A dryer load testing method and system

Abstract

The present application relates to a kind of dryer load test method and system, it is related to the field of dryer test, it includes obtaining current dryer model;Determine current valve number;Perform valve adjustment operation, and obtain current test air;Current test air temperature, current test air humidity are obtained, and reference test air temperature, reference test air humidity;Determine temperature and humidity coordinated adjustment parameter, and perform temperature and humidity adjustment operation;Open valve;Obtain reference operating parameter range;Perform valve adjustment operation, and obtain current dryer operating parameter;If current dryer operating parameter falls into reference operating parameter range, output dryer qualified signal;If current dryer operating parameter does not fall into reference operating parameter range, output dryer unqualified signal.The present application has the effect of significantly improving dryer test efficiency and accuracy.

Description

Technical Field

[0001] This invention relates to the field of dryer testing, and in particular to a dryer load testing method and system. Background Technology

[0002] Dryers are key equipment in industrial production, energy supply, and electronics manufacturing. Their core function is to remove moisture (or other impurities) from the gas being processed, bringing it to a preset dryness standard to prevent moisture from adversely affecting subsequent production processes, equipment operation, or product quality. Based on their working principles, dryers can be classified into various types, including adsorption, refrigeration, and membrane separation dryers. Different models of dryers exhibit significant differences in core performance parameters such as rated processing capacity, gas path design, regeneration media consumption, and drying efficiency. Therefore, standardized testing is required to verify their performance before shipment.

[0003] The testing quality of a dryer directly determines the product's factory pass rate and subsequent application reliability. In the existing technology, the dryer testing process usually includes steps such as initial operating condition setting, test gas introduction, regeneration process execution, index data collection, and pass / fail determination.

[0004] Regarding the aforementioned technologies, the initial temperature, pressure, and humidity are simply controlled during the testing process, without dynamic adjustment for real-time fluctuations in the temperature, humidity, and pressure of the test air. Changes in the temperature, pressure, and humidity of the gas can cause non-performance deviations in the operating parameters of the dryer, leading to misjudgments of whether the dryer is qualified. Summary of the Invention

[0005] To achieve dynamic adjustment of gas temperature and pressure during dryer testing, this invention provides a dryer load testing method and system.

[0006] In a first aspect, the present invention provides a method for testing the load of a dryer, employing the following technical solution:

[0007] A method for testing the load of a dryer, comprising:

[0008] Step 1: Obtain the current dryer model;

[0009] Step 2: Determine the current valve number based on the current dryer model;

[0010] Step 3: Perform valve adjustment operation based on the current valve number and obtain the current test air;

[0011] Step 4: Real-time acquisition of the current test air temperature, current test air humidity, and the reference test air temperature and reference test air humidity corresponding to the current dryer model;

[0012] Step 5: Based on the difference between the current test air temperature and the reference test air temperature, and the difference between the current test air humidity and the reference test air humidity, determine the temperature and humidity coordination adjustment parameters, and perform temperature and humidity adjustment operations according to the temperature and humidity coordination adjustment parameters;

[0013] Step 6: During the temperature and humidity adjustment operation, simultaneously open the valve corresponding to the import valve number of the current dryer model;

[0014] Step 7: Obtain the reference operating parameter range corresponding to the current dryer model;

[0015] Step 8: Perform valve adjustment operations based on the imported valve number, and obtain the current dryer operating parameters corresponding to the current dryer model;

[0016] Step 90: If the current dryer is running stably and the current dryer operating parameters fall within the reference operating parameter range, output the preset dryer qualified signal;

[0017] Step 91: If the current dryer is unstable or the current dryer operating parameters do not fall within the reference operating parameter range, output a preset dryer failure signal.

[0018] By adopting the above technical solution, the current test air temperature and humidity can be compared and analyzed with the reference test air temperature and humidity in real time to accurately determine the temperature and humidity adjustment parameters, and then execute the corresponding temperature and humidity adjustment operations. This process effectively solves the problem of non-performance deviations in dryer operating parameters caused by fluctuations in gas temperature, pressure, and humidity in traditional testing methods, and avoids misjudgments of dryer qualification due to these deviations.

[0019] Optionally, methods for performing valve adjustment operations based on the current valve number include:

[0020] Step 30: Determine the current required flow rate based on the current dryer model;

[0021] Step 31: Based on the current required flow rate, search in the preset valve flow rate database to determine the current valve group number and the corresponding valve group opening degree;

[0022] Step 32: Perform valve adjustment operations based on the current valve group number and the current valve group opening degree, and obtain the current flow rate in real time;

[0023] Step 33: Subtract the current demand flow from the current flow to obtain the current demand flow deviation;

[0024] Step 34: When there is a deviation in the current required flow rate, determine the adjustable amount based on the current valve group number and the current valve group opening degree;

[0025] Step 350: When the deviation of the current demand flow rate does not exceed the adjustable amount, determine the valve group opening adjustment parameter corresponding to the current valve group number based on the deviation of the current demand flow rate;

[0026] Step 351: Perform valve adjustment operation based on valve group opening adjustment parameters.

[0027] By adopting the above technical solution, the required flow rate can be accurately determined based on the current dryer model, and the corresponding valve group number and opening degree can be precisely found according to the preset valve flow rate library, thereby performing valve adjustment operations. During the adjustment process, the current flow rate is acquired in real time and compared with the required flow rate to obtain the required flow rate deviation. When the deviation is within the adjustable range, the valve group opening adjustment parameters can be accurately determined based on the deviation, and the corresponding valve adjustment operation can be performed, thereby ensuring the accuracy and effectiveness of valve adjustment and providing stable airflow conditions for subsequent dryer testing.

[0028] Optionally, it also includes a method for performing valve adjustment when the current demand flow deviation exceeds the adjustable amount, the method comprising:

[0029] Step 360: When the deviation of the current demand flow exceeds the adjustable amount, determine the correction valve group number based on the deviation of the current demand flow.

[0030] Step 361: When a correction valve group number exists, determine the opening degree of the correction valve group based on the current required flow rate;

[0031] Step 362: Perform valve adjustment operation based on the corrected valve group number and the corrected valve group opening degree, and obtain the corrected current flow rate in real time;

[0032] Step 363: Subtract the current demand flow from the corrected current flow to obtain the corrected current demand flow deviation;

[0033] Step 364: Determine the adjustable amount of correction based on the current required flow deviation, and determine the adjustment parameters of the valve group opening based on the adjustable amount of correction;

[0034] Step 365: Perform valve adjustment operation based on the corrected valve group number and the corrected valve group opening adjustment parameters.

[0035] By adopting the above technical solution, if the deviation of the current demand flow exceeds the adjustable range, the corrective valve group number can be quickly determined based on the deviation, and the opening degree of the corrective valve group can be accurately calculated based on the current demand flow. Subsequently, the valve adjustment operation is performed, and the corrected current flow is acquired in real time. The deviation of the current demand flow is obtained by subtracting it from the current demand flow. Furthermore, the corrected adjustable range is determined based on the corrected deviation, and the final corrective valve group opening adjustment parameters are determined accordingly. The valve adjustment operation is then performed again. This process ensures that even when the demand flow deviation is large, precise control of valve adjustment can be achieved by dynamically correcting the valve group number and opening parameters, effectively coping with complex and changing test conditions and ensuring the stability and reliability of the dryer testing process.

[0036] Optionally, it also includes a method for obtaining the regeneration gas consumption corresponding to the current dryer model, the method comprising:

[0037] Step 700: Real-time acquisition of current test temperature, baseline test temperature, and regeneration gas consumption;

[0038] Step 701: Substitute the regeneration gas consumption, the current test temperature, and the reference test temperature into the gas correction formula to determine the corrected regeneration gas consumption. The gas correction formula is: Q 标 =Q 实 ×(T 标 +273) / (T) 实 +273), where Q 标 To correct the regeneration gas consumption, Q 实 For regeneration gas consumption, T 标 As the reference test temperature, T 实 The current test temperature;

[0039] Step 702: Output the corrected regeneration gas consumption as the regeneration gas consumption.

