow-through monoliths and filters can be used within an exhaust system to remove components from exhaust gas. Removing components from exhaust gas can include forcing exhaust gas through small pores of a filter, which can physically block some components (e.g., particulate components) and / or chemically transform some components using a flow-through monolith or filter through a reaction of catalytic components (e.g., reduction of nitrogen oxides, oxidation of carbon monoxide, oxidation of hydrocarbons, and / or similar reactions). By removing some components and / or changing the chemical composition of some components, exhaust gas can be made less harmful and / or less damaging to the environment.

[0005] A pressure change can result when exhaust gas flow passes through a porous substrate, particularly a filter. The pressure change can be referred to as back pressure. Too high of a back pressure for a particular mass flow rate can impair the function of an exhaust system and / or damage the exhaust system. Therefore, filter manufacturers will typically seek to demonstrate that the back pressure of a manufactured component (e.g., a filter) falls within a particular range of mass flow rates that is representative of mass flow rates in an exhaust system.

[0006] Manufacturers can test the back pressure of filters and / or other manufactured components using back pressure test equipment such as a SuperFlow flow bench. However, SuperFlow flow benches (e.g., Model SF1020 available from SuperFlow Dynamometers and Flow Benches) are designed for infrequent measurement of modified automotive components such as cylinder heads and ports. Factors such as cost, long cycle times (approximately 20-25 s), and the size of the SuperFlow flow bench can hinder their suitability for inline testing of filters and / or other manufactured components. For these reasons, manufacturers typically do not test 100% of end products for compliance with back pressure standards, thereby leaving the possibility that defective filters and / or other manufactured components can pass unnoticed.

[0007] In this context, it is desirable to provide an improved method of back pressure testing of filters and / or other manufactured components. SUMMARY

[0008] In some aspects of the disclosure, there is provided a method of back pressure testing of manufactured components, the method comprising:

[0009] a) obtaining one or more reference components and determining, when or if tested on a reference test cell, a reference back pressure measurement for each reference component indicative of the back pressure of the reference component;

[0010] b) calibrating one or more test locations of a back pressure test cell using the one or more reference components;

[0011] c) setting an upper back pressure limit and a lower back pressure limit for each of the one or more test locations; and

[0012] d) thereafter, using the one or more test locations to assess the back pressure of one or more manufactured components;

[0013] wherein calibrating one or more test locations of the back pressure test cell in step b) comprises:

[0014] b) i) installing one of the reference components in one or each of the test locations of the back pressure test cell;

[0015] b) ii) generating a flow through the test location or locations;

[0016] b) iii) establishing a calibration flow for the test location or locations by adjusting the flow through the test location or locations until the back pressure measurement of the reference component in the test location or locations corresponds to the reference back pressure measurement of the respective reference component.

[0017] b) iv) thereafter, using a calibration flow for the test position or each test position during step d);

[0018] wherein using the one or more test positions in step d) to assess the back pressure of one or more manufacturing components comprises:

[0019] d) i) installing a manufacturing component in one test position or each test position of the back pressure test unit;

[0020] d) ii) flowing a calibration flow determined from step b) iii) through the test position or each test position;

[0021] d) iii) measuring a back pressure measurement of the manufacturing component or each manufacturing component;

[0022] d) iv) comparing the back pressure measurement of the manufacturing component or each manufacturing component to the upper back pressure limit and the lower back pressure limit of the respective test position and generating and outputting a test result indicating whether the back pressure measurement is within an acceptable range compared to the upper back pressure limit and the lower back pressure limit.

[0023] In this way, the back pressure of manufacturing components can be tested with increased efficiency. For example, manufacturing components can be tested in a shorter time and / or in parallel. In this way, it can be made possible to test 100% of a large group of manufacturing components without the tests taking an excessive amount of time.

[0024] According to another aspect of the disclosure, there is provided a controller configured to perform the method.

[0025] In this way, the controller can be used to control the testing of the back pressure of manufacturing components with increased efficiency. For example, manufacturing components can be tested in a shorter time and / or in parallel. In this way, it can be made possible to test 100% of a large group of manufacturing components without the tests taking an excessive amount of time.

[0026] According to another aspect of the disclosure, there is provided:

[0027] A system for back pressure testing of manufacturing components, the system comprising:

[0028] a controller configured to perform the method; and

[0029] a back pressure test unit comprising:

[0030] one or more test positions configured to accommodate manufacturing components and / or reference components;

[0031] a flow generator configured to generate a flow through each test location; and

[0032] a back pressure sensor configured to measure a back pressure at each test location.

[0033] In this way, the controller can be used to control testing of the back pressure of the manufacturing component on the back pressure test unit with improved efficiency. For example, the manufacturing component can be tested on the back pressure test unit in a shorter amount of time and / or in parallel when compared to back pressure testing performed on an alternative test unit, such as a reference test unit. In this way, it can be possible to test 100% of a large number of manufacturing components without the testing taking an excessive amount of time, but would likely take an excessive amount of time if the reference test unit was used to test the back pressure of the manufacturing component. BRIEF DESCRIPTION OF DRAWINGS

[0034] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

[0035] Figure 1 A front view of an orifice plate is shown.

[0036] Figure 2 A side view of a system for measuring back pressure of an orifice plate is shown.

[0037] Figure 3 A side view of a system for measuring back pressure of a manufacturing component is shown.

[0038] Figure 4 Flow through a portion of a filter is shown.

[0039] Figure 5 A back pressure test unit is shown.

[0040] Figure 6 A reference test unit is shown.

[0041] Figure 7 A back pressure test unit is shown.

[0042] Figure 8 A graph showing back pressure measurements taken using a back pressure test unit plotted against back pressure measurements taken using a reference test unit is shown.

[0043] Figure 9 A schematic diagram to help understand how back pressure measurements taken on a back pressure test unit relate to back pressure measurements taken on a reference test unit is shown.

[0044] Figure 10 A system for back pressure testing of a manufacturing component is shown.

[0045] Figure 11 An automated system for back pressure testing of manufacturing components is shown.

[0046] Figure 12 A method of back pressure testing of manufacturing components is shown.

[0047] Figure 13 A method of obtaining one or more reference components and determining for each reference component a reference back pressure measurement indicative of a back pressure of the reference component when or if the reference component is tested on a reference test cell is shown.

[0048] Figure 14 A method of calibrating one or more test locations of a back pressure cell using one or more reference components is shown.

[0049] Figure 15 A method of setting an upper back pressure limit and a lower back pressure limit for each of one or more test locations is shown.

[0050] Figure 16 A method of using one or more test locations to assess a back pressure of one or more manufacturing components is shown.

[0051] Figure 17 A method of obtaining one or more validation reference components having a back pressure measurement between an upper limit and a lower limit when tested on one of one or more test locations is shown.

[0052] Figure 18 A photo of a part of a filter is shown. DETAILED DESCRIPTION

[0053] In some aspects of the present disclosure, a method 1000 of back pressure testing of manufacturing components 250 is provided. Figure 12 Embodiments of the method 1000 are shown.

[0054] In the present specification, a flow is described which comprises movement of a flowing material. The flowing material can comprise air, particles, gas, exhaust gas, and / or the like. In the flow, the flowing material can travel, for example, through a pipe, from one location to another. The direction of travel of the flow is shown in the figures by an arrow, wherein the head of the arrow indicates a downstream location of the flow and the tail of the arrow indicates an upstream location of the flow.

[0055] For the purpose of performing the method 1000 of back pressure testing, a back pressure test cell 730 can be provided, as Figure 5The back pressure test unit 730 can include a test location 722 configured to house a manufacturing component 250, a flow generator 724 configured to generate a flow through the test location 722, a back pressure sensor 726 configured to measure a back pressure at the test location 722, and a controller 710 configured to perform the method 1000. As air flows through the manufacturing component, the manufacturing component and / or the reference component creates a resistance to the flow. This in turn creates a pressure differential across the manufacturing component and / or the reference component, which can be measured by the back pressure sensor.

[0056] The manufacturing component can be any component through which a flow material can pass. The manufacturing component can be a filter, an orifice plate, a pipe, and / or the like. In some embodiments, the manufacturing component can include a manufacturing component used in an exhaust system. The reference component can be configured to provide a reference back pressure measurement when tested on the reference test unit 400 (such as the reference test unit 400 shown) or if tested on the reference test unit. In some embodiments, one or more manufacturing components can be provided from a manufacturing station 832 (such as a production line of manufacturing components). The manufacturing components for back pressure testing can have an untested back pressure, and thus the method 1000 can be used to determine whether the back pressure of the manufacturing component is within an acceptable back pressure range. The reference component can be a filter, an orifice plate, a pipe, and / or the like. In some embodiments, the manufacturing component and the reference component can be the same type of component. For example, the manufacturing component for back pressure testing can be a filter, and the reference component can also be a filter. In some embodiments, the manufacturing component and the reference component for testing can be different types of components. For example, the manufacturing component for testing can be a filter, and the reference component can be an orifice plate. Figure 6 The reference test unit 400 shown can provide a reference back pressure measurement when tested or if tested on the reference test unit. In some embodiments, one or more manufacturing components can be provided from a manufacturing station 832 (such as a production line of manufacturing components). The manufacturing components for back pressure testing can have an untested back pressure, and thus the method 1000 can be used to determine whether the back pressure of the manufacturing component is within an acceptable back pressure range. The reference component can be a filter, an orifice plate, a pipe, and / or the like. In some embodiments, the manufacturing component and the reference component can be the same type of component. For example, the manufacturing component for back pressure testing can be a filter, and the reference component can also be a filter. In some embodiments, the manufacturing component and the reference component for testing can be different types of components. For example, the manufacturing component for testing can be a filter, and the reference component can be an orifice plate.

