A device for testing the tightness of a sensor by means of a barometric ratio

Abstract

This utility model relates to a device for testing the sealing performance of a sensor using a pressure comparison method, comprising: a gas source module; a control module for controlling the on / off state and flow path of the gas; a gas chamber module, including a first gas chamber and a second gas chamber with identical structures, both of which are sealed structures; the first gas chamber is used to place a standard sensor, and the second gas chamber is used to place the sensor under test; a monitoring module for monitoring the pressure fluctuations in the first and second gas chambers; and a host computer, which is communicatively connected to the control module and the monitoring module respectively. The host computer is configured to control the control module to control the on / off state of the gas chamber module and receive pressure data transmitted from two pressure calibration gauges. The sealing performance of the sensor under test is determined by comparing the pressure changes in the first and second gas chambers. This device uses gas as the detection cutoff, eliminating the need for liquid contact with the sensor and avoiding the circuit board damage problem caused by the water pressure test method.

Description

Technical Field

[0001] This application relates to the field of sensor detection, specifically to a device for testing the sealing performance of sensors using a pressure comparison method. Background Technology

[0002] In fields such as water environment monitoring and industrial fluid control, water quality sensors, pressure sensors, and other devices are exposed to complex environments such as immersion in water, high-pressure washing, and corrosive liquids for extended periods. The sealing performance of these sensors directly determines their reliability and lifespan. If the seal fails, moisture or corrosive media can seep into the interior, causing short circuits in the circuit board, damage to sensitive elements, and consequently, loss of monitoring data, equipment downtime, or even safety accidents. Therefore, sealing testing before products leave the factory is a crucial step in ensuring the long-term stable operation of sensors.

[0003] In existing technologies, the water pressure test is used to test the sealing performance of sensors. This method simulates the sensor's operating water depth by adding water to a container until the water level covers the sensor. The container is then sealed and pressurized. After a period of time, the product's condition is checked. While the water pressure test can screen out products with poor sealing to some extent, if water gets inside during the test, the internal circuit board may need to be scrapped, increasing costs.

[0004] Therefore, it is necessary to improve the existing technology to overcome the aforementioned defects. Utility Model Content

[0005] In view of this, this application provides an apparatus for testing the sealing performance of a sensor using a pressure comparison method to solve at least one problem existing in the prior art, comprising: The gas supply module is used to provide gas at a stable pressure and has a gas outlet. A control module for controlling the on / off state and flow path of gas, having an inlet and at least two outlets, wherein the inlet is connected to the outlet of the gas source module. The air chamber module includes a first air chamber and a second air chamber with identical structures. Both the first air chamber and the second air chamber are sealed structures. The first air chamber is used to place a standard sensor, and the second air chamber is used to place the sensor under test. The first air chamber and the second air chamber are respectively connected to the two air outlets of the control module. The monitoring module includes at least two barometers for monitoring pressure fluctuations in the first and second air chambers. The host computer is communicatively connected to the control module and the monitoring module. The host computer is configured to control the control module to switch the air chamber module on and off, and to receive air pressure data transmitted by the two air pressure calibration gauges. The sealing performance of the sensor under test is determined by comparing the air pressure changes of the first air chamber and the second air chamber.

[0006] Optionally, in the above-mentioned apparatus for testing the sealing performance of a sensor using the air pressure comparison method, the air source module includes an air compressor, a pressure reducing valve, a high-pressure gas cylinder disposed between the air compressor and the pressure reducing valve, and a pressure gauge disposed on the high-pressure gas cylinder. The air compressor is used to buffer the fluctuations in the air source pressure output by the air compressor, and the pressure reducing valve is used to reduce the air source pressure output by the air compressor.

[0007] Optionally, in the above-mentioned apparatus for testing the sealing performance of a sensor using the pressure comparison method, the control module includes a first solenoid valve disposed at the output end of the pressure reducing valve, a flow divider, a first one-way throttle valve and a second one-way throttle valve disposed between the flow divider and the first and second air chambers respectively, a second solenoid valve disposed between the first one-way throttle valve and one of the pressure gauges, and a third solenoid valve disposed between the second one-way throttle valve and another pressure gauge.

[0008] Optionally, in the above-described apparatus for testing sensor sealing performance using the air pressure comparison method, the control module further includes a first vent valve disposed at the rear end of the first air chamber and a second vent valve disposed at the rear end of the second air chamber.