[0040] By adopting the above technical solution, the current test temperature and the reference test temperature can be obtained in real time, and the regeneration gas consumption can be corrected using a gas correction formula. This eliminates the measurement error in regeneration gas consumption caused by the inconsistency between the test temperature and the reference temperature. This ensures the accuracy and reliability of the regeneration gas consumption data, thereby improving the accuracy and effectiveness of dryer testing.

[0041] Optionally, it also includes a method for performing temperature, pressure, and humidity adjustment operations, the method comprising:

[0042] Step 703: Determine the curve of the change in current demand flow deviation based on the current demand flow deviation;

[0043] Step 704: Determine the rate of change of the current demand flow deviation based on the current demand flow deviation change curve;

[0044] Step 705: When the rate of change of the current demand flow deviation falls within the preset unstable flow fluctuation range, perform a coarse adjustment operation of the booster frequency flow and output a preset unstable flow status signal.

[0045] Step 706: In response to the unstable flow status signal, the expected temperature adjustment, expected humidity adjustment and expected pressure adjustment are determined in real time by searching the preset temperature, pressure and humidity curve library based on the current dryer model and the rate of change of the current required flow deviation.

[0046] Step 7060: Determine the expected dryer operating parameters based on the expected temperature adjustment, expected humidity adjustment, expected pressure adjustment, and current dryer operating parameters;

[0047] Step 7061: When the expected dryer operating parameters do not fall within the reference operating parameter range, output a manual signal;

[0048] Step 707: When the expected dryer operating parameters fall within the reference operating parameter range, perform temperature, pressure and humidity adjustment operations based on the expected temperature adjustment, expected humidity adjustment and expected pressure adjustment.

[0049] By adopting the above technical solution, the dynamic trend of flow deviation is monitored in real time. When the flow fluctuation exceeds the stable range, the flow is first coarsely adjusted by regulating the frequency of the booster compressor. Then, based on the dryer model and flow fluctuation characteristics, the optimal adjustment parameters are matched from the temperature, pressure, and humidity curve library to perform triple coordinated regulation of temperature, pressure, and humidity. This process not only solves the problem of humidity-related fluctuations caused by relying solely on temperature and pressure flow regulation, but also ensures that multiple parameters such as temperature, pressure, humidity, and flow meet the standards during the test by quickly stabilizing the operating conditions, thereby improving test accuracy and efficiency.

[0050] Optionally, it also includes a method for gas recovery operation, the method comprising:

[0051] Step 708: Real-time collection and testing of exhaust gas volume;

[0052] Step 709: When the test exhaust gas volume exceeds the preset recovery threshold, locate the preset recovery valve number;

[0053] Step 710: Perform valve adjustment operation based on the recovered valve number;

[0054] Step 711: After the valve adjustment operation, collect the amount of recovered gas in real time;

[0055] Step 712: Determine the current corrected flow rate based on the amount of recovered gas and the current flow rate demand;

[0056] Step 713: Determine the valve group number to be adjusted when there is a current correction requirement flow rate;

[0057] Step 714: Determine the valve group opening degree corresponding to the valve group number to be adjusted based on the current corrected flow rate;

[0058] Step 715: Perform gas recovery operation based on the valve group number to be adjusted and the valve group opening degree.

[0059] By adopting the above technical solution, the exhaust gas emission is monitored in real time. When the emission exceeds the recovery threshold, the recovery process is automatically initiated, and the exhaust gas is introduced into the test gas path for recycling through a dedicated recovery valve assembly. At the same time, the required flow rate is dynamically adjusted based on the amount of recovered gas, and the valve assembly opening and closing degree is rematched to achieve coordinated control of exhaust gas recovery and flow stability.

[0060] Optionally, it also includes a method for performing temperature, pressure, and humidity adjustment operations during the gas recovery operation, the method comprising:

[0061] Step 7150: During the gas recovery operation, determine the gas to be recovered and the test gas;

[0062] Step 7151: Obtain the temperature, pressure, and humidity parameters of the recovered gas and the temperature, pressure, and humidity parameters of the test gas;

[0063] Step 7152: Determine the temperature, pressure, and humidity deviation rate based on the temperature, pressure, and humidity parameters of the recovered gas and the test gas;

[0064] Step 7153: When the temperature, pressure and humidity deviation rate exceeds the preset maximum temperature, pressure and humidity deviation rate threshold, determine the recovery gas temperature adjustment amount, recovery gas pressure adjustment amount and recovery gas humidity adjustment amount based on the temperature, pressure and humidity deviation rate.

[0065] Step 7154: Perform temperature, pressure and humidity adjustment operations based on the recovered gas temperature adjustment amount, recovered gas pressure adjustment amount and recovered gas humidity adjustment amount.

[0066] By employing the above technical solution, the recovered gas and the test gas are clearly distinguished, and their temperature, pressure, and humidity parameters are collected separately. By comparing these two sets of data, the system can accurately calculate the temperature, pressure, and humidity deviation rate. Once the temperature, pressure, and humidity deviation rate exceeds the preset safety range, the system will immediately determine the required temperature, pressure, and humidity adjustments for the recovered gas based on the magnitude of the deviation rate. Subsequently, the system will perform corresponding temperature, pressure, and humidity adjustments for the recovered gas based on these adjustments to ensure the stability and accuracy of the gas temperature and pressure throughout the testing process, thereby further improving the reliability and effectiveness of the dryer test.

[0067] Optionally, a correction method for the temperature, pressure, and humidity curve library is also included, which includes:

[0068] Step 7070: Determine the end time of temperature, pressure and humidity adjustment based on the current demand flow deviation and the rate of change of the current demand flow deviation;

[0069] Step 7071: Stop the temperature, pressure and humidity adjustment operation based on the end time of the temperature, pressure and humidity adjustment, and obtain the rate of change of the current required flow deviation.

[0070] Step 7072: When the rate of change of the current demand flow deviation falls within the range of unstable flow fluctuation, output the preset temperature, pressure and humidity curve library adjustment signal;

[0071] Step 7073: In response to the temperature, pressure and humidity curve library adjustment signal, perform automatic temperature, pressure and humidity adjustment operation based on the rate of change of the current demand flow deviation until the rate of change of the current demand flow deviation does not fall within the range of unstable flow fluctuations.

[0072] Step 7074: Record the adjustment records corresponding to the automatic temperature, pressure and humidity adjustment operations in real time;

[0073] Step 7075: Update the temperature, pressure and humidity curve library based on the adjustment records.

[0074] By employing the above technical solution, the system can determine the timing for ending temperature, pressure, and humidity adjustments by combining the current demand flow deviation and its rate of change. After stopping the temperature, pressure, and humidity adjustment operation, the system will further acquire and evaluate the corrected rate of change of the demand flow deviation. If this rate of change is still within an unstable range, the system will automatically output a temperature, pressure, and humidity curve library adjustment signal, triggering an automatic temperature, pressure, and humidity adjustment process. This process will continue until the rate of change of the demand flow deviation stabilizes within a preset range. During this process, the system will record the specific parameters and effects of each adjustment operation in real time, forming a detailed adjustment record. Finally, based on these adjustment records, the system will update and optimize the temperature, pressure, and humidity curve library to ensure that it can more accurately reflect the gas temperature and pressure changes during the actual testing process, thereby improving the accuracy and stability of subsequent dryer tests.

[0075] Optionally, it also includes a method for performing anticipated temperature, pressure, and humidity adjustment operations, the method comprising:

[0076] Step 7076: During the process of collecting test exhaust gas, search the temperature, pressure and humidity adjustment parameters of the most recent recovery scenario corresponding to the current dryer model in the temperature, pressure and humidity curve library;

[0077] Step 7077: Determine the test exhaust gas volume growth rate based on the test exhaust gas volume;

[0078] Step 7078: Determine the adjustment window time point based on the test exhaust gas volume, the test exhaust gas volume growth rate, and the recovery threshold;

[0079] Step 7079: When the adjustment window time point is reached, import the temperature, pressure and humidity adjustment parameters of the most recent recovery scene and perform the expected temperature, pressure and humidity adjustment operation;

[0080] Step 7080: When the temperature, pressure and humidity deviation rate exceeds the maximum temperature, pressure and humidity deviation rate threshold during the execution of the expected temperature, pressure and humidity adjustment operation, determine the recovery gas temperature adjustment amount, recovery gas humidity adjustment amount and recovery gas pressure adjustment amount based on the temperature, pressure and humidity deviation rate, and execute step 7154.