[0057] How back pressure measurements are taken on the manufacturing component and / or the reference component will now be explained in more detail below.

[0058] Figure 1 An orifice plate 100 is shown. The orifice plate 100 can include a material sheet 102 and an orifice 104 of diameter d through the material sheet 102. In some embodiments, the material sheet 102 can include a handle 106, which can be used to position the orifice plate 100 in a flow. In some embodiments, the material sheet 102 can have an outer diameter D. When positioned in a flow, air can be forced through the orifice 104 to travel from an upstream side of the orifice plate 100 to a downstream side of the orifice plate 100.

[0059] Figure 2 A side view of a system 200 for measuring a back pressure of the orifice plate 100 is shown. As Figure 2 shown, a flow can travel within a wall 202 of a pipe from an upstream location to a downstream location. Figure 2How the flow is generated is not shown, but will be explained in more detail later in this specification. The flow is indicated by the arrows, travelling from an upstream location at the tail of the arrow to a downstream location at the head of the arrow. Also as shown Figure 2 The flow can pass through an orifice plate 100 positioned in the path of the flow, as shown. In this way, the flow can be forced through the orifice 104 of the orifice plate 100. As can be seen, this causes a constriction of the flow as it passes through the orifice 104. This constriction in the flow creates a change in pressure of the flow. Thus, the pressure at a first location upstream of the orifice plate 100 can be different compared to a second location downstream of the orifice plate 100. Thus, the pressure at the first location upstream of the orifice pi can be different compared to the pressure at the second location downstream of the orifice p2. In some embodiments, there can be a pressure loss between the pressure at the first location upstream of the orifice pi and the pressure at the second location downstream of the orifice p2. The pressure change pi-p2 can be defined as the back pressure P of the orifice plate 100. Notably, in this disclosure, the back pressure is denoted by a capital letter P. Other pressure measurements, such as those taken at the first and second locations as described above, are denoted using a lower case letter p. Thus, the back pressure P can be provided by the following equation:

[0060] P = pi - p2 (1)

[0061] The back pressure of the orifice plate 100 can be determined by a back pressure sensor 220, which includes a downstream pressure sensor 224 configured to measure the pressure at the second location downstream of the orifice p2. In some embodiments, the pressure pi at the first location upstream of the plate can be determined and / or assumed to be atmospheric pressure. The back pressure sensor 220 can output the difference between the atmospheric pressure and the pressure detected by the downstream pressure sensor 224. In some embodiments, the back pressure sensor 220 can include an upstream pressure sensor 222 configured to measure the pressure at the first location upstream of the orifice pi and a downstream pressure sensor 224 configured to measure the pressure at the second location downstream of the orifice p2. The back pressure sensor 220 can output the difference between the pressures detected by the upstream pressure sensor 222 and the downstream pressure sensor 224.

[0062] The geometry of the orifice plate 100 can affect the back pressure of the orifice plate 100. For example, the back pressure of the orifice plate 100 can change as the diameter of the orifice 104 changes relative to the overall size of the orifice plate 100. The geometry of the orifice plate 100 can include the flatness of the orifice plate, the diameter of the orifice, the diameter of the orifice plate, the relative diameter (the ratio of the diameter of the orifice to the diameter of the orifice plate), the shape of the orifice, the thickness of the orifice plate, and / or other parameters. For the orifice plate 100 shown, the diameter of the orifice is denoted as d. The diameter of the pipe is denoted as D. The relative diameter β can be provided by the following equation: Figure 1 For the orifice plate 100 shown, the diameter of the orifice is denoted as d. The diameter of the pipe is denoted as D. The relative diameter β can be provided by the following equation:

[0063] β = d / D (2)

[0064] The relative diameter β can vary between 0 and 1. A relative diameter β of 1 can correspond to an open pipe 202, and a relative diameter β of 0 can correspond to a blocked pipe 202. Thus, as the relative diameter β decreases, the back pressure increases.

[0065] In some embodiments, the orifice plate 100 can be produced according to a specific set of standards, such as the set of standards defined by "ISO 5167-2 Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduit running full - part 2: orifice plates". By manufacturing the orifice plate according to a set of standards, it can be possible to predict how changes in the geometry will affect the back pressure of the orifice plate. In some embodiments, the machining precision of the cutting tool used to prepare the orifice 104 can affect the degree of precision with which the orifice plate can be prepared, which in turn can affect the back pressure of the orifice plate 100. Thus, for preparing the orifice plate 100, it can be desirable to have as high machining precision as possible. In some embodiments, machining precision below 100 pm can be used. In some embodiments, machining precision below 10 pm can be used. In some embodiments, machining precision below 1 pm can be used.

[0066] In some embodiments, the shape of the orifice 104 can be other than circular, such as elliptical and / or other non-circular shapes. In some embodiments, the orifice can be a portion of a circular shape, such as an annulus. In some embodiments, the diameter of the orifice on the upstream side of the orifice plate 100 can be different than the diameter of the orifice on the downstream side of the orifice plate 100, such as the orifice 104 can define a section of a cone. In some embodiments, there can be one or more orifices 104.

[0067] Figure 2 The system 200 shown in FIG. 2 can be used to measure the back pressure of other manufacturing components placed in the path of a flow, such as filters. Figure 3 A side view of a manufacturing component placed in a flow is shown. In Figure 3In some embodiments, instead of an orifice plate 100, a manufacturing component 250 is placed in the path of the flow. In much the same way as described above, the back pressure across the manufacturing component can then be measured by the back pressure sensor 220. In some embodiments, the manufacturing component 250 can be a filter. In Figure 3 In some embodiments, the flow is indicated by a single arrow to show the general direction of the flow. In general, the flow pattern can be complex and will depend on the manufacturing component used. Thus, in some embodiments, the flow is indicated by multiple arrows to show the general direction of the flow. Figure 3 In some embodiments, the flow is indicated by a single arrow to show the general direction of the flow.

[0068] As described above, the manufacturing component 250 can be a filter 300. Figure 4 The flow through a portion of the filter 300 is shown. Figure 3 The flow through the filter 300 is shown. Figure 4 In some embodiments, the flow indicated by the arrows passes from upstream locations 943, 945, 947, through the porous walls 903, 905, and 907 to downstream locations 923, 925, and 927. By forcing the flow through the porous walls 903, 905, and 907, the direction and speed of the flow changes, which correspondingly changes the air pressure at the downstream locations compared to the upstream locations. Thus, a pressure difference can exist between the upstream and downstream locations. The pressure difference can be defined as the back pressure of the filter 300. As previously described, as Figure 2 shown, the back pressure measurement of the filter 300 can be made by using the back pressure sensor 220 to calculate the difference between the pressure measurement of the upstream pressure sensor 222 and the pressure measurement of the downstream pressure sensor 224.

[0069] The porous walls 903, 905, 907 of the filter 300 can include pores through which the flow can pass. The pores of the filter 300 can be numerous and small. The pores of the filter 300 can exist in the porous walls 903, 905, and / or 907. In some embodiments, the diameter of the pores of the filter 300 can be less than 100 pm. In some embodiments, the diameter of the pores of the filter 300 can be less than 10 nm, and / or less than 1 nm in diameter. In some embodiments, the pores of the filter 300 can be smaller than the particulate components of the flow, such that the particulate components cannot pass through the pores. In some embodiments, the pores can define a large surface area for catalyzing reactions with components of the flow. Additionally, the pores of the filter 300 can vary in shape and / or be arranged in a non-predictable or heterogeneous pattern. In general, it is theoretically difficult to predict how the back pressure of the filter 300 will change with adjustments in mass flow rate. However, because a particular filter 300 will provide a consistent back pressure, an orifice plate 100 can be manufactured with an equivalent back pressure to the particular filter 300. For example, the diameter ratio b of the orifice plate 100 can be adjusted until the back pressure of the orifice plate 100 is the same as the back pressure of the filter 300.

[0070] In the above description of measuring the back pressure of manufacturing components 250 (e.g., orifice plate 100 and / or filter 300), how the flow is generated and controlled was not described. How the flow is generated and controlled will now be described.

[0071] The back pressure test unit 730 can be used at a controlled mass flow rate Q. m Measure the back pressure of manufacturing component 250. Figure 5 A back pressure test unit 730 is shown. The back pressure test unit 730 includes: a test location 722 configured to receive a manufacturing component 250; a flow generator 724 configured to generate a flow through each test location 722; and a back pressure sensor 726 configured to measure the back pressure at each test location 722. In some embodiments, the back pressure sensor 726 may include a downstream pressure sensor 7264. The upstream pressure may be determined as and / or assumed to be atmospheric pressure. In some embodiments, the back pressure sensor 726 may include an upstream pressure sensor 7262 and a downstream pressure sensor 7264.

