Multi-gas airtight detection and practical training system

Abstract

The utility model relates to hydrogen energy industry automation detection equipment and airtight test control technical field, concretely relates to a variety of gas airtight detection and practical training system, including the perception layer, execution layer, control layer, function layer and application layer. The perception layer contains multiple pressure sensor and temperature sensor, the execution layer contains solenoid valve group and booster pump, the control layer is responsible for data processing and instruction sending, the function layer integrates five big modules of multivariate gas supply, multichannel airtight detection, intelligent practical training teaching, hierarchical safety control and integrated data management, the application layer provides two application modes of industrial detection and teaching practical training. The utility model solves the single gas adaptability of existing equipment, low detection efficiency, lacks teaching function and the problem of insufficient safety protection, realizes multi -gas accurate detection, multichannel parallel operation, intelligent practical training teaching and hierarchical safety control, and significantly improves the detection efficiency, safety and teaching training effect.

Description

Technical Field

[0001] This utility model relates to the field of automated testing equipment and air tightness testing and control technology for the hydrogen energy industry, and in particular to a multi-gas air tightness testing and training system. Background Technology

[0002] With the rapid development of the hydrogen energy industry, the requirements for airtightness testing of hydrogen-related components (such as hydrogen pipelines and hydrogen storage equipment) are becoming increasingly stringent. Currently, airtightness testing equipment on the market generally suffers from the following technical deficiencies:

[0003] The existing equipment suffers from several shortcomings: limited gas compatibility (mostly designed for single gases, such as nitrogen or hydrogen), failing to meet the industrial demand for different gases for different components. Low testing efficiency, employing a single-channel, single-sample testing mode without multi-channel data synchronization, necessitates sequential testing of each sample in batch scenarios, resulting in extremely low efficiency. Inadequate practical training capabilities, as the equipment is designed solely for industrial testing scenarios, neglecting the industry's training needs for testing personnel. Fragmented data management, with dispersed data management functions failing to form an integrated system. Insufficient safety control layers, with incomplete safety control mechanisms and limited risk prevention capabilities.

[0004] Therefore, there is an urgent need for a comprehensive system that can simultaneously meet the needs of precise industrial testing and convenient teaching and training. Utility Model Content

[0005] In view of this, the purpose of this utility model is to propose a variety of gas tightness detection and training systems to solve the comprehensive problems of existing gas tightness detection equipment, such as poor gas adaptability, low detection efficiency, high safety risks, lack of teaching and training functions, and fragmented data management, which are caused by the single function and lack of systematic design.

[0006] To achieve the above objectives, this utility model provides various gas tightness detection and training systems, including a sensing layer, an execution layer, a control layer, a functional layer, and an application layer, wherein:

[0007] The sensing layer includes multiple pressure sensors (PT101, PT102, PT103) and at least one temperature sensor (T101), which are used to collect gas pressure and temperature data in real time.

[0008] The execution layer includes multiple solenoid valves (SV201, SV202, SV301), a booster pump, an emergency stop button, and a three-color alarm unit, which are used to perform gas on / off, pressurization, emergency stop, and alarm indication operations, respectively.

[0009] The control layer is connected to the perception layer and the execution layer respectively, and is used to process the data of the perception layer and send control commands to the execution layer, supporting both manual and automatic control modes.

[0010] The functional layer is implemented based on the control layer and includes a multi-gas supply module, a multi-channel airtightness detection module, an intelligent training and teaching module, a hierarchical safety control module, and an integrated data management module; wherein, the functions of the multi-gas supply module and the multi-channel airtightness detection module depend on reading sensor data in the perception layer and driving the components in the execution layer through the control layer.

[0011] The application layer is built upon the functional layer and includes airtightness testing applications for industrial inspection and practical training applications for education and training.

[0012] Preferably, the pressure sensor of the sensing layer includes:

[0013] The first pressure sensor, with a range of 0-25MPa, is used to monitor the gas supply pressure.

[0014] The second pressure sensor, with a range of 0-60MPa, is used to monitor the pressure of the component being measured.

