A multi-environment factor multi-form corrosion and wear integrated test system

Abstract

The application provides a multi-environment-factor multi-form corrosion and wear integrated test system, and relates to the field of performance testing, which comprises an environment test box (10) and a sensor assembly. The upper and lower ends of the environment test box (10) are respectively provided with upper and lower main shafts (1) and (2). The top end of the lower main shaft (2) is provided with a fixing assembly. The outer wall of the upper main shaft (1) is slidably provided with a positioning plate (3), and the bottom surface of the positioning plate (3) is provided with a loading ring (4). The loading ring (4) is uniformly provided with a plurality of loading blocks (5). The environment test box (10) is provided with a heating device and a spraying device. The sensor assembly comprises a laser displacement sensor, a pressure sensor, a torque sensor, an LPR corrosion sensor, a temperature and humidity sensor and a salt mist concentration sensor. The system can realize synchronous online detection of wear and corrosion, and avoid the hysteresis of offline measurement and the limitation of single index.

Description

Technical Field

[0001] This invention relates to the field of performance testing technology, and specifically to an integrated testing system for multi-form corrosion and wear under multiple environmental factors. Background Technology

[0002] Construction machinery operates in complex environments. Its key moving parts face a complex and multifaceted natural environment with factors such as high temperature, high humidity, corrosion, and aging during operation. At the same time, the mechanical environment also varies with the environment. Under the coupled effect of complex natural and mechanical environmental factors, key moving parts often fail more quickly, leading to a reduction in the lifespan and performance of construction machinery. This seriously affects the reliability and stability of construction machinery and may even lead to irreversible safety hazards.

[0003] Currently, the life and performance evaluation of key moving components in construction machinery involves real-world testing of these components alongside the entire machine in specific natural environments. However, this method is costly, time-consuming, and requires sophisticated environmental setups with poor reproducibility. Another approach involves creating scaled-down samples of key moving components and conducting environmental and tribological performance tests in simulated laboratory environments. However, this method differs significantly from actual component failure and damage patterns under real-world conditions, and the data obtained cannot fully characterize the damage behavior of full-size components during service. Furthermore, current multi-factor testing typically involves periodic inspections (i.e., checking the condition of the test specimen after each cycle), resulting in limited direct data and an inability to determine corrosion and wear in real time, leading to a certain degree of lag in the evaluation. Moreover, during testing, the initial mechanical force may gradually become distorted due to gradual corrosion and wear, causing changes in the coefficient of friction. Maintaining a fixed load fails to accurately simulate the dynamic failure process of components under actual working conditions, resulting in low accuracy and large errors in performance evaluation. Summary of the Invention

[0004] To address the problems existing in the prior art, the present invention aims to provide an integrated testing system for multi-form corrosion and wear under multiple environmental factors. This system can achieve simultaneous online detection of wear and corrosion, avoiding the lag and limitations of offline measurements and single indicators. At the same time, the system can dynamically adjust the loading force to adapt to the dynamic failure process of components under actual working conditions, and realistically and quickly complete the performance evaluation of moving components in multi-factor environments, providing real and effective data support for material selection and performance optimization of moving components in engineering machinery.

[0005] The objective of this invention is achieved through the following technical solution:

[0006] An integrated testing system for multi-form corrosion and wear under multiple environmental factors includes an environmental testing chamber and a sensor assembly. An upper spindle and a lower spindle are rotatably mounted at the upper and lower ends of the environmental testing chamber, with their central axes collinear. A fixing component is installed at the top of the lower spindle to fix the sample to be tested. A positioning plate is slidably mounted on the outer wall of the upper spindle, and a loading ring is fixedly connected to the bottom surface of the positioning plate via a connecting block. The loading ring is coaxial with the lower spindle. Multiple arc-shaped loading blocks are evenly arranged on the inner wall of the loading ring around its central axis. A push rod is installed on the side of each loading block away from the central axis of the loading ring. A heating device and a spraying device are installed inside the environmental testing chamber. The sensor assembly includes a laser displacement sensor, a pressure sensor, a torque sensor, an LPR corrosion sensor, a temperature and humidity sensor, and a salt spray concentration sensor.

[0007] Based on further optimization of the above scheme, a spline is provided on the outer wall of the upper spindle, and a spline hole is correspondingly opened in the middle of the positioning plate. The spline hole is slidably sleeved on the outer wall of the spline, which not only realizes the up and down sliding of the positioning plate relative to the upper spindle, but also ensures that the positioning plate and the upper spindle rotate synchronously. A limit block is provided at the bottom of the upper spindle to hard limit the downward movement of the positioning plate.

[0008] Based on further optimization of the above scheme, multiple telescopic rods are evenly arranged on the top surface of the inner cavity of the environmental test chamber and on the outer ring of the upper main shaft. The top surface of the positioning plate is provided with an annular groove corresponding to the telescopic rods. The bottom end of the telescopic rod is slidably engaged in the annular groove, thereby realizing the control and positioning of the up and down sliding of the positioning plate.

[0009] Based on further optimization of the above scheme, the number of loading blocks is 3 to 6.

