Compressor stall testing device

Abstract

The utility model discloses a kind of compressor stall testing device, including T-type groove workstation, sample fixed subassembly, stall execution subassembly, electric control system and detection module, sample fixed subassembly and stall execution subassembly are located on T-type groove workstation, sample fixed subassembly at least includes one of lifting platform and compressor clamp, stall execution subassembly includes three-jaw clamp and three-jaw clamp frame;Electric control system includes electric control box and electric control operating platform, for being tested compressor and entire testing device power supply and realizes electric control function;Detection module is integrated in electric control system, for real-time monitoring voltage value and current value when being tested compressor stall test, detection module contains power meter.The utility model is fixed flexible, can be adapted to different size, type compressor;Adopt integrated electric control system, simplify power supply switching, real-time acquisition voltage, current data and generate data curve, convenient operation, improve test efficiency.

Description

Technical Field

[0001] This utility model relates to the technical field of testing equipment for verifying the durability of compressors by performing stall tests. Background Technology

[0002] During production and use, compressors require stall testing to verify their electrical and durability performance when the shaft is fixed (stalled), ensuring the compressor's safety and reliability under abnormal operating conditions. Existing compressor stall testing equipment has the following shortcomings: The sample fixing method is limited: most devices only use a single clamp to fix the compressor, which cannot be adapted to compressors of different sizes and models, resulting in poor flexibility; Inadequate electrical control functions: It lacks an integrated power supply, control and monitoring system, requires the connection of multiple external devices (such as power supply, ammeter, voltmeter), is cumbersome to operate, and cannot display test curves or store historical data in real time; The alarm mechanism is incomplete: it can only provide a simple alarm for overload current, and cannot monitor faults such as communication abnormalities and emergency stop triggering. Furthermore, it lacks an alarm record query function, which is not conducive to fault tracing. To address the aforementioned issues, there is an urgent need for a compressor stall testing device that offers flexible fixing methods, comprehensive electronic control functions, and timely alarms. Utility Model Content

[0003] The purpose of this invention is to overcome the above-mentioned defects of existing compressor stall testing equipment and to provide a stall testing device that can be adapted to different compressors and can monitor and display test parameters in real time.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A compressor stall test device includes: a T-slot worktable, a sample fixing assembly, a stall actuator, an electrical control system, and a detection module. The sample fixing assembly is disposed on the T-slot worktable and is used to fix the compressor under test. The stall actuator is disposed on the T-slot worktable and is used to fix the shaft of the compressor under test to achieve stall. The sample fixing assembly includes at least one of a lifting platform and a compressor clamp; The stall actuator includes a three-jaw clamp and a three-jaw clamp holder, wherein the three-jaw clamp is fixed on the three-jaw clamp holder and the three-jaw clamp holder is mounted on the T-slot worktable; The electrical control system includes an electrical control box and an electrical control console. The electrical control box is connected to an external power source to supply power to the compressor under test and the entire test device and to realize electrical control functions. The electrical control console is electrically connected to the electrical control box and is equipped with operation buttons and display components. The detection module is integrated into the electronic control system and is used to monitor the voltage and current values ​​of the compressor under test during the stall test in real time. The detection module includes a power meter.

[0005] Furthermore, the lifting platform can be adjusted in height vertically and in horizontal position along the groove of the T-slot worktable; the three-jaw clamp can be adjusted in horizontal position along the groove of the T-slot worktable.

[0006] Furthermore, the electrical control box includes an AC power supply unit and a DC power supply unit, wherein the AC power supply unit is a frequency converter; both the AC power supply unit and the DC power supply unit have identification plates on their wiring terminals.

[0007] Furthermore, the electrical control system also includes a PLC control module, which is integrated in the electrical control box and is used to control the test process and receive monitoring data from the detection module. The display component of the electrical control console is a display screen, which is electrically connected to the PLC control module and is used to display real-time voltage curves, real-time current curves, test status, and parameter setting interface.

[0008] Furthermore, the parameter settings include the number of runs, starting current, stopping current, and alarm current; the alarm current includes three-phase current protection value, single-phase current protection value, and DC current protection value. When the current value detected by the detection module is greater than the alarm current, the test automatically stops.

