Programmable analog compressor for control board testing

Abstract

The present application relates to the compressor related field, specifically disclose a kind of program-controlled analog compressor for control panel test, including control panel, compressor, motor and torque sensor, further including hysteresis brake, the end bearing of the motor is equipped with the hysteresis brake, the end of the hysteresis brake is connected with the connecting shaft of the air compression screw end in the compressor through output shaft, two air compression screws are matched with each other, and are connected by driving gear and driven gear gear transmission, the inner cavity end of the motor is equipped with the torque sensor matched with rotor, the torque sensor and hysteresis brake output end are electrically connected with the input end of the control panel.The gear box of the compressor end of the present application is connected with limiting plate by support rod, the assembly of motor and compressor is facilitated by limiting plate, and hysteresis brake is arranged between the drive of air compression screw in motor and compressor.

Description

Technical Field

[0001] This invention relates to the field of compressors, specifically to a programmable simulated compressor for control board testing. Background Technology

[0002] A hysteresis brake is a non-contact torque control device based on the principle of hysteresis, which can achieve a constant torque output independent of rotational speed. A compressor is a driven fluid machine that raises low-pressure gas to high-pressure gas; it is the heart of a refrigeration system. It draws in low-temperature, low-pressure refrigerant gas through the suction pipe, compresses it, and discharges high-temperature, high-pressure refrigerant gas through the discharge pipe, providing power for the refrigeration cycle. The compressor is considered the heart of the refrigeration system, and the most specific term describing its characteristics is "vapor pump." The actual function of a compressor is to increase pressure, raising the suction pressure to the discharge pressure.

[0003] For example, the authorized patent with publication number CN101644246A (rotary reciprocating piston compressor): includes a cylinder, a piston, and a connecting rod. Its features include a rotor, a slide block, several sliders, and several thrust pins. A rotary track is provided on the rotor, and several slide blocks parallel to the rotor axis are provided on the slide block. The sliders slide or roll with the slide blocks. One end of the thrust pin is connected to the slider and moves along the slide block with it. The other end or middle end of the thrust pin engages with the rotary track and is driven to move relative to it along the working surface of the rotary track. One end of the connecting rod is connected to the piston, and the other end is connected to the slider. Because a rotary track structure is used to realize the reciprocating motion of the piston, the crank-connecting rod mechanism of traditional compressors is abandoned. It inherits the compact structure of swashplate compressors and increases the flexibility of the layout. Furthermore, it can realize the design of large displacement compressors. More importantly, it can control the reciprocating motion law of the piston. The compressors in the aforementioned prior art cannot detect torque in real time during the compression control process, making it inconvenient to control and test the compressor. They also cannot regulate the torque output of the motor, resulting in inaccurate testing and insufficient functionality. Furthermore, the compressor control panel is not easy to install and fix, making it inconvenient for intelligent testing and simulation control. Summary of the Invention

[0004] The purpose of this invention is to provide a programmable simulated compressor for control board testing, in order to solve the problems mentioned in the background art, such as the inability to detect torque in real time during the compression control process of the compressor, which makes the control and testing of the compressor inconvenient, the inability to regulate the torque of the motor output process, the lack of accuracy in testing, the lack of comprehensive functionality, the inconvenience of installing and fixing the compressor control panel, and the inconvenience of intelligent testing and simulation control.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a programmable simulated compressor for control board testing, comprising a control panel, a compressor, a motor, and a torque sensor, and further comprising a hysteresis brake. The hysteresis brake is provided on the end bearing of the motor. The end of the hysteresis brake is connected to the connecting shaft at the end of the air compression screw inside the compressor via an output shaft. The two air compression screws cooperate with each other and are connected by a drive gear and a driven gear. The torque sensor is provided at the end of the inner cavity of the motor and cooperates with the rotor. The output ends of the torque sensor and the hysteresis brake are both electrically connected to the input end of the control panel.

[0006] In a further embodiment, a limiting plate is also included. The limiting plate is located at the end of the motor, and a bearing slot is provided in the middle of the limiting plate. The bearing is installed by passing through the bearing slot. An integrated limiting baffle is provided on the top of the limiting plate. An installation port is provided on the limiting baffle. Support rods are provided at the upper and lower positions on the side of the limiting plate.

[0007] In a further embodiment, a first power cable and a second power cable are respectively provided on both sides of the control panel, a signal antenna is provided on one side of the top of the control panel, and a connector is provided on one side of the bottom of the control panel, and the connector is connected to the mounting port.