[0010] Based on further optimization of the above scheme, six laser displacement sensors are installed on the inner wall of the loading ring. Each laser displacement sensor is located between two adjacent loading blocks with its laser emission end pointing vertically towards the outer wall of the sample under test, used to collect the thickness change (i.e., wear) of the outer wall of the sample under test in real time. Six strain gauge pressure sensors are used, located at the connection between the push rod and the loading block, used to collect the instantaneous compressive force of the loading block on the sample under test in real time. Dynamic torque sensors are used, installed on the connecting shaft between the lower spindle and its corresponding servo motor, used to collect the torque of the sample under test during rotation in real time. LPR corrosion sensors are uniformly pasted on the non-friction contact area of ​​the sample surface (such as the outer ring of the upper surface of the sample), and the probe of the LPR corrosion sensor is electrically connected to the surface of the sample, used to collect the polarization resistance in real time. Temperature and humidity sensors are uniformly arranged in the inner cavity of the environmental test chamber and close to the sample under test, used to collect the temperature and relative humidity inside the environmental test chamber in real time. Salt spray concentration sensors are installed below the outlet of the spray device, used to collect the salt spray concentration in real time.

[0011] A multi-environmental factor corrosion and wear testing method includes: Step S1, Pre-test preparation: Fix the sample to be tested at the top of the lower spindle, and drive the loading block to move so that its inner wall can effectively contact the outer wall of the sample to be tested; at the same time, set the target temperature through the heating device, and spray through the spray device to make the environmental test chamber reach the target relative humidity and salt spray concentration. Step S2, Start the test: Control the upper and lower spindles to rotate simultaneously and in opposite directions, with the upper spindle rotating at low speed and the lower spindle rotating at high speed, so that the loading block and the sample under test rotate synchronously and in opposite directions to achieve friction; during the rotation, the loading block is moved synchronously to enhance friction; Step S3, Real-time monitoring: During the test, multi-dimensional data is collected synchronously and preprocessed. Wear amount, corrosion rate, and friction coefficient are obtained in real time through the preprocessed data. Performance evaluation is completed by combining environmental correction with wear amount and corrosion degree. Step S4, Dynamic Adjustment of Loading Force: Based on the real-time damage level, the loading force is dynamically adjusted using a PID control algorithm.

[0012] Based on further optimization of the above scheme, in step S3, the multi-dimensional data includes: obtaining laser displacement data through a laser displacement sensor. s i (t) , i =1,2,…,6; Extrusion pressure data is obtained through pressure sensors: F i (t) , i =1,2,…,6; Torque data is obtained through a torque sensor: T(t) Corrosion data was obtained using an LPR corrosion sensor. R p (t) , p =1,2,…, n Temperature data is obtained through a temperature and humidity sensor. T env (t) relative humidity data H env (t) Salt spray concentration is obtained through a salt spray concentration sensor. S env (t) .

[0013] Based on further optimization of the above scheme, in step S3, the data preprocessing specifically includes: For laser displacement data, a dynamic moving average filter is first used to resolve data fluctuations caused by the counter-rotation of the upper and lower spindles: ; In the formula: s r,i (t) Indicates the first i A laser displacement sensor t Raw data collected in real time; s fil,i (t) This represents the filtered data; This indicates the time interval for data acquisition by the laser displacement sensor; N Indicates the rotation of the sample under test S q The number of collection points corresponding to the circle: ; In the formula: n 1 indicates the rotational speed of the sample under test, i.e., the lower spindle; f s Indicates the sampling frequency of the laser displacement sensor; Next, temperature compensation is performed on the filtered data to avoid sensor drift and sample thermal expansion caused by temperature changes. ; In the formula: k T This represents the temperature correction factor; Finally, adopt The criteria apply to temperature-compensated data: ; In the formula: M This indicates the number of data points within the statistics window; This represents the mean of the data. The standard deviation of the data; like or If it is an outlier, it is considered an outlier and removed; the valid data from the previous time point is used instead. Substitute; For extrusion pressure and torque data, dynamic moving average filtering and... Criterion processing enables data preprocessing; Finally, the data is synchronized and aligned: Since different sensors collect data at different frequencies, low-frequency data (such as corrosion, temperature and humidity, salt spray concentration, etc.) are linearly interpolated and aligned with the target frequency data (compression pressure, torque, laser displacement, etc.). ; In the formula: t x Indicates the timestamp at the target synchronization frequency. t k ,t k-1 This represents two adjacent timestamps in low-frequency raw data; x low This represents low-frequency raw data. x syn This indicates the synchronized data.

