A wide-range flow control device

Abstract

This utility model and the field of fluid control technology specifically disclose a wide-range flow control device. The device consists of a circulating water tank, a variable frequency water pump, a three-way electric ball valve, large / small flow sensors, a flow splitting loop, and a level sensor. The core functionality lies in: using the three-way electric ball valve to selectively connect to either the large or small flow sensor to match different flow requirements; activating the flow splitting loop under low flow conditions, with the ball valve manually adjusting the flow splitting ratio to maintain efficient pump operation; and combining the variable frequency water pump with closed-loop feedback from the dual sensors to achieve continuous and stable control over a wide range. This device solves the problem of controlling a wide flow range in new energy vehicle battery testing, breaking through the range and accuracy limitations of traditional systems, and possessing characteristics of low cost, high reliability, and low energy consumption.

Description

Technical Field

[0001] This utility model relates to the field of flow control and detection systems, specifically to a wide-range flow control device. Background Technology

[0002] Against the backdrop of the rapid development of the new energy vehicle industry, battery performance module testing has become a crucial step in ensuring battery safety and reliability. With increasingly sophisticated testing standards, some customers have raised high requirements for liquid flow control, specifically the need to output and control a wide range of liquid flow rates (e.g., from extremely low to extremely high flow rates) to simulate battery cooling or heating needs under different operating conditions.

[0003] However, existing technologies face significant bottlenecks: the detection range of a single flow meter is limited, typically covering only a specific flow range, and the output range of a single variable frequency pump is also limited by its design parameters (e.g., insufficient maximum flow output capacity or low accuracy in low flow control). This results in the inability to meet customers' precise control needs for a wide range of flow rates (e.g., from 0.5 L / min to 500 L / min), thus affecting the accuracy and efficiency of testing. For example, in battery thermal management testing, an insufficient flow range may lead to inaccurate temperature control, causing battery performance degradation or safety hazards. Furthermore, it fails to meet customers' needs for outputting and controlling liquids over a wide flow range.

[0004] Therefore, there is an urgent need for an innovative device to overcome these limitations and improve the adaptability and reliability of the testing system. Utility Model Content

[0005] The purpose of this invention is to provide a wide-range flow control device, which aims to overcome the shortcomings of the prior art and solve the problems that the detection range of a single flow meter is limited and the output range of a single variable frequency water pump is also limited by its design parameters.

[0006] Therefore, this utility model proposes a wide-range flow control device, comprising:

[0007] A circulating water tank is used to store circulating liquids.

[0008] Variable frequency water pump, with its inlet connected to the outlet of the circulating water tank;

[0009] The three-way electric ball valve has its inlet connected to the outlet of a variable frequency water pump, its first outlet connected to flow sensor one, and its second outlet connected to flow sensor two.

[0010] The diversion circuit includes a straight-through electric ball valve connected in parallel with the flow sensor, and the outlet returns to the circulating water tank;

[0011] A manual ball valve is installed in series at the front end of the two inlets of the flow sensor to adjust the flow split ratio;

[0012] The inlet of the device under test is connected to the outlets of both flow sensor one and flow sensor two.

[0013] The PLC controller is used to control the variable frequency water pump to adjust the output flow rate, control the three-way electric ball valve to adjust the flow direction to selectively connect to flow sensor one or flow sensor two, and control the straight-through electric ball valve to open and divert liquid back to the circulating water tank.

[0014] Preferably, the device includes a high-flow mode: the variable frequency water pump maintains a high frequency output of high flow, the three-way electric ball valve adjusts the flow direction so that the liquid flows to the flow sensor, and is linked with the variable frequency water pump to provide a wide range of flow control to the device under test.

[0015] Preferably, the device includes a low-flow mode: the variable frequency water pump maintains a low frequency output and a low flow rate, the three-way electric ball valve adjusts the flow direction so that the liquid flows to the flow sensor two, the straight-through electric ball valve opens to divert the liquid back to the circulating water tank, the manual ball valve adjusts the diversion ratio and is linked with the variable frequency water pump to provide a small range of flow control to the device under test.

[0016] Preferably, a liquid level sensor is installed inside the circulating water tank to detect the liquid level in the circulating water tank and trigger an alarm.

[0017] Preferably, the manual ball valve is a lockable knob valve used to fix the flow ratio.

[0018] Preferably, the outlet of the tested component returns to the circulating water tank through a pipeline, completing the liquid circulation.

[0019] Preferably, the upper limit of the flow range of the first flow sensor is more than 10 times the upper limit of the flow range of the second flow sensor.

[0020] Preferably, the flow sensor one and flow sensor two have complementary detection ranges, covering a flow range from 0.1L / min to 1000L / min.

