A method and system for testing the service life of a compressor with adjustable working conditions and loads

Abstract

The application discloses a kind of adjustable working condition and load compressor life test method and test system, it is related to compressor performance test technical field, including following method steps: step S1, test selection, select the compressor to be measured and several groups of evaporator, condenser according to test requirement;Step S2, the installation of compressor to be measured, is installed to second test cabinet with the refrigeration circuit, forms closed refrigeration cycle system with compressor to be measured;Step S3, set the working condition of test cabinet, by adjusting the part of adjustable chamber of first test cabinet, for matching refrigeration volume and refrigerating capacity, and set the temperature and humidity of test cabinet;Step S4, start operation and monitoring, set the temperature difference of evaporator import and export, and when monitoring each test parameter of system is reasonable, enter test period;Step S5, test result evaluation, after testing, carry out compressor structure dissection and characteristic evaluation, and make evaluation report.

Description

Technical Field

[0001] This invention relates to the field of compressor performance testing technology, and in particular to a compressor life testing method and system with adjustable operating conditions and loads. Background Technology

[0002] Compressors are core power equipment in refrigeration and industrial systems, responsible for compressing low-temperature, low-pressure gases into high-temperature, high-pressure gases to drive the entire refrigeration or pneumatic cycle. For example, in commercial freezers, the compressors used are crucial components for ensuring the low-temperature storage of food, pharmaceuticals, and other goods, requiring stringent requirements such as long-term operation, frequent start-stop cycles, and efficient refrigeration. Therefore, manufacturers need to test the compressor's lifespan and other performance parameters to ensure they meet standards before putting it into use.

[0003] However, the following issues still exist regarding compressor lifespan testing:

[0004] The existing testing systems used by manufacturers have limited operating condition adjustments. For example, for different compressors, they can only be rematched with the corresponding freezers and refrigeration systems for performance testing. They cannot adapt different types of compressors by adjusting the operating conditions of the freezers and refrigeration systems. Therefore, each time a new testing system is used for testing, the manufacturer's engineers need to conduct initial debugging of the freezer's operating conditions, load, refrigeration system and other items for more than 6 months before installing the compressor for actual testing. This results in very long compressor testing time and low performance testing efficiency.

[0005] Moreover, existing manufacturers use traditional compressor testing methods, which are time-consuming, energy-intensive, and require a lot of manpower, resulting in extremely high testing costs throughout the entire compressor testing process. Summary of the Invention

[0006] In order to overcome the shortcomings of the prior art, one of the objectives of this invention is to provide a compressor life test method with adjustable operating conditions and load.

[0007] One of the objectives of this invention is achieved through the following technical solution: a method for testing the lifespan of a compressor with adjustable operating conditions and load, comprising the following steps:

[0008] Step S1: Test and select the appropriate compressor based on its cooling capacity and the preset compressor operating rate and total heat load of the test cabinet. The test cabinet includes a first test cabinet equipped with an evaporator and a second test cabinet equipped with a condenser. Several sets of evaporators and condensers are selected according to the cooling capacity of the compressor to be tested.

[0009] Step S2: Installation of the compressor under test. The compressor under test selected in step S1 is installed in the second test cabinet, and its suction end and exhaust end are connected to the preset refrigeration circuit to form a closed refrigeration cycle system.

[0010] Step S3: Set the operating conditions of the test cabinet. The first test cabinet has several adjustable chambers. The adjustable chambers, which are connected or separated, are used to adjust the first test cabinet to a cooling volume that matches the cooling capacity of the compressor under test. At the same time, set the temperature and humidity conditions inside the first test cabinet and the second test cabinet.

[0011] Step S4: Start-up and monitoring. By adjusting the valve opening in the refrigeration circuit, setting the inlet and outlet temperature difference of the evaporator, and monitoring that the various test parameters of the refrigeration system are within a reasonable range, the test cycle begins.

[0012] Step S5: Evaluation of test results. After the performance test cycle of the compressor under test is completed, the compressor is taken out and its structure is dissected and its characteristics are evaluated. A performance evaluation report is made based on the evaluation results, which serves as a reference standard for evaluating the performance of compressors of the same type.

[0013] Furthermore, in step S1, the total heat load of the test cabinet is set to Q. 总 The total heat load of the test cabinet includes the heat load Q1 of the first and second test cabinets, the heat load Q2 of the door opening, and the heat load Q3 of the electrical components, and the total heat load Q of the test cabinet is... 总 The final calculation results are fine-tuned to obtain the adjusted total heat load Q. 总调 ;

[0014] The compressor under test is set to operate at 80% capacity.

[0015] Let the cooling capacity of the compressor under test be Q. 压 And the cooling capacity Q of the compressor under test 压 By calculating the total heat load Q 总调 The trade value is obtained when the compressor under test has an 80% operating rate.

[0016] Furthermore, in step S1, the operating power Q of the compressor under test is also determined. 功率 Select the condenser;

[0017] When configuring the combined circuit of the condenser, the formula for calculating the total heat exchange area of ​​the condenser is: A 冷凝 =(Q 压+ Q 功率 )÷U÷△T;

[0018] When configuring the combined circuit of the evaporator, the formula for calculating the total heat exchange area of ​​the evaporator is: A 蒸发 =Q压 ÷U÷△T;

[0019] In the above formula, U is the overall heat transfer coefficient, and ΔT is the temperature difference between the refrigerant and the outside air.

[0020] Then, based on the total heat exchange area, the combined circuits that the condenser and evaporator need to connect are selected, and the remaining circuits are closed.

[0021] Further, in step S2, the suction end and discharge end of the compressor under test in the second test cabinet are respectively connected to the outlet of the evaporator and the inlet of the condenser, and the outlet of the condenser is connected to the inlet of the evaporator to form a closed-loop refrigeration system.

[0022] The compressor under test was evacuated, and the initial refrigerant charge was set.

[0023] Furthermore, in step S3, several first test cabinets are arranged in parallel. Each first test cabinet is provided with two or more adjustable chambers with equal or unequal cooling volumes, and adjacent two adjustable chambers are separated by inserting insulation partitions or connected by removing the insulation partitions.

