A cold-state rapid hydraulic pressure test verification system and a verification method thereof

Abstract

The application discloses a cold-state rapid impact test verification system and a verification method thereof, and the system comprises a nitrogen preparation unit, a nitrogen storage and supply unit, a high-pressure section gas supply station, a medium-pressure section gas supply station, a system control unit and a system high-speed signal acquisition unit. The application integrates the high-pressure section ultrahigh-pressure fast-response pressure charging and the medium-pressure section high-pressure large-flow constant-pressure gas supply functions, realizes full coverage of wide-pressure-range tests, does not need to replace multiple sets of equipment, adopts a bursting disc + an acoustic nozzle to replace traditional valve parts in the high-pressure section, avoids the risk of a firework and realizes millisecond-level pressure charging, adopts three-way fast-opening and fast-closing electromagnetic valves + a confluence tank to avoid crosstalk in the medium-pressure section, and the pressure control precision reaches ±0.5 MPa. Meanwhile, the remote measurement and control unit and the full-process automatic operation are matched, precise calculation is combined to realize high-pressure section wide-range pressure increasing rate adjustment and medium-pressure section stable flow output, different test objects can be adapted, and the universality, safety, automation degree and control precision of tests are comprehensively improved.

Description

Technical Field

[0001] This invention relates to the field of cold-state rapid stamping test technology, and in particular to a cold-state rapid stamping test verification system and its verification method. Background Technology

[0002] In the field of high-end manufacturing, many core products need to work under different pressure environments. Some products need to withstand pressure shocks from ultra-high pressure and rapid pressure increase, while others need to work for a long time in a constant pressure gas environment with high pressure and large flow. Therefore, a comprehensive cold-state rapid stamping test verification system is needed to verify the performance of products under different pressure ranges, different flow rates, and different pressure increase rates.

[0003] Existing cold flow pressure testing systems are mostly single-function designs, capable of only low-pressure, low-flow-rate tests or only high-pressure or medium-pressure tests. They cannot meet the requirements of cold flow pressure testing across a wide range of 5MPa to 100MPa. Furthermore, in existing high-pressure testing technologies, electric explosion valves and high-speed switching valves have drawbacks such as high safety risks and slow response. In medium-pressure testing technologies, parallel electronic pressure regulating valves suffer from crosstalk, low pressure control accuracy, and a lack of application cases. In addition, existing systems have low automation levels and lack comprehensive remote monitoring and control and interlocking protection functions, and the safety and efficiency of the testing process need to be improved. In view of the above, this application proposes a cold-state rapid stamping test verification system and its verification method. Summary of the Invention

[0004] Based on the technical problems existing in the background technology, the present invention proposes a cold-state rapid stamping test verification system and its verification method.

[0005] The present invention proposes a cold-state rapid stamping test verification system, which includes a nitrogen preparation unit, a nitrogen storage and supply unit, a high-pressure section gas supply and distribution station, a medium-pressure section gas supply and distribution station, a system control unit, and a system high-speed signal acquisition unit.

[0006] The nitrogen preparation unit adopts pressure swing adsorption (PSA) nitrogen generation technology, which includes an air compressor, a refrigerated dryer, an adsorption dryer, a filter, a PSA nitrogen generator and a nitrogen buffer tank, and is used to prepare and output low-pressure clean nitrogen.

[0007] The nitrogen storage and supply unit is connected to the nitrogen preparation unit and is used to pressurize and store low-pressure nitrogen in stages to provide a suitable nitrogen source for high-pressure and medium-pressure tests. It includes a diaphragm compressor, a gas storage cylinder group, a high-pressure booster pump, a medium-pressure nitrogen stabilizing tank and a high-pressure nitrogen stabilizing tank.

[0008] The high-pressure section gas supply and distribution station is connected to the high-pressure nitrogen stabilizing tank of the nitrogen storage and supply unit, and is used to carry out ultra-high pressure fast response pressurization tests in the cold flow pressure range of 30MPa to 100MPa. It includes a rupture disc assembly, a sonic nozzle assembly, an explosion-proof container, and a high-pressure pipeline assembly.

[0009] The medium-pressure section gas supply and distribution station is connected to the medium-pressure nitrogen stabilizing tank of the nitrogen storage and supply unit, and is used to carry out high-pressure, high-flow constant-pressure gas supply tests in the cold flow pressure range of 5MPa to 30MPa. It includes three-way quick-opening and quick-closing solenoid valves, manifold tanks, solenoid valves and medium-pressure pipeline components.

[0010] The system control unit is electrically connected to the nitrogen preparation unit, nitrogen storage and supply unit, high-pressure section gas supply and distribution station, medium-pressure section gas supply and distribution station and system high-speed signal acquisition unit, and is used to realize remote operation, human-machine isolation, automatic parameter matching and calculation, closed-loop control and interlock protection during the test process. It includes a power supply and distribution electronic system and a measurement and control subsystem.

[0011] The high-speed signal acquisition unit of the system is used for the accurate synchronous acquisition of transient signals during the test. It includes an NI synchronous acquisition unit, a pressure transmitter, and a displacement sensor.

[0012] Preferably, the technical specifications of the nitrogen preparation unit are as follows: nitrogen flow rate ≥ 200 Nm³ / h, purity ≥ 95.0%, water content ≤ 0.176 g / m³, oxygen content ≤ 5%, nitrogen generator outlet pressure ≥ 0.5 MPa, nitrogen buffer tank rated pressure ≥ 1.0 MPa, the nitrogen preparation unit has manual / automatic sewage discharge and operation modes, noise ≤ 75 dB, and an overpressure safety alarm function to ensure a continuous, stable, and clean supply of nitrogen.

[0013] Preferably, the diaphragm compressor is a pollution-free booster compressor with an exhaust pressure ≥45MPa and a volumetric flow rate of 200Nm³ / h, used to boost the low-pressure nitrogen in the nitrogen preparation unit to 45MPa;

[0014] The gas storage cylinder group consists of four cascaded high-pressure gas storage cylinders of 1m³ / 45MPa, with a total volume of 4m³. It supports automatic / manual switching and arbitrary combination to achieve large-capacity storage of nitrogen.

[0015] The high-pressure booster pump has a maximum exhaust pressure of 140MPa and a flow rate of ≥60ML / min. It pressurizes the nitrogen in the gas storage cylinder group to 140MPa and stores it in the high-pressure nitrogen pressure stabilizing tank, providing an ultra-high pressure gas source for the high-pressure section test.

[0016] The medium-pressure nitrogen stabilizing tank consists of a gas storage cylinder group and a 2m³ / 30MPa manifold, with a total volume ≥6m³ and a rated pressure ≥35MPa. It provides a high-pressure, high-flow-rate gas source for medium-pressure tests, and the outlet flow of the booster pump meets the requirement that the pressurization time between two consecutive tests is ≤2 hours, ensuring the continuity of the test.

[0017] Preferably, the rupture disc assembly can be customized for rupture pressure, has a short venting time, produces no sparks or fragments after venting, and has a rupture tolerance of ±5%, achieving rapid release of high-pressure nitrogen through instantaneous venting.

[0018] The throat diameter of the sonic nozzle assembly ranges from 0.17 mm to 10.78 mm. By changing the sonic nozzle with different throat diameters, the mass flow rate of nitrogen gas can be controlled, thereby precisely adjusting the pressurization rate of the test sample. The adjustable range of the pressurization rate is 0.1 MPa / ms to 2.0 MPa / ms, 30 MPa to 60 MPa, 15 MPa / ms to 35 MPa / ms, and 60 MPa to 100 MPa.

[0019] The explosion-proof container is used to place the test sample to avoid experimental safety accidents;

[0020] The high-pressure pipeline assembly has an inner diameter of 14.27 mm, which is suitable for the maximum throat diameter of the sound-rate nozzle. The interface between the test process pipeline and the test sample is a standard flange connection, and it has no less than two pressure regulation capabilities to support multi-channel testing.

[0021] The three-way quick-opening and quick-closing solenoid valves are set in parallel, with a response time of ≤350ms. They achieve precise pressure regulation through intelligent switching by software algorithms and high-frequency switching, with a pressure control accuracy of ±0.5MPa.

[0022] The manifold is used to ensure constant pressure gas supply. During the test, the pressure drop is ≤1.0MPa, which meets the technical requirement of mass flow rate ≥40kg / s. The manifold is equipped with a pressure transmitter, safety valve and exhaust valve to realize real-time pressure monitoring and overpressure protection.

[0023] The solenoid valve ensures a high-pressure, high-flow-rate gas supply capacity;

[0024] The medium-pressure pipeline assembly has an interface size ≥ DN100, a test specimen opening size ≥ Φ30mm, and at least two pressure regulation capabilities, supporting multi-channel testing.

[0025] Preferably, the power supply and distribution electronic system provides a 220V AC / 5kVA purified power supply to protect the power supply and signal acquisition from surges and electromagnetic interference. It includes a power distribution cabinet, a purified power supply and a UPS uninterruptible power supply. The UPS uninterruptible power supply provides power to the measurement and control system when the mains power fails, ensuring data storage and system security.