[0015] The third pressure sensor, with a range of 0-2 MPa, is used to monitor the pressure at the vent.

[0016] The temperature sensor has a range of -20 to 150°C and is used to monitor gas temperature.

[0017] Preferably, the solenoid valve of the actuator layer is a 24V normally closed solenoid valve, comprising:

[0018] The gas switching solenoid valve (SV201) is used to control the switching of gas channels;

[0019] The pressure relief solenoid valve (SV202) is used to relieve pressure on the tested component after testing is completed.

[0020] The booster solenoid valve (SV301) is used to control the start and stop of the booster pump.

[0021] Preferably, the control layer is configured in automatic mode to execute at least one of the following experimental procedures:

[0022] Boosting and refueling process: After checking the gas source pressure, start the boosting process and stop once the target pressure is reached;

[0023] Cyclic experiment procedure: Repeat the pressurization and holding process according to the set number of cycles and time parameters;

[0024] Air tightness testing process: The air tightness of the component under test is determined based on the set pressure difference ΔP and temperature difference ΔT parameters.

[0025] Preferably, the multi-gas supply module includes:

[0026] The gas source access unit is equipped with multiple independent gas interfaces, which are respectively adapted to oxygen, hydrogen and nitrogen;

[0027] The filtration unit has a dedicated filter connected in series for each gas interface. The hydrogen interface uses a hydrogen corrosion resistant filter, the oxygen interface uses a degreasing filter, and the nitrogen interface uses a conventional precision filter.

[0028] The pressure control unit includes a pressure reducing valve and receives pressure data collected by the first pressure sensor (PT101) of the sensing layer.

[0029] The gas switching unit sends a switching command to the gas switching solenoid valve (SV201) of the execution layer through the control layer;

[0030] The safety protection unit includes a one-way valve and a leak detection probe installed in the hydrogen passage.

[0031] Preferably, the multi-channel airtightness detection module includes at least two independent detection channels, each detection channel including:

[0032] A set of solenoid valves, through the control layer, calls the pressure relief solenoid valve (SV202) and the pressure boosting solenoid valve (SV301) of the execution layer.

[0033] A set of sensors receives data from the second pressure sensor (PT102), the third pressure sensor (PT103), and the temperature sensor (T101) of the sensing layer;

[0034] A booster pump controlled by a booster solenoid valve (SV301) of the aforementioned actuator layer;

[0035] The experimental parameters for each detection channel can be set independently, and the experimental parameters include at least one of the following: target pressure, experimental duration, number of cycles, temperature difference ΔT, and pressure difference ΔP.

[0036] Preferably, the intelligent training and teaching module includes:

[0037] The operation guide submodule is used to guide users through the operation steps via a pop-up window with pictures and text.

[0038] The simulation exercise submodule is used to provide a virtual interface to simulate the detection process and supports actively triggering error scenarios to guide users to make corrections;

[0039] The teaching assessment submodule is used to generate assessment reports based on the completeness of operational procedures, the accuracy of data recording, and error handling capabilities.

[0040] Preferably, the graded safety control module includes:

[0041] The emergency stop unit includes at least one emergency stop button (ESB), which, when pressed, cuts off the power to all solenoid valves via the control layer and locks the software operation;

[0042] The tri-color light alarm unit is used to indicate the system status through the different states of the tri-color lights;

[0043] The sensor over-limit setting unit is used to set two levels of alarm thresholds for each sensor in the sensing layer.

[0044] The over-limit handling unit is used to issue a warning without interrupting the detection when the first level of over-limit occurs, and to immediately interrupt the detection and cut off the gas supply when the second level of over-limit occurs or the emergency stop button is triggered.

[0045] The sensor over-limit setting unit sets two levels of alarm thresholds for each sensor, including:

[0046] The first-level threshold of the first pressure sensor (PT101) is 22 MPa, and the second-level threshold is 25 MPa.

[0047] The first-level threshold of the second pressure sensor (PT102) is 54 MPa, and the second-level threshold is 60 MPa.

[0048] The first-level threshold of the third pressure sensor (PT103) is 1.8 MPa, and the second-level threshold is 2 MPa.

