A secondary high pressure leak test device for a manifold injector

Abstract

The utility model relates to a kind of oil atomizer testing device, specifically to a kind of secondary high pressure leakage testing device for manifold oil atomizer, comprising: gas source;Pressure regulating gas path, first end is connected gas source;Leakage tester, first interface is connected in the second end of pressure regulating gas path;Fixing tool, air inlet and the second interface of leakage tester are connected through test gas path, exhaust and the third interface of leakage tester are connected through test gas path;Control module;Control module is electrically connected with pressure regulating gas path, leakage tester and fixing tool respectively.Compared with prior art, the utility model solves the defects that the test result accuracy of low pressure testing device in prior art is low, and existing low pressure testing device is difficult to adapt to the performance requirement of secondary high pressure test pressure.The structure improvement design of leakage testing device is realized to the secondary high pressure leakage test of manifold oil atomizer.

Description

Technical Field

[0001] This utility model relates to an injector testing device, specifically to a sub-high pressure leakage testing device for manifold injectors. Background Technology

[0002] Hybrid and range-extended vehicles are increasingly favored by consumers and continue to expand their market share due to their excellent fuel economy and gradually decreasing purchase costs. Meanwhile, manifold injection engines occupy an important position in this type of vehicle due to their mature technology and controllable costs. However, the operating characteristics of hybrid systems mean that their internal combustion engines are mostly idle. In this situation, if fuel leakage occurs in the manifold injectors, and the leakage exceeds the allowable range, it can easily cause two main risks: first, difficulty starting the engine or immediate stalling after starting due to an overly rich air-fuel mixture; second, fuel vapors accumulated in the intake manifold will evaporate into the atmosphere, causing excessive hydrocarbon emissions and making it difficult to comply with increasingly stringent environmental regulations. Therefore, to meet end-user expectations for reliability and environmental performance, the market has placed stricter requirements on the low-leakage performance of manifold injectors.

[0003] To effectively overcome the potential leakage problem of manifold injectors, in addition to continuously improving the machining accuracy in the component manufacturing process, it is also necessary to simultaneously upgrade the corresponding testing technologies and standards to ensure the quality of products leaving the factory. Currently, leakage detection of manifold injectors is carried out using a test pressure of 4.2 bar. However, under this test pressure, it is difficult to quickly and accurately identify manifold injectors with minute leaks. It is evident that relying solely on traditional leakage detection methods is no longer sufficient to effectively identify and screen out defective products with micro-leakage levels.

[0004] Theoretical analysis shows that, with the volume of the manifold injector under test remaining constant and without damaging the structure, increasing the test pressure will exponentially increase the product yield. However, increasing the test pressure places higher demands on the system reliability and pressure holding capacity (sealing) of the testing device.

[0005] In the prior art, CN216899664U discloses an offline performance testing device for fuel injectors based on the gas pressure drop method. This device includes a bracket and an upper sealing fixture fixed to the bracket for sealing the fuel injector, a power supply device for providing voltage to the fuel injector, a pressure controller, a pressurizing device, and a control module. The fuel injector is fixed to the bracket, and the pressure controller is located on the pipeline between the pressurizing device and the fuel injector. The control module is connected to the upper sealing fixture, the power supply device, and the pressurizing device. However, this method uses the pressure drop method to measure the injector's lift index, neglecting the issue of leakage.

[0006] In the prior art, CN210689965U discloses an offline pressure drop leakage testing device for fuel injectors. This device includes a frame, an upper tooling assembly, a lower tooling, a pressure monitor, and a moving assembly. The lower tooling is fixedly mounted at the bottom of the frame, and the moving assembly is located above the lower tooling and fixedly connected to the frame. The upper tooling assembly is connected to the moving assembly. The upper tooling assembly includes an upper tool, a one-way valve, and a compressed air pipeline. The upper tooling is located at the bottom of the moving assembly, and a punch port is opened at the bottom of the upper tooling. The punch port is connected to the compressed air pipeline, and the one-way valve is located between the compressed air pipeline and the punch port. The pressure sensor of the pressure monitor is located at the one-way valve. However, the suitable test pressure for this scheme is 0.5±0.05MPa (approximately 5±0.5bar), which is basically equivalent to the existing test pressure of 4.2bar, making it difficult to obtain more accurate test results.

[0007] Therefore, there is a need to provide a testing device suitable for manifold injectors under sub-high pressure leakage testing. Utility Model Content

[0008] The purpose of this invention is to provide a sub-high pressure leakage testing device for manifold injectors to solve at least one of the aforementioned problems. This addresses the shortcomings of existing low-pressure testing devices, such as low accuracy and difficulty in adapting to the performance requirements of sub-high pressure testing. This solution, through structural improvements to the leakage testing device, enables sub-high pressure leakage testing of manifold injectors at a test pressure of 10 bar.