[0021] The wide-range flow control device provided by this utility model has the following beneficial effects: 1) Through the intelligent switching between dual flow sensors and a three-way electric ball valve, combined with the synergistic effect of the direct-flow electric ball valve and the manual ball valve in the diversion circuit, a single pump system can cover a flow range of more than 1:100, breaking through the range limitation of traditional single flowmeters and single water pumps; 2) The manual ball valve in the diversion circuit finely adjusts the diversion ratio, and the direct-flow electric ball valve dynamically opens and closes, ensuring that the variable frequency water pump always works in the high-efficiency frequency range and eliminating low-frequency fluctuations; 3) The liquid level sensor monitors the liquid level of the circulating water tank in real time, triggers a low liquid level alarm and links to stop the machine, eliminating the risk of dry burning; the closed-loop control of electric valves and water pumps reduces the need for manual intervention.

[0022] In addition to the purposes, features, and advantages described above, this application has other purposes, features, and advantages. A further detailed description of this application will be provided below with reference to the figures. Attached Figure Description

[0023] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments and descriptions of this application are used to explain this application and do not constitute an undue limitation of this application. In the drawings:

[0024] Figure 1 This is a schematic diagram of the structure of the wide-range flow control device of this utility model;

[0025] Figure 2 This is a control diagram of the wide-range flow control device of this utility model;

[0026] Explanation of reference numerals in the attached diagram: 1. Liquid level sensor; 2. Circulating water tank; 3. Variable frequency water pump; 4. Three-way electric ball valve; 5. Flow sensor one; 6. Measured component; 7. Flow sensor two; 8. Manual ball valve; 9. Straight-through electric ball valve; 10. PLC controller. Detailed Implementation

[0027] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0028] like Figure 1 , Figure 2 As shown, the wide-range flow control device of this utility model includes: a liquid level sensor 1, a circulating water tank 2, a variable frequency water pump 3, a three-way electric ball valve 4, a flow sensor 1 5, a measured component 6, a flow sensor 2 7, a manual ball valve 8, a straight-through electric ball valve 9, and a PLC controller 10. Among them, the liquid level sensor 1, the variable frequency water pump 3, the three-way electric ball valve 4, the flow sensor 1 5, the flow sensor 2 7, and the straight-through electric ball valve 9 are connected to the PLC controller 10. The flow detection value of flow sensor 2 7 is relatively small. The flow detection value of flow sensor 1 5 is relatively large, and the upper limit of the flow range of flow sensor 1 5 is more than 10 times that of flow sensor 2 7. The detection ranges of the two are complementary, covering a flow range from 0.1 L / min to 1000 L / min.

[0029] Specifically, the level sensor 1 is directly installed on the circulating water tank 2. The level sensor 1 monitors the liquid level in the tank in real time via an electrical or mechanical interface. When the liquid level is too low, the level sensor 1 triggers an alarm signal to prevent the equipment from running dry. The circulating water tank 2, as a liquid storage unit, is directly connected to the inlet of the variable frequency water pump 3 via a pipe (usually a pressure-resistant hose or rigid pipe). Liquid is drawn from the circulating water tank 2 into the variable frequency water pump 3, forming the liquid supply source for the device.

[0030] The outlet of the variable frequency water pump 3 is connected to the inlet of the three-way electric ball valve 4 via a pipeline. The variable frequency water pump 3 outputs a variable flow rate based on the control signal from the PLC controller, and the liquid flows into the three-way electric ball valve 4 through this pipeline. The connection is a rigid pipeline connection. The electric actuator of the three-way electric ball valve 4 receives the control signal and adjusts the valve position to select the liquid path.

[0031] The three-way electric ball valve 4 has two outlet ports: one connected to the inlet of flow sensor 5 and the other connected to the inlet of flow sensor 7. In high flow mode, the three-way electric ball valve 4 adjusts the flow direction, directing the liquid to flow sensor 5 while blocking the flow to flow sensor 7; in low flow mode, it operates in the opposite direction, directing the liquid to flow sensor 7 and blocking the flow to flow sensor 5.

[0032] The outlets of flow sensor 5 and flow sensor 7 are both connected to the inlet of the test component 6 via pipes. After flow sensors 5 and 7 detect the flow rate, the liquid flows directly into the test component 6 for testing. The connection adopts a parallel design, but the actual path is controlled by a three-way electric ball valve 4 to ensure that only one path is active. The output signals of flow sensors 5 and 7 are fed back to the PLC controller of the control system, which is linked with the variable frequency water pump 3 to form a closed-loop control.

[0033] In low flow mode, the inlet of the direct-flow electric ball valve 9 is connected to the bypass of the flow sensor 7, and the outlet returns to the circulating water tank 2 through a pipeline. The manual ball valve 8 is installed in series at the inlet of the flow sensor 7, and the flow split ratio is finely adjusted by manually adjusting (knob control) the opening degree to reduce the flow to the measured component 6.

