Air-air heat exchanger and fan testing system and method

Abstract

The invention provides an air-to-air heat exchanger and a fan testing system and method. The system comprises a heat exchanger body, a sealing gasket, an external circulation air inlet assembly, an external circulation air inlet assembly, an internal circulation air inlet assembly, an internal circulation air outlet assembly and a test board. The method comprises the following steps: obtaining the heating power of a heating wire through an internal logic measurement and calculation unit according to the actually measured resistance value of a slide rheostat, the heating wire resistance value of the heating wire and the terminal voltage of the heating wire, and if the heat exchange working state is a heat exchange stable state, obtaining the evaluation data of an internal circulation fan, the evaluation data of an external circulation fan and the environment temperature; analyzing and processing to obtain heat exchange capability evaluation data; the air channel is divided into the internal circulation space and the external circulation space, the internal circulation space is formed by sealing the transparent glass cover, the required heating power of the heating wire is obtained by adjusting the resistance value of the slide rheostat, internal and external circulation fans or heat exchangers of different manufacturers are tested respectively, and therefore efficient and accurate testing of the air-to-air heat exchangers and the fans is achieved.

Description

Technical Field

[0001] This application relates to the field of heat exchanger testing, and more specifically, to a testing system and method for air-to-air heat exchangers and fans. Background Technology

[0002] Power conversion devices such as photovoltaic inverters and energy storage converters are often used in harsh environments. To ensure the reliability and stability of these devices, they are often designed with an IP65 or higher protection rating, meaning the main components are encapsulated within an internal cavity. As power conversion devices have evolved, their power output has increased, and their integration has become more sophisticated. Consequently, the heat generated by internal components has also increased. Simply using internal fans to transfer heat to the chassis surface, followed by natural convection or radiation, is no longer sufficient to effectively dissipate heat from these internal components. Increasingly, heat exchangers are being installed to address this issue, with air-to-air heat exchangers being a key method. However, air-to-air heat exchangers from different manufacturers often exhibit performance differences even with the same dimensions. Furthermore, the fans paired with the heat exchangers require actual testing to verify their performance. This verification necessitates installing the air-to-air heat exchanger and fan on the entire unit for testing, which involves disassembling the entire unit and running charge-discharge cycles. This not only occupies a prototype and results in lengthy testing times but also involves a significant workload and is quite cumbersome.

[0003] Effective technical solutions are urgently needed to address the above problems. Summary of the Invention

[0004] The purpose of this application is to provide a testing system and method for air-to-air heat exchangers and fans. The system divides the air duct into an inner circulation space and an outer circulation space. The inner circulation space is sealed by a transparent glass cover. The required heating power of the heating wire is obtained by adjusting the resistance value of the sliding rheostat. The system can then test the inner and outer circulation fans or heat exchangers from different manufacturers, thereby achieving efficient and accurate testing of air-to-air heat exchangers and fans.

[0005] Firstly, this application provides a test system for air-to-air heat exchangers and fans, including: The heat exchanger body (100), sealing gasket (101), external circulation air inlet assembly (102), external circulation air inlet assembly (103), internal circulation air inlet assembly (104) and internal circulation air outlet assembly (105) and test bench (200). The heat exchanger body (100) is installed on the test bench (200) to simulate the heat exchange performance of a preset air-to-air heat exchanger; The sealing gasket (101) is installed between the heat exchanger body (100) and the internal circulation air inlet assembly (104) and the internal circulation air outlet assembly (105) to achieve sealing of the machine cavity; The external circulation air intake assembly (102) is installed on the left side of the heat exchanger body (100) and is used to install the external circulation fan and form an air intake duct; The internal circulation air outlet assembly (103) is installed on the right side of the heat exchanger body (100) for external circulation testing; The internal circulation air intake assembly (104) is installed on the upper left side of the heat exchanger body (100) for installing the internal circulation fan and forming an air intake duct; The internal circulation air outlet assembly (105) is installed on the upper right side of the heat exchanger body (100) for internal circulation testing; The test bench (200) is used to install a preset air-to-air heat exchanger, simulate the internal environment of the power conversion device, simulate the internal heat generation under different working conditions, control the power supply and provide circuit overload protection.

[0006] Optionally, in the air-to-air heat exchanger and fan testing system described in this application, the external circulation air intake assembly (102) includes: External circulation air inlet frame (1021), external circulation fan mounting plate (1022) and external circulation fan (1023); The external circulation air inlet frame (1021) is used to fix the external circulation fan mounting plate (1022) and form an air inlet duct; The external circulation fan mounting plate (1022) is used to install the external circulation fan; The external circulation fan (1023) is installed in the external circulation air inlet frame (1021) via the external circulation fan mounting plate (1022).

[0007] Optionally, in the air-to-air heat exchanger and fan testing system described in this application, the external circulation air intake assembly (103) includes: External circulation air outlet frame (1031) and external circulation air outlet test point bracket (1032); The external circulation air outlet frame (1031) is used to install the external circulation air outlet test point frame and form an air outlet duct; The external circulation air outlet test point frame (1032) is used to obtain the air outlet speed and air outlet temperature through preset test points.