[0024] Furthermore, in step S3, each of the first test cabinets is equipped with at least one evaporator. The evaporators in the several first test cabinets arranged in parallel are evenly distributed with refrigerant through a liquid distributor, and each of the evaporators is equipped with a liquid valve on its inlet pipe.

[0025] Further, in step S3, by inserting an insulation partition into the first test cabinet, its cooling capacity is adjusted to 100 to 2000L to match the displacement range of the compressor under test, which is 3 to 30cc; and the temperature and humidity parameter ranges of the first test cabinet are respectively 0 to 43℃ and 40% to 95%RH, and the temperature and humidity parameter ranges of the second test cabinet are respectively 0 to 60℃ and 40% to 95%RH.

[0026] Furthermore, in step S4, a solenoid valve is installed on the pipeline connecting the condenser and the evaporator, and the inlet and outlet temperature difference of the evaporator is set by adjusting the opening of the solenoid valve.

[0027] After setting the evaporation temperature of the test cabinet, the test parameters of the refrigeration system should be monitored, including at least the temperature difference between the inlet and outlet of the evaporator. If the temperature difference between the inlet and outlet of the evaporator is less than 2°C, the refrigerant charge and the solenoid valve opening are considered reasonable.

[0028] In order to overcome the shortcomings of the prior art, the second objective of this invention is to provide a compressor life testing system with adjustable operating conditions and load.

[0029] The second objective of this invention is achieved by the following technical solution: a compressor life testing system with adjustable operating conditions and load, comprising a test cabinet, an evaporator, a condenser, and a compressor under test;

[0030] The test cabinet includes a first test cabinet, the evaporator is disposed in the first test cabinet, the first test cabinet is provided with a number of adjustable compartments, and an insulation partition is provided between two adjacent adjustable compartments. The adjustable compartments are connected by removing the insulation partition or separated by inserting an insulation partition, which is used to adjust the first test cabinet to a refrigeration volume that matches the refrigeration capacity of the compressor under test.

[0031] The test cabinet includes a second test cabinet, in which the condenser and the compressor under test are configured. The combined circuits of the condenser and the evaporator are configured according to their total heat exchange area. The suction end and discharge end of the compressor under test are respectively connected to the outlet of the evaporator and the inlet of the condenser, and the outlet of the condenser is connected to the inlet of the evaporator to form a closed-loop refrigeration cycle system.

[0032] Furthermore, a first liquid distributor is provided on the liquid inlet pipe of the condenser. One end of the first liquid distributor is connected to the exhaust end of the compressor, and the other end is connected to the condenser through several gas valves. This is used to distribute the high-temperature and high-pressure gas from the compressor to several condensers in a proportional manner by passing through the first liquid distributor and several gas valves in sequence.

[0033] A second liquid distributor is provided on the liquid inlet pipe of the evaporator. One end of the second liquid distributor is connected to the condenser, and the other end is connected to the evaporator through several liquid valves. It is used to distribute the low-temperature and low-pressure gas from the condenser to several evaporators in a proportional manner through the second liquid distributor and several liquid valves.

[0034] Furthermore, a solenoid valve is installed on the pipeline connecting the condenser and the evaporator, and the inlet and outlet temperature difference of the evaporator is set by adjusting the opening degree of the solenoid valve.

[0035] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0036] (1) In this embodiment, by setting up a first test cabinet and a second test cabinet, the evaporator and condenser are pre-configured respectively. When selecting the compressor to be tested, it is only necessary to match the condenser and evaporator with the corresponding total heat exchange area for the compressor's cooling capacity. This allows for a quick initial matching of the cooling capacity of the compressor under test with the test system. Compared with the traditional implementation method that requires temporary configuration of a new test system when testing a new compressor, this embodiment saves the time of the original initial matching and initial debugging of the system, which would have taken more than 6 months, and allows the actual testing phase of about 4,000 hours to begin. The overall compressor life test time is significantly shortened.

[0037] Moreover, by designing the first test cabinet with an adjustable cooling capacity to flexibly match compressors of different displacements, this change in cooling capacity rather than replacing the entire test cabinet enables rapid and low-cost adjustment of test conditions (especially cabinet heat load), greatly improving the versatility and flexibility of the test system, saving time, equipment energy consumption and labor costs in the heat load adjustment stage of the test cabinet, and saving at least 40% of the test cost.

[0038] (2) This embodiment provides a first test cabinet that can be flexibly assembled and the insulation partition can be freely inserted inside the cabinet to adjust the refrigeration volume. Through this highly expandable and flexible modular test cabinet structure, the refrigeration volume of the test system can be flexibly matched with various specifications of compressors with a displacement range of 3 to 30cc, further saving test time and other costs, and making the test more efficient; moreover, the first test cabinet can be modularly and standardized to produce, making production and manufacturing more convenient and cost-effective.

[0039] (3) In this embodiment, by designing the adjustable compartment of the first test cabinet and flexibly adjusting the refrigeration volume, the condenser and evaporator system components are configured in accordance with the first and second test cabinets, and the combined circuit is configured according to the total heat exchange area of ​​the heat exchanger, so as to realize the independent and rapid adjustment of the two core parameters of refrigeration volume and heat exchange area, fundamentally solving the problems of the limitations of traditional test system operating conditions and heat load adjustment and the long initial adjustment cycle. Attached Figure Description

[0040] Figure 1 This is a flowchart illustrating steps S1-S5 of the compressor life test method with adjustable operating conditions and load in Embodiment 1 of the present invention.

[0041] Figure 2 The following is a schematic diagram of the process of the compressor being connected to several condensers in sequence through a liquid separator, a gas valve, and then to a liquid collection pipe in the compressor life test method for adjustable operating conditions and load in Embodiment 1 of the present invention.

[0042] Figure 3The flow chart of the compressor life test method with adjustable operating conditions and load in Embodiment 1 of the present invention is shown in which the liquid distribution head is connected to the evaporator through several liquid valves and then connected to the gas collecting pipe.