[0014] Based on further optimization of the above scheme, in step S3, the real-time wear amount is: ; In the formula: This indicates the fixed distance after the laser displacement sensor has been calibrated; R 0 represents the initial radius of the sample to be tested; R (t) Indicates the real-time radius of the sample under test; and R 0 is obtained through initial calibration, specifically: First, obtain the fixed distance from the installation position of each laser displacement sensor to the central axis of the loading ring. L i ( i =1,2,…,6), and the fixed distance is obtained by averaging the values ​​of each laser displacement sensor: ; Then, after fixing the sample to be tested, without starting the spindle rotation or applying any load, adjust the position of the positioning plate using the telescopic rod so that the laser displacement sensor is aligned with the center of the sample (outside the loading block area to avoid initial contact wear). Each laser displacement sensor collects data. n c Initial distance data: s 0i,k ( k =1,2,…, n c ), to obtain the initial radius of the sample to be tested: ; The real-time corrosion rate is: ; In the formula: K This represents the calibrated corrosion rate conversion factor; B Indicates the metal corrosion constant; R p (t) This represents the real-time polarization resistance measured by the LPR sensor; M k Indicates the molar mass of the material in the sample being tested. n KIt represents the number of reaction electrons of the sample material under test (i.e., the number of electrons gained or lost by a single atom in the corrosion electrochemical reaction of the material). This indicates the density of the material in the sample being tested. z K It indicates the valence of the sample material (i.e., the valence state of the main metal element in the material in the corrosion products, which is usually consistent with the number of electrons in the reaction). f F Denotes Faraday's constant; Real-time friction coefficient: ; In the formula: T(t) The real-time torque measured by the torque sensor; T 0 represents the no-load torque, which is the torque when the upper and lower main shafts rotate at the test speed without applying any load (the push rod is not pushed forward). The average loading force is obtained by averaging the real-time values ​​from each pressure sensor.

[0015] Based on further optimization of the above scheme, in step S3, the performance evaluation is completed by combining environmental correction with wear and corrosion levels as follows: First, obtain the environmental correction factor: ; In the formula: Represents the regression coefficient; Then, by combining the wear amount and corrosion rate, the overall damage degree is obtained: ; In the formula: W max This indicates the maximum allowable wear of the sample under test (i.e., the wear threshold for component failure). v c,max This indicates the maximum permissible corrosion rate of the sample under test; Indicates the weighting coefficient; Preset minor damage threshold D all,f With the threshold of severe injury D all,e ,like If , then the sample under test is considered to have minor damage at that moment. If , then the sample under test is considered to have moderate damage at that moment. If the value is 0, then the sample under test at that moment is considered to be severely damaged. When this occurs, it is considered a failure state; Synchronously acquire the wear rate at the corresponding moment. With corrosion rate v cor (t)This enables individual and comprehensive evaluation of wear and corrosion during the testing of the sample under test; ; In the formula: Indicates the adjustment period.

[0016] Based on further optimization of the above scheme, step S4 specifically involves: employing an incremental PID control algorithm to output the loading force adjustment amount. ; In the formula: K p , K i , K d These represent the proportional coefficient, integral coefficient, and differential coefficient, respectively. deviation signal e(t) : ; In the formula: This represents the target overall damage rate (the damage rate that is preset and expected to be maintained during the experiment). Afterwards, new loading force is obtained: ; ; In the formula: F min This indicates the minimum load constraint (the minimum compressive force that ensures effective contact between the loading block and the test sample). F max This indicates the maximum constraint on the applied force (the maximum compressive force to prevent plastic deformation of the test specimen). Finally, the new loading force will be applied. Converted into displacement commands for each push rod: ; In the formula: k g This indicates the stiffness of the loaded system.

[0017] The following are the technical effects of the present invention: This invention simulates the wear patterns of multiple components by synergistically simulating three environmental factors: temperature, humidity, and salt spray. It also achieves multi-directional friction and dynamic stress wear patterns through the reverse rotation of dual spindles at high and low speeds and the synchronous movement of multiple loading blocks. This completes the coupled simulation test of multiple environments and multiple forms of components, solving the problem of the disconnect between single environment or single friction and actual working conditions. It more realistically and effectively matches the actual working conditions of key moving components of engineering machinery, ensuring the accuracy and effectiveness of test data.

[0018] Meanwhile, this invention integrates sensors to simultaneously collect data from four dimensions: wear, corrosion, mechanics, and environment, avoiding the limitations of single indicators. Preprocessing of the collected data effectively counteracts interference from rotational fluctuations, temperature drift, and frequency differences, significantly improving data accuracy. In performance evaluation, by integrating the effects of wear, corrosion, and environment, damage grading and failure prediction are effectively achieved, addressing the problem of traditional performance evaluations focusing on single indicators and failing to quantify synergistic effects. Furthermore, this invention uses PID dynamic loading to adaptively assess sample damage states, balancing testing efficiency and data integrity. Compared to traditional fixed-load tests, it not only effectively shortens the testing cycle and acquires damage data throughout the entire lifecycle, but also solves the problem that inherent loading cannot accurately reflect the actual failure process, improving the authenticity and stability of test data. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the experimental system in an embodiment of the present invention.

[0020] Figure 2 for Figure 1 A sectional view along the AA direction.

[0021] Figure 3 for Figure 1 BB-direction sectional view.

[0022] Among them, 10. Environmental test chamber; 1. Upper spindle; 11. Annular slide groove; 12. Limit block; 2. Lower spindle; 3. Positioning plate; 31. Connecting block; 4. Loading ring; 5. Loading block; 51. Push rod; 6. Telescopic rod; 7. Sample to be tested. Detailed Implementation

[0023] The technical solutions in the embodiments of the present invention will be clearly and completely described below. In the following description, specific details such as specific system structures and technologies are presented for illustration rather than limitation, so as to provide a thorough understanding of the embodiments of the present invention.