[0049] The primary threshold of the temperature sensor (T101) is 135℃, and the secondary threshold is 150℃.

[0050] Preferably, the integrated data management module includes:

[0051] The data acquisition unit records sensor data, user operation data, and device status data of the perception layer at a settable frequency.

[0052] Data storage units store data categorized by date and channel.

[0053] The data visualization unit is used to display real-time curves and historical curves;

[0054] The report generation unit supports importing Word templates to automatically generate test reports or training evaluation reports that include experimental parameters, data curves, and evaluation results.

[0055] The beneficial effects of this utility model are as follows:

[0056] First, the multi-gas supply module design supports the detection of multiple gases such as oxygen, hydrogen, and nitrogen. It can be adapted to different components without changing the equipment, thus improving the versatility and economy of the equipment.

[0057] Second, it adopts a multi-channel parallel detection architecture, which supports 2-4 independent detection channels to work at the same time, significantly improving detection efficiency and meeting the needs of industrial mass production.

[0058] Third, the integrated intelligent training module lowers the barrier to entry for beginners and improves training effectiveness through operation guides, simulation exercises, and teaching evaluation functions.

[0059] Fourth, a graded safety control mechanism was established, which fills the existing safety blind spots and greatly improves the safety of the equipment through two-level over-limit handling and temperature over-limit protection.

[0060] Fifth, it achieves integrated data management, improving the accuracy of data traceability and management efficiency through data binding storage and customized report generation. Attached Figure Description

[0061] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0062] Figure 1 This is a schematic diagram of the system architecture of this utility model;

[0063] Figure 2 This is a flowchart illustrating the present invention. Detailed Implementation

[0064] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0065] It should be noted that, unless otherwise defined, the technical or scientific terms used in the embodiments of this utility model should have the ordinary meaning understood by one of ordinary skill in the art to which this utility model pertains. The terms "first," "second," and similar terms used in this utility model do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as "comprising" or "including" mean that the element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects. Terms such as "connected" or "linked" are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as "upper," "lower," "left," and "right" are only used to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0066] like Figure 1 , Figure 2 As shown, a multi-gas airtightness detection and training system includes a sensing layer, an execution layer, a control layer, a functional layer, and an application layer, wherein:

[0067] The sensing layer includes multiple pressure sensors (PT101, PT102, PT103) and at least one temperature sensor (T101), which are used to collect gas pressure and temperature data in real time.

[0068] The pressure sensors in the sensing layer include:

[0069] The first pressure sensor, with a range of 0-25MPa, is used to monitor the gas supply pressure.

[0070] The second pressure sensor, with a range of 0-60MPa, is used to monitor the pressure of the component being measured.

[0071] The third pressure sensor, with a range of 0-2 MPa, is used to monitor the pressure at the vent.

[0072] The temperature sensor has a range of -20 to 150°C and is used to monitor gas temperature.

[0073] The execution layer includes multiple solenoid valves (SV201, SV202, SV301), a booster pump, an emergency stop button, and a three-color alarm unit, which are used to perform gas on / off, pressurization, emergency stop, and alarm indication operations, respectively.

[0074] The solenoid valves in the actuator layer are 24V normally closed solenoid valves, including:

[0075] The gas switching solenoid valve (SV201) is used to control the switching of gas channels;

[0076] The pressure relief solenoid valve (SV202) is used to relieve pressure on the tested component after testing is completed.

[0077] The booster solenoid valve (SV301) is used to control the start and stop of the booster pump.

[0078] The control layer is connected to the perception layer and the execution layer respectively, and is used to process the data of the perception layer and send control commands to the execution layer. It supports two control modes: manual and automatic, including mode switching logic, process control logic, safety monitoring logic and data processing logic.

[0079] In automatic mode, the control layer is configured to execute at least one of the following experimental procedures:

[0080] Boosting and refueling process: After checking the gas source pressure, start the boosting process and stop once the target pressure is reached;

[0081] Cyclic experiment procedure: Repeat the pressurization and holding process according to the set number of cycles and time parameters;

[0082] Air tightness testing process: The air tightness of the component under test is determined based on the set pressure difference ΔP and temperature difference ΔT parameters.