[0026] The measurement and control subsystem includes a PLC controller, an industrial computer, and control software developed based on LabVIEW. The PLC controller acts as a lower-level machine to realize the logic control of the equipment, and the industrial computer is located in the remote measurement and control hall to achieve human-machine isolation.

[0027] The high-speed signal acquisition unit of the system is used to acquire no less than 16 displacement signals and no less than 6 pressure signals, realize the real-time acquisition and storage of pressure time and displacement time data of the test sample, and can complete the comparison and analysis of measured data and command data, as well as the superposition and comparison of historical data.

[0028] This invention also proposes a cold-state rapid stamping test verification method, comprising the following steps:

[0029] S1: System full-domain initialization: Check the equipment operation status of nitrogen preparation, nitrogen storage and supply, high-pressure section gas supply and distribution station, medium-pressure section gas supply and distribution station, system control unit and high-speed signal acquisition unit, confirm that there is no leakage in the pipeline, all valves are in the initial closed state, and the sensors and data acquisition equipment are calibrated normally. Select the high-pressure section or medium-pressure section test mode according to the test requirements and complete the preliminary preparation of the corresponding test gas path.

[0030] S2: On-site installation of test specimen and gas circuit adaptation: Complete the sealed connection between the test specimen and the pipeline assembly of the corresponding test section. In the high-pressure section, the test specimen must be placed in an explosion-proof container and connected with a standard flange. In the medium-pressure section, ensure that the opening size of the test specimen is ≥Φ30mm. Select the test gas circuit through the manual needle valve of the corresponding test section, open the manual ball valve of the air inlet, and after completing all on-site operations, the test personnel shall leave the test area to achieve human-machine isolation.

[0031] S3: Intelligent Simulation and Calculation of Test Parameters: Through the test software of the system control unit, the basic parameters such as the free volume of the test sample, the target test pressure, the target pressurization rate, the mass flow rate, and the constant pressure duration are entered. Based on the simulation software, the simulation calculation is completed in combination with the actual gas state equation and the law of conservation of mass. In the high-pressure section, the pre-charge pressure of the high-pressure nitrogen stabilizing tank, the matching throat diameter of the sonic nozzle, the pre-charge pressure of the gas storage cylinder group and the required amount of nitrogen are automatically calculated. In the medium-pressure section, the pre-charge pressure of the gas storage cylinder group and the target pressure of the manifold are automatically calculated. At the same time, the automatic matching and setting of the test equipment control parameters are completed.

[0032] S4: Staged pressurization and gas source stabilization: The system control unit remotely starts the nitrogen preparation unit to produce low-pressure clean nitrogen with a flow rate ≥200Nm³ / h and a purity ≥95.0%. Then, the diaphragm compressor of the nitrogen storage and supply unit is started to pressurize the low-pressure nitrogen to the pre-charge pressure of the gas storage cylinder group and store it. In the high-pressure section, the nitrogen in the gas storage cylinder group is pressurized again to the pre-charge pressure of the high-pressure nitrogen stabilizing tank through the high-pressure booster pump. In the medium-pressure section, the three-way quick-opening and quick-closing solenoid valve is directly opened to pressurize the manifold to the target pressure. The entire pressurization process adopts closed-loop control. After the pressure reaches the set value, the equipment automatically stops and closes the corresponding pneumatic valve. In case of overpressure, the pressure is automatically released.

[0033] S5: Precise pressurization / gas supply in the test section: In the high-pressure section, when the pressure in front of the rupture disc reaches the design rupture pressure, the rupture disc instantly deflates. High-pressure nitrogen gas is introduced into the test sample after being maintained in a critical flow state through a sonic nozzle, achieving ultra-high pressure fast response pressurization. The pressurization rate is precisely controlled within the set range, and the pressure build-up time can be as short as 1.7ms. In the medium-pressure section, the solenoid valve is remotely opened, and the test sample begins to be inhaled. The three-way fast-opening and fast-closing solenoid valves are closed-loop high-frequency switches in real time according to the manifold pressure, achieving high-pressure, high-flow, constant-pressure gas supply, ensuring that the manifold pressure drop is ≤1.0MPa, and meeting the flow rate and duration requirements of ≥40kg / s.

[0034] S6: Transient data synchronous acquisition and monitoring: During the entire pressurization / gas supply process, the system's high-speed signal acquisition unit uses pressure transmitters and displacement sensors to achieve high-frequency synchronous acquisition of no less than 16 displacement signals and no less than 6 pressure signals, thereby acquiring real-time transient data of the test sample's pressure-time and displacement-time. The data is transmitted to the system control unit in real time and stored in the local database and files, enabling real-time monitoring of the test process.

[0035] S7: Pressure Holding / Constant Pressure End and Full-Range Pressure Relief: In the high-pressure section, after the pressure of the high-pressure nitrogen stabilizing tank and the test sample reaches equilibrium, the pressure holding stage begins. The pressure drop during the pressure holding stage is ≤0.5MPa / 10s. After the pressure holding is completed, the exhaust valve is remotely opened to release the nitrogen in the test sample, pipeline, and stabilizing tank to atmospheric pressure. In the medium-pressure section, after the set constant pressure duration is reached, the solenoid valve and the three-way quick-opening and quick-closing solenoid valve are remotely closed to stop the gas supply. The exhaust valve is then opened to release the nitrogen in the manifold, pipeline, and test sample to atmospheric pressure.

[0036] S8: Test Completion and Data Processing: Test personnel enter the site to remove the test specimen and transfer it as required. The system control unit automatically analyzes and processes the collected test data, compares the measured data with the command data, and overlays and compares historical data to accurately determine whether the test indicators meet the standards. At the same time, it automatically generates a standardized test report with one click. Test data and reports can be queried and traced through the test date and product number. Finally, the system exhausts and powers off the system according to the test schedule.

[0037] Preferably, the specific logical steps of S3 are as follows:

[0038] S301: Through the system control unit test software, the core parameters of the test sample are entered, and specific parameters are supplemented according to the selected test mode. At the same time, the general boundary parameters of the test are entered. The software automatically determines the high-pressure / medium-pressure test mode based on the entered parameters and calls the corresponding calculation module. The core parameters of the test sample include free volume. Test target pressure Specific parameters include the target boost rate for the high-voltage section. Input the target mass flow rate in the medium-pressure section. Constant voltage output duration The general boundary parameters for the experiment include the thermodynamic temperature of the experimental environment. Nitrogen specific heat ratio Nitrogen gas constant Molar mass of nitrogen Nitrogen van der Waals constant , ;

[0039] S302: The experimental software loads the van der Waals equation of state for real gases as the core conversion basis for pressure, density, and volume. It also derives variations for density calculation to adapt to the parameter calculation requirements of different test sections. The formulas used are as follows:

[0040] van der Waals' equation of state for real gases: ;

[0041] Density calculation variation: ;

[0042] Where p is the gas pressure. For specific volume of gas, The density of the gas;

[0043] S303: The test software completes the volume correction and core exclusive parameter calculation for the high-voltage section and the medium-voltage section according to the test mode, providing a basis for subsequent simulation;

[0044] When making volume corrections for the high-pressure section, the volume of the downstream pipeline of the high-pressure section must be considered. The effect of pressure adjustment is used to obtain the actual total pressure volume: ,in The total pressurized volume of the test sample and the downstream pipeline. The free volume of the test sample. This refers to the total volume of the pipeline at the rear end of the high-pressure section;

[0045] Basic calculation of gas consumption in the medium-pressure section: Based on the target mass flow rate and constant pressure duration in the medium-pressure section, calculate the minimum gas consumption for a single test: ,in This represents the minimum gas consumption for a single test in the medium-pressure section. This represents the target mass flow rate for the medium-pressure section. This refers to the duration of constant pressure output in the medium-voltage section.

[0046] S304: By calling simulation software and combining the law of conservation of mass with the van der Waals equation of state for real gases, simulation iterative calculations are performed in high-pressure and medium-pressure sections to obtain the core parameters of each test section, and the entire process is automated.

[0047] S305: Pre-charge pressure of the gas cylinder group calculated based on S304 Substituting the values ​​into the density variation of van der Waals' real gas equation of state, the nitrogen density under the pre-charge pressure of the gas storage cylinder group is calculated. Then, combining the volume of the gas cylinder group, calculate the total mass of nitrogen required for pre-filling the gas cylinder group, and convert it to the nitrogen volume under standard conditions. The formula used is as follows:

[0048] ;

[0049] ;

[0050] in The total mass of nitrogen required for pre-charging the gas cylinder group. 1.251 represents the required volume of nitrogen under standard conditions, and 1.251 represents the density of nitrogen under standard conditions.

[0051] S306: Based on all the core parameters obtained from the simulation calculation in S304, automatically match and set the control parameters of each test device;

[0052] S307: Cross-check all calculation results. For the high-pressure section, verify that the deviation between the simulated pressure rise rate and pressure build-up time and the target value is ≤5%. For the medium-pressure section, verify that the gas supply of the gas storage cylinder group and the pressure stabilization capacity of the manifold meet the test requirements. After the verification is passed, a standardized test parameter report is automatically generated, which includes all core calculation parameters and equipment control parameters, as the formal basis for test execution. If the verification fails, it automatically returns to S304 to re-iterate the calculation until the test index requirements are met.

