A full-automatic high-pressure air-tightness detection and classification system and method for pressure-limiting valves

Abstract

This invention belongs to the field of valve testing technology and relates to a fully automatic high-pressure airtightness testing and classification system for pressure-limiting valves. It includes a frame, a high-pressure airtightness testing unit, a feeding and sorting unit, and a control system. The high-pressure airtightness testing unit employs a dual-cylinder driven clamping structure combined with an electromagnet sealing structure for its testing fixture, adaptable to high-pressure environments ≥15MPa, and features a built-in silencer to optimize the working environment. The feeding and sorting unit achieves fully automated operation and includes a QR code identification module. The control system implements a three-level performance classification based on leakage rate and synchronizes with the MES system through a data interaction module, enabling full-process data traceability. This invention achieves fully automatic, high-precision testing and refined classification of high-pressure pressure-limiting valves, significantly improving testing efficiency and accuracy, and can be widely applied to batch testing scenarios for high-pressure pressure-limiting valves.

Description

Technical Field

[0001] This invention belongs to the field of pressure relief valve testing technology, specifically relating to a fully automatic high-pressure airtightness testing and classification system and method for pressure relief valves. Background Technology

[0002] As a critical safety component in high-pressure fluid systems, the airtightness of pressure relief valves directly determines the safety and reliability of system operation. This is especially true in high-pressure scenarios with operating pressures ≥15MPa, where the airtightness requirements for pressure relief valves are even more stringent. Currently, existing pressure relief valve airtightness testing equipment generally suffers from the following technical deficiencies:

[0003] 1. Low level of automation: Most testing equipment requires manual operation for loading, clamping, unloading and sorting, which is not only inefficient, but also prone to affecting the accuracy of testing due to human error. In addition, manual operation under high pressure poses safety hazards.

[0004] 2. Poor high pressure adaptability: Most existing testing equipment is designed for medium and low pressure scenarios and lacks a sealing structure suitable for high pressure environments of ≥15MPa. This makes it prone to high pressure leakage, resulting in inaccurate test results and failing to meet the testing requirements of high pressure relief valves.

[0005] 3. Limited classification function: It can only achieve a binary classification of qualified / unqualified, and cannot perform fine-grained classification of pressure relief valve performance based on leakage rate, making it difficult to meet the quality control needs of different scenarios;

[0006] 4. Poor data traceability: The test data is not effectively linked to the identity information of the pressure relief valve, making it impossible to achieve data traceability throughout the entire testing process, which is not conducive to subsequent quality inspection and product life cycle management.

[0007] The existing technology (CN119972561B) discloses a fully automated airtightness detection and coding classification system for automotive pipelines. However, this system is applicable to low- and medium-pressure scenarios and does not address high-pressure adaptability structures and three-level performance grading, thus failing to solve the aforementioned technical problems in high-pressure pressure relief valve detection. Therefore, developing a fully automated, high-pressure adaptable, finely graded, and traceable airtightness detection system for pressure relief valves has become an urgent technical problem to be solved in this field. Summary of the Invention

[0008] The purpose of this invention is to overcome the shortcomings of the prior art and provide a fully automatic high-pressure airtightness detection and classification system and method for pressure relief valves.

[0009] To achieve the objectives of this invention, the following technical solutions are adopted.

[0010] A fully automatic high-pressure airtightness detection and classification system for pressure relief valves includes:

[0011] One rack;

[0012] At least one high-pressure airtightness testing unit, including a testing fixture with a double-cylinder clamping structure and an electromagnet sealing structure, is used to test the airtightness of a pressure relief valve with a working pressure ≥15MPa;

[0013] At least one feeding and sorting unit is used to automatically transport the pressure relief valve to the testing fixture of the high-pressure airtightness testing unit and complete the clamping during feeding; and to automatically sort the pressure relief valve and place it into the corresponding discharge channel during unloading.

[0014] A control system is electrically connected to both the high-pressure airtightness detection unit and the feeding and sorting unit. The control system calculates the pressure difference and leakage rate based on the inlet / outlet pressure values ​​of the pressure relief valve under energized and de-energized conditions detected by the high-pressure airtightness detection unit. By comparing the leakage rate with a preset threshold, the control system determines the airtightness level of the pressure relief valve and sorts the valves to the corresponding discharge channels via the feeding and sorting unit according to the airtightness level. The airtightness level includes three grades: high, medium, and low.