[0009] Furthermore, the operation buttons include at least a start / stop button, a fault reset button, a voltage curve setting button, a current curve setting button, and an operating mode setting button. Even further, the operating mode setting button can switch the test operating mode, which includes at least single-phase mode, three-phase mode, and DC mode.

[0010] The beneficial effects of this utility model are: Compared with the prior art, the compressor stall test device provided by this utility model has the following advantages: Flexible fixing: It not only has two sample fixing methods, but also the positions of multiple components are adjustable, which can be adapted to compressors of different sizes and types; Easy to operate: It adopts an integrated electronic control system, which simplifies power supply switching. Combined with the visual interface of the display screen, it can quickly and easily set parameters and perform test start and stop operations. Comprehensive monitoring: Real-time acquisition of voltage and current data and generation of data curves, which can fully cover three test scenarios: three-phase, single-phase, and DC. Safe and reliable: Sets up multiple alarm levels and fault records for overcurrent, communication abnormality, emergency stop, etc., to reduce testing risks and facilitate traceability; Efficiency Improvement: Integrated design and real-time data display and monitoring reduce manual intervention and improve testing efficiency.

[0011] The technical solution of this utility model will be illustrated below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the overall structure of the compressor stall test device provided in this embodiment of the utility model.

[0013] Figure 2 This is a front view of the compressor stall test device provided in this embodiment of the utility model.

[0014] Figure 3 This is a side view of the compressor stall test device provided in this embodiment of the utility model.

[0015] Figure 4 This is a top view of the compressor stall test device provided in this embodiment of the utility model.

[0016] Figure 5 This is a test flowchart of the compressor stall test device provided in this embodiment of the utility model.

[0017] Explanation of reference numerals in the attached figures: 1 T-slot worktable, 2 Sample fixing assembly, 201 Lifting platform, 202 Compressor clamp 3. Stall actuator assembly, 301 three-jaw clamp, 302 three-jaw clamp holder 4. Electrical control system, 401 electrical control box, 402 electrical control console 5. Compressor under test Detailed Implementation

[0018] The specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the disclosed technical solutions. It should also be noted that, for ease of description, the accompanying drawings show only the parts relevant to the technical solutions of this application, not the entire structure.

[0019] Before discussing the exemplary embodiments in more detail, it should be mentioned that the structure of the device components and / or modules mentioned in the embodiments, unless otherwise described in detail, is something that can be understood by those skilled in the art based on existing public technologies or is a commercially available product.

[0020] refer to Figure 1The compressor stall test device of this embodiment includes: a T-slot worktable 1, a sample fixing assembly 2, a stall actuator 3, an electrical control system 4, and a detection module. The sample fixing assembly 2 is disposed on the T-slot worktable 1 and is used to fix the compressor under test. The stall actuator 3 is disposed on the T-slot worktable 1 and is used to fix the rotating shaft of the compressor under test to achieve stall. The sample fixing assembly 2 includes at least one of a lifting platform 201 and a compressor clamp 202. The stall actuator 3 includes a three-jaw clamp 301 and a three-jaw clamp bracket 302. The clamp 301 is fixed to the three-jaw clamp 302, which is located on the T-slot workbench 1. The electrical control system 4 includes an electrical control box 401 and an electrical control operating table 402. The electrical control box 401 is connected to an external power supply to power the compressor under test and the entire testing device and to realize electrical control functions. The electrical control operating table 402 is electrically connected to the electrical control box 401 and is equipped with operating buttons and display components. The detection module is integrated into the electrical control system 4 and is used to monitor the voltage and current values ​​of the compressor under test during the stall test in real time. The detection module contains a power meter.

[0021] The lifting platform 201 can be adjusted vertically for height and horizontally along the T-slot worktable 1. The three-jaw clamp 302 can also be adjusted horizontally along the T-slot worktable 1.

[0022] A preferred embodiment is to integrate an AC power supply unit and a DC power supply unit within the electrical control box 401, wherein the AC power supply unit is a frequency converter. Identification plates are provided at the wiring terminals of both the AC and DC power supply units for easy identification and confirmation.