[0053] Preferably, in step S304, the formula used for the high-voltage section simulation calculation is as follows:

[0054] Pre-charge density of high-pressure nitrogen pressure stabilizing tank calculate: ,in The density of nitrogen gas at the target pressure of the test sample. Volume of the high-pressure nitrogen pressure stabilizing tank;

[0055] High-pressure nitrogen pressure stabilizing tank pre-charge pressure Calculate: Substituting the density variation of the van der Waals real gas equation of state (S302), we can inversely calculate... The rupture pressure is then adjusted to a ±5% tolerance for the rupture disc. ;

[0056] Sonic nozzle throat diameter matching calculation: First, calculate the required critical mass flow rate using the formula relating pressure rise rate and mass flow rate. Then substitute the values ​​into the critical mass flow rate formula to calculate the throat area. Finally, it is converted to a matching throat diameter. The formula used is: ;

[0057] ;

[0058] ;

[0059] in The stagnation temperature, K, is the same as the ambient temperature of the test. , Match the throat diameter to the sonic nozzle;

[0060] Pre-charge pressure of gas cylinder group Calculation: Combined with the total gas consumption of the high-pressure section Gas cylinder group volume Substituting into the van der Waals equation of state for a real gas, and considering the pipeline flow resistance redundancy coefficient k=1.2, the following iterative result is obtained: ;

[0061] The formulas used in the simulation calculations for the medium-pressure section are as follows:

[0062] Manifold target pressure Calculate: Target pressure in the medium-pressure section As the basic target pressure for the manifold, and considering the constraint that the manifold pressure drop ≤ 1.0 MPa, the following correction is obtained: ;

[0063] Pre-charge pressure of gas cylinder group Calculation: Based on the law of conservation of mass, consider the gas cylinder group. manifold The total volume, combined with the minimum gas consumption in a single test. Substituting into the S302 van der Waals equation of state for a real gas, and considering pipeline flow resistance and pressure holding margin, the pre-charge pressure of the gas storage cylinder group is obtained iteratively. ;

[0064] Manifold density check: Substitute into the density variation of S302 to calculate the nitrogen density at the target pressure of the manifold. This verifies whether the gas storage capacity of the manifold under the target pressure meets the constant pressure gas supply requirements.

[0065] Preferably, the specific logical steps of S5 are as follows:

[0066] S501: The system control unit continuously collects the pressure of the core test points in the high-pressure section and medium-pressure section through the pressure transmitter, and compares it with the set pressure value calculated in S3. After the start-up conditions are met, the corresponding test section's pressurization / gas supply process is automatically triggered.

[0067] S502: The rupture disc ruptures instantaneously upon reaching the designed burst pressure. High-pressure nitrogen gas flows from the high-pressure nitrogen stabilizing tank through the rupture disc into the sonic nozzle assembly. The system control unit maintains the critical flow state of nitrogen gas through the structural characteristics of the sonic nozzle, ensuring a constant mass flow rate during pressurization. The critical flow determination condition is: ,in For the real-time pressure at the test sample end, The stagnation pressure of the high-pressure nitrogen pressure stabilizing tank;

[0068] S503: Nitrogen gas maintains a critical flow state within the sonic nozzle, passing through the throat area of ​​the sonic nozzle matched by S3. To achieve constant critical mass flow rate output, the standard critical mass flow rate formula is: ,in This is the critical mass flow rate of nitrogen. Where K is the stagnation temperature, K is the specific heat ratio of nitrogen, and R is the nitrogen gas constant.

[0069] Nitrogen gas at a constant mass flow rate is introduced into the test sample through a high-pressure pipeline to achieve ultra-high pressure fast response pressurization. The pressurization process is a univariate isentropic adiabatic process, and the actual pressurization rate of the test sample is consistent with the theoretical value.

[0070] S504: The system control unit remotely sends commands to synchronously open the high-flow solenoid valve in the medium-pressure section. The high-pressure nitrogen in the gas storage cylinder group is transported to the manifold through the medium-pressure pipeline, and then supplied to the test sample through the manifold. The diameter design of the solenoid valve ensures the nitrogen flow capacity and meets the technical requirements of high-flow gas supply of ≥40kg / s in the medium-pressure section. The opening size of the test sample is ≥Φ30mm, which matches the diameter of the gas supply pipeline, and there is no bottleneck in the airflow delivery.

[0071] S505: The medium-pressure section uses a three-way quick-opening and quick-closing solenoid valve to achieve closed-loop control of constant pressure gas supply. The system control unit collects the actual pressure of the manifold in real time and compares it with the target pressure. By comparing the results, the software algorithm controls the solenoid valve to switch on and off at high frequency / multi-channel switching to achieve precise pressure compensation. The core control logic is as follows:

[0072] when When the time comes, the 1st to 3rd quick-opening and quick-closing solenoid valves will automatically open to quickly replenish the pressure in the manifold;

[0073] when When this happens, all quick-opening and quick-closing solenoid valves will automatically close, stopping pressure replenishment;

[0074] S506: Throughout the entire process of pressurizing in the high-pressure section and supplying gas in the medium-pressure section, the system control unit performs real-time monitoring and anomaly detection of core test parameters.

[0075] High-pressure section: Monitor the real-time pressurization rate of the test sample, the rupture disc venting status, and the high-pressure pipeline pressure. If the pressurization rate deviation exceeds ±5% or the pipeline is over-pressurized, immediately trigger the interlock protection.

[0076] Medium-pressure section: Monitor the manifold pressure drop, the operation status of the fast-opening and fast-closing solenoid valve, and the nitrogen mass flow rate. If the manifold pressure drop is greater than 1.0 MPa or the flow rate does not meet the set requirements, automatically adjust the solenoid valve pressure compensation frequency / number of opening channels. At the same time, the high-speed signal acquisition unit synchronously collects pressure time and displacement time transient data to provide a basis for test process traceability and result analysis.

[0077] S507: When the preset endpoint conditions are met, the pressurization / gas supply process of the corresponding test section is automatically terminated. The endpoint determination logic is executed independently in two stages without manual intervention.

[0078] High-pressure section: When the actual pressure inside the high-pressure nitrogen pressure stabilizing tank... With the actual pressure inside the test sample Once pressure balance is achieved, i.e., in real time, the pressurization is determined to be complete, and the system automatically switches to the pressure holding stage.

[0079] Medium pressure section: When the constant pressure gas supply duration reaches the set value of S3. If the flow rate at the test sample end meets the test requirements and there is no excessive pressure drop, the gas supply is deemed complete, and a gas stop command is automatically triggered.

[0080] Compared with existing technologies, the beneficial effects of this invention are:

[0081] 1. This invention integrates two major functions: high-pressure section ultra-high pressure fast response pressurization and medium-pressure section high-pressure large flow constant pressure gas supply, realizing full coverage of cold flow pressure test in a wide range of 5MPa to 100MPa, without the need to replace multiple sets of test equipment, solving the problem of existing systems having single functions and being unable to adapt to wide pressure range tests, and greatly improving the versatility and convenience of the test;

[0082] 2. The high-pressure section uses rupture discs and sonic nozzles to replace traditional electric explosion valves and high-speed switching valves, which not only eliminates the restrictions on the supervision and storage of pyrotechnics and avoids safety risks, but also achieves millisecond-level rapid pressurization to meet the requirements of fast response; the medium-pressure section uses three-way fast-opening and fast-closing solenoid valves and manifolds to replace parallel electronic pressure regulating valves, avoiding valve group crosstalk, achieving a pressure control accuracy of ±0.5MPa, and relying on mature technology to ensure equipment stability, thus solving the defects of existing high / medium-pressure section testing technology;

[0083] 3. This invention, combined with a complete remote measurement and control unit and system control software, realizes fully automated operation of the entire process, including intelligent simulation calculation of test parameters, remote start and stop of equipment, synchronous acquisition of transient data, and automatic generation of test reports. Combined with closed-loop control and interlocking protection mechanisms, it reduces on-site manual intervention and greatly improves the degree of test automation, operational safety and test efficiency.

[0084] 4. This invention achieves wide-range pressure ramp rate adjustment from 0.1MPa / ms to 35MPa / ms in the high-pressure section and stable output of dual flow levels of ≥40kg / s / ≥8kg / s in the medium-pressure section by changing the throat diameter of the sonic nozzle, high-frequency closed-loop control of the sonic valve, and accurate calculation of the actual gas state equation. It can be adapted to test samples with different free volumes and different performance requirements, and solves the problems of poor adaptability and low control accuracy of existing systems.

