PTC heater test tool integrating surface temperature and air leakage

Abstract

The utility model discloses a kind of PTC heater test fixtures of metering temperature, air leakage integration. It includes upper and lower through cover, the inside of cover forms test cavity and lower part is equipped with the insulating plate for carrying PTC heater, insulating plate has openwork part, PTC heater includes the main part in test cavity and the exposed part outside test cavity, the side wall of cover is equipped with the through slot above insulating plate, PTC heater is inserted into through slot and exposed part is left in through slot outside, simultaneously make its main part sit on openwork part, simulate airflow environment under different working conditions in actual operation process of new energy automobile by adjusting wind speed;The upper side of PTC heater is equipped with screen plate, screen plate is fixed with thermocouple at different height positions to evaluate the temperature distribution characteristics of PTC heater. Advantage is: greatly improve the detection efficiency, provide convenient, efficient detection means for new energy automobile PTC heater production enterprise and detection mechanism.

Description

Technical Field

[0001] This utility model relates to the field of performance testing technology for electric heaters used in new energy vehicles, and in particular to a PTC heater testing fixture that integrates surface temperature and air leakage detection. Background Technology

[0002] With the rapid development of the new energy vehicle industry, PTC heaters, as core components for power batteries and cabin heating, directly impact the energy consumption and safety of the entire vehicle. In practical applications, the surface temperature uniformity of the PTC heater becomes a key factor affecting heating efficiency. For example, when heating power batteries in low-temperature environments, uneven surface temperature distribution of the PTC heater can lead to localized overheating, potentially causing battery performance degradation or even safety issues. Conversely, insufficiently heated areas cannot effectively raise the battery's operating temperature, affecting the vehicle's range. Furthermore, when used for cabin heating, uneven temperature distribution can severely reduce driving comfort. At the same time, air leakage in PTC heaters is also a significant concern. Air leakage not only leads to heat loss, drastically reducing heating efficiency and increasing energy consumption, but can also cause equipment instability and shorten its lifespan. Summary of the Invention

[0003] The technical problem to be solved by this utility model is to provide a PTC heater testing fixture that integrates surface temperature and air leakage detection, which can efficiently detect the surface temperature uniformity and air leakage of PTC heaters.

[0004] To address the aforementioned technical issues, this utility model provides a PTC heater testing fixture integrating surface temperature and air leakage detection. The fixture includes a vertically integrated outer casing, with a test chamber formed inside and an insulating plate at the bottom to support the PTC heater. The insulating plate has a perforated portion. The PTC heater comprises a main body inside the test chamber and an exposed portion outside the chamber. A through groove is provided on one side wall of the outer casing above the insulating plate. The PTC heater is inserted into the through groove, leaving the exposed portion outside, while its main body rests on the perforated portion. By adjusting the wind speed, the airflow environment under different operating conditions of a new energy vehicle during actual operation is simulated. A mesh plate is provided above the PTC heater, with thermocouples fixed at different heights to evaluate the temperature distribution characteristics of the PTC heater.

[0005] The test chamber is equipped with a support frame for placing the insulating plate. Different PTC heaters of different shapes and sizes can be adapted by replacing the insulating plates with different sizes of hollowed-out parts placed on the support frame.

[0006] The opening edge of the through groove is provided with a sealing component for filling the gap between the through groove and the PTC heater.

[0007] The sealing assembly includes tape and adhesive-backed sponge.

[0008] The insulating board is an epoxy board with a thickness of 2mm-5mm.

[0009] The mesh is made of copper wire with an outer diameter of 0.4mm-0.7mm.

[0010] The outer cover is made of aluminum plate and has three outward-curving sides at the top.

[0011] An anemometer is installed on the exposed part.

[0012] The outer cover has mounting holes on its side wall that are compatible with the mesh panel, and the mesh panel is inserted and fixed inside the outer cover through the mounting holes.