[0072] In some embodiments, the flow generator 724 may include a fan configured to rotate to cause the flow material to flow. The rotational speed ω of the flow generator can be adjusted to control the flow. For example, if the rotational speed ω of the flow generator increases, the mass flow rate Q... m The mass flow rate Q may increase, and if the rotational speed ω of the flow generator decreases, the mass flow rate Q will also increase. m This may decrease. In this way, the flow generator 724 can be used to generate and control the flow through the manufacturing component 250. The back pressure of the manufacturing component 250 can then be measured using the back pressure sensor 726 by calculating the difference between the pressure at the upstream pressure sensor 7262 and the pressure at the downstream pressure sensor 7264.

[0073] Therefore, the back pressure of the manufactured part 250 can be measured within the range of the rotational speed ω of the flow generator, which in turn defines the mass flow rate Q using the back pressure test unit 730. m The range. However, while the rotational speed ω of the flow generator can be known and / or determined, for example by using a calibrated flow generator (e.g., using a tachometer to calibrate / determine the rotational speed ω of the flow generator), the mass flow rate Q... m It may not be possible to determine this using the back pressure test unit 730.

[0074] As previously explained, the manufacturer may wish to indicate the back pressure of the manufactured part 250 under specific flow conditions. For example, the manufacturer may wish to measure the back pressure of the manufactured part 250 at a specific mass flow rate v. The manufacturer may wish to measure the back pressure of the manufactured part at an industry-standard mass flow rate, for example, equivalent to 600 m³ / s.3 / hr. The mass flow rate and the volume flow rate can be converted to each other based on the density of the flowing material.

[0075] Figure 6 A reference test unit 400 is shown. The reference test unit 400 is similar to the back pressure test unit 730, but the reference test unit 400 further comprises a variable orifice plate 450 and a variable orifice plate back pressure sensor 420. The variable orifice plate back pressure sensor 420 can comprise an upstream back pressure sensor 424 configured to measure the pressure upstream of the variable orifice plate and a downstream back pressure sensor 422 configured to measure the pressure downstream of the variable orifice plate.

[0076] The variable orifice plate 450 can comprise an adjustable orifice plate and / or one or more switchable orifice plates. The reference test unit 400 can be a flow test bench, such as a SuperFlow SF 1020 and / or the like. The variable orifice plate 450 and the variable orifice plate back pressure sensor 420 allow to adjust the flow (generated by the flow generator 724) by adjusting the geometric properties of the variable orifice plate 450. For example, the relative diameter β of the variable orifice plate 450 can be increased or decreased to increase or decrease the flow. In some embodiments, the relative diameter β can be increased or decreased by adjusting the adjustable orifice plate. In some embodiments, the relative diameter β can be increased or decreased by exchanging a first switchable orifice plate for a second switchable orifice plate having an increased or decreased relative diameter β.

[0077] By providing the back pressure sensor 420, the mass flow rate can be determined. For example, the dependency of the mass flow rate on the relative diameter β of the variable orifice plate and the back pressure determined by the back pressure sensor 420 can be known and / or calibrated. In this way, the mass flow rate can be determined based on the measurements provided by the back pressure sensor 420.

[0078] Thus, by using the reference test unit 400, the back pressure and the mass flow rate Q m of the manufacturing component 250 and / or the reference component can be measured simultaneously. In this way, the back pressure of the manufacturing component 250 and / or the reference component can be measured at a specific mass flow rate.

[0079] In some embodiments, the reference test unit 400 can be used to test the back pressure of a reference component (e.g. a reference orifice plate) at a specific mass flow rate. As will be explained in more detail below, one or more manufacturing components 250 can be tested on the back pressure test unit 730 by comparison with the test of the reference component on the back pressure test unit 730. In this way, the need to test the manufacturing components 250 on the reference test unit 400 can be avoided.

[0080] Figure 7An example three-dimensional representation of a back pressure test unit 730 is shown. As Figure 7 can be seen, the back pressure test unit 730 includes a test location 722. In Figure 7 the illustrated embodiment, the back pressure test location 722 can include a vacuum cone 603, a filter assembly 602, and a vacuum tool 604 affixed to the filter assembly 602 by a positioning bolt 605. The vacuum tool 604 can include a central opening configured to hold a manufacturing component 250 (manufacturing component 250 not shown in Figure 7 ). Alternatively, the vacuum tool 604 can be configured to hold a reference component, such as a reference orifice plate. In some embodiments, a first vacuum tool for a manufacturing component 250 and a second vacuum tool for a reference component can be provided, which vacuum tools function as adapters to connect the manufacturing component 250 and / or the reference component to the back pressure test unit 730.

[0081] A flow generator 724, which can include a fan, can then be used to induce flow through the manufacturing component 250. A back pressure sensor 726 (indicated by a dashed line to be within the vacuum cone 603) can then be used to measure the back pressure of the manufacturing component 250. The back pressure test unit 730 can also include a frame assembly 601, which is welded to the vacuum cone assembly at the point indicated by label 603.

[0082] The back pressure test unit 730 can also include a flow switching assembly 620, which includes a valve 622 and a valve actuator 621. In the case that a manufacturing component 250 is being measured, the valve 622 can be in a first position such that the flow generator 724 causes flow through the manufacturing component 250, a measurement conduit 626, through the valve 622, and through an end conduit 627. Since the vacuum created by this flow creates a suction on the manufacturing component 250, it can be difficult to remove the manufacturing component 250 without stopping the flow through the manufacturing component 250. The valve 622 can be moved to a second position by the valve actuator 621 such that the flow generator 724 causes flow from an inlet 630 (which can be a filtered inlet to prevent dust from entering the system) through a redirected flow conduit 625, and through the valve 622, and through the end conduit 627. In this way, the suction on the manufacturing component 250 can be released, for example, air can enter the vacuum cone 603 through the filter assembly 602 to reduce or eliminate the pressure difference between the interior of the vacuum cone 603 and the outside pressure (which can be atmospheric pressure). This allows the manufacturing component 250 to be removed without the need to shut off the air flow generator 724. Since the valve 622 can be switched faster than shutting off and restarting the flow generator 724, the time taken between measurements of the manufacturing component 250 can be reduced, resulting in a greater throughput of testing of the manufacturing component 250.

[0083] Figure 8 A plot showing back pressure measurements (on the y-axis) taken using back pressure test unit 730 plotted against back pressure measurements (on the x-axis) taken using reference test unit 400 (such as a Superflow SF 1020) is shown. Back pressure measurements on back pressure test unit 730 can be denoted as P. Back pressure measurements on reference test unit 400 can be denoted as P’.

[0084] From here on in this specification, the following convention for denoting pressure measurements can apply. Back pressures indicative of measurements taken by reference test unit 400 (e.g., as shown in Figure 6 ) are denoted by an apostrophe (’). Back pressures indicative of measurements taken by back pressure test unit 730 (e.g., as shown in Figure 5 ) are denoted without an apostrophe (’). Subscripts are used to denote the manufactured component being measured. For example, a back pressure measurement of manufactured component A on reference test unit 400 is referred to as P A ’. A back pressure measurement of manufactured component A on back pressure test unit 730 is referred to as P A .

[0085] As shown in Figure 8 , a total of ten manufactured components 250 were tested. The ten manufactured components can be ten reference components. Two circles are plotted for each manufactured component 250 to indicate the back pressure measurement uncertainty in the measurements taken on back pressure test unit 730, with the higher circle indicating the upper error bound and the lower circle indicating the lower error bound. The x-axis uncertainty due to the uncertainty in the measurements taken on reference test unit 400 can be too small to be visible on the plot.

[0086] From a determination coefficient of 0.9995, denoted as R 2 It can be appreciated that there is a strong correlation between the back pressure measurements taken using back pressure test unit 730 and the comparative back pressure measurements taken using the reference test unit. As can be seen by the equation of the best fit line (P = 0.8732P’ + 0.9985), the values according to back pressure test unit 730 and Superflow measurements can differ numerically, for example, they can differ due to the gradient not being equal to 1 and due to the offset. In the above example, the gradient is 0.8732 and the offset is 0.9985.

[0087] In some embodiments, Figure 8The ten components shown plotted in FIG. 8 can be one or more reference components. The ten components have consistent measurements (y data) on the back pressure test unit 730 and consistent measurements (x data) on the reference test unit 400. Thus, the back pressure measurements of a manufactured component on the back pressure test unit 730 can be compared to the back pressure measurements of a reference component on the back pressure test unit 730. In this way, it can be understood how another manufactured component 250 would perform on the reference test unit 400 without testing that manufactured component 250 on the reference test unit 400. This is because the comparison point can be provided by the reference component.