[0043] Figure 4 This is a schematic diagram of the overall system module connection principle of the compressor life testing system with adjustable operating conditions and load in Embodiment 2 of the present invention;

[0044] Figure 5 This is a schematic diagram of the first test cabinet structure of the compressor life test system with adjustable operating conditions and load in Embodiment 2 of the present invention;

[0045] Figure 6 for Figure 5 Enlarged view of point A in the middle;

[0046] Figure 7 This is a schematic diagram of the connection structure between the compressor and condenser unit in the compressor life test system with adjustable operating conditions and load in Embodiment 2 of the present invention.

[0047] In the picture:

[0048] 10. First test cabinet; 101. Adjustable compartment; 102. Slide rail; 103. Insulation partition;

[0049] 20. Second test cabinet;

[0050] 30. Compressor; 31. First distributor; 32. Gas valve; 33. Condenser; 34. Liquid collecting pipe;

[0051] 40. Second distributor head; 41. Liquid valve; 42. Evaporator; 43. Gas collecting pipe;

[0052] 50. Solenoid valve;

[0053] b1, the suction end of the compressor under test; b2, the outlet pipe of the condenser. Detailed Implementation

[0054] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0055] Example 1

[0056] like Figures 1 to 3 As shown, this embodiment provides a compressor 30-year life test method with adjustable operating conditions and load. This method aims to solve the problems of limited adjustment of operating conditions and load, long debugging cycle, many interference factors, and difficulty in judging test results in the existing compressor 30-year life test system.

[0057] The method specifically includes the following steps:

[0058] Step S1: Test and select the compressor 30. Based on the cooling capacity of the compressor 30, select the preset compressor 30 start-up rate and the total heat load of the test cabinet to accurately select the compressor 30 to be tested.

[0059] In this embodiment, the test cabinet used includes a first test cabinet 10 and a second test cabinet 20. The first test cabinet 10 is equipped with an evaporator 42 (simulating the heat absorption environment of the user's freezer), and the second test cabinet 20 is equipped with a condenser 33 (simulating the heat dissipation environment of the compressor 30 and the condenser 33 group).

[0060] When selecting the compressor, it is also necessary to select several sets of evaporators 42 and condensers 33 according to the cooling capacity of the compressor 30 to be tested, and match their total heat exchange area by configuring their respective combination circuits (for example, by controlling multiple sets of parallel condensers 33 or evaporators 42 to be put into operation through valves).

[0061] Therefore, in this embodiment, by setting up a first test cabinet 10 and a second test cabinet 20, the evaporator 42 and condenser 33 are pre-configured respectively. When selecting the compressor 30 to be tested, it is only necessary to match the condenser 33 and evaporator 42 with the corresponding total heat exchange area based on the cooling capacity of the compressor 30. This quickly completes the initial matching of the cooling capacity of the compressor 30 under test with the test system. Compared with the traditional implementation method that requires temporary configuration of a new test system when testing a new compressor 30, this embodiment saves the time of initial system matching and initial debugging that originally required more than 6 months, and can enter the actual testing stage of about 4000 hours. The overall life test time of the compressor 30 is significantly shortened.

[0062] Step S2: Installation of the compressor under test 30. The compressor under test 30 selected in step S1 is installed in the second test cabinet 20, and its suction end and exhaust end are sealed and connected to the preset refrigeration circuit to form a closed refrigeration cycle system.

[0063] Step S3: Set the operating conditions of the test cabinet. The first test cabinet 10 is designed with several adjustable chambers 101 that can be connected or separated. In actual use, some chambers can be physically connected or separated (e.g., by removing or inserting insulation partitions 103), thereby flexibly changing the total cooling volume of the first test cabinet 10 when participating in heat exchange, so as to match the cooling capacity of the compressor 30 under test. For example, the 3cc, 5cc, and 7cc displacements of the compressor 30 under test correspond to the first test cabinet 10 with cooling volumes of 200L, 300L, and 400L, respectively.

[0064] At the same time, based on the preset test standards or actual application scenarios of the current specification compressor 30 lifespan test, the temperature and humidity parameters inside the first test cabinet 10 and the second test cabinet 20 are set.

[0065] Therefore, by designing the first test cabinet 10 as having an adjustable cooling capacity to flexibly match compressors 30 with different displacements, this change in cooling capacity instead of replacing the entire test cabinet enables rapid and low-cost adjustment of test conditions (especially cabinet heat load), greatly improving the versatility and flexibility of the test system, saving time, equipment energy consumption and labor costs in the heat load adjustment stage of the test cabinet, and saving at least 40% of the test cost.

[0066] Step S4: Start-up and Monitoring. Start the compressor 30 and precisely control the inlet and outlet temperature difference of the evaporator 42 by adjusting the valve core opening in the refrigeration circuit (e.g., solenoid valve 50). This is crucial for ensuring the efficient and stable operation of the refrigeration system. Simultaneously, monitoring instruments such as flow meters can be used to continuously monitor various key parameters of the refrigeration system (such as the inlet and outlet temperature difference of the evaporator 42, as well as the system pressure, temperature, and flow rate). Only when all parameters are within the preset reasonable range will the system officially enter a long-term, stable testing cycle.

[0067] Therefore, by introducing the valve core opening of the active regulating valve, the temperature difference between the inlet and outlet of the evaporator 42 is controlled while the operating parameters of the refrigeration system are continuously monitored, thereby ensuring the repeatability and stability of the system test conditions and laying the foundation for accurate evaluation of the performance of the compressor 30.

[0068] Step S5: Evaluation of test results. After the predetermined performance test cycle ends (the test cycle in this embodiment is 4000 hours), the compressor 30 is stopped and taken out of the second test cabinet 20 of the test system. The compressor 30 after the test is dissected and its characteristics are evaluated by means of visual inspection, microscopic measurement, oil analysis and other methods to assess the performance of its various system components.

