A high-rigidity low-mass tooling for pneumatic control valve vibration testing

Abstract

The utility model relates to test frock technical field, especially in kind for pneumatic governing valve vibration test's high rigidity low quality frock, a kind of high rigidity low quality frock for pneumatic governing valve vibration test, including multiple frock support beams, multiple frock support beams upper end and lower end are connected top plate and bottom plate respectively, the bottom plate is fixedly connected on test platform, the middle part of top plate and bottom plate is provided with open structure, the pneumatic governing valve to be tested passes through the open structure of top plate and the open structure of bottom plate, the part of pneumatic governing valve close to upper end is fixed on top plate, the lower end of pneumatic governing valve passes through the open structure of bottom plate and is fixed on test platform;The frock support beam, top plate and bottom plate are integrally formed.The utility model provides a kind of high rigidity low quality frock for pneumatic governing valve vibration test, provides a "rigid body" high-fidelity test installation platform.

Description

Technical Field

[0001] This utility model relates to the field of testing tooling technology, and in particular to a high-rigidity, low-mass tooling for vibration testing of pneumatic control valves. Background Technology

[0002] As a key actuator in industrial automation control systems, the structural integrity and functional reliability of pneumatic control valves are crucial in vibration environments. To verify their ability to resist vibration during transportation, installation, and actual operating conditions, rigorous vibration tests must be conducted in accordance with relevant standards (such as GB / T2423-10-2008, GB / T 4213-2024, etc.).

[0003] In vibration testing, the fixture serves as the bridge connecting the vibration platform and the valve under test. Its performance directly determines the success or failure of the test and the accuracy of the data; the fixture should possess the following characteristics: High rigidity: The natural frequency of the fixture itself should be much higher than the upper limit of the test frequency to avoid resonance within the test frequency band. Otherwise, the resonance response of the fixture will be superimposed on the valve under test, resulting in serious distortion of the test results or even damage to the test component.

[0004] High connection strength: It can reliably transmit the huge dynamic loads generated by the vibration platform, ensuring that the connection does not loosen or fail.

[0005] Excellent dynamic transmission characteristics: The tooling should be able to accurately transmit the excitation of the vibration table to the valve under test without amplitude attenuation or phase distortion.

[0006] However, existing technologies have the following obvious drawbacks: Ordinary welded or cast fixtures: While these fixtures have reasonable rigidity, they are often massive and cumbersome. This not only severely limits the effective thrust and usable acceleration of the vibration table, but their enormous inertial forces also generate strong cross-coupling interference in multi-axis testing, affecting test accuracy. Furthermore, they may contain casting defects or residual welding stress, making them prone to fatigue cracks under long-term high-frequency vibration, resulting in low reliability.

[0007] Simple bolted frame fixtures: These fixtures are assembled from standard profiles (such as square steel and channel steel) using bolts. Their fatal weakness lies in the insufficient contact stiffness of the connection interface. Under dynamic loads, minute relative displacements and friction occur at the bolted connections, creating a "nonlinear hysteresis" effect, leading to energy dissipation and signal transmission distortion, failing to meet high-precision testing requirements.

[0008] Lack of systematic lightweight design: Existing tooling designs rely heavily on experience and lack methods for systematically optimizing stiffness and mass. In pursuit of stiffness, mass is often sacrificed, resulting in poor tooling performance that cannot meet the testing requirements of modern high-thrust, high-frequency, and high-bandwidth vibration tables.

[0009] Therefore, there is an urgent need to develop a new type of high-rigidity, low-mass fixture to solve the problems of insufficient rigidity, excessive mass, and poor dynamic characteristics in the existing technology, and to provide a reliable and accurate installation benchmark for vibration testing of pneumatic control valves. Utility Model Content

[0010] This utility model provides a high-rigidity, low-mass fixture for vibration testing of pneumatic control valves. It can ensure that the fixture has extremely high rigidity (to avoid resonance within the test frequency band) while minimizing its own mass and ensuring excellent dynamic signal transmission characteristics, thereby providing a "rigid" and high-fidelity test installation platform for pneumatic control valves.

[0011] This utility model embodiment provides a high-rigidity, low-mass fixture for vibration testing of pneumatic control valves, including multiple fixture support beams. The upper and lower ends of the multiple fixture support beams are respectively connected to a top plate and a bottom plate. The bottom plate is fixedly connected to a test platform. Both the top plate and the bottom plate have a hollow structure in the middle. The pneumatic control valve to be tested passes through the hollow structure of the top plate and the hollow structure of the bottom plate. The upper part of the pneumatic control valve is fixed to the top plate, and the lower end of the pneumatic control valve passes through the hollow structure of the bottom plate and is fixed to the test platform. The tooling support beam, the top plate, and the bottom plate are integrally formed.

