Refrigerant leak detection device and leak detection method thereof

Abstract

This invention discloses a refrigerant leak detection device and method, relating to the field of refrigeration equipment testing technology. The device includes an openable / closable sealed enclosure, a refrigerant release pipeline, a control cabinet, a water bath heating mechanism, a testing chamber, and an exhaust system. The sealed enclosure fully encloses a refrigerant storage tank, securely connected with a self-sealing connector. The refrigerant release pipeline, after flow closed-loop control and water bath constant temperature treatment, precisely releases the refrigerant to the dead corner of the equipment under test through a flexible hose, replicating the actual leakage conditions. The testing chamber has multiple independent testing areas, equipped with a sliding guide rail and height-adjustable testing mechanism, allowing the probe to penetrate deep into dead corners without blind spots. The control cabinet integrates temperature control, data processing, and alarm functions, while the exhaust system accommodates both gas replacement and emergency ventilation. The leak detection method covers the entire process of preparation, configuration, data collection, analysis, and reset, solving the problems of large blind spots and distorted simulation of operating conditions in existing devices, achieving accurate, efficient, and safe detection of leaks in dead corners of refrigeration equipment.

Description

Technical Field

[0001] This invention relates to the field of refrigeration equipment testing technology, specifically to a leak detection device for simulating and detecting refrigerant leaks in hidden blind spots of refrigeration equipment, and a matching leak detection method. Background Technology

[0002] Refrigerant, as the core working medium in refrigeration and air conditioning equipment such as commercial refrigeration units and automotive air conditioning systems, directly determines the stability, energy efficiency, and safety of equipment operation through the sealing performance of its pipelines and components. With the miniaturization, integration, and modularization of refrigeration equipment, hidden areas such as welded seams, bends, valve interfaces, and shell gaps have become high-risk locations for refrigerant leaks. These dead-angle leaks are highly concealed and difficult to detect. Even minor leaks can lead to reduced refrigeration efficiency and medium loss, as well as environmental pollution. For new low-GWP flammable refrigerants, accumulated leaks can pose significant safety hazards such as explosions and fires. Therefore, accurate simulation and detection of leaks in dead-angle areas of refrigeration equipment is a core aspect of factory quality inspection and maintenance.

[0003] Currently available refrigerant leak detection devices suffer from numerous technical shortcomings in practical applications, failing to meet the demands for high precision, high safety, and high simulation accuracy in leak detection. Specific problems include: Firstly, the lack of secure sealing protection for refrigerant gas storage poses significant safety and operational hazards. Most existing systems expose refrigerant storage tanks directly to the work environment, connecting them to pipelines only via simple valves, without dedicated sealing structures. This not only makes leakage at the connection points prone to occur, but the accumulation of flammable refrigerant leaks can easily trigger safety accidents. Furthermore, the disassembly and assembly of storage tanks are cumbersome, with poor compatibility between different tank sizes. During disassembly and assembly, residual refrigerant in the pipelines can easily be released uncontrollably, polluting the work environment and endangering the health of operators.

[0004] Secondly, it cannot simulate the real-world operating conditions of leaks in dead corners of refrigeration equipment, resulting in highly distorted test results. Existing leak detection devices can only release refrigerant into the entire testing chamber or perform leak detection in open spaces outside the equipment. They cannot accurately deliver refrigerant to the hidden dead corner areas of the equipment under test, completely failing to reproduce the real scenario of refrigerant leaking from internal dead corners and spreading along gaps during actual equipment operation. This leads to the failure of leak detection sensitivity calibration, resulting in a large number of micro-leakage problems in dead corners going undetected, and the test results deviating greatly from actual operating conditions.

[0005] Third, the refrigerant release parameters lack precise control capabilities, and the operating condition simulation is limited. In actual operation of refrigeration equipment, the refrigerant leakage flow rate and operating temperature directly affect the leakage diffusion characteristics and detection effectiveness. However, existing devices cannot achieve closed-loop precise adjustment of the refrigerant release flow rate, nor do they have a stable and controllable heating and temperature control structure. They can only conduct static detection at normal temperature and pressure, and cannot simulate real operating conditions such as high-temperature operation and low-temperature start-up, making it difficult to capture micro-leakage defects under variable temperature and flow rates.

[0006] Fourth, the rigid layout of testing facilities results in numerous blind spots in inspection. Most existing testing probes are fixed in position and cannot be adjusted, making it impossible to reach the complex and hidden blind spots of the equipment under inspection. Some use handheld probes, which not only leads to low testing efficiency but also makes the consistency of testing entirely dependent on human experience, making it prone to missed detections and unable to meet the needs of large-scale and standardized quality inspection.

[0007] Fifth, the equipment has low functional integration and lacks supporting safety and environmental protection designs. The existing equipment's flow control, temperature regulation, and data processing functions are scattered and independent, making it impossible to achieve integrated and collaborative management and control, resulting in an extremely low level of automation. At the same time, the testing chamber lacks a standardized exhaust emergency system, and residual refrigerant is directly discharged after testing, which not only fails to meet environmental protection requirements but also cannot cope with emergency ventilation in case of excessive leakage, resulting in insufficient safety management capabilities.