[0081] By adopting the above technical solution, historical temperature, pressure, and humidity adjustment parameters for recovery scenarios are retrieved in advance during the exhaust gas collection process. Combined with the exhaust gas growth rate, the triggering timing of the recovery threshold is predicted, and the expected temperature, pressure, and humidity adjustments are initiated ahead of time. If parameter deviations exceed limits during the predicted adjustment process, a real-time correction mechanism is immediately activated to ensure that the temperature, pressure, and humidity parameters seamlessly adapt to the test conditions when the recovered gas is introduced. This avoids operational fluctuations and waiting during the recovery process, shortens the test cycle, and ensures the stability and accuracy of the test indicators.

[0082] Secondly, the present invention provides a dryer load testing system, which adopts the following technical solution:

[0083] A dryer load testing system, comprising:

[0084] The acquisition module is used to obtain the current dryer model;

[0085] A memory for storing a program for a dryer load testing method as described above;

[0086] The processor loads and executes programs from memory.

[0087] By adopting the above technical solution, the acquisition module can accurately capture the model of the dryer currently being tested, providing basic data support for subsequent testing procedures. The memory stores the complete program for the dryer testing method detailed above. This program covers all operational steps after temperature and pressure debugging, including valve adjustment, temperature and pressure regulation, acquisition and processing of regeneration gas consumption, gas recovery, and correction of temperature, pressure, and humidity curves. The processor, as the core computing unit of the system, loads and executes the program stored in the memory, strictly following the preset logic and steps to precisely control and process data at each stage of the dryer testing process. This ensures the entire dryer testing system operates stably, accurately, and efficiently, thereby achieving accurate evaluation and reliable testing of the dryer's performance.

[0088] In summary, the present invention has at least one of the following beneficial technical effects:

[0089] 1. By dynamically adjusting the temperature and pressure of the test air in real time, calibrating the regeneration gas consumption using a gas correction formula, and accurately matching the temperature and pressure parameters of the recovered gas and the test gas in the recovery scenario, the non-performance deviation of the core indicators caused by temperature and pressure fluctuations is completely eliminated, avoiding misjudgment of pass or fail, and ensuring the authenticity and reliability of the dryer performance evaluation results.

[0090] 2. On the one hand, the flow rate demand can be quickly adapted by dynamically combining and adjusting the valve group, reducing the time spent on adjusting the operating conditions; on the other hand, the test exhaust gas can be recovered and reused, and the temperature and pressure adaptation can be started in advance by predicting the adjustment window, which not only saves the consumption of test gas source, but also avoids the waiting for the operating condition oscillation when the recovered gas is introduced, which greatly improves the test efficiency and environmental economy.

[0091] 3. Construct a dynamic correction mechanism for temperature, pressure, and humidity curves. Parameters are optimized and adjusted in reverse using actual stable data to make subsequent tests more accurate. At the same time, it covers multiple scenarios such as routine testing and test exhaust gas recovery. It adapts to different working conditions through dedicated temperature and pressure adjustment logic. The entire process is standardized and automatically executed to reduce manual intervention and ensure the consistency of results and process stability for different models of dryers and different test batches. Attached Figure Description

[0092] Figure 1 This is a flowchart of a dryer load testing method in an embodiment of this application. Detailed Implementation

[0093] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0094] This invention discloses a method for testing the load of a dryer. (Refer to...) Figure 1 A method for testing the load of a dryer includes:

[0095] Step 1: Obtain the current dryer model.

[0096] The current dryer model refers to the specific type of dryer determined by scanning a preset equipment identification code using a pre-set camera. Here, we need to introduce the dryer load testing method, which is compatible with three operating conditions: Condition 1 (pressurized circulation and flow regulation operation), Condition 2 (pressurized humidification and temperature control circulation operation), and Condition 3 (pressurized humidification and heating circulation operation). Condition 2 is based on Condition 1, implementing humidification and temperature control, while Condition 3 adds a heating element to Condition 2 to simulate the inlet conditions of a compression heat dryer. The system automatically matches the corresponding operating condition based on the current dryer model.

[0097] Step 2: Determine the current valve number based on the current dryer model.

[0098] The current valve number is a unique identifier for the functional valve used to control the opening and closing of the test gas path, which is uniquely matched with the dryer model. The system has a valve configuration table. Different dryer models have different inlet diameters and gas path designs, so the corresponding valve specifications (such as DN50 / DN80 diameter valves) and installation positions are different. The valve configuration table marks the exclusive control valve of each model with a unique number.

[0099] Step 3: Perform valve adjustment operation based on the current valve number and obtain the current test air.

[0100] Valve adjustment operation refers to the precise on / off and opening adjustment actions performed according to the dryer's test air circuit requirements. The current test air refers to the gas medium that enters the dryer's test chamber after the valve adjustment operation, conforming to the basic test conditions for this model. Here, the pre-set air compressor needs to be turned on to replenish and pressurize the system until the system pressure reaches the reference pressure corresponding to the current dryer model, then the air compressor is turned off; then the pre-set booster compressor is started to circulate the gas within the system. A reference flow rate is set via PID control, and the test air flow rate is collected in real time and the valve opening is automatically adjusted to the reference flow rate. When testing equipment with air consumption, the air compressor is started to replenish the system, and the valve opening is adjusted simultaneously to maintain the reference flow rate and reference pressure.

[0101] Step 4: Real-time acquisition of the current test air temperature, current test air humidity, and the reference test air temperature and reference test air humidity corresponding to the current dryer model.

[0102] The current test air temperature refers to the instantaneous temperature value of the test air entering the dryer's test chamber, as collected in real time by a temperature sensor installed downstream of the test chamber's air inlet. The current test air humidity refers to the instantaneous relative humidity value of the test air entering the dryer's test chamber, as collected in real time by a humidity sensor installed downstream of the test chamber's air inlet.

[0103] The benchmark air temperature and humidity refer to the air temperature and humidity reference values ​​that conform to the current dryer model's testing standards and the GB / T10893-2025 standard. These values ​​are determined jointly by the dryer's design operating conditions, installation location, and standard requirements. The GB / T10893-2025 standard specifies that the commonly used test condition benchmark for general-purpose dryers is 38℃ saturated compressed air at 7 barg, which is suitable for most industrial scenarios and dryer tests without special requirements. Other operating conditions are determined based on the actual application scenario.

[0104] Step 5: Based on the difference between the current test air temperature and the reference test air temperature, and the difference between the current test air humidity and the reference test air humidity, determine the temperature and humidity coordination adjustment parameters, and perform temperature and humidity adjustment operations according to the temperature and humidity coordination adjustment parameters.

[0105] Temperature and humidity coordinated adjustment parameters refer to the specific parameters used to control the operation of the temperature control module and the humidification module, calculated by comprehensively considering the differences between the current test air temperature and the reference temperature, and the differences between the current test air humidity and the reference humidity. For example, if the current temperature is 35℃, which is lower than the reference temperature of 38℃, the calculated adjustment parameters are: heating direction, power increase of 20%, and continuous adjustment for 30 seconds. Temperature adjustment operation refers to the specific actions performed by the temperature control module in response to the temperature adjustment parameters. If the current test condition is condition 2 or 3, temperature regulation can be performed through pre-set water chiller, heat exchanger, heater, and humidification nozzle. Specifically, turn on the water chiller, set the cooling water temperature, and control the test air temperature through the heat exchanger; turn on the heater and set the air heating temperature to increase the gas temperature, which is beneficial for humidification; turn on the humidification nozzle to humidify the heated test air in the humidification tank; the humidified gas flows into the heat exchanger, the temperature decreases, liquid water precipitates out, flows out from the filter, the gas is saturated, and humidification is complete; set the temperature of the gas after cooling by the heat exchanger, and automatically control the water flow into the heat exchanger through PID control valve opening to achieve the purpose of temperature and humidity control, so that the test gas is stabilized at the reference test air temperature.