[0023] A preferred embodiment is to integrate the PLC control module into the electrical control system 4, which is used to control the testing process and receive monitoring data from the detection module. The display component of the electrical control console 402 is a display screen, which is electrically connected to the PLC control module and is used to display real-time voltage curves, real-time current curves, test status, and parameter setting interface. The parameter settings include the number of runs, starting current, stopping current, and alarm current; the alarm current includes three-phase current protection values, single-phase current protection values, and DC current protection values. When the current value monitored by the detection module exceeds the alarm current, the test can automatically stop.

[0024] The display screen interface may include a running monitoring screen, a parameter setting screen, a manual debugging screen, a historical curve screen, a historical record screen, an IO monitoring screen, and an alarm query screen; the operation buttons include at least a start / stop button, a fault reset button, a voltage curve setting button, a current curve setting button, and a running mode setting button. Preferably, the running mode setting button can switch the test running mode, and the running modes include at least single-phase mode, three-phase mode, and DC mode.

[0025] The parameter setting screen allows setting the number of runs, start current, stop current, and alarm current. The alarm current may include three-phase current protection value, single-phase current protection value, and DC current protection value. When the current value detected by the detection module is greater than the alarm current, the test can be automatically stopped.

[0026] The historical data display may include test data within a specified time period. This test data includes at least single-phase voltage, single-phase current, three-phase voltage, three-phase current, DC voltage, and DC current. The electrical control system may further include a storage module integrated within the electrical control box for storing historical test data. The historical data can be exported to a USB drive in CSV format via the "Data Export" function menu on the historical data display screen. The exported file is named after the test time (year, month, day, hour, minute, second).

[0027] The IO monitoring screen is electrically connected to the PLC control module and is used to display the status of the IO points of the PLC module. The IO points include at least three-phase motor signals, single-phase motor signals, DC motor signals, start / stop button signals, emergency stop button signals, alarm signal lights, and output signal lights.

[0028] The alarm query screen is used to display alarm information, including alarm date, alarm time, alarm object name, alarm value, and alarm description. The electrical control system also includes an alarm module. When an IO module communication failure, a power meter communication failure, or an emergency stop button is pressed, the alarm module triggers an alarm and records the alarm information on the alarm query screen.

[0029] The manual debugging screen allows manual control of the relay's on / off state to verify whether the device output is normal.

[0030] The T-slot worktable can be made of cast iron with a slot spacing of 50mm to ensure stable component installation; the lifting platform has a lifting range of 0-300mm, and horizontal adjustment is achieved through the T-slot slider, with a load-bearing capacity of ≥50kg; the compressor clamp can use adjustable clamps with a clamp spacing adjustment range of 100-500mm, suitable for compressors with a diameter of 100-500mm; the three-jaw chuck has a jaw adjustment range of 10-100mm, a clamping force of ≥100N, ensuring reliable shaft fixation; the bottom of the three-jaw chuck is equipped with a T-slot slider, which can be horizontally adjusted along the T-slot worktable with an adjustment accuracy of ±1mm; the electrical control box has a built-in 380V inverter AC power supply (output frequency 50-60Hz) and 240V DC power supply, and integrates a PLC control module (model Siemens S7-200SMART) and a storage module (capacity 8GB); the electrical control console is equipped with a 10.1-inch touch screen (resolution 1280×800), with start / stop buttons, emergency stop buttons, and fault reset buttons, and the buttons have LED indicator lights.

[0031] Structurally, the testing device is based on a T-slot worktable and integrates sample fixing components, stall actuator components, electrical control system, and detection module to form an integrated testing system. Among them: T-slot worktable is the basic support component: it provides an installation base for other functional components and realizes the function of adjusting the position of the components on it through the slot structure; Sample fixing components (lifting platform and compressor clamp): Two parallel fixing methods are adopted, which can be selected to adapt to compressors of different sizes. The lifting platform can adjust the height and horizontal position to further improve adaptability. Stall actuator (three-jaw clamp and three-jaw clamp holder): The three-jaw clamp is used to clamp the compressor shaft to achieve stall, and the three-jaw clamp holder can be adjusted along the T-slot to ensure precise alignment with the shaft; Electrical control system (electrical control box and electrical control console that can be connected to an external power supply): integrates power supply, control and display functions, and the power supply module distinguishes between AC (frequency conversion) and DC power supply; the console realizes visual operation and data display through the display screen; Detection module (power meter): It can collect three-phase / single-phase / DC voltage and current data in real time, providing a basis for testing, monitoring and alarm.