[0088] Figure 9 A diagram is shown for understanding how back pressure measurements made on the back pressure test unit 730 relate to back pressure measurements made on the reference test unit 400 without directly testing a manufactured component on the reference test unit 400. As Figure 9 can be seen, a lower reference component denoted as L, a reference component denoted as R, and an upper reference component denoted as U have been tested on the back pressure test unit 730 (not denoted with a prime) and on the reference test unit 400 (denoted with a prime). The solid line plots the relationship of the back pressure value P on the back pressure test unit corresponding to the back pressure value P' on the reference test unit. In Figure 9 , the solid line is a straight line parameterized by values a and b. If the relationship between P and P' is the same as the relationship shown in Figure 8 , then a can equal 0.8732 and b can equal 0.9985. However, as will be further explained below, to perform the methods described herein, the function of the solid line can not need to be known, e.g., both a and b can be unknown. In general, P can depend on some function of P'. The dashed line indicates how the back pressure P L , P R , P U on the back pressure test unit maps to the back pressure measurement value P L ', P R ', P U ' on the reference test unit. The dashed line indicates the set of points on the plot where P equals P'. As Figure 9 can be seen, for the reference component R, the back pressure P R obtained using the back pressure test unit equals the back pressure P R ' obtained using the reference test unit. This can be seen by the intersection of the solid line with the dashed line. In Figure 9 the example shown, there is only a single coordinate P R , P R ') for which the back pressures on the back pressure test unit 730 and the reference test unit 400 are the same. For the upper and lower reference components, P U ' differs in value from PU and P L ’ is numerically different from P L .

[0089] In some embodiments, P can depend on an increasing function of P’, i.e. any increase of P corresponds to an increase of P’ and any decrease of P corresponds to a decrease of P’. In some embodiments, P can depend on a non-linear increasing function of P’. Thus, the manufacturing component used for the back pressure test on the back pressure test unit 730 has a back pressure measurement P L and P U ’ between P M may be determined to also fall within P L ’ and P U ’ without determining the back pressure value P M ’ of the manufacturing component on the reference test unit. In this way, it can be determined that if

[0090] P L < P M < P U (3)

[0091] is true, it follows that

[0092] P L ’ < P M ’ < P U ’ (4)

[0093] is also true. Thus, the need to directly determine P M ’ can be avoided. In this way, the need to test every manufacturing component 250 on the reference test unit 400 is avoided, but a reliable determination of whether the back pressure P M ’ of the manufacturing component will be within the upper and lower limits on the reference test unit 400 can still be obtained.

[0094] Figure 10 A system 700 for back pressure testing of manufacturing components is shown, which system comprises one or more test locations 722, 742, 762. The system 700 for back pressure testing of manufacturing components 250 comprises a back pressure test unit 730, e.g. a back pressure test unit 730 as shown in Figure 5 and / or Figure 7 . Similar to the back pressure test unit 730 as shown in Figure 5 and / or Figure 7 , the back pressure test unit 730 shown as part of the system 700 in Figure 10 comprises a test location 722, a back pressure sensor 726 and a flow generator 724. As shown in Figure 10As shown, the back pressure test unit 730 can also include a controller 710 for performing the method 1000 of back pressure testing. The method 1000 will be described in more detail below. As Figure 10 As can be seen, the back pressure test unit 730 can also include one or more additional test locations.

[0095] An advantage of some embodiments of the present disclosure is the ability to test one or more manufactured components 250 in parallel / simultaneously. Accordingly, in some embodiments, the back pressure test unit 730 can include one or more test locations 722, 742, 762 configured to house a manufactured component 250 and / or a reference component; one or more flow generators 724, 744, 764 configured to generate a flow through each test location 722, 742, 762; and one or more back pressure sensors 726, 746, 766 configured to measure a back pressure at each test location 722, 742, 762. In some embodiments, for each of the one or more test locations 722, 742, 762, a respective flow generator 724, 744, 764 is provided, such that a 1stflow generator 724, a 2ndflow generator 744, up to an n*flow generator 764 can be configured to generate a flow through a 1sttest location 722, a second test location 742, up to an n*test location, respectively. In some embodiments, for each of the one or more test locations 722, 742, 762, a respective back pressure sensor 726, 746, 766 is provided, such that a 1stback pressure sensor 726, a 2ndback pressure sensor 746, up to an n*back pressure sensor 766 can be configured to measure a back pressure at a 1sttest location 722, a second test location 742, up to an n*test location, respectively. In this way, each of the test locations 722, 742, 762 can represent a location at which a manufactured component 250 can be tested. In this way, n manufactured components 250 can be tested in parallel. It should be noted that by providing a respective flow generator 726, 746, 766 for each test location 722, 742, 762, the flow of each test location 722, 742, 762 can be calibrated independently.

[0096] In some embodiments, an automated system 800 for back pressure testing of manufactured components 250 can be provided. For example, a robotic arm 850 can be provided to perform testing of manufactured components 250. Figure 11An automated system 800 for back pressure testing of manufactured components 250 is shown. The automated system 800 is similar to the system 700, but the automated system 800 further includes a robotic arm 850 for automatically placing one or more manufactured components 250 at one or more test locations 722, 742, 762. The robotic arm 850 can place a manufactured component 250 and / or a reference component for back pressure testing at one or more test locations 722, 742, 762.

[0097] As Figure 11 As can be seen in FIG. 8, the back pressure testing unit 730 can be provided as part of a production line including a manufacturing station 832. In this way, testing of manufactured components 250 output from the manufacturing station 832 can be performed. The manufacturing station 832 can be a device configured to produce manufactured components 250. A conveyance, such as a conveyor belt, can transport manufactured components 250 from the manufacturing station 832 to the back pressure testing unit 730. The robotic arm 850 can then pick up one of the manufactured components 250 and place the manufactured component 250 at one of the one or more test locations 722, 742, 762, and then use the corresponding back pressure sensor 726, 746, 766 to measure the back pressure of the manufactured component as a flow is generated through the manufactured component 250 by the corresponding flow generator 724, 744, 764. Similarly, the robotic arm 850 can pick up a reference component and place the reference component at one of the one or more test locations 722, 742, 762, and then use the corresponding back pressure sensor 726, 746, 766 to measure the back pressure of the reference component as a flow is generated through the manufactured component 250 by the corresponding flow generator 724, 744, 764.

[0098] Once the back pressure of the reference component has been measured, the reference component can be provided to a shop accessible by the robotic arm 850 for additional calibration or verification. Alternatively, the reference component can be provided to one or more of the other test locations 722, 742, 762. Once the back pressure of the manufacturing component 250 has been measured, the manufacturing component can be provided to one or more additional stations 870, such as a rework station 876, a visual inspection station 872, and / or a packaging station 874. The manufacturing component can be provided to the one or more additional stations by a conveyor, such as by the robotic arm 850 removing the manufacturing component from one of the test locations 722, 742, 762 and placing the manufacturing component on the conveyor, such as a conveyor belt. Where the manufacturing component is sent to can depend on the test result based on the back pressure measurement by the respective back pressure sensor 726, 746, 766. According to some methods disclosed herein, the test result can be determined based on the back pressure measurement. How the test result is determined will be explained in more detail below with reference to the method steps. For example, if the test result is a negative test result, the manufacturing component can be directed to the rework station 876. Alternatively, if the test result is a positive test result, the manufacturing component can be directed to the visual inspection station 872 and / or the packaging station 874.

[0099] In some embodiments, each manufacturing component 250 comprises a unique identifier, such as a barcode. In this way, when the manufacturing component is positioned in or removed from one of the one or more test locations 722, 742, 762, the unique identifier of the manufacturing component 250 can be identified (e.g. by scanning the barcode). In this way, the back pressure measurement by the respective back pressure sensor 726, 746, 766 can be associated with the unique identifier. Thus, the unique identifier can allow the test result to be associated with each manufacturing component 250.

[0100] The back pressure test unit can further comprise a controller 710 configured to perform the method 1000 of back pressure testing. The controller can comprise a memory for storing instructions and / or data, a processor, and / or a signal output / input for sending / receiving instructions to / from other components of the system 700, 800 for back pressure testing. The controller 710 can be configured to send instructions to the robotic arm 850.

[0101] A method 1000 for performing a back pressure test of a manufacturing component 250 will now be described.

[0102] In some aspects of the present disclosure, a method 1000 of back pressure testing a manufacturing component 250 is provided. The method can comprise comparing a back pressure measurement of a manufacturing component 250 on a back pressure testing unit 730 to a back pressure measurement of a reference component on the back pressure testing unit 730, and checking whether the back pressure measurement of the manufacturing component 250 falls within upper and lower limits defined relative to the back pressure measurement of the reference component. In this way, the back pressure of the manufacturing component 250 can be checked against the reference component. The reference component itself can be checked on a reference testing unit 400. As will be explained in more detail below, by testing the back pressure of the manufacturing component 250 in this way, the amount of time taken to test each manufacturing component 250 and / or to test one or more manufacturing components 250 in parallel can be reduced. Additionally, the need to test the manufacturing component 250 on the reference testing unit 400 can be avoided.

[0103] In some embodiments, the reference component can be an orifice plate 100 configured to have a back pressure that matches a reference back pressure when tested on, or if tested on, the reference testing unit 400. The reference back pressure can comprise a back pressure that would be suitable for the manufacturing component 250 to have when in use, for example, when used as part of an exhaust system.