[0008] Optionally, in the air-to-air heat exchanger and fan testing system described in this application, the internal circulation air inlet assembly (104) includes: Internal circulation air inlet frame (1041), internal circulation fan mounting plate (1042), internal circulation fan (1043) and heating wire assembly (1044). The inner circulation air inlet frame (1041) is used to fix the outer circulation fan mounting plate (1042) and the heating wire assembly (1044) and form an air inlet duct; The internal circulation fan mounting plate (1042) is used to install the external circulation fan (1043). The heating wire assembly (1044) is used to simulate the heat generated in the cavity.

[0009] Optionally, in the air-to-air heat exchanger and fan testing system described in this application, the heating wire assembly (1044) includes: Heating wire (10441), power input line (10442), power output line (10443), connecting wire (10444), insulating sleeve (10445).

[0010] Optionally, in the air-to-air heat exchanger and fan testing system described in this application, the internal circulation air outlet assembly (105) includes: Internal circulation air outlet frame (1051), internal circulation air outlet test point frame (1052), air direction adjustment plate (1053), air guide plate (1054), first adjustment gear assembly (1055), and second adjustment gear assembly (1056); The internal circulation air outlet frame (1051) is used to install the internal circulation air outlet test point frame (1052), the air direction adjustment plate (1053), the guide plate (1054), the first adjustment gear assembly (1055), and the second adjustment gear assembly (1056), and to form an air outlet duct; The internal circulation air outlet test point frame (1052) is used to obtain the air outlet speed and air outlet temperature through preset test points; The airflow adjustment plate (1053) is used to adjust the airflow direction of the internal circulation outlet and make the airflow uniform; The guide vane (1054) is used to evenly distribute the air volume; The first adjusting gear assembly (1055) and the second adjusting gear assembly (1056) adjust the deflection angle of the corresponding wind direction adjusting plate.

[0011] Optionally, in the air-to-air heat exchanger and fan testing system described in this application, the first adjusting gear assembly (1055) and the second adjusting gear assembly (1056) include: The first adjusting gear assembly (1055) includes a first gear set (10551), a first gear belt (10552), a first knob (10553), and a first pointer (10554). The second adjusting gear assembly (1056) includes a first gear set (10561), a first gear belt (10562), a first knob (10563), and a first pointer (10564).

[0012] Optionally, in the air-to-air heat exchanger and fan testing system described in this application, the test bench (200) includes: Test bench top plate (2001), transparent glass cover (2002), adjusting support rod (2003), third knob (2004), micro circuit breaker (2005), power cord (2006), multi-function instrument (2007) and test bench base plate (2008). The test platform upper plate (2001) is used to install a preset air-to-air heat exchanger; The transparent glass cover (2002) is used to form an internal circulation space; The adjusting support rod (2003) is used to adjust according to the preset size of the air-to-air heat exchanger; The third knob (2004) is used to lock the adjusting support rod (2003); The micro-circuit (2005) is used for circuit protection and to control the power supply of the device to be turned on or off; The power cord (2006) is used to connect the circuit and provide power to the test system; The multi-functional instrument (2007) includes a sliding rheostat, a display screen and an internal logic measurement and calculation unit. The sliding rheostat is connected in series with the heating wire (10441). The resistance of the entire circuit is adjusted to the required resistance by the slider of the sliding rheostat. The internal logic measurement and calculation unit calculates the heating power of the heating wire based on the resistance value of the sliding rheostat and displays it on the display screen. The test bench base plate (2008) is used to install the multi-functional instrument (2007), the heat exchanger body (100), the external circulation air intake assembly (102), and the external circulation air intake assembly (103).

[0013] Secondly, this application provides a testing method for an air-to-air heat exchanger and a fan, comprising the following steps: Obtain the real-time resistance curve of the heat exchange system corresponding to the preset hot side temperature, and analyze and process it in conjunction with the preset fan performance characteristic curve to obtain the target fan speed; The operation of the fan is controlled according to the target speed of the fan, and the measured resistance value of the sliding rheostat, the resistance value of the heating wire, and the voltage at the heating wire end are obtained. Based on the measured resistance value, the resistance value of the heating wire, and the voltage at the end of the heating wire, the internal logic measurement and calculation unit is used to analyze and process the data to obtain the heating power of the heating wire. The heat exchange working status is obtained. If the heat exchange is in a stable state, heating is performed according to the heating power of the heating wire, and the evaluation data of the internal circulation fan, the evaluation data of the external circulation fan, and the ambient temperature are obtained. Based on the evaluation data of the internal circulation fan and the evaluation data of the external circulation fan, as well as the ambient temperature, the heat exchange capacity assessment data is obtained, including the internal circulation heat exchange capacity assessment data and the external circulation heat exchange capacity assessment data. A suitable air-to-air heat exchanger is obtained based on the heat exchange capacity assessment data.

