A thermostat quick fault judging device based on double transparent inspection tubes

Abstract

The utility model relates to the technical field of engine cooling system diagnosis discloses a kind of thermostats rapid fault judging device based on double transparent inspection tube, including thermostat, large circulation monitoring component and small circulation monitoring component, the large circulation monitoring component includes large circulation transparent inspection tube, the large circulation transparent inspection tube input end is communicated with the large circulation main pipeline of thermostat by pressure-resistant sealing joint, the small circulation monitoring component includes small circulation transparent inspection tube, and the small circulation transparent inspection tube input end is communicated with the small circulation main pipeline of thermostat by pressure-resistant sealing joint.The utility model's two inspection tubes respectively gather large, small circulation flow state, and the thermostat fault diagnosis accuracy is improved to 98% or more using state difference;Compared with electronic sensor scheme, there is no electromagnetic interference risk, low in cost, high reliability, suitable for engine test stand test and whole car mass production assembly.

Description

Technical Field

[0001] This utility model relates to the field of engine cooling system diagnostic technology, specifically to a rapid fault diagnosis device for thermostats based on dual transparent inspection tubes. Background Technology

[0002] As a core component regulating the engine coolant circulation path, the thermostat's function is to automatically adjust the coolant circulation path based on the engine temperature, controlling the switching between the large and small circulation loops to ensure the engine operates at an optimal temperature. When the thermostat malfunctions, such as becoming stuck in the closed or fully open position, it can lead to excessively high or low engine temperatures, affecting the engine's normal operation and lifespan.

[0003] Currently, there are three main methods for diagnosing thermostat malfunctions: First, measuring the thermostat's opening temperature and lift using specialized testing equipment. This method requires removing the thermostat from the engine, which is complex and time-consuming. Second, judging by observing changes in the engine coolant temperature gauge and combining it with experience. However, this method is not very accurate and prone to misdiagnosis. Third, installing mechanical or electronic display devices on the thermostat itself to monitor its operating status. However, these devices require modification of the thermostat, resulting in a relatively complex structure and high cost. To address these issues, there is an urgent need for a simple, transparent inspection device based on dual-cycle state comparison, requiring no complex operation, to achieve rapid and accurate diagnosis of thermostat malfunctions. Utility Model Content

[0004] The technical problem this invention aims to solve is that existing thermostat fault diagnosis devices have complex structures and low accuracy.

[0005] To solve the above-mentioned technical problems, the present invention provides a rapid fault diagnosis device for a thermostat based on dual transparent inspection tubes, comprising a thermostat, a large circulation monitoring component, a small circulation monitoring component, and a fixing mechanism. The thermostat has a large circulation main circuit and a small circulation main circuit. The large circulation monitoring component includes a large circulation transparent inspection tube, the input end of which is connected to the large circulation main circuit of the thermostat through a pressure-resistant sealing joint, and the output end extends upward to the visible area of ​​the engine. The small circulation monitoring component includes a small circulation transparent inspection tube, the input end of which is connected to the small circulation main circuit of the thermostat through a pressure-resistant sealing joint, and the output end extends upward and is arranged parallel to the large circulation transparent inspection tube. The fixing mechanism fixes the large circulation transparent inspection tube and the small circulation transparent inspection tube together.

[0006] Optionally, the fixing mechanism includes a pipe clamp and a fixing bracket. A pipe clamp is provided at each end of the fixing bracket. The pipe clamp is fixed to the fixing bracket by bolts and pads. The large circulation transparent inspection tube and the small circulation transparent inspection tube are respectively fixed on the pipe clamp. A shock-absorbing bushing is provided between the pipe clamp and the large circulation transparent inspection tube and the small circulation transparent inspection tube.

[0007] Optionally, the large-circulation transparent inspection tube and the small-circulation transparent inspection tube are made of transparent engineering plastic with a temperature resistance of ≥120℃, a burst pressure of ≥0.5MPa, and a light transmittance of ≥85%.

[0008] Optionally, the inner walls of the large circulation transparent inspection tube and the small circulation transparent inspection tube are provided with a polytetrafluoroethylene anti-scaling coating, and the outer walls are laser-etched with circulation markings and flow direction arrows.

[0009] Optionally, the pressure-resistant sealing joint is a 90° right-angle joint, with one end being a 60° sealing pipe thread connected to the thermostat, and the other end being a bamboo joint head connected to the large circulation transparent inspection tube or the small circulation transparent inspection tube.

[0010] Optionally, the shock-absorbing bushing is made of silicone rubber.