[0008] In view of the many shortcomings of the existing technologies, the development of a refrigerant leak detection device that can accurately simulate dead zone leaks, ensure gas source safety and sealing, achieve closed-loop parameter control, detect without blind spots, and has highly integrated functions has become an urgent problem to be solved in this field. Summary of the Invention

[0009] I. Purpose of the Invention This invention aims to solve the technical problems of existing refrigerant leak detection devices, such as lack of sealing protection for gas source storage, inability to accurately simulate dead zone leaks, poor accuracy in controlling refrigerant release parameters, blind spots in detection probes, low functional integration, and lack of a safe and environmentally friendly exhaust system. It provides a refrigerant leak detection device and matching leak detection method with reasonable structural design, accurate operating condition simulation, comprehensive detection, and safety and environmental protection.

[0010] II. Technical Solution

[0011] To achieve the above-mentioned objectives, the present invention adopts the following technical solution: (a) Refrigerant leak detection device A refrigerant leak detection device, the key features of which include an openable and closable sealed enclosure, a refrigerant release pipeline, a control cabinet, a heating mechanism, a detection chamber, and an exhaust system; The internal space of the openable and closable sealed enclosure forms a sealed cavity for sealing and accommodating the refrigerant storage tank. A pipeline connection interface is provided in the sealed cavity. The pipeline connection interface is connected to the inlet of the refrigerant release pipeline. When the refrigerant storage tank is placed in the sealed cavity, its outlet is sealed and connected to the pipeline connection interface. Along the medium flow direction of the refrigerant release pipeline, the flow control unit and heating mechanism built into the control cabinet are connected in series on the refrigerant release pipeline. The refrigerant release pipeline extends to the experimental area of ​​the testing chamber after passing through the heating mechanism. The end of the refrigerant release pipeline is provided with a refrigerant release end that can be positioned to the dead corner area of ​​the equipment under test, so as to accurately release refrigerant in the dead corner area of ​​the equipment under test to simulate the dead corner leakage condition in actual operation of the refrigeration equipment. The testing chamber is an openable and closable simulation test chamber. Inside, a refrigerant detector is arranged in the corresponding experimental area. The probe of the refrigerant detector can extend to the dead corner area of ​​the equipment under test, and is used to detect the refrigerant leakage of the equipment under test under simulated dead corner leakage conditions. The control cabinet also has a built-in temperature control unit and a data processing unit. The temperature control unit is connected to the heating mechanism to adjust the operating temperature of the refrigerant release. The data processing unit is connected to each of the refrigerant detectors to receive, display and analyze the leakage detection data returned by the refrigerant detectors. The exhaust system is connected to the internal space of the testing chamber and is used for gas replacement and emergency ventilation of the testing chamber.

[0012] Furthermore, the sealed enclosure wall adopts an explosion-proof and heat-insulating structure, and its opening is equipped with a sealed door with a safety interlock. The sealed cavity is equipped with a rotating tray for placing a refrigerant storage tank, and the pipeline connection interface is a self-sealing quick connector. When the refrigerant storage tank is placed on the rotating tray, its outlet can achieve a sealed connection with the self-sealing quick connector.

[0013] Furthermore, the flow control unit includes an electric proportional regulating valve and a mass flow sensor connected in series on the refrigerant release pipeline. The signal output terminal of the mass flow sensor is electrically connected to the data processing unit. The data processing unit outputs a control signal to the electric proportional regulating valve based on a preset leakage simulation flow threshold and real-time collected flow data to regulate the refrigerant release flow in a closed loop. The refrigerant release pipeline also includes a shut-off valve and a filter pressure reducing valve connected in series between the pipeline connection interface and the flow control unit.

[0014] Furthermore, the heating mechanism includes a sealed water bath chamber, a circulating heating pump, a refrigerant pipe, and temperature sensors. The refrigerant pipe is arranged in a circuitous manner inside the water bath chamber, with its two ends serving as a refrigerant inlet and a refrigerant outlet, respectively, connected to a refrigerant release pipeline. The circulating heating pump is connected to the water bath chamber and is used to drive the water bath medium to circulate and heat, maintaining a constant temperature. The temperature sensors are respectively located at the refrigerant inlet and refrigerant outlet of the water bath chamber, and are both connected to the temperature control unit of the control cabinet. The temperature control unit adjusts the heating power of the circulating heating pump based on the feedback data from the temperature sensors to achieve constant temperature control of the refrigerant.

[0015] Furthermore, at least one section of the refrigerant pipe employs a spiral winding structure.

[0016] Furthermore, the interior of the testing chamber is divided into multiple independent testing zones. The refrigerant release pipeline branches into refrigerant release branches corresponding to each testing zone. Each refrigerant release branch is connected in series with an electromagnetic valve controlled by the control cabinet. The end of each refrigerant release branch serves as the refrigerant release end for the corresponding testing zone. This refrigerant release end extends to the blind spot area of ​​the equipment under test within the corresponding testing zone through a detachable flexible metal hose, realizing zoned and fixed-point refrigerant release.

[0017] Furthermore, the individual detection zones are connected in series via guide rails, on which a sliding frame is provided. The sliding frame is provided with a height-adjustable mounting base, and a clamp is provided on the mounting base via a flexible metal bracket. The refrigerant detector is clamped and fixed on the clamp.

[0018] Furthermore, the sliding frame can slide and switch between independent detection zones along the guide rail, the mounting base can be infinitely adjusted in height on the sliding frame via a hand-adjusting bolt, and the flexible metal bracket can be shaped and bent to position the probe of the refrigerant detector to any blind spot area of ​​the equipment under test.

