A dual-mode cam pump unit comprehensive test detection system

Abstract

The present application relates to the technical field of cam pump performance detection, and discloses a double-mode cam pump unit comprehensive test detection system, which fixes the cam pump unit to be detected through a test bench, and a double-mode water storage tank system is in sealed communication with the cam pump unit through a connecting pipeline; the double-mode water storage tank system is composed of a water storage tank body and a control system module, the water storage tank body includes a tank body, a valve combination, a pressure balancing device and a connecting pipeline, normal pressure and negative pressure double working condition switching of the tank body is realized by relying on the valve combination, normal pressure operation test and negative pressure pressure maintaining detection requirements are respectively met, the control system module synchronously collects multiple data, and working condition pressure indexes, flow stability indexes, vibration speed indexes, noise sound pressure indexes, operation smoothness indexes and pressure maintaining pressure attenuation indexes are sequentially calculated, then working condition abnormality judgment is completed by comparing with preset threshold values, and cam pump performance automatic detection, data quantitative analysis and safety early warning are realized.

Description

Technical Field

[0001] This invention relates to the field of cam pump performance testing technology, specifically a dual-mode cam pump unit comprehensive testing system. Background Technology

[0002] As a positive displacement pump, the cam pump is widely used in various industrial fields due to its stable flow rate, strong self-priming capability, and wide range of applicable media. Its operational performance directly determines the reliability, safety, and economy in practical applications. Inlet and outlet pressure, flow rate, operational stability, vibration and noise levels, and continuous operation capability are core indicators for evaluating the performance of cam pump units. Negative pressure sealing performance (verified through negative pressure holding tests) is also crucial to ensuring the normal operation of the cam pump under negative pressure conditions, especially in self-priming and suction scenarios.

[0003] Currently, existing testing and inspection equipment for cam pump units suffers from several technical challenges: First, its testing function is limited; most equipment can only perform single-parameter testing, failing to simultaneously complete comprehensive testing of pressure, flow, vibration, noise, continuous operation capability, and negative pressure holding. This necessitates multiple equipment replacements or device adjustments, resulting in low testing efficiency and a lack of data consistency. Second, the water storage tank has a fixed function, either serving only as an atmospheric pressure container for pumping and drainage circulation testing or as a closed container for negative pressure testing. It cannot achieve dual-mode switching, exhibiting poor adaptability and increasing the investment cost of testing equipment. Third, vibration and noise detection is susceptible to environmental interference, and unreasonable sampling points fail to accurately reflect the unit's operating status, leading to insufficient testing accuracy. Fourth, continuous operation tests rely heavily on manual monitoring, resulting in low automation and difficulty in achieving real-time parameter acquisition, anomaly warning, and long-term data storage. Fifth, it lacks versatility; different models of cam pump units require readjustment of pipelines and fixing structures, making operation cumbersome and increasing testing costs.

[0004] Furthermore, existing testing systems for cam pumps do not fully consider their volumetric operating characteristics and negative pressure requirements. Negative pressure holding tests often use separate equipment, distinct from atmospheric pressure circulation testing, failing to achieve integrated testing. Moreover, there is no clear and precise control scheme for negative pressure holding, resulting in low pressure holding accuracy and inaccurate leak detection. Additionally, according to industry standards such as JB / T14540-2024 "Sanitary Cam Rotary Pumps," cam pumps require multiple tests, including trial operation, continuous operation, and performance testing. However, existing equipment struggles to simultaneously meet the testing requirements of all parameters in the standards, particularly lacking an effective integrated solution for negative pressure sealing performance testing, thus failing to provide reliable support for the comprehensive performance evaluation of cam pump units. Summary of the Invention

[0005] (a) Technical problems to be solved

[0006] To address the shortcomings of existing technologies, this invention provides a dual-mode integrated testing and inspection system for cam pump units. This system can simultaneously perform inlet and outlet pressure and flow measurement, operational stability and vibration noise detection, continuous operation capability verification, and negative pressure holding test. It enables rapid switching between two operating modes of the water storage tank, improves testing efficiency and accuracy, reduces testing costs, and is adaptable to different models and testing requirements of cam pump units. This provides reliable technical support for the comprehensive performance evaluation and quality control of cam pump units.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, the present invention provides the following technical solution: a dual-mode cam pump unit comprehensive test and detection system, including a test bench and a dual-mode water storage tank system;

[0009] The test bench is used to clamp and fix the cam pump unit to be tested. The test bench includes a placement platform for placing the cam pump unit, an adjustable fixing clamp for clamping the cam pump unit, a rubber buffer pad to isolate the adjustable fixing clamp from the cam pump unit, and a polyurethane shock-absorbing pad to buffer the placement platform. The placement platform is welded from steel profiles. The adjustable fixing clamp is installed on the top of the placement platform and has a rubber buffer pad installed on its inner side. The polyurethane shock-absorbing pad is installed at the bottom of the placement platform. The dual-mode water storage tank system is sealed and connected to the cam pump unit clamped on the test bench through connecting pipes.

