Intelligent airtight detection system for truck fuel tank
Through the intelligent airtight detection system, pressure sensors and PLC controllers are used to automatically monitor the pressure changes in the truck fuel tank, solving the problems of high artificial dependence and inaccurate detection in the existing technology, and achieving efficient and intelligent leakage detection. Ensure the accuracy and traceability of the test results.
Patent Information
- Application Number
- CN202420862935.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-04-24
- Publication Date
- 2024-12-20
- Estimated Expiration
- 2034-04-24
AI Technical Summary
The existing truck fuel tank leak detection methods rely on artificial vision, have high artificial dependence and lack of error-proof functions, making it difficult to accurately detect micro leakage, and cannot provide data-based information to trace leakage situations.
An intelligent airtight detection system including air source unit, air circuit connection pipeline, pressure control unit, pressure sensor and airtight detection instrument was designed. The compressed air is charged into the oil tank and monitored and recorded using pressure sensor and PLC controller. Pressure changes are realized, and data-based judgment and real-time recording are provided through the data acquisition system and alarm unit.
It improves the automation and accuracy of leak detection, avoids manual errors, and realizes efficient and intelligent leak detection, can accurately track leakage points, and control costs under strict emission requirements, providing high-precision and traceable detection results.
Smart Images
Figure CN222212160U_ABST
Abstract
Description
[Technical field]
[0001] The utility model relates to the technical field of truck oil tank leakage detection, in particular to an intelligent airtightness detection system for truck oil tanks. [Background Technology]
[0002] After investigating and analyzing the leakage detection technology of truck fuel tanks at home and abroad, it is found that the existing truck fuel tank leakage detection is through water detection, that is, the truck fuel tank is placed below the water level of the water tank and filled with a certain amount of positive pressure gas. If there is a leak, a bubble reaction will be generated in the water tank. The inspection personnel visually determine whether there is a leak point in the truck fuel tank, such as the attached Figure 2 shown.
[0003] According to current usage, this detection method is highly dependent on manual labor, has no error-proofing functionality, and is prone to ignoring the existence of leaks. In addition, for micro-leakage points, bubbles cannot effectively reflect the digital information of the leak, and thus cannot accurately trace the data.
[0004] Therefore, the emission requirements for fuel systems have been greatly increased, and the leak detection technology for truck fuel tanks is also facing updates and upgrades, aiming to provide customers with more competitive leak detection technology to meet the stringent emission requirements of the new regulations. [Contents of the utility model]
[0005] The utility model aims to provide an intelligent airtightness detection system for a truck fuel tank, so as to solve the problems raised in the above-mentioned background technology and avoid the outflow of defective products due to human factors.
[0006] In order to achieve the above-mentioned purpose, an intelligent airtightness detection system for a truck fuel tank is designed, comprising an air source unit 1, an air circuit connecting pipeline 2, a pressure control unit 3, a pressure sensor 7 and an airtightness detection instrument 9, wherein the air source unit 1 is connected to a truck fuel tank 6 via the air circuit connecting pipeline 2, and compressed air is filled into the truck fuel tank 6, the air circuit connecting pipeline 2 is connected to the pressure control unit 3, the pressure control unit 3 and the truck fuel tank 6 are electrically connected to the pressure sensor 7, the pressure sensor 7 is used to monitor the pressure changes of the air circuit connecting pipeline 2 and the truck fuel tank 6, the pressure sensor 7 is electrically connected to the airtightness detection instrument 9, and the pressure control unit 3, the pressure sensor 7 and the airtightness detection instrument 9 are electrically connected to a PLC controller respectively.
[0007] Furthermore, a pressurized air tank is provided in the air source unit 1, and the pressurized air tank is connected to a pressure regulating valve through high and low pressure channels. The other end of the pressure regulating valve is connected to an air circuit connecting pipeline 2, and compressed air is filled into the inner cavity of the truck fuel tank 6 through the air circuit connecting pipeline 2. An electromagnetic valve is installed between the air circuit connecting pipeline 2 and the truck fuel tank 6, so that the pressure is adjusted by the pressure regulating valve and the air circuit pipeline between the truck fuel tank and the air source is cut off by the electromagnetic valve, so as to maintain the pressure stable for a certain period of time.
[0008] Furthermore, the pressure control unit 3 is connected to the power supply unit 4 through a line, and the power supply unit 4 is connected to the pressure sensor 7 and the airtightness detection instrument 9 respectively through the RS232\rj45 communication interface 8.