[0069] The performance evaluation includes at least the assessment of the wear degree of moving parts (such as crankshaft, connecting rod, piston, cylinder seat, valve plate assembly, etc.), the color grade of compressor oil 30 (to determine its oxidation and contamination level), and the color and integrity of the intake and exhaust valve plates. The wear grade includes five levels: A, AB, B, BC / C, and D. A represents negligible change, AB represents wear, B represents severe wear / minor scratches, BC / C represents severe scratches, and D represents unacceptable wear. The criteria for judging other aspects such as the color grade of compressor oil 30 and the color of intake and exhaust valve plates can be found in this technical field and will not be elaborated upon here.

[0070] Then, based on the above test data and evaluation results, a detailed performance evaluation report is produced. This report is not only used for this test, but can also serve as a reference standard for evaluating the performance of similar compressors in the future.

[0071] Therefore, by structural analysis and standardized evaluation, the physical / chemical changes inside the compressor 30 are transformed into quantifiable indicators, improving the accuracy of the evaluation results. Moreover, in this embodiment, with the factors of the condenser 33, evaporator 42, and other system components fixed in the test system beforehand, only the factors of the new compressor 30 under test need to be considered, significantly reducing a large number of variable factors. This further saves engineers' evaluation efficiency and accuracy, and can truly and effectively measure and reflect the actual service life of the compressor 30, improving the performance test quality of the compressor 30.

[0072] This embodiment further describes the calculation of the total heat load of the test cabinet and the selection of compressor 30 in step S1. Specifically, let the total heat load of the test cabinet be Q. 总 The calculation includes at least three parts: cabinet heat load Q1, door heat load Q2, and electrical component heat load Q3.

[0073] The total heat load Q1 of the cabinet includes at least the heat load of the first and second test cabinets. The heat load of the first test cabinet is determined according to the actual number of adjustable compartments used. Each test cabinet includes the heat load dissipated by the insulation surface enclosure structure of 6 surfaces. In the specific calculation, Q1 = A × K × Δt, where A is the area of ​​the insulation surface, K is the heat conduction system corresponding to the insulation surface, and Δt is the temperature difference between the inside and outside of the insulation surface. By summarizing the calculations, the total heat load Q1 of the 6 insulation surfaces can be obtained.

[0074] The heat load Q2 from door opening simulates the heat brought in by operators opening and closing the door during use; in specific calculations, Q2 = Vexo × ρ × Cp × ΔT / t cycle Where Vexo is the volume of air entering each time the door is opened, ρ is the air density, Cp is the specific heat capacity of the air, ΔT is the temperature difference between the inside and outside, and t is the air density. cycle This represents the total door opening time within a single cycle.

[0075] The heat load Q3 of electrical components includes the heat generated by fan motors, defrosting heaters, etc.; in specific calculations, Q3 = Q 电机 +Q 照明灯 .

[0076] Therefore, the total heat load Q of the test cabinet 总 =Q1+Q2+Q3.

[0077] Furthermore, considering uncertainties such as cooling loss, defrosting cycle effects, and slight decrease in insulation performance after long-term operation, a safety factor is introduced to fine-tune the total heat load, resulting in the adjusted total heat load Q. 总调 In this embodiment, the safety factor is set to 1.2, i.e., Q. 总调 =Q 总 ×1.2; This safety factor is set based on extensive engineering experience in the industry and a comprehensive consideration of the long-term operating degradation characteristics of refrigeration systems. It solves the error problem caused by a small number of calculated values ​​not covered in the actual total refrigeration load calculation, and avoids the problem of wasting resources due to oversized compressor selection or overloading due to undersized compressor selection.

[0078] Meanwhile, based on industry statistics and typical application scenarios, the compressor under test 30 is set to have an 80% uptime during the life test. The compressor uptime refers to the percentage of actual operating time during the start-up and shutdown cycle relative to the total cycle operating time (uptime / total time × 100%). In this embodiment, the compressor uptime is set to 80% to balance efficiency and equipment lifespan, avoiding increased energy consumption and mechanical wear caused by frequent start-ups and shutdowns and high-load operation. Ultimately, the theoretical cooling capacity Q of the compressor under test 30 is... 压 Q is calculated using the following formula: 压 =Q 总调 ÷80%.

[0079] Therefore, by accurately calculating the total heat load of the test cabinet and introducing a reasonable safety factor to fine-tune the total heat load, the selection deviation caused by relying solely on the engineer's experience in the traditional method is avoided. This enables the load of the test system to be precisely matched with the cooling capacity of the compressor 30, further shortening the initial debugging time and improving the test accuracy.

[0080] This embodiment further describes the selection method for the condenser 33 and evaporator 42 in step S1. Specifically, when selecting the condenser 33 and evaporator 42, in addition to considering the cooling capacity Q of the compressor 30... 压 Its operating power Q can also be considered. 功率 Because the work done by the compressor 30 motor is ultimately converted into heat, which needs to be dissipated through the condenser 33.

[0081] Therefore, the total heat exchange area A of condenser 33 冷凝 The calculation formula is: A 冷凝 =(Q 压+ Q 功率 )÷U÷△T. Where, U is the overall heat transfer coefficient on the condenser 33 side (W / (m²·K)), which depends on the structure, material and heat exchange conditions on the air / refrigerant side of the condenser 33; △T is the heat exchange temperature difference between the refrigerant and the outside air (K).

[0082] This calculation formula is based on the fundamental heat transfer equation: Heat exchange = Heat transfer coefficient × Area × Temperature difference. Here, the total heat that the condenser 33 needs to dissipate is equal to the cooling capacity Q of the compressor 30. 压 With input power Q 功率 The sum of these is the application of the first law of thermodynamics in the refrigeration cycle.

[0083] In addition, the total heat exchange area A of the evaporator 42 蒸发 The calculation formula is: A 蒸发 =Q 压 ÷U÷△T. Here, △T is the temperature difference between the refrigerant and the air inside the first test chamber 10, and U is the corresponding total heat transfer coefficient on the evaporator side. The calculation formula differs from that for condenser 33 in that the total heat transfer area calculation for evaporator 42 does not require adding the operating power Q of the compressor under test. 功率 Because, for the evaporator, the compressor's cooling capacity Q 压 This refers to its heat exchange capacity; however, for the condenser, since the compressor's input power is also converted into heat dissipation, in addition to the cooling capacity, the compressor's input power also needs to be increased. Minor heat losses in the piping are essentially negligible.