[0010] The dual-mode water storage tank system includes a water storage tank body and a control system module. The water storage tank body includes a tank body, a valve assembly, a pressure balancing device, and connecting pipes. The valve assembly is installed on the top of the tank body and at the interface of the connecting pipes. The pressure balancing device is installed on the top of the tank body and communicates with the tank body. The connecting pipes are installed between the tank body inlet and outlet and between the valve assembly and the pressure balancing device, and one end is connected to the cam pump unit to be tested on the test bench.

[0011] The tank is made of stainless steel and the inner wall is treated with anti-corrosion. A pressure gauge and a vacuum gauge are installed on the top of the tank, and a drain outlet is installed at the bottom of the tank.

[0012] The tank has an ultra-high liquid level at the top and an ultra-low liquid level at the bottom, and a high liquid level and a low liquid level near the middle of the tank.

[0013] The valve assembly includes an atmospheric pressure valve, a shut-off valve, a negative pressure valve, and a vent valve, all of which are corrosion-resistant and sealing valves. The atmospheric pressure valve connects the tank to the atmosphere, and when open, the tank is connected to the atmosphere. The shut-off valve is used to close the connection between the tank and the atmosphere, and works with the negative pressure valve to achieve a sealed state. The negative pressure valve is connected to the tank and is used to control the generation and cessation of negative pressure. The vent valve is used to slowly release the negative pressure in the tank after the negative pressure holding test is completed.

[0014] The pressure balancing device includes a pressure stabilizing tank and a pressure regulating valve, which are connected to the tank body and are used to stabilize the pressure inside the tank during normal pressure cyclic testing.

[0015] The connecting pipeline includes an inlet pipeline, an outlet pipeline, a circulation pipeline, a regulating pipeline, and connecting joints. One end of the inlet pipeline connects to the tank outlet, and the other end connects to the inlet of the cam pump unit under test. A filter and an inlet pressure sensor are installed on the inlet pipeline, positioned close to the inlet of the cam pump unit, to collect inlet pressure data in real time. One end of the outlet pipeline connects to the outlet of the cam pump unit under test, and the other end connects to the tank return outlet. An outlet pressure sensor and an electromagnetic flow meter are installed on the outlet pipeline to collect outlet pressure and flow data in real time. A flow regulating bypass is connected in parallel to the outlet pipeline. The circulation pipeline connects the outlet pipeline and the inlet pipeline, forming a closed-loop circulation. A circulation pump is installed on the circulation pipeline. The regulating pipeline includes a regulating valve and a throttle valve, respectively installed on the inlet and outlet pipelines, to regulate the pressure and flow within the pipelines, simulating different actual operating conditions of the cam pump unit. Sealed joints are used for connections in the circulation pipeline. All pipelines in the connecting pipeline are made of 304 stainless steel.

[0016] The control system module includes a pressure detection unit, a flow detection unit, a vibration detection unit, a noise detection unit, an operating status detection unit, a negative pressure holding detection unit, a comprehensive analysis unit, and an early warning unit. Each of the pressure detection unit, flow detection unit, vibration detection unit, noise detection unit, operating status detection unit, and negative pressure holding detection unit is linearly connected to the comprehensive analysis unit, and the comprehensive analysis unit is linearly connected to the early warning unit.

[0017] The pressure detection unit is used to collect operating pressure data from the inlet pipe, outlet pipe, and tank, and calculate the operating pressure index; the flow detection unit is used to collect flow data from the outlet of the cam pump unit and calculate the flow stability index; the vibration detection unit is used to collect vibration acceleration and vibration velocity data from the cam pump unit, and calculate the vibration velocity index after filtering the vibration signal using FFT (Fast Fourier Transform); the noise detection unit is used to collect noise sound pressure level data around the test bench, and calculate the noise sound pressure index after noise filtering; the operating status detection unit is used to collect operating status data such as speed, temperature, and current of the cam pump unit, and calculate the operating stability index; the negative pressure holding detection unit is used to collect pressure holding data from the tank and calculate the pressure holding attenuation index.

[0018] The comprehensive analysis unit has preset threshold ranges for operating pressure index, flow stability index, vibration velocity index, noise pressure index, stable operation index, and pressure holding attenuation index. If any calculated result of the operating pressure index, flow stability index, vibration velocity index, noise pressure index, stable operation index, or pressure holding attenuation index exceeds the threshold range of the corresponding index, it is determined that the cam pump unit has an operational abnormality in the corresponding detection dimension, and a corresponding abnormal signal is sent to the early warning unit. The early warning unit receives the abnormal signal and issues an alarm.

[0019] If the operating pressure index, flow stability index, vibration velocity index, noise pressure index, stable operation index, and pressure holding attenuation index are all within the corresponding threshold range, then the cam pump unit is judged to be operating stably.

[0020] Compared with the prior art, the present invention provides a dual-mode integrated testing and inspection system for cam pump units, which has the following beneficial effects:

[0021] 1. This invention achieves flexible switching between normal and negative pressure modes of the water storage tank through valve combination control, without the need to replace the water storage equipment. It integrates the normal pressure circulation operation and negative pressure holding test of the cam pump unit, solving the pain points of the existing equipment's single function and poor adaptability of the water storage tank. The adjustable fixing fixture and adjustable pipeline system of the test bench can be adapted to different models and specifications of cam pump units without the need to redesign and adjust the test device. Test parameters can be flexibly set to meet different testing standards, working conditions and industry needs, greatly reducing the investment and adjustment costs of testing equipment and improving the platform's applicability.