[0015] Furthermore, the high-pressure airtightness detection unit also includes a high-pressure air circuit system for pressurizing the pressure relief valve, which has a built-in silencer for reducing noise when the high-pressure gas is depressurized, and a pressure sensor for detecting the pressure at the inlet and outlet of the pressure relief valve.

[0016] Furthermore, the feeding and sorting unit includes:

[0017] The barcode scanning and recognition module uses a barcode scanner to scan the QR code on the pressure relief valve. It synchronizes with the MES system in real time via LabVIEW to bind the QR code and associate it with the detection data and grading results.

[0018] The robotic arm handling module includes a three-axis servo robotic arm or a six-axis robot with a pneumatic gripper at the end for loading, clamping and sorting, in order to achieve precise positioning.

[0019] Furthermore, the control system includes a host computer, a slave computer communicating with the host computer, and a data interaction module connecting the host computer and the MES system via Ethernet communication. The host computer includes programs written in LabVIEW, C#, or Python for process control, data acquisition, QR code binding, and uploading to the MES system. The slave computer includes a PLC or motion control card for controlling the robotic arm, dual cylinders, electromagnet, and pressure sensor. The data interaction module synchronizes the pressure relief valve's QR code, detection time, leakage rate, and airtightness level to the MES system in real time to ensure traceability of the detection data.

[0020] Furthermore, the logic for comparing and judging the airtightness level is as follows:

[0021] When the leakage rate is less than or equal to the first preset threshold, it is classified as a high-level leak.

[0022] When the leakage rate is greater than the first preset threshold and less than or equal to the second preset threshold, it is judged as medium level;

[0023] When the leakage rate exceeds the second preset threshold, it is judged as a low level.

[0024] Furthermore, a fully automatic high-pressure airtightness detection and classification system for pressure relief valves also includes a touch panel box integrating a host computer, a human-machine interactive touch screen, a start button, a power-on button, and an emergency stop button.

[0025] Furthermore, a fully automatic high-pressure airtightness detection and classification system for pressure relief valves also includes a classification tray consisting of high-grade trays, medium-grade trays, and low-grade trays.

[0026] A fully automated method for high-pressure airtightness detection and classification of pressure relief valves includes the following steps:

[0027] S1. When loading materials, the feeding and sorting unit automatically delivers the pressure relief valve to the testing fixture of the high-pressure airtightness testing unit and completes the clamping.

[0028] S2. Use the high-pressure air circuit system in the high-pressure airtightness detection unit to introduce high-pressure gas of ≥15MPa into the pressure relief valve, and detect the inlet / outlet pressure values ​​of the pressure relief valve in the non-powered and powered states.

[0029] S3. The control system calculates the pressure difference and leakage rate based on the inlet / outlet pressure values ​​detected by the high-pressure airtightness detection unit. By comparing the leakage rate with a preset threshold, it determines the airtightness level of the pressure relief valve. The airtightness level includes three levels: high, medium, and low.

[0030] S4. When unloading, the feeding and sorting unit automatically sorts the pressure relief valves according to the airtightness level and puts them into the corresponding discharge channels.

[0031] Furthermore, a fully automatic high-pressure airtightness detection and classification method for pressure relief valves also includes a data traceability step: using the data interaction module in the control system to synchronize the QR code, detection data, and classification results to the MES system to achieve traceability of the detection data.

[0032] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0033] 1. Strong high pressure adaptability: Through the design of a dual-cylinder drive structure and an electromagnet sealing fixture, the sealing problem in high pressure environment is effectively solved. It can stably adapt to the detection requirements of high pressure relief valves with pressure ≥15MPa, with a detection leakage rate error ≤0.01MPa, and the detection accuracy is significantly improved.

[0034] 2. High degree of automation: It realizes unmanned operation of the entire process from automatic feeding, identity recognition, high-pressure airtightness testing, performance grading to unloading and sorting, improving the detection efficiency by ≥50% and reducing manual operation costs and safety hazards;

[0035] 3. Refined classification: Based on leakage rate, a three-level performance classification is implemented, which can better meet the quality control needs of different scenarios and improve the scientificity and rationality of product quality classification compared with the existing binary classification.

[0036] 4. Data traceability: Through data interaction between the identity recognition module and the MES system, the identity information of the pressure relief valve, test data, and grading results are bound and synchronized in real time, forming a closed loop of data traceability throughout the entire process, which facilitates subsequent quality inspection and product management.