[0009] The objective of this utility model is achieved through the following technical solution: A sub-high pressure leakage testing device for manifold injectors, comprising: Gas source; A pressure regulating air circuit is used to adjust the air pressure output from the air source to a sub-high pressure range; the first end of the pressure regulating air circuit is connected to the air source; Leakage tester; the first interface of the leakage tester is connected to the second end of the pressure regulating gas circuit; A fixture is used to assemble a manifold injector; the air inlet of the fixture is connected to the second interface of a leak tester through a test air circuit, and the exhaust port of the fixture is connected to the third interface of the leak tester through a test air circuit. The control module is electrically connected to the pressure regulating gas circuit, the leak tester, and the fixed fixture.

[0010] Preferably, the pressure regulating air circuit includes at least one pressure regulating valve and a pressure sensor; The control module is electrically connected to the pressure regulating valve and the pressure sensor, respectively.

[0011] Preferably, the pressure regulating valve includes a coarse pressure regulating valve and a fine pressure regulating valve arranged in series along the airflow direction.

[0012] Preferably, the leakage tester is an Ateq tester.

[0013] Preferably, the fixed tooling includes an upper tooling and a lower tooling; The upper fixture is provided with an air inlet that connects to a second interface of a leak tester; The lower tooling is provided with an exhaust port that connects to the third interface of the leak tester; The manifold injector is assembled between the upper and lower tooling, with the air inlet end of the manifold injector connected to the air inlet of the upper tooling and the exhaust end of the manifold injector connected to the exhaust outlet of the lower tooling.

[0014] Preferably, the upper tooling is provided with a first air-filled sealing ring in the groove for assembling the manifold injector. The first air-filled sealing ring is used to perform air-filled sealing after the air inlet end of the manifold injector is assembled with the air inlet of the upper tooling.

[0015] Preferably, the lower tooling is provided with a second air-filled sealing ring in the groove for assembling the manifold injector. The second air-filled sealing ring is used to perform air-filled sealing after the exhaust end of the manifold injector is assembled with the exhaust port of the lower tooling.

[0016] Preferably, the fixed tooling further includes a tooling body; The upper tooling is connected to the tooling body via a lifting module; The lower tooling is fixedly assembled onto the tooling body.

[0017] Preferably, the control module is a PLC controller, a microcontroller, or an industrial computer.

[0018] Preferably, the sub-high pressure leakage testing device further includes an identification module; The identification module is positioned facing the manifold injector assembled within the fixed fixture and is used to identify the manifold injector; the identification module is electrically connected to the control module.

[0019] The working principle of this utility model is as follows: The operator places the manifold injector to be tested into the fixture of the sub-high pressure leak test device and assembles and secures it; then, the high-pressure gas output from the gas source is adjusted to the target sub-high pressure through the pressure regulating gas circuit and charged into the leak tester and manifold injector for pressure holding test; after the test is completed, the pressure is released and the operator removes the manifold injector from the fixture.

[0020] Compared with the prior art, the present invention has the following beneficial effects: This solution, through its designed pressure-regulating gas path, can control the gas pressure output from the gas source within a sub-high pressure range, specifically within 10 bar to meet testing requirements. Simultaneously, in conjunction with the first and second inflation sealing rings within the upper and lower fixtures of the fixed tooling, reliable sealing and pressure maintenance are achieved for the overall airflow path of the testing device. This ensures that the testing system will not suffer from structural leakage during testing, preventing insufficient testing accuracy. Consequently, the likelihood of failed manifold injectors leaving the factory is reduced, and customer complaints are minimized.

[0021] This solution is equipped with an identification module, which can automatically match, associate, and store test results with test objects through identification methods such as code recognition and image recognition, thereby enabling traceable performance testing of each manifold injector.

[0022] This solution has a simple overall structure and is easy to automate. It can be improved based on existing testing systems, with lower testing and modification costs and higher testing accuracy, thus meeting the market demand for leak testing of manifold injectors. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the sub-high pressure leakage test device in Example 1.

[0024] In the diagram: 1-Air source; 2-Pressure regulating air path; 21-Pressure coarse adjustment valve; 22-Pressure fine adjustment valve; 23-Pressure sensor; 3-Leak tester; 4-Fixed fixture; 41-Upper fixture; 42-Lower fixture; 43-First inflation seal ring; 44-Second inflation seal ring; 5-Manifold injector. Detailed Implementation

[0025] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0026] Example 1 A sub-high pressure leakage testing device for a manifold injector 5, such as Figure 1 As shown, it includes: Gas source 1; Pressure regulating air path 2 is used to regulate the air pressure output by air source 1 to the sub-high pressure range; the first end of the pressure regulating air path 2 is connected to air source 1; Leak tester 3; the first interface of the leak tester 3 is connected to the second end of the pressure regulating gas circuit 2; Fixture 4 is used to assemble manifold injector 5; the air inlet of fixture 4 is connected to the second interface of leak tester 3 through a test air path, and the exhaust port of fixture 4 is connected to the third interface of leak tester 3 through a test air path. The control module is electrically connected to the pressure regulating gas path 2, the leak tester 3, and the fixed fixture 4.