[0084] Based on the calculated total heat exchange area, the operator can precisely select the number of combined loops that need to be connected for each of the condenser 33 and the evaporator 42 (for example, if the area of ​​each condenser 33 is 10m², and the calculation requires 50m², then connect 5 condenser 33 loops), and shut down the remaining loops.

[0085] Therefore, by further combining the operating power of the compressor 30 under test, the total heat exchange area of ​​the condenser 33 and the evaporator 42 is accurately calculated, ensuring that the heat exchange capacity of the evaporator 42 and the condenser 33 is precisely matched with the characteristics of the compressor 30. This avoids the problems of excessive heat exchange area leading to cost waste and system control difficulties, or excessive heat exchange area leading to low system efficiency and excessive load on the compressor 30, thereby ensuring the stable and rapid operation of the test system.

[0086] This embodiment further describes the installation of compressor 30 and the initial system setup in step S2. Specifically, after installing the compressor 30 under test into the second test cabinet 20, its suction end needs to be connected to the outlet pipe of evaporator 42, its discharge end needs to be connected to the inlet pipe of condenser 33, and the outlet pipe of condenser needs to be connected to the inlet pipe of evaporator, thereby forming a complete closed-loop refrigeration cycle system. This connection method in this embodiment follows the basic vapor compression refrigeration cycle path.

[0087] To ensure the purity of the test system and the absence of any impurities, a rigorous vacuuming operation must be performed on the compressor 30 under test and the entire refrigeration circuit. For example, a vacuum pump can be used to evacuate the system to 20 Bar. After vacuuming, the refrigerant is initially charged. In this embodiment, the initial refrigerant charge is set to 80% of the charge of a standard refrigeration system of the same specifications and pipe length. For example, if the theoretical charge of a benchmark test system with the same configuration is 100g, then the initial charge of this test system is set to 80g.

[0088] Therefore, by setting the charging amount to 80% of the equivalent configuration test system, the principle is to adopt an "undercharged" initial charging method. This prevents the evaporator 42 from failing to completely evaporate all the liquid refrigerant into gas when the refrigerant is overcharged, and prevents unevaporated liquid refrigerant from returning to the compressor 30 through the return gas line, thus preventing the "liquid slugging" phenomenon in the compressor 30. This also leaves room for fine-tuning the charging amount by adjusting the valve opening in the subsequent step S4, improving the safety of system debugging.

[0089] This embodiment further describes the assembly structure and adjustment method of the first test cabinet 10 in step S3. Specifically, in order to further expand the refrigeration volume adjustment range of the first test cabinet 10, this test system has several first test cabinets 10 arranged in parallel. Each first test cabinet 10 has two or more adjustable compartments 101 with equal (e.g., 100L) or unequal refrigeration volumes. When installing the evaporator 42, the evaporator 42 can be installed in the uppermost adjustable compartment 101 of the first test cabinet 10 via the panel.

[0090] An insulation partition 103 (sheet metal + foam) is installed between two adjacent adjustable compartments 101 of the same first test cabinet 10. The insulation partition 103 is designed with a pluggable installation structure. For example, the front of the first test cabinet 10 is designed with a cabinet door. From the direction of the cabinet door, the left and right walls and the back wall of the cabinet are provided with sliding grooves 102. A sealing strip (S-PVC) is embedded in the sliding groove 102, which is tightly fitted with the insulation partition 103 to improve the sealing effect. When it is necessary to increase the cooling capacity, the insulation partition 103 is removed, and the two compartments are connected and the total volume is added; when it is necessary to reduce the cooling capacity, the insulation partition 103 is inserted to separate the compartments.

[0091] For example, each adjustable compartment 101 has a volume of 100L, and each first test cabinet 10 has 5 compartments, for a total volume of 500L. The test system has 4 such test cabinets arranged side-by-side. By flexibly manipulating the insulation partitions 103 to combine different refrigeration volumes, it can simulate the heat load model of variable-volume freezers ranging from a minimum of 100L (using only one compartment) to a maximum of 2000L (all five cabinets connected). For example, to simulate an 800L test cabinet, the 400L volumes of two adjacent first test cabinets 10 can be connected.

[0092] Therefore, this embodiment provides a first test cabinet 10 that can be flexibly assembled and has insulation partitions 103 inserted inside the cabinet to adjust the refrigeration capacity. Through this highly expandable and flexible modular test cabinet structure, the refrigeration capacity of the test system can be flexibly matched with various compressors 30 with a displacement range of 3 to 30cc, further saving test time and other costs, and improving test efficiency. Moreover, the first test cabinet can be modularly and standardized in production, making manufacturing more convenient and cost-effective.

[0093] This embodiment further describes the configuration of the evaporator 42 and the temperature and humidity settings of the test cabinet. Specifically, in the several first test cabinets 10 arranged in parallel, each test cabinet is equipped with at least one evaporator 42. In order to ensure the uniformity of the cooling effect of each evaporator 42, the high-pressure liquid refrigerant from the condenser 33 is first evenly distributed through a distributor and then sent to each evaporator 42.

[0094] Meanwhile, in order to independently control each evaporator 42, a liquid valve 41 (e.g., a thermostatic expansion valve) is installed on the liquid inlet pipe of each evaporator 42. In this way, when a test cabinet does not need cooling, its corresponding liquid valve 41 can be closed. Moreover, these liquid valves 41 can also be used to throttle and reduce pressure, regulate the refrigerant flow, and prevent liquid slugging, so as to achieve flexible control of the refrigerant entering the evaporator 42.

[0095] Regarding the temperature and humidity settings of the first test cabinet 10 and the second test cabinet 20, this embodiment takes the standard operating conditions of the optimal commercial refrigeration cabinet or household refrigerator as an example, refers to the operating condition requirements for performance testing of refrigeration equipment in international standards (such as ISO, ASHRAE), and considers the extreme environment of actual application of compressor 30, and provides the following example.