[0019] Furthermore, the control cabinet is also equipped with an alarm unit and a human-machine interaction unit. The alarm unit is used to trigger audible and visual alarms when leakage exceeds the standard, flow is abnormal, or temperature is abnormal. The human-machine interaction unit is used for setting detection parameters, controlling the detection process, and visually displaying detection data. The data processing unit is also used to store the entire process detection data, automatically generate standardized detection reports, and has the function of full-process traceability and remote transmission of detection data.

[0020] (ii) Leak detection methods Based on the above-mentioned refrigerant leak detection device, the present invention also provides a matching leak detection method, the key of which includes the following steps: S1 device preparation stage: Place the refrigerant storage tank on the rotating tray of the sealed box, and make its outlet seal with the self-sealing quick connector. Close the sealed box and lock the safety interlock. Fix the device to be tested in the experimental area of ​​the target detection area. Use a flexible metal hose to accurately position the refrigerant release end of the corresponding detection area to the blind spot area of ​​the device to be tested. At the same time, adjust the sliding frame, height-adjustable mounting base and flexible metal bracket so that the probe of the refrigerant detector extends to the same blind spot area. S2 operating condition parameter configuration stage: The target leakage simulation flow rate and refrigerant heating temperature are set through the human-machine interaction unit of the control cabinet, and the target detection area to be detected is selected. The control cabinet controls the electromagnetic opening and closing valve of the corresponding detection area to be in the ready-to-open state according to the selection. S3 Simulation Leakage and Data Acquisition Stage: The control cabinet controls the opening of the electromagnetic valves in the corresponding detection area. The refrigerant release flow is adjusted to the preset value through the electric proportional regulating valve of the flow control unit and the mass flow sensor in a closed loop. At the same time, the temperature control unit adjusts the heating power of the circulating heating pump based on the feedback data from the temperature sensors at the refrigerant inlet and outlet of the water bath chamber, so that the refrigerant maintains the preset operating temperature and is accurately released from the dead zone area of ​​the equipment under test. The refrigerant detector collects leakage data in real time and transmits it back to the data processing unit of the control cabinet. S4 Leakage Analysis and Result Output Stage: The data processing unit analyzes the collected leakage data, determines whether the leakage of the equipment under test meets the preset qualification standards under the simulated dead zone leakage condition, automatically generates a standardized test report, and completes the storage, visualization and traceability of the test data. S5 Exhaust and Device Reset Stage: After the test is completed, the control cabinet closes the electromagnetic valves and refrigerant release pipelines of the corresponding test area, and starts the exhaust system to replace the gas inside the test chamber; after the refrigerant concentration in the chamber drops to the preset safety threshold, the sliding frame, height-adjustable mounting base and flexible metal bracket are reset, the test chamber is opened and the equipment to be tested is taken out, and the complete leak detection process is completed.

[0021] III. Beneficial Effects Compared with the prior art, the present invention has the following beneficial effects: (i) Safe and sealed gas source storage eliminates leakage and operational hazards. The sealed enclosure with explosion-proof heat insulation structure and safety interlock sealing door is used, along with self-sealing quick connectors and rotating trays, to achieve fully enclosed containment and quick sealing connection of refrigerant storage tanks, effectively avoiding storage tank exposure and connection leakage problems; the rotating tray can improve tank adaptability and ease of disassembly and assembly, eliminating fugitive refrigerant emissions and safety accidents from the source, ensuring operational safety and environmental protection.

[0022] (ii) Accurately simulate dead zone leakage conditions, and the test results are close to reality. Through branch pipelines and flexible metal hoses, the refrigerant release end is accurately extended into the dead zone area of ​​the equipment under test to achieve targeted release and completely restore the dead zone leakage diffusion scenario in the actual operation of refrigeration equipment; with the multi-detection zone design, multi-station leak detection can be carried out simultaneously, which greatly improves the authenticity and efficiency of the test.

[0023] (III) Closed-loop control of release parameters and comprehensive and accurate simulation of operating conditions. The flow control unit realizes closed-loop precise regulation of refrigerant release flow through an electric proportional regulating valve and a mass flow sensor; the water bath heating mechanism, in conjunction with a dual-point temperature sensor, achieves constant temperature heating and temperature control of the refrigerant; the spiral-wound refrigerant pipe can improve heating uniformity, thereby simulating real operating conditions at different temperatures and flow rates, accurately capturing micro-leakage defects, and avoiding detection distortion.

[0024] (iv) The testing mechanism is flexible and adjustable, completely eliminating blind spots in the testing. The guide rail sliding frame, together with the height-adjustable mounting base and the fixed flexible metal bracket, can realize multi-dimensional and all-round adjustment of the refrigerant detector, allowing the probe to penetrate into any hidden dead corner; the sliding switching design is suitable for multi-testing area transfer testing, replacing manual hand operation, improving the consistency and comprehensiveness of testing, and eliminating missed detections.