[0027] More specifically, in this embodiment: The high-pressure leakage test device was used to test the leakage of the manifold injector 5 under a test pressure of 10 bar. Specifically, the high-pressure leakage test device consists of an air source 1 (high-pressure air source 1), a pressure regulating air circuit 2, a leakage tester 3, a fixed fixture 4, a control module, and an optional identification module.

[0028] Gas source 1 has a pressure of at least 10 bar, and the specific gas type can be selected according to the experimental design; gas source 1 can be a high-pressure gas cylinder or a gas pump connected to a gas cylinder or the atmosphere.

[0029] The pressure regulating gas path 2 connects the gas source 1 and the leak tester 3. A coarse pressure regulating valve 21, a fine pressure regulating valve 22, and a pressure sensor 23 are sequentially installed on the pressure regulating gas path 2 from the gas source 1 to the leak tester 3 to achieve precise control of the gas pressure entering the leak tester 3 and the downstream manifold injector 5. The coarse pressure regulating valve 21 and the fine pressure regulating valve 22 can both be solenoid valves of different precision and electrically connected to the control module. Meanwhile, the pressure sensor 23 can be a suitable commercially available sensor product, such as a surface-mount, capacitive, or piezoresistive pressure sensor. Thus, the real-time pressure measurement of the pressure regulating gas path 2 by the pressure sensor 23 enables precise adjustment of the test pressure in the system. Furthermore, the pressure regulating gas path 2 can also be designed with check valves / non-return valves, venting branches, and sensor devices such as temperature sensors and flow sensors, as needed.

[0030] The leak tester 3 uses an Ateq tester, which has at least three gas path interfaces. The first interface is used to connect to the pressure regulating gas path 2 to receive gas from the gas source 1; the second interface is used to connect to the air inlet of the fixed fixture 4 and further connect to the air inlet of the manifold injector 5, thereby inputting gas from the gas source 1 into the manifold injector 5 for testing; the third interface is used to connect to the exhaust port of the fixed fixture 4 and further connect to the exhaust port of the manifold injector 5 to receive gas flowing out of the manifold injector 5.

[0031] The fixed fixture 4 may specifically include a fixture body and an upper fixture 41 and a lower fixture 42 respectively connected to the fixture body; wherein, the upper fixture 41 is further connected to the fixture body through a lifting module (such as a cylinder / motor that can be used as a power source), so that it can be lifted and pressed down to fix and unlock the manifold injector 5; the lower fixture 42 can be directly fixed to the fixture body and directly below the movement path of the upper fixture 41 by means of screws or the like. The upper fixture 41 and the lower fixture 42 have grooves on their opposing surfaces to accommodate the manifold injector 5. Inside each groove are an inflatable first inflation sealing ring 43 and a second inflation sealing ring 44, respectively, for inflation and sealing after the manifold injector 5 is assembled inside. The first inflation sealing ring 43 and the second inflation sealing ring 44 are led out from the fixed fixture 4 and connected to an inflation air source (such as an air pump, which can be set independently) to provide a gas pressure of 4-6 bar when inflation and sealing are required, so that the sealing rings expand and fit against the surface of the manifold injector 5. The upper fixture 41 has an air inlet that mates with the air inlet end of the manifold injector 5, and this air inlet is connected to the second interface of the leak tester 3 via a gas line (gas pipeline). The lower fixture 42 has an exhaust port that mates with the exhaust end of the manifold injector 5, and this exhaust port is connected to the third interface of the leak tester 3 via a gas line (gas pipeline). In this air circuit, appropriate control valves (such as solenoid valves) and sensors (pressure sensor 23) can also be installed as needed to achieve air pressure control.

[0032] In this embodiment, the control module specifically adopts a PLC controller, which can be a commercially available product. In other embodiments, other commercially available control devices such as microcontrollers or industrial computers can also be used. This control module is electrically connected to the regulating valves and sensors on the pressure regulating air circuit 2, the leak tester 3, the lifting module of the fixed fixture 4, and the control valves and sensors on the air circuit.

[0033] The identification module is positioned facing the fixed fixture 4, specifically towards the manifold injector 5, and is used to identify pre-set identification codes and identifiers on the manifold injector 5. This identification module can be a barcode scanner or a camera. After acquiring the corresponding image or content, it further feeds the data back to the control module, thereby associating the test results with the corresponding manifold injector 5 and enabling performance traceability of the manifold injector 5. The identification module can be mounted on the main body of the fixed fixture 4 or set independently on the fixed fixture 4; more preferably, the identification module is mounted on a robotic arm with at least three axes, thus satisfying the scanning and identification of identification codes or identifiers at different locations on the manifold injector 5.

[0034] During the high-pressure leakage test, the manifold injector 5 was tested for leakage using the high-pressure leakage test device. First, the operator places the manifold injector 5 into the lower fixture 42, and then uses the drive lifting module to press down the upper fixture 41 to fix the manifold injector 5.

[0035] Subsequently, the identification module scans the identification code of the fixed manifold injector 5 (a QR code is used in this embodiment). At the same time, the air supply connecting the first air sealing ring 43 and the second air sealing ring 44 is started and the two sealing rings are inflