Detection tool and detection method for inner leakage of intelligent electric control valve of water meter

Abstract

The invention relates to the technical field of water meter valves, in particular to a valve sealing performance testing device. An inner leakage detection tool for an intelligent electric control valve of a water meter comprises an assembly simulation driver which is connected with a valve body to be detected and used for reproducing a mechanical connection state and an accumulated error after the valve body and an intelligent control actuator are assembled in a test; the detection equipment is used for testing the sealing performance of the valve body provided with the assembly simulation driver; the control module is in communication connection with the assembly simulation driver and the detection equipment; the assembly simulation driver comprises an actuator and a fixed transmission structure; the actuator is in driving connection with the valve body through a fixed transmission structure; the control module is configured to control the actuator to conduct at least one time of closing operation and opening operation on a valve element of the valve body. And after the actuator is controlled to be in the closed state, the detection equipment is triggered to detect the sealing performance of the valve body.

Description

Technical Field

[0001] This invention relates to the field of water meter valve technology, and more particularly to a testing device for valve sealing performance. Background Technology

[0002] During production, electrically controlled valves often fail pre-assembly sealing tests but develop internal leaks after assembly. This is mainly due to significant cumulative errors in the valve stem, ball, and actuator during assembly, preventing the valve from fully closing. Currently, most valve internal leakage testing fixtures lack actuators, failing to simulate the actual valve assembly state. Once internal leakage occurs, it often requires disassembling sealed components to replace the valve, severely impacting production efficiency. Furthermore, valve testing processes typically lack systematic recording, making it difficult to trace valve information and testing history after delivery, causing inconvenience for later maintenance.

[0003] Chinese patent document CN118243305A discloses a valve sealing performance testing fixture. This solution uses a vacuum pump and an air compressor to quickly establish a pressure difference across the valve core when the valve is closed, efficiently testing the static sealing performance of the valve core body. Specifically, the valve is first fixed and ensured to be in the closed state, and two sealing components are used to seal both ends of the valve. Then, the vacuum pump extracts air from one side of the valve core to create a negative pressure zone, while the air compressor pressurizes the extracted gas and injects it into the other side to create a positive pressure zone, rapidly achieving the required pressure difference for the test. After the test, the valve is opened via a drive mechanism or manually, allowing the gas in the positive pressure zone to naturally and quickly replenish the negative pressure zone, achieving silent pressure relief and shortening the test cycle.

[0004] However, this device has significant limitations: its testing presupposes that the valve has been manually or automatically driven to the closed position beforehand, essentially verifying the valve core's sealing performance under the assumption that the valve is fully closed. The entire testing process completely lacks the ability to simulate the actual assembled state of the valve and external actuator. It cannot reproduce the cumulative dimensional errors generated during assembly of the actuator drive shaft, valve stem, and valve ball, nor does it integrate the actuator to actively and repeatedly control the valve's opening and closing actions during the test. Therefore, this fixture is fundamentally incapable of diagnosing internal leakage problems caused by assembly errors preventing the valve from being driven to a fully sealed position. Summary of the Invention

[0005] To overcome the shortcomings of the existing technology, a tooling for detecting internal leakage of intelligent electronically controlled valves in water meters is provided.

[0006] This invention is achieved through the following technical solution: First aspect: A tooling for detecting internal leakage of a smart electronically controlled valve in a water meter, comprising: an assembly simulation driver connected to the valve body to be tested, used to reproduce the mechanical connection state and cumulative error after the valve body and the smart actuator are assembled during testing; a testing device for performing a sealing test on the valve body equipped with the assembly simulation driver; and a control module communicatively connected to the assembly simulation driver and the testing device; the assembly simulation driver includes an actuator and a fixed transmission structure; the actuator is driven to the valve body through the fixed transmission structure; the control module is configured to: control the actuator to perform at least one closing and opening operation on the valve core of the valve body; and, after the actuator is controlled to be in the closed state, trigger the testing device to perform a sealing test on the valve body.

[0007] In a preferred embodiment of the present invention, the fixed transmission structure includes a fixed plate, a base plate, a top cover, an adapter rod, and a sealing ring; the fixed plate is used to connect the valve body and the base plate, the adapter rod is connected to the output end of the actuator and used to drive the valve core inside the valve body; the sealing ring is assembled between the top cover and the base plate.

[0008] In a preferred embodiment of the present invention, the detection device includes a pressure supply unit, a high-precision pressure sensor, a high-definition camera, and a pneumatic valve; the pressure supply unit is used to supply test gas to the inlet end of the valve body in the closed state through the pneumatic valve; the high-precision pressure sensor is used to monitor the pressure change at the inlet end of the valve body; the high-definition camera is mounted on the top of the valve body and is used to capture images of the outlet end area of ​​the valve body immersed in the liquid; the control module is also configured to receive and analyze the pressure data from the high-precision pressure sensor and the image data acquired by the high-definition camera, and automatically determine whether the internal leakage of the valve body is qualified based on the analysis results.

[0009] In a preferred embodiment of the present invention, the pressure supply unit includes a pressure regulating valve for regulating and stabilizing the pressure of the test gas input to the valve body at a preset value; and a pneumatic valve for communicating with the control module for automatically connecting or disconnecting the test gas supply to the valve body according to the instructions of the control module.

[0010] In a preferred embodiment of the present invention, the testing device further includes a base and a clamping mechanism. The base is used to support and position the test assembly formed after the valve body is connected to the assembly simulation driver, and the clamping mechanism is used to fix the test assembly on the base.

[0011] In a preferred embodiment of the present invention, the testing device further includes a water tank for containing the testing liquid; both the inlet and outlet ends of the valve body are provided with sealing components, so that both the inlet and outlet ends of the valve body are submerged below the liquid surface of the water tank during testing.

[0012] In a preferred embodiment of the present invention, the sealing assembly includes a PTFE gasket and a baffle disposed at the outlet end of the valve body, and a rubber gasket disposed at the inlet end of the valve body.

[0013] In a preferred embodiment of the present invention, the base is provided with a length adjustment mechanism to accommodate valve bodies of different lengths; the length adjustment mechanism includes at least one screw and two adjusting nuts; the screw passes through the side wall of the base and its end is connected to a baffle; the two nuts are screwed to the screw and assembled on both sides of the side wall of the base.

[0014] In a preferred embodiment of the present invention, the control module further includes a data communication unit for uploading valve body identification information, test process data and test results to the manufacturing execution system (MES).

[0015] The second aspect: A method for detecting internal leakage in a smart water meter valve, comprising the following steps: S1. Pre-assemble the valve body with the assembly simulation actuator to form a test assembly; S2. Install and secure the test assembly in the testing equipment; S3. The actuator is controlled by the control module to drive the valve body to complete at least one closing operation; S4. With the valve body closed, the control module controls the pneumatic valve to connect the test gas and triggers the testing equipment to perform a sealing test; after the test is completed, the control module controls the pneumatic valve to cut off the gas. S5. The control module analyzes the pressure data and image data obtained from the sealing test and generates a judgment result.

[0016] Compared with the prior art, the present invention has the following beneficial effects: A smart electronically controlled valve internal leakage detection fixture for water meters actively reproduces the cumulative assembly error and performs dynamic switching tests through an "assembly simulation driver". It can accurately diagnose internal leakage caused by the specific reason of "not closing properly after assembly", avoiding the problem of qualified valves still needing to be reworked after assembly due to traditional static testing, and significantly improving the production first pass rate and reliability.

[0017] Furthermore, the specific implementation structure of the assembly simulation actuator was clarified, ensuring the accuracy and reliability of the simulated assembly state. The fixing plate realizes the standard interface connection with the valve body; the adapter rod ensures the effective transmission of driving force; the sealing structure formed by the sealing ring and the housing ensures the sealing of the actuator's internal structure under test pressure, preventing external leakage from interfering with the test results and improving the stability and accuracy of the entire test system.

[0018] Furthermore, by introducing a dual data acquisition mechanism combining a high-precision pressure sensor and a high-definition camera, multi-dimensional and highly sensitive detection of valve internal leakage is achieved. Combined with intelligent analysis algorithms, this overcomes the limitations of single pressure detection, which may be affected by environmental interference, or single visual detection, which may be affected by factors such as air bubble adhesion. This significantly improves the accuracy, reliability, and automation level of internal leakage determination, and reduces human error.

[0019] Furthermore, the pressure supply unit is refined into precisely adjustable and automatically controlled components, achieving standardization of test conditions and full automation of the test process. The pressure regulating valve ensures the consistency and accuracy of the test pressure for each test, which is the basis for quantitative comparison. The automatic on / off control of the pneumatic valve enables precise timing control of the test process without manual intervention, improving testing efficiency, consistency, and safety.

[0020] Furthermore, by incorporating a base and clamping mechanism, a stable and repeatable installation and positioning scheme is provided for the test assembly. This ensures that the relative position of the valve body and the testing equipment remains consistent during multiple tests or tests on different valves, eliminating test variables caused by inconsistent clamping, ensuring the repeatability and comparability of test results, and improving operational safety.

[0021] Furthermore, by setting up a water tank and immersing both ends of the valve body, an ideal "bubble observation" environment was created. This immersion method transforms invisible trace gas leaks into clearly visible bubbles, allowing a high-definition camera to intuitively and sensitively capture the leak signal. At the same time, the immersion environment also helps cool and stabilize the temperature of the test gas and the valve body, reducing short-term interference of thermal expansion and contraction on the test results.

[0022] Furthermore, the sealing and observation interfaces for immersion testing have been specifically optimized. PTFE gaskets and rubber gaskets provide reliable elastic seals for different sealing surfaces, ensuring that test gases do not leak out. A baffle is used to press the PTFE gasket, while its through-holes form a clear gas release channel, concentrating the generated bubbles and making them easy to observe, avoiding the observation difficulties caused by gas escaping in complex gaps.

[0023] Furthermore, the length adjustment mechanism gives this tooling excellent versatility and adaptability. With simple mechanical adjustments, it can quickly adapt to water meter valve bodies of different models and lengths, eliminating the need for custom-made fixtures or tooling for each valve body specification. This significantly reduces equipment costs, increases the flexibility of the testing line, and is suitable for multi-variety, small-batch production.

[0024] Furthermore, by adding a data communication unit, this tooling is upgraded from an isolated testing device into a node in a smart manufacturing network. This enables the automatic collection, binding, and uploading of product quality data, providing a complete and reliable data foundation for production quality traceability, big data analysis, process improvement, and after-sales maintenance, greatly enhancing the digitalization and intelligence of production management.

[0025] A method for detecting internal leakage in intelligent water meter valves combines simulated assembly, functional operation, dual detection, and data analysis to form a closed-loop detection logic. This not only ensures the scientific validity of the test results but also guarantees consistency in results across different operators and time points through standardized procedures, while simultaneously improving overall detection efficiency.

[0026] Other features and advantages of the present invention will be disclosed in detail in the following detailed description and accompanying drawings. Attached Figure Description

[0027] The invention will be further described below with reference to the accompanying drawings: Figure 1 This is a top view of the structure of a smart electronically controlled valve internal leakage detection tool for water meters according to the present invention; Figure 2 This is a cross-sectional view of the structural components of a smart electronically controlled valve internal leakage detection tool for water meters according to the present invention. Figure 3 This is a schematic diagram of the structure of the test assembly formed by assembling the simulated driver and valve body according to the present invention.

[0028] The annotations in the attached figures are explained as follows: The assembly includes: 1. Analog driver; 2. Valve body; 3. High-precision pressure sensor; 4. High-definition camera; 5. Pneumatic valve; 6. Pressure regulating valve; 7. Base; 8. Clamping mechanism; 9. Water tank; 10. Sealing assembly; 11. Actuator; 12. Fixed transmission structure; 121. Fixing plate; 122. Base plate; 123. Top cover; 124. Adapter rod; 125. Sealing ring; 21. Inlet end; 22. Outlet end; 71. Length adjustment mechanism; 71. Screw; 711. Adjusting nut; 712. PTFE gasket; 101. Baffle; 102. Rubber gasket; 103. Detailed Implementation

[0029] The technical solutions of the embodiments of the present invention will be explained and described below with reference to the accompanying drawings. However, the following embodiments are only preferred embodiments of the present invention and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments in the implementation methods without creative effort are all within the protection scope of the present invention.

[0030] In the following description, terms such as “inner,” “outer,” “upper,” “lower,” “left,” and “right” are used only to indicate orientation or positional relationship for the convenience of describing the embodiments and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0031] like Figures 1 to 3 As shown, the present invention provides a tooling for detecting internal leakage of intelligent electronically controlled valves in water meters. Its core concept is to connect an "assembly simulation driver" that can simulate the real assembly state to the valve body, actively reproduce the cumulative assembly error during testing, and use automated equipment that integrates pressure sensing and visual inspection for accurate judgment, while realizing the information traceability of test data.

[0032] The testing fixture of this invention mainly comprises three parts: an assembly simulation driver 1, a testing device, and a control module. The assembly simulation driver 1 is a key component for simulating the function and assembly state of a real intelligent control actuator. The assembly simulation driver 1 includes an actuator 11 and a fixed transmission structure 12. The fixed transmission structure 12 includes a fixed plate 121, a base plate 122, an upper cover 123, an adapter rod 124, and a sealing ring 125. During assembly, firstly, the fixed plate 121 is connected to the valve body 2 under test using screws, and then the base plate 122 is connected to the fixed plate 121. The actuator 11 is installed in the cavity formed by the upper cover 123 and the base plate 122, and transmits the rotational motion of its output end to the valve core inside the valve body 2 through the adapter rod 124. The sealing ring 125 is disposed between the upper cover 123 and the base plate 122 to ensure the internal sealing of the actuator. Through this series of connections, the assembly simulation driver 1 fully replicates the assembly state of the intelligent control actuator and valve body in the real product in terms of physical connection and driving relationship, so that the cumulative error caused by the machining and assembly tolerance of the parts can be reproduced during the test.

[0033] The testing equipment is used to perform automated sealing tests on the test assembly formed by connecting the valve body 2 and the assembly simulation driver 1. The equipment includes a pressure supply unit, a sensing and observation unit, and a clamping and support unit.

[0034] The pressure supply unit includes a pressure regulating valve 6 and a pneumatic valve 5. The pressure regulating valve 6 is used to regulate and stabilize the compressed air from the air source at the preset pressure value specified in the testing procedure. The pneumatic valve 5, as a gas supply switch, is controlled by the control module and is used to automatically supply or cut off the test gas to the inlet 21 of the valve body 2 during the testing process.

[0035] The sensing and observation unit includes a high-precision pressure sensor 3 and a high-definition camera 4. The high-precision pressure sensor 3 is installed on the air inlet channel to monitor and record changes in the gas pressure entering the valve body 2 in real time. The high-definition camera 4 is fixedly mounted above the detection station by a bracket, with its lens aimed at the outlet end 22 area of ​​the valve body 2, to capture images of this area during the detection process.

[0036] The clamping and support unit includes a base 7, a clamping mechanism 8, and a length adjustment mechanism 71. The base 7 serves as the foundation of the entire testing equipment. The length adjustment mechanism 71 is mounted on the base 7 to accommodate valve bodies 2 of different lengths. Its specific structure includes a screw 711 horizontally passing through the side wall of the base 7, and two adjusting nuts 712 screwed onto the screw 711 and located on either side of the base side wall. The other end of the screw 711 is connected and fixed to a baffle 102. By rotating the two adjusting nuts 712, their positions on the screw 711 can be adjusted, thus forming adjustable limit stops to accommodate and position test assemblies of different lengths. The clamping mechanism 8 is preferably a pneumatic clamp, its operation controlled by a control module, used to quickly and reliably clamp and fix the test assembly placed on the base 7.

[0037] In addition, the testing equipment includes a water tank 9 for holding transparent liquids such as clear water as the observation medium. Both the inlet end 21 and the outlet end 22 of the valve body 2 are equipped with sealing components 10 to ensure a sealed testing environment during testing, and to ensure that the outlet end 22 is submerged below the liquid surface. Specifically, the sealing component 10 includes a PTFE gasket 101 disposed at the outlet end 22 of the valve body 2 and a baffle 102 for pressing the gasket, and a rubber gasket 103 disposed at the inlet end 21 of the valve body 2 and connected to the air inlet on the base 7. The test gas passes sequentially through the rubber gasket 103, the interior of the valve body 2, and the central hole of the PTFE gasket 101, and is finally released from the outlet end 22 below the liquid surface.

[0038] The control module is the "brain" of the tooling, usually implemented by a PLC, an industrial computer or an embedded system. It is communicatively connected to all electrical components such as the actuator 11 of the assembly simulation driver 1, the pneumatic valve 5, the high-precision pressure sensor 3, the high-definition camera 4, and the clamping mechanism 8 in the detection device through cables. The control module is configured to execute a complete set of automated detection processes and has data analysis and communication functions. Its core control logic includes: controlling the actuator 11 to perform specified valve opening and closing operations on the valve body 2; after the valve is closed, triggering the pneumatic valve 5 to introduce a stabilized test gas and simultaneously starting the data acquisition of the high-precision pressure sensor 3 and the image capture of the high-definition camera 4; receiving the pressure data and image data, analyzing whether there are bubbles and their characteristics in the image through the built-in image recognition algorithm, and at the same time analyzing the attenuation situation during the pressure holding stage; automatically determining whether the valve body has internal leakage based on these two pieces of data. The control module also integrates a data communication unit, which can package and upload the whole process data such as the unique identification code of the valve body, the test time, the action sequence, the pressure curve, the key images, and the final determination result to the manufacturing execution system, realizing the full life cycle traceability of product quality.

[0039] Based on the above tooling, the method for detecting internal leakage of the intelligent control valve of the water meter according to the present invention includes the following steps: S1. Pre-assembly: Assemble the valve body 2 and the assembly simulation driver 1 through connectors such as the fixing plate 121 to form a test assembly. This step simulates the assembly process of the final product.

[0040] S2. Clamping and positioning: Place the test assembly on the base 7 of the detection device, adjust the nut 712 of the length adjustment mechanism 71 for axial positioning, and then start the clamping mechanism 8 to firmly fix it. Inject clean water into the water tank 9 until it submerges the outlet end 22 of the valve body.

[0041] S3. Driving the valve to close: Send an instruction to the actuator 11 of the assembly simulation driver 1 through the control module to drive the valve core of the valve body 2 to complete at least one closing operation. This operation reproduces the cumulative error that may cause the valve not to close in place.

[0042] S4. Sealing performance detection: After confirming that the valve is in the closed state, the control module first controls the pneumatic valve 5 to open, and introduces the test gas stabilized by the pressure regulating valve ⑥ into the valve body 2. At the same time, trigger the high-precision pressure sensor 3 to record the pressure data, and control the high-definition camera 4 to take pictures of the submersible area of the outlet end 22. After maintaining the pressure for a period of time, control the pneumatic valve 5 to close and cut off the gas source.

[0043] S5. Analysis, Judgment, and Upload: The control module uses an image recognition algorithm to analyze the captured images and identify bubble features; simultaneously, it analyzes the pressure decay curve recorded by the pressure sensor. Based on preset judgment logic, it automatically generates the judgment result for internal leak detection. Finally, all relevant data and judgment results from this test are uploaded to the MES system via the data communication unit.

[0044] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Those skilled in the art should understand that the present invention includes, but is not limited to, the contents described in the accompanying drawings and the specific embodiments above. Any modifications that do not depart from the functional and structural principles of the present invention will be included within the scope of the claims.

Claims

1. A tooling for detecting internal leakage of a smart electronically controlled valve in a water meter, characterized in that, include: An assembly simulation driver (1) is connected to the valve body (2) under test and is used to reproduce the mechanical connection state and cumulative error of the valve body (2) after assembly with the intelligent actuator in the test; a testing device is used to perform a sealing test on the valve body (2) equipped with the assembly simulation driver (1); a control module is communicatively connected to the assembly simulation driver (1) and the testing device; the assembly simulation driver (1) includes an actuator (11) and a fixed transmission structure (12); the actuator (11) is driven to the valve body (2) through the fixed transmission structure (12); the control module is configured to: control the actuator (11) to perform at least one closing operation and one opening operation on the valve core of the valve body (2); and after the actuator (11) is controlled to be in the closed state, trigger the testing device to perform a sealing test on the valve body (2).