[0013] Advantages of this utility model: (1) By flexibly adjusting the size of the hollow part of the insulation board, it can be adapted to PTC heaters of different shapes and sizes. At the same time, by adjusting the height of the thermocouple on the mesh board according to actual needs, it can meet the parameter acquisition requirements of various heaters under different test standards. This high versatility not only reduces the cost of enterprise testing equipment, but also greatly improves testing efficiency, providing convenient and efficient testing methods for new energy vehicle PTC heater manufacturers and testing institutions. (2) Use auxiliary materials such as tape and adhesive sponge to seal the gap between the PTC heater and the tooling to avoid air leakage during the test and ensure the accuracy of the test results. (3) It can achieve accurate and efficient detection of product temperature uniformity and air leakage, providing the industry with an efficient, accurate and universal comprehensive testing solution, and helping to improve the quality and technological innovation of electric heaters for new energy vehicles. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the PTC heater testing fixture that integrates surface temperature and air leakage detection according to this utility model. Figure 2 This is a top view schematic diagram of the PTC heater testing fixture that integrates surface temperature and air leakage detection according to this utility model. Figure 3 This is a side view of the PTC heater testing fixture that integrates surface temperature and air leakage detection according to this utility model. Figure 4 This is an assembly diagram of the PTC heater testing fixture that integrates surface temperature and air leakage detection according to this utility model. Detailed Implementation

[0015] The following detailed description of the PTC heater testing fixture integrating surface temperature and air leakage detection, in conjunction with the accompanying drawings and specific embodiments, further illustrates this utility model. Example

[0016] like Figure 1-4 As shown, the PTC heater testing fixture integrating surface temperature and air leakage detection of this utility model includes an outer cover 1 that runs vertically through the interior. The interior of the outer cover 1 forms a test chamber, and an insulating plate 2 is provided at the bottom. The insulating plate 2 has a perforated portion and is used to support the PTC heater 5. The insulating plate 2 has a perforated portion. A support frame for placing the insulating plate 2 is provided inside the test chamber. Different sizes of PTC heaters 5 can be adapted by replacing the insulating plates 2 with different perforated portions placed on the support frame. The PTC heater includes a main body located inside the test chamber and an exposed portion outside the test chamber. A mesh plate 3 is provided above the PTC heater 5. Thermocouples at different heights are fixed on the mesh plate 3 to evaluate the temperature distribution characteristics of the PTC heater 5. The height of the thermocouples and the PTC heater 5 is adjustable. The thermocouples are fixed in predetermined positions by cable ties. The height of the thermocouples can be flexibly changed by adjusting the length and tightness of the connecting wires. The temperature distribution characteristics of the PTC heater 5 are evaluated by adjusting the height of the thermocouples and the PTC heater 5. The PTC heater includes a main body located inside the test chamber and an exposed portion outside the test chamber. The exposed portion outside the test chamber has a through groove 4 on one side wall of the outer cover 1, located above the insulating plate 2. The PTC heater 5 is inserted into the through groove 4, with its exposed portion remaining outside the through groove 4, while its main body sits on the hollowed-out portion. An anemometer is placed on the exposed portion of the PTC heater, which can accurately measure the airflow velocity between the gaps in the heater base. By adjusting the wind speed, it can simulate the airflow environment under different operating conditions of new energy vehicles during actual operation. The side wall of the outer cover 1 has mounting holes adapted to the mesh plate 3, which is made of copper wire with an outer diameter of 0.6mm. Plate 3 is inserted and fixed inside the outer cover 1 through mounting hole 7; insulating plate 2 is placed on the support frame located inside the test chamber; the opening edge of the through groove 4 is provided with a sealing component for filling the gap between the through groove 4 and the PTC heater, the sealing component includes tape and adhesive sponge; insulating plate 2 is an epoxy board with a thickness of 2mm-5mm, preferably 3mm; outer cover 1 is made of aluminum plate, preferably with a thickness of 1.5cm; the top of outer cover 1 forms three outward-turned sides, the side wall with through groove 4 is surface A, and the three sides are horizontal platform surfaces extending from the top of the other three sides besides surface A.