[0025] (V) Highly integrated functions and effective safety and environmental protection management. The control cabinet integrates flow regulation, temperature control, data processing, alarm and human-machine interaction functions to realize automated and collaborative management of the entire leak detection process; the supporting exhaust system can complete routine gas replacement and emergency ventilation, and the sound and light alarm function can monitor abnormal operating conditions in real time; the data storage and report generation function realizes full traceability of the detection process, taking into account automation, safety and environmental protection. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the overall structure of the refrigerant leak detection device in this invention (I); Figure 2 This is a schematic diagram (II) of the overall structure of the refrigerant leak detection device in this invention. Figure 3 yes Figure 2 Enlarged view of part A in the middle; Figure 4 This is a schematic diagram of the internal structure of the main components of the refrigerant leak detection device in this invention (I). Figure 5 yes Figure 4 Enlarged view of part B in the middle; Figure 6 This is a schematic diagram (II) of the internal structure of the main components of the refrigerant leak detection device in this invention. Figure 7 yes Figure 6 Enlarged view of a section in the middle C; Figure 8 This is a schematic diagram (a) of the internal structure of the detection chamber of the refrigerant leak detection device in this invention. Figure 9 This is a schematic diagram (II) of the internal structure of the detection chamber of the refrigerant leak detection device in this invention; The markings in the diagram are as follows: 1-Openable and closable sealed enclosure, 2-Refrigerant release pipeline, 3-Control cabinet, 4-Heating mechanism, 5-Detection chamber, 6-Exhaust system, 7-Refrigerant storage tank, 8-Pipeline connection interface, 9-Refrigerant detector, 101-Sealed door, 102-Rotating tray, 401-Sealed water bath chamber, 402-Circulating heating pump, 403-Refrigerant pipe, 404-Temperature sensor, 201-Refrigerant release branch pipe, 202-Electromagnetic opening and closing valve, 203-Removable flexible metal hose, 501-Guide rail, 502-Sliding frame, 503-Mounting base, 504-Flexible metal bracket, 505-Clamp, 506-Manual adjustment bolt. Detailed Implementation

[0028] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0029] In the description of this invention, it should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, in the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0030] Please see Figures 1 to 9The core of this refrigerant leak detection device consists of six major modules: an openable and closable sealed housing 1, a refrigerant release pipeline 2, a control cabinet 3, a heating mechanism 4, a detection chamber 5, and an exhaust system 6. These modules work together to simulate and accurately detect refrigerant leaks in dead zones.

[0031] The openable and closable sealed enclosure 1 serves as the gas source storage module. The enclosure walls are constructed from explosion-proof and heat-insulating materials, providing explosion-proof, flame-retardant, and heat-insulating properties. This effectively prevents heat transfer between the interior and the external environment, while also mitigating safety risks caused by leaks. A sealed door 101 with a safety interlock is installed at the enclosure opening. The device can only be started and operated after the sealed door 101 is completely closed and locked, preventing refrigerant leaks due to misoperation. A rotating tray 102 is installed inside the sealed cavity to accommodate refrigerant storage tanks 7 of different sizes. The angle of the tank can be adjusted by rotation, facilitating precise connection between the tank outlet and the pipeline connection interface 8. The pipeline connection interface 8 uses a self-sealing quick-connect coupling. After the refrigerant storage tank 7 is placed in position, the coupling quickly and tightly seals with the tank outlet. No additional tools are required for assembly and disassembly, and the coupling has a built-in check valve to prevent backflow and leakage of residual refrigerant in the pipeline.

[0032] The refrigerant release pipeline 2 serves as the medium delivery channel, with the flow control unit and heating mechanism 4 connected in series along the medium flow direction. The pipeline is made of pressure-resistant and corrosion-resistant material, suitable for various refrigerant delivery requirements. The flow control unit includes an electric proportional regulating valve, a mass flow sensor, a shut-off valve, and a filter pressure reducing valve. The shut-off valve, located at the beginning of the pipeline, acts as the main control valve for pipeline on / off, enabling control of the gas source. The filter pressure reducing valve filters and removes impurities from the refrigerant and performs preliminary pressure reduction, ensuring stable operation of subsequent components. The mass flow sensor collects real-time refrigerant flow data and transmits it to the data processing unit in the control cabinet 3. The data processing unit compares the data with a preset flow threshold and outputs a control signal to the electric proportional regulating valve, adjusting the valve opening in real time to form a closed-loop flow control, ensuring accurate and stable refrigerant release flow.

[0033] The heating mechanism 4 adopts a water bath heating method, including a sealed water bath cavity 401, a circulating heating pump 402, a refrigerant pipe 403, and two sets of stabilizing sensors 404. The refrigerant pipe 403 is arranged in a circuitous manner inside the water bath cavity, with at least one section employing a spiral winding structure to extend the flow path of the refrigerant within the water bath cavity, increase the heat exchange area between the refrigerant and the water bath medium, and improve heating uniformity and efficiency. The circulating heating pump 402 is connected to the water bath cavity, driving the water bath medium to circulate, avoiding local temperature unevenness, and ensuring a constant temperature inside the cavity. The two sets of stabilizing sensors 404 are respectively installed at the refrigerant inlet and outlet of the water bath cavity, monitoring the temperature of the refrigerant entering and exiting the heating mechanism 4 in real time, and transmitting the temperature data to the temperature control unit of the control cabinet 3 in real time. The temperature control unit adjusts the heating power of the circulating heating pump 402 according to the preset temperature and the measured temperature difference, achieving precise and constant control of the refrigerant temperature to meet the simulation requirements of different working conditions.