[0104] Figure 12 An overview of the method 1000 of back pressure testing a manufacturing component is shown. As shown in Figure 12 The method 1000 comprises:

[0105] a) obtaining one or more reference components, and determining a reference back pressure measurement for each reference component indicative of a back pressure of that reference component when tested on, or if tested on, a reference testing unit 400;

[0106] b) calibrating one or more test locations 722, 742, 762 of a back pressure testing unit 730 using the one or more reference components;

[0107] c) setting a back pressure upper limit and a back pressure lower limit for each of the one or more test locations 722, 742, 762; and

[0108] d) thereafter, using the one or more test locations 722, 742, 762 to assess a back pressure of one or more manufacturing components 250;

[0109] In this way, the back pressure of the one or more manufacturing components 250 in step d) can be evaluated by comparing the back pressure of the one or more manufacturing components 250 to a limit set in step c). The limit set in step c) can itself be based on a measurement derived from the measurement in step b) of the reference components. Alternatively, the limit set in step c) can be based on a back pressure measurement of the upper limit reference component and / or the lower limit reference component. Each of these steps will now be discussed in more detail.

[0110] As mentioned above, the method 1000 of back pressure testing manufacturing components comprises:

[0111] a) obtaining one or more reference components and determining a reference back pressure measurement for each reference component indicative of the back pressure of that reference component when tested on a reference test unit 400 or if tested on a reference test unit;

[0112] As already explained, an advantage of the method 1000 can be that the one or more manufacturing components can be tested on the back pressure test unit 730 without the need to test the one or more manufacturing components 250 on the reference test unit 400. However, by providing one or more reference components, it can be understood how the one or more manufacturing components 250 can behave on the reference test unit 400 without the need to directly test the one or more manufacturing components 250 on the reference test unit 400. As outlined in the statement above in relation to step a), it can be important to determine the back pressure (P R ’) of the reference components when tested on a reference test unit or if tested on a reference test unit. As will be explained further below, the back pressure (P R ’) of the reference components when tested on a reference test unit or if tested on a reference test unit can be determined experimentally (e.g. measured on a reference test unit 400 as in step a)i) and / or theoretically calculated (e.g. as in step a)ii) where steps a)i) and a)ii) are illustrated in Figure 13 and elaborated on below). Reference will now be made to Figure 13 the back pressure (P R ’) of the reference components when tested on a reference test unit or if tested on a reference test unit can be explained in more detail.

[0113] Figure 13 An embodiment of step a) of obtaining one or more reference components and determining a reference back pressure measurement for each reference component indicative of the back pressure (P R ’) of that reference component when tested on a reference test unit or if tested on a reference test unit is illustrated. As Figure 13In some embodiments, the reference back pressure measurement value (P R ’ ) for each reference component comprises:

[0114] a) i) measuring the back pressure of the reference component on the reference test unit 400; and / or

[0115] a) ii) calculating the back pressure of the reference component to simulate testing the reference component on the reference test unit 400.

[0116] In some embodiments, obtaining a reference component can comprise obtaining an orifice plate configured to provide a reference back pressure measurement value (P R ’ ) when tested on or if tested on a back pressure test unit. In some embodiments, obtaining a reference component can comprise obtaining a reference component of the same type as the manufacturing component 250 (e.g. if the manufacturing component comprises a filter, the reference component can also comprise a filter) configured to provide a reference back pressure measurement value (P R ’ ) when tested on or if tested on a back pressure test unit. In some embodiments, the reference back pressure measurement value (P R ’ ) when tested on or if tested on a back pressure test unit can correspond to the target pressure or the pressure resistance of the manufacturing component 250 when installed in or if installed in an end use system such as an exhaust system.

[0117] In some embodiments, the back pressure (P R ’ ) of the reference component when tested on or if tested on a reference test unit can vary as a function of the mass flow rate Q m as follows:

[0118] P R ’ = g(Q m ) (5)

[0119] where g is a function and Q m is the mass flow rate.

[0120] Accordingly, in some embodiments, a target mass flow rate Q m目标 may be used as the mass flow rate. In some embodiments, the target mass flow rate Q m目标 may be equal to an industry standard test volume flow rate such as 600 m 3 / hr. In such embodiments, the back pressure P R of the reference component when tested on or if tested on a reference test unit can be equal to 0.5 mbar.It can be provided by the following:

[0121] P R '=g(Q m目标 (6)

[0122] After step a)i), when testing on the reference test unit, or if testing on the reference test unit, the back pressure P of the reference component R This can be determined experimentally. More specifically, after step a)i), when testing on the reference test unit 400, or if testing is being conducted on the reference test unit 400, the back pressure of the reference component can be determined by measuring the back pressure of the reference component on the back pressure test unit 400. For example, the back pressure of the reference component can be tested on the back pressure test unit 400 by positioning the reference component at one of the test positions 722, 742, 762. From there, a flow can be generated using the corresponding flow generators 724, 744, 764. As already discussed in... Figure 6 As explained in the above discussion, the mass flow rate can be determined by using a variable orifice plate 450 and a variable orifice plate back pressure sensor 420. For example, by using the variable orifice plate 450 to adjust the mass flow rate, it can be ensured that the back pressure of the reference component is at the target value of mass flow rate Q when measured on the reference test unit 400. m目标 The target mass flow rate Q was measured below. m目标 It can be the typical mass flow rate Q of the exhaust system. m目标 Or industry standard test mass flow rate, for example, equivalent to 600m³ 3 The mass flow rate is the volumetric flow rate per hr. In this way, measurements of the reference component on the reference test unit 400 can be performed.

[0123] After steps a) and ii), when testing on the reference test unit, or if testing on the reference test unit, the back pressure P of the reference component... RThe back pressure P of the reference component can be determined by theoretical calculation, in particular in embodiments where the pressure has a mathematically derivable influence on the flow through the reference component. In some embodiments, the reference component can comprise an orifice plate 100. As has been explained previously, the orifice plate 100 can be provided with a specific back pressure by changing the relative diameter b (or another geometric parameter) of the orifice plate 100. In some embodiments, the reference component can be an orifice plate 100 produced according to a specific set of standards, for example the set of standards defined by “ISO 5167-2 Measurement of fluid flow by means of pressure differential devices inserted in circular cross-section conduit running full - part 2: orifice plates”.

[0124] In some of said embodiments, the back pressure P of the reference component is determined when tested on the reference test unit or if tested on the reference test unit. R The back pressure P of the reference component can be determined by the following steps a)i), step a)ii) and / or step a)i) and step a)ii). In this way, the experimental determination, the theoretical determination and / or the experimental and theoretical determination of the back pressure P of the reference component can be performed when tested on the reference test unit or if tested on the reference test unit. R The back pressure P of the reference component can be determined by the following steps a)i), step a)ii) and / or step a)i) and step a)ii). In this way, the experimental determination, the theoretical determination and / or the experimental and theoretical determination of the back pressure P of the reference component can be performed when tested on the reference test unit or if tested on the reference test unit.

[0125] As described above, the method 1000 of performing a back pressure test on a manufactured component further comprises:

[0126] b) calibrating one or more test positions 722, 742, 762 of a back pressure test unit 730 using the one or more reference components;

[0127] Figure 14 Embodiments of step b) of calibrating one or more test positions 722 of a back pressure unit 730 using one or more reference components are shown. Calibrating one or more test positions of a back pressure test unit 730 in step b) comprises:

[0128] b)i) installing one of the reference components in one or each test position 722, 742, 762 of the back pressure test unit 730;

[0129] b)ii) generating a flow through the or each test position 722, 742, 762;

[0130] b) iii) by adjusting the flow through the test position or each test position 722, 742, 762 until a back pressure measurement P of a reference component in the test position or each test position R corresponding to the respective reference component P R to establish a calibration flow for the test position or each test position 722, 742, 762;

[0131] b) iv) thereafter, the calibration flow for the test position or each test position is used during step d);

[0132] In some embodiments, the flow generator 724, 744, 764 of the back pressure test unit 730 comprises a fan. In such embodiments, by increasing the rotational speed ω and / or the rotational frequency of the flow generator 724, 744, 764, the mass flow rate Q m may be increased. Correspondingly, by decreasing the rotational speed ω and / or the rotational frequency of the flow generator 724, the speed of the flow can be decreased. Thus, the calibration flow can correspond to one specific rotational speed ω and / or rotational frequency of the flow generator 724. In this way, the reference component is used to obtain the calibration flow.

[0133] In step b)i), the reference component can be installed at one of the one or more test positions 722, 742, 762. For example, a robot arm 850 can be used to install the reference component at the one or more test positions 722, 742, 762. In some embodiments, in case the one or more test positions 722, 742, 762 are sequentially calibrated, the robot arm can sequentially install the reference component at the one or more test positions 722, 742, 762. In some embodiments, in case the one or more test positions 722, 742, 762 are simultaneously calibrated, the robot arm 850 can simultaneously install the reference component at the one or more test positions 722, 742, 762. In embodiments in which the one or more test positions 722, 742, 762 are simultaneously calibrated, one reference component can be provided for each test position 722, 742, 762 that is simultaneously calibrated.