[0009] Furthermore, the truck fuel tank 6 is connected to the gas circuit connecting pipeline 2 through a sealing joint fixture 5 , one end of the sealing joint fixture 5 is sealingly connected to the truck fuel tank joint, and the other end of the sealing joint fixture 5 is sealingly connected to the gas circuit connecting pipeline 2 .
[0010] Furthermore, the airtightness detection instrument 9 is electrically connected to the output end of the host computer terminal 10, and the input end of the host computer terminal 10 is connected to the data acquisition system 11. The data acquisition system 11 includes a database and a server, and the database is connected to the server.
[0011] Furthermore, the PLC controller is connected to the pressure control unit 3 through the I / O input and output module, and controls the pressure control unit 3 through the I / O input and output module. The pressure control unit 3 controls feedback through the pressure sensor 7 to open or close its pressure valve.
[0012] Furthermore, the output end of the pressure sensor 7 is connected to an amplifier, the output end of the amplifier is connected to the input end of the filter, and the output end of the filter is connected to the PLC controller through a digital-to-analog converter, so that the pressure signal is converted into an electrical signal through the pressure sensor 7 and transmitted to the amplifier. The amplifier amplifies the electrical signal and sends it to the filter. After filtering out the interference signal, the filter transmits the electrical signal to the digital-to-analog converter, and then the digital-to-analog converter converts the voltage signal into a corresponding digital signal and sends it to the PLC controller, and the PLC controller processes the digital signal.
[0013] Furthermore, it also includes an alarm unit, which includes a buzzer, an indicator light and an alarm control module. One end of the alarm control module is connected to the pressure sensor 7 through a PLC controller, and the other end of the alarm control module is connected to the buzzer and the indicator light.
[0014] Compared with the prior art, the utility model has the following advantages:
[0015] (1) Compared with the existing visual water inspection method used for truck tank leak detection, the utility model can improve the automation, intelligence and efficiency of leak detection, and avoid the outflow of defective products due to human factors;
[0016] (2) The utility model can realize the automatic determination of measurement results in digital form, improve the passive detection accuracy of leakage points, and simplify the summary to have the characteristics of intelligent error prevention integration, high-precision leakage detection, automatic and efficient traceable records, etc.;
[0017] (3) The utility model greatly improves the repetitiveness and complexity of manual operation from the perspective of ergonomics, and achieves the advantages of controlling cost investment while ensuring price quality under the background of new emission regulations. [Drawings]
[0018] Figure 1 It is a structural schematic diagram of the utility model;
[0019] Figure 2 This is a schematic diagram of the structure before the improvement of the utility model (the truck tank is immersed in a water tank to observe the detection of leaking bubbles);
[0020] In the figure: 1. Air source unit 2. Air connection pipeline 3. Pressure control unit 4. Power supply unit 5. Sealing joint fixture 6. Truck fuel tank 7. Pressure sensor 8. RS232\rj45 communication interface 9. Air tightness detection instrument 10. Upper computer terminal 11. Data acquisition system 12. Water tank. [Specific implementation method]
[0021] The utility model is further described below in conjunction with the accompanying drawings:
[0022] As attached Figure 1 As shown, the utility model provides an intelligent airtightness detection system for a truck fuel tank, comprising an air source unit 1, an air circuit connecting pipeline 2, a pressure control unit 3, a pressure sensor 7 and an airtightness detection instrument 9, wherein the air source unit 1 is connected to a truck fuel tank 6 via the air circuit connecting pipeline 2, and compressed air is filled into the truck fuel tank 6, the air circuit connecting pipeline 2 is connected to the pressure control unit 3, the pressure control unit 3 and the truck fuel tank 6 are electrically connected to the pressure sensor 7, the pressure sensor 7 is used to monitor the pressure changes of the air circuit connecting pipeline 2 and the truck fuel tank 6, the pressure sensor 7 is electrically connected to the airtightness detection instrument 9, the pressure control unit 3, the pressure sensor 7 and the airtightness detection instrument 9 are electrically connected to a PLC controller respectively; the PLC controller is connected to the pressure control unit 3 via an I / O input and output module, and controls the pressure control unit 3 via the I / O input and output module, and the pressure control unit 3 controls feedback via the pressure sensor 7 to open or close its pressure valve.