[0008] In a further embodiment, a power distribution connector is provided on one side of the top of the motor, the first power cable is connected to the power distribution connector, and the bottom end of the power distribution connector is connected to the torque sensor through a third power cable, and one end of the second power cable is connected to the hysteresis brake.

[0009] In a further embodiment, the compressor has a gearbox on its end face, and both the driving gear and the driven gear are located inside the gearbox. The end of the support rod is connected to the end of the gearbox, and the compressor has an exhaust port and an intake port on its upper and lower sides, respectively.

[0010] In a further embodiment, a plurality of floating pressure blocks are provided on the inner side of one end of the hysteresis brake, and the plurality of floating pressure blocks are secured to the bearing.

[0011] In a further embodiment, the output shaft is located at the end of the rotor and passes through the middle of the hysteresis brake.

[0012] In a further embodiment, the control panel integrates an overload protection module. When the torque sensor detects that the motor torque exceeds a preset threshold, the control panel automatically cuts off the power supply to the hysteresis brake and the motor, and issues an audible and visual alarm signal.

[0013] In a further embodiment, a pressure sensor is provided at the air inlet of the compressor. The pressure sensor is electrically connected to the control panel and is used to monitor the air inlet pressure in real time and automatically adjust the output torque of the hysteresis brake in conjunction with the torque.

[0014] In a further embodiment, the motor is equipped with a temperature sensor, which is electrically connected to the control panel to monitor the motor's operating temperature in real time. If the temperature exceeds the limit, the load is automatically reduced or the motor is shut down.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. The gearbox at the end of the compressor of this invention is connected to the limiting plate through a support rod. The limiting plate facilitates the assembly of the motor and the compressor. A hysteresis brake is provided between the motor and the air compression screw drive in the compressor. The torque of the motor can be adjusted through the hysteresis brake and can be connected to the control panel to facilitate the adjustment of the compressor compression control for different torques, thereby increasing versatility.

[0016] 2. The limiting plate of this invention is provided with a limiting baffle at the top, and an installation port is provided on the limiting baffle. The installation port facilitates connection with the connector at the bottom of the control panel, making it convenient to install the control panel. In addition, a torque sensor is provided inside the motor, and the torque sensor is connected to the end of the rotor, which facilitates the real-time detection of the motor torque and can feed back to the control panel, facilitating real-time adjustment and accurate detection of the motor torque.

[0017] 3. The control panel integrates an overload protection module. When the torque sensor detects that the motor torque exceeds a preset threshold, the control panel automatically cuts off the power supply to the hysteresis brake and the motor, and issues an audible and visual alarm signal. Real-time monitoring of the motor output torque prevents damage to the motor, hysteresis brake, and compressor screw due to excessive torque, thus extending equipment lifespan and improving test safety. A pressure sensor is installed at the compressor inlet, electrically connected to the control panel. This sensor monitors the inlet pressure in real time and automatically adjusts the hysteresis brake output torque in conjunction with the torque measurement. Real-time acquisition of inlet pressure allows torque control to be linked to actual operating pressure, simulating a more realistic compressor operating environment and significantly improving test accuracy. Automatic matching of the hysteresis brake output torque eliminates the need for manual intervention, achieving closed-loop intelligent adjustment of pressure and torque for greater versatility. An internal temperature sensor, electrically connected to the control panel, monitors the motor operating temperature in real time. If the temperature exceeds the limit, the load is automatically reduced or the machine is shut down. Real-time monitoring of motor temperature rise prevents overheating and burnout, insulation aging, and ensures stable long-term continuous testing. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of a programmable analog compressor for testing a control board according to the present invention; Figure 2 This is a schematic diagram of the assembly of the motor and the hysteresis brake of the present invention; Figure 3 This is a schematic diagram of the structure of the limiting plate of the present invention; Figure 4 This is a schematic diagram of the control panel of the present invention; Figure 5 This is a schematic diagram of the hysteresis brake of the present invention; Figure 6 This is a cross-sectional view of the present invention; Figure 7 This is a schematic diagram of the structure of part A of the present invention.