[0085] This invention integrates ultra-high pressure rapid response pressurization in the high-pressure section with high-pressure, high-flow constant pressure gas supply in the medium-pressure section, achieving full coverage of a wide pressure range without the need to replace multiple sets of equipment. The high-pressure section uses rupture discs and sonic nozzles to replace traditional valves, avoiding the risks of pyrotechnics and achieving millisecond-level pressurization. The medium-pressure section uses three-way fast-opening and fast-closing solenoid valves and manifolds to avoid crosstalk, achieving a pressure control accuracy of ±0.5MPa. Combined with a remote monitoring and control unit and fully automated operation, along with precise calculations, it achieves wide-range pressure ramp-up rate adjustment in the high-pressure section and stable flow output in the medium-pressure section. It is adaptable to different test samples, comprehensively improving the versatility, safety, automation, and control accuracy of the test. Attached Figure Description

[0086] Figure 1 This is a block diagram of a cold-state rapid stamping test verification system proposed in this invention;

[0087] Figure 2 This is a flowchart of a cold-state rapid stamping test verification method proposed in this invention. Detailed Implementation

[0088] The present invention will be further explained below with reference to specific embodiments.

[0089] Example

[0090] Reference Figure 1 This embodiment proposes a cold-state rapid stamping test verification system, including a nitrogen preparation unit, a nitrogen storage and supply unit, a high-pressure section gas supply and distribution station, a medium-pressure section gas supply and distribution station, a system control unit, and a system high-speed signal acquisition unit;

[0091] The nitrogen preparation unit adopts the pressure swing adsorption nitrogen generation process, which includes an air compressor, a refrigerated dryer, an adsorption dryer, a filter, a pressure swing adsorption nitrogen generator and a nitrogen buffer tank, used to prepare and output low-pressure clean nitrogen.

[0092] The technical specifications of the nitrogen preparation unit are as follows: nitrogen flow rate ≥200 Nm³ / h, purity ≥95.0%, water content ≤0.176 g / m³, oxygen content ≤5%, nitrogen generator outlet pressure ≥0.5 MPa, nitrogen buffer tank rated pressure ≥1.0 MPa, the nitrogen preparation unit has manual / automatic sewage discharge and operation modes, noise ≤75 dB, and an overpressure safety alarm function to ensure a continuous, stable, and clean supply of nitrogen.

[0093] The nitrogen storage and supply unit is connected to the nitrogen preparation unit and is used to pressurize and store low-pressure nitrogen in stages to provide a suitable nitrogen source for high-pressure and medium-pressure tests. It includes a diaphragm compressor, a gas storage cylinder group, a high-pressure booster pump, a medium-pressure nitrogen stabilizing tank and a high-pressure nitrogen stabilizing tank.

[0094] The diaphragm compressor is a pollution-free booster compressor with an exhaust pressure ≥45MPa and a volumetric flow rate of 200Nm³ / h, used to boost the low-pressure nitrogen in the nitrogen preparation unit to 45MPa.

[0095] The gas cylinder group consists of four cascaded high-pressure gas cylinders of 1m³ / 45MPa, with a total volume of 4m³. It supports automatic / manual switching and arbitrary combination to achieve large-capacity storage of nitrogen.

[0096] The high-pressure booster pump has a maximum exhaust pressure of 140MPa and a flow rate of ≥60ML / min. It pressurizes the nitrogen in the gas storage cylinder group to 140MPa and stores it in the high-pressure nitrogen pressure stabilizing tank, providing an ultra-high pressure gas source for high-pressure section tests.

[0097] The medium-pressure nitrogen pressure stabilizing tank consists of a gas storage cylinder group and a 2m³ / 30MPa manifold, with a total volume ≥6m³ and a rated pressure ≥35MPa. It provides a high-pressure, high-flow gas source for medium-pressure section tests, and the outlet flow of the booster pump meets the requirement that the pressurization time between two consecutive tests is ≤2 hours, ensuring the continuity of the test.

[0098] The high-pressure section gas supply and distribution station is connected to the high-pressure nitrogen pressure stabilizing tank of the nitrogen storage and supply unit, which is used to carry out ultra-high pressure fast response pressurization tests in the cold flow pressure range of 30MPa to 100MPa. It includes rupture disc assembly, sonic nozzle assembly, explosion-proof container and high-pressure pipeline assembly.

[0099] The rupture disc assembly can be customized for rupture pressure, has a short venting time, and produces no sparks or fragments after venting. The rupture tolerance is ±5%, and it achieves rapid release of high-pressure nitrogen through instantaneous venting.

[0100] The throat diameter of the sonic nozzle assembly ranges from 0.17 mm to 10.78 mm. By changing the sonic nozzle with different throat diameters, the mass flow rate of nitrogen can be controlled, thereby precisely adjusting the pressurization rate of the test sample. The adjustable range of the pressurization rate is 0.1 MPa / ms to 2.0 MPa / ms, 30 MPa to 60 MPa, 15 MPa / ms to 35 MPa / ms, and 60 MPa to 100 MPa.

[0101] Explosion-proof containers are used to hold test samples to prevent experimental safety accidents;

[0102] The high-pressure pipeline assembly has an inner diameter of 14.27 mm, which is suitable for the maximum throat diameter of the sound-rate nozzle. The interface between the test process pipeline and the test specimen is a standard flange connection, and it has no less than two pressure regulation capabilities to support multi-channel testing.

[0103] The medium-pressure section gas supply and distribution station is connected to the medium-pressure nitrogen pressure stabilizing tank of the nitrogen storage and supply unit, and is used to carry out high-pressure, high-flow constant-pressure gas supply tests in the cold flow pressure range of 5MPa to 30MPa. It includes three-way quick-opening and quick-closing solenoid valves, manifolds, solenoid valves and medium-pressure pipeline components.

[0104] The three-way quick-opening and quick-closing solenoid valves are set in parallel, with a response time of ≤350ms. The pressure is precisely regulated through intelligent switching by software algorithm and high-frequency switching, with a pressure control accuracy of ±0.5MPa.

[0105] The manifold is used to ensure constant pressure gas supply. During the test, the pressure drop is ≤1.0MPa, and the mass flow rate is ≥40kg / s. The manifold is equipped with a pressure transmitter, safety valve and exhaust valve to realize real-time pressure monitoring and overpressure protection.

[0106] The solenoid valve ensures high-pressure, high-flow-rate gas supply capability;

[0107] The interface size of the medium-pressure pipeline assembly is ≥DN100, the opening size of the test specimen is ≥Φ30mm, and it has no less than 2 pressure regulation capabilities to support multi-channel testing;

[0108] The system control unit is electrically connected to the nitrogen preparation unit, nitrogen storage and supply unit, high-pressure section gas supply and distribution station, medium-pressure section gas supply and distribution station and system high-speed signal acquisition unit. It is used to realize remote operation, human-machine isolation, automatic parameter matching and calculation, closed-loop control and interlock protection during the test process. It includes the power supply and distribution electronic system and the measurement and control subsystem.

[0109] The power supply and distribution electronic system provides a 220V_AC / 5kVA purified power supply to protect the power supply and signal acquisition from surges and electromagnetic interference. It includes a power distribution cabinet, a purified power supply and a UPS uninterruptible power supply. The UPS uninterruptible power supply provides power to the measurement and control system when the mains power fails, ensuring data storage and system safety.

[0110] The measurement and control subsystem includes a PLC controller, an industrial computer, and control software developed based on LabVIEW. The PLC controller acts as a lower-level machine to realize the logic control of the equipment, and the industrial computer is deployed in the remote measurement and control hall to achieve human-machine isolation.

[0111] The system's high-speed signal acquisition unit is used for the precise synchronous acquisition of transient signals during the test. It includes an NI synchronous acquisition unit, a pressure transmitter, and a displacement sensor.

[0112] The system's high-speed signal acquisition unit is used to acquire no less than 16 channels of displacement signals and no less than 6 channels of pressure signals, enabling real-time acquisition and storage of test sample pressure-time and displacement-time data. It can also perform comparative analysis of measured data and command data, as well as superimposed comparison of historical data.

[0113] Reference Figure 2 This embodiment proposes a cold-state rapid stamping test verification method, including the following steps:

[0114] S1: System full-domain initialization: Check the equipment operation status of nitrogen preparation, nitrogen storage and supply, high-pressure section gas supply and distribution station, medium-pressure section gas supply and distribution station, system control unit and high-speed signal acquisition unit, confirm that there is no leakage in the pipeline, all valves are in the initial closed state, and the sensors and data acquisition equipment are calibrated normally. Select the high-pressure section or medium-pressure section test mode according to the test requirements and complete the preliminary preparation of the corresponding test gas path.

[0115] S2: On-site installation of test specimen and gas circuit adaptation: Complete the sealed connection between the test specimen and the pipeline assembly of the corresponding test section. In the high-pressure section, the test specimen must be placed in an explosion-proof container and connected with a standard flange. In the medium-pressure section, ensure that the opening size of the test specimen is ≥Φ30mm. Select the test gas circuit through the manual needle valve of the corresponding test section, open the manual ball valve of the air inlet, and after completing all on-site operations, the test personnel shall leave the test area to achieve human-machine isolation.