[0009] Optionally, in the above-mentioned apparatus for testing the sealing performance of a sensor using the air pressure comparison method, the inner walls of the first and second air chambers are provided with horizontal limiting protrusions. A breathable carrier plate is placed on the limiting protrusions, and ventilation holes are evenly distributed on the breathable carrier plate. The standard sensor or the sensor under test is placed on the breathable carrier plate, with a gap between it and the inner wall of the air chamber.

[0010] Optionally, in the above-mentioned apparatus for testing the sealing performance of sensors using the air pressure comparison method, the air chamber module further includes a temperature-controlled sleeve wrapped around the outer wall of the air chamber.

[0011] Compared with the prior art, this application has the following advantages: By setting up a gas source module, a control module, and a first and second gas chamber with identical and sealed structures, the standard sensor and the sensor under test are placed in the first and second gas chambers respectively. The same gas source is used to pressurize the first and second gas chambers simultaneously to achieve a sealed environment. The sealing performance of the sensor under test can be judged by observing the pressure fluctuations of the two pressure calibration gauges. This device uses gas as the detection cutoff, and the absence of liquid contact with the sensor avoids the problem of circuit board damage caused by the water pressure test method. Furthermore, no other processes are required after the test, and the structure is simple and the cost is reduced. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the connection of the apparatus for testing the sealing performance of a sensor using the air pressure comparison method as shown in this application.

[0013] Figure label: 1. Air compressor; 2. High-pressure gas cylinder; 3. Pressure gauge; 4. Pressure reducing valve; 5. First solenoid valve; 6. Diverter; 7. First one-way throttle valve; 8. Second one-way throttle valve; 9. Third solenoid valve; 10. Pressure calibration gauge; 11. First air chamber; 12. Second air chamber; 13. First vent valve; 14. Second vent valve; 15. Detailed Implementation

[0014] The exemplary embodiments disclosed in this application will now be described in more detail. Numerous specific details are set forth in the following description to provide a more thorough understanding of this application. However, it will be apparent to those skilled in the art that this application can be implemented without one or more of these details. In other instances, to avoid confusion with this application, some technical features well-known in the art have not been described; that is, not all features of actual embodiments are described herein, nor are well-known functions and structures described in detail.

[0015] It should be understood that when an element or layer is referred to as "on," "adjacent to," "connected to," or "coupled to" other elements or layers, it may be directly on, adjacent to, connected to, or coupled to other elements or layers, or there may be intervening elements or layers. Conversely, when an element is referred to as "directly on," "directly adjacent to," "directly connected to," or "directly coupled to" other elements or layers, there are no intervening elements or layers. It should be understood that although the terms first, second, third, etc., may be used to describe various elements, components, areas, layers, and / or portions, these elements, components, areas, layers, and / or portions should not be limited by these terms. These terms are only used to distinguish one element, component, area, layer, or portion from another element, component, area, layer, or portion. Therefore, without departing from the teachings of this application, the first element, component, area, layer, or portion discussed below may be referred to as a second element, component, area, layer, or portion. And the discussion of a second element, component, area, layer, or portion does not imply that the first element, component, area, layer, or portion necessarily exists in this application.

[0016] Spatial relation terms such as “below,” “under,” “below,” “under,” “above,” “above,” etc., are used here for convenience to describe the relationship between one element or feature shown in the figure and other elements or features. It should be understood that, in addition to the orientation shown in the figure, spatial relation terms are intended to also include different orientations of devices in use and operation.

[0017] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. When used herein, the singular forms “a,” “an,” and “ / the” are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “compose” and / or “comprising,” when used in this specification, identify the presence of features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups. When used herein, the term “and / or” includes any and all combinations of the associated listed items.

[0018] To fully understand this application, detailed steps and structures will be presented in the following description to illustrate the technical solution of this application. Preferred embodiments of this application are described in detail below; however, in addition to these detailed descriptions, this application may have other implementation methods.

[0019] Please refer to Figure 1 As shown in the preferred embodiment of this application, an apparatus for testing the sealing performance of a sensor using a pressure comparison method is provided for detecting the sealing performance of the sensor. In this embodiment, the sensor is a water quality sensor. The apparatus for testing the sealing performance of a sensor using a pressure comparison method (hereinafter referred to as the apparatus) includes a gas source module, a control module, a gas chamber module, a monitoring module, and a host computer. The system comprises the following modules: a gas source module for providing stable pressure gas and an outlet; a control module for controlling the gas flow path and having an inlet and at least two outlets, with the inlet connected to the outlet of the gas source module; a chamber module including a first chamber 12 and a second chamber 13 with identical structures, both being sealed; the first chamber 12 for housing a standard sensor and the second chamber 13 for housing the sensor under test, both connected to the two outlets of the control module; a monitoring module including at least two pressure gauges 11 for monitoring pressure fluctuations within the two chambers; and a host computer communicating with both the control module and the monitoring module, controlling the control module's operation, receiving pressure data from the pressure gauges 11, and determining the sealing performance of the sensor under test by comparing the pressure changes in the two chambers. In this embodiment, the host computer can be a PLC (Programmable Logic Controller), RS485, RS232, etc., and the pressure gauges 11 require zero-point calibration before each use.