[0024] Example 1: An integrated testing system for multi-form corrosion and wear under multiple environmental factors, such as Figure 1As shown, the test chamber includes an environmental testing chamber 10 and a sensor assembly. The environmental testing chamber 10 has an upper spindle 1 and a lower spindle 2 rotatably mounted at its upper and lower ends, respectively, with their central axes collinear. (The upper spindle 1 and lower spindle 2 are driven by servo motors located outside the environmental testing chamber 10; the rotation directions of the upper spindle 1 and lower spindle 2 are opposite, and during testing, the upper spindle 1 rotates at low speed while the lower spindle 2 rotates at high speed.) A fixing assembly is mounted at the top of the lower spindle 2 to fix the sample 7 to be tested (e.g., using a common gripper-type fixing machine). The upper spindle 1 is slidably mounted on the outer wall of the upper spindle 1, and the bottom surface of the positioning plate 3 is fixedly connected to the loading ring 4 via connecting blocks 31 (the connecting blocks 31 are evenly distributed around the central axis of the upper spindle 1, and their number is set according to the actual situation. Generally, it is necessary to ensure the connection rigidity between the positioning plate 3 and the loading ring 4 and to avoid the connecting blocks from cracking due to shear force during the test). The outer wall of the upper spindle 1 is provided with a spline, and the middle of the positioning plate 3 is correspondingly provided with a spline hole. The spline hole is slidably fitted onto the outer wall of the spline (e.g., ...). Figure 3 As shown), this not only enables the positioning plate 3 to slide up and down relative to the upper spindle 1, but also ensures that the positioning plate 3 and the upper spindle 1 rotate synchronously; a limiting block 12 is provided at the bottom of the upper spindle 1 (as shown). Figure 1 As shown), it is used to hard limit the downward movement of the positioning plate 3. Multiple telescopic rods 6 are evenly arranged on the top surface of the inner cavity of the environmental test chamber 10 and on the outer ring of the upper main shaft 1 (the number of telescopic rods 6 is not less than 2, such as...). Figure 3 As shown, this embodiment uses four telescopic rods 6; and the telescopic rods 6 can be conventional hydraulic telescopic rods or mechanical telescopic rods, whichever is appropriate for the actual situation. The top surface of the positioning plate 3 has an annular groove 11 corresponding to the telescopic rod 6. The bottom end of the telescopic rod 6 slides and engages within the annular groove 11, thereby controlling and positioning the positioning plate 3 as it slides up and down. The loading ring 4 is coaxially arranged with the lower main shaft 2. Multiple arc-shaped loading blocks 5 are evenly arranged on the inner wall of the loading ring 4 around its central axis. The number of loading blocks 5 is 3 to 6 (e.g., ...). Figure 2 As shown, this embodiment uses six loading blocks. A push rod 51 is provided on the side of the loading block 5 away from the central axis of the loading ring 4 (the push rod 51 is used to control the movement of the loading block 51); a heating device and a spraying device are provided inside the environmental test chamber 10.

[0025] The sensor assembly includes a laser displacement sensor, a pressure sensor, a torque sensor, an LPR corrosion sensor, a temperature and humidity sensor, and a salt spray concentration sensor. Six laser displacement sensors (KEYENCE IL-600 model) are installed on the inner wall of the loading ring 4. Each laser displacement sensor is located between two adjacent loading blocks 5 with its laser emission end pointing perpendicularly to the outer wall of the sample 7 under test, used to collect the thickness change (i.e., wear) of the outer wall of the sample 7 under test in real time. Six strain gauge pressure sensors (Honeywell 13 series strain gauge force sensors) are used, located at the connection between the push rod 51 and the loading block 5, used to collect the instantaneous compressive force of the loading block 5 on the sample 7 under test in real time. A dynamic torque sensor (HBM T20WN torque sensor) is used, installed on the connecting shaft between the lower spindle 2 and its corresponding servo motor, used to collect the torque of the sample 7 under test in real time during rotation. LPR corrosion sensors are uniformly pasted on the non-friction contact area of ​​the surface of the sample 7 under test (such as the outer ring of the upper surface of the sample 7 under test; Gamry Reference LPR corrosion sensors can be used). The 600+ electrochemical workstation's matching electrodes are used for real-time acquisition of polarization resistance. The LPR corrosion sensor probe is electrically connected to the surface of the sample 7 under test for real-time acquisition of polarization resistance. Temperature and humidity sensors are evenly arranged inside the environmental test chamber 1 and close to the sample 7 under test for real-time acquisition of temperature and relative humidity inside the environmental test chamber 7 (the temperature sensor model can be PT100, and the humidity sensor model can be SHT30). The salt spray concentration sensor is installed below the outlet of the spray device (the salt spray concentration sensor model can be HAD-YWH6) for real-time acquisition of salt spray concentration.