[0012] In one possible design, the angle between the plane of the top plate or the plane of the bottom plate and the tooling support beam is 75°.

[0013] In one possible design, the multiple tooling support beams are connected by crossbeams and diagonal beams, and the interior of the structure formed by the multiple tooling support beams is also provided with internal reinforcing beams that connect the different tooling support beams.

[0014] In one possible design, the bottom of the tooling support beam is provided with multiple side reinforcing ribs.

[0015] In one possible design, the top plate is fixedly connected to a connecting plate, the connecting plate being provided with mounting holes matching the size of the pneumatic regulating valve, and the upper portion of the pneumatic regulating valve being fixed to the connecting plate through the mounting holes.

[0016] In one possible design, the connecting plate is fixedly connected to the top plate by bolts and threaded holes.

[0017] In one possible design, the bottom of the pneumatic regulating valve is fixed to the test platform by a left auxiliary fixture and a right auxiliary fixture. Both the left and right auxiliary fixtures are Z-shaped. One end of each of the left and right auxiliary fixtures is fixed to the test platform, and the other end is arc-shaped and opposite to each other to hug the bottom of the pneumatic regulating valve. The ends of the left and right auxiliary fixtures used for hugging and clamping are padded with PTFE gaskets.

[0018] In one possible design, the left auxiliary fixture and the right auxiliary fixture are fixed to the test platform by bolts and threaded holes.

[0019] In one possible design, the base plate is provided with high-strength bolt connection holes, and the base plate is connected to the test platform by high-strength bolts.

[0020] In one possible design, the tooling support beam, the top plate, and the bottom plate are made of carbon structural steel Q235 steel.

[0021] Compared with the prior art, the present invention has at least the following advantages: Exceptional stiffness-to-weight ratio: Through a combination design of "integrated molding + tooling support beam," this tooling achieves extremely high stiffness while successfully reducing weight significantly. Finite element analysis and experimental verification show that its first natural frequency exceeds 200Hz, sufficient to cover the frequency range of valve vibration testing, while its weight is reduced by 40% to 60% compared to traditional cast tooling of the same stiffness. This allows the thrust of the vibration table to act more effectively on the valve under test, significantly improving the dynamic range and accuracy of the test. Attached Figure Description

[0022] 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 some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the structure of a high-rigidity, low-mass tooling for vibration testing of pneumatic control valves provided in this embodiment of the present invention; Figure 2 This is a cross-sectional structural schematic diagram of a high-rigidity, low-mass tooling for vibration testing of pneumatic control valves provided in an embodiment of this utility model. Figure 3 This is a schematic diagram showing the relationship between a pneumatic regulating valve and a connecting plate provided in an embodiment of this utility model; Figure 4 This is a schematic diagram of the structure of a left auxiliary tooling and a right auxiliary tooling provided in an embodiment of this utility model; Figure 5 This is a schematic diagram of another high-rigidity, low-mass tooling for vibration testing of pneumatic control valves provided in this embodiment of the present invention.

[0024] In the picture: 100-Pneumatic regulating valve; 1-Base plate; 2-Tooling support beam; 3-Top plate; 4-Side reinforcing rib; 5-Crossbeam; 6-Inclined beam; 7-Internal reinforcing beam; 8-Connecting plate; 9-Left auxiliary tooling; 10-Right auxiliary tooling; 11-Shim. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without creative effort are within the scope of protection of this utility model.

[0026] In the description of the embodiments of this utility model, unless otherwise expressly specified and limited, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; unless otherwise specified or explained, the term "multiple" refers to two or more; the terms "connected," "fixed," etc., should be interpreted broadly. For example, "connected" can be a fixed connection, a detachable connection, an integral connection, or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0027] In this specification, it should be understood that the directional terms such as "upper" and "lower" used in the description of the embodiments of this utility model are used to describe the angles shown in the accompanying drawings and should not be construed as limiting the embodiments of this utility model. Furthermore, in the context, it should also be understood that when it is mentioned that one element is connected "upper" or "lower" to another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected to the other element "upper" or "lower" through an intermediate element.