[0020] Understandably, this device uses gas as the detection medium, eliminating the need for liquid to contact the sensor, thus avoiding the risk of circuit board damage caused by water pressure testing. After testing, no drying process is required, improving production efficiency.

[0021] Understandably, setting up a first air chamber 12 and a second air chamber 13 with identical structures can ensure that the environment of the standard sensor and the sensor under test is consistent, and can offset interference factors such as ambient temperature and gas source fluctuations, thereby improving detection accuracy.

[0022] Specifically, the air source module includes an air compressor 1, a pressure reducing valve 4, a high-pressure gas cylinder 2 located between the air compressor 1 and the pressure reducing valve 4, and a pressure gauge 3 located on the high-pressure gas cylinder 2. The air compressor 1 is used to buffer the fluctuation of the air source pressure output by the air compressor 1, and the pressure reducing valve 4 is used to reduce the air source pressure output by the air compressor 1 to the target value.

[0023] It is worth noting that when the air compressor 1 is working, pulse-like pressure fluctuations, or airflow pulsations, will occur due to the reciprocating motion of the piston or changes in load. The high-pressure gas cylinder 2 is located between the air compressor 1 and the pressure reducing valve 4. It can act as a pressure buffer container to first store the compressed gas output by the air compressor 1, and then offset this fluctuation through its own volume, so that the gas pressure entering the subsequent pipeline is more stable, and the test benchmark is avoided due to instantaneous pressure jumps.

[0024] Furthermore, the control module includes a first solenoid valve 5 located at the output of the pressure reducing valve 4, a flow divider 6, a first one-way throttle valve 7 and a second one-way throttle valve 8 respectively located between the flow divider 6 and the first air chamber 12 and the second air chamber 13, a second solenoid valve 9 located between the first one-way throttle valve 7 and one of the pressure calibration gauges 11, and a third solenoid valve 10 located between the second one-way throttle valve 8 and the other pressure calibration gauge 11. The first solenoid valve 5 controls the on / off state of the total gas supply, while the second and third solenoid valves 9 and 10 respectively control the pressure monitoring paths of the first and second air chambers 12 and 13. This enables precise control of both overall gas supply and individual monitoring, avoiding mutual interference between the pressures of the two chambers and improving the independence and accuracy of the test. The flow divider 6, in conjunction with the first and second one-way throttle valves 7 and 8, can evenly distribute a stable gas source to the two chambers and adjust the gas inflow rate to prevent airflow impact from damaging the sensor or the air chamber sealing structure. Simultaneously, it ensures that the pressures of the two chambers rise synchronously, reducing errors caused by the initial pressure difference.

[0025] Furthermore, the control module also includes a first vent valve 14 located at the rear end of the first air chamber 12 and a second vent valve 15 located at the rear end of the second air chamber 13, so that the air pressure in the two air chambers can be released individually or simultaneously after the test, and the pressure can be released without disassembling the sensor, which facilitates quick replacement of the sensor under test.

[0026] In this embodiment, the inner walls of both the first air chamber 12 and the second air chamber 13 are provided with horizontal limiting protrusions. A ventilated carrier plate is placed on the limiting protrusion, and vent holes are evenly distributed on the ventilated carrier plate. The standard sensor or the sensor under test is placed on the ventilated carrier plate, with a gap between it and the inner wall of the air chamber. The purpose of this arrangement is that the horizontal limiting protrusion, together with the ventilated carrier plate, can fix the sensor position, preventing sensor displacement during testing and causing poor air chamber sealing. At the same time, the vent holes on the carrier plate allow gas to evenly surround the sensor, ensuring consistent force on the sensor surface and avoiding local pressure differences from affecting the sealing judgment. On the other hand, the gap between the sensor and the inner wall of the air chamber can avoid wear caused by direct contact between the sensor and the air chamber, while providing space for gas flow, ensuring uniform air pressure distribution in the air chamber, and improving the accuracy of pressure monitoring.