[0017] During assembly, the outer cover 1 with ventilation support function is first placed stably on the workbench. The structural design of the outer cover ensures uniform airflow during testing. Next, the insulation board 2 is precisely placed on the support frame inside the outer cover. The limiting effect of the support frame ensures the accuracy of the insulation board's installation position. Then, using professional tools, the mesh plate 3 is firmly fixed to the pre-set mounting holes 7 on the outer cover, ensuring a tight connection between the mesh plate and the outer cover without any looseness. In the actual testing operation, the PTC heater to be tested is placed in a suitable position inside the fixture. The gap between the heater and the fixture is sealed using auxiliary materials such as tape and adhesive sponge to prevent air leakage from affecting the test results. After completing the above preparations, the testing equipment is started, and the surface temperature test and air leakage test are performed sequentially according to the pre-set test parameters. During the test, the operator must closely monitor the operating status of the testing equipment and the data acquisition to ensure the accuracy and reliability of the test data.

[0018] Specifically, in the temperature testing phase, the outer casing 1 is placed stably on professional testing equipment. The testing equipment can flexibly adjust the wind speed according to different testing requirements to simulate the airflow environment under different operating conditions of new energy vehicles during actual operation. Through this device, the surface temperature of the PTC heater under different ambient temperatures and wind speeds can be accurately tested. When testing the dry-burning temperature, the thermocouple is firmly fixed to the iron mesh plate. According to the technical specifications of different manufacturers, the thermocouple can be vertically set at different heights such as 3mm and 5mm above the heater to obtain temperature data at different spatial distances and comprehensively evaluate the temperature distribution characteristics of the heater. For the air leakage test, the outer cover is also installed on the test equipment. The equipment adjusts the wind speed according to the set requirements, and then a high-precision anemometer is placed on the exposed part of the heater to accurately measure the airflow speed in the gap of the heater base.

Claims

1. A PTC heater testing fixture integrating surface temperature and air leakage detection, characterized in that: The device includes a top-to-bottom through-cover (1), the interior of which forms a test chamber and the lower part is provided with an insulating plate (2) for supporting a PTC heater (5). The insulating plate (2) has a hollowed-out portion. The PTC heater includes a main body located inside the test chamber and an exposed portion located outside the test chamber. A through groove (4) is provided on one side wall of the cover (1) above the insulating plate (2). The PTC heater (5) is inserted into the through groove (4) and the exposed portion is left outside the through groove (4), while its main body sits on the hollowed-out portion. By adjusting the wind speed, the airflow environment of new energy vehicles under different operating conditions during actual operation is simulated. A mesh plate (3) is provided above the PTC heater (5). Thermocouples at different heights are fixed on the mesh plate (3) to evaluate the temperature distribution characteristics of the PTC heater (5).

2. The PTC heater testing fixture integrating surface temperature and air leakage detection as described in claim 1, characterized in that: The test chamber is equipped with a support frame for placing the insulating plate (2). The PTC heater (5) of different shapes and sizes can be adapted by replacing the insulating plate (2) with different hollow parts placed on the support frame.

3. The PTC heater testing fixture integrating surface temperature and air leakage detection as described in claim 1, characterized in that: The opening edge of the through groove (4) is provided with a sealing component (6) for filling the gap between the through groove (4) and the PTC heater.

4. The PTC heater testing fixture integrating surface temperature and air leakage detection as described in claim 3, characterized in that: The sealing assembly includes tape and adhesive-backed sponge.

5. The PTC heater testing fixture integrating surface temperature and air leakage detection as described in claim 1, characterized in that: The insulating board (2) is an epoxy board with a thickness of 2mm-5mm.

6. The PTC heater testing fixture integrating surface temperature and air leakage detection as described in claim 1, characterized in that: The mesh plate (3) is made of copper wire with an outer diameter of 0.4mm-0.7mm.

7. The PTC heater testing fixture integrating surface temperature and air leakage detection as described in claim 1, characterized in that: The outer cover (1) is made of aluminum plate and has three outward-turned sides on the top.

8. The PTC heater testing fixture integrating surface temperature and air leakage detection as described in claim 1, characterized in that: An anemometer is installed on the exposed part.

9. The PTC heater testing fixture integrating surface temperature and air leakage detection as described in claim 1, characterized in that: The outer cover (1) has mounting holes (7) on its side wall that are adapted to the mesh plate (3), and the mesh plate (3) is fixed inside the outer cover (1) by being inserted through the mounting holes.

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