[0026] Example 2: As another preferred embodiment of the present invention, a multi-form corrosion and wear testing method under multiple environmental factors employs the testing system described in Example 1, comprising: Step S1, Pre-test Preparation: Fix the sample 7 to be tested at the top of the lower main shaft 2, and simultaneously drive the loading block 5 to move so that its inner wall effectively contacts the outer wall of the sample 7. Specifically, control the positioning plate 3 to move downward along the axis of the upper main shaft 1 via the telescopic rod 6, so that the loading block 5 corresponds with the sample 7. Stop the movement of the telescopic rod 6, and then start the push rod 51 to push the loading block 5 towards the side closer to the sample 7 until the loading block 5 contacts the outer wall of the sample 7. At the same time, set the target temperature through the heating device, and spray through the spray device to make the environmental test chamber reach the target relative humidity and salt spray concentration.

[0027] Step S2, Start the test: Control the upper spindle 1 and the lower spindle 2 to rotate simultaneously and in opposite directions, with the upper spindle 1 rotating at a low speed and the lower spindle 2 rotating at a high speed, so that the loading block 5 and the sample to be tested 7 rotate synchronously and in opposite directions to achieve friction; during the rotation, the loading block 5 is moved synchronously (the control of multiple loading blocks 5 is synchronized and the moving distance is synchronized) to enhance friction and accelerate aging.

[0028] Step S3, Real-time Monitoring: During the test, multi-dimensional data is collected synchronously and preprocessed. This multi-dimensional data includes: laser displacement data obtained through a laser displacement sensor. s i (t) , i =1,2,…,6; Extrusion pressure data is obtained through pressure sensors: F i (t) , i =1,2,…,6; Torque data is obtained through a torque sensor: T(t) Corrosion data was obtained using an LPR corrosion sensor. R p (t) , p =1,2,…, n Temperature data is obtained through a temperature and humidity sensor. T env (t) relative humidity data H env (t) Salt spray concentration is obtained through a salt spray concentration sensor. S env (t) .

[0029] Data preprocessing specifically includes: For laser displacement data, a dynamic moving average filter is first used to resolve data fluctuations caused by the counter-rotation of the upper and lower spindles: ; In the formula: s r,i (t) Indicates the first i A laser displacement sensor t Raw data collected in real time; s fil,i (t) This represents the filtered data; This indicates the time interval for data acquisition by the laser displacement sensor; N Indicates the rotation of the sample under test S q The number of collection points corresponding to the circle: ; In the formula: n 1 indicates the rotational speed of the sample under test, i.e., the lower spindle; f s Indicates the sampling frequency of the laser displacement sensor; Next, temperature compensation is performed on the filtered data to avoid sensor drift and sample thermal expansion caused by temperature changes. ; In the formula: k T This represents the temperature correction factor (obtained through calibration); for example: setting three temperatures (e.g., 25℃, 50℃, 80℃) in an environmental test chamber, maintaining a dry environment free of salt spray, stabilizing at each temperature for 30 minutes, and then collecting sensor distance data. Calculate the distance deviation at different temperatures: ; In the formula: Indicates temperature as T env Average distance over time; This represents the average distance at a temperature of 25℃ (i.e., room temperature). The temperature correction coefficient was obtained by linear fitting: ; Finally, adopt The criteria apply to temperature-compensated data: ; In the formula: M This indicates the number of data points within the statistics window; This represents the mean of the data. The standard deviation of the data; like or If it is an outlier, it is considered an outlier and removed; the valid data from the previous time point is used instead. Substitute; For extrusion pressure and torque data, dynamic moving average filtering and... Criterion processing enables data preprocessing; Finally, the data is synchronized and aligned: Since different sensors collect data at different frequencies, low-frequency data (such as corrosion, temperature and humidity, salt spray concentration, etc.) are linearly interpolated and aligned with the target frequency data (compression pressure, torque, laser displacement, etc.). ; In the formula: t x Indicates the timestamp at the target synchronization frequency. t k ,t k-1 This represents two adjacent timestamps in low-frequency raw data; x low This represents low-frequency raw data. x syn This indicates the synchronized data.