[0037] In summary, this invention, through the collaborative design of its components, solves the core technical pain points of existing high-pressure limiting valve detection, achieving significant technical effects, possessing outstanding substantive features and remarkable progress, and meeting the inventiveness requirements for patent authorization. Attached Figure Description

[0038] Figure 1 A perspective view of the fully automatic high-pressure airtightness detection and classification system for pressure relief valves.

[0039] Figure 2 for Figure 1 The main view;

[0040] Figure 3 for Figure 1 The left view;

[0041] Figure 4 for Figure 1 Top view;

[0042] Figure 5 Here is a flowchart illustrating the specific process of the detection and classification method.

[0043] Attached reference numerals: 1 is the frame, 2 is the feeding and sorting unit, 3 is the high-pressure airtightness detection unit, 4 is the control system, and 5 is the sorting tray; among which: 21 is the X-axis robotic arm, 22 is the Y-axis robotic arm, 23 is the Z-axis robotic arm, 24 is the pneumatic gripper, and 25 is the barcode scanner; 31 is the pressure regulator, 32 is the stop cylinder, 33 is the upper cylinder, 34 is the lower cylinder, 35 is the pressure sensor A, 36 is the pressure sensor B, 37 is the silencer, and 38 is the detection fixture; 41 is the host computer, and 42 is the touch panel box. Detailed Implementation

[0044] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0045] As an embodiment of the present invention, such as Figures 1 to 4 As shown, a fully automatic high-pressure airtightness detection and classification system for pressure relief valves includes:

[0046] One rack 1;

[0047] A high-pressure airtightness testing unit 3 includes a testing fixture 38 with a double-cylinder driven clamping structure and an electromagnet sealing structure, used to test the airtightness of a pressure relief valve with a working pressure ≥15MPa;

[0048] A feeding and sorting unit 2 is used to automatically transport the pressure relief valves to the testing fixture 38 and complete the clamping during feeding; during unloading, it automatically sorts the pressure relief valves to the corresponding discharge channels according to the airtightness level and sends them to the classification tray 5; wherein: the classification tray 5 includes a high-grade pressure relief valve tray 51, a medium-grade pressure relief valve tray 52 and a low-grade pressure relief valve tray 53;

[0049] A control system 4 is electrically connected to the high-pressure airtightness detection unit 3 and the feeding and sorting unit 2 respectively. The control system 4 calculates the pressure difference and leakage rate based on the inlet / outlet pressure values ​​of the pressure relief valve in the non-energized and energized states detected by the high-pressure airtightness detection unit 3. By comparing the leakage rate with a preset threshold, the airtightness level of the pressure relief valve is determined. The airtightness level includes three levels: high, medium and low.

[0050] Among them: the testing fixture adopts a double-cylinder clamping structure: the upper cylinder 33 is equipped with an electromagnet, which can be energized to lift the valve core; the lower cylinder 34 fixes the valve body;

[0051] As an embodiment of the present invention, such as Figures 1 to 4 As shown, the high-pressure airtightness detection unit also includes a high-pressure air circuit system for pressurizing the pressure relief valve, which has a built-in silencer 37 for reducing noise when the high-pressure gas is depressurized, and a pressure sensor A35 for detecting the air pressure at the inlet of the pressure relief valve and a pressure sensor B36 for detecting the air pressure at the outlet.

[0052] As an embodiment of the present invention, such as Figures 1 to 4 As shown, the feeding and sorting unit includes:

[0053] The barcode scanning module uses a barcode scanner 25 to scan the QR code on the pressure relief valve. It then synchronizes with the MES system in real time via a LabVIEW host computer 41 to bind the QR code and associate it with the detection data and grading results.

[0054] The robotic arm handling module includes a three-axis servo robotic arm with a pneumatic gripper 24 at the end for loading, clamping and sorting, so as to achieve precise positioning; wherein: the three-axis robotic arm is composed of an X-axis robotic arm 21, a Y-axis robotic arm 22 and a Z-axis robotic arm 23.

[0055] As an embodiment of the present invention, such as Figures 1 to 4 As shown, the control system includes a host computer 41, a slave computer communicating with the host computer, and a data interaction module connecting the host computer 41 and the MES system via Ethernet communication. The host computer 41 includes programs written in LabVIEW, C#, or Python for process control, data acquisition, QR code binding, and uploading to the MES system. The slave computer includes a PLC for controlling a three-axis robotic arm, dual cylinders, electromagnets, and pressure sensors. The data interaction module synchronizes the pressure relief valve's QR code, detection time, leakage rate, and airtightness level to the MES system in real time to ensure traceability of the detection data. The three-axis robotic arm can be replaced by a six-axis robot, and the PLC can be replaced by a motion control card.