[0083] The functional layer is implemented based on the control layer and includes a multi-gas supply module, a multi-channel airtightness detection module, an intelligent training and teaching module, a hierarchical safety control module, and an integrated data management module; wherein, the functions of the multi-gas supply module and the multi-channel airtightness detection module depend on reading sensor data in the perception layer and driving the components in the execution layer through the control layer.

[0084] The multi-gas supply module includes:

[0085] The gas source access unit is equipped with multiple independent gas interfaces, which are respectively adapted to oxygen, hydrogen and nitrogen;

[0086] The filtration unit has a dedicated filter connected in series for each gas interface. The hydrogen interface uses a hydrogen corrosion resistant filter, the oxygen interface uses a degreasing filter, and the nitrogen interface uses a conventional precision filter.

[0087] The pressure control unit includes a pressure reducing valve and receives pressure data collected by the first pressure sensor (PT101) of the sensing layer.

[0088] The gas switching unit sends a switching command to the gas switching solenoid valve (SV201) of the execution layer through the control layer.

[0089] The multi-channel airtightness testing module includes at least two independent testing channels, each of which includes:

[0090] A set of solenoid valves, through the control layer, calls the pressure relief solenoid valve (SV202) and the pressure boosting solenoid valve (SV301) of the execution layer.

[0091] A set of sensors receives data from the second pressure sensor (PT102), the third pressure sensor (PT103), and the temperature sensor (T101) of the sensing layer;

[0092] A booster pump controlled by a booster solenoid valve (SV301) of the aforementioned actuator layer;

[0093] The experimental parameters for each detection channel can be set independently, and the experimental parameters include at least one of the following: target pressure, experimental duration, number of cycles, temperature difference ΔT, and pressure difference ΔP.

[0094] The intelligent practical training module includes:

[0095] The operation guide submodule is used to guide users through the operation steps via a pop-up window with pictures and text.

[0096] The simulation exercise submodule is used to provide a virtual interface to simulate the detection process and supports actively triggering error scenarios to guide users to make corrections;

[0097] The teaching assessment submodule is used to generate assessment reports based on the completeness of operational procedures, the accuracy of data recording, and error handling capabilities.

[0098] The graded safety control module includes:

[0099] The emergency stop unit includes at least one emergency stop button (ESB), which, when pressed, cuts off the power to all solenoid valves via the control layer and locks the software operation;

[0100] The tri-color light alarm unit is used to indicate the system status through the different states of the tri-color lights;

[0101] The sensor over-limit setting unit is used to set two levels of alarm thresholds for each sensor in the sensing layer.

[0102] The over-limit handling unit is used to issue a warning without interrupting the detection when the first level of over-limit occurs, and to immediately interrupt the detection and cut off the gas supply when the second level of over-limit occurs or the emergency stop button is triggered.

[0103] The sensor over-limit setting unit sets two levels of alarm thresholds for each sensor, including:

[0104] The first-level threshold of the first pressure sensor (PT101) is 22 MPa, and the second-level threshold is 25 MPa.

[0105] The first-level threshold of the second pressure sensor (PT102) is 54 MPa, and the second-level threshold is 60 MPa.

[0106] The first-level threshold of the third pressure sensor (PT103) is 1.8 MPa, and the second-level threshold is 2 MPa.

[0107] The primary threshold of the temperature sensor (T101) is 135℃, and the secondary threshold is 150℃.

[0108] The integrated data management module includes:

[0109] The data acquisition unit records sensor data, user operation data, and device status data of the perception layer at a settable frequency.

[0110] Data storage units store data categorized by date and channel.

[0111] The data visualization unit is used to display real-time curves and historical curves;

[0112] The report generation unit supports importing Word templates to automatically generate test reports or training evaluation reports that include experimental parameters, data curves, and evaluation results.

[0113] The application layer is built upon the functional layer and includes airtightness testing applications for industrial inspection and practical training applications for education and training.