[0022] 2. This invention integrates multiple detection functions, with all parameters collected synchronously on the same platform, eliminating the need for multiple equipment replacements and improving detection efficiency. It employs high-precision sensors, combined with FFT signal filtering technology, vibration damping design of the test bench, and windproof protection, filtering out irrelevant interference from the environment and pipelines to ensure that the detection accuracy of parameters such as pressure, flow, and noise meets high industry standards. The negative pressure holding test uses precise pressure control and real-time monitoring, referencing the requirements for pump negative pressure sealing vacuum testing and airtightness testing, ensuring pressure holding accuracy and leak detection accuracy. Simultaneously, the testing process complies with industry standards such as JB / T14540-2024 and JB / T13974-2020, comprehensively and accurately evaluating the cam pump's operational stability, sealing performance, and continuous operation capability.

[0023] 3. This invention achieves full automation of the test process, parameter adjustment, data acquisition, processing, storage and anomaly early warning through the control system module, eliminating the need for manual monitoring, greatly reducing the labor intensity of staff, improving the intelligence level and efficiency of testing work, and reducing human operation errors. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the system operation process of the present invention. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. It is worth noting that this application also relates to prior art. Since prior art is well known to those skilled in the art, it will not be described in detail in this application.

[0026] Please see Figure 1 A comprehensive testing and inspection system for a dual-mode cam pump unit, including a test bench and a dual-mode water storage tank system;

[0027] The test bench is used to clamp and fix the cam pump unit to be tested. The test bench includes a platform for placing the cam pump unit, an adjustable fixing clamp for holding the cam pump unit, a rubber buffer pad to isolate the adjustable fixing clamp from the cam pump unit, and a polyurethane shock-absorbing pad to cushion the platform. The platform is welded from structural steel, providing a stable structure and effectively supporting the weight of cam pump units of different specifications, ensuring reliable equipment fixation during testing. The adjustable fixing clamp is installed on the top of the platform and has a rubber buffer pad on its inner side, allowing for adjustment according to the model of the cam pump unit to be tested. Specifications: The clamping position and force can be adjusted by adjusting the screw to adapt to different sizes of cam pump units. Meanwhile, the rubber buffer pad prevents damage to the surface of the cam pump unit during clamping, protecting the equipment under test. Polyurethane shock-absorbing pads are installed at the bottom of the placement platform to reduce the interference of vibration on the test results, ensuring accurate test data and improving the reliability of the test. The dual-mode water storage tank system is connected to the cam pump unit clamped on the test bench via connecting pipes, achieving closed-loop transmission of the medium, ensuring the continuity and sealing of the test, and preventing medium leakage from affecting the test results.

[0028] The dual-mode water storage tank system includes a water storage tank body and a control system module. The water storage tank body includes a tank body, a valve assembly, a pressure balancing device, and connecting pipes. The valve assembly is installed on the top of the tank body and at the interface of the connecting pipes. The pressure balancing device is installed on the top of the tank body and connected to the tank body. The connecting pipes are installed between the tank body inlet and outlet and between the valve assembly and the pressure balancing device, and one end is connected to the cam pump unit to be tested on the test bench.

[0029] The tank is made of stainless steel with anti-corrosion treatment on the inner wall, which has sufficient pressure bearing capacity and effectively prevents media corrosion, extending the service life of the tank. It is suitable for both atmospheric pressure and negative pressure test modes. The top of the tank is equipped with a pressure gauge and a vacuum gauge, which can monitor the pressure status inside the tank in real time, allowing the staff to intuitively grasp the pressure changes inside the tank and adjust the test parameters in a timely manner. The bottom of the tank is equipped with a drain port, which facilitates the regular cleaning of impurities inside the tank and avoids the accumulation of impurities affecting the test accuracy and equipment operation.

[0030] The tank has an ultra-high liquid level at the top and an ultra-low liquid level at the bottom to detect and control whether the test water in the tank is too much or too little, and then drain and replenish water through the drainage and water replenishment pipes. The tank also has high and low liquid levels near the middle, which can be set to different values. The suction pipe inlet of the test platform is located between the high and low liquid levels. By controlling the high and low liquid levels, the amount of water and air drawn in by the suction pipe can be controlled. This can simulate the operation of the cam pump unit under different conditions, such as the suction pipe drawing in all air, part air, and all liquid.

[0031] The valve assembly includes atmospheric pressure valves, shut-off valves, negative pressure valves, and vent valves. All valves are corrosion-resistant and have excellent sealing performance, effectively preventing media leakage and air ingress. They meet the sealing requirements of negative pressure holding tests, ensuring test accuracy. The atmospheric pressure valve connects the tank to the atmosphere; when open, it allows the tank to communicate with the atmosphere, enabling switching to atmospheric pressure mode for the water storage tank and meeting the pump unit's pumping and drainage cycle operation test requirements. The shut-off valve closes the connection between the tank and the atmosphere, working in conjunction with the negative pressure valve to achieve a sealed state, providing a closed environment for the negative pressure holding test. The negative pressure valve connects to the tank and controls the generation and cessation of negative pressure, achieving precise control of the negative pressure holding test. The vent valve slowly releases the negative pressure in the tank after the negative pressure holding test, preventing sudden pressure changes from damaging the equipment and ensuring the safe operation of the testing equipment.