[0096] The temperature of the first test chamber 10 (simulating the environment inside a freezer) is set to 25°C, and the humidity is set to 60%RH, which simulates the average internal temperature of a freezer or refrigerator under normal conditions. The temperature adjustment range of the first test chamber 10 provided in this embodiment is 0 to 43°C, and the humidity adjustment range is 40% to 95%RH.

[0097] The temperature of the second test cabinet 20 (simulating the installation environment of the compressor 30, such as the unit compartment) is set to 40°C and the humidity is set to 60%RH, which simulates the harsh heat dissipation environment of the compressor 30 under high temperature weather. The temperature adjustment range of the second test cabinet 20 provided in this embodiment is 0 to 60°C, and the humidity adjustment range is 40% to 95%RH.

[0098] In actual operation, the temperature and humidity adjustment method of the first test cabinet 10 and the second test cabinet 20 is to gradually approach and stabilize at the target value through the coordinated work of the heater, humidifier, refrigeration system and PID (proportional-integral-derivative) controller of the test cabinet itself. The specific adjustment operation process is not limited and can be referred to the existing technology, which will not be elaborated here.

[0099] Therefore, by setting a liquid distributor and independently configuring a liquid valve 41 on the liquid inlet pipe of the evaporator 42, uniform liquid supply and independent control of multiple evaporators 42 can be achieved when multiple evaporators 42 are configured according to the displacement requirements of the compressor 30. At the same time, the temperature and humidity of the test cabinet are reasonably adjusted according to international standards, which provides a good hardware foundation for simulating the real working environment of the compressor 30 in different regions and seasons, and further improves the testing efficiency and accuracy.

[0100] This embodiment uses extreme parameter values ​​to conduct extreme tests on the performance of compressor 30, thereby further shortening the test cycle. Taking the maximum operating condition of the extreme test as an example, the test condition of the smallest displacement compressor 30 is adjusted to the extreme state in order to quickly evaluate the reliability of compressor 30 under extreme conditions.

[0101] Specifically, using the method described in step S3 above, the temperature and humidity of the test chamber are set as follows: the refrigeration capacity is adjusted to the minimum value that matches the 3cc displacement of the compressor 30 under test. For example, a 3cc compressor corresponds to a 200L refrigeration capacity. The temperature of the first test chamber 10 (evaporator 42 environment) is set to the upper limit of the specification, 43°C and 95%RH, while the temperature of the second test chamber 20 (condenser 33 environment) is set to its upper limit of the specification, 60°C and 95%RH. Both are the highest ambient temperatures, simulating a high-temperature chamber, to conduct small-displacement compressor performance tests under the maximum heat load environment.

[0102] Under these extreme operating conditions, the discharge pressure, discharge temperature, and motor winding temperature of compressor 30 will increase significantly, accelerating the deterioration of lubricating oil, wear of moving parts, and fatigue of valve plates. Compared with the aforementioned standard operating condition life test of 4000 hours, this extreme test in this embodiment can shorten the life test cycle to 1000 hours or even 500 hours.

[0103] After the test, the compressor 30 was dissected and evaluated. Under the above test duration, the wear level of the compressor's moving parts, the color grade of the compressor 30 oil, and the color of the suction and discharge valve plates were still basically acceptable. The purpose of this performance test was to test the normal operating time and service life that a small displacement compressor can achieve under extreme conditions.

[0104] Therefore, by applying environmental parameters far exceeding standard operating conditions, the testing time of several months can be compressed into several weeks while ensuring that the compression characteristics meet the standards and are relevant to actual applications. Furthermore, by recording the performance test characteristics of the compressor 30 under these extreme tests, an accelerated life evaluation model can be established. A compressor that meets the requirements under extreme tests can be considered to meet the requirements under conventional tests as well. This can greatly improve the R&D iteration efficiency of new compressor 30 products and the speed of factory quality spot checks, further demonstrating the significant advantages of this invention in shortening testing time and improving testing efficiency.

[0105] This embodiment further describes the valve adjustment and parameter monitoring in step S4 according to the test cycle. Specifically, a solenoid valve 50 is installed on the pipeline connecting the condenser 33 and the evaporator 42. By precisely adjusting the valve core opening of the solenoid valve 50, the flow rate of refrigerant flowing into the evaporator 42 can be controlled, thereby setting and stabilizing the inlet and outlet temperature difference of the evaporator 42.

[0106] In practice, the core criterion for judging the proper commissioning of a refrigeration system is monitoring the inlet and outlet temperature difference of the evaporator 42. For example, the criteria are: when the evaporation temperature inside the refrigerator is between -8 and -10℃, the return pipe temperature is between 10℃ and the ambient temperature, and the inlet and outlet temperature difference of the evaporator 42 is consistently less than 2℃, it indicates that the refrigerant charge and the valve core opening setting of the solenoid valve 50 are matched and reasonable, and the commissioning can be deemed successful. This is because a smaller inlet and outlet temperature difference means that the refrigerant has achieved sufficient and uniform boiling heat exchange within the evaporator 42, without the "liquid carryover" caused by excessive flow or the "overheating" phenomenon caused by insufficient flow.

[0107] The entire life test cycle is set at 4000 hours. During this process, the inlet and outlet temperatures and pressures of compressor 30 are closely monitored, ensuring they are within the allowable range according to its specifications (typically, discharge temperature <120℃, suction temperature ≥10℃, and casing temperature <110℃). In addition, a handheld noise meter is used to test the operating noise of compressor 30 every 500 hours under the same location and ambient noise conditions, and the results are recorded to confirm whether the noise of compressor 30 increases with the extension of the test time.

[0108] Therefore, by installing a solenoid valve 50 between the condenser 33 and the evaporator 42, the inlet and outlet temperature difference can be precisely adjusted to regulate the refrigerant flow. This provides clear and quantifiable system commissioning criteria (e.g., inlet and outlet temperature difference of evaporator 42 < 2℃), eliminating excessive reliance on traditional engineer experience and enabling standardized testing and monitoring processes, significantly reducing operational difficulty and commissioning time. Simultaneously, continuous monitoring of the refrigeration system's test parameters, including monitoring of key compressor indicators (such as temperature, pressure, and noise) during a 4000-hour long-term life test, provides ample data support for comprehensively evaluating the performance degradation trend of compressor 30 over time, further improving the accuracy of compressor 30 life testing.