[0034] The testing chamber 5 is an openable and closable sealed chamber, internally divided into multiple independent testing areas. These areas are connected in series via guide rails 501, forming a streamlined testing layout. The refrigerant release pipeline 2 branches into multiple refrigerant release branch pipes 201, each corresponding to an independent testing area. Each branch pipe is equipped with an electromagnetic on / off valve 202, controlled individually by the control cabinet 3, allowing for flexible switching between independent leak detection in a single area and simultaneous leak detection in multiple areas. Each branch pipe is connected to a detachable flexible metal hose 203, which can be bent and shaped at will, reaching deep into various hidden corners of the equipment under inspection to precisely deliver refrigerant to the simulated leak point.

[0035] A sliding frame 502 is mounted on the guide rail 501. The sliding frame 502 can slide freely between the independent detection zones along the guide rail 501. An adjustable mounting base 503 is installed on the sliding frame 502. The height of the mounting base 503 can be infinitely adjusted by the manual adjustment bolt 506 to adapt to equipment of different heights. A flexible metal bracket 504 is connected to the mounting base 503. A clamp 505 is set at the end of the bracket. The refrigerant detector 9 is clamped and fixed on the clamp 505. The flexible metal bracket 504 can be shaped and bent to drive the probe of the detection mechanism to adjust in multiple angles and directions, accurately fit the dead corner area of ​​the equipment under inspection, and ensure that the probe can effectively capture the leakage signal.

[0036] Control cabinet 3, as the core management module, integrates a temperature control unit, a data processing unit, an alarm unit, and a human-machine interface unit. The human-machine interface unit uses a touch screen display, which allows operators to set parameters such as simulated leakage flow, heating temperature, and detection area, control the start and stop of the detection process, and display the detection data in real time. When the alarm unit detects excessive refrigerant leakage, abnormal flow, or excessive temperature, it immediately triggers an audible and visual alarm to remind the operator to take action. The data processing unit is responsible for receiving and analyzing the data returned by the testing agency, determining whether the equipment under test is qualified, automatically generating a standardized test report, storing the entire process test data, and supporting data traceability and remote transmission.

[0037] The exhaust system 6 is connected to the interior of the testing chamber 5 and includes an exhaust fan, exhaust ducts and filter components. It can both replace and discharge the residual refrigerant in the testing chamber 5 after the test is completed, and also receive a signal from the control cabinet 3 to start emergency ventilation when the refrigerant leakage exceeds the standard, so as to quickly reduce the refrigerant concentration in the chamber and ensure safety. The refrigerant is filtered before being discharged, so it meets the environmental protection emission requirements.

[0038] When using this device for leak detection, strictly follow these steps to ensure a standardized leak detection process and accurate results: The first step is to prepare the device. The operator first places the refrigerant storage tank 7 on the rotating tray 102 of the sealed box, adjusts the position of the tank so that the outlet is sealed and connected with the self-sealing quick connector, closes the sealing door 101 of the sealed box and locks the safety interlock to complete the gas source preparation; then, the door of the detection chamber 5 is opened, the equipment to be tested is fixed in the experimental area of ​​the target detection area, the flexible metal hose 203 is stretched, and the refrigerant release end is fixed at the target dead corner position of the equipment to be tested. Then, the position of the sliding frame 502 and the height of the mounting base 503 are adjusted, and the flexible metal bracket 504 is bent so that the probe of the refrigerant detector 9 is aligned with the same dead corner area to ensure that the detection point coincides with the leakage simulation point. Finally, the door of the detection chamber 5 is closed.

[0039] The second step is parameter configuration. Through the human-machine interaction unit of control cabinet 3, input the target leakage simulation flow rate, refrigerant heating temperature and other operating condition parameters, select the target detection area to be activated, and after receiving the instruction, control cabinet 3 controls the electromagnetic opening and closing valve 202 of the corresponding detection area to switch to the ready-to-open state, while the valves of the other detection areas remain closed.

[0040] The third step is to simulate leakage and acquire data. Control cabinet 3 issues a start command, first opening the shut-off valve, and then controlling the electromagnetic valve 202 in the target detection area to open; the flow control unit starts closed-loop control, the mass flow sensor collects flow data in real time, and the electric proportional regulating valve precisely adjusts the opening to make the refrigerant release flow reach the preset value; at the same time, the heating mechanism 4 starts, the circulating heating pump 402 heats the water bath medium, the stabilizing sensor 404 monitors the refrigerant temperature in real time, and the temperature control unit adjusts the heating power to maintain the refrigerant at the preset temperature; the constant temperature refrigerant is precisely released from the dead corner of the equipment under test through the flexible metal hose 203 to simulate a real leakage scenario, and the refrigerant detector 9 collects the leakage signal in real time and transmits the data synchronously to the data processing unit of control cabinet 3.

[0041] The fourth step is leakage analysis and result output. The data processing unit compares and analyzes the collected leakage data to determine whether the leakage of the equipment under test meets the qualification standards. After the analysis is completed, the test results are visualized on the human-machine interaction unit, and a standardized report containing test parameters, data curves, and qualification judgments is automatically generated. All data is stored and archived for easy traceability and query in the future.

[0042] The fifth step is venting and resetting. After the test is completed, the control cabinet 3 automatically closes the electromagnetic opening and closing valve 202 and the shut-off valve to stop the refrigerant release. At the same time, the venting system 6 is started to replace the residual refrigerant in the test chamber 5. After the refrigerant concentration in the test chamber 5 drops to the safe threshold, the system prompts the operator to open the door. Then, the sliding frame 502, the mounting base 503, and the flexible metal bracket 504 are reset, the test chamber 5 is opened, and the equipment to be tested is taken out, completing the entire process of a single leak test.