[0014] Optionally, in the air-to-air heat exchanger and fan testing method described in this application, the step of analyzing and processing the internal circulation fan evaluation data, external circulation fan evaluation data, and ambient temperature to obtain heat exchange capacity evaluation data includes: The evaluation data for the internal circulation fan includes the average internal circulation inlet air temperature, the average internal circulation outlet air temperature, and the average internal circulation outlet air velocity. The evaluation data for the external circulation fan includes the average external circulation outlet airflow intensity and the average external circulation outlet airflow velocity; The internal circulation heat exchange capacity evaluation data are obtained by analyzing and processing the average internal circulation inlet air temperature, average internal circulation outlet air temperature, and average internal circulation outlet air velocity in conjunction with the preset internal circulation outlet cross-sectional area, preset air specific heat capacity, and preset air density. The average external circulation outlet airflow intensity and average external circulation outlet airflow velocity are analyzed and processed in conjunction with the ambient temperature, preset external circulation outlet cross-sectional area, preset air specific heat capacity, and preset air density to obtain external circulation heat exchange capacity evaluation data.

[0015] As can be seen from the above, the air-to-air heat exchanger and fan testing system and method provided in this application divides the air duct into an inner circulation space and an outer circulation space. The inner circulation space is formed by sealing a transparent glass cover. The required heating power of the heating wire is obtained by adjusting the resistance value of the sliding rheostat. The inner and outer circulation fans or heat exchangers from different manufacturers are tested respectively, thereby achieving efficient and accurate testing of air-to-air heat exchangers and fans.

[0016] Other features and advantages of this application will be set forth in the following description and will be apparent in part from the description or may be learned by practicing embodiments of this application. The objectives and other advantages of this application may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments of this application will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A device diagram of an air-to-air heat exchanger and fan testing system provided in this application embodiment; Figure 2 A diagram of an external circulation air intake component device for an air-to-air heat exchanger and fan testing system provided in this application embodiment; Figure 3 A diagram of the external circulation air outlet component of an air-to-air heat exchanger and fan testing system provided in this application embodiment; Figure 4 A diagram of an internal circulation air intake component device for an air-to-air heat exchanger and fan testing system provided in this application embodiment; Figure 5 A heating wire assembly diagram of an air-to-air heat exchanger and fan testing system provided in this application embodiment; Figure 6 A diagram of an internal circulation air outlet component of an air-to-air heat exchanger and fan testing system provided in this application embodiment; Figure 7 A first adjusting gear assembly and a second adjusting gear assembly are provided for an embodiment of this application for testing an air-to-air heat exchanger and a fan. Figure 8 A test bench device diagram of an air-to-air heat exchanger and fan testing system provided in this application embodiment; Figure 9 A flowchart illustrating a testing method for an air-to-air heat exchanger and a fan, provided in an embodiment of this application. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0020] It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. Furthermore, in the description of this application, the terms "first," "second," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0021] Please refer to Figure 1 , Figure 1 This is a diagram of a test system for an air-to-air heat exchanger and a fan, as described in some embodiments of this application. The present invention discloses a test system for an air-to-air heat exchanger and a fan, comprising: The heat exchanger body (100), sealing gasket (101), external circulation air inlet assembly (102), external circulation air inlet assembly (103), internal circulation air inlet assembly (104) and internal circulation air outlet assembly (105) and test bench (200). The heat exchanger body (100) is installed on the test bench (200) to simulate the heat exchange performance of a preset air-to-air heat exchanger; The sealing gasket (101) is installed between the heat exchanger body (100) and the internal circulation air inlet assembly (104) and the internal circulation air outlet assembly (105) to achieve sealing of the machine cavity; The external circulation air intake assembly (102) is installed on the left side of the heat exchanger body (100) and is used to install the external circulation fan and form an air intake duct; The internal circulation air outlet assembly (103) is installed on the right side of the heat exchanger body (100) for external circulation testing; The internal circulation air intake assembly (104) is installed on the upper left side of the heat exchanger body (100) for installing the internal circulation fan and forming an air intake duct; The internal circulation air outlet assembly (105) is installed on the upper right side of the heat exchanger body (100) for internal circulation testing; The test bench (200) is used to install a preset air-to-air heat exchanger, simulate the internal environment of the power conversion device, simulate the internal heat generation under different working conditions, control the power supply and provide circuit overload protection.

[0022] It should be noted that the air duct of the test system in this embodiment is divided into an internal circulation air duct and an external circulation air duct. The internal circulation air duct is designed with a heating wire to simulate the heat generation of the internal cavity. The heating power of the heating wire can be easily and simply adjusted to the required level through a multi-functional instrument. When the system temperature is stable, the temperature and speed of the air inlet and outlet at different positions are recorded to obtain the heat dissipation performance of different heat exchangers and different fans under the system. Finally, a satisfactory solution can be found. The whole process is fast and efficient. In addition, the circuit of this test system has a three-level protection function, which can effectively avoid electric shock accidents to test personnel. It has high practicality and reliability.

[0023] Please refer to Figure 2 , Figure 2 This is a diagram of an external circulation air intake assembly for an air-to-air heat exchanger and fan testing system, as described in some embodiments of this application. According to an embodiment of the present invention, the external circulation air intake assembly (102) includes: External circulation air inlet frame (1021), external circulation fan mounting plate (1022) and external circulation fan (1023); The external circulation air inlet frame (1021) is used to fix the external circulation fan mounting plate (1022) and form an air inlet duct; The external circulation fan mounting plate (1022) is used to install the external circulation fan; The external circulation fan (1023) is installed in the external circulation air inlet frame (1021) via the external circulation fan mounting plate (1022).

[0024] It should be noted that the external circulation fan is installed and fixed on the external circulation fan mounting plate, and then fixed on the external circulation air inlet frame, and installed together on the left side of the heat exchanger body.

[0025] Please refer to Figure 3 , Figure 3 This is a diagram of an external circulation air intake assembly for an air-to-air heat exchanger and fan testing system, as described in some embodiments of this application. According to an embodiment of the present invention, the external circulation air intake assembly (103) includes: External circulation air outlet frame (1031) and external circulation air outlet test point bracket (1032); The external circulation air outlet frame (1031) is used to install the external circulation air outlet test point frame and form an air outlet duct; The external circulation air outlet test point frame (1032) is used to obtain the air outlet speed and air outlet temperature through preset test points.

[0026] It should be noted that the external circulation air outlet test point rack is set up in a 9-grid configuration, dividing the air outlet section into 9 equal parts, and evenly placing 9 air outlet velocity and temperature test points on each part to accurately obtain the air outlet velocity and temperature. Please refer to Figure 4 , Figure 4 This is a diagram of an internal circulation air intake assembly for an air-to-air heat exchanger and fan testing system, as described in some embodiments of this application. According to an embodiment of the present invention, the internal circulation air intake assembly (104) includes: Internal circulation air inlet frame (1041), internal circulation fan mounting plate (1042), internal circulation fan (1043) and heating wire assembly (1044). The inner circulation air inlet frame (1041) is used to fix the outer circulation fan mounting plate (1042) and the heating wire assembly (1044) and form an air inlet duct; The internal circulation fan mounting plate (1042) is used to install the external circulation fan (1043). The heating wire assembly (1044) is used to simulate the heat generated in the cavity.

[0027] It should be noted that the internal circulation air inlet frame is used to fix the internal circulation fan mounting plate, form an air inlet duct, and place the heating wire. Its material is non-metallic, such as PA, PC, and ABS, for insulation, serving as secondary circuit protection to prevent leakage of the heating wire or electric shock.

[0028] Please refer to Figure 5 , Figure 5This is a diagram of a heating wire assembly for an air-to-air heat exchanger and fan testing system according to some embodiments of this application. According to an embodiment of the present invention, the heating wire assembly (1044) includes: Heating wire (10441), power input line (10442), power output line (10443), connecting wire (10444), insulating sleeve (10445).

[0029] It should be noted that the heating wire is essentially a resistance wire, formed by connecting four sets of resistance wires in series with connecting wires. When current is passed through the heating wire, it generates heat. When the temperature of the heating wire becomes constant and no longer rises, the power of the heating wire can be considered equal to the heating power. The power input line is connected to the input end of the heating wire, and the power output line is connected to the output end of the heating wire. The insulating sleeve is used to fix the heating wire to both ends of the internal circulation air intake frame for insulation, serving as primary circuit protection to prevent system leakage.

[0030] Please refer to Figure 6 , Figure 6 This is a diagram of an internal circulation air outlet assembly of an air-to-air heat exchanger and fan testing system according to some embodiments of this application. According to an embodiment of the present invention, the internal circulation air outlet assembly (105) includes: Internal circulation air outlet frame (1051), internal circulation air outlet test point frame (1052), air direction adjustment plate (1053), air guide plate (1054), first adjustment gear assembly (1055), and second adjustment gear assembly (1056); The internal circulation air outlet frame (1051) is used to install the internal circulation air outlet test point frame (1052), the air direction adjustment plate (1053), the guide plate (1054), the first adjustment gear assembly (1055), and the second adjustment gear assembly (1056), and to form an air outlet duct; The internal circulation air outlet test point frame (1052) is used to obtain the air outlet speed and air outlet temperature through preset test points; The airflow adjustment plate (1053) is used to adjust the airflow direction of the internal circulation outlet and make the airflow uniform; The guide vane (1054) is used to evenly distribute the air volume; The first adjusting gear assembly (1055) and the second adjusting gear assembly (1056) adjust the deflection angle of the corresponding wind direction adjusting plate.

[0031] It should be noted that the internal circulation air outlet frame is used to place the internal circulation air outlet test point rack, air direction adjustment plate, guide plate, and install gear set, forming an air outlet duct. Since the internal circulation air outlet is uneven and not vertically upward, the air direction adjustment plate is divided into two groups to more flexibly adjust the air outlet direction at different positions. The air direction adjustment plate can smoothly transition the air direction, and the wind resistance is negligible. Its function is to adjust the air outlet direction of the internal circulation and make the air outlet uniform. The internal circulation air outlet test point rack is also set in a 9-grid configuration, dividing the air outlet section into 9 equal parts, and evenly setting 9 air outlet speed and temperature test points on it to accurately obtain the air outlet speed and temperature. The guide plate is a flat parallel thin plate, which further adjusts the air outlet direction and makes the air outlet evenly distributed.

[0032] Please refer to Figure 7 , Figure 7 This is a diagram of a first adjusting gear assembly and a second adjusting gear assembly of a test system for an air-to-air heat exchanger and a fan, according to some embodiments of this application. According to an embodiment of the present invention, the first adjusting gear assembly (1055) and the second adjusting gear assembly (1056) include: The first adjusting gear assembly (1055) includes a first gear set (10551), a first gear belt (10552), a first knob (10553), and a first pointer (10554). The second adjusting gear assembly (1056) includes a first gear set (10561), a first gear belt (10562), a first knob (10563), and a first pointer (10564).

[0033] It should be noted that the first gear set includes three gears. Adjusting the pointer will cause the airflow direction adjustment plate to rotate in different directions. Adjustment is complete when the airflow is vertically upward and relatively uniform. Similarly, the second adjustment mechanism includes a second gear set, a second gear belt, a second knob, and a second pointer. The second gear set includes five gears because the airflow direction at the second adjustment mechanism is wider, facilitating adjustment. Adjusting the pointer will cause the airflow direction adjustment plate to rotate in different directions. Adjustment is complete when the airflow is vertically upward and relatively uniform.

[0034] Please refer to Figure 8 , Figure 8 This is a diagram of a test bench apparatus for a test system of an air-to-air heat exchanger and a fan, as described in some embodiments of this application. According to an embodiment of the present invention, the test bench (200) includes: Test bench top plate (2001), transparent glass cover (2002), adjusting support rod (2003), third knob (2004), micro circuit breaker (2005), power cord (2006), multi-function instrument (2007) and test bench base plate (2008). The test platform upper plate (2001) is used to install a preset air-to-air heat exchanger; The transparent glass cover (2002) is used to form an internal circulation space; The adjusting support rod (2003) is used to adjust according to the preset size of the air-to-air heat exchanger; The third knob (2004) is used to lock the adjusting support rod (2003); The micro-circuit (2005) is used for circuit protection and to control the power supply of the device to be turned on or off; The power cord (2006) is used to connect the circuit and provide power to the test system; The multi-functional instrument (2007) includes a sliding rheostat, a display screen and an internal logic measurement and calculation unit. The sliding rheostat is connected in series with the heating wire (10441). The resistance of the entire circuit is adjusted to the required resistance by the slider of the sliding rheostat. The internal logic measurement and calculation unit calculates the heating power of the heating wire based on the resistance value of the sliding rheostat and displays it on the display screen. The test bench base plate (2008) is used to install the multi-functional instrument (2007), the heat exchanger body (100), the external circulation air intake assembly (102), and the external circulation air intake assembly (103).

[0035] It should be noted that the test bench base is placed on the test table, and the test bench top is used to place the heat exchanger. The test bench top has bolt holes for mounting the heat exchanger. There are four adjustable support rods, which can be extended or retracted according to the size of the heat exchanger and other needs. The third knob fixes the position of the support rods. The power cord connects the circuit and provides power to the test system. The transparent glass cover is used to create an internal circulation space, simulating the internal cavity of the inverter, PCS, and other components. The internal air volume is comparable to that of the entire unit, and the emissivity of the outer surface and the thermal resistance of the wall of the transparent glass cover are similar to those of the main unit. The overall frame of the machine is quite large. The micro-circuit circuit is used as a third layer of circuit protection, which can turn the entire test system circuit on and off. Different resistance values ​​of the entire circuit can be set by rotating the sliding rheostat knob. The system connects the entire circuit to 220V voltage, that is, different voltages can be obtained for the heating wire through the voltage division principle, so that different heating powers required by the heating wire can be obtained. The internal logic measurement and calculation unit will measure the resistance value of the sliding rheostat in the circuit and calculate the power value of the heating wire based on the current resistance of the rheostat. Both are displayed on the display screen for easy recording and adjustment by the tester.

[0036] Please refer to point 9. Figure 9 This is a flowchart illustrating a testing method for an air-to-air heat exchanger and fan, as described in some embodiments of this application. This air-to-air heat exchanger and fan testing method is used in terminal devices, such as computers and mobile terminals. The air-to-air heat exchanger and fan testing method includes the following steps: S11. Obtain the real-time resistance curve of the heat exchange system corresponding to the preset hot side temperature, and analyze and process it in conjunction with the preset fan performance characteristic curve to obtain the target fan speed. S12. Control the operation of the fan according to the target speed of the fan, and obtain the measured resistance value of the sliding rheostat, the heating wire resistance value and the heating wire terminal voltage; S13. Based on the measured resistance value, the resistance value of the heating wire, and the voltage at the end of the heating wire, the internal logic measurement and calculation unit is used to analyze and process the data to obtain the heating power of the heating wire. S14. Obtain the heat exchange working status. If it is a stable heat exchange state, perform heating according to the heating power of the heating wire, and obtain the evaluation data of the internal circulation fan, the evaluation data of the external circulation fan, and the ambient temperature. S15. Analyze and process the evaluation data of the internal circulation fan and the external circulation fan, as well as the ambient temperature, to obtain heat exchange capacity evaluation data, including internal circulation heat exchange capacity evaluation data and external circulation heat exchange capacity evaluation data. S16. Obtain a suitable air-to-air heat exchanger based on the heat exchange capacity evaluation data.

[0037] It should be noted that, in order to determine the actual performance of the heat exchanger and fan and eliminate the error between individual unit testing and system application, this embodiment introduces an automatic operating point tracking algorithm. First, the heat exchanger is removed (or a bypass pipe is used to allow air to bypass the heat exchanger), leaving only the fan. The fan is started, and its speed is adjusted via a frequency converter, such as to 1000 rpm or 1500 rpm. At each fixed speed, the resistance at the fan outlet is changed, and the air volume and air pressure generated by the fan are recorded. A preset fan performance characteristic curve is fitted at different speeds. Then, a preset hot-side temperature is determined, such as a simulated hot-side inlet temperature of 180°C. The fan is started, and its speed is gradually increased from low to high. During the fan speed change, the total air volume and total pressure drop of the entire system are measured in real time, and the resistance generated by the heat exchanger at different air volumes is recorded. A real-time resistance curve of the heat exchange system is automatically fitted. Finally, the real-time resistance curve of the heat exchange system is calculated. The force curve and the preset fan performance characteristic curve are placed in the same coordinate system. The point where the two lines intersect is the equilibrium point. At this point, the air volume blown by the fan can just overcome the system resistance, the system works stably, and the fan is automatically adjusted to the corresponding target fan speed. The required heating power of the heating wire is obtained by adjusting the sliding rheostat. When the system heat exchange reaches a stable state, the evaluation data of the internal circulation fan and the external circulation fan, as well as the ambient temperature, are recorded. The air volume of the internal circulation fan and the external circulation fan can be obtained by calculation. The heat exchanger heat exchange capacity Q can be obtained by Q=CM△T, where C is the specific heat capacity of air, M is the air mass flow rate (the product of air volume and air density), and △T is the temperature drop of the internal circulation air after passing through the heat exchanger or the temperature rise of the external circulation air after passing through the heat exchanger. By testing the internal and external circulation fans or heat exchangers from different manufacturers, the fan and heat exchanger that meet the heat dissipation requirements can be obtained.

[0038] According to an example of the present invention, the step of analyzing and processing the evaluation data of the internal circulation fan and the external circulation fan, along with the ambient temperature, to obtain heat exchange capacity evaluation data includes: The evaluation data for the internal circulation fan includes the average internal circulation inlet air temperature, the average internal circulation outlet air temperature, and the average internal circulation outlet air velocity. The evaluation data for the external circulation fan includes the average external circulation outlet airflow intensity and the average external circulation outlet airflow velocity; The internal circulation heat exchange capacity evaluation data are obtained by analyzing and processing the average internal circulation inlet air temperature, average internal circulation outlet air temperature, and average internal circulation outlet air velocity in conjunction with the preset internal circulation outlet cross-sectional area, preset air specific heat capacity, and preset air density. The average external circulation outlet airflow intensity and average external circulation outlet airflow velocity are analyzed and processed in conjunction with the ambient temperature, preset external circulation outlet cross-sectional area, preset air specific heat capacity, and preset air density to obtain external circulation heat exchange capacity evaluation data.

[0039] It should be noted that the product of the average internal circulation outlet air velocity and the preset internal circulation outlet cross-sectional area is the air volume, which is then multiplied by the preset air density to obtain the air mass flow rate M. The difference between the average internal circulation inlet air temperature and the average internal circulation outlet air temperature is ΔT, thus obtaining the internal circulation heat exchange capacity assessment data, i.e., the heat exchange capacity Q. Similarly, the external circulation heat exchange capacity assessment data can be obtained. The preset air specific heat capacity and preset air density are determined by those skilled in the art based on the preset ambient temperature and can be dynamically adjusted.

[0040] It is worth mentioning that, according to embodiments of the present invention, it further includes: Obtain the heating wire temperature and the internal circulation air inlet node temperature at preset time points; The heating wire temperature and the internal circulation air inlet node temperature at adjacent preset time points are compared to obtain the heating wire temperature change rate and the air duct node temperature change rate. The temperature change rate of the heating wire and the temperature change rate of the air duct node are compared with the preset temperature change rate evaluation threshold. If the temperature change rate of the heating wire and the temperature change rate of the air duct node are both less than the preset temperature change rate evaluation threshold, then the heat exchange working state is determined to be a stable heat exchange state. Conversely, the heat exchange working state is determined to be an unsteady state. It should be noted that the heat exchange operation is assessed based on the temperature changes of the heating wire and the internal circulation air inlet node at adjacent time points to determine whether the heat exchange has reached a stable state.

[0041] It is worth mentioning that, according to embodiments of the present invention, it further includes: Based on the ambient temperature, query the preset ambient temperature and air density correction mapping table to obtain the air density correction parameter; The preset air density is corrected according to the air density correction parameter to obtain the preset air density.

[0042] It should be noted that when the ambient temperature changes from 0℃ to 40℃, the air density decreases from approximately 1.293 kg / m³ to approximately 1.127 kg / m³. Air density is greatly affected by changes in ambient temperature. Therefore, the preset air density is corrected by querying the preset ambient temperature and air density correction mapping table based on the real-time monitored ambient temperature. The preset ambient temperature and air density correction mapping table is preset by those skilled in the art based on experimental results and can be dynamically adjusted.

[0043] This invention discloses a testing system and method for air-to-air heat exchangers and fans. By dividing the air duct into an inner circulation space and an outer circulation space, the inner circulation space is formed by sealing a transparent glass cover. The required heating power of the heating wire is obtained by adjusting the resistance value of the sliding rheostat. The inner and outer circulation fans or heat exchangers from different manufacturers are tested respectively, thereby achieving efficient and accurate testing of air-to-air heat exchangers and fans.

[0044] In the several embodiments provided in this application, it should be understood that the disclosed devices and methods can be implemented in other ways. The device embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and in actual implementation, there may be other division methods, such as: multiple units or components can be combined, or integrated into another system, or some features can be ignored or not executed. In addition, the coupling, direct coupling, or communication connection between the various components shown or discussed can be through some interfaces, and the indirect coupling or communication connection between devices or units can be electrical, mechanical, or other forms.

[0045] The units described above as separate components may or may not be physically separate. The components shown as units may or may not be physical units. They may be located in one place or distributed across multiple network units. Some or all of the units may be selected to achieve the purpose of this embodiment according to actual needs.

[0046] In addition, in the various embodiments of the present invention, each functional unit can be integrated into one processing unit, or each unit can be a separate unit, or two or more units can be integrated into one unit; the integrated unit can be implemented in hardware or in the form of hardware plus software functional units.

[0047] Those skilled in the art will understand that all or part of the steps of the above method embodiments can be implemented by hardware related to program instructions. The aforementioned program can be stored in a readable storage medium. When the program is executed, it performs the steps of the above method embodiments. The aforementioned storage medium includes various media capable of storing program code, such as mobile storage devices, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0048] Alternatively, if the integrated units of this invention are implemented as software functional modules and sold or used as independent products, they can also be stored in a readable storage medium. Based on this understanding, the technical solutions of the embodiments of this invention, or the parts that contribute to the prior art, can be embodied in the form of a software product. This software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as mobile storage devices, ROM, RAM, magnetic disks, or optical disks.

Claims

1. An air-to-air heat exchanger and fan testing system, comprising: include: The heat exchanger body (100), sealing gasket (101), external circulation air inlet assembly (102), external circulation air inlet assembly (103), internal circulation air inlet assembly (104) and internal circulation air outlet assembly (105) and test bench (200). The heat exchanger body (100) is installed on the test bench (200) to simulate the heat exchange performance of a preset air-to-air heat exchanger; The sealing gasket (101) is installed between the heat exchanger body (100) and the internal circulation air inlet assembly (104) and the internal circulation air outlet assembly (105) to achieve sealing of the machine cavity; The external circulation air intake assembly (102) is installed on the left side of the heat exchanger body (100) and is used to install the external circulation fan and form an air intake duct; The internal circulation air outlet assembly (103) is installed on the right side of the heat exchanger body (100) for external circulation testing; The internal circulation air intake assembly (104) is installed on the upper left side of the heat exchanger body (100) for installing the internal circulation fan and forming an air intake duct; The internal circulation air outlet assembly (105) is installed on the upper right side of the heat exchanger body (100) for internal circulation testing; The test bench (200) is used to install a preset air-to-air heat exchanger, simulate the internal environment of the power conversion device, simulate the internal heat generation under different working conditions, control the power supply and provide circuit overload protection.

2. The air-to-air heat exchanger and fan testing system of claim 1, wherein, The external circulation air intake assembly (102) includes: External circulation air inlet frame (1021), external circulation fan mounting plate (1022) and external circulation fan (1023); The external circulation air inlet frame (1021) is used to fix the external circulation fan mounting plate (1022) and form an air inlet duct; The external circulation fan mounting plate (1022) is used to install the external circulation fan; The external circulation fan (1023) is installed in the external circulation air inlet frame (1021) via the external circulation fan mounting plate (1022).

3. The air-to-air heat exchanger and fan testing system of claim 1, wherein, The external circulation air intake assembly (103) includes: External circulation air outlet frame (1031) and external circulation air outlet test point bracket (1032); The external circulation air outlet frame (1031) is used to install the external circulation air outlet test point frame and form an air outlet duct; The external circulation air outlet test point frame (1032) is used to obtain the air outlet speed and air outlet temperature through preset test points.

4. The air-to-air heat exchanger and fan testing system of claim 1, wherein, The internal circulation air intake assembly (104) includes: Internal circulation air inlet frame (1041), internal circulation fan mounting plate (1042), internal circulation fan (1043) and heating wire assembly (1044). The inner circulation air inlet frame (1041) is used to fix the outer circulation fan mounting plate (1042) and the heating wire assembly (1044) and form an air inlet duct; The internal circulation fan mounting plate (1042) is used to install the external circulation fan (1043). The heating wire assembly (1044) is used to simulate the heat generated in the cavity.

5. The air-to-air heat exchanger and fan testing system of claim 4, wherein, The heating wire assembly (1044) includes: Heating wire (10441), power input line (10442), power output line (10443), connecting wire (10444), insulating sleeve (10445).