[0134] In step b)ii), a flow can be generated through one or more test positions 722, 742, 762. For example, the rotational speed ω of the corresponding flow generators 724, 744, 764 can be increased to generate a flow through one or more test positions 722, 742, 762. Increasing the rotational speed ω increases the mass flow rate, while decreasing the rotational speed ω decreases the mass flow rate. As the mass flow rate through the reference component increases or decreases, the back pressure measured by the corresponding back pressure sensors 726, 746, 766 can increase or decrease. Therefore, when tested on the back pressure test unit, the back pressure P of the reference component... R This depends on the mass flow rate, which in turn depends on the rotational speed ω. The back pressure P of the reference component is used when testing on the back pressure test unit. R It can also depend on the back pressure P of the reference component when testing on the reference test unit, or if testing on the reference test unit. R '. Represented as an equation, when tested on the back pressure test unit, the back pressure P of the reference component. R It can be provided by the following equation:

[0135] P R =f(P R ',ω)(7)

[0136] Where f can be an unknown function.

[0137] In steps b)iii), the calibration flow can be determined. As explained above, the reference test unit 730 may further include a calibration orifice plate 450 compared to the back pressure test unit 730, and therefore the mass flow rate Q can be determined using the reference test unit 400. m In some implementations, the back pressure test unit 730 may lack the ability to determine the mass flow rate Q. m Therefore, although the rotational speed (ω) can be used to increase or decrease the mass flow rate Q, the ability of rotation is limited. m However, the mass flow rate Q may not be known. m In the back pressure test unit 730, the speed can be increased or decreased by increasing the rotational speed ω of the flow generators 724, 744, and 764 until the calibrated rotational speed ω is obtained. Cal To determine the calibration flow, such that:

[0138] P R =f(P) R ',ω Cal =P R '(8)

[0139] In other words, calibrating the rotational speed ω Cal This could include a rotational speed such that when testing on the back pressure test unit, or if testing on the back pressure test unit, the back pressure P of the reference component is...R This is equal to the back pressure P of the reference component when tested on the reference test unit, or if tested on the reference test unit. R Therefore, at the calibrated fan speed:

[0140] P R =P R '(9)

[0141] For example, the speed of the fan from the corresponding flow generator 724, 744, 764 can be adjusted to a calibrated rotational speed ω. Cal The calibrated rotational speed ω can be determined from this. Cal Because the back pressure determined by the corresponding back pressure sensors 726, 746, and 766 has a value equal to P. R The value of '.

[0142] In steps b) and iv), the calibration flow can subsequently be used in step d) for each of one or more test locations 722, 742, and 762. For example, the calibrated fan speed ω Cal This can be provided to controller 710 and / or stored in the memory of controller 710. Controller 710 can also be configured to adjust the rotational speed ω by sending an electronic signal to the fan motor. In this way, controller 710 can be used to adjust the rotational speed ω of the corresponding flow generators 724, 744, 764 to a calibrated rotational speed ω. Cal In some implementations, once the calibrated rotational speed ω is reached by the corresponding flow generators 724, 744, 764... Cal Then the fan speeds of the corresponding flow generators 724, 744, and 764 can be monitored by the controller 710 and / or not maintained at the calibrated rotational speed ω. Cal。

[0143] As already explained, the back pressure test unit 730 may include one or more test locations 722, 742, 762 and corresponding back pressure sensors 726, 746, 766 and corresponding flow generators 724, 744, 764. In some embodiments, the controller 710 may be configured to perform step b) individually and / or simultaneously for each test location 722, 742, 762. In some embodiments, a calibration flow ω for each test location 722, 742, 762... Cal They can be equal. However, due to the variability in the back pressure test unit 730 and / or to improve the accuracy of the results, it is preferable to determine the calibration flow ω individually for each of the one or more test positions 722, 742, 762. Cal .

[0144] As described above, the method 1000 of performing a back pressure test on a manufacturing component 250 further comprises:

[0145] c) setting an upper back pressure limit and a lower back pressure limit for each of the one or more test positions.

[0146] In some embodiments, step c) comprises setting the upper back pressure limit and the lower back pressure limit as a multiple x of a reference back pressure measurement P R and / or a pressure offset from a reference back pressure measurement P R . Thus, the upper back pressure limit can be P R + x P R and the lower back pressure limit can be P R - x P R

[0147] In some embodiments, step c) comprises using one or more upper limit reference components and one or more lower limit reference components.

[0148] Figure 15 Embodiments of step c) of setting an upper back pressure limit and a lower back pressure limit for each of the one or more test positions using one or more upper limit reference components and one or more lower limit reference components are shown. In the embodiments shown, step c) of setting an upper back pressure limit and a lower back pressure limit for each of the one or more test positions in step c) comprises: Figure 15

[0149] c)i) obtaining one or more upper limit reference components and one or more lower limit reference components;

[0150] c)ii) installing one of the upper limit reference components in a test position 722, 742, 762 of the back pressure test unit 730 and setting the upper back pressure limit as the back pressure measured for the upper limit reference component when a calibration flow is caused to flow through the test position 722, 742, 762;

[0151] c)iii) installing one of the lower limit reference components in a test position 722, 742, 762 of the back pressure test unit 730 and setting the lower back pressure limit as the back pressure measured for the lower limit reference component when a calibration flow is caused to flow through the test position 722, 742, 762.

[0152] The upper back pressure limit can be the back pressure of the upper limit reference component when tested on the back pressure test unit P U . The lower back pressure limit can be the back pressure of the lower limit reference component when tested on the back pressure test unit P L .

[0153] ​Each of the steps c)i) to c)iii) will now be explained in more detail. The one or more upper limit reference components can comprise one or more similar components configured to provide an upper limit reference at the one or more test locations 722, 742, 762. In this way, the one or more upper limit reference components can be used to simultaneously calibrate the upper limit at the one or more test locations 722, 742, 762. Similarly, the one or more lower limit reference components can comprise one or more similar components configured to provide a lower limit reference at the one or more test locations 722, 742, 762. In this way, the one or more lower limit reference components can be used to simultaneously calibrate the lower limit at the one or more test locations 722, 742, 762. Alternatively, one of the upper limit reference components and one of the lower limit reference components can be used to calibrate the one or more test locations 722, 742, 762, which can be calibrated sequentially.

[0154] In step c)i), one or more upper limit reference components and one or more lower limit reference components can be obtained. The one or more upper limit reference components and the one or more lower limit reference components can comprise orifice plates. As has been explained previously, by changing the relative diameter β (or another geometric parameter) of the orifice plate, the back pressure of the orifice plate can be changed. In some embodiments, the upper limit reference components can comprise orifice plates having an increased back pressure compared to the reference components. In some embodiments, the lower limit reference components can comprise orifice plates having a decreased back pressure compared to the reference components. For example, the lower limit reference components can have a lower relative diameter compared to the upper limit reference components. As has been explained previously, the back pressure of an orifice plate can increase with a decrease of the relative diameter. Thus, the lower limit reference components can comprise orifice plates having a larger relative diameter β compared to the relative diameter of the upper limit reference components, which comprise orifice plates. In some embodiments, the reference components can comprise orifice plates. In some embodiments, the relative diameter β of the lower limit reference components can be greater than the relative diameter β of the reference components. In some embodiments, the relative diameter β of the upper limit reference components can be greater than the relative diameter β of the reference components. L The relative diameter β of the upper limit reference components U and the relative diameter β of the reference components R may be related by the following inequality:

[0155] The relative diameter β of the upper limit reference components L may be greater than the relative diameter β of the reference components R may be greater than the relative diameter β of the reference components U (10)

[0156] In some embodiments, the back pressure P R of the lower limit reference components when tested on the reference test unit can be greater than the back pressure P L'It can be lower. In some of the described schemes, the back pressure P of the reference component is compared with that of the reference component when tested on the reference test unit or if tested on the reference test unit.' R In comparison, the upper limit of the back pressure P of the reference component when tested on the reference test unit is... U 'It can be higher. As already explained, the flow generators 724, 744, and 764 in the back pressure test unit 730 are at a calibrated rotational speed ω.' Cal In the case of testing on the back pressure test unit, the back pressure P of the reference component is... R This can be equal to the back pressure P of the reference component when tested on the reference test unit, or if tested on the reference test unit. R '. However, as in Figure 9 As explained in the above discussion, the flow generators 724, 744, and 764 of the back pressure test unit 730 are at a calibrated rotational speed ω. Cal In the case of testing on the back pressure test unit, the lower limit reference component's back pressure P L The back pressure P of the lower limit reference component can be numerically different from that of the reference test unit when tested on the reference test cell. L Similarly, the flow generators 724, 744, and 764 in the back pressure test unit 730 are at a calibrated rotational speed ω. Cal In the case of testing on the back pressure test unit, the back pressure P of the upper limit reference component is... U The back pressure P of the upper reference component may differ numerically from that of the upper reference component when tested on the reference test unit. U The above summarizes the calibrated rotational speed ω of the flow generators 724, 744, and 764 in the back pressure test unit 730. Cal In this case, the following can be correct:

[0157] P R =P R '

[0158] P U ≠P U '(11)

[0159] P L ≠P L '

[0160] However, as in Figure 9 As explained in the above discussion, since the relationship between the back pressures P on the back pressure test unit is an increasing function of the back pressure P' on the reference test unit, it can be concluded that if:

[0161] The back pressure P of the manufacturing part 250 on the back pressure test unit M Given the back pressure P of the lower limit reference component when tested on the back pressure test unit LThe back pressure P of the upper limit reference component when tested on the back pressure test unit U Between; then we can conclude:

[0162] If tested on a reference test unit, the back pressure P of manufactured part 250 is... M 'It will also be between the lower limit reference component back pressure P when tested on the reference test unit.' L 'The back pressure P of the upper limit reference component when tested on the reference test unit' U Between '. Summarizing the above, we conclude that if:

[0163] P L <P M <P U (12)

[0164] If true, then we get

[0165] P L ' <P M ' <P U '(13)

[0166] It is also true. Therefore, it can be determined that if the manufacturing part 250 is tested on the reference test unit 400, the manufacturing part 250 will have a back pressure within the upper and lower limits, without needing to test the manufacturing part 250 on the reference test unit 400.