[0011] In summary, this utility model has a simple external structure. By visually comparing the "small circulation flow when cold" and "large circulation flow when hot" states through the dual inspection tubes, fault diagnosis can be completed within 10 seconds, meeting the needs of rapid troubleshooting. The two inspection tubes collect the large and small circulation flow states respectively, and the accuracy of thermostat fault diagnosis is improved to over 98% by utilizing the state difference. The inner wall of the dual inspection tubes is equipped with a polytetrafluoroethylene anti-scaling coating, which can ensure that the inspection clarity is not affected. Compared with electronic sensor solutions, there is no risk of electromagnetic interference, and the cost is low and the reliability is high, making it suitable for engine bench testing and mass production assembly of vehicles. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the overall assembly of the thermostat rapid fault diagnosis device based on dual transparent inspection tubes according to this utility model.

[0013] Figure 2 This is an overall cross-sectional view of the thermostat rapid fault diagnosis device based on dual transparent inspection tubes of this utility model;

[0014] Figure 3 This is a schematic diagram of the fixing mechanism of the thermostat rapid fault diagnosis device based on double transparent inspection tubes of this utility model.

[0015] Figure 4 This is a schematic diagram of the large and small circulating transparent inspection tubes of the thermostat rapid fault diagnosis device based on the dual transparent inspection tubes of this utility model;

[0016] Figure 5This is a schematic diagram of the thermostat of the thermostat rapid fault diagnosis device based on the dual transparent inspection tube of this utility model;

[0017] In the diagram: 1. Large circulation transparent inspection tube; 2. Small circulation transparent inspection tube; 3. Fixing mechanism; 31. Pipe clamp; 32. Shock-absorbing bushing; 33. Pad; 34. Fixing bracket; 4. Pressure-resistant sealing joint; 5. Large circulation main pipeline; 6. Small circulation main pipeline; 7. Circulation indicator; 8. Anti-scaling coating; 9. Thermostat. Detailed Implementation

[0018] The following combination Figure 1-5 The present invention will be described in further detail below.

[0019] This utility model discloses a rapid fault diagnosis device for thermostats based on dual transparent inspection tubes, referring to... Figure 1 and Figure 2 The system includes a thermostat 9, a large circulation monitoring component, a small circulation monitoring component, and a fixing mechanism 3. The thermostat 9 contains a large circulation main line 5 and a small circulation main line 6. The large circulation monitoring component includes a large circulation transparent inspection tube 1. The input end of the large circulation transparent inspection tube 1 is connected to the large circulation main line 5 from the thermostat 9 outlet to the radiator via a pressure-resistant sealing joint 4, and the output end extends upwards to the engine's visible area. The small circulation monitoring component includes a small circulation transparent inspection tube 2. The input end of the small circulation transparent inspection tube 2 is connected to the bypass port of the thermostat 9 to the small circulation water pump via a pressure-resistant sealing joint 4. The main circulation pipeline 6 is connected, and the output end extends upward and is set parallel to the large circulation transparent inspection tube 1. The fixing mechanism 3 fixes the large circulation transparent inspection tube 1 and the small circulation transparent inspection tube 2. The pressure-resistant sealing joint 4 is a 90° right-angle joint. One end is a 60° sealing pipe thread connected to the thermostat 9. The pipe thread is filled with sealant to ensure no leakage under the pressure of the cooling system (withstanding pressure of 0.1-0.5MPa). The other end is a bamboo joint head connected to the large circulation transparent inspection tube 1 or the small circulation transparent inspection tube 2. The bamboo joint head is crimped to the transparent inspection tube.

[0020] In a further implementation, refer to Figure 3 The fixing mechanism 3 includes a pipe clamp 31 and a fixing bracket 34. A pipe clamp 31 is provided at each end of the fixing bracket 34. The pipe clamp 31 is fixed to the fixing bracket 34 by bolts and pads 33. The large circulation transparent inspection tube 1 and the small circulation transparent inspection tube 2 are respectively fixed on the pipe clamp 31. A shock-absorbing bushing 32 is provided between the pipe clamp 31 and the large circulation transparent inspection tube 1 and the small circulation transparent inspection tube 2. The shock-absorbing bushing 32 is made of silicone rubber to avoid vibration interference.

[0021] In a further implementation, refer to Figure 4The large circulation transparent inspection tube 1 and the small circulation transparent inspection tube 2 are made of transparent engineering plastics such as PA12 with a temperature resistance of ≥120℃ and a burst pressure of ≥0.5MPa and a light transmittance of ≥85%. The inner wall of the large circulation transparent inspection tube 1 and the small circulation transparent inspection tube 2 is provided with a polytetrafluoroethylene anti-scaling coating 8, and the outer wall is laser-etched with circulation markings 7 ("large circulation" / "small circulation") and flow direction arrows.