[0032] The pressure balancing device includes a pressure stabilizing tank and a pressure regulating valve, which are connected to the tank body. It is used to stabilize the pressure inside the tank during atmospheric pressure cycling tests, avoid pressure fluctuations caused by water flow disturbances, and ensure stable acquisition of pressure parameters during atmospheric pressure cycling tests. During negative pressure holding tests, it helps to maintain the stability of negative pressure inside the tank, reduce pressure decay, and improve the accuracy of the holding test. It also ensures the stability of vacuum degree by referring to the relevant technical requirements for vacuum testing of pump negative pressure sealing.

[0033] When a pumping and drainage circulation test is required, the atmospheric pressure valve is opened, the airtight valve and the negative pressure valve are closed, and the water storage tank is connected to the atmosphere. As an atmospheric pressure container, it works with the pipeline system to achieve medium circulation. When a negative pressure holding test is required, the atmospheric pressure valve and the vent valve are closed, the airtight valve and the negative pressure valve are opened, and the negative pressure valve is closed to enter the pressure holding state. The pressure sensor monitors the pressure change in the tank in real time to verify the negative pressure sealing performance of the cam pump unit. The leakage rate is determined by the pressure decay method to ensure the reliability of the seal.

[0034] The connecting pipeline includes an inlet pipeline, an outlet pipeline, a circulation pipeline, a regulating pipeline, and connecting joints. One end of the inlet pipeline connects to the tank outlet, and the other end connects to the inlet of the cam pump unit under test. A filter is installed on the inlet pipeline to remove impurities from the medium, preventing damage to the cam pump unit and the detection sensor, extending the equipment's lifespan, and ensuring the normal operation of the detection components. An inlet pressure sensor is also installed near the cam pump unit's inlet to collect inlet pressure data in real time, ensuring that the collected pressure data closely reflects the unit's actual operating conditions and improving data accuracy. One end of the outlet pipeline connects to the outlet of the cam pump unit under test, and the other end connects to the tank return outlet. An outlet pressure sensor and an electromagnetic flow meter are installed on the outlet pipeline to collect outlet pressure and flow data in real time. A parallel flow regulating bypass is connected to the outlet pipeline for precise adjustment under low flow conditions, preventing insufficient adjustment range of the main pipeline from affecting detection accuracy. The system is designed to meet the testing needs of different flow rates. The circulation pipeline connects the inlet and outlet water lines, forming a closed-loop circulation system that allows for media reuse, conserving water resources and reducing testing costs. A circulation pump is installed on the circulation pipeline to assist in regulating flow and pressure, adapting to different testing conditions and ensuring testing flexibility. The regulating pipeline includes regulating valves and throttle valves, respectively installed on the inlet and outlet water lines, to regulate pressure and flow within the pipeline, simulating different actual operating conditions of the cam pump unit. This makes the test results more closely match the actual usage scenarios of the unit, improving the practicality and relevance of the testing. Sealed joints are used at the connection points of the circulation pipeline to ensure sealing performance and prevent media leakage, especially during negative pressure holding tests, to prevent air from entering and affecting the test results. All pipelines in the connection system are made of 304 stainless steel, ensuring corrosion resistance and structural strength, and adapting to the requirements of the test media.

[0035] The control system module includes a pressure detection unit, a flow detection unit, a vibration detection unit, a noise detection unit, an operating status detection unit, a negative pressure holding detection unit, a comprehensive analysis unit, and an early warning unit. The pressure detection unit, flow detection unit, vibration detection unit, noise detection unit, operating status detection unit, and negative pressure holding detection unit are each linearly connected to the comprehensive analysis unit, and the comprehensive analysis unit is linearly connected to the early warning unit.

[0036] The control system module is also equipped with a PLC controller. The PLC controller is an industrial-grade PLC with high-speed data processing capability and a processing speed of no less than 100Hz. It is used to connect all detection units and execution components to realize the automated control of the test process, including mode switching, parameter adjustment, test start and stop, etc.

[0037] The pressure detection unit is equipped with an inlet pressure sensor and an outlet pressure sensor, employing a high-precision pressure transmitter. These are installed near the cam pump unit on the inlet and outlet water pipes, respectively, to collect operating pressure data from the inlet and outlet water pipes and the tank. The unit calculates the operating pressure index, enabling real-time and accurate capture of pressure changes in the pipes and tank, providing reliable pressure data support for evaluating the unit's operating status. The formula for calculating the operating pressure index is:

[0038] ;

[0039] In the formula, Represents the working condition pressure index; This represents the real-time pressure of the inlet pipe of the cam pump unit; This represents the real-time pressure of the outlet water pipe of the cam pump unit. Represents the real-time pressure of the tank; , , Represents the weighting coefficients for each pressure level; This represents the upper limit of the full scale of the pressure transmitter;

[0040] The operating pressure index is calculated by weighted fusion and normalization of the pressure in the cam pump inlet pipe, the pressure in the outlet pipe, and the pressure in the water storage tank. It integrates multiple pressure monitoring data to comprehensively reflect the overall pressure operating status of the system and provides a quantitative basis for pipeline pressure fluctuation analysis and unit load condition judgment.