[0030] Wear amount, corrosion rate, and friction coefficient are obtained in real time from the preprocessed data. The real-time wear amount is: ; In the formula: This indicates the fixed distance after the laser displacement sensor has been calibrated; R 0 represents the initial radius of the sample to be tested; R (t) Indicates the real-time radius of the sample under test; and R 0 is obtained through initial calibration, specifically: First, obtain the fixed distance from the installation position of each laser displacement sensor to the central axis of the loading ring. L i ( i =1,2,…,6 (which can be measured using a coordinate measuring machine), and the fixed distance is obtained by taking the average value of each laser displacement sensor: ; Then, after fixing the sample to be tested, without starting the spindle rotation or applying any load, adjust the position of the positioning plate using the telescopic rod so that the laser displacement sensor is aligned with the center of the sample (outside the loading block area to avoid initial contact wear). Each laser displacement sensor collects data. n c Initial distance data: s 0i,k ( k =1,2,…, n c ), to obtain the initial radius of the sample to be tested: ; The real-time corrosion rate is: ; In the formula: K This represents the calibrated corrosion rate conversion factor; B This represents the metal corrosion constant (e.g., 26 mV). R p (t) This represents the real-time polarization resistance measured by the LPR sensor; M k Indicates the molar mass of the material in the sample being tested. n KThis indicates the number of reaction electrons in the sample material (i.e., the number of electrons gained or lost by a single atom in the corrosion electrochemical reaction, which can be determined by consulting the electrochemical corrosion equation of the material in the corresponding corrosion environment or by combining polarization curve testing). Tafel (slope obtained) This indicates the density of the material in the sample being tested. z K The valence of the sample material is indicated (i.e., the valence state of the main metal element in the corrosion product, which is usually consistent with the number of electrons in the reaction; the valence of the corresponding metal element can be obtained by looking up the common corrosion product composition of the corresponding material). f F This represents the Faraday constant (typically 96500 C / mol). Real-time friction coefficient: ; In the formula: T(t) The real-time torque measured by the torque sensor; T 0 represents the no-load torque, which is the torque when the upper and lower main shafts rotate at the test speed without applying any load (the push rod is not pushed forward). The average loading force is obtained by averaging the real-time values ​​from each pressure sensor.

[0031] The performance evaluation was completed by combining environmental remediation with wear and corrosion levels, specifically as follows: First, obtain the environmental correction factor: ; In the formula: The regression coefficients are obtained through prior experimental calibration, for example, by testing comprehensive damage data at different times under three different combinations of environmental parameters and fitting the data using the least squares method; in this embodiment, (Adjustments can be made based on the actual materials) Then, by combining the wear amount and corrosion rate, the overall damage degree is obtained: ; In the formula: W max This indicates the maximum allowable wear of the sample under test (i.e., the wear threshold for component failure, which is preset based on a large amount of empirical data). v c,max This indicates the maximum permissible corrosion rate of the sample under test (pre-set based on material conditions and extensive empirical data). This represents the weighting coefficient (pre-calibrated based on material properties). For example: for wear-sensitive materials For corrosion-sensitive materials ); Preset minor damage threshold D all,f With the threshold of severe injury D all,e (generally D all,f =0.3、 D all,e =0.7), if If , then the sample under test is considered to have minor damage at that moment. If , then the sample under test is considered to have moderate damage at that moment. If the value is 0, then the sample under test at that moment is considered to be severely damaged. When this occurs, it is considered a failure state; Synchronously acquire the wear rate at the corresponding moment. With corrosion rate v cor (t) This enables individual and comprehensive evaluation of wear and corrosion during the testing of the sample under test; ; In the formula: This indicates the adjustment period (usually 0.5s).

[0032] Step S4, Dynamic Adjustment of Loading Force: Based on the real-time damage level, the loading force is dynamically adjusted using a PID control algorithm. Specifically, an incremental PID control algorithm is used to output the adjustment amount of the loading force. ; In the formula: K p , K i , K d These represent the proportional coefficient, integral coefficient, and differential coefficient, respectively (determined by the Ziegler-Nichols calibration method). deviation signal e(t) : ; In the formula: This represents the target overall damage rate (the damage rate that is preset and expected to be maintained during the experiment). Afterwards, new loading force is obtained: ; ; In the formula: F min This indicates the minimum load constraint (the minimum compressive force that ensures effective contact between the loading block and the test sample). F maxThis indicates the maximum constraint on the applied force (the maximum compressive force to prevent plastic deformation of the test specimen). Finally, the new loading force will be applied. Converted into displacement commands for each push rod: ; In the formula: k g This indicates the stiffness of the loading system (obtained through prior calibration).

[0033] For example: In a non-corrosive environment (normal temperature, dry) and non-rotating state, five sets of known standard forces are applied to each loading block via a push rod. F std,j , ( j =1,2,…,5 (values ​​100N, 200N, 300N, 400N, 500N), record the displacement sensor readings corresponding to each force group. d std,ij ; The stiffness of each loaded system is fitted using the least squares method. k g,i : ; Finally, the average stiffness of the six loaded blocks was obtained. k g : .

[0034] Example 3 As another preferred embodiment of the present invention, based on the above-described embodiment 2, the present invention further includes a final performance evaluation of the components, specifically: The corrosion wear test shall be terminated and all components shall be reset when any of the following conditions are met: 1) Overall damage level D all (t) ≥1, component failure; 2) Real-time wear W(t) ≥ W max ; 3) Real-time corrosion rate v cor (t) ≥2· v c,max Uncontrolled corrosion; 4) Coefficient of friction U(t) ≥0.8 or U(t) ≤0.1, abrupt change in surface state; 5) The preset maximum test time is reached; The time ends at [time].t end The wear performance, corrosion performance and comprehensive performance were evaluated after termination. Wear performance includes cumulative wear, average wear rate, and wear stability. Cumulative wear is: ; The average wear rate is: ; Wear stability ( The smaller the value, the more stable the wear and tear. ; ; In the formula: Indicates the first k Instantaneous wear rate per cycle; Corrosion performance includes cumulative corrosion depth, average corrosion rate, and corrosion susceptibility. The cumulative corrosion depth is: ; The average corrosion rate is: ; Corrosion sensitivity ( m cor The larger the value, the more sensitive the material is to environmental changes. ; The comprehensive performance evaluation includes a comprehensive performance index and failure mode determination. The comprehensive performance index is: ; In the formula: This indicates the average adjustment efficiency of the applied force. Indicates the average corrosion-wear synergy coefficient; ; ; P The larger the value, the better the overall performance. Failure mode determination: when W total / h cor,total When the value is greater than 10, the dominant failure mode is determined to be wear. W total / h cor,total When the value is less than 0.1, the dominant failure mode is determined to be corrosion; when 0.1 ≤ W total / h cor,totalWhen the value is ≤10, the dominant failure mode is determined to be the coupling of corrosion and wear.