[0022] Example

[0023] In this embodiment:

[0024] The large circulation transparent inspection tube 1 and the small circulation transparent inspection tube 2 are made of transparent materials with a temperature resistance of ≥120℃ and a pressure resistance of ≥0.5MPa, such as PA12. The inner wall of the tube is provided with a polytetrafluoroethylene anti-scaling coating 8. The outer wall of the inspection tube is laser-etched with circulation markings 7 ("large circulation" / "small circulation") and flow direction arrows. The coating thickness is 1-3μm to ensure that the light transmittance decreases by ≤5% after immersion in 50% ethylene glycol solution for 1000 hours.

[0025] The pressure-resistant sealing joint 4 is a 90° right-angle joint, with a 60° sealing pipe thread on one end and a bamboo joint head on the other. The pipe thread is filled with sealant to ensure no leakage under the pressure of the cooling system (withstanding pressure of 0.1-0.5MPa). The bamboo joint head is crimped to the transparent inspection tube material for sealing.

[0026] Pipe clamp 31 is made of die-cast aluminum alloy (ADC12) with anodized surface treatment; shock-absorbing bushing 32 is made of silicone rubber (Shore A hardness 60±5); fixing bracket 34 is made of Q235B material with a thickness of 3-5mm; pad 33 is made of 45 steel with environmentally friendly white zinc plating, height of 8-12mm, and M6 threaded hole in the center.

[0027] Installation and debugging process

[0028] Interface pretreatment: Depending on the engine and vehicle, NPT3 / 8 mounting holes are made at 10-20mm from the thermostat outlet on the main circulation line 5 and at 10-20mm from the bypass port on the small circulation line 6. The holes are deburred.

[0029] Tighten the 60° sealing pipe thread end of the pressure-resistant sealing joint 4 to the NPT3 / 8 mounting hole of the large and small circulation pipeline with a torque wrench to the specified torque, and then adjust the direction to be vertical and upward.

[0030] Inspection tube assembly: The large and small circulating transparent inspection tubes are snapped together with the bamboo joint end of the pressure-resistant sealing joint 4, or fixed and sealed by spring clamps, American-style strong clamps, etc.

[0031] Assembly of the fixed mechanism: According to the space of the large and small circulation pipelines, use the pad 33 and fixed bracket 34 for debugging. After adjusting to the appropriate position, tighten the hexagonal flange bolts to the specified torque to complete the assembly.

[0032] Reference Figure 2 and Figure 5 The engine cooling system controls the coolant circulation path via a thermostat as follows:

[0033] Small circulation: When the engine is cold-started or the water temperature is low (usually below 70-85℃), the main valve of thermostat 9 is closed and the bypass valve is open. The coolant does not pass through the radiator, but only circulates between the engine block, cylinder head water jacket and water pump (small circulation path), the purpose of which is to quickly raise the engine temperature.

[0034] Large circulation: When the water temperature rises to the thermostat opening threshold (usually 80-90℃), the thermostat main valve opens and the bypass valve closes. The coolant enters the radiator through the main valve to dissipate heat and then returns to the engine (large circulation path) to avoid engine overheating.

[0035] In the large circulation state, the bypass valve of thermostat 9 is completely closed, directly cutting off the flow path of the small circulation. At this time, the main flow of coolant enters the large circulation through the main valve. The small circulation path (such as the bypass channel from the cylinder block to the water pump) has no continuous coolant flow because the bypass valve is closed. A small amount of coolant may remain in the small circulation path (such as the part that has not been drained from the pipe), but this coolant is in a static state, does not participate in the circulation, and does not affect the normal operation of the large circulation.

[0036] The fault diagnosis logic of this utility model is as follows:

[0037] 1. Dynamic inspection characteristics under normal operating conditions

[0038] 1. Cold start phase (0-3 minutes, water temperature rises from ambient temperature to 60℃)

[0039] Small circulation transparent inspection tube 2: Flow appears within 10 seconds after startup, with an initial flow rate of 0.2-0.3 m / s, which increases to 0.5-0.6 m / s as the temperature rises, and the flow is stable without fluctuations; Large circulation transparent inspection tube 1: There is no flow throughout the entire process.

[0040] 2. Temperature transition phase (3-8 minutes, water temperature 60-85℃)

[0041] Small circulation transparent inspection tube 2: The flow velocity drops from 0.5m / s to 0.1-0.2m / s, with intermittent stagnation for 2-3 seconds; Large circulation transparent inspection tube 1: The first signs of flow appear when the water temperature is 75-80℃, and gradually form continuous flow (initial flow velocity 0.3-0.4m / s).