[0106] Step 6: During the temperature and humidity adjustment operation, simultaneously open the valve corresponding to the import valve number of the current dryer model.

[0107] The valve number refers to the valve identifier in the valve configuration table that uniquely matches the regeneration gas path of the current dryer model. The regeneration gas path refers to the gas path that controls the entry of regeneration gas (the gas that reactivates the adsorbent) into the regeneration chamber of the dryer. The core of the dryer relies on the internal adsorbent to absorb moisture from the air. However, once the adsorbent is saturated with water, it becomes ineffective. It needs to be blown through the adsorbent with dry regeneration gas to remove the moisture and restore its drying capacity. This is a crucial step in testing the dryer's performance. The test air mentioned earlier refers to the air entering the dryer's test chamber, which is the air to be processed by the dryer.

[0108] Step 7: Obtain the reference operating parameter range corresponding to the current dryer model.

[0109] The reference operating parameter range refers to the set of comprehensive performance judgment reference intervals pre-stored by the system and adapted to the current dryer model. It includes at least the reference regeneration gas consumption range, reference pressure dew point range, reference test gas pressure drop range, reference capacity consumption range, and reference gas outlet temperature range that meet the requirements of GB / T10893-2025 standard. Each reference sub-range is determined in combination with the dryer model design parameters, rated operating capacity, and national standards. Due to differences in structure and operating condition adaptability, the numerical ranges of each reference sub-range are different for different dryer models.

[0110] Step 8: Perform valve adjustment operation based on the imported valve number, and obtain the current dryer operating parameters corresponding to the current dryer model.

[0111] The current dryer operating parameters refer to the set of comprehensive dryer performance data corresponding to the baseline operating parameter range, which are collected and calculated in real time by corresponding testing equipment during the testing process. These data include regeneration gas consumption, pressure dew point, test gas path pressure drop, actual capacity consumption, and gas outlet temperature. Specifically: regeneration gas consumption is statistically analyzed in real time by a regeneration gas path flow meter; pressure dew point is detected by a dew point meter at the test chamber outlet; test gas path pressure drop is calculated from the difference between the values ​​collected by the pressure sensors at the dryer's inlet and outlet; actual capacity consumption is monitored according to existing dryer testing technical specifications, monitoring the energy consumption of the entire dryer (which may include components such as blowers, heaters, and control cabinets); and gas outlet temperature is collected in real time by a temperature sensor installed at the dryer's test chamber outlet.

[0112] Step 90: If the current dryer is running stably and the current dryer operating parameters fall within the reference operating parameter range, output the preset dryer qualified signal.

[0113] The dryer qualification signal refers to the judgment signal generated by the system based on a comprehensive comparison of the current dryer operating parameters with the reference operating parameter range, indicating that the dryer's performance meets the standards. Stable current dryer operation means that the various parameters of the current dryer operation remain relatively stable over a period of time, with fluctuations within an acceptable range, and without drastic changes or abnormal fluctuations.

[0114] If the current operating parameters of the dryer fall within the range of the baseline operating parameters, it means that the dryer, under the test conditions, meets the design standards and the requirements of GB / T10893-2025 standard in terms of regeneration economy (regeneration gas consumption), core drying effect (pressure dew point), gas path operation stability (pressure drop), energy consumption level (actual capacity consumption), and outlet gas quality (outlet temperature), and its comprehensive performance meets the standards.

[0115] Step 91: If the current dryer is unstable or the current dryer operating parameters do not fall within the reference operating parameter range, output a preset dryer failure signal.

[0116] The dryer failure signal refers to the judgment signal generated by the system based on the comparison results between the current dryer operating parameters and the reference operating parameter range, indicating that the dryer performance has not met the standard.

[0117] The current instability of the dryer operation refers to the frequent and significant fluctuations in various operating parameters during the testing process, making it impossible to maintain a relatively stable state within a certain period of time. For example, the regeneration gas consumption fluctuates by more than ±10% of the baseline regeneration gas consumption range within a short period of time, and this fluctuation is not caused by normal operating condition adjustments.

[0118] If the current dryer is unstable or its operating parameters do not fall within the reference operating parameter range, it means that at least one of the dryer's comprehensive performance indicators does not meet the design standards or national standards. This may be due to problems such as insufficient adsorbent performance, gas path design defects, or abnormal energy consumption control, making it unsuitable for direct industrial application.

[0119] The methods for performing valve adjustment operations based on the current valve number include:

[0120] Step 30: Determine the current required flow rate based on the current dryer model.

[0121] The current required flow rate refers to the gas volumetric flow rate that needs to be maintained during the test, determined by a preset flow rate mapping table based on the design parameters and testing standards of the current dryer model. This parameter is jointly determined by the rated processing capacity of the dryer model, the test operating conditions, and industry standards. For example, a dryer of model A needs to maintain a test flow rate of 50 m³ / h under standard operating conditions.

[0122] Step 31: Based on the current required flow rate, search in the preset valve flow rate database to determine the current valve group number and the corresponding valve group opening degree.

[0123] The valve flow library refers to a comprehensive database pre-stored in the system, containing flow rate and opening characteristic data of individual valves, as well as flow rate superposition algorithms for valve combinations. The library pre-records the basic characteristic curves of each independent valve under standard test conditions (such as standard pressure difference and medium temperature). For example, under standard conditions, the flow rate corresponding to an opening of 10% to 100% for valve V1 is 1 to 10 m³ / h, and the flow rate corresponding to an opening of 10% to 100% for valve V2 is 2 to 20 m³ / h. It should be noted that these characteristic curves are calibration values ​​under standard conditions; in actual applications, the flow rate at the same opening will fluctuate due to changes in pressure difference across the valve, medium temperature and pressure, and other operating conditions.

[0124] Meanwhile, the library includes a built-in flow superposition algorithm that can calculate the required opening degree of each valve after combining any number of valves to approximate the target flow rate, based on the required flow rate and current actual operating parameters. It supports selecting suitable combinations from all valves in the system. Among them, the valve flow library adapted to operating conditions 2 or 3 additionally includes the flow rate and opening degree correlation characteristics of humidifiers, heat exchangers, and auxiliary heaters (also based on standard operating condition calibration).

[0125] The current valve group number refers to the set of identifiers of suitable valves temporarily selected and combined from all available valves by the system based on the current demand flow. The current valve group opening degree refers to the independent opening degree value of each valve calculated by the system for any valve in the temporary combination.

[0126] Step 32: Perform valve adjustment operation based on the current valve group number and the current valve group opening degree, and obtain the current flow rate in real time.

[0127] Current flow rate refers to the actual volumetric flow rate of the gas collected in real time by a flow meter installed on the main pipeline of the test gas line.

[0128] Step 33: Calculate the difference between the current demand flow and the current flow to obtain the current demand flow deviation.

[0129] The current demand flow deviation refers to the difference between the current demand flow and the current flow. A positive deviation indicates that the actual flow is lower than the demand value, and the valve opening needs to be increased; a negative deviation indicates that the actual flow is higher than the demand value, and the valve opening needs to be decreased.

[0130] Step 34: When there is a deviation in the current required flow rate, determine the adjustable amount based on the current valve group number and the current valve group opening degree.

[0131] Adjustable range refers to the sum of the flow adjustment ranges of any valve in the current temporary combination within its mechanical limits.

[0132] Step 350: When the deviation of the current demand flow rate does not exceed the adjustable amount, determine the valve group opening adjustment parameter corresponding to the current valve group number based on the deviation of the current demand flow rate.