[0043] Other implementation methods Based on the overall structure and working logic of the above embodiments, this embodiment adds an arc and spark simulation mechanism to meet the needs of studying the ignition conditions of unknown component refrigerants and various mixed refrigerants. This mechanism can simulate the arc and spark generated under the operating and fault conditions of the electrical components of the equipment under test. At the same time, it is equipped with a complete linkage safety protection system. While restoring the actual electrical ignition source working conditions and realizing the accurate study of refrigerant ignition boundary conditions, it ensures the inherent safety of the entire test process.

[0044] This embodiment features an improved device structure. This embodiment retains all the structures and connections of the openable and closable sealed enclosure, refrigerant release pipeline, control cabinet, heating mechanism, detection chamber, and exhaust system from the above embodiments. Only an arc spark simulation mechanism is added, and the control unit of the control cabinet is adapted accordingly, as detailed below: 1. Arc spark simulation mechanism The device is set up in each independent testing area of ​​the testing room. Its core components include an arc generating unit, a spark generating unit, flame-retardant isolation and protection components, and an explosion-proof power supply module. It can be directly installed on the fixture of the refrigerant detector through an adapter interface without the need for additional installation components. Positioning and adjustment can be achieved by using the existing fixture.

[0045] The arc spark simulation mechanism is fixedly connected to the fixture via an adapter interface, eliminating the need for additional installation structures. Utilizing the fixture's existing height adjustment and angle bending functions, the working ends of the arc generating unit and spark generating unit can be precisely positioned at any target point within the detection area. Furthermore, it can achieve precise positional matching with the release area of ​​the refrigerant release end and the detection area of ​​the refrigerant detector, accurately recreating the real working condition of refrigerant leakage contacting the ignition source of electrical components. At the same time, it simplifies the mechanism structure and reduces installation and debugging difficulty.

[0046] The arc generating unit is used to simulate instantaneous or continuous arcs generated under scenarios such as electrical component switching and short circuit faults. The spark generating unit is used to simulate intermittent weak sparks generated under scenarios such as poor contact of electrical components and electrostatic discharge. The triggering mode, output energy level, working time, and triggering interval of the two units can be independently adjusted, which can cover various ignition source conditions under different electrical fault scenarios and meet the research needs of ignition conditions of different types of single refrigerants and multi-component mixed refrigerants.

[0047] The flame-retardant isolation and protection component covers the non-working ends of the arc generating unit and the spark generating unit, exposing only the working ends. This achieves flame retardancy, explosion protection, and electromagnetic shielding, avoiding additional safety risks caused by arc sparks and preventing interference with the normal data acquisition of the testing instruments. The explosion-proof power supply module provides isolated power to the arc generating unit and the spark generating unit, preventing the power supply circuit itself from generating additional ignition sources and further improving test safety.

[0048] 2. Control cabinet compatibility An ignition source control unit is added to the control cabinet. This unit is connected to the human-machine interface unit, data processing unit, alarm unit, temperature control unit, and flow control unit. Operators can set various operating parameters for the arc and spark through the human-machine interface unit. The ignition source control unit can receive real-time data on refrigerant concentration, flow rate, and temperature from the data processing unit, as well as abnormal trigger signals from the alarm unit, realizing the linkage control between the ignition source operating condition and the refrigerant release operating condition. It can also execute emergency shutdown logic under abnormal operating conditions.

[0049] 3. Joint security protection system The power supply circuit of the arc spark simulation mechanism is connected in series with the safety interlock of the sealed box and the door interlock of the testing chamber. The power supply circuit can only be turned on when the sealed door of the sealed box and the door of the testing chamber are completely closed and locked, thus eliminating the safety risks caused by misoperation during the test.

[0050] Meanwhile, the control circuit of the arc spark simulation mechanism is linked with the refrigerant concentration detection element and exhaust system signal in the testing chamber. When the refrigerant concentration in the chamber reaches the preset warning threshold, the control circuit immediately locks the trigger function of the mechanism, prohibits the ignition source from starting, and triggers the alarm unit to issue a warning. When the refrigerant concentration in the chamber reaches the preset emergency threshold, all power supply to the mechanism is immediately cut off, and the emergency exhaust mode of the exhaust system is activated simultaneously to quickly reduce the refrigerant concentration in the chamber and ensure test safety.

[0051] In addition, physical emergency stop switches are installed at many key locations of the device, which can cut off the power supply to the arc spark simulation mechanism and the entire device with one click, in order to deal with various sudden abnormal situations.

[0052] Implementation steps of this embodiment Based on the apparatus of this embodiment, the complete operation procedure for conducting refrigerant ignition condition research is as follows: S1' Device Preparation Stage: Place the refrigerant storage tank (which can be a single refrigerant storage tank or a multi-component mixed refrigerant storage tank) for the target test on the rotating tray of the sealed enclosure, complete the sealing connection with the pipeline interface, close the sealed enclosure and lock the safety interlock; locate the refrigerant release point in the test area of ​​the detection zone, fix the refrigerant release end to the target release area through a flexible metal hose, install the arc spark simulation mechanism on the clamp of the refrigerant detector through the adapter interface, adjust the height and bending angle with the clamp, and accurately position the working end of the arc generating unit / spark generating unit to the preset test position in the refrigerant release area, while adjusting the probe of the refrigerant detector to the corresponding detection area. After completion, close the detection chamber door and lock the door interlock.