[0042] 3. Warm-up steady-state stage (after 8 minutes, water temperature 85-95℃)

[0043] Small circulation transparent inspection tube 2: flow completely stopped; Large circulation transparent inspection tube 1: flow velocity stabilized at 0.8-1.0 m / s.

[0044] 2. Inspection characteristics of typical fault conditions

[0045] 1. Thermostat stuck shut

[0046] Large circulation transparent inspection tube 1: No flow after more than 15 minutes of warm-up;

[0047] Small circulation transparent inspection tube 2: When the water temperature is >100℃, bubbles with a diameter of 1-3mm appear and the liquid surface churns violently;

[0048] Related phenomena: Water temperature gauge exceeds 105℃, cooling fan runs continuously at high speed.

[0049] 2. Thermostat stuck at full open fault

[0050] Large circulation transparent inspection tube 1: It starts flowing within 30 seconds of cold start (initial flow rate 0.3-0.4m / s);

[0051] Small circulation transparent inspection tube 2: No flow throughout;

[0052] Related phenomena: water temperature is consistently below 70℃, and the temperature of the warm air outlet is low.

[0053] 3. Thermostat partially stuck (insufficient opening)

[0054] Large circulation transparent inspection tube 1: After warming up, the flow rate is <0.3m / s, exhibiting an intermittent characteristic of flow stagnation for 5-10 seconds;

[0055] Small circulation transparent inspection tube 2: There is still a weak flow of 0.1-0.2 m / s;

[0056] Related phenomenon: Water temperature fluctuates between 95-100℃, and occasionally triggers over-temperature alarm.

[0057] This invention enables rapid and accurate diagnosis of thermostat faults by comparing the flow state of the dual transparent inspection tubes. It has a simple structure, intuitive operation, and high reliability, making it suitable for engine bench testing and mass production assembly of vehicles.

[0058] It should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of the technical solution of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A rapid fault diagnosis device for thermostats based on dual transparent inspection tubes, characterized in that, The system includes a thermostat (9), a large circulation monitoring component, a small circulation monitoring component, and a fixing mechanism (3). The thermostat (9) has a large circulation main pipeline (5) and a small circulation main pipeline (6). The large circulation monitoring component includes a large circulation transparent inspection tube (1). The input end of the large circulation transparent inspection tube (1) is connected to the large circulation main pipeline (5) of the thermostat (9) through a pressure-resistant sealing joint (4), and the output end extends upward to the visible area of ​​the engine. The small circulation monitoring component includes a small circulation transparent inspection tube (2). The input end of the small circulation transparent inspection tube (2) is connected to the small circulation main pipeline (6) of the thermostat (9) through a pressure-resistant sealing joint (4), and the output end extends upward and is arranged parallel to the large circulation transparent inspection tube (1). The fixing mechanism (3) fixes the large circulation transparent inspection tube (1) and the small circulation transparent inspection tube (2) together.

2. The rapid fault diagnosis device for thermostats based on dual transparent inspection tubes according to claim 1, characterized in that, The fixing mechanism (3) includes a pipe clamp (31) and a fixing bracket (34). A pipe clamp (31) is provided at each end of the fixing bracket (34). The pipe clamp (31) is fixed to the fixing bracket (34) by bolts and pads (33). The large circulation transparent inspection tube (1) and the small circulation transparent inspection tube (2) are respectively fixed on the pipe clamp (31). A shock-absorbing bushing (32) is provided between the pipe clamp (31) and the large circulation transparent inspection tube (1) and the small circulation transparent inspection tube (2).

3. The rapid fault diagnosis device for thermostats based on dual transparent inspection tubes according to claim 1, characterized in that, The large-circulation transparent inspection tube (1) and the small-circulation transparent inspection tube (2) are made of transparent engineering plastic with a temperature resistance of ≥120℃ and a burst pressure of ≥0.5MPa, and a light transmittance of ≥85%.

4. The rapid fault diagnosis device for thermostats based on dual transparent inspection tubes according to claim 3, characterized in that, The inner walls of the large circulation transparent inspection tube (1) and the small circulation transparent inspection tube (2) are provided with a polytetrafluoroethylene anti-scaling coating (8), and the outer walls are laser-etched with circulation markings (7) and flow direction arrows.

5. The rapid fault diagnosis device for thermostats based on dual transparent inspection tubes according to claim 1, characterized in that, The pressure-resistant sealing joint (4) is a 90° right-angle joint, with one end being a 60° sealing pipe thread connected to the thermostat (9), and the other end being a bamboo joint head connected to the large circulation transparent inspection tube (1) or the small circulation transparent inspection tube (2).

6. The rapid fault diagnosis device for thermostats based on dual transparent inspection tubes according to claim 2, characterized in that, The shock-absorbing bushing (32) is made of silicone rubber.

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