[0133] If the current demand flow deviation does not exceed the adjustable amount, it means that any valve in the current temporary combination does not need to be replaced. The flow deviation can be made up by simply adjusting the opening of each valve in the group. Therefore, the valve group opening adjustment parameter corresponding to the current valve group number is determined based on the current demand flow deviation.

[0134] Step 351: Perform valve adjustment operation based on valve group opening adjustment parameters.

[0135] When valve group opening adjustment parameters exist, it means that the current combination valves can meet the flow requirements by fine-tuning the opening. At this time, valve adjustment operation is performed based on valve group opening adjustment parameters.

[0136] This also includes a method for performing valve adjustment when the current demand flow deviation exceeds the adjustable amount, the method comprising:

[0137] Step 360: When the deviation of the current demand flow exceeds the adjustable amount, determine the correction valve group number based on the deviation of the current demand flow.

[0138] The corrected valve group number refers to the set of arbitrary valve identifiers formed by the system re-selecting and temporarily combining all available valves based on the current demand flow deviation when the current temporary combination of valve groups has insufficient regulating capacity.

[0139] If the current demand flow deviation exceeds the adjustable amount, it means that even if the opening of any valve in the current temporary combination is adjusted to the mechanical limit, it is impossible to make up for the flow deviation. Simply fine-tuning the original combination of valves is no longer enough to meet the current demand flow. It is necessary to replace the combination members, such as adding, replacing or reducing valves, to form a new valve group with stronger regulation capabilities.

[0140] Step 361: When a correction valve group number exists, determine the opening degree of the correction valve group based on the current required flow rate.

[0141] The corrected valve group opening degree refers to the initial opening degree value of each valve in the group calculated individually by the system for the recombined corrected valve group based on the current demand flow and the flow superposition algorithm.

[0142] Step 362: Perform valve adjustment operation based on the corrected valve group number and the corrected valve group opening degree, and obtain the corrected current flow rate in real time.

[0143] Corrected current flow rate refers to the actual volumetric flow rate value output by the new combination valves, which is collected in real time by the flow meter of the main gas pipeline after the adjustment operation of the correction valve group is performed.

[0144] Step 363: Subtract the current demand flow from the corrected current flow to obtain the corrected current demand flow deviation.

[0145] The corrected current demand flow deviation refers to the difference between the current demand flow and the corrected current flow. Because the combined valve group may experience flow attenuation due to the superposition of air resistance, the valve opening degree needs to be adjusted according to the corrected current demand flow deviation.

[0146] Step 364: Determine the adjustment amount based on the current required flow deviation, and determine the adjustment parameters for the valve group opening based on the adjustment amount.

[0147] The adjustable range of the correction refers to the sum of the flow regulation ranges of each valve in the correction valve group within the safe range of mechanical structure and air circuit. The valve group opening adjustment parameters refer to the specific adjustment parameters of each valve in the correction valve group calculated by the system based on the deviation of the current required flow rate.

[0148] Step 365: Perform valve adjustment operation based on the corrected valve group number and the corrected valve group opening adjustment parameters.

[0149] When there is a corrected valve group number and a corrected valve group opening adjustment parameter, it means that the new combination of corrected valve groups needs to be adjusted in opening to meet the flow requirements. At this time, valve adjustment operation is performed based on the corrected valve group number and the corrected valve group opening adjustment parameter.

[0150] This also includes a method for obtaining the regeneration gas consumption corresponding to the current dryer model, the method comprising:

[0151] Step 700: Real-time acquisition of current test temperature, baseline test temperature, and regeneration gas consumption.

[0152] The current test temperature refers to the gas temperature value collected in real time by the temperature sensor installed at the outlet of the regeneration gas path during the regeneration process. It is a key environmental parameter that affects the measured volume of regeneration gas consumption.

[0153] The reference test temperature refers to the standard temperature reference value pre-stored by the system and used to correct the gas volume.

[0154] Regeneration gas consumption refers to the volume of finished gas consumed by a portion of the dryer during the regeneration of the adsorption tower. Typically, this portion of the finished gas is desorbed from the adsorbent inside the tower through pressure reduction or heating, and then discharged directly from the regeneration gas path after regeneration is complete. Data is collected in real-time using a flow meter in the regeneration gas path.

[0155] Step 701: Substitute the regeneration gas consumption, current test temperature, and reference test temperature into the gas correction formula to determine the corrected regeneration gas consumption. The gas correction formula is: Q 标 =Q 实 ×(T 标 +273) / (T) 实 +273), where Q 标 To correct the regeneration gas consumption, Q 实 For regeneration gas consumption, T 标 As the reference test temperature, T 实 This is the current test temperature.

[0156] Corrected regeneration gas consumption refers to the regeneration gas consumption under standard temperature conditions obtained by using a gas correction formula to eliminate the influence of the current test temperature on the measured value of regeneration gas consumption.

[0157] Step 702: Output the corrected regeneration gas consumption as the regeneration gas consumption.

[0158] This also includes a method for performing temperature, pressure, and humidity adjustment operations, the method comprising:

[0159] Step 703: Determine the curve of the change in current demand flow deviation based on the current demand flow deviation.

[0160] The current demand flow deviation curve is a real-time chart that plots time on the horizontal axis and the current demand flow deviation on the vertical axis, reflecting the dynamic change of flow deviation over time.

[0161] Step 704: Determine the rate of change of the current demand flow deviation based on the current demand flow deviation change curve.

[0162] The rate of change of the current demand flow deviation refers to the magnitude of change in the current demand flow deviation per unit time. It is obtained by calculating the ratio of the difference in deviation between adjacent time points in the curve to the time interval. This parameter reflects the dynamic adjustment trend of the flow deviation. For example, when the deviation increases at a rate of 2 m³ / h per second, it indicates that the actual flow is continuously lower than the demand value and the gap is widening, requiring a faster adjustment of the valve opening to avoid flow shortage. Conversely, if the deviation decreases at a rate of 1.5 m³ / h per second, it indicates that the actual flow is gradually approaching the demand value, and the adjustment frequency can be appropriately slowed down.

[0163] Step 705: When the rate of change of the current demand flow deviation falls within the preset unstable flow fluctuation range, perform a coarse adjustment operation of the booster frequency flow and output a preset unstable flow status signal.

[0164] The unstable flow fluctuation range refers to a pre-defined numerical range used by the system to define whether the rate of change of flow deviation is abnormal. This range is determined by the design characteristics of the dryer model, the stability requirements of the test conditions, and industry experience. For example, if the rate of change of flow deviation exceeds ±3 m³ / h / s under standard operating conditions, the flow state of a certain dryer model is considered unstable. The booster frequency and flow coarse adjustment operation refers to the initial adjustment operation of the system dynamically adjusting the booster operating frequency to quickly correct the airflow when the rate of change of the current demand flow deviation falls within the unstable flow fluctuation range. This adjustment is based on the rated flow characteristics of the current dryer model, the magnitude of the current demand flow deviation, and the rate of change of the deviation. For example, when the flow deviation increases rapidly, the booster speed is increased by a preset frequency increment; when the flow deviation decreases rapidly, the booster speed is decreased by a preset frequency decrement. This technology is common knowledge in the field and will not be elaborated further here.

[0165] The unstable flow status signal refers to the warning signal output by the system in response to drastic fluctuations in flow, which is used to trigger adjustments in temperature, pressure, and humidity.

[0166] Step 706: In response to the unstable flow status signal, the expected temperature adjustment, expected humidity adjustment, and expected pressure adjustment are determined in real time by searching the preset temperature, pressure, and humidity curve library based on the current dryer model and the rate of change of the current required flow deviation.