[0056] As an embodiment of the present invention, the comparison and judgment logic of the airtightness level is as follows:

[0057] When the leakage rate is less than or equal to the first preset threshold, it is classified as a high-level leak.

[0058] When the leakage rate is greater than the first preset threshold and less than or equal to the second preset threshold, it is judged as medium level;

[0059] When the leakage rate exceeds the second preset threshold, it is judged as a low level.

[0060] As an embodiment of the present invention, such as Figures 1 to 4 As shown, a fully automatic high-pressure airtightness detection and classification system for pressure relief valves also includes a host computer 41 and a touch panel box 42; wherein: the touch panel box 42 is integrated with a start button, a power button, an emergency stop button, and a human-machine interactive touch screen.

[0061] As an embodiment of the present invention, such as Figures 1 to 4 As shown, a fully automatic high-pressure airtightness detection and classification system for pressure relief valves also includes a classification tray 5 composed of high-grade trays, medium-grade trays and low-grade trays.

[0062] As an embodiment of the present invention, such as Figures 1 to 5 As shown, a fully automatic high-pressure airtightness detection and classification method for pressure relief valves includes the following steps:

[0063] S1. The feeding and sorting unit 2 automatically delivers the pressure relief valve to the testing fixture 38 of the high-pressure airtightness testing unit 3 and completes the clamping.

[0064] S2. Using the high-pressure air circuit system in the high-pressure air tightness detection unit 3, high-pressure gas of ≥15MPa is introduced into the pressure relief valve, and the inlet / outlet pressure values ​​of the pressure relief valve are detected in the non-powered and powered states.

[0065] S3. The host computer calculates the pressure difference and leakage rate based on the inlet / outlet pressure values ​​detected by the high-pressure airtightness detection unit. By comparing the leakage rate with the preset threshold, it determines the airtightness level of the pressure relief valve. The airtightness level includes three levels: high, medium and low.

[0066] S4. The feeding and sorting unit 2 automatically sorts the pressure relief valves to the corresponding discharge channels and sends them into the sorting tray 5 according to the airtightness level.

[0067] As an embodiment of the present invention, such as Figure 5 As shown, a fully automatic high-pressure airtightness detection and classification method for pressure relief valves also includes a data traceability step: using the data interaction module in the control system to synchronize the QR code, detection data, and classification results to the MES system to achieve traceability of the detection data.

[0068] As an embodiment of the present invention, such as Figures 1 to 5 As shown, a fully automatic high-pressure airtightness detection and classification method for pressure relief valves includes the following steps:

[0069] S1. Loading and clamping: The conveyor belt of the loading and sorting unit 2 transports the pressure relief valve to be tested to the testing station. The scanning and identification module scans the QR code through the scanning gun 25 to obtain the identity information and transmits it to the control system 4. The three-axis robotic arm with a pneumatic gripper 24 at the end grabs the pressure relief valve and clamps it to the sealing fixture 38 of the high pressure airtightness testing unit 3.

[0070] S2. High-pressure air tightness detection: The control system 4 controls the high-pressure air circuit system to introduce 18MPa high-pressure gas into the pressure relief valve. Pressure sensors 35 and 36 detect the leakage rate data in real time and feed it back to the control system 4.

[0071] S3. Performance Classification: The control system 4 classifies the pressure relief valve into three levels: high, medium, and low, based on leakage rate data and preset thresholds.

[0072] S4. Sorting and unloading: Based on the grading results, the robotic arm automatically sorts the pressure relief valves to the corresponding discharge channels and sends them into the sorting tray 5;

[0073] S5. Data Traceability: Control system 4 synchronizes identity information, detection data, and grading results to the MES system through the data interaction module to complete one detection process.

[0074] The preferred embodiments of the present application have been described above with reference to the accompanying drawings, but this does not limit the scope of the claims of the present application. Any modifications, equivalent substitutions, and improvements made by those skilled in the art without departing from the scope and substance of the embodiments of the present application shall be within the scope of the claims of the present application.