[0028] like Figures 1 to 5As shown, this utility model embodiment provides a high-rigidity, low-mass tooling for vibration testing of a pneumatic regulating valve 100, including multiple tooling support beams 2. The upper and lower ends of the multiple tooling support beams 2 are respectively connected to a top plate 3 and a bottom plate 1. The bottom plate 1 is fixedly connected to the test platform. Both the top plate 3 and the bottom plate 1 have a hollow structure in the middle. The pneumatic regulating valve 100 to be tested passes through the hollow structure of the top plate 3 and the hollow structure of the bottom plate 1. The part of the pneumatic regulating valve 100 near the upper end is fixed on the top plate 3, and the lower end of the pneumatic regulating valve 100 passes through the hollow structure of the bottom plate 1 and is fixed on the test platform. The tooling support beam 2, top plate 3 and bottom plate 1 are integrally formed.

[0029] Integrated tooling base: The base forms the foundation of the entire tooling and is made of Q235 steel, a type of carbon structural steel, cut from a single thick plate rather than welded or bolted together. The bottom of the base is designed with positioning holes and high-strength bolt connection holes that precisely match the vibration table surface, further ensuring a "rigid connection" with the vibration table and eliminating fretting wear and nonlinearity at the interface.

[0030] The main load-bearing structure, composed of various beams, extends upwards from the base plate 1 at the bottom of the foundation and is the main part supporting the pneumatic regulating valve 100. During the design phase, finite element analysis combined with topology optimization algorithms can be used to optimize within a given design space, aiming for "maximum stiffness and minimum mass." The final structure is not a traditional solid block or simple stiffener, but rather exhibits a biomimetic configuration resembling a biological skeleton with uneven material distribution. Specifically: The main force transmission path is clear: the material is highly concentrated on the main load transmission path from the valve installation point to the base connection point, forming a robust "main beam".

[0031] Non-critical area hollowing: Large-area hollowing or thinning is carried out in low-stress areas to form complex hollow grids or thin-walled structures, effectively removing redundant mass.

[0032] Smooth transition: All structural corners use large arcs or variable thickness transitions to avoid stress concentration and improve fatigue life.

[0033] In some embodiments of this utility model, the included angle between the plane where the top plate 3 or the plane where the bottom plate 1 is located and the tooling support beam 2 is 75°.

[0034] In some embodiments of this utility model, multiple tooling support beams 2 are connected by crossbeams 5 and diagonal beams 6, and the structure formed by multiple tooling support beams 2 is also provided with internal reinforcing beams 7 that connect different tooling support beams 2.

[0035] In some embodiments of this utility model, the bottom of the tooling support beam 2 is provided with multiple side reinforcing ribs 4.

[0036] In some embodiments of this utility model, a connecting plate 8 is fixedly connected to the top plate 3. The connecting plate 8 is provided with mounting holes that match the size of the pneumatic regulating valve 100. The upper part of the pneumatic regulating valve 100 is fixed to the connecting plate 8 through the mounting holes.

[0037] In some embodiments of this utility model, the connecting plate 8 is fixedly connected to the top plate 3 by bolts and screw holes.

[0038] Considering the diverse flange standards (such as flange size and connection method) of the pneumatic regulating valve 100, this utility model designs a modular connecting plate 8 scheme. After the main load-bearing structure is welded, a standardized high-precision mounting plane is machined between the top plate 3 and the base plate using a large gantry milling machine. For different valve models, the matching connecting plate 8 can be quickly replaced. This connecting plate 8 is connected to the main load-bearing structure via high-strength bolts with controllable pre-tightening torque, and precision machining is used on the mating surface to ensure a contact area greater than 90%, thereby achieving extremely high contact rigidity and realizing a "quasi-integration" between the connecting plate 8 and the main load-bearing structure.

[0039] The integrated base and quasi-integrated modular connecting plate 8 completely eliminate the nonlinear hysteresis problem of traditional bolted connections. The fixture exhibits near-ideal "rigid body" transmission characteristics within the test frequency band, with minimal amplitude attenuation and phase distortion of the vibration signal, ensuring the authenticity and accuracy of the test data.

[0040] The modular design of the connecting plate 8 allows a single main load-bearing structural base to be quickly adapted to various models and sizes of pneumatic control valves 100 by replacing different connecting plates 8. This greatly improves the utilization rate of tooling and avoids the waste of manufacturing an expensive set of tooling for each type of pneumatic control valve 100, resulting in significant economic benefits.

[0041] In some embodiments of this utility model, the bottom of the pneumatic regulating valve 100 is fixed to the test platform by the left auxiliary tool 9 and the right auxiliary tool 10. The left auxiliary tool 9 and the right auxiliary tool 10 are both Z-shaped. One end of the left auxiliary tool 9 and the right auxiliary tool 10 are fixed to the test platform, and the other end is arc-shaped and opposite to each other to hug the bottom of the pneumatic regulating valve 100. The end of the left auxiliary tool 9 and the right auxiliary tool 10 used for hugging and clamping is padded with a PTFE gasket 11.