[0019] In the diagram: 1. Control panel; 2. Hysteresis brake; 3. Compressor; 4. Exhaust port; 5. Motor; 6. Limit plate; 7. Air inlet; 8. Limit baffle; 9. Support rod; 10. Rotor; 11. Output shaft; 12. Mounting port; 13. Bearing socket; 14. Signal antenna; 15. First power cable; 16. Connector; 17. Second power cable; 18. Drive gear; 19. Driven gear; 20. Gearbox; 21. Air compressor screw; 22. Floating pressure block; 23. Bearing; 24. Third power cable; 25. Power connector; 26. Torque sensor. Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0021] Please see Figure 1-7 This invention provides an embodiment of a programmable simulated compressor for control board testing, comprising a control panel 1, a compressor 3, a motor 5, and a torque sensor 26, and also includes a hysteresis brake 2. The hysteresis brake 2 is mounted on the end bearing 23 of the motor 5. The hysteresis brake 2 is a non-contact torque control device based on the principle of hysteresis, which can achieve a constant torque output independent of the rotational speed. The hysteresis brake 2 is a DC24V model. The end of the hysteresis brake 2 is connected to the connecting shaft at the end of the air compression screw 21 inside the compressor 3 through an output shaft 11. The output shaft 11 drives the air compression screw 21 to rotate, thereby compressing the contents of the compressor 3. The two air compression screws 21 cooperate with each other and are connected by a gear transmission between a driving gear 18 and a driven gear 19. The inner cavity end of the motor 5 is provided with a torque sensor 26 that cooperates with the rotor 10. The torque sensor 26 is a JFG-AS06 model, used to detect the torque of the rotor 10 of the motor 5. The output ends of the torque sensor 26 and the hysteresis brake 2 are both electrically connected to the input end of the control panel 1, and the detected data can be fed back to the control panel 1 in real time.

[0022] It also includes a limiting plate 6, which is located at the end of the motor 5. The limiting plate 6 has a bearing socket 13 in the middle, which facilitates the installation of the limiting plate 6 and the end of the motor 5. The bearing 23 is installed by passing through the bearing socket 13. The top of the limiting plate 6 is provided with an integrated limiting baffle 8, which facilitates the installation of the control panel 1. The limiting baffle 8 is provided with an installation port 12. Support rods 9 are provided at the upper and lower positions on the side of the limiting plate 6, which are used to support and connect with the end of the compressor 3.

[0023] The control panel 1 has a first power cable 15 and a second power cable 17 on both sides. The top side of the control panel 1 has a signal antenna 14 and the bottom side of the control panel 1 has a connector 16, which is connected to the mounting port 12. The signal antenna 14 facilitates the control panel 1 to wirelessly receive control signals.

[0024] A power distribution connector 25 is provided on one side of the top of the motor 5. The first power cable 15 is connected to the power distribution connector 25, and the bottom end of the power distribution connector 25 is connected to the torque sensor 26 through the third power cable 24. One end of the second power cable 17 is connected to the hysteresis brake 2. The first power cable 15 and the second power cable 17 facilitate the connection of the control panel 1 to the torque sensor 26 and the hysteresis brake 2, respectively.

[0025] The compressor 3 has a gearbox 20 on its end face. The driving gear 18 and the driven gear 19 are both located in the gearbox 20. The end of the support rod 9 is connected to the end of the gearbox 20. The compressor 3 has an exhaust port 4 and an air inlet 7 on its upper and lower sides, respectively. The gearbox 20 facilitates the installation of the driving gear 18 and the driven gear 19, and the exhaust port 4 and the air inlet 7 facilitate exhaust and intake.

[0026] Multiple floating blocks 22 are provided on the inner side of one end of the hysteresis brake 2, and the multiple floating blocks 22 are locked with the bearing 23. The multiple floating blocks 22 can conveniently lock the hysteresis brake 2 and the bearing 23.

[0027] The output shaft 11 is located at the end of the rotor 10 and passes through the middle of the hysteresis brake 2. The output shaft 11 facilitates the control of the transmission connection between the rotor 10 and the air compression screw 21.

[0028] The control panel 1 integrates an overload protection module. When the torque sensor 26 detects that the torque of the motor 5 exceeds a preset threshold, the control panel 1 automatically cuts off the power supply to the hysteresis brake 2 and the motor 5, and issues an audible and visual alarm signal. Real-time monitoring of the motor's output torque prevents damage to the motor, hysteresis brake, and compressor screw due to excessive torque, thereby improving equipment lifespan and testing safety.

[0029] A pressure sensor is installed at the compressor's air inlet, electrically connected to control panel 1. This sensor monitors the intake pressure in real time and automatically adjusts the output torque of the hysteresis brake 2 in conjunction with the torque measurement. Real-time intake pressure acquisition allows torque control to be linked to actual operating pressure, simulating a more realistic compressor operating environment and significantly improving testing accuracy. Automatic matching of the hysteresis brake's output torque eliminates the need for manual intervention, achieving closed-loop intelligent adjustment of pressure and torque, thus enhancing versatility.