[0167] The temperature, pressure, and humidity curve library refers to a pre-stored database containing the corresponding relationships between five parameters: dryer model, flow deviation rate, temperature adjustment, humidity adjustment, and pressure adjustment. The data originates from extensive experimental verification. The expected temperature adjustment is the target temperature change value matched from the temperature, pressure, and humidity curve library to suppress flow fluctuations. The adjustment direction adapts to the flow fluctuation trend. For example, when the flow rate increases rapidly, the temperature needs to be lowered to suppress gas expansion, and the expected temperature adjustment is set to -2℃; when the flow rate decreases rapidly, the temperature needs to be raised to compensate for gas contraction, and the adjustment is set to +1.5℃. The expected humidity adjustment is the target humidity change value matched from the temperature, pressure, and humidity curve library to stabilize the flow rate. Humidity adjustments are also based on flow fluctuations. For example, when the flow rate increases rapidly, appropriately increasing humidity can suppress excessive gas expansion to some extent, assuming the expected humidity adjustment is set to +3%; when the flow rate decreases rapidly, lowering humidity helps the gas flow better, and the expected humidity adjustment is set to -2%. The expected pressure adjustment refers to the target pressure change value matched from the temperature-pressure-humidity curve library, which works in conjunction with the expected temperature adjustment. It forms a linkage effect with the temperature adjustment, either increasing or decreasing simultaneously. For example, when the temperature is adjusted by -2℃, the pressure increases by 0.05MPa simultaneously. Through the synergy of temperature and pressure, the gas path resistance is stabilized, thereby suppressing flow fluctuations.

[0168] Step 7060: Determine the expected dryer operating parameters based on the expected temperature adjustment, expected humidity adjustment, expected pressure adjustment, and current dryer operating parameters;

[0169] The expected operating parameters of a dryer refer to the anticipated values ​​of various parameters of the dryer during subsequent operation, which are estimated based on the dryer's model, structural characteristics, operating principle, and various working conditions during the testing process, taking into account factors such as the expected temperature adjustment, the expected humidity adjustment, and the expected pressure adjustment.

[0170] Step 7061: When the expected dryer operating parameters do not fall within the reference operating parameter range, output a manual signal.

[0171] Manual signals refer to intervention alerts issued by the system to operators when it detects that the expected operating parameters of the dryer are outside the safe and reasonable range, which may lead to equipment failure or inaccurate test results.

[0172] When the expected operating parameters of the dryer do not fall within the range of the reference operating parameters, it indicates that the dryer cannot meet the parameter requirements for normal operation when running according to the expected temperature, humidity and pressure adjustments. There may be problems such as unstable performance or equipment failure. At this time, the unstable flow status signal cannot be adjusted by the system itself, so a manual signal needs to be output.

[0173] Step 707: When the expected dryer operating parameters fall within the reference operating parameter range, perform temperature, pressure and humidity adjustment operations based on the expected temperature adjustment, expected humidity adjustment and expected pressure adjustment.

[0174] Temperature, pressure, and humidity adjustment refers to the targeted adjustment actions performed by the temperature control module and the pressure stabilization module in response to the expected adjustment amount. The purpose is to stabilize the gas path state and meet the requirements of the benchmark test conditions.

[0175] This also includes a method for gas recovery operations, which includes:

[0176] Step 708: Real-time collection and testing of exhaust gas volume.

[0177] The test exhaust gas volume refers to the total amount of gas discharged from the test gas path after being processed by the dryer under test during the test process, which has completed the drying performance verification task. It is collected in real time by a flow meter installed downstream of the dryer outlet, and its volume will change dynamically with the test conditions.

[0178] Step 709: When the test exhaust gas volume exceeds the preset recovery threshold, locate the preset recovery valve number.

[0179] The recovery threshold refers to the minimum gas consumption standard preset by the system to trigger the test exhaust gas recovery process. It is determined by the regeneration requirements of the current dryer model and the storage capacity of the recovery system. When the test exhaust gas volume exceeds this value, the excess gas has recovery and reuse value, and initiating recovery can avoid resource waste. The recovery valve number refers to any valve combination identifier in the valve configuration table that is compatible with the recovery gas path of the current dryer model.

[0180] Step 710: Perform valve adjustment operation based on the recovered valve number.

[0181] Step 711: After the valve adjustment operation, collect the amount of recovered gas in real time.

[0182] The recovered gas volume refers to the actual volume of test exhaust gas collected in real time by a flow meter installed at the outlet of the recovered gas path, and then recovered and stored.

[0183] Step 712: Determine the current corrected demand flow rate based on the amount of recovered gas and the current demand flow rate.

[0184] The current corrected demand flow rate refers to the target flow rate of the test gas path after the recovered gas volume is reused in the test gas path. The calculation formula is: Current corrected demand flow rate = Current demand flow rate - Equivalent flow rate corresponding to the recovered gas volume.

[0185] Step 713: Determine the valve group number to be adjusted when there is a current correction requirement flow rate.

[0186] The valve group number to be adjusted refers to any valve combination identifier that is temporarily formed by the system from all available valves based on the current required flow rate and is adapted to the required flow rate.

[0187] Step 714: Determine the valve group opening degree corresponding to the valve group number to be adjusted based on the current corrected flow rate.

[0188] When there is a corrected flow requirement, it means that the valve combination needs to be readjusted after the recovered gas is reused to meet the new flow requirement. At this time, the system calculates the initial opening value of each valve in the valve group to be adjusted based on the current corrected flow requirement and the flow superposition algorithm.

[0189] Step 715: Perform gas recovery operation based on the valve group number to be adjusted and the valve group opening degree.

[0190] Gas recovery operation refers to the process of recovering and storing test exhaust gas, pressurizing and stabilizing it, and then introducing it into the test gas path. At the same time, valve adjustments are performed according to the valve group number and opening degree to be adjusted, so that the actual flow rate of the test gas path is stabilized at the current correction requirement flow rate.

[0191] This also includes a method for performing temperature, pressure, and humidity adjustment operations during the gas recovery process, the method comprising:

[0192] Step 7150: During the gas recovery operation, determine the gas to be recovered and the test gas.

[0193] Recovered gas refers to the test exhaust gas that has been recovered and stored, and then processed by a dryer to complete the testing task.

[0194] Step 7151: Obtain the temperature, pressure, and humidity parameters of the recovered gas and the temperature, pressure, and humidity parameters of the test gas.

[0195] The temperature, pressure, and humidity parameters of the recovered gas refer to the core state parameters of the test exhaust gas to be imported into the test gas path for reuse, which are collected in real time by temperature sensors, pressure sensors, and humidity sensors installed at the outlet of the recovered gas path. Specifically, these parameters are the instantaneous temperature, static pressure, and pressure dew point of the test exhaust gas.

[0196] The temperature, pressure, and humidity parameters of the test gas refer to the core state parameters of the gas that is being tested and is awaiting drying by the dryer. These parameters are collected in real time by temperature, pressure, and humidity sensors installed at the front end of the test gas recovery inlet. The parameters include the instantaneous temperature, static pressure, and relative humidity of the test gas.

[0197] Step 7152: Determine the temperature, pressure, and humidity deviation rate based on the temperature, pressure, and humidity parameters of the recovered gas and the test gas.

[0198] Temperature, pressure and humidity deviation rate refers to the degree of difference between the temperature and pressure parameters of the recovered gas and the temperature and pressure parameters of the test gas. Temperature deviation rate = |Recovered gas temperature - Test gas temperature| / Test gas temperature × 100%; Pressure deviation rate = |Recovered gas pressure - Test gas pressure| / Test gas pressure × 100%; Humidity deviation rate = |Recovered gas absolute humidity - Test gas absolute humidity| / Test gas absolute humidity × 100%.

[0199] Step 7153: When the temperature, pressure and humidity deviation rate exceeds the preset maximum temperature, pressure and humidity deviation rate threshold, determine the recovery gas temperature adjustment amount, recovery gas humidity adjustment amount and recovery gas pressure adjustment amount based on the temperature, pressure and humidity deviation rate.

[0200] The maximum temperature, pressure, and humidity deviation rate threshold refers to the upper limit of the allowable difference between the temperature, pressure, and humidity parameters of the recovered gas and the test gas, preset by the system. The recovered gas temperature adjustment amount refers to the target temperature change calculated to bring the recovered gas temperature closer to the test gas temperature. The recovered gas humidity adjustment amount refers to the target humidity change calculated to match the humidity of the recovered gas with that of the test gas. The recovered gas pressure adjustment amount refers to the target pressure change calculated to bring the recovered gas pressure closer to that of the test gas.