[0041] The flow detection unit is equipped with an electromagnetic flow meter, which is installed on the outlet pipe to collect flow data at the outlet of the cam pump unit and calculate the flow stability index. This meets the rated operating point flow detection requirements in JB / T13974-2020 "Elastomer Cam Rotor Pumps," ensuring the accuracy and standardization of flow detection. The formula for calculating the flow stability index is:

[0042] ;

[0043] In the formula, Represents the traffic stability index; This represents the instantaneous flow rate at the outlet of the cam pump unit's water outlet pipe; Represents the average flow rate under rated operating conditions; This represents the full-scale flow meter. This represents the average reference pressure of the inlet pipe of the cam pump unit;

[0044] The flow stability index takes the deviation between instantaneous flow and rated average flow as its core, and combines the inlet reference pressure to complete the disturbance correction. It quantitatively characterizes the fluctuation range and stability of the cam pump outlet flow, effectively identifies abnormal operating conditions caused by flow instability and pipeline disturbance, and provides quantitative indicators for evaluating the unit's delivery performance.

[0045] The vibration detection unit is equipped with four piezoelectric accelerometers, distributed across the front and rear ends of the cam pump unit, the motor housing, and the bearing housing. These sensors collect vibration acceleration and velocity data from the cam pump unit. The vibration signals are then filtered using a Fast Fourier Transform (FFT) to calculate the vibration velocity index. This comprehensive system captures vibration signals during unit operation, filtering out environmental vibrations, pipeline vibrations, and other interference signals. It accurately reflects the unit's operational stability and provides precise data for evaluating unit operational stability. The formula for calculating the vibration velocity index is:

[0046] ;

[0047] In the formula, Represents the vibration velocity index; The effective value of vibration velocity after FFT filtering represents the four measuring points: the front and rear ends of the pump body, the motor housing, and the bearing housing.

[0048] The vibration velocity index is calculated by fusing the effective values ​​of vibration velocity from four distributed measuring points (front and rear ends of the pump body, motor housing, and bearing housing) after FFT filtering. It integrates vibration data from multiple locations to obtain a unified vibration evaluation index. It can eliminate environmental vibration and pipeline-related vibration interference, accurately reflect the vibration level of the cam pump unit itself, quantify the unit's operational stability, and facilitate the identification of vibration over-limit faults and the assessment of equipment operating status.

[0049] The noise detection unit is equipped with omnidirectional noise sensors, installed around the test bench at a distance of 1-1.5m from the cam pump unit. It is also equipped with a windproof cover. The unit collects noise sound pressure level data around the test bench, and calculates the noise sound pressure index after noise filtering, conforming to GB / T29529 regulations for pump noise measurement. This filters out environmental interference noise, ensuring the authenticity and standardization of the noise detection data. The formula for calculating the noise sound pressure index is:

[0050] ;

[0051] In the formula, Represents the sound pressure level (SPL). The measured sound pressure level of the representative unit; This represents the background noise of the environment after filtering. This represents the upper limit of the noise sensor's measurement range. This represents the lower limit of the noise sensor's measurement range.

[0052] The noise sound pressure index extracts the true noise sound pressure level of the cam pump unit itself after eliminating background noise interference from the environment, and completes normalization processing by combining the upper and lower limits of the sensor range; outputs a unified and quantitative noise evaluation value, which strictly conforms to the national standard for pump noise measurement, effectively eliminates external interference such as airflow and surrounding noise, accurately reflects the noise level of the unit operation, and realizes standardized and quantitative evaluation of noise conditions.

[0053] The operating status detection unit is equipped with a speed sensor, a temperature sensor, and a current sensor. The speed sensor is installed on the motor output shaft of the cam pump unit; the temperature sensor is installed on the pump body and motor bearing housing of the cam pump unit; and the current sensor is installed on the motor power supply line of the cam pump unit. It collects operating status data such as speed, temperature, and current of the cam pump unit and calculates the operating stability index. These data are used in conjunction to evaluate the unit's operating stability and provide data support for verifying continuous operation capability, thus comprehensively understanding the unit's operating status. The formula for calculating the operating stability index is:

[0054] ;

[0055] In the formula, Represents the index of stable operation; Represents the real-time speed of the motor; This represents the rated speed of the motor; This represents the upper limit of the allowable temperature for the unit; Represents the real-time temperature of the unit; This represents the rated operating current of the motor; Represents the real-time operating current of the motor;

[0056] The operational stability index integrates three operating parameters: motor speed, unit operating temperature, and motor operating current. It is calculated by coupling and normalizing the average values ​​of the three parameters to comprehensively evaluate the overall operational stability of the cam pump unit. It is quantitatively integrated from multiple dimensions such as speed matching degree, temperature safety margin, and motor load rate, comprehensively covering the electrical and mechanical operating status of the unit, and providing a unified quantitative indicator for the continuous operation performance verification and comprehensive evaluation of operating conditions of the unit.