[0034] The outlet of the tested component 6 is usually returned to the circulating water tank 2 through a pipeline to complete the liquid circulation, which ensures the reuse of liquid and reduces waste.

[0035] The working principle of the wide-range flow control device of this utility model is briefly described below.

[0036] The liquid level sensor 1 in the device detects whether the liquid in the circulating water tank 2 is sufficient, and alarms when the liquid level is low. The circulating water tank 2 stores liquid. The variable frequency water pump 3 outputs and controls the flow rate, selecting the pump based on the larger flow rate value. Flow sensor 5 detects the liquid flow rate, and the detected flow rate value is relatively large. Flow sensor 7 detects the liquid flow rate, and the detected flow rate value is relatively small.

[0037] When a wide range of liquid flow needs to be output and controlled, the variable frequency pump 3 maintains a high frequency, outputting a large flow rate. Simultaneously, the flow direction of the three-way electric ball valve 4 is adjusted, directing the liquid from the variable frequency pump 3 to flow sensor 5, preventing it from flowing to flow sensor 7. This allows for the detection of large flow rates. The variable frequency pump 3 and flow sensor 5 work together to provide a wide range of flow rates to the measured component 6.

[0038] When a small flow rate of liquid needs to be output and controlled, the variable frequency water pump 3 maintains a low frequency to output a small flow rate. Simultaneously, the flow direction of the three-way electric ball valve 4 is adjusted, directing the liquid from the variable frequency water pump 3 to the flow sensor 7, preventing it from flowing to the flow sensor 5. At the same time, the straight-through electric ball valve 9 is opened to divert the liquid to the circulating water tank 2, reducing the amount of liquid reaching the measured component 6. The diversion ratio is adjusted by manually controlling the opening of the manual ball valve 8. The variable frequency water pump 3 and the flow sensor 7 work together to provide a larger flow rate to the measured component 6.

[0039] like Figure 2 As shown, the entire system is automated through a PLC controller. A level sensor monitors the liquid level in the circulating water tank, triggering an alarm when the level is too low to ensure safe operation. The advantage of this device lies in its modular design, making it easy to integrate into existing testing platforms.

[0040] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A large range flow control device characterized by, include: Circulating water tank (2) is used to store circulating liquid; Variable frequency water pump (3), the inlet is connected to the outlet of the circulating water tank; The three-way electric ball valve (4) is connected to the outlet of the variable frequency water pump (3) at the inlet, the first outlet is connected to the flow sensor one (5), and the second outlet is connected to the flow sensor two (7). The diversion circuit includes a straight-through electric ball valve (9) connected in parallel with the flow sensor (7), and the outlet returns to the circulating water tank; A manual ball valve (8) is installed in series at the inlet of flow sensor 2 (7) to adjust the flow split ratio; The inlet of the test piece (6) is simultaneously connected to the outlets of flow sensor 1 (5) and flow sensor 2 (7); The PLC controller (10) is used to control the variable frequency water pump (3) to adjust the output flow rate, control the three-way electric ball valve (4) to adjust the flow direction to selectively connect the flow sensor one (5) or the flow sensor two (7), and control the straight-through electric ball valve (9) to open the diversion liquid back to the circulating water tank (2).

2. The wide-range flow control device according to claim 1, characterized in that, The device includes a high flow mode: the variable frequency water pump (3) maintains a high frequency output of high flow, the three-way electric ball valve (4) adjusts the flow direction so that the liquid flows to the flow sensor (5), and is linked with the variable frequency water pump (3) to provide a wide range of flow control to the device under test (6).

3. The wide-range flow control device according to claim 1, characterized in that, The device includes a low flow mode: the variable frequency water pump (3) maintains a low frequency output of low flow, the three-way electric ball valve (4) adjusts the flow direction so that the liquid flows to the flow sensor (7), the straight-through electric ball valve (9) opens to divert the liquid back to the circulating water tank (2), and the manual ball valve (8) adjusts the diversion ratio and is linked with the variable frequency water pump (3) to provide a small range of flow control to the device under test (6).

4. The wide-range flow control device according to claim 1, characterized in that, A liquid level sensor (1) is installed inside the circulating water tank (2) to detect the liquid level in the circulating water tank (2) and trigger an alarm.

5. The wide-range flow control device according to claim 1, characterized in that, The manual ball valve (8) is a lockable knob valve used to fix the flow ratio.

6. The wide-range flow control device according to claim 1, characterized in that, The outlet of the tested component (6) returns to the circulating water tank (2) through a pipeline, completing the liquid circulation.

7. The wide-range flow control device according to claim 1, characterized in that, The upper limit of the range of the flow sensor 1 (5) is more than 10 times the upper limit of the range of the flow sensor 2 (7).

8. The wide-range flow control device according to claim 7, characterized in that, The flow sensor 1 (5) and flow sensor 2 (7) have complementary detection ranges, covering a flow range from 0.1L / min to 1000L / min.

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