[0109] Example 2

[0110] This embodiment provides a compressor 30-year life testing system with adjustable operating conditions and loads, which is the hardware foundation for implementing the above method. For example... Figures 4 to 7 As shown, the testing system mainly includes a test cabinet, an evaporator 42, a condenser 33, and a compressor under test 30. The test cabinet includes a first test cabinet 10 and a second test cabinet 20. The evaporator 42 is placed inside the first test cabinet 10, which also contains several adjustable compartments 101. Adjacent adjustable compartments 101 are separated by pluggable insulation partitions 103. When installing the evaporator 42, it can be installed in the uppermost adjustable compartment 101 of the first test cabinet 10 via the panel. Removing the insulation partitions 103 allows adjacent compartments to be connected, increasing the total refrigeration volume; inserting insulation partitions 103 can separate the compartments, reducing the total refrigeration volume.

[0111] Therefore, by designing the first test cabinet 10 in this way, it can be flexibly adjusted to a cooling volume that matches the different cooling capacities of the compressor 30 under test, making it flexible in operation, widely applicable, and improving overall testing efficiency.

[0112] The condenser 33 and the compressor 30 under test are arranged in the second test cabinet 20. Based on the total heat exchange area calculation formula of the aforementioned test method, this test system also configures separate combined circuits (i.e., multiple sets of parallel heat exchanger units) for the condenser 33 and evaporator 42. The system then sequentially connects the pre-set outlet of the evaporator 42 in the first test cabinet 10 to the suction end of the compressor 30 under test in the second test cabinet 20 (e.g.,...). Figure 7 (As shown at b1) The circuit connection is such that the exhaust end of the compressor 30 under test in the second test cabinet 20 is connected to the preset inlet circuit of the condenser 33, and the outlet pipe of the condenser in the second test cabinet 20 (as shown at b1) is connected to the circuit connection. Figure 7 (As shown at b2) is connected to the inlet pipe of the evaporator in the first test cabinet 10, ultimately forming a closed-loop refrigeration cycle system that can flexibly adjust operating conditions and heat load.

[0113] Therefore, this embodiment achieves independent and rapid adjustment of the two core parameters, namely refrigeration capacity and heat exchange area, by designing the adjustable compartment 101 of the first test cabinet 10 and flexibly adjusting the refrigeration capacity, configuring the condenser 33 and evaporator 42 system components in correspondence with the first test cabinet 10 and the second test cabinet 20, and configuring combined circuits according to the total heat exchange area of ​​the heat exchanger. This fundamentally solves the problems of limitations in the adjustment of operating conditions and heat load, and long initial adjustment cycle of traditional test systems.

[0114] This embodiment further describes the connection relationship of the test system, especially the refrigerant distribution and flow control section. Specifically, a first distributor 31 is provided on the liquid inlet pipe of the condenser 33 (here, the pipe from the discharge end of the compressor 30 to the inlet of the condenser 33). The inlet end of the first distributor 31 is connected to the discharge end of the compressor 30, and its outlet end is connected to the inlet of multiple condensers 33 through several parallel gas valves 32, and finally collected through the collecting pipe 34 and connected to the evaporator 42. The main purpose of this part of the system component configuration is to distribute the high-temperature and high-pressure gaseous refrigerant discharged from the compressor 30 equally or proportionally through the first distributor 31, and then send it into each condenser 33 after adjustment by multiple gas valves 32, so as to achieve uniform heat dissipation.

[0115] A second distributor 40 is installed on the liquid inlet pipe of the evaporator 42 (here, the pipe from the outlet of the condenser 33 to the inlet of the evaporator 42). The inlet end of the second distributor 40 is connected to the liquid collection pipe 34 at the outlet of the condenser 33, and the outlet end of the second distributor 40 is connected to the inlet of multiple evaporators 42 through several parallel liquid valves 41. Finally, the outlets of multiple evaporators 42 are collected through a gas collection pipe 43, and then connected to the suction end of the compressor 30 after being collected through the gas collection pipe 43. The main function of this system component is to distribute the low-temperature, high-pressure liquid refrigerant from the condenser 33 equally or proportionally through the second distributor 40, and then send it to each evaporator 42 after being regulated by multiple liquid valves 41, so as to achieve uniform heat absorption.

[0116] Furthermore, a solenoid valve 50 is installed on the pipe connecting the condenser 33 and the evaporator 42 (i.e., the liquid collection pipe 34). By adjusting the valve core opening of the solenoid valve 50, the refrigerant circulation volume of the entire system and the inlet and outlet temperature difference of the evaporator 42 can be precisely controlled. In the test system of this embodiment, the corresponding inlet and outlet pipes are also equipped with a flow monitoring system, a pressure monitoring system, a temperature monitoring system, a sight glass, and a current power monitoring instrument to monitor the starting power of the compressor 30.

[0117] Therefore, by configuring the first distributor 31, the second distributor 40, and corresponding valves on this test system, uniform distribution and independent control of the refrigerant can be achieved in the complex system of multiple condensers 33 and multiple evaporators 42 connected in parallel, avoiding local operating abnormalities caused by uneven refrigerant distribution. Meanwhile, the solenoid valve 50 installed on the liquid collection pipe 34 provides global flow regulation for the test system, enabling precise control of the core indicator of the temperature difference between the inlet and outlet of the evaporator 42, thus realizing the modular and adjustable design of the entire system.