[0053] S2' Operating Parameter Configuration Stage: Through the human-machine interface unit of the control cabinet, the target flow rate and heating temperature of refrigerant release are set, and the ignition source parameters such as the arc / spark trigger mode, output energy level, trigger timing, and working duration are configured. Correspondingly, the warning threshold, emergency threshold, and safety interlock logic of the refrigerant concentration are set. After receiving the parameters, the control cabinet controls the electromagnetic opening and closing valve of the corresponding refrigerant release branch to switch to the ready-to-open state, and at the same time completes the parameter preloading and safety interlock self-test of the ignition source control unit.

[0054] S3' Operating Condition Simulation and Data Acquisition Stage: The control cabinet issues a start command, controlling the corresponding electromagnetic valve to open. The flow control unit regulates the refrigerant release flow to a preset value via a closed loop. Simultaneously, the temperature control unit adjusts the heating mechanism's operating state to maintain the refrigerant at a preset operating temperature. The refrigerant is stably released in the target area, creating a refrigerant atmosphere of a preset concentration within the detection zone. Once the concentration data returned by the refrigerant detector stabilizes to the preset test value, the control cabinet triggers the arc generation unit / spark generation unit via the ignition source control unit, outputting an arc or spark according to preset parameters to simulate the actual ignition source scenario of electrical components. The refrigerant detector collects real-time refrigerant concentration change data within the detection zone, and the accompanying operating condition detection element synchronously collects temperature and pressure change data during the test. All data is transmitted back to the control cabinet's data processing unit in real time.

[0055] S4' Data Analysis and Result Output Stage: The data processing unit integrates and analyzes the collected refrigerant concentration, cabin temperature, and pressure data throughout the entire process. Combining the preset ignition source parameters and refrigerant release operating condition parameters, it determines whether the refrigerant ignites under the corresponding operating condition, and clarifies the core ignition boundary conditions such as the critical ignition concentration, minimum ignition energy, and ultimate ignition temperature of the refrigerant used in the test. After the analysis is completed, a standardized test report is automatically generated, and the entire process of test data is archived and stored, supporting full-process traceability and query of the test process.

[0056] S5' Safety Handling and Device Reset Phase: After the test is completed, the control cabinet immediately closes all valves on the refrigerant release pipeline to stop the refrigerant release. At the same time, it cuts off the power supply circuit of the arc spark simulation mechanism and starts the exhaust system to force gas replacement inside the test chamber. After the refrigerant concentration in the test chamber drops below the preset safety threshold and the temperature and pressure inside the chamber return to normal, the control cabinet releases the safety interlock. The operator can then open the test chamber door and reset the multi-degree-of-freedom adjustable mounting components, the refrigerant detector probe, and the refrigerant release pipeline in sequence to complete the entire test process.

[0057] The above description discloses only one preferred embodiment of the present invention, and should not be construed as limiting the scope of the present invention. Those skilled in the art will understand that all or part of the processes of the above embodiments can be implemented, and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A refrigerant leak detection device, characterized in that, It includes an openable and closable sealed enclosure, refrigerant release piping, control cabinet, heating mechanism, testing chamber, and exhaust system; The internal space of the openable and closable sealed enclosure forms a sealed cavity for sealing and accommodating the refrigerant storage tank. A pipeline connection interface is provided in the sealed cavity. The pipeline connection interface is connected to the inlet of the refrigerant release pipeline. When the refrigerant storage tank is placed in the sealed cavity, its outlet is sealed and connected to the pipeline connection interface. Along the medium flow direction of the refrigerant release pipeline, the flow control unit and heating mechanism built into the control cabinet are connected in series on the refrigerant release pipeline. The refrigerant release pipeline extends to the experimental area of ​​the testing chamber after passing through the heating mechanism. The end of the refrigerant release pipeline is provided with a refrigerant release end that can be positioned to the dead corner area of ​​the equipment under test, so as to accurately release refrigerant in the dead corner area of ​​the equipment under test to simulate the dead corner leakage condition in actual operation of the refrigeration equipment. The testing chamber is an openable and closable simulation test chamber. Inside, a refrigerant detector is arranged in the corresponding experimental area. The probe of the refrigerant detector can extend to the dead corner area of ​​the equipment under test, and is used to detect the refrigerant leakage of the equipment under test under simulated dead corner leakage conditions. The control cabinet also has a built-in temperature control unit and a data processing unit. The temperature control unit is connected to the heating mechanism to adjust the operating temperature of the refrigerant release. The data processing unit is connected to the refrigerant detector to receive, display and analyze the leakage detection data returned by the refrigerant detector. The exhaust system is connected to the internal space of the testing chamber and is used for gas replacement and emergency ventilation of the testing chamber; The detection chamber is divided into multiple independent detection zones. The refrigerant release pipeline branches into refrigerant release branches corresponding to each detection zone. Each refrigerant release branch is connected in series with an electromagnetic valve controlled by the control cabinet. The end of each refrigerant release branch serves as the refrigerant release end for the corresponding detection zone. This refrigerant release end extends to the blind spot area of ​​the equipment under inspection in the corresponding detection zone through a detachable flexible metal hose, realizing zoned and fixed-point refrigerant release. Each independent detection zone is connected in series by a guide rail. A sliding frame is provided on the guide rail. A height-adjustable mounting base is provided on the sliding frame. A clamp is provided on the mounting base by a flexible metal bracket. The refrigerant detector is clamped and fixed on the clamp. The sliding frame can slide and switch between independent detection zones along the guide rail. The mounting base can be infinitely adjusted in height on the sliding frame via a hand-adjusting bolt. The flexible metal bracket can be shaped and bent to position the probe of the refrigerant detector to any blind spot area of ​​the equipment under test.