[0167] In some implementations, the appropriate diameters for the upper and lower reference components can be determined theoretically, for example, by using a standard set by ISO 5167-2 and / or by using hydrodynamic calculations. Alternatively or additionally, the diameters of the upper and lower reference components can be determined experimentally using the reference test unit 400. For example, a series of diameters can be tested until a component with appropriate back pressure is obtained.

[0168] In step c)ii), the upper limit reference component can be mounted on one or more test positions of the back pressure test unit 730. For example, a robotic arm 860 can be used to mount the upper limit reference component on one or more test positions 722, 724, 726. Then, the corresponding flow generators 724, 744, 764 are set to a calibrated rotational speed ω. CalThe respective flow generator 724, 744, 764 can be used to provide a calibration flow through the respective test location 722, 742, 762. Then, a back pressure measurement can be made by the respective back pressure sensor 726, 746, 766 of the upper limit reference component in one of the one or more test locations 722, 742, 762. As explained above, the measurement made by the back pressure test unit 730 can correspond to the measurement made by the reference test unit 400, but differ in value.

[0169] In step c) iii), the upper limit reference component can be mounted on one of the one or more test locations of the back pressure test unit 730. For example, the robot arm 860 can be used to mount the upper limit reference component on one of the one or more test locations 722, 742, 762. Then, the respective flow generator 724, 744, 764 can be used to provide a calibration flow through the respective test location 722, 742, 762 by setting the rotational speed ω Cal The respective flow generator 724, 744, 764 can be used to provide a calibration flow through the respective test location 722, 742, 762. Then, a back pressure measurement can be made by the respective back pressure sensor 726, 746, 766 of the upper limit reference component in one of the one or more test locations 722, 742, 762. As explained above, the measurement made by the back pressure test unit 730 can correspond to the measurement made by the reference test unit 400, but differ in value.

[0170] As described above, the method 1000 of back pressure testing of manufacturing components further comprises:

[0171] d) thereafter, using the one or more test locations 722, 742, 762 to assess the back pressure of the one or more manufacturing components 250;

[0172] Figure 16 Embodiments of step d) of using the one or more test locations to assess the back pressure of the one or more manufacturing components are shown.

[0173] In some embodiments, using the one or more test locations to assess the back pressure of the one or more manufacturing components 250 in step d) comprises:

[0174] d) i) mounting the manufacturing component 250 in the or each test location 722, 742, 762 of the back pressure test unit 730;

[0175] d) ii) flowing the calibration flow determined from step b) iii) through the or each test location 722, 742, 762;

[0176] d) iii) measuring a back pressure measurement of the manufacturing component 250 or each manufacturing component;

[0177] d) iv) comparing the back pressure measurement of the manufacturing component 250 or each manufacturing component with the upper back pressure limit and the lower back pressure limit of the respective test position and generating and outputting a rest result indicating whether the back pressure measurement is within an acceptable range compared to the upper back pressure limit and the lower back pressure limit.

[0178] Each of the steps d)i) to d)iv) will now be explained in more detail. The manufacturing component or each manufacturing component referred to in steps d)i) to d)iv) can comprise the manufacturing component or each manufacturing component used for the back pressure test. For example, the manufacturing component or each manufacturing component referred to in steps d)i) to d)iv) can comprise the manufacturing component obtained from the manufacturing station 832 used for the back pressure test.

[0179] In step d)i), the manufacturing component 250 or each manufacturing component can be mounted on one of the one or more test positions 722, 742, 762 of the back pressure test unit 730. For example, the robotic arm 860 can be used to mount the manufacturing component 250 or each manufacturing component on one of the one or more test positions 722, 742, 762.

[0180] In step d)ii), the flow generator 724, 744, 764 can be used to flow air through the test position 722, 724, 726. As already explained, the flow generator 724, 744, 764 flows air at the calibrated rotational speed co Cal operation.

[0181] In step d)iii), the back pressure measurement P M of the manufacturing component or each manufacturing component can be measured by the respective back pressure sensor 726, 746, 766. The back pressure measurement can be provided to the controller 710.

[0182] In step d)iv), it is determined whether the back pressure measurement is within an acceptable range. For example, the controller 730 can evaluate the inequality:

[0183] P L < P M < P U (14)

[0184] is true. Alternatively, in embodiments where the upper back pressure limit and the lower back pressure limit are set by a multiple / fraction x of the back pressure P R of the reference component when tested on the back pressure test unit, the controller 730 can evaluate the inequality:

[0185] P R -xP R <P M <P R +xP R (15)

[0186] is true. In some embodiments, the upper back pressure limit and the lower back pressure limit include an offset to account for the precision of the test. However, the upper limit and the lower limit are provided, P M may be within an acceptable range, and the manufacturing component 250 can be assigned a positive result. In particular, it can be determined from the above that if the test were performed on a reference test unit, the back pressure P M ’ of the manufacturing component would also be within an acceptable range. In some embodiments, a unique identifier of the manufacturing component can be scanned to associate the manufacturing component with the positive result. If the inequality (14) and / or (15) is false, P M may not be within an acceptable range, and the manufacturing component 250 can be assigned a negative result. In particular, it can be determined from the above that if the test were performed on a reference test unit, the back pressure P M ’ of the manufacturing component would also not be within an acceptable range. In some embodiments, a unique identifier of the manufacturing component 250 can be scanned to associate the manufacturing component 250 with the negative result.

[0187] In some embodiments, the method 1000 further comprises:

[0188] e) periodically verifying the back pressure measurements at the one or more test locations 722, 742, 762 by evaluating the back pressure of one or more verification reference components at each of the one or more test locations 722, 742, 762.

[0189] Figure 17 An embodiment of step e) of periodically verifying the back pressure measurements at the one or more test locations by evaluating the back pressure of one or more verification reference components at each of the one or more test locations is shown.

[0190] In some embodiments, step e) can comprise a step e)0) of obtaining one or more verification reference components having a back pressure measurement P VCorresponding calibration of the back pressure sensors 726, 746, 766, calibration rotational speed provided by the corresponding flow generators 724, 744, 764, dirt or dust introduced into the system, temperature fluctuations can cause the back pressure measurement determined by the back pressure sensor 726 to increase and / or decrease in relation to previous measurements by the same back pressure sensor 726. As a result, the manufacturing component 250 can be falsely assigned a negative result and / or falsely assigned a positive result. To avoid this, the method 1000 can further comprise periodically verifying step e) of the method 1000. Step e)0) can comprise determining a back pressure measurement P V In some embodiments, P V may be between P L and P U .

[0191] Step e)0) can comprise obtaining one or more verification reference components having a back pressure measurement P V between the upper back pressure limit and the lower back pressure limit when tested on the back pressure test unit. The verification reference components can be equivalent to the reference components, e.g. P V may be equal to P R In some embodiments, the verification reference can comprise the orifice plate 100. In some embodiments, the verification reference component can comprise the filter 300.

[0192] Once the verification reference components are obtained in step e)0), the verification reference components can be tested similar to how the manufacturing components 250 are tested. For example, the verification reference components can be periodically tested by:

[0193] e)i) installing the verification reference component in the test position 722, 742, 762 or each test position of the back pressure test unit;

[0194] e)ii) causing the calibration flow determined from step b)iii) to flow through the test position 722, 742, 762 or each test position;

[0195] e)iii) measuring a back pressure measurement of the verification reference component or each verification reference component;

[0196] e)iv) comparing the back pressure measurement of the verification reference component or each verification reference component to the upper back pressure limit and the lower back pressure limit for the corresponding test position 722, 742, 762 and generating a verification pressure measurement and determining whether the verification pressure measurement is within an acceptable range compared to the upper back pressure limit and the lower back pressure limit.