[0057] The negative pressure holding test unit is equipped with a vacuum gauge and a high-precision pressure sensor, adapted for negative pressure measurement with an accuracy class of no less than 0.1. Installed on top of the water storage tank, it collects the holding pressure data within the tank and calculates the holding pressure decay index. It can monitor the pressure change within the tank in real time during the negative pressure holding process, recording the pressure decay value and decay time to determine the negative pressure sealing performance and pressure holding capacity of the cam pump unit. Referring to relevant standards for static pressure decay testing in pump airtightness testing ensures testing accuracy. The formula for calculating the holding pressure decay index is:

[0058] ;

[0059] In the formula, Represents the pressure attenuation index; This represents the difference in pressure attenuation during negative pressure maintenance within the tank. This represents the corresponding pressure decay time; This represents the initial reference negative pressure value for pressure holding;

[0060] The pressure attenuation index is calculated by comparing the pressure attenuation difference and attenuation time during the negative pressure holding process with the initial reference negative pressure. It directly quantifies the overall negative pressure seal leakage rate of the water storage tank and cam pump unit. The index value is positively correlated with the degree of seal leakage, which can accurately determine the negative pressure sealing performance and pressure holding capacity of the unit. It conforms to the static pressure attenuation test specifications for pump air tightness and facilitates abnormal seal leakage warning and seal performance qualification.

[0061] The comprehensive analysis unit has preset threshold ranges for operating pressure index, flow stability index, vibration velocity index, noise pressure index, stable operation index, and pressure holding attenuation index. If any calculated result of the operating pressure index, flow stability index, vibration velocity index, noise pressure index, stable operation index, or pressure holding attenuation index exceeds the threshold range of the corresponding index, it is determined that the cam pump unit has an operational abnormality in the corresponding detection dimension. The corresponding abnormal signal is sent to the early warning unit, which receives the abnormal signal and issues an alarm. This can promptly detect abnormal unit operation, avoid equipment damage and test interruption, and ensure the safety and continuity of the test process.

[0062] If the operating pressure index, flow stability index, vibration velocity index, noise sound pressure index, operational stability index, and pressure holding attenuation index are all within the corresponding threshold range, the cam pump unit is determined to be operating stably. The test data is then saved before proceeding to the next round of testing, thus achieving automatic saving of test data. This facilitates subsequent data retrieval, analysis, and archiving, improving the efficiency and standardization of the testing work.

[0063] This testing system can perform comprehensive testing of cam pump units under both atmospheric pressure circulation and negative pressure holding modes. The specific operation procedure is as follows:

[0064] I. Atmospheric Pressure Cyclic Operation Testing Procedure

[0065] (1) Fix the cam pump unit to be tested on the test bench, and adjust the clamping position and force through the adjustable fixing fixture of the test bench to ensure that the unit is firmly fixed; then connect each connecting pipeline, check the sealing joints of the pipeline connection parts to ensure that the pipeline is sealed without leakage, and avoid the medium leakage affecting the test accuracy.

[0066] (2) Set test-related parameters (including test time, working condition pressure index threshold, flow stability index threshold, etc.) through the touch screen of the control system module of the dual-mode water storage tank system. Operate the control system module to open the atmospheric pressure valve, close the sealed valve and the negative pressure valve in the valve combination, so that the tank body of the water storage tank is connected to the atmosphere and switched to atmospheric pressure mode to meet the atmospheric pressure cycle test requirements.

[0067] (3) The top of the tank is equipped with an ultra-high liquid level and the bottom of the tank is equipped with an ultra-low liquid level. This is used to detect and control whether the test water in the tank is too much or too little. Then, the water is drained and replenished through the drainage pipe and the water replenishment pipe. The high liquid level and the low liquid level are set near the middle of the tank. The high liquid level and the low liquid level can be set to different values. The pipe opening of the test platform suction pipe is located between the high and low liquid levels. By controlling the high and low liquid levels, the water intake and air intake of the suction pipe can be realized. The operation status test of the cam pump unit under different working conditions such as the suction pipe sucking in all air, part air and all liquid can be simulated.

[0068] (4) Start the cam pump unit and the circulating pump on the connecting pipeline, and simultaneously turn on the various detection units of the cooling module and the control system module to enter the pumping and drainage circulation test stage, simulate the actual operating conditions of the cam pump unit, and ensure that the test results are consistent with the actual use scenario.

[0069] (5) The pressure detection unit, flow detection unit, vibration detection unit, noise detection unit, and operation status detection unit of the control system module work synchronously to collect data on inlet pipe pressure, outlet pipe pressure and tank pressure in real time (pressure detection unit), instantaneous flow data at the outlet of the cam pump unit (flow detection unit), vibration acceleration and vibration velocity data of the unit (vibration detection unit), noise sound pressure level data around the test bench (noise detection unit), motor speed, unit temperature, and motor operating current data (operation status detection unit). Each detection unit synchronously calculates the corresponding index (operating pressure index, flow stability index, vibration velocity index, noise sound pressure index, and stable operation index) and transmits the data and index calculation results to the comprehensive analysis unit. The control system module processes and stores the collected data and index results in real time and displays the unit operation status on the touch screen in real time.