[0032] In terms of functionality: Select the corresponding power interface according to the compressor type (AC / DC). The interface with the label can avoid incorrect connection. The number of runs, starting current, stopping current, and alarm current can be set via the display screen. The test will stop when the number of tests reaches the set value or the current exceeds the alarm value. Real-time monitoring and recording: The display screen can directly show the real-time curves and data of voltage / current, and the storage module records historical test data and supports export in CSV format (files are named by time to avoid conflicts). Fault monitoring and tracing: The IO monitoring screen displays the status of the PLC's IO points in real time, and the alarm query screen records alarm information such as communication abnormalities and emergency stop triggers, which facilitates fault diagnosis; Manual debugging function: Manually control the relay to turn on and off, verify whether the device output is normal, and ensure that the equipment is in a reliable state before testing.

[0033] refer to Figure 5 The testing process is as follows: Start endurance test: Select three-phase / single-phase / DC mode → the corresponding contactor engages → check if the current is greater than the starting current → if yes, enter the motor stall state → check if the current is lower than the shut-off current → if yes, the motor enters the protection state, and the protection count is incremented by 1 → check if the count is greater than the set value → if yes, end the test, otherwise return to the "check if the current is greater than the starting current" step.

[0034] The specific operating steps are as follows: 1. Power connection Depending on the type of compressor being tested (AC / DC), connect the external power supply to the power interface of the device: connect the AC compressor to the inverter power terminal, and connect the DC compressor to the DC power terminal. The terminals should be clearly marked to avoid incorrect connection.

[0035] 2. Motor wiring Disconnect the main power supply to the device, connect the motor leads of the compressor to be tested to the terminal block of the electrical control box. The AC and DC terminals on the terminal block are labeled. After ensuring that the wiring is correct, close the main power supply.

[0036] 3. Sample fixation and stall alignment If the compressor is large, choose to fix it on a lifting platform: place the compressor on the lifting platform, adjust the height of the lifting platform (so that the rotating shaft is coaxial with the three-jaw clamp) and the horizontal position, and lock it in place; If the compressor is small, use a compressor clamp to fix it: clamp the compressor in the clamp, adjust the horizontal position of the clamp so that the shaft is aligned with the three-jaw chuck; Adjust the horizontal position of the three-jaw clamp, start the three-jaw clamp to clamp the compressor shaft, and complete the preparation for stall.

[0037] 4. Parameter Settings Turn on the control power. The touchscreen will enter the "Operation Monitoring" screen. Click on the "Parameter Settings" screen: Run count setting: Enter the number of tests (e.g., 100 times). The test will automatically end when the actual number of tests exceeds the set value. Starting current setting: Input the starting current value (e.g., 5A). When the motor current is greater than this value, the motor is determined to resume operation from the protection state. Stop current setting: Input the stop current value (e.g., 2A). When the motor current is less than this value, the motor is determined to enter the protection state, and the number of durability counts is incremented by 1. Alarm current setting: Input the three-phase / single-phase / DC current protection value (e.g., 10A). When the monitored current exceeds the protection value, the test will automatically stop and an alarm will sound.

[0038] 5. Running mode selection and test startup Click the "Running Mode Setting" button, select the corresponding mode (such as three-phase mode), and click the "Start / Stop" button to start the test: The device controls the corresponding contactor to engage according to the operating mode, thereby supplying power to the motor; The detection module (power meter) collects voltage and current data in real time, and the touch screen displays the real-time voltage / current curves and real-time data (such as three-phase voltage 380V and current 5A). When the motor current is lower than the stopping current, the motor is identified as being under protection, and the number of endurance tests is incremented by 1; when the number of endurance tests reaches the set value, the test automatically ends.

[0039] 6. Data Query and Export Historical curve query: Click on the "Historical Curves" screen, set the query time range (e.g., the last hour), and you can view past voltage / current curves; Exporting historical data: Click on the "History" screen, set the start / end time, and click "Export Data". The historical data will be exported to the USB drive in CSV format, and the file will be named "202509253608.csv" (year, month, day, hour, minute, second).