[0197] In step e)i), the verification component can be mounted on one of the one or more test positions of the back pressure test unit 730. For example, the robotic arm 860 can be used to mount the upper limit reference component on one of the one or more test positions 722, 742, 762.

[0198] In step e)ii), the flow generator 724, 744, 764 can be used to generate a flow through the test position 722, 724, 726. As already explained, the flow generator 722, 742, 762 can be operated at the calibrated rotational speed ω Cal the next operation.

[0199] In step e)iii), the back pressure measurement P V of the verification component on the back pressure test unit can be measured by the respective back pressure sensor 726, 746, 766. The back pressure measurement P V of the verification component on the back pressure test unit can be provided to the controller.

[0200] In step e)iv), it can be determined whether the back pressure measurement P V of the verification component on the back pressure test unit is within an acceptable range. For example, the controller 730 can evaluate the inequality:

[0201] P L < P V < P U (16)

[0202] is true. Alternatively, in embodiments where the upper back pressure limit and the lower back pressure limit are set by a multiple / fraction x of the back pressure P R of the reference component when tested on the back pressure test unit, the controller 730 can evaluate the inequality:

[0203] P R - xP R < P V < P R + xP R (17)

[0204] is true. In some embodiments, the upper back pressure limit and the lower back pressure limit include an offset to account for the precision of the test. However, the upper limit and the lower limit are provided, if the inequality (16) and / or (17) is true, P V may be within an acceptable range. This in turn can indicate that the back pressure measurement by the back pressure sensor 726 has not increased and / or decreased with respect to a previous measurement by the same back pressure sensor 726. Thus, based on the inequality (16) and / or (17) being true, the measurement of the manufactured component in step d) can be verified.

[0205] In some embodiments, the plurality of previously tested manufacturing components and / or the plurality of subsequently tested manufacturing components are validated. In some embodiments, the manufacturing components tested within the time window in which the inequality is determined to be true can be validated. If the inequality is false, then P V may not be within an acceptable range. This in turn can indicate that the back pressure measurement by the back pressure sensor 726, 746, 766 has increased and / or decreased relative to a previous measurement by the same back pressure sensor 726. Accordingly, based on the inequality being false, the measurement of the manufacturing component in step d) can be invalidated. In some embodiments, the plurality of previously tested manufacturing components 250 and / or the plurality of subsequently tested manufacturing components 250 are invalidated. In some embodiments, the manufacturing components 250 tested within the time window in which the inequality is determined to be false can be invalidated.

[0206] In some embodiments, validating the manufacturing component 250 can include associating, using the controller 710, the validation signal with the unique identifier of the manufacturing component. In some embodiments, invalidating the manufacturing component can include associating, using the controller, the invalidation signal with the unique identifier of the manufacturing component.

[0207] The controller 710 can be configured to periodically perform the above steps by performing steps e)i) through e)iv) every 1 s, every 100 s, every 1000 s, every 10,000 s of operation of the method 1000. The controller 710 can be configured to periodically perform the above steps by performing steps 1920 through 1980 before and / or after each measurement of a manufacturing component for back pressure testing, before and / or after measurements of 10 manufacturing components for back pressure testing, before and / or after measurements of 100 manufacturing components for back pressure testing, before and / or after measurements of 1000 manufacturing components for back pressure testing.

[0208] As has been explained above, the manufacturing component 250 can include a filter 300. In some embodiments, the manufacturing component 250 can include a filter 300, such as a catalytic filter for use in an exhaust system. The filter 300 can include pores through which a flow can pass such that one or more components of the flow can be blocked and / or catalyzed by the filter 300. In some embodiments, not shown in the figures, the filter 300 can include a planar sheet of material that includes pores. In some embodiments, as schematically shown in FIG. 3, the filter 300 can include one or more plugs 922, 924, 926, 942, 944, 946, and one or more channels 943, 945, 947, 923, 925, 927. As has been explained, the flow can travel through the walls 903, 905, 907, which include pores. Figure 4

[0209] ​Figure 18 A photograph showing a top view of catalytic filter 900 is shown generally at Figure 4 Filter 300, shown schematically as a side view in FIG. 3, is similarly configured. Figure 18 and Figure 4 The dashed lines in FIGS. 9-11 can indicate the same direction. Catalytic filter 900 includes channels 942, 944, 946 and plugs 922, 924, and 926. Flow can travel through channels 942, 944, 946, through the walls, and out through a set of channels located below plugs 922, 924, 926, which are not visible in the figures. The checkerboard structure of filter 900 ensures that flow must pass through the pores in the walls to pass through filter 900.

Claims

1. A method of back pressure testing of manufactured components, the method comprising: a) obtaining one or more reference components and determining a reference back pressure measurement for each reference component indicative of the back pressure of the reference component when tested on or if tested on a reference test cell; b) calibrating one or more test locations of a back pressure test cell using the one or more reference components; c) setting an upper back pressure limit and a lower back pressure limit for each of the one or more test locations; and d) thereafter, using the one or more test locations to assess the back pressure of one or more manufactured components; wherein calibrating one or more test locations of the back pressure test cell in step b) comprises: b)i) installing one of the reference components in one or each of the test locations of the back pressure test cell; b)ii) generating a flow through the or each test location; b)iii) establishing a calibration flow for the or each test location by adjusting the flow through the or each test location until the back pressure measurement of the reference component in the or each test location corresponds to the reference back pressure measurement of the respective reference component; b)iv) thereafter, using the calibration flow for the or each test location during step d); wherein using the one or more test locations to assess the back pressure of one or more manufactured components in step d) comprises: d)i) installing a manufactured component in one or each of the test locations of the back pressure test cell; d)ii) flowing the calibration flow determined from step b)iii) through the or each test location; d)iii) measuring a back pressure measurement of the or each manufactured component; d)iv) comparing the back pressure measurement of the or each manufactured component to the upper back pressure limit and the lower back pressure limit of the respective test location and generating and outputting a test result indicating whether the back pressure measurement is within an acceptable range compared to the upper back pressure limit and the lower back pressure limit.

2. The method of claim 1, wherein, In step a), determining a reference back pressure measurement for each reference component indicative of the back pressure of the reference component when tested on or if tested on the reference test cell comprises: - measuring the back pressure of the reference component on the reference test cell; and / or - calculating the back pressure of the reference component to simulate testing the reference component on the reference test cell.

3. The method of claim 1 or claim 2, wherein, The reference back pressure of the or each reference component when tested on or if tested on a reference test cell refers to a specified air flow rate of the reference test cell.

4. The method of any preceding claim, wherein, In step c), setting the upper back pressure limit and the lower back pressure limit for each of the one or more test locations comprises: - obtaining one or more upper limit reference components and one or more lower limit reference components; - installing one of the upper limit reference components in the test position of the back pressure test unit and setting the upper back pressure limit to the back pressure measured for the upper limit reference component when flowing the calibration flow through the test position; - installing one of the lower limit reference components in the test position of the back pressure test unit and setting the lower back pressure limit to the back pressure measured for the lower limit reference component when flowing the calibration flow through the test position.

5. The method of any one of claims 1 to 3, wherein, Setting the upper back pressure limit and the lower back pressure limit for each of the one or more test positions in step c) comprises setting the upper back pressure limit and the lower back pressure limit as a percentage of the reference back pressure measurement and / or offset from the absolute pressure of the reference back pressure measurement.

6. The method of any preceding claim, further comprising: obtaining one or more validation reference components having a back pressure measurement between the upper limit and the lower limit when tested on one of the one or more test positions, and periodically: i) installing a validation reference component in the or each test position of the back pressure test unit; ii) flowing a calibration flow determined from step b) iii) through the or each test position; iii) measuring a back pressure measurement of the or each validation reference component; iv) comparing the back pressure measurement of the or each validation reference component to the upper back pressure limit and the lower back pressure limit of the respective test position and generating a validation pressure measurement and determining whether the validation pressure measurement is within an acceptable range compared to the upper back pressure limit and the lower back pressure limit.

7. The method of any preceding claim, wherein, One or more of the reference components and / or upper limit reference components and / or lower limit reference components and / or validation reference components are orifice plates.

8. The method of any preceding claim, wherein the one or more manufacturing components are flow-through substrates or filter substrates for purifying exhaust gas.

9. The method of any preceding claim, further comprising a robotic arm for automatically placing calibration reference components, validation reference components and / or manufacturing components.

10. The method of any preceding claim, wherein the or each manufacturing component of the one or more manufacturing components comprises a unique identifier.

11. The method of claim 10, wherein the unique identifier is a barcode.

12. A controller configured to perform the method of any of claims 1 to 11.

13. A system for back pressure testing of manufacturing components, the system comprising: a controller according to claim 12; and a back pressure test unit comprising: one or more test positions configured to accommodate manufacturing components and / or reference components; a flow generator configured to generate a flow through each test position; and a controller according to claim 12; and a back pressure test unit comprising: one or more test positions configured to accommodate manufacturing components and / or reference components; a flow generator configured to generate a flow through each test position; and a back pressure sensor configured to measure a back pressure at each test location.

14. The system of claim 13, further comprising a robotic arm for automatically placing one or more manufacturing components and / or reference components at the one or more test locations.

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