[0070] (6) After the test reaches the preset time, the control system module automatically stops the cam pump unit, the circulating pump and each detection unit, and generates an atmospheric pressure circulating test report at the same time to complete the comprehensive evaluation of the continuous operation capability, operation stability and other parameters of the cam pump unit. The test process refers to the requirements of continuous operation test in JB / T14540-2024 "Sanitary Cam Rotary Pump". The cumulative continuous operation time can be flexibly set according to the test requirements. The conventional setting is not less than 200h.

[0071] II. Negative Pressure Holding Test Procedure

[0072] (1) In accordance with the requirements of the atmospheric pressure circulation test process, after the cam pump unit to be tested is fixed and the connection of each connecting pipeline is sealed, the operation control system module closes the atmospheric pressure valve and vent valve in the valve combination, and opens the sealing valve and negative pressure valve, so that the tank body of the water storage tank is switched to the sealed mode, providing a sealed environment for the negative pressure holding test.

[0073] (2) Set the preset negative pressure value and pressure holding time through the touch screen of the control system module, close the negative pressure valve, and the tank enters the negative pressure holding state. The pressure regulating module of the negative pressure generating device ensures the stability of the negative pressure value.

[0074] (3) The negative pressure holding detection unit of the control system module starts working. Through the vacuum gauge and high-precision pressure sensor installed on the top of the tank, it monitors the pressure change in the tank in real time, records the pressure decay difference and decay time synchronously, and links the vibration detection unit and the operation status detection unit to detect the sealing status and operation stability of the cam pump unit. All relevant units transmit the detection data to the comprehensive analysis unit synchronously.

[0075] (4) After the pressure holding time reaches the preset value, slowly open the vent valve in the valve assembly to gradually release the negative pressure in the tank, so as to avoid sudden pressure changes that could damage the tank, the cam pump unit and the sensors of each detection unit. After the pressure in the tank returns to normal pressure, stop all detection operations and related execution components of the control system module.

[0076] (5) The comprehensive analysis unit of the control system module analyzes the pressure decay data collected by the negative pressure holding detection unit and the calculated pressure decay index. Combined with the data and index results of other relevant detection units, it judges the negative pressure sealing performance of the cam pump unit and automatically generates a negative pressure holding test report. According to the pump air tightness test standard, if the pressure decay value is ≤0.5%, the negative pressure sealing performance of the cam pump unit is deemed qualified; otherwise, it is deemed unqualified. The comprehensive analysis unit simultaneously sends an abnormal signal to the early warning unit, which issues an alarm to remind the staff to handle it in time.

[0077] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A dual-mode cam pump unit comprehensive testing and inspection system, characterized in that, Includes a test bench and a dual-mode water storage tank system; The test bench is used to clamp and fix the cam pump unit to be tested, and the dual-mode water storage tank system is sealed and connected to the cam pump unit clamped on the test bench through connecting pipelines. The dual-mode water storage tank system includes a water storage tank body and a control system module. The water storage tank body includes a tank body, a valve assembly, a pressure balancing device, and connecting pipes. The valve assembly is installed on the top of the tank body and at the interface of the connecting pipes. The pressure balancing device is installed on the top of the tank body and communicates with the tank body. The connecting pipes are installed between the tank body inlet and outlet and between the valve assembly, the negative pressure generating device, and the pressure balancing device, and one end is connected to the cam pump unit to be tested on the test bench. The control system module includes a pressure detection unit, a flow detection unit, a vibration detection unit, a noise detection unit, an operating status detection unit, a negative pressure holding detection unit, a comprehensive analysis unit, and an early warning unit. Each of the pressure detection unit, flow detection unit, vibration detection unit, noise detection unit, operating status detection unit, and negative pressure holding detection unit is linearly connected to the comprehensive analysis unit, and the comprehensive analysis unit is linearly connected to the early warning unit. The pressure detection unit is used to collect operating pressure data from the inlet pipe, outlet pipe, and tank, and calculate the operating pressure index; the flow detection unit is used to collect flow data from the outlet of the cam pump unit and calculate the flow stability index; the vibration detection unit is used to collect vibration acceleration and vibration velocity data from the cam pump unit, and calculate the vibration velocity index after filtering the vibration signal using FFT (Fast Fourier Transform); the noise detection unit is used to collect noise sound pressure level data around the test bench, and calculate the noise sound pressure index after noise filtering; the operating status detection unit is used to collect operating status data such as speed, temperature, and current of the cam pump unit, and calculate the operating stability index; the negative pressure holding detection unit is used to collect pressure holding data from the tank and calculate the pressure holding attenuation index. The comprehensive analysis unit performs analysis based on the calculation results and sends a signal to the early warning unit to issue an early warning if the analysis is abnormal.

2. The dual-mode cam pump unit comprehensive testing and inspection system according to claim 1, characterized in that, The test bench includes a platform for placing the cam pump unit, an adjustable fixing clamp for holding the cam pump unit, a rubber buffer pad for isolating the adjustable fixing clamp from the cam pump unit, and a polyurethane shock-absorbing pad for cushioning the platform. The platform is welded from steel profiles, the adjustable fixing clamp is installed on the top of the platform and has a rubber buffer pad installed on its inner side, and the polyurethane shock-absorbing pad is installed at the bottom of the platform.