Claims

1. An integrated testing system for multi-form corrosion and wear under multiple environmental factors, characterized in that: The system includes an environmental testing chamber and sensor components. The environmental testing chamber has an upper spindle and a lower spindle, which are rotatably mounted at the top and bottom, respectively, with their central axes collinear. A fixing component is mounted at the top of the lower spindle. A positioning plate is slidably mounted on the outer wall of the upper spindle, and a loading ring is fixedly connected to the bottom of the positioning plate via a connecting block. The loading ring is coaxial with the lower spindle. Multiple arc-shaped loading blocks are evenly arranged on the inner wall of the loading ring around its central axis. A push rod is mounted on the side of each loading block away from the central axis of the loading ring. The environmental testing chamber contains a heating device and a spray device. The sensor components include a laser displacement sensor, a pressure sensor, a torque sensor, an LPR corrosion sensor, a temperature and humidity sensor, and a salt spray concentration sensor. The testing methods for this system include: Step S1, Pre-test preparation: Fix the sample to be tested at the top of the lower spindle, and drive the loading block to move so that its inner wall can effectively contact the outer wall of the sample to be tested; at the same time, set the target temperature through the heating device, and spray through the spray device to make the environmental test chamber reach the target relative humidity and salt spray concentration. Step S2, Start the test: Control the upper and lower spindles to rotate simultaneously and in opposite directions, with the upper spindle rotating at low speed and the lower spindle rotating at high speed, so that the loading block and the sample under test rotate synchronously and in opposite directions to achieve friction; during the rotation, the loading block is moved synchronously to enhance friction; Step S3, Real-time monitoring: During the test, multi-dimensional data is collected synchronously and preprocessed. Wear amount, corrosion rate, and friction coefficient are obtained in real time through the preprocessed data. Performance evaluation is completed by combining environmental correction with wear amount and corrosion degree. Performance evaluation is completed by combining environmental remediation with the comprehensive damage level of wear and corrosion. Specifically: First, obtain the environmental correction factor: ； In the formula: Represents the regression coefficient. T env (t) Representing temperature data, H env (t) This represents relative humidity data. S env (t) Indicates salt spray concentration; Then, by combining the wear amount and corrosion rate, the overall damage degree is obtained: ； In the formula: W max This indicates the maximum allowable wear on the sample under test; v c,max This indicates the maximum permissible corrosion rate of the sample under test; Indicates the weighting coefficient; Preset minor damage threshold D all,f With the threshold of severe injury D all,e ,like If , then the sample under test is considered to have minor damage at that moment. If , then the sample under test is considered to have moderate damage at that moment. If the value is 0, then the sample under test at that moment is considered to be severely damaged. When this occurs, it is considered a failure state; Synchronously acquire the wear rate at the corresponding moment. With corrosion rate v cor (t) This enables individual and comprehensive evaluation of wear and corrosion during the testing of the sample under test; ； In the formula: Indicates the adjustment period; Step S4, Dynamic Adjustment of Loading Force: Based on the real-time damage level, the loading force is dynamically adjusted using a PID control algorithm.

2. The integrated testing system for multi-form corrosion and wear under multiple environmental factors according to claim 1, characterized in that: The upper spindle is provided with a spline on its outer wall, and a spline hole is correspondingly opened in the middle of the positioning plate. The spline hole is slidably sleeved on the outer wall of the spline. A limit block is provided at the bottom of the upper spindle.

3. The integrated testing system for multi-form corrosion and wear under multiple environmental factors according to claim 1 or 2, characterized in that: Multiple telescopic rods are evenly arranged on the top surface of the inner cavity of the environmental test chamber and on the outer ring of the upper main shaft. An annular groove is opened on the top surface of the positioning plate corresponding to the telescopic rods. The bottom end of the telescopic rod is slidably engaged in the annular groove to realize the control and positioning of the up and down sliding of the positioning plate.