[0040] 7. Fault Monitoring and Handling IO Monitoring: Click on the "IO Monitoring" screen to view the status of the PLC's IO points (such as whether the emergency stop button is triggered or whether the alarm indicator lights are on). Alarm Inquiry: Click the "Alarm Inquiry" screen to view alarm information (such as IO module communication abnormality, power meter communication abnormality). After troubleshooting, click "Fault Reset" to resume testing.

[0041] 8. Manual debugging (optional) To verify the device output, click the "Manual Debugging" screen, manually turn the relay (such as a three-phase motor relay) on / off, and observe whether the motor responds normally to ensure that the device output is reliable.

[0042] This utility model's compressor stall test device solves the problems of poor adaptability, cumbersome operation, and difficulty in tracing faults in existing devices through its flexible sample fixing structure, integrated electronic control system, and comprehensive monitoring and alarm functions. It can be widely used in stall durability testing of various compressors such as household air conditioner compressors and refrigerator compressors, and has high practical value and promising prospects for promotion.

Claims

1. A compressor stall test device, characterized in that: include: The system comprises a T-slot worktable (1), a sample fixing component (2), a stall actuator (3), an electrical control system (4), and a detection module. The sample fixing component (2) is mounted on the T-slot worktable (1) and is used to fix the compressor under test. The stall actuator (3) is mounted on the T-slot worktable (1) and is used to fix the shaft of the compressor under test to achieve stall. The sample fixing assembly (2) includes at least one of a lifting platform (201) and a compressor clamp (202); The stall actuator (3) includes a three-jaw clamp (301) and a three-jaw clamp frame (302). The three-jaw clamp (301) is fixed on the three-jaw clamp frame (302), and the three-jaw clamp frame (302) is located on the T-slot worktable (1). The electrical control system (4) includes an electrical control box (401) and an electrical control console (402). The electrical control box (401) is connected to an external power supply and is used to supply power to the compressor under test and the entire test device and to realize electrical control functions. The electrical control console (402) is electrically connected to the electrical control box (401) and is equipped with operation buttons and display components. The detection module is integrated into the electronic control system (4) and is used to monitor the voltage and current values ​​of the compressor under test during the stall test in real time. The detection module contains a power meter.

2. The compressor stall test device as described in claim 1, characterized in that: The lifting platform (201) is adjusted in height in the vertical direction and in horizontal position along the groove of the T-slot worktable (1).

3. The compressor stall test device as described in claim 1, characterized in that: The three-jaw clamp (302) is adjusted to a horizontal position along the groove of the T-slot worktable (1).

4. The compressor stall test device as described in claim 1, characterized in that: The electrical control box (401) includes an AC power supply unit and a DC power supply unit, wherein the AC power supply unit is a frequency converter.

5. The compressor stall test device as described in claim 4, characterized in that: Both the AC power supply unit and the DC power supply unit have identification plates on their wiring terminals.

6. The compressor stall test device as described in claim 1, characterized in that: The electrical control system (4) further includes a PLC control module, which is integrated in the electrical control box (401) and is used to control the test process and receive the monitoring data of the detection module. The display component of the electrical control console (402) is a display screen, which is electrically connected to the PLC control module and is used to display the real-time voltage curve, the real-time current curve, the test status and the parameter setting interface.

7. The compressor stall test device as described in claim 6, characterized in that: The parameter settings include the number of runs, start current, stop current, and alarm current.

8. The compressor stall test device as described in claim 7, characterized in that: The alarm current includes three-phase current protection value, single-phase current protection value and DC current protection value. When the current value detected by the detection module is greater than the alarm current, the test will automatically stop.

9. The compressor stall test device as described in claim 1, characterized in that: The operation buttons include at least a start / stop button, a fault reset button, a voltage curve setting button, a current curve setting button, and an operating mode setting button.

10. The compressor stall test device as described in claim 9, characterized in that: The operating mode setting button is used to switch the operating mode of the test, and the operating mode includes at least single-phase mode, three-phase mode and DC mode.

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