[0023] Among them, a pressurized air storage tank is provided in the air source unit 1, and the pressurized air storage tank is connected to the pressure regulating valve through high and low pressure channels. The other end of the pressure regulating valve is connected to the air circuit connecting pipeline 2, and compressed air is filled into the inner cavity of the truck fuel tank 6 through the air circuit connecting pipeline 2. A solenoid valve is installed between the air circuit connecting pipeline 2 and the truck fuel tank 6, so that the pressure is adjusted by the pressure regulating valve and the air circuit pipeline between the truck fuel tank and the air source is cut off by the solenoid valve to maintain its pressure stable for a certain period of time.
[0024] The pressure control unit 3 is connected to the power supply unit 4 through a line, and the power supply unit 4 is respectively connected to the pressure sensor 7 and the airtightness detection instrument 9 through the RS232\rj45 communication interface 8; the airtightness detection instrument 9 is electrically connected to the output end of the host computer terminal 10, and the input end of the host computer terminal 10 is connected to the data acquisition system 11, and the data acquisition system 11 includes a database and a server, and the database is connected to the server. The truck tank 6 is connected to the gas line connection pipeline 2 through the sealing joint fixture 5, one end of the sealing joint fixture 5 is sealed and connected to the truck tank joint, and the other end of the sealing joint fixture 5 is sealed and connected to the gas line connection pipeline 2.
[0025] As a further embodiment, the output end of the pressure sensor 7 is connected to an amplifier, the output end of the amplifier is connected to the input end of the filter, and the output end of the filter is connected to the PLC controller through a digital-to-analog converter, so that the pressure signal is converted into an electrical signal through the pressure sensor 7 and transmitted to the amplifier. The amplifier amplifies the electrical signal and sends it to the filter. After filtering out the interference signal, the filter transmits the electrical signal to the digital-to-analog converter, and then the digital-to-analog converter converts the voltage signal into a corresponding digital signal and sends it to the PLC controller, and the PLC controller processes the digital signal.
[0026] As a further embodiment, the utility model also includes an alarm unit, which includes a buzzer, an indicator light and an alarm control module. One end of the alarm control module is connected to the pressure sensor 7 through a PLC controller, and the other end of the alarm control module is connected to the buzzer and the indicator light.
[0027] The utility model mainly includes an air source unit (including a pressurized air storage tank for quickly filling a large-volume truck tank), related air connection pipelines, a control unit and a sensor for feedback monitoring the internal pressure of the truck tank, a PLC control and system power supply unit, a clamp for sealing the truck tank joint, a truck tank product, I / O input and output and related RS232\rj45 communication interface, an airtightness detection instrument, a host computer display and control terminal, a data acquisition system (including Microsoft VisualStudio 2013 development environment, SQL Server 2018 database, Windows server 2016 standard edition server), etc. Its working principle is: after the corresponding connection between the truck tank and the sealing fixture is sealed, the pressure control unit is controlled by the PLC I / O input and output to quickly inject compressed air of about 0.2bar-0.3bar into the truck tank, and the pressure sensor is used to control the feedback to close the pressure valve. The tank is kept under pressure for 20-30s. At the same time, the airtight detection instrument connected to it monitors and collects feedback on the real-time internal pressure data changes during the inflation and pressure-maintaining processes. In the leakage test phase, the actual leakage data can be compared with the leakage data of the traditional water detection method, and the equal amount of simulation and strict control can be performed to convert it into a quantifiable 50ml / min as the qualified leakage limit value. Finally, all process parameters and result data are uploaded to the database through the acquisition system, and the data is recorded in real time and the process is traced through the host computer application terminal.
[0028] The utility model is based on the traditional air tightness detection equipment and further optimizes and updates the leak detection system. In view of the volume range of the truck fuel tank is 260L-800L, based on the differential pressure leakage detection principle, a certain pressure of gas can be quickly rushed into the inner cavity of the truck fuel tank through the pressure regulating valve. After reaching the set pressure balance, the gas pipeline between the truck fuel tank and the gas source is cut off through the solenoid valve, and the pressure is maintained for a certain period of time to stabilize. During the pressure stabilization period, the micro-differential pressure sensor will compare the differential pressure values recorded over a period of time to obtain the pressure drop caused by the actual leakage of the fuel tank, thereby judging whether the fuel tank is leaking.