4. The integrated testing system for multi-form corrosion and wear under multiple environmental factors according to claim 3, characterized in that: Multiple laser displacement sensors are installed on the inner wall of the loading ring. Each laser displacement sensor is located between two adjacent loading blocks with its laser emission end pointing vertically towards the outer wall of the sample under test. The pressure sensor is a strain gauge type pressure sensor, which is located at the connection between the push rod and the loading block. The torque sensor is a dynamic torque sensor, installed on the connecting shaft between the lower spindle and its corresponding servo motor. The LPR corrosion sensor is uniformly pasted on the non-friction contact area of ​​the sample surface, and the probe of the LPR corrosion sensor is electrically connected to the sample surface. The temperature and humidity sensors are uniformly arranged in the inner cavity of the environmental test chamber and close to the sample. The salt spray concentration sensor is installed below the outlet of the spray device.

5. The integrated testing system for multi-form corrosion and wear under multiple environmental factors according to claim 4, characterized in that: In step S3, the multi-dimensional data includes: laser displacement data obtained through a laser displacement sensor. s i (t) , i =1,2,…,6; Extrusion pressure data is obtained through pressure sensors: F i (t) , i =1,2,…,6; Torque data is obtained through a torque sensor: T(t) Corrosion data was obtained using an LPR corrosion sensor. R p (t) , p =1,2,…, n Temperature data is obtained through a temperature and humidity sensor. T env (t) relative humidity data H env (t) Salt spray concentration is obtained through a salt spray concentration sensor. S env (t) .

6. The integrated testing system for multi-form corrosion and wear under multiple environmental factors according to claim 5, characterized in that: In step S3, the data preprocessing specifically includes: For laser displacement data, a dynamic moving average filter is first used to resolve data fluctuations caused by the counter-rotation of the upper and lower spindles: ； In the formula: s r,i (t) Indicates the first i A laser displacement sensor t Raw data collected in real time; s fil,i (t) This represents the filtered data; This indicates the time interval for data acquisition by the laser displacement sensor; N Indicates the rotation of the sample under test S q The number of collection points corresponding to the circle: ； In the formula: n 1 indicates the rotational speed of the sample under test, i.e., the lower spindle; f s This indicates the sampling frequency of the laser displacement sensor; Next, temperature compensation is performed on the filtered data to avoid sensor drift and sample thermal expansion caused by temperature changes. ； In the formula: k T This represents the temperature correction factor; Finally, adopt The criteria apply to temperature-compensated data: ； In the formula: M This indicates the number of data points within the statistics window; This represents the mean of the data. The standard deviation of the data; like or If it is an outlier, it is considered an outlier and removed; the valid data from the previous time point is used instead. Substitute; For extrusion pressure and torque data, dynamic moving average filtering and... Criterion processing enables data preprocessing; Finally, the data is synchronized and aligned: Since different sensors collect data at different frequencies, low-frequency data is linearly interpolated to match the target frequency data. ； In the formula: t x Indicates the timestamp at the target synchronization frequency. t k , t k-1 This represents two adjacent timestamps in low-frequency raw data; x low This represents low-frequency raw data. x syn This indicates the synchronized data.

7. The integrated testing system for multi-form corrosion and wear under multiple environmental factors according to claim 6, characterized in that: In step S3, the real-time wear amount is: ； In the formula: This indicates the fixed distance after the laser displacement sensor has been calibrated; R 0 represents the initial radius of the sample to be tested; R(t) Indicates the real-time radius of the sample under test; and R 0 is obtained through initial calibration, specifically: First, obtain the fixed distance from the installation position of each laser displacement sensor to the central axis of the loading ring. L i , i =1,2,…,6, and the fixed distance is obtained by averaging the values ​​of each laser displacement sensor: ； Then, after fixing the sample to be tested, without starting the spindle rotation or applying any load, the position of the positioning plate is adjusted by the telescopic rod so that the laser displacement sensor is aligned with the center of the sample. Each laser displacement sensor collects data. n c Initial distance data: s 0i,k , k =1,2,…, n c To obtain the initial radius of the sample to be tested: ； The real-time corrosion rate is: ； In the formula: K This represents the calibrated corrosion rate conversion factor; B Indicates the metal corrosion constant; R p (t) This represents the real-time polarization resistance measured by the LPR sensor; M k Indicates the molar mass of the material in the sample being tested. n K Indicates the number of reaction electrons in the sample material being tested. This indicates the density of the material in the sample being tested. z K Indicates the valence of the material in the sample to be tested. f F Denotes Faraday's constant; Real-time friction coefficient: ； In the formula: T(t) The real-time torque measured by the torque sensor; T 0 represents the no-load torque, which is the torque when the upper and lower spindles rotate at the test speed without any applied force. This represents the average applied force.

8. The integrated testing system for multi-form corrosion and wear under multiple environmental factors according to claim 7, characterized in that: Step S4 specifically involves: employing an incremental PID control algorithm to output the adjustment amount of the loading force. ； In the formula: K p , K i , K d These represent the proportional coefficient, integral coefficient, and differential coefficient, respectively. Deviation signal e(t) : ； In the formula: Indicates the overall damage rate of the target; Afterwards, new loading force is obtained: ； ； In the formula: F min This indicates a minimum load constraint. F max This indicates the maximum constraint on the applied force; Finally, the new loading force will be applied. Converted into displacement commands for each push rod: ； In the formula: k g This indicates the stiffness of the loaded system.

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