Claims

1. A fully automatic high-pressure airtightness detection and classification system for pressure relief valves, characterized in that: include: One rack; At least one high-pressure airtightness testing unit, including a testing fixture with a double-cylinder clamping structure and an electromagnet sealing structure, is used to test the airtightness of a pressure relief valve with a working pressure ≥15MPa; At least one feeding and sorting unit is used to automatically transport the pressure relief valve to the testing fixture of the high-pressure airtightness testing unit and complete the clamping during feeding; and to automatically sort the pressure relief valve and place it into the corresponding discharge channel during unloading. A control system is electrically connected to both the high-pressure airtightness detection unit and the feeding and sorting unit. The control system calculates the pressure difference and leakage rate based on the inlet / outlet pressure values ​​of the pressure relief valve under energized and de-energized conditions detected by the high-pressure airtightness detection unit. By comparing the leakage rate with a preset threshold, the control system determines the airtightness level of the pressure relief valve and sorts the valves to the corresponding discharge channels via the feeding and sorting unit according to the airtightness level. The airtightness level includes three grades: high, medium, and low.

2. The fully automatic high-pressure airtightness detection and classification system for pressure relief valves according to claim 1, characterized in that: The high-pressure airtightness detection unit also includes a high-pressure air circuit system for pressurizing the pressure relief valve, which has a built-in silencer for reducing noise when the high-pressure gas is released and a pressure sensor for detecting the pressure at the inlet and outlet of the pressure relief valve.

3. The fully automatic high-pressure airtightness detection and classification system for pressure relief valves according to claim 2, characterized in that: The feeding and sorting unit includes: The barcode scanning and recognition module uses a barcode scanner to scan the QR code on the pressure relief valve. It synchronizes with the MES system in real time via LabVIEW to bind the QR code and associate it with the detection data and grading results. The robotic arm handling module includes a three-axis servo robotic arm or a six-axis robot with a pneumatic gripper at the end for loading, clamping and sorting, in order to achieve precise positioning.

4. The fully automatic high-pressure airtightness detection and classification system for pressure relief valves according to claim 3, characterized in that: The control system includes a host computer, a slave computer communicating with the host computer, and a data interaction module connecting the host computer and the MES system via Ethernet communication. The host computer includes programs written in LabVIEW, C#, or Python for process control, data acquisition, QR code binding, and uploading to the MES system. The slave computer includes a PLC or motion control card for controlling the robotic arm, dual cylinders, electromagnets, and pressure sensors. The data interaction module synchronizes the pressure relief valve's QR code, detection time, leakage rate, and airtightness level to the MES system in real time to ensure traceability of the detection data.

5. The fully automatic high-pressure airtightness detection and classification system for pressure relief valves according to claim 4, characterized in that: The logic for comparing and judging the airtightness level is as follows: When the leakage rate is less than or equal to the first preset threshold, it is classified as a high-level leak. When the leakage rate is greater than the first preset threshold and less than or equal to the second preset threshold, it is judged as medium level; When the leakage rate exceeds the second preset threshold, it is judged as a low level.

6. The fully automatic high-pressure airtightness detection and classification system for pressure relief valves according to claim 5, characterized in that: It also includes a touch panel box that integrates a host computer, a human-computer interaction touch screen, a start button, a power-on button, and an emergency stop button.

7. The fully automatic high-pressure airtightness detection and classification system for pressure relief valves according to claim 6, characterized in that: It also includes categorized pallets consisting of high-grade pallets, medium-grade pallets, and low-grade pallets.

8. A fully automatic high-pressure airtightness detection and classification method for pressure relief valves, characterized in that: Includes the following steps: S1. The feeding and sorting unit automatically delivers the pressure relief valve to the testing fixture of the high-pressure airtightness testing unit and completes the clamping. S2. The high-pressure airtightness detection unit introduces high-pressure gas of ≥15MPa into the pressure relief valve and detects the inlet / outlet pressure values ​​of the pressure relief valve in the non-powered and powered states. S3. The control system calculates the pressure difference and leakage rate based on the inlet / outlet pressure values ​​detected by the high-pressure airtightness detection unit. By comparing the leakage rate with a preset threshold, it determines the airtightness level of the pressure relief valve and sorts the pressure relief valves to the corresponding discharge channels through the feeding and sorting unit according to the airtightness level. Among them, the airtightness level includes three levels: high, medium and low. S4. The feeding and sorting unit automatically sorts the pressure relief valves according to the airtightness level and places them into the corresponding discharge channels and sends them into the sorting trays.

9. The fully automatic high-pressure airtightness detection and classification method for pressure relief valves according to claim 8, characterized in that: It also includes a data traceability step: using the data interaction module in the control system to synchronize the QR code, test data, and grading results to the MES system to achieve traceability of test data.

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