3. The dual mode cam pump unit integrated test detection system according to claim 1, wherein, The tank is made of stainless steel and the inner wall is treated with anti-corrosion. A pressure gauge and a vacuum gauge are installed on the top of the tank, and a drain outlet is installed at the bottom of the tank. The tank has an ultra-high liquid level at the top and an ultra-low liquid level at the bottom, and a high liquid level and a low liquid level near the middle of the tank. The valve assembly includes an atmospheric pressure valve, a shut-off valve, a negative pressure valve, and a vent valve, all of which are corrosion-resistant and sealing valves. The atmospheric pressure valve connects the tank to the atmosphere, and when open, the tank is connected to the atmosphere. The shut-off valve is used to close the connection between the tank and the atmosphere, and works with the negative pressure valve to achieve a sealed state. The negative pressure valve is connected to the tank and is used to control the generation and cessation of negative pressure. The vent valve is used to slowly release the negative pressure in the tank after the negative pressure holding test is completed. The pressure balancing device includes a pressure stabilizing tank and a pressure regulating valve, which are connected to the tank body and are used to stabilize the pressure inside the tank during normal pressure cyclic testing. The connecting pipeline includes an inlet pipeline, an outlet pipeline, a circulation pipeline, a regulating pipeline, and connecting joints. One end of the inlet pipeline connects to the tank outlet, and the other end connects to the inlet of the cam pump unit under test. A filter and an inlet pressure sensor are installed on the inlet pipeline, positioned close to the inlet of the cam pump unit, to collect inlet pressure data in real time. One end of the outlet pipeline connects to the outlet of the cam pump unit under test, and the other end connects to the tank return outlet. An outlet pressure sensor and an electromagnetic flow meter are installed on the outlet pipeline to collect outlet pressure and flow data in real time. A flow regulating bypass is connected in parallel to the outlet pipeline. The circulation pipeline connects the outlet pipeline and the inlet pipeline, forming a closed-loop circulation. A circulation pump is installed on the circulation pipeline. The regulating pipeline includes a regulating valve and a throttle valve, respectively installed on the inlet and outlet pipelines, to regulate the pressure and flow within the pipelines, simulating different actual operating conditions of the cam pump unit. Sealed joints are used for connections in the circulation pipeline. All pipelines in the connecting pipeline are made of 304 stainless steel.

4. The dual mode cam pump unit comprehensive test detection system according to claim 3, characterized in that, The formula for calculating the working condition pressure index is as follows: ； In the formula, Represents the working condition pressure index; This represents the real-time pressure of the inlet pipe of the cam pump unit; This represents the real-time pressure of the outlet water pipe of the cam pump unit. Represents the real-time pressure of the tank; , , Represents the weighting coefficients for each pressure level; This represents the upper limit of the full scale of the pressure transmitter.

5. The dual mode cam pump unit integrated test detection system according to claim 3, wherein, The formula for calculating the flow stability index is: ； In the formula, Represents the traffic stability index; This represents the instantaneous flow rate at the outlet of the cam pump unit's water outlet pipe; Represents the average flow rate under rated operating conditions; This represents the full-scale flow meter. This represents the average reference pressure of the inlet pipe of the cam pump unit.

6. The dual mode cam pump unit integrated test detection system according to claim 3, wherein, The formula for calculating the vibration velocity index is as follows: ； In the formula, Represents the vibration velocity index; The effective value of vibration velocity after FFT filtering represents the four measuring points: the front and rear ends of the pump body, the motor housing, and the bearing housing.

7. The dual mode cam pump unit integrated test detection system according to claim 3, wherein, The formula for calculating the noise sound pressure index is: ； wherein represents the noise sound pressure index; represents the measured sound pressure level of the unit; represents the filtered ambient background noise; represents the upper limit of the noise sensor range; represents the lower limit of the noise sensor range.

8. The dual mode cam pump unit integrated test detection system according to claim 3, wherein, The formula for calculating the operational stability index is as follows: ； In the formula, Represents the index of stable operation; Represents the real-time speed of the motor; This represents the rated speed of the motor; This represents the upper limit of the allowable temperature for the unit; Represents the real-time temperature of the unit; This represents the rated operating current of the motor; This represents the real-time operating current of the motor.

9. The dual-mode cam pump unit comprehensive testing and inspection system according to claim 3, characterized in that, The formula for calculating the pressure holding attenuation index is as follows: ； In the formula, Represents the pressure attenuation index; This represents the difference in pressure attenuation during negative pressure maintenance within the tank. This represents the corresponding pressure decay time; This represents the initial negative pressure value for pressure holding.

10. The dual mode cam pump package comprehensive test and detection system according to claim 9, characterized in that, The comprehensive analysis unit has preset threshold ranges for operating pressure index, flow stability index, vibration velocity index, noise pressure index, stable operation index, and pressure holding attenuation index. If any calculated result of the operating pressure index, flow stability index, vibration velocity index, noise pressure index, stable operation index, or pressure holding attenuation index exceeds the threshold range of the corresponding index, it is determined that the cam pump unit has an operational abnormality in the corresponding detection dimension, and the corresponding abnormal signal is sent to the early warning unit. If the operating pressure index, flow stability index, vibration velocity index, noise pressure index, stable operation index, and pressure holding attenuation index are all within the corresponding threshold range, then the cam pump unit is judged to be operating stably.

Images