[0029] The airtight detection system of the utility model is composed of an air source, an interface and connecting pipelines, an acquisition and control unit and a sensor unit, an execution module, a test fixture, etc., and is equipped with built-in communication ports such as rs232\rj45, and can be developed by a host computer system, remotely monitored, and the host computer can automatically read the test result data and control the product testing process, and enrich the human-computer interactive operation visualization interface. The utility model intends to use multiple pressure regulating valves and high and low pressure channels for inflation, and is equipped with an external pressure gas storage tank, so as to achieve rapid filling to the required internal pressure. The differential pressure detection range of the leakage can be further optimized and controlled at 0-1000Pa, and the data accuracy of the leak detection system can be controlled at ±(1% Rdg+3Pa).
[0030] The contents not described in detail in this specification belong to the prior art known to professional and technical personnel in the field. The standard parts used can be purchased from the market, and special-shaped parts can be customized according to the records in the specification and drawings. The specific connection methods of each part adopt mature conventional means such as bolts, rivets, welding, etc. in the prior art. Machinery, parts and equipment adopt conventional models in the prior art, and circuit connections adopt conventional connection methods in the prior art, which will not be described in detail here.
[0031] The present invention is not limited to the above-mentioned implementation modes, and any other changes, modifications, substitutions, combinations, and simplifications made without departing from the spirit and principle of the present invention shall be considered as equivalent replacement modes and shall be included in the protection scope of the present invention.
Claims
1. An intelligent air tightness detection system for truck fuel tanks, Features: The invention comprises an air source unit (1), an air circuit connecting pipeline (2), a pressure control unit (3), a pressure sensor (7) and an air tightness detection instrument (9); the air source unit (1) is connected to a truck fuel tank (6) via the air circuit connecting pipeline (2) and compressed air is filled into the truck fuel tank (6); the air circuit connecting pipeline (2) is connected to a pressure control unit (3); the pressure control unit (3) and the truck fuel tank (6) are both electrically connected to the pressure sensor (7); the pressure sensor (7) is used to monitor the pressure changes of the air circuit connecting pipeline (2) and the truck fuel tank (6); the pressure sensor (7) is electrically connected to the air tightness detection instrument (9); the pressure control unit (3), the pressure sensor (7) and the air tightness detection instrument (9) are respectively electrically connected to a PLC controller.
2. The intelligent air tightness detection system for truck fuel tanks according to claim 1, Features: The gas source unit (1) is provided with a pressurized gas storage tank, which is connected to a pressure regulating valve via high and low pressure channels, the other end of which is connected to an air circuit connecting pipeline (2), and compressed air is filled into the inner cavity of a truck fuel tank (6) via the air circuit connecting pipeline (2), and an electromagnetic valve is installed between the air circuit connecting pipeline (2) and the truck fuel tank (6).
3. The intelligent air tightness detection system for truck fuel tanks according to claim 1, Features: The pressure control unit (3) is connected to the power supply unit (4) via a line, and the power supply unit (4) is respectively connected to the pressure sensor (7) and the airtightness detection instrument (9) via the RS232\rj45 communication interface (8).
4. The intelligent air tightness detection system for truck fuel tanks according to claim 1, Features: The truck fuel tank (6) is connected to the gas circuit connection pipeline (2) via a sealing joint fixture (5); one end of the sealing joint fixture (5) is sealingly connected to the truck fuel tank joint, and the other end of the sealing joint fixture (5) is sealingly connected to the gas circuit connection pipeline (2).
5. The intelligent air tightness detection system for truck fuel tanks according to claim 1, Features: The airtightness detection instrument (9) is electrically connected to the output end of the host computer terminal (10), and the input end of the host computer terminal (10) is connected to the data acquisition system (11). The data acquisition system (11) includes a database and a server, and the database is connected to the server.
6. The intelligent air tightness detection system for truck fuel tanks according to claim 1, Features: The PLC controller is connected to the pressure control unit (3) via an I / O input / output module, and controls the pressure control unit (3) via the I / O input / output module. The pressure control unit (3) controls feedback via a pressure sensor (7) to open or close its pressure valve.
7. The intelligent air tightness detection system for truck fuel tanks according to any one of claims 1 to 6, Features: The output end of the pressure sensor (7) is connected to an amplifier, the output end of the amplifier is connected to the input end of a filter, and the output end of the filter is connected to a PLC controller via a digital-to-analog converter.
8. The intelligent air tightness detection system for truck fuel tanks according to any one of claims 1 to 6, Features: It also includes an alarm unit, which includes a buzzer, an indicator light and an alarm control module. One end of the alarm control module is connected to a pressure sensor (7) via a PLC controller, and the other end of the alarm control module is connected to the buzzer and the indicator light.