[0027] In an optional embodiment, the gas chamber module further includes a thermostatic sleeve wrapped around the outer wall of the gas chamber to maintain a stable temperature inside the gas chamber, prevent changes in ambient temperature from causing thermal expansion and contraction of the gas, which in turn causes gas pressure fluctuations, eliminate the influence of temperature interference on the test results, and improve the accuracy of the sealing judgment.

[0028] The test steps of the device for testing the sealing performance of a sensor using the air pressure comparison method shown in this application are as follows: Turn on the air compressor 1, and in conjunction with the high-pressure gas cylinder 2, stabilize the gas source pressure to 0.5 MPa through the pressure reducing valve 4 to provide a constant pressure source for the test; control the opening of the first solenoid valve 5, the second solenoid valve 9, the third solenoid valve 10, the first vent valve 14, and the second vent valve 15 via the host computer, allowing gas at a stable pressure to simultaneously enter the first air chamber 12 and the second air chamber 13, with ventilation lasting for 30 seconds to ensure that the pressure in the two air chambers is fully balanced and consistent with the gas source pressure; close the first solenoid valve 5, the second solenoid valve 9, the third solenoid valve 10, the first vent valve 14, and the second vent valve 15, so that both air chambers are in a completely sealed state; subsequently, monitor and record the pressure change data in the first air chamber 12 and the second air chamber 13 in real time using two air pressure calibration gauges 11; compare and analyze the pressure changes in the two air chambers per unit time. If the pressure in the second chamber 13 remains consistent with the pressure in the first chamber 12 without significant decrease, it indicates that the sensor under test has good sealing performance. If the pressure in the second chamber 13 decreases and the pressure difference with the first chamber 12 exceeds the set threshold, it indicates that the sensor under test has a sealing leak and its sealing performance is substandard.

[0029] The above is only one specific implementation of this application, and any other improvements made based on the concept of this application shall be considered within the scope of protection of this application.

Claims

1. A device for testing the sealing performance of a sensor using a pressure comparison method, characterized in that, include: The gas supply module is used to provide gas at a stable pressure and has a gas outlet. A control module for controlling the on / off state and flow path of gas, having an inlet and at least two outlets, wherein the inlet is connected to the outlet of the gas source module. The air chamber module includes a first air chamber and a second air chamber with identical structures. Both the first air chamber and the second air chamber are sealed structures. The first air chamber is used to place a standard sensor, and the second air chamber is used to place the sensor under test. The first air chamber and the second air chamber are respectively connected to the two air outlets of the control module. The monitoring module includes at least two barometers for monitoring pressure fluctuations in the first and second air chambers. The host computer is communicatively connected to the control module and the monitoring module. The host computer is configured to control the control module to switch the air chamber module on and off, and to receive air pressure data transmitted by the two air pressure calibration gauges. The sealing performance of the sensor under test is determined by comparing the air pressure changes of the first air chamber and the second air chamber.

2. The apparatus for testing sensor sealing performance using the air pressure comparison method according to claim 1, characterized in that, The air source module includes an air compressor, a pressure reducing valve, a high-pressure gas cylinder disposed between the air compressor and the pressure reducing valve, and a pressure gauge disposed on the high-pressure gas cylinder. The air compressor is used to buffer the fluctuations in the air source pressure output by the air compressor, and the pressure reducing valve is used to reduce the air source pressure output by the air compressor.

3. The apparatus for testing sensor sealing performance using the air pressure comparison method according to claim 2, characterized in that, The control module includes a first solenoid valve disposed at the output end of the pressure reducing valve, a flow divider, a first one-way throttle valve and a second one-way throttle valve disposed between the flow divider and the first and second air chambers respectively, a second solenoid valve disposed between the first one-way throttle valve and one of the air pressure gauges, and a third solenoid valve disposed between the second one-way throttle valve and another air pressure gauge.

4. The apparatus for testing sensor sealing performance using the air pressure comparison method according to claim 3, characterized in that, The control module also includes a first vent valve located at the rear end of the first air chamber and a second vent valve located at the rear end of the second air chamber.

5. The apparatus for testing sensor sealing performance using the air pressure comparison method according to claim 1, characterized in that, The inner walls of the first and second air chambers are provided with horizontal limiting protrusions. A breathable carrier plate is placed on the limiting protrusion. Ventilation holes are evenly distributed on the breathable carrier plate. The standard sensor or the sensor under test is placed on the breathable carrier plate, with a gap between it and the inner wall of the air chamber.

6. The apparatus for testing sensor sealing performance using the air pressure comparison method according to claim 5, characterized in that, The air chamber module also includes a thermostatic sleeve wrapped around the outer wall of the air chamber.

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