6. The air-to-air heat exchanger and fan testing system of claim 1, wherein, The internal circulation air outlet assembly (105) includes: Internal circulation air outlet frame (1051), internal circulation air outlet test point frame (1052), air direction adjustment plate (1053), air guide plate (1054), first adjustment gear assembly (1055), and second adjustment gear assembly (1056); The internal circulation air outlet frame (1051) is used to install the internal circulation air outlet test point frame (1052), the air direction adjustment plate (1053), the guide plate (1054), the first adjustment gear assembly (1055), and the second adjustment gear assembly (1056), and to form an air outlet duct; The internal circulation air outlet test point frame (1052) is used to obtain the air outlet speed and air outlet temperature through preset test points; The airflow adjustment plate (1053) is used to adjust the airflow direction of the internal circulation outlet and make the airflow uniform; The air guide plate (1054) is used to evenly distribute the air volume; The first adjusting gear assembly (1055) and the second adjusting gear assembly (1056) adjust the deflection angle of the corresponding wind direction adjusting plate.

7. The air-to-air heat exchanger and fan testing system of claim 6, wherein, The first adjusting gear assembly (1055) and the second adjusting gear assembly (1056) include: The first adjusting gear assembly (1055) includes a first gear set (10551), a first gear belt (10552), a first knob (10553), and a first pointer (10554). The second adjusting gear assembly (1056) includes a first gear set (10561), a first gear belt (10562), a first knob (10563), and a first pointer (10564).

8. The air-to-air heat exchanger and fan testing system of claim 1, wherein, The test bench (200) includes: Test bench top plate (2001), transparent glass cover (2002), adjusting support rod (2003), third knob (2004), micro circuit breaker (2005), power cord (2006), multi-function instrument (2007) and test bench base plate (2008). The test platform upper plate (2001) is used to install a preset air-to-air heat exchanger; The transparent glass cover (2002) is used to form an internal circulation space; The adjusting support rod (2003) is used to adjust according to the preset size of the air-to-air heat exchanger; The third knob (2004) is used to lock the adjusting support rod (2003); The micro-circuit (2005) is used for circuit protection and to control the power supply of the device to be turned on or off; The power cord (2006) is used to connect the circuit and provide power to the test system; The multi-functional instrument (2007) includes a sliding rheostat, a display screen and an internal logic measurement and calculation unit. The sliding rheostat is connected in series with the heating wire (10441). The resistance of the entire circuit is adjusted to the required resistance by the slider of the sliding rheostat. The internal logic measurement and calculation unit calculates the heating power of the heating wire based on the resistance value of the sliding rheostat and displays it on the display screen. The test bench base plate (2008) is used to install the multi-functional instrument (2007), the heat exchanger body (100), the external circulation air intake assembly (102), and the external circulation air intake assembly (103).

9. The air-to-air heat exchanger and fan testing method applied to the air-to-air heat exchanger and fan testing system, characterized in that, The steps include: Obtain the real-time resistance curve of the heat exchange system corresponding to the preset hot side temperature, and analyze and process it in conjunction with the preset fan performance characteristic curve to obtain the target fan speed; The operation of the fan is controlled according to the target speed of the fan, and the measured resistance value of the sliding rheostat, the resistance value of the heating wire, and the voltage at the heating wire end are obtained. Based on the measured resistance value, the resistance value of the heating wire, and the voltage at the end of the heating wire, the internal logic measurement and calculation unit is used to analyze and process the data to obtain the heating power of the heating wire. The heat exchange working status is obtained. If the heat exchange is in a stable state, heating is performed according to the heating power of the heating wire, and the evaluation data of the internal circulation fan, the evaluation data of the external circulation fan, and the ambient temperature are obtained. Based on the evaluation data of the internal circulation fan and the evaluation data of the external circulation fan, as well as the ambient temperature, the heat exchange capacity assessment data is obtained, including the internal circulation heat exchange capacity assessment data and the external circulation heat exchange capacity assessment data. A suitable air-to-air heat exchanger is obtained based on the heat exchange capacity assessment data.

10. The air-to-air heat exchanger and fan testing method of claim 9, wherein, The process of analyzing and processing the evaluation data of the internal circulation fan and the external circulation fan, along with the ambient temperature, to obtain heat exchange capacity assessment data includes: The evaluation data for the internal circulation fan includes the average internal circulation inlet air temperature, the average internal circulation outlet air temperature, and the average internal circulation outlet air velocity. The evaluation data for the external circulation fan includes the average external circulation outlet airflow intensity and the average external circulation outlet airflow velocity; The internal circulation heat exchange capacity evaluation data are obtained by analyzing and processing the average internal circulation inlet air temperature, average internal circulation outlet air temperature, and average internal circulation outlet air velocity in conjunction with the preset internal circulation outlet cross-sectional area, preset air specific heat capacity, and preset air density. The average external circulation outlet airflow intensity and average external circulation outlet airflow velocity are analyzed and processed in conjunction with the ambient temperature, preset external circulation outlet cross-sectional area, preset air specific heat capacity, and preset air density to obtain external circulation heat exchange capacity evaluation data.

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