2. The refrigerant leak detection device according to claim 1, characterized in that, The sealed enclosure has an explosion-proof and heat-insulating structure, and its opening is equipped with a sealed door with a safety interlock. The sealed cavity is equipped with a rotating tray for placing a refrigerant storage tank, and the pipeline connection interface is a self-sealing quick connector. When the refrigerant storage tank is placed on the rotating tray, its outlet can achieve a sealed connection with the self-sealing quick connector.

3. The refrigerant leak detection device according to claim 2, characterized in that, The flow control unit includes an electric proportional regulating valve and a mass flow sensor connected in series on the refrigerant release pipeline. The signal output terminal of the mass flow sensor is electrically connected to the data processing unit. The data processing unit outputs a control signal to the electric proportional regulating valve based on a preset leakage simulation flow threshold and real-time collected flow data to regulate the refrigerant release flow in a closed loop. The refrigerant release pipeline also includes a shut-off valve and a filter pressure reducing valve connected in series between the pipeline connection interface and the flow control unit.

4. The refrigerant leak detection device according to claim 3, characterized in that, The heating mechanism includes a sealed water bath chamber, a circulating heating pump, a refrigerant pipe, and a temperature sensor; the refrigerant pipe is arranged in a circuitous manner inside the water bath chamber, with its two ends serving as a refrigerant inlet and a refrigerant outlet respectively, which are connected to the refrigerant release pipeline. The circulating heating pump is connected to the water bath chamber and is used to drive the water bath medium to circulate and heat and maintain a constant temperature. The temperature sensors are respectively located at the refrigerant inlet and refrigerant outlet of the refrigerant pipe, and are both connected to the temperature control unit of the control cabinet. The temperature control unit adjusts the heating power of the circulating heating pump according to the feedback data of the temperature sensors to achieve constant temperature control of the refrigerant.

5. The refrigerant leak detection device according to claim 4, characterized in that, At least one section of the refrigerant pipe uses a spiral winding structure.

6. The refrigerant leak detection device according to claim 5, characterized in that, The control cabinet is also equipped with an alarm unit and a human-machine interaction unit. The alarm unit is used to trigger an audible and visual alarm when leakage exceeds the standard, flow is abnormal, or temperature is abnormal. The human-machine interaction unit is used for setting detection parameters, controlling the detection process, and visually displaying detection data. The data processing unit is also used to store the entire process detection data, automatically generate standardized detection reports, and has the function of full-process traceability and remote transmission of detection data.

7. A leak detection method based on the refrigerant leak detection device according to claim 6, characterized in that... Includes the following steps: S1 device preparation stage: Place the refrigerant storage tank on the rotating tray of the sealed box, and make its outlet seal with the self-sealing quick connector. Close the sealed box and lock the safety interlock. Fix the device to be tested in the experimental area of ​​the target detection area. Use a flexible metal hose to accurately position the refrigerant release end of the corresponding detection area to the blind spot area of ​​the device to be tested. At the same time, adjust the sliding frame, height-adjustable mounting base and flexible metal bracket so that the probe of the refrigerant detector extends to the same blind spot area. S2 operating condition parameter configuration stage: The target leakage simulation flow rate and refrigerant heating temperature are set through the human-machine interaction unit of the control cabinet, and the target detection area to be detected is selected. The control cabinet controls the electromagnetic opening and closing valve of the corresponding detection area to be in the ready-to-open state according to the selection. S3 Simulation Leakage and Data Acquisition Stage: The control cabinet controls the opening of the electromagnetic valves in the corresponding detection area. The refrigerant release flow is adjusted to the preset value through the electric proportional regulating valve of the flow control unit and the mass flow sensor in a closed loop. At the same time, the temperature control unit adjusts the heating power of the circulating heating pump based on the feedback data from the temperature sensors at the inlet and outlet of the refrigerant in the water bath chamber, so that the refrigerant maintains the preset operating temperature and is accurately released from the dead zone area of ​​the equipment under test. The refrigerant detector collects leak data in real time and transmits it back to the data processing unit in the control cabinet. S4 Leakage Analysis and Result Output Stage: The data processing unit analyzes the collected leakage data, determines whether the leakage of the equipment under test meets the preset qualification standards under the simulated dead zone leakage condition, automatically generates a standardized test report, and completes the storage, visualization and traceability of the test data. S5 Exhaust and Device Reset Stage: After the test is completed, the control cabinet closes the electromagnetic valves and refrigerant release pipelines of the corresponding test area, and starts the exhaust system to replace the gas inside the test chamber; after the refrigerant concentration in the chamber drops to the preset safety threshold, the sliding frame, height-adjustable mounting base and flexible metal bracket are reset, the test chamber is opened and the equipment to be tested is taken out, and the complete leak detection process is completed.

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