[0116] S3: Intelligent Simulation and Calculation of Test Parameters: Through the test software of the system control unit, the basic parameters such as the free volume of the test sample, the target test pressure, the target pressurization rate, the mass flow rate, and the constant pressure duration are entered. Based on the simulation software, the simulation calculation is completed in combination with the actual gas state equation and the law of conservation of mass. In the high-pressure section, the pre-charge pressure of the high-pressure nitrogen stabilizing tank, the matching throat diameter of the sonic nozzle, the pre-charge pressure of the gas storage cylinder group and the required amount of nitrogen are automatically calculated. In the medium-pressure section, the pre-charge pressure of the gas storage cylinder group and the target pressure of the manifold are automatically calculated. At the same time, the automatic matching and setting of the test equipment control parameters are completed.

[0117] The specific logical steps are as follows:

[0118] S301: Through the system control unit test software, the core parameters of the test sample are entered, and specific parameters are supplemented according to the selected test mode. At the same time, the general boundary parameters of the test are entered. The software automatically determines the high-pressure / medium-pressure test mode based on the entered parameters and calls the corresponding calculation module. The core parameters of the test sample include free volume. Test target pressure Specific parameters include the target boost rate for the high-voltage section. Input the target mass flow rate in the medium-pressure section. Constant voltage output duration The general boundary parameters for the experiment include the thermodynamic temperature of the experimental environment. Nitrogen specific heat ratio Nitrogen gas constant Molar mass of nitrogen Nitrogen van der Waals constant , ;

[0119] S302: The experimental software loads the van der Waals equation of state for real gases as the core conversion basis for pressure, density, and volume. It also derives variations for density calculation to adapt to the parameter calculation requirements of different test sections. The formulas used are as follows:

[0120] van der Waals' equation of state for real gases: ;

[0121] Density calculation variation: ;

[0122] Where p is the gas pressure. For specific volume of gas, The density of the gas;

[0123] S303: The test software completes the volume correction and core exclusive parameter calculation for the high-voltage section and the medium-voltage section according to the test mode, providing a basis for subsequent simulation;

[0124] When making volume corrections for the high-pressure section, the volume of the downstream pipeline of the high-pressure section must be considered. The effect of pressure adjustment is used to obtain the actual total pressure volume: ,in The total pressurized volume of the test sample and the downstream pipeline. The free volume of the test sample. This refers to the total volume of the pipeline at the rear end of the high-pressure section;

[0125] Basic calculation of gas consumption in the medium-pressure section: Based on the target mass flow rate and constant pressure duration in the medium-pressure section, calculate the minimum gas consumption for a single test: ,in This represents the minimum gas consumption for a single test in the medium-pressure section. This represents the target mass flow rate for the medium-pressure section. This refers to the duration of constant pressure output in the medium-voltage section.

[0126] S304: By calling simulation software and combining the law of conservation of mass with the van der Waals equation of state for real gases, simulation iterative calculations are performed in high-pressure and medium-pressure sections to obtain the core parameters of each test section, and the entire process is automated.

[0127] The formulas used in the simulation calculations for the high-voltage section are as follows:

[0128] Pre-charge density of high-pressure nitrogen pressure stabilizing tank calculate: ,in The density of nitrogen gas at the target pressure of the test sample. Volume of the high-pressure nitrogen pressure stabilizing tank;

[0129] High-pressure nitrogen pressure stabilizing tank pre-charge pressure Calculate: Substituting the density variation of the van der Waals real gas equation of state (S302), we can inversely calculate... The rupture pressure is then adjusted to a ±5% tolerance for the rupture disc. ;

[0130] Sonic nozzle throat diameter matching calculation: First, calculate the required critical mass flow rate using the formula relating pressure rise rate and mass flow rate. Then substitute the values ​​into the critical mass flow rate formula to calculate the throat area. Finally, it is converted to a matching throat diameter. The formula used is: ;

[0131] ;

[0132] ;

[0133] in The stagnation temperature, K, is the same as the ambient temperature of the test. , Match the throat diameter to the sonic nozzle;

[0134] Pre-charge pressure of gas cylinder group Calculation: Combined with the total gas consumption of the high-pressure section Gas cylinder group volume Substituting into the van der Waals equation of state for a real gas, and considering the pipeline flow resistance redundancy coefficient k=1.2, the following iterative result is obtained: ;

[0135] The formulas used in the simulation calculations for the medium-pressure section are as follows:

[0136] Manifold target pressure Calculate: Target pressure in the medium-pressure section As the basic target pressure for the manifold, and considering the constraint that the manifold pressure drop ≤ 1.0 MPa, the following correction is obtained: ;

[0137] Pre-charge pressure of gas cylinder group Calculation: Based on the law of conservation of mass, consider the gas cylinder group. manifold The total volume, combined with the minimum gas consumption in a single test. Substituting into the S302 van der Waals equation of state for a real gas, and considering pipeline flow resistance and pressure holding margin, the pre-charge pressure of the gas storage cylinder group is obtained iteratively. ;

[0138] Manifold density check: Substitute into the density variation of S302 to calculate the nitrogen density at the target pressure of the manifold. To verify whether the gas storage capacity of the manifold under the target pressure meets the constant pressure gas supply requirements;

[0139] S305: Pre-charge pressure of the gas cylinder group calculated based on S304 Substituting the values ​​into the density variation of van der Waals' real gas equation of state, the nitrogen density under the pre-charge pressure of the gas storage cylinder group is calculated. Then, combining the volume of the gas cylinder group, calculate the total mass of nitrogen required for pre-filling the gas cylinder group, and convert it to the nitrogen volume under standard conditions. The formula used is as follows:

[0140] ;

[0141] ;

[0142] in The total mass of nitrogen required for pre-charging the gas cylinder group. 1.251 represents the required volume of nitrogen under standard conditions, and 1.251 represents the density of nitrogen under standard conditions.

[0143] S306: Based on all the core parameters obtained from the simulation calculation in S304, automatically match and set the control parameters of each test device;

[0144] S307: Cross-check all calculation results. For the high-pressure section, verify that the deviation between the simulated pressure rise rate and pressure build-up time and the target value is ≤5%. For the medium-pressure section, verify that the gas supply of the gas storage cylinder group and the pressure stabilization capacity of the manifold meet the test requirements. After the verification is passed, a standardized test parameter report is automatically generated, which includes all core calculation parameters and equipment control parameters, as the formal basis for test execution. If the verification fails, it automatically returns to S304 to re-iterate the calculation until the test index requirements are met.

[0145] S4: Staged pressurization and gas source stabilization: The system control unit remotely starts the nitrogen preparation unit to produce low-pressure clean nitrogen with a flow rate ≥200Nm³ / h and a purity ≥95.0%. Then, the diaphragm compressor of the nitrogen storage and supply unit is started to pressurize the low-pressure nitrogen to the pre-charge pressure of the gas storage cylinder group and store it. In the high-pressure section, the nitrogen in the gas storage cylinder group is pressurized again to the pre-charge pressure of the high-pressure nitrogen stabilizing tank through the high-pressure booster pump. In the medium-pressure section, the three-way quick-opening and quick-closing solenoid valve is directly opened to pressurize the manifold to the target pressure. The entire pressurization process adopts closed-loop control. After the pressure reaches the set value, the equipment automatically stops and closes the corresponding pneumatic valve. In case of overpressure, the pressure is automatically released.

[0146] S5: Precise pressurization / gas supply in the test section: In the high-pressure section, when the pressure in front of the rupture disc reaches the design rupture pressure, the rupture disc instantly deflates. High-pressure nitrogen gas is introduced into the test sample after being maintained in a critical flow state through a sonic nozzle, achieving ultra-high pressure fast response pressurization. The pressurization rate is precisely controlled within the set range, and the pressure build-up time can be as short as 1.7ms. In the medium-pressure section, the solenoid valve is remotely opened, and the test sample begins to be inhaled. The three-way fast-opening and fast-closing solenoid valves are closed-loop high-frequency switches in real time according to the manifold pressure, achieving high-pressure, high-flow, constant-pressure gas supply, ensuring that the manifold pressure drop is ≤1.0MPa, and meeting the flow rate and duration requirements of ≥40kg / s.

[0147] The specific logical steps are as follows:

[0148] S501: The system control unit continuously collects the pressure of the core test points in the high-pressure section and medium-pressure section through the pressure transmitter, and compares it with the set pressure value calculated in S3. After the start-up conditions are met, the corresponding test section's pressurization / gas supply process is automatically triggered.

[0149] S502: The rupture disc ruptures instantaneously upon reaching the designed burst pressure. High-pressure nitrogen gas flows from the high-pressure nitrogen stabilizing tank through the rupture disc into the sonic nozzle assembly. The system control unit maintains the critical flow state of nitrogen gas through the structural characteristics of the sonic nozzle, ensuring a constant mass flow rate during pressurization. The critical flow determination condition is: ,in For the real-time pressure at the test sample end, The stagnation pressure of the high-pressure nitrogen pressure stabilizing tank;

[0150] S503: Nitrogen gas maintains a critical flow state within the sonic nozzle, passing through the throat area of ​​the sonic nozzle matched by S3. To achieve constant critical mass flow rate output, the standard critical mass flow rate formula is: ,in This is the critical mass flow rate of nitrogen. Where K is the stagnation temperature, K is the specific heat ratio of nitrogen, and R is the nitrogen gas constant.