[0042] In some embodiments of this utility model, the left auxiliary fixture 9 and the right auxiliary fixture 10 are fixed on the test platform by bolts and screw holes.

[0043] Inside the main load-bearing structure, primarily supported by the tooling beam 2, below the connection area between the connecting plate 8 and the main load-bearing structure, two arc-shaped gripping tooling fixtures—left auxiliary tooling 9 and right auxiliary tooling 10—are added. Their function is to rapidly and evenly distribute the concentrated load from the connecting plate 8 throughout the entire main load-bearing structure, preventing excessive local stress from causing yielding or fatigue failure, and further improving the overall stiffness and load-bearing capacity of the tooling.

[0044] The overall structure avoids welding deformation defects. The lower valve body is flexibly connected by gaskets 11 of the left auxiliary tooling 9 and the right auxiliary tooling 10, effectively reducing stress concentration. This gives the tooling extremely high static and dynamic strength, enabling it to withstand severe vibration and impact loads. Its fatigue life far exceeds that of traditional tooling, reducing testing risks and long-term operating costs.

[0045] In some embodiments of this utility model, the base plate 1 is provided with high-strength bolt connection holes, and the base plate 1 is connected to the test platform by high-strength bolts.

[0046] In some embodiments of this utility model, the tooling support beam 2, top plate 3 and bottom plate 1 are made of carbon structural steel Q235 steel.

[0047] Testing process operation instructions: 1. Test Plan The vibration test technical requirements are in accordance with section 5.12 of GB / T 4213-2024 Pneumatic Control Valves. Control valves should undergo sinusoidal sweep vibration tests with a vibration frequency of 10 Hz-55 Hz and an amplitude of 0.15 mm, and a vibration frequency of 55 Hz-150 Hz and an acceleration of 20 m / s². A 30-minute vibration endurance test should also be conducted at the resonant frequency. After the test, the basic error (5.5), hysteresis (5.6), air chamber sealing (5.4), and sealing performance of the stuffing box and other connections (5.2) of the control valve should still meet the requirements of this document. Control valves weighing over 50 kg are exempt from the test. Specific performance parameters are described below: (1) The basic error shall not exceed the basic error limit specified in GB / T 4213-2024 Pneumatic Control Valves. The basic error is expressed as a percentage of the rated stroke. On / off type control valves are exempt from testing. The test object is a valve with a positioner and a sealing material of polytetrafluoroethylene. It can be tested according to Class E indicators, with a basic error index of ±1%, or equivalent to the data before the test.

[0048] (2) The hysteresis shall not exceed the basic error limit specified in GB / T 4213-2024 Pneumatic Control Valves. The hysteresis shall be expressed as a percentage of the rated stroke. The test object is equipped with a positioner and the sealing material is polytetrafluoroethylene. It can be tested according to Class E index, and the hysteresis index is 1.0%, or equivalent to the data before the test.

[0049] (3) The air chamber of the pneumatic actuator shall be airtight. Under the rated air source pressure, the pressure drop in the diaphragm chamber shall not exceed 2.5 kPa within 5 minutes; the pressure drop in each air chamber of the cylinder shall not exceed 5 kPa.

[0050] (4) This sample is a bellows seal without a stuffing box; testing the sealing performance of the connection is sufficient. Based on the on-site testing conditions, clean gas should be preferred as the test medium. The control valve connection should be guaranteed to be leak-free under a test pressure of 0.35 MPa. When the valve's maximum allowable working pressure is lower than 0.35 MPa, the test pressure should be the maximum allowable working pressure.

[0051] 2. Test Operation Procedure Description A. Pre-test inspection process 2.1 The test platform was run under no-load test (5Hz-100Hz frequency sweep) to confirm that there were no abnormalities in the system.

[0052] B. Tooling Testing 2.2 Lift the test fixture and transfer it to the test platform for installation. The test platform and the area of ​​the fixture base that are in contact with it need to be cleaned. Then slowly place the test fixture on the test platform, and then adjust the fixture base and the test platform surface to ensure that the contact area is greater than 90%. Then use bolts to fix it with uniform force.

[0053] 2.3 For the tooling sinusoidal sweep frequency test, refer to the following parameters and record the resonant frequency and peak amplitude.

[0054]

[0055] Performance testing Test the basic error, hysteresis, chamber sealing performance, and connection sealing performance of the control valve according to GB / T 4213. C. Valve Standard Operating Condition Test 2.4 Lift the valve under test and transfer it to the test fixture (the valve under test and the connecting plate should be welded and fixed). Adjust the connecting plate to fit the contact platform of the test fixture to ensure that the contact area is greater than 90%. Fix it with bolts with uniform force. First, put the PTFE gasket on the lower valve body. Then install the left and right auxiliary fixtures in sequence. After confirming that they are in place, tighten them with bolts. Finally, find the point where you need to test and install and fix the corresponding sensors, etc.