[0114] The software portion of this system was developed using the C# language on the Visual Studio platform, and mainly implements the following functions:

[0115] Multi-channel data synchronous display: The software interface simultaneously displays sensor data, valve status, and parameter settings from 2-4 detection channels.

[0116] Intelligent training guidance: Through graphic pop-up windows, users are guided step by step to complete the operation, simulating common error scenarios and providing correction guidance.

[0117] Tiered safety monitoring: Two alarm thresholds are set for each sensor, with a first-level warning when the threshold is exceeded and an emergency shutdown when the threshold is exceeded by the second level.

[0118] Data Management: The system uses an SQLite database to store test data and supports multi-dimensional queries and report generation by time, channel, and experiment mode.

[0119] The system operates according to the following procedure:

[0120] System startup: After power-on, the system performs a self-test, initializes all sensors, and the green light on the three-color indicator indicates standby mode.

[0121] Mode selection: Users can choose between industrial testing mode or teaching and training mode.

[0122] Parameter settings: In industrial detection mode, users set the gas type, detection channel parameters, and safety thresholds.

[0123] Detection execution: The system performs detection according to the preset process, monitors sensor data in real time, and triggers corresponding alarms when thresholds are exceeded.

[0124] Data logging: During the detection process, the system automatically records all sensor data, operation logs, and equipment status.

[0125] Report generation: The system automatically generates a test report or training evaluation report after the test is completed.

[0126] The security control mechanisms of this system include:

[0127] Level 1 alarm handling: When the sensor value approaches 90% of the range (e.g., PT102=55MPa), the three-color yellow light will remain on and a buzzer alarm will sound. The detection will not be interrupted, but starting a new channel will be prohibited.

[0128] Level 2 alarm handling: When the sensor exceeds its range or the temperature exceeds 150℃, the three-color red light will remain on and a buzzer alarm will sound, immediately cutting off the power supply to all solenoid valves.

[0129] Emergency Stop Procedure: Pressing the emergency stop button will immediately put the system into a safe state, which requires an administrator password to unlock.

[0130] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the present invention is limited to these examples; within the framework of the present invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of the different aspects of the present invention as described above, which are not provided in the details for the sake of brevity.

[0131] The embodiments of this utility model are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A multi-gas airtightness detection and training system, characterized in that, It includes the perception layer, execution layer, control layer, functional layer, and application layer, among which: The sensing layer includes multiple pressure sensors and at least one temperature sensor, which are used to collect gas pressure and temperature data in real time, respectively. The execution layer includes multiple solenoid valves, a booster pump, an emergency stop button, and a three-color alarm unit, which are used to perform gas on / off, pressurization, emergency stop, and alarm indication operations, respectively. The control layer is connected to the perception layer and the execution layer respectively, and is used to process the data of the perception layer and send control commands to the execution layer, supporting both manual and automatic control modes. The functional layer is implemented based on the control layer and includes a multi-gas supply module, a multi-channel airtightness detection module, an intelligent training and teaching module, a hierarchical safety control module, and an integrated data management module; wherein, the functions of the multi-gas supply module and the multi-channel airtightness detection module depend on reading sensor data in the perception layer and driving the components in the execution layer through the control layer. The application layer is built upon the functional layer and includes airtightness testing applications for industrial inspection and practical training applications for education and training.

2. The multi-gas airtightness detection and training system according to claim 1, characterized in that, The pressure sensor in the sensing layer includes: The first pressure sensor, with a range of 0-25MPa, is used to monitor the gas supply pressure. The second pressure sensor, with a range of 0-60MPa, is used to monitor the pressure of the component being measured. The third pressure sensor, with a range of 0-2 MPa, is used to monitor the pressure at the vent. The temperature sensor has a range of -20 to 150°C and is used to monitor gas temperature.

3. The multi-gas airtightness detection and training system according to claim 2, characterized in that, The solenoid valve in the actuator layer is a 24V normally closed solenoid valve, including: Gas switching solenoid valve is used to control the switching of gas channels; The pressure relief solenoid valve is used to relieve pressure on the tested component after testing is completed. The booster solenoid valve is used to control the start and stop of the booster pump.