[0151] Nitrogen gas at a constant mass flow rate is introduced into the test sample through a high-pressure pipeline to achieve ultra-high pressure fast response pressurization. The pressurization process is a univariate isentropic adiabatic process, and the actual pressurization rate of the test sample is consistent with the theoretical value.

[0152] S504: The system control unit remotely sends commands to synchronously open the high-flow solenoid valve in the medium-pressure section. The high-pressure nitrogen in the gas storage cylinder group is transported to the manifold through the medium-pressure pipeline, and then supplied to the test sample through the manifold. The diameter design of the solenoid valve ensures the nitrogen flow capacity and meets the technical requirements of high-flow gas supply of ≥40kg / s in the medium-pressure section. The opening size of the test sample is ≥Φ30mm, which matches the diameter of the gas supply pipeline, and there is no bottleneck in the airflow delivery.

[0153] S505: The medium-pressure section uses a three-way quick-opening and quick-closing solenoid valve to achieve closed-loop control of constant pressure gas supply. The system control unit collects the actual pressure of the manifold in real time and compares it with the target pressure. By comparing the results, the software algorithm controls the solenoid valve to switch on and off at high frequency / multi-channel switching to achieve precise pressure compensation. The core control logic is as follows:

[0154] when When the time comes, the 1st to 3rd quick-opening and quick-closing solenoid valves will automatically open to quickly replenish the pressure in the manifold;

[0155] when When this happens, all quick-opening and quick-closing solenoid valves will automatically close, stopping pressure replenishment;

[0156] S506: Throughout the entire process of pressurizing in the high-pressure section and supplying gas in the medium-pressure section, the system control unit performs real-time monitoring and anomaly detection of core test parameters.

[0157] High-pressure section: Monitor the real-time pressurization rate of the test sample, the rupture disc venting status, and the high-pressure pipeline pressure. If the pressurization rate deviation exceeds ±5% or the pipeline is over-pressurized, immediately trigger the interlock protection.

[0158] Medium-pressure section: Monitor the manifold pressure drop, the operation status of the fast-opening and fast-closing solenoid valve, and the nitrogen mass flow rate. If the manifold pressure drop is greater than 1.0 MPa or the flow rate does not meet the set requirements, automatically adjust the solenoid valve pressure compensation frequency / number of opening channels. At the same time, the high-speed signal acquisition unit synchronously collects pressure time and displacement time transient data to provide a basis for test process traceability and result analysis.

[0159] S507: When the preset endpoint conditions are met, the pressurization / gas supply process of the corresponding test section is automatically terminated. The endpoint determination logic is executed independently in two stages without manual intervention.

[0160] High-pressure section: When the actual pressure inside the high-pressure nitrogen pressure stabilizing tank... With the actual pressure inside the test sample Once pressure balance is achieved, i.e., in real time, the pressurization is determined to be complete, and the system automatically switches to the pressure holding stage.

[0161] Medium pressure section: When the constant pressure gas supply duration reaches the set value of S3. When the flow rate at the test sample end meets the test requirements and there is no excessive pressure drop, the gas supply is determined to be complete and the gas stop command is automatically triggered.

[0162] S6: Transient data synchronous acquisition and monitoring: During the entire pressurization / gas supply process, the system's high-speed signal acquisition unit uses pressure transmitters and displacement sensors to achieve high-frequency synchronous acquisition of no less than 16 displacement signals and no less than 6 pressure signals, thereby acquiring real-time transient data of the test sample's pressure-time and displacement-time. The data is transmitted to the system control unit in real time and stored in the local database and files, enabling real-time monitoring of the test process.

[0163] S7: Pressure Holding / Constant Pressure End and Full-Range Pressure Relief: In the high-pressure section, after the pressure of the high-pressure nitrogen stabilizing tank and the test sample reaches equilibrium, the pressure holding stage begins. The pressure drop during the pressure holding stage is ≤0.5MPa / 10s. After the pressure holding is completed, the exhaust valve is remotely opened to release the nitrogen in the test sample, pipeline, and stabilizing tank to atmospheric pressure. In the medium-pressure section, after the set constant pressure duration is reached, the solenoid valve and the three-way quick-opening and quick-closing solenoid valve are remotely closed to stop the gas supply. The exhaust valve is then opened to release the nitrogen in the manifold, pipeline, and test sample to atmospheric pressure.

[0164] S8: Test completion and full data processing: Test personnel enter the site to remove the test sample and transfer it as required. The system control unit automatically analyzes and processes the collected test data, compares the measured data with the command data, and compares the historical data to accurately determine whether the test indicators meet the standards. At the same time, it automatically generates a standardized test report with one click. Test data and reports can be queried and traced by test date and product number. Finally, the system exhaust and power-off operations are completed according to the test schedule.

[0165] This embodiment integrates ultra-high pressure rapid response pressurization in the high-pressure section with high-pressure, high-flow constant pressure gas supply in the medium-pressure section, achieving full coverage of a wide pressure range without the need to replace multiple sets of equipment. The high-pressure section uses rupture discs and sonic nozzles to replace traditional valves, avoiding the risks of pyrotechnics and achieving millisecond-level pressurization. The medium-pressure section uses three-way fast-opening and fast-closing solenoid valves and manifolds to avoid crosstalk, achieving a pressure control accuracy of ±0.5MPa. It is also equipped with a remote monitoring and control unit and fully automated operation, combined with precise calculations to achieve wide-range pressure ramp-up rate adjustment in the high-pressure section and stable flow output in the medium-pressure section. It can be adapted to different test samples, comprehensively improving the versatility, safety, automation, and control accuracy of the test.

[0166] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A cold-state rapid stamping test verification system, characterized in that, It includes a nitrogen preparation unit, a nitrogen storage and supply unit, a high-pressure gas supply and distribution station, a medium-pressure gas supply and distribution station, a system control unit, and a system high-speed signal acquisition unit; The nitrogen preparation unit adopts pressure swing adsorption (PSA) nitrogen generation technology, which includes an air compressor, a refrigerated dryer, an adsorption dryer, a filter, a PSA nitrogen generator and a nitrogen buffer tank, and is used to prepare and output low-pressure clean nitrogen. The nitrogen storage and supply unit is connected to the nitrogen preparation unit and is used to pressurize and store low-pressure nitrogen in stages to provide a suitable nitrogen source for high-pressure and medium-pressure tests. It includes a diaphragm compressor, a gas storage cylinder group, a high-pressure booster pump, a medium-pressure nitrogen stabilizing tank and a high-pressure nitrogen stabilizing tank. The high-pressure section gas supply and distribution station is connected to the high-pressure nitrogen stabilizing tank of the nitrogen storage and supply unit, and is used to carry out ultra-high pressure fast response pressurization tests in the cold flow pressure range of 30MPa to 100MPa. It includes a rupture disc assembly, a sonic nozzle assembly, an explosion-proof container, and a high-pressure pipeline assembly. The medium-pressure section gas supply and distribution station is connected to the medium-pressure nitrogen stabilizing tank of the nitrogen storage and supply unit, and is used to carry out high-pressure, high-flow constant-pressure gas supply tests in the cold flow pressure range of 5MPa to 30MPa. It includes three-way quick-opening and quick-closing solenoid valves, manifold tanks, solenoid valves and medium-pressure pipeline components. The system control unit is electrically connected to the nitrogen preparation unit, nitrogen storage and supply unit, high-pressure section gas supply and distribution station, medium-pressure section gas supply and distribution station and system high-speed signal acquisition unit, and is used to realize remote operation, human-machine isolation, automatic parameter matching and calculation, closed-loop control and interlock protection during the test process. It includes a power supply and distribution electronic system and a measurement and control subsystem. The high-speed signal acquisition unit of the system is used for the accurate synchronous acquisition of transient signals during the test. It includes an NI synchronous acquisition unit, a pressure transmitter, and a displacement sensor.

2. The cold-state rapid stamping test verification system according to claim 1, characterized in that, The technical specifications of the nitrogen preparation unit are as follows: nitrogen flow rate ≥ 200 Nm³ / h, purity ≥ 95.0%, water content ≤ 0.176 g / m³, oxygen content ≤ 5%, nitrogen generator outlet pressure ≥ 0.5 MPa, nitrogen buffer tank rated pressure ≥ 1.0 MPa, the nitrogen preparation unit has manual / automatic sewage discharge and operation modes, noise ≤ 75 dB, and an overpressure safety alarm function to ensure a continuous, stable, and clean supply of nitrogen.

3. The cold-state rapid stamping test verification system according to claim 1, characterized in that, The diaphragm compressor is a pollution-free booster compressor with an exhaust pressure ≥45MPa and a volumetric flow rate of 200Nm³ / h, used to boost the low-pressure nitrogen in the nitrogen preparation unit to 45MPa; The gas storage cylinder group consists of four cascaded high-pressure gas storage cylinders of 1m³ / 45MPa, with a total volume of 4m³. It supports automatic / manual switching and arbitrary combination to achieve large-capacity storage of nitrogen. The high-pressure booster pump has a maximum exhaust pressure of 140MPa and a flow rate of ≥60ML / min. It pressurizes the nitrogen in the gas storage cylinder group to 140MPa and stores it in the high-pressure nitrogen pressure stabilizing tank, providing an ultra-high pressure gas source for the high-pressure section test. The medium-pressure nitrogen stabilizing tank consists of a gas storage cylinder group and a 2m³ / 30MPa manifold, with a total volume ≥6m³ and a rated pressure ≥35MPa. It provides a high-pressure, high-flow-rate gas source for medium-pressure tests, and the outlet flow of the booster pump meets the requirement that the pressurization time between two consecutive tests is ≤2 hours, ensuring the continuity of the test.