[0056] 2.5 Begin valve performance testing, and record the basic error, hysteresis, air chamber sealing performance, and connection sealing performance before vibration testing; 2.6 Input 50% of the signal pressure into the valve (condition 1), conduct a sinusoidal frequency sweep test, and record the resonant frequency and amplitude; 2.7 Based on the resonant frequency recorded in item 2.6, after excluding the tooling resonant frequency, conduct a fixed-frequency vibration resistance test on the valve for 30±1 min; if there is no resonant point, vibrate at 150 Hz for 30±1 min.

[0057] 2.8 After the vibration test, the basic error, hysteresis, air chamber sealing and connection sealing are tested.

[0058] D. Other valve operating condition tests (optional, depending on actual conditions) 2.9 Repeat steps 2.7 and 2.8, changing the following test conditions until the test ends.

[0059] Operating Condition 2: 0% signal pressure (regulating valve closed) Operating Condition 3: 100% signal pressure (regulating valve fully open) Operating Condition 4: Dynamic opening of the regulating valve: 0%~100% Operating Condition 5: Dynamic Closure of Control Valve: 100%~0% E. After completing the test, disassemble the pneumatic control valve (first disassemble the sensor, power cord, left and right auxiliary fixtures, etc.) → disassemble the test fixture.

[0060] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A high-rigidity, low-mass tooling for vibration testing of pneumatic control valves, characterized in that, The device includes multiple tooling support beams, with the upper and lower ends of the multiple tooling support beams respectively connected to a top plate and a bottom plate. The bottom plate is fixedly connected to a test platform. Both the top plate and the bottom plate have a hollow structure in the middle. The pneumatic regulating valve to be tested passes through the hollow structure of the top plate and the hollow structure of the bottom plate. The upper part of the pneumatic regulating valve is fixed to the top plate, and the lower end of the pneumatic regulating valve passes through the hollow structure of the bottom plate and is fixed to the test platform. The tooling support beam, the top plate, and the bottom plate are integrally formed.

2. The high-rigidity, low-mass tooling for vibration testing of pneumatic control valves according to claim 1, characterized in that, The angle between the plane of the top plate or the plane of the bottom plate and the tooling support beam is 75°.

3. The high-rigidity, low-mass tooling for vibration testing of pneumatic control valves according to claim 1, characterized in that, The multiple tooling support beams are connected by crossbeams and diagonal beams, and the structure formed by the multiple tooling support beams is also provided with internal reinforcing beams that connect the different tooling support beams.

4. The high-rigidity, low-mass tooling for vibration testing of pneumatic control valves according to claim 1, characterized in that, The bottom of the tooling support beam is provided with multiple side reinforcing ribs.

5. A high-rigidity, low-mass tooling for vibration testing of pneumatic control valves according to claim 1, characterized in that, The top plate is fixedly connected to a connecting plate, which has mounting holes that match the size of the pneumatic regulating valve. The upper part of the pneumatic regulating valve is fixed to the connecting plate through the mounting holes.

6. A high-rigidity, low-mass tooling for vibration testing of pneumatic control valves according to claim 5, characterized in that, The connecting plate is fixedly connected to the top plate by bolts and screw holes.

7. The high-rigidity, low-mass tooling for vibration testing of pneumatic control valves according to claim 1, characterized in that, The bottom of the pneumatic regulating valve is fixed to the test platform by a left auxiliary fixture and a right auxiliary fixture. Both the left and right auxiliary fixtures are Z-shaped. One end of each of the left and right auxiliary fixtures is fixed to the test platform, and the other end is arc-shaped and opposite to each other to hug the bottom of the pneumatic regulating valve. The ends of the left and right auxiliary fixtures used for hugging and clamping are padded with PTFE gaskets.

8. A high-rigidity, low-mass tooling for vibration testing of pneumatic control valves according to claim 7, characterized in that, The left auxiliary fixture and the right auxiliary fixture are fixed to the test platform by bolts and screw holes.

9. A high-rigidity, low-mass tooling for vibration testing of pneumatic control valves according to claim 1, characterized in that, The base plate is provided with high-strength bolt connection holes, and the base plate is connected to the test platform by high-strength bolts.

10. A high-rigidity, low-mass tooling for vibration testing of pneumatic control valves according to claim 1, characterized in that, The tooling support beam, the top plate, and the bottom plate are made of carbon structural steel Q235 steel.

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