[0030] The motor 5 is equipped with a temperature sensor, which is electrically connected to the control panel 1 to monitor the operating temperature of the motor 5 in real time. If the temperature exceeds the limit, the load is automatically reduced or the motor is shut down. Real-time monitoring of motor temperature rise prevents overheating and burnout, insulation aging, and ensures stable operation during long-term continuous testing.

[0031] Working principle: In use, the limit plate 6 is connected to the motor 5, and the double support rod 9 on one side is connected to the end of the gearbox 20. The control panel 1 is connected to the mounting port 12 through the connector 16. The end of the hysteresis brake 2 is locked and fixed to the end of the bearing 23 through the floating pressure block 22. As the rotor 10 rotates, the hysteresis brake 2 applies different torques to the rotor 10. At the same time, the torque sensor 26 detects the real-time torque of the rotor 10 and feeds it back to the control panel 1 for display. The rotor 10 drives the air compression screw 21 to rotate through the output shaft 11. The gear transmission between the driving gear 18 and the driven gear 19 drives both air compression screws 21 to rotate, compressing the air. The air is then intaked and exhausted through the air inlet 7 and the exhaust port 4, respectively.

[0032] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A programmable simulated compressor for control board testing, comprising a control panel (1), a compressor (3), a motor (5), and a torque sensor (26), characterized in that: It also includes a hysteresis brake (2), which is provided on the end bearing (23) of the motor (5). The end of the hysteresis brake (2) is connected to the connecting shaft at the end of the air compression screw (21) in the compressor (3) through the output shaft (11). The two air compression screws (21) cooperate with each other and are connected by gear transmission through the driving gear (18) and the driven gear (19). The end of the inner cavity of the motor (5) is provided with the torque sensor (26) that cooperates with the rotor (10). The output ends of the torque sensor (26) and the hysteresis brake (2) are both electrically connected to the input end of the control panel (1).

2. The programmable simulated compressor for control board testing according to claim 1, characterized in that: It also includes a limiting plate (6), which is located at the end of the motor (5), and the limiting plate (6) has a bearing socket (13) in the middle, through which the bearing (23) is installed. The top of the limiting plate (6) is provided with an integrated limiting baffle (8), and the limiting baffle (8) has an installation port (12). Support rods (9) are provided at the upper and lower positions on the side of the limiting plate (6).

3. The programmable simulated compressor for control board testing according to claim 1, characterized in that: The control panel (1) has a first power cable (15) and a second power cable (17) on both sides respectively. The control panel (1) has a signal antenna (14) on one side of the top and a connector (16) on one side of the bottom. The connector (16) is connected to the mounting port (12).

4. A programmable simulated compressor for control board testing according to claim 3, characterized in that: The motor (5) has a power distribution connector (25) on one side of its top. The first power cable (15) is connected to the power distribution connector (25), and the bottom end of the power distribution connector (25) is connected to the torque sensor (26) through the third power cable (24). One end of the second power cable (17) is connected to the hysteresis brake (2).

5. A programmable simulated compressor for control board testing according to claim 2, characterized in that: The compressor (3) has a gearbox (20) on its end face. The driving gear (18) and driven gear (19) are both located in the gearbox (20). The end of the support rod (9) is connected to the end of the gearbox (20). The compressor (3) has an exhaust port (4) and an air inlet (7) on its upper and lower sides, respectively.

6. A programmable simulated compressor for control board testing according to claim 1, characterized in that: The hysteresis brake (2) has multiple floating blocks (22) on the inner side of one end, and the multiple floating blocks (22) are locked with the bearing (23).

7. A programmable simulated compressor for control board testing according to claim 1, characterized in that: The output shaft (11) is located at the end of the rotor (10) and passes through the middle of the hysteresis brake (2).

8. A programmable simulated compressor for control board testing according to claim 1, characterized in that: The control panel (1) integrates an overload protection module. When the torque sensor (26) detects that the torque of the motor (5) exceeds the preset threshold, the control panel (1) automatically cuts off the power supply to the hysteresis brake (2) and the motor (5) and issues an audible and visual alarm signal.

9. A programmable simulated compressor for control board testing according to claim 1, characterized in that: The compressor is equipped with a pressure sensor at the air inlet. The pressure sensor is electrically connected to the control panel (1) and is used to monitor the air inlet pressure in real time and coordinate with the torque to automatically adjust the output torque of the hysteresis brake (2).

10. A programmable simulated compressor for control board testing according to claim 1, characterized in that: The motor (5) is equipped with a temperature sensor, which is electrically connected to the control panel (1) to monitor the operating temperature of the motor (5) in real time. When the temperature exceeds the limit, the load is automatically reduced or the machine is stopped.

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