[0201] Step 7154: Perform temperature, pressure and humidity adjustment operations based on the recovered gas temperature adjustment amount, recovered gas humidity adjustment amount and recovered gas pressure adjustment amount.

[0202] When adjustments for recovered gas temperature, humidity, and pressure are present, it indicates a significant difference between the recovered gas and the test gas in terms of temperature, pressure, and humidity. Adjustments are necessary to ensure the stability of the test gas path and the accuracy of the test results. The temperature of the recovered gas is adjusted using a temperature control module, raising or lowering it according to the adjustment amount to bring it closer to the test gas temperature. Humidity control equipment is used to increase or decrease the humidity of the recovered gas according to the adjustment amount, achieving a match with the test gas humidity. Finally, a pressure regulator is used to increase or decrease the pressure of the recovered gas according to the adjustment amount, bringing it closer to the test gas pressure.

[0203] This also includes a method for correcting the temperature, pressure, and humidity curve library, which includes:

[0204] Step 7070: Determine the end time of temperature, pressure and humidity adjustment based on the current demand flow deviation and the rate of change of the current demand flow deviation.

[0205] The end time of temperature, pressure and humidity adjustment refers to the specific point in time when it is determined that the temperature, pressure and humidity adjustment no longer needs to be executed, based on the changing trend and rate of change of the current demand flow deviation.

[0206] Step 7071: Stop the temperature, pressure and humidity adjustment operation based on the end time of the temperature, pressure and humidity adjustment, and obtain the rate of change of the current required flow deviation.

[0207] The rate of change of the current demand flow deviation refers to the unit time change of the corrected current demand flow deviation, which is collected in real time by the system after the temperature and pressure adjustment stops.

[0208] Step 7072: When the rate of change of the current demand flow deviation falls within the range of unstable flow fluctuation, output the preset temperature, pressure and humidity curve library adjustment signal.

[0209] The temperature, pressure, and humidity curve library adjustment signal refers to the instruction signal output by the system to trigger the update of the temperature, pressure, and humidity curve library when the rate of change of the current demand flow deviation is still within an unstable range.

[0210] Step 7073: In response to the temperature, pressure and humidity curve library adjustment signal, perform automatic temperature, pressure and humidity adjustment operation based on the rate of change of the current demand flow deviation until the rate of change of the current demand flow deviation does not fall within the range of unstable flow fluctuations.

[0211] Step 7074: Record the adjustment records corresponding to the automatic temperature, pressure and humidity adjustment operations in real time.

[0212] The adjustment record refers to the complete data record of the automatic temperature, pressure and humidity adjustment operation, including but not limited to: the current dryer model, adjustment time, initial deviation change rate, the amount of temperature, pressure and humidity adjustment each time, the deviation change rate after adjustment, and the temperature, pressure and humidity parameters when finally stabilized.

[0213] Step 7075: Update the temperature, pressure and humidity curve library based on the adjustment records.

[0214] The temperature, pressure, and humidity curve library is updated based on the adjustment records. The actual temperature, pressure, and humidity adjustments that ultimately stabilize the system are used to replace the original expected adjustments corresponding to the current operating conditions in the curve library. This ensures that the system can directly call the accurate adjustment amount when encountering the same operating conditions again, avoiding repeated instability issues.

[0215] This also includes a method for performing anticipated temperature, pressure, and humidity adjustments, the method comprising:

[0216] Step 7076: During the process of collecting test exhaust gas, search the temperature, pressure and humidity adjustment parameters of the most recent recovery scenario corresponding to the current dryer model in the temperature, pressure and humidity curve library.

[0217] The temperature, pressure, and humidity adjustment parameters for the most recent recovery scenario refer to the combination of temperature, humidity, and pressure adjustment parameters used during the most recent gas recovery, retrieved from the temperature, pressure, and humidity curve library for the current dryer model. These parameters record the temperature, pressure, and humidity adjustment experience of this dryer model under similar recovery scenarios, providing a reference benchmark for this adjustment.

[0218] Step 7077: Determine the rate of change of the test exhaust gas volume based on the test exhaust gas volume.

[0219] The test exhaust gas volume change rate refers to the proportion of change in test exhaust gas volume per unit time. The calculation formula is: test exhaust gas volume growth rate = (current test exhaust gas volume - previous test exhaust gas volume) / previous test exhaust gas volume × 100%.

[0220] Step 7078: Determine the adjustment window time point based on the test exhaust gas volume, the test exhaust gas volume change rate, and the recovery threshold.

[0221] The adjustment window time point refers to the specific time point at which the system calculates the appropriate time to start the temperature, pressure and humidity adjustment operation based on the real-time changes and trends of the test exhaust gas volume and the preset recovery threshold. Temperature and pressure adjustments can be performed in advance before the test exhaust gas volume reaches the recovery conditions.

[0222] Step 7079: When the adjustment window time point is reached, import the temperature, pressure and humidity adjustment parameters of the most recent recovery scene and perform the expected temperature, pressure and humidity adjustment operation.

[0223] The anticipated temperature, pressure, and humidity adjustment operation refers to the system automatically importing temperature, pressure, and humidity adjustment parameters from the temperature, pressure, and humidity curve library, matching the current dryer model, after reaching the preset adjustment window time point, to perform targeted adjustments to the temperature, pressure, and humidity of the recovered gas path. Here, the temperature, pressure, and humidity adjustment parameters for the most recent recovery scenario are time-series parameters that change continuously over time. Specifically, during the temperature, pressure, and humidity adjustment process of the previous recovery scenario, the system records the sequence of temperature and pressure adjustments over the entire adjustment cycle in real time at preset acquisition intervals, with the acquisition interval being once per second.

[0224] Step 7080: When the temperature, pressure and humidity deviation rate exceeds the maximum temperature, pressure and humidity deviation rate threshold during the execution of the expected temperature, pressure and humidity adjustment operation, determine the recovery gas temperature adjustment amount, recovery gas humidity adjustment amount and recovery gas pressure adjustment amount based on the temperature, pressure and humidity deviation rate, and execute step 7154.

[0225] When the temperature, pressure, and humidity deviation rate exceeds the maximum threshold, it indicates that the temperature, humidity, and pressure differences between the current recovered gas and the test gas are too large. Without targeted adjustments, this will lead to fluctuations in gas path resistance, thereby affecting flow stability. Therefore, the system needs to determine the adjustment amounts for the recovered gas temperature, humidity, and pressure based on the temperature, pressure, and humidity deviation rate to perform temperature, pressure, and humidity adjustment operations.

[0226] Based on the same inventive concept, embodiments of the present invention provide a dryer load testing system.

[0227] One of the dryer load testing systems includes:

[0228] The acquisition module is used to obtain the current dryer model;

[0229] A memory for storing a program for a dryer load test method;

[0230] The processor loads and executes programs from memory.

[0231] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for testing the load of a dryer, characterized in that, include: Step 1: Obtain the current dryer model; Step 2: Determine the current valve number based on the current dryer model; Step 3: Perform valve adjustment operation based on the current valve number and obtain the current test air; Step 4: Real-time acquisition of the current test air temperature, current test air humidity, and the reference test air temperature and reference test air humidity corresponding to the current dryer model; Step 5: Based on the difference between the current test air temperature and the reference test air temperature, and the difference between the current test air humidity and the reference test air humidity, determine the temperature and humidity coordination adjustment parameters, and perform temperature and humidity adjustment operations according to the temperature and humidity coordination adjustment parameters; Step 6: During the temperature and humidity adjustment operation, simultaneously open the valve corresponding to the import valve number of the current dryer model; Step 7: Obtain the reference operating parameter range corresponding to the current dryer model; Step 8: Perform valve adjustment operations based on the imported valve number, and obtain the current dryer operating parameters corresponding to the current dryer model; Step 90: If the current dryer is running stably and the current dryer operating parameters fall within the reference operating parameter range, output the preset dryer qualified signal; Step 91: If the current dryer is unstable or the current dryer operating parameters do not fall within the reference operating parameter range, output a preset dryer failure signal.