4. The cold-state rapid stamping test verification system according to claim 1, characterized in that, The rupture disc assembly can be customized for rupture pressure, has a short venting time, produces no sparks or fragments after venting, and has a rupture tolerance of ±5%. It achieves rapid release of high-pressure nitrogen through instantaneous venting. The throat diameter of the sonic nozzle assembly ranges from 0.17 mm to 10.78 mm. By changing the sonic nozzle with different throat diameters, the mass flow rate of nitrogen gas can be controlled, thereby precisely adjusting the pressurization rate of the test sample. The adjustable range of the pressurization rate is 0.1 MPa / ms to 2.0 MPa / ms, 30 MPa to 60 MPa, 15 MPa / ms to 35 MPa / ms, and 60 MPa to 100 MPa. The explosion-proof container is used to place the test sample to avoid experimental safety accidents; The high-pressure pipeline assembly has an inner diameter of 14.27 mm, which is suitable for the maximum throat diameter of the sound-rate nozzle. The interface between the test process pipeline and the test sample is a standard flange connection, and it has no less than two pressure regulation capabilities to support multi-channel testing. The three-way quick-opening and quick-closing solenoid valves are set in parallel, with a response time of ≤350ms. They achieve precise pressure regulation through intelligent switching by software algorithms and high-frequency switching, with a pressure control accuracy of ±0.5MPa. The manifold is used to ensure constant pressure gas supply. During the test, the pressure drop is ≤1.0MPa, which meets the technical requirement of mass flow rate ≥40kg / s. The manifold is equipped with a pressure transmitter, safety valve and exhaust valve to realize real-time pressure monitoring and overpressure protection. The solenoid valve ensures a high-pressure, high-flow-rate gas supply capacity; The medium-pressure pipeline assembly has an interface size ≥ DN100, a test specimen opening size ≥ Φ30mm, and at least two pressure regulation capabilities, supporting multi-channel testing.

5. The cold-state rapid stamping test verification system according to claim 1, characterized in that, The power supply and distribution electronic system provides a 220V AC / 5kVA purified power supply, which provides surge and electromagnetic interference protection for power supply and signal acquisition. It includes a power distribution cabinet, a purified power supply and a UPS uninterruptible power supply. The UPS uninterruptible power supply provides power to the measurement and control system when the mains power fails, ensuring data storage and system security. The measurement and control subsystem includes a PLC controller, an industrial computer, and control software developed based on LabVIEW. The PLC controller acts as a lower-level machine to realize the logic control of the equipment, and the industrial computer is located in the remote measurement and control hall to achieve human-machine isolation. The high-speed signal acquisition unit of the system is used to acquire no less than 16 displacement signals and no less than 6 pressure signals, realize the real-time acquisition and storage of pressure time and displacement time data of the test sample, and can complete the comparison and analysis of measured data and command data, as well as the superposition and comparison of historical data.

6. A cold-state rapid stamping test verification method, based on the system described in any one of claims 1-5, characterized in that, Includes the following steps: S1: System full-domain initialization: Check the equipment operation status of nitrogen preparation, nitrogen storage and supply, high-pressure section gas supply and distribution station, medium-pressure section gas supply and distribution station, system control unit and high-speed signal acquisition unit, confirm that there is no leakage in the pipeline, all valves are in the initial closed state, and the sensors and data acquisition equipment are calibrated normally. Select the high-pressure section or medium-pressure section test mode according to the test requirements and complete the preliminary preparation of the corresponding test gas path. S2: On-site installation of test specimen and gas circuit adaptation: Complete the sealed connection between the test specimen and the pipeline assembly of the corresponding test section. In the high-pressure section, the test specimen must be placed in an explosion-proof container and connected with a standard flange. In the medium-pressure section, ensure that the opening size of the test specimen is ≥Φ30mm. Select the test gas circuit through the manual needle valve of the corresponding test section, open the manual ball valve of the air inlet, and after completing all on-site operations, the test personnel shall leave the test area to achieve human-machine isolation. S3: Intelligent Simulation and Calculation of Test Parameters: Through the test software of the system control unit, the basic parameters such as the free volume of the test sample, the target test pressure, the target pressurization rate, the mass flow rate, and the constant pressure duration are entered. Based on the simulation software, the simulation calculation is completed in combination with the actual gas state equation and the law of conservation of mass. In the high-pressure section, the pre-charge pressure of the high-pressure nitrogen stabilizing tank, the matching throat diameter of the sonic nozzle, the pre-charge pressure of the gas storage cylinder group and the required amount of nitrogen are automatically calculated. In the medium-pressure section, the pre-charge pressure of the gas storage cylinder group and the target pressure of the manifold are automatically calculated. At the same time, the automatic matching and setting of the test equipment control parameters are completed. S4: Staged pressurization and gas source stabilization: The system control unit remotely starts the nitrogen preparation unit to produce low-pressure clean nitrogen with a flow rate ≥200Nm³ / h and a purity ≥95.0%. Then, the diaphragm compressor of the nitrogen storage and supply unit is started to pressurize the low-pressure nitrogen to the pre-charge pressure of the gas storage cylinder group and store it. In the high-pressure section, the nitrogen in the gas storage cylinder group is pressurized again to the pre-charge pressure of the high-pressure nitrogen stabilizing tank through the high-pressure booster pump. In the medium-pressure section, the three-way quick-opening and quick-closing solenoid valve is directly opened to pressurize the manifold to the target pressure. The entire pressurization process adopts closed-loop control. After the pressure reaches the set value, the equipment automatically stops and closes the corresponding pneumatic valve. In case of overpressure, the pressure is automatically released. S5: Precise pressurization / gas supply in the test section: In the high-pressure section, when the pressure in front of the rupture disc reaches the design rupture pressure, the rupture disc instantly deflates. High-pressure nitrogen gas is introduced into the test sample after being maintained in a critical flow state through a sonic nozzle, achieving ultra-high pressure fast response pressurization. The pressurization rate is precisely controlled within the set range, and the pressure build-up time can be as short as 1.7ms. In the medium-pressure section, the solenoid valve is remotely opened, and the test sample begins to be inhaled. The three-way fast-opening and fast-closing solenoid valves are closed-loop high-frequency switches in real time according to the manifold pressure, achieving high-pressure, high-flow, constant-pressure gas supply, ensuring that the manifold pressure drop is ≤1.0MPa, and meeting the flow rate and duration requirements of ≥40kg / s. S6: Transient data synchronous acquisition and monitoring: During the entire pressurization / gas supply process, the system's high-speed signal acquisition unit uses pressure transmitters and displacement sensors to achieve high-frequency synchronous acquisition of no less than 16 displacement signals and no less than 6 pressure signals, thereby acquiring real-time transient data of the test sample's pressure-time and displacement-time. The data is transmitted to the system control unit in real time and stored in the local database and files, enabling real-time monitoring of the test process. S7: Pressure Holding / Constant Pressure End and Full-Range Pressure Relief: In the high-pressure section, after the pressure of the high-pressure nitrogen stabilizing tank and the test sample reaches equilibrium, the pressure holding stage begins. The pressure drop during the pressure holding stage is ≤0.5MPa / 10s. After the pressure holding is completed, the exhaust valve is remotely opened to release the nitrogen in the test sample, pipeline, and stabilizing tank to atmospheric pressure. In the medium-pressure section, after the set constant pressure duration is reached, the solenoid valve and the three-way quick-opening and quick-closing solenoid valve are remotely closed to stop the gas supply. The exhaust valve is then opened to release the nitrogen in the manifold, pipeline, and test sample to atmospheric pressure. S8: Test Completion and Data Processing: Test personnel enter the site to remove the test specimen and transfer it as required. The system control unit automatically analyzes and processes the collected test data, compares the measured data with the command data, and overlays and compares historical data to accurately determine whether the test indicators meet the standards. At the same time, it automatically generates a standardized test report with one click. Test data and reports can be queried and traced through the test date and product number. Finally, the system exhausts and powers off the system according to the test schedule.