4. The multi-gas airtightness detection and training system according to claim 3, characterized in that, In automatic mode, the control layer is configured to execute at least one of the following experimental procedures: Boosting and refueling process: After checking the gas source pressure, start the boosting process and stop once the target pressure is reached; Cyclic experiment procedure: Repeat the pressurization and holding process according to the set number of cycles and time parameters; Air tightness testing process: The air tightness of the component under test is determined based on the set pressure difference ΔP and temperature difference ΔT parameters.

5. The multi-gas airtightness detection and training system according to claim 2, characterized in that, The multi-gas supply module includes: The gas source access unit is equipped with multiple independent gas interfaces, which are respectively adapted to oxygen, hydrogen and nitrogen; The filtration unit has a dedicated filter connected in series for each gas interface. The hydrogen interface uses a hydrogen corrosion resistant filter, the oxygen interface uses a degreasing filter, and the nitrogen interface uses a conventional precision filter. The pressure regulation unit includes a pressure reducing valve and receives pressure data collected by the first pressure sensor of the sensing layer. The gas switching unit sends a switching command to the gas switching solenoid valve in the execution layer through the control layer; The safety protection unit includes a one-way valve and a leak detection probe installed in the hydrogen passage.

6. The multi-gas airtightness detection and training system according to claim 4, characterized in that, The multi-channel airtightness detection module includes at least two independent detection channels, each detection channel including: A set of solenoid valves, through the control layer, calls the pressure relief solenoid valve and the pressure boosting solenoid valve of the execution layer; A sensor array receives data from the second pressure sensor, the third pressure sensor, and the temperature sensor in the sensing layer; A booster pump controlled by a booster solenoid valve of the execution layer; The experimental parameters for each detection channel can be set independently, and the experimental parameters include at least one of the following: target pressure, experimental duration, number of cycles, temperature difference ΔT, and pressure difference ΔP.

7. The multi-gas airtightness detection and training system according to claim 1, characterized in that, The intelligent training module includes: The operation guide submodule is used to guide users through the operation steps via a pop-up window with pictures and text. The simulation exercise submodule is used to provide a virtual interface to simulate the detection process and supports actively triggering error scenarios to guide users to make corrections; The teaching assessment submodule is used to generate assessment reports based on the completeness of operational procedures, the accuracy of data recording, and error handling capabilities.

8. The multi-gas airtightness detection and training system according to claim 1, characterized in that, The hierarchical security control module includes: An emergency stop unit includes at least one emergency stop button, which, when pressed, cuts off the power to all solenoid valves via the control layer and locks the software operation. The tri-color light alarm unit is used to indicate the system status through the different states of the tri-color lights; The sensor over-limit setting unit is used to set two levels of alarm thresholds for each sensor in the sensing layer. The over-limit handling unit is used to issue a warning without interrupting the detection when the first level of over-limit occurs, and to immediately interrupt the detection and cut off the gas supply when the second level of over-limit occurs or the emergency stop button is triggered.

9. The multi-gas airtightness detection and training system according to claim 8, characterized in that, The sensor over-limit setting unit sets two levels of alarm thresholds for each sensor, including: The first-level threshold of the first pressure sensor is 22 MPa, and the second-level threshold is 25 MPa. The first-level threshold of the second pressure sensor is 54 MPa, and the second-level threshold is 60 MPa. The first-level threshold of the third pressure sensor is 1.8 MPa, and the second-level threshold is 2 MPa. The temperature sensor has a first-level threshold of 135℃ and a second-level threshold of 150℃.

10. The multi-gas airtightness detection and training system according to claim 1, characterized in that, The integrated data management module includes: The data acquisition unit records sensor data, user operation data, and device status data of the perception layer at a settable frequency. Data storage units store data categorized by date and channel. The data visualization unit is used to display real-time curves and historical curves; The report generation unit supports importing Word templates to automatically generate test reports or training evaluation reports that include experimental parameters, data curves, and evaluation results.

Images