2. The water meter intelligent electronically controlled valve internal leakage detection fixture according to claim 1, characterized in that, The fixed transmission structure (12) includes a fixed plate (121), a base plate (122), a top cover (123), an adapter rod (124), and a sealing ring (125); the fixed plate (121) is used to connect the valve body (2) and the base plate (122), the adapter rod (124) is connected to the output end of the actuator (11) and is used to drive the valve core inside the valve body (2); the sealing ring (125) is assembled between the top cover (123) and the base plate (122).

3. A tooling for detecting internal leakage of a smart electronically controlled valve in a water meter according to claim 1 or 2, characterized in that, The detection equipment includes a pressure supply unit, a high-precision pressure sensor (3), a high-definition camera (4), and a pneumatic valve (5); the pressure supply unit is used to supply test gas to the inlet end of the valve body (2) in the closed state through the pneumatic valve (5); the high-precision pressure sensor (3) is used to monitor the pressure change at the inlet end of the valve body (2); the high-definition camera (4) is mounted on the top of the valve body (2) and is used to capture images of the outlet end area of ​​the valve body (2) immersed in the liquid; the control module is also configured to receive and analyze the pressure data of the high-precision pressure sensor (3) and the image data collected by the high-definition camera (4), and automatically determine whether the internal leakage of the valve body is qualified based on the analysis results.

4. The water meter intelligent electronically controlled valve internal leakage detection fixture according to claim 3, characterized in that, The pressure supply unit includes a pressure regulating valve (6) for regulating and stabilizing the pressure of the test gas input to the valve body (2) at a preset value; the pneumatic valve (5) is connected to the control module for automatically connecting or disconnecting the test gas to the valve body (2) according to the instructions of the control module.

5. The water meter intelligent electronically controlled valve internal leakage detection fixture according to claim 1, characterized in that, The testing equipment also includes a base (7) and a clamping mechanism (8). The base (7) is used to support and position the test assembly formed after the valve body (2) is connected to the assembly simulation driver (1). The clamping mechanism (8) is used to fix the test assembly on the base (7).

6. The water meter intelligent electronically controlled valve internal leakage detection fixture according to claim 5, characterized in that, The testing equipment also includes a water tank (9) for containing the testing liquid; the inlet end (21) and outlet end (22) of the valve body (2) are both provided with sealing components (10), so that the inlet end (21) and outlet end (22) of the valve body (2) are submerged below the liquid surface of the water tank (9) during testing.

7. The water meter intelligent electronically controlled valve internal leakage detection fixture according to claim 6, characterized in that, The sealing assembly (10) includes a PTFE gasket (101) and a baffle (102) disposed at the outlet end (22) of the valve body (2), and a rubber gasket (103) disposed at the inlet end (21) of the valve body (2).

8. The water meter intelligent electronically controlled valve internal leakage detection fixture according to claim 7, characterized in that, The base (7) is provided with a length adjustment mechanism (71) to accommodate valve bodies (2) of different lengths; the length adjustment mechanism (71) includes at least one screw (711) and two adjusting nuts (712); the screw (711) passes through the side wall of the base (7) and its end is connected to the baffle (102); the two nuts (712) are screwed to the screw (711) and assembled on both sides of the side wall of the base (7).

9. The water meter intelligent electronically controlled valve internal leakage detection fixture according to claim 1, characterized in that, The control module also includes a data communication unit for uploading valve body identification information, test process data and test results to the Manufacturing Execution System (MES).

10. A method for detecting internal leakage in a smart water meter valve, characterized in that, A water meter intelligent electronically controlled valve internal leakage detection fixture according to any one of claims 1-9 includes the following steps: S1. Pre-assemble the valve body (2) with the assembly simulation driver (1) to form a test assembly; S2. Install the test assembly into the testing equipment and fix it in place; S3. The control module controls the actuator (11) to drive the valve body (2) to complete at least one closing operation. S4. With the valve body (2) closed, the control module controls the pneumatic valve (5) to connect the test gas and triggers the detection device to perform a sealing test; after the test is completed, the control module controls the pneumatic valve (5) to cut off the gas. S5. The control module analyzes the pressure data and image data obtained from the sealing test and generates a judgment result.

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