7. The cold-state rapid stamping test verification method according to claim 6, characterized in that, The specific logical steps of S3 are as follows: S301: Through the system control unit test software, the core parameters of the test sample are entered, and specific parameters are supplemented according to the selected test mode. At the same time, the general boundary parameters of the test are entered. The software automatically determines the high-pressure / medium-pressure test mode based on the entered parameters and calls the corresponding calculation module. The core parameters of the test sample include free volume. Test target pressure Specific parameters include the target boost rate for the high-voltage section. Input the target mass flow rate in the medium-pressure section. Constant voltage output duration The general boundary parameters for the experiment include the thermodynamic temperature of the experimental environment. Nitrogen specific heat ratio Nitrogen gas constant Molar mass of nitrogen Nitrogen van der Waals constant , ; S302: The experimental software loads the van der Waals equation of state for real gases as the core conversion basis for pressure, density, and volume. It also derives variations for density calculation to adapt to the parameter calculation requirements of different test sections. The formulas used are as follows: van der Waals' equation of state for real gases: ; Density calculation variation: ; Where p is the gas pressure. For specific volume of gas, The density of the gas; S303: The test software completes the volume correction and core exclusive parameter calculation for the high-voltage section and the medium-voltage section according to the test mode, providing a basis for subsequent simulation; When making volume corrections for the high-pressure section, the volume of the downstream pipeline of the high-pressure section must be considered. The effect of pressure adjustment is used to obtain the actual total pressure volume: ,in The total pressurized volume of the test sample and the downstream pipeline. The free volume of the test sample. This refers to the total volume of the pipeline at the rear end of the high-pressure section; Basic calculation of gas consumption in the medium-pressure section: Based on the target mass flow rate and constant pressure duration in the medium-pressure section, calculate the minimum gas consumption for a single test: ,in This represents the minimum gas consumption for a single test in the medium-pressure section. This represents the target mass flow rate for the medium-pressure section. This refers to the duration of constant pressure output in the medium-voltage section. S304: By calling simulation software and combining the law of conservation of mass with the van der Waals equation of state for real gases, simulation iterative calculations are performed in high-pressure and medium-pressure sections to obtain the core parameters of each test section, and the entire process is automated. S305: Pre-charge pressure of the gas cylinder group calculated based on S304 Substituting the values ​​into the density variation of van der Waals' real gas equation of state, the nitrogen density under the pre-charge pressure of the gas storage cylinder group is calculated. Then, combining the volume of the gas cylinder group, calculate the total mass of nitrogen required for pre-filling the gas cylinder group, and convert it to the nitrogen volume under standard conditions. The formula used is as follows: ； ； in The total mass of nitrogen required for pre-charging the gas cylinder group. 1.251 represents the required volume of nitrogen under standard conditions, and 1.251 represents the density of nitrogen under standard conditions. S306: Based on all the core parameters obtained from the simulation calculation in S304, automatically match and set the control parameters of each test device; S307: Cross-check all calculation results. For the high-pressure section, verify that the deviation between the simulated pressure rise rate and pressure build-up time and the target value is ≤5%. For the medium-pressure section, verify that the gas supply of the gas storage cylinder group and the pressure stabilization capacity of the manifold meet the test requirements. After the verification is passed, a standardized test parameter report is automatically generated, which includes all core calculation parameters and equipment control parameters, as the formal basis for test execution. If the verification fails, it automatically returns to S304 to re-iterate the calculation until the test index requirements are met.

8. The cold-state rapid stamping test verification method according to claim 7, characterized in that, In S304, the formula used for the high-voltage section simulation calculation is as follows: Pre-charge density of high-pressure nitrogen pressure stabilizing tank calculate: ,in The density of nitrogen gas at the target pressure of the test sample. Volume of the high-pressure nitrogen pressure stabilizing tank; High-pressure nitrogen pressure stabilizing tank pre-charge pressure Calculate: Substituting the density variation of the van der Waals real gas equation of state (S302), we can inversely calculate... The rupture pressure is then adjusted to a ±5% tolerance for the rupture disc. ; Sonic nozzle throat diameter matching calculation: First, calculate the required critical mass flow rate using the formula relating pressure rise rate and mass flow rate. Then substitute the values ​​into the critical mass flow rate formula to calculate the throat area. Finally, it is converted to a matching throat diameter. The formula used is: ; ； ； in The stagnation temperature, K, is the same as the ambient temperature of the test. , Match the throat diameter to the sonic nozzle; Pre-charge pressure of gas cylinder group Calculation: Combined with the total gas consumption of the high-pressure section Gas cylinder group volume Substituting into the van der Waals equation of state for a real gas, and considering the pipeline flow resistance redundancy coefficient k=1.2, the following iterative result is obtained: ; The formulas used in the simulation calculations for the medium-pressure section are as follows: Manifold target pressure Calculate: Target pressure in the medium-pressure section As the basic target pressure for the manifold, and considering the constraint that the manifold pressure drop ≤ 1.0 MPa, the following correction is obtained: ; Pre-charge pressure of gas cylinder group Calculation: Based on the law of conservation of mass, consider the gas cylinder group. manifold The total volume, combined with the minimum gas consumption in a single test. Substituting into the S302 van der Waals equation of state for a real gas, and considering pipeline flow resistance and pressure holding margin, the pre-charge pressure of the gas storage cylinder group is obtained iteratively. ; Manifold density check: Substitute into the density variation of S302 to calculate the nitrogen density at the target pressure of the manifold. This verifies whether the gas storage capacity of the manifold under the target pressure meets the constant pressure gas supply requirements.

9. The cold-state rapid stamping test verification method according to claim 6, characterized in that, The specific logical steps of S5 are as follows: S501: The system control unit continuously collects the pressure of the core test points in the high-pressure section and medium-pressure section through the pressure transmitter, and compares it with the set pressure value calculated in S3. After the start-up conditions are met, the corresponding test section's pressurization / gas supply process is automatically triggered. S502: The rupture disc ruptures instantaneously upon reaching the designed burst pressure. High-pressure nitrogen gas flows from the high-pressure nitrogen stabilizing tank through the rupture disc into the sonic nozzle assembly. The system control unit maintains the critical flow state of nitrogen gas through the structural characteristics of the sonic nozzle, ensuring a constant mass flow rate during pressurization. The critical flow determination condition is: ,in For the real-time pressure at the test sample end, The stagnation pressure of the high-pressure nitrogen pressure stabilizing tank; S503: Nitrogen gas maintains a critical flow state within the sonic nozzle, passing through the throat area of ​​the sonic nozzle matched by S3. To achieve constant critical mass flow rate output, the standard critical mass flow rate formula is: ,in This is the critical mass flow rate of nitrogen. Where K is the stagnation temperature, K is the specific heat ratio of nitrogen, and R is the nitrogen gas constant. Nitrogen gas at a constant mass flow rate is introduced into the test sample through a high-pressure pipeline to achieve ultra-high pressure fast response pressurization. The pressurization process is a univariate isentropic adiabatic process, and the actual pressurization rate of the test sample is consistent with the theoretical value. S504: The system control unit remotely sends commands to synchronously open the high-flow solenoid valve in the medium-pressure section. The high-pressure nitrogen in the gas storage cylinder group is transported to the manifold through the medium-pressure pipeline, and then supplied to the test sample through the manifold. The diameter design of the solenoid valve ensures the nitrogen flow capacity and meets the technical requirements of high-flow gas supply of ≥40kg / s in the medium-pressure section. The opening size of the test sample is ≥Φ30mm, which matches the diameter of the gas supply pipeline, and there is no bottleneck in the airflow delivery. S505: The medium-pressure section uses a three-way quick-opening and quick-closing solenoid valve to achieve closed-loop control of constant pressure gas supply. The system control unit collects the actual pressure of the manifold in real time and compares it with the target pressure. By comparing the results, the software algorithm controls the solenoid valve to switch on and off at high frequency / multi-channel switching to achieve precise pressure compensation. The core control logic is as follows: when When the time comes, the 1st to 3rd quick-opening and quick-closing solenoid valves will automatically open to quickly replenish the pressure in the manifold; when When this happens, all quick-opening and quick-closing solenoid valves will automatically close, stopping pressure replenishment; S506: Throughout the entire process of pressurizing in the high-pressure section and supplying gas in the medium-pressure section, the system control unit performs real-time monitoring and anomaly detection of core test parameters. High-pressure section: Monitor the real-time pressurization rate of the test sample, the rupture disc venting status, and the high-pressure pipeline pressure. If the pressurization rate deviation exceeds ±5% or the pipeline is over-pressurized, immediately trigger the interlock protection. Medium-pressure section: Monitor the manifold pressure drop, the operation status of the fast-opening and fast-closing solenoid valve, and the nitrogen mass flow rate. If the manifold pressure drop is greater than 1.0 MPa or the flow rate does not meet the set requirements, automatically adjust the solenoid valve pressure compensation frequency / number of opening channels. At the same time, the high-speed signal acquisition unit synchronously collects pressure time and displacement time transient data to provide a basis for test process traceability and result analysis. S507: When the preset endpoint conditions are met, the pressurization / gas supply process of the corresponding test section is automatically terminated. The endpoint determination logic is executed independently in two stages without manual intervention. High-pressure section: When the actual pressure inside the high-pressure nitrogen pressure stabilizing tank... With the actual pressure inside the test sample Once pressure balance is achieved, i.e., in real time, the pressurization is determined to be complete, and the system automatically switches to the pressure holding stage. Medium pressure section: When the constant pressure gas supply duration reaches the set value of S3. If the flow rate at the test sample end meets the test requirements and there is no excessive pressure drop, the gas supply is deemed complete, and a gas stop command is automatically triggered.

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