[0118] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A method for testing the lifespan of a compressor with adjustable operating conditions and load, characterized in that, The methods and steps include the following: Step S1: Test and select the appropriate compressor based on its cooling capacity and the preset compressor operating rate and total heat load of the test cabinet. The test cabinet includes a first test cabinet equipped with an evaporator and a second test cabinet equipped with a condenser. Several sets of evaporators and condensers are selected according to the cooling capacity of the compressor to be tested. In step S1, let the total heat load of the test cabinet be Q. 总 The total heat load of the test cabinet includes the heat load Q1 of the first and second test cabinets, the heat load Q2 of the door opening, and the heat load Q3 of the electrical components, and the total heat load Q of the test cabinet is... 总 The final calculation results are fine-tuned to obtain the adjusted total heat load Q. 总调 ; The compressor under test is set to operate at 80% capacity. Let the cooling capacity of the compressor under test be Q. 压 And the cooling capacity Q of the compressor under test 压 By calculating the total heat load Q 总调 The trade value can be obtained when the compressor under test is operating at 80% capacity; In step S1, the operating power Q of the compressor under test is also determined. 功率 Select the condenser; When configuring the combined circuit of the condenser, the formula for calculating the total heat exchange area of ​​the condenser is: A 冷凝 = (Q) 压+ Q 功率 )÷U÷△T; When configuring the combined circuit of the evaporator, the formula for calculating the total heat exchange area of ​​the evaporator is: A 蒸发 =Q 压 ÷U÷△T; In the above formula, U is the overall heat transfer coefficient, and ΔT is the temperature difference between the refrigerant and the outside air. Then, based on the total heat exchange area, select the combined circuits that the condenser and evaporator need to connect, and shut down the remaining circuits; Step S2: Installation of the compressor under test. The compressor under test selected in step S1 is installed in the second test cabinet, and its suction end and exhaust end are connected to the preset refrigeration circuit to form a closed refrigeration cycle system. Step S3: Set the operating conditions of the test cabinet. The first test cabinet has several adjustable chambers. The adjustable chambers, which are connected or separated, are used to adjust the first test cabinet to a cooling volume that matches the cooling capacity of the compressor under test. At the same time, set the temperature and humidity conditions inside the first test cabinet and the second test cabinet. Step S4: Start-up and monitoring. By adjusting the valve opening in the refrigeration circuit, setting the inlet and outlet temperature difference of the evaporator, and monitoring that the various test parameters of the refrigeration system are within a reasonable range, the test cycle begins. Step S5: Evaluation of test results. After the performance test cycle of the compressor under test is completed, the compressor is taken out and its structure is dissected and its characteristics are evaluated. A performance evaluation report is made based on the evaluation results, which serves as a reference standard for evaluating the performance of compressors of the same type.

2. The compressor life testing method with adjustable operating conditions and load as described in claim 1, characterized in that, In step S2, the suction end and discharge end of the compressor under test in the second test cabinet are connected to the outlet of the evaporator and the inlet of the condenser respectively, and the outlet of the condenser is connected to the inlet of the evaporator to form a closed-loop refrigeration system. The compressor under test is evacuated, and the initial refrigerant charge is set.

3. The compressor life testing method with adjustable operating conditions and load as described in claim 1, characterized in that, In step S3, several first test cabinets are arranged in parallel. Each first test cabinet is provided with two or more adjustable chambers with equal or unequal cooling volumes. Adjacent adjustable chambers are separated by inserting insulation partitions or connected by removing the insulation partitions.

4. The compressor life testing method with adjustable operating conditions and load as described in claim 3, characterized in that, In step S3, each of the first test cabinets is equipped with at least one evaporator. The evaporators in the several first test cabinets arranged in parallel are evenly distributed with refrigerant through a liquid distributor, and each of the evaporators is equipped with a liquid valve on its inlet pipe.

5. The compressor life testing method with adjustable operating conditions and load as described in claim 1, characterized in that, In step S3, by inserting an insulation partition into the first test cabinet, its cooling capacity is adjusted to 100 to 2000L, which matches the displacement range of the compressor under test (3 to 30cc); and the temperature and humidity parameter ranges of the first test cabinet are respectively 0 to 43℃ and 40% to 95%RH, and the temperature and humidity parameter ranges of the second test cabinet are respectively 0 to 60℃ and 40% to 95%RH.

6. The compressor life testing method with adjustable operating conditions and load as described in claim 1, characterized in that, In step S4, a solenoid valve is installed on the pipeline connecting the condenser and the evaporator, and the inlet and outlet temperature difference of the evaporator is set by adjusting the opening of the solenoid valve. After setting the evaporation temperature of the test cabinet, the test parameters of the refrigeration system should be monitored, including at least the temperature difference between the inlet and outlet of the evaporator. If the temperature difference between the inlet and outlet of the evaporator is less than 2°C, the refrigerant charge and the solenoid valve opening are considered reasonable.

7. A compressor life testing system with adjustable operating conditions and load, characterized in that, Includes a test cabinet, evaporator, condenser, and compressor under test; The test cabinet includes a first test cabinet, the evaporator is disposed in the first test cabinet, the first test cabinet is provided with a number of adjustable compartments, and an insulation partition is provided between two adjacent adjustable compartments. The adjustable compartments are connected by removing the insulation partition or separated by inserting an insulation partition, which is used to adjust the first test cabinet to a refrigeration volume that matches the refrigeration capacity of the compressor under test. The test cabinet includes a second test cabinet, in which the condenser and the compressor under test are configured. The combined circuits of the condenser and the evaporator are configured according to their total heat exchange area. The suction end and discharge end of the compressor under test are respectively connected to the outlet of the evaporator and the inlet of the condenser, and the outlet of the condenser is connected to the inlet of the evaporator to form a closed-loop refrigeration cycle system. The condenser is provided with a first liquid distributor on its liquid inlet pipe. One end of the first liquid distributor is connected to the discharge end of the compressor, and the other end is connected to the condenser through several gas valves. The first liquid distributor is used to distribute the high-temperature and high-pressure gas from the compressor to several condensers in a proportional manner through the first liquid distributor and several gas valves. A second liquid distributor is provided on the liquid inlet pipe of the evaporator. One end of the second liquid distributor is connected to the condenser, and the other end is connected to the evaporator through several liquid valves. It is used to distribute the low-temperature and low-pressure gas from the condenser to several evaporators in a proportional manner through the second liquid distributor and several liquid valves. Furthermore, a solenoid valve is installed on the pipeline connecting the condenser and the evaporator, and the inlet and outlet temperature difference of the evaporator is set by adjusting the opening degree of the solenoid valve.

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