2. The method for testing the load of a dryer according to claim 1, characterized in that, Methods for performing valve adjustment operations based on the current valve number include: Step 30: Determine the current required flow rate based on the current dryer model; Step 31: Based on the current required flow rate, search in the preset valve flow rate database to determine the current valve group number and the corresponding valve group opening degree; Step 32: Perform valve adjustment operations based on the current valve group number and the current valve group opening degree, and obtain the current flow rate in real time; Step 33: Subtract the current demand flow from the current flow to obtain the current demand flow deviation; Step 34: When there is a deviation in the current required flow rate, determine the adjustable amount based on the current valve group number and the current valve group opening degree; Step 350: When the deviation of the current demand flow rate does not exceed the adjustable amount, determine the valve group opening adjustment parameter corresponding to the current valve group number based on the deviation of the current demand flow rate; Step 351: Perform valve adjustment operation based on valve group opening adjustment parameters.

3. The method for testing the load of a dryer according to claim 2, characterized in that, It also includes a method for performing valve adjustment when the current demand flow deviation exceeds the adjustable amount, the method including: Step 360: When the deviation of the current demand flow exceeds the adjustable amount, determine the correction valve group number based on the deviation of the current demand flow. Step 361: When a correction valve group number exists, determine the opening degree of the correction valve group based on the current required flow rate; Step 362: Perform valve adjustment operation based on the corrected valve group number and the corrected valve group opening degree, and obtain the corrected current flow rate in real time; Step 363: Subtract the current demand flow from the corrected current flow to obtain the corrected current demand flow deviation; Step 364: Determine the adjustable amount of correction based on the current required flow deviation, and determine the adjustment parameters of the valve group opening based on the adjustable amount of correction; Step 365: Perform valve adjustment operation based on the corrected valve group number and the corrected valve group opening adjustment parameters.

4. The dryer load testing method according to claim 3, characterized in that, It also includes a method for obtaining the regeneration gas consumption corresponding to the current dryer model, the method comprising: Step 700: Real-time acquisition of current test temperature, baseline test temperature, and regeneration gas consumption; Step 701: Substitute the regeneration gas consumption, the current test temperature, and the reference test temperature into the gas correction formula to determine the corrected regeneration gas consumption. The gas correction formula is: Q 标 =Q 实 ×(T 标 +273) / (T) 实 +273), where Q 标 To correct the regeneration gas consumption, Q 实 For regeneration gas consumption, T 标 As the reference test temperature, T 实 The current test temperature; Step 702: Output the corrected regeneration gas consumption as the regeneration gas consumption.

5. The dryer load testing method according to claim 4, characterized in that, It also includes a method for performing temperature, pressure, and humidity adjustment operations, the method comprising: Step 703: Determine the curve of the change in current demand flow deviation based on the current demand flow deviation; Step 704: Determine the rate of change of the current demand flow deviation based on the current demand flow deviation change curve; Step 705: When the rate of change of the current demand flow deviation falls within the preset unstable flow fluctuation range, perform a coarse adjustment operation of the booster frequency flow and output a preset unstable flow status signal. Step 706: In response to the unstable flow status signal, the expected temperature adjustment, expected humidity adjustment and expected pressure adjustment are determined in real time by searching the preset temperature, pressure and humidity curve library based on the current dryer model and the rate of change of the current required flow deviation. Step 7060: Determine the expected dryer operating parameters based on the expected temperature adjustment, expected humidity adjustment, expected pressure adjustment, and current dryer operating parameters; Step 7061: When the expected dryer operating parameters do not fall within the reference operating parameter range, output a manual signal; Step 707: When the expected dryer operating parameters fall within the reference operating parameter range, perform temperature, pressure and humidity adjustment operations based on the expected temperature adjustment, expected humidity adjustment and expected pressure adjustment.

6. The method for testing the load of a dryer according to claim 5, characterized in that, It also includes methods for gas recovery operations, which include: Step 708: Real-time collection and testing of exhaust gas volume; Step 709: When the test exhaust gas volume exceeds the preset recovery threshold, locate the preset recovery valve number; Step 710: Perform valve adjustment operation based on the recovered valve number; Step 711: After the valve adjustment operation, collect the amount of recovered gas in real time; Step 712: Determine the current corrected flow rate based on the amount of recovered gas and the current flow rate demand; Step 713: Determine the valve group number to be adjusted when there is a current correction requirement flow rate; Step 714: Determine the valve group opening degree corresponding to the valve group number to be adjusted based on the current corrected flow rate; Step 715: Perform gas recovery operation based on the valve group number to be adjusted and the valve group opening degree.

7. A dryer load testing method according to claim 6, characterized in that, It also includes a method for performing temperature, pressure, and humidity adjustment operations during the gas recovery process, the method comprising: Step 7150: During the gas recovery operation, determine the gas to be recovered and the test gas; Step 7151: Obtain the temperature, pressure, and humidity parameters of the recovered gas and the temperature, pressure, and humidity parameters of the test gas; Step 7152: Determine the temperature, pressure, and humidity deviation rate based on the temperature, pressure, and humidity parameters of the recovered gas and the test gas; Step 7153: When the temperature, pressure and humidity deviation rate exceeds the preset maximum temperature, pressure and humidity deviation rate threshold, determine the recovery gas temperature adjustment amount, recovery gas pressure adjustment amount and recovery gas humidity adjustment amount based on the temperature, pressure and humidity deviation rate. Step 7154: Perform temperature, pressure and humidity adjustment operations based on the recovered gas temperature adjustment amount, recovered gas pressure adjustment amount and recovered gas humidity adjustment amount.

8. The method for testing the load of a dryer according to claim 7, characterized in that, It also includes a method for correcting the temperature, pressure, and humidity curve library, which includes: Step 7070: Determine the end time of temperature, pressure and humidity adjustment based on the current demand flow deviation and the rate of change of the current demand flow deviation; Step 7071: Stop the temperature, pressure and humidity adjustment operation based on the end time of the temperature, pressure and humidity adjustment, and obtain the rate of change of the current required flow deviation. Step 7072: When the rate of change of the current demand flow deviation falls within the range of unstable flow fluctuation, output the preset temperature, pressure and humidity curve library adjustment signal; Step 7073: In response to the temperature, pressure and humidity curve library adjustment signal, perform automatic temperature, pressure and humidity adjustment operation based on the rate of change of the current demand flow deviation until the rate of change of the current demand flow deviation does not fall within the range of unstable flow fluctuations. Step 7074: Record the adjustment records corresponding to the automatic temperature, pressure and humidity adjustment operations in real time; Step 7075: Update the temperature, pressure and humidity curve library based on the adjustment records.

9. A dryer load testing method according to claim 8, characterized in that, It also includes a method for performing anticipated temperature, pressure, and humidity adjustments, the method comprising: Step 7076: During the process of collecting test exhaust gas, search the temperature, pressure and humidity adjustment parameters of the most recent recovery scenario corresponding to the current dryer model in the temperature, pressure and humidity curve library; Step 7077: Determine the test exhaust gas volume growth rate based on the test exhaust gas volume; Step 7078: Determine the adjustment window time point based on the test exhaust gas volume, the test exhaust gas volume growth rate, and the recovery threshold; Step 7079: When the adjustment window time point is reached, import the temperature, pressure and humidity adjustment parameters of the most recent recovery scene and perform the expected temperature, pressure and humidity adjustment operation; Step 7080: When the temperature, pressure and humidity deviation rate exceeds the maximum temperature, pressure and humidity deviation rate threshold during the execution of the expected temperature, pressure and humidity adjustment operation, determine the recovery gas temperature adjustment amount, recovery gas humidity adjustment amount and recovery gas pressure adjustment amount based on the temperature, pressure and humidity deviation rate, and execute step 7154.

10. A dryer load testing system, characterized in that, include: The acquisition module is used to obtain the current dryer model; A memory for storing a program for a dryer load testing method as described in any one of claims 1 to 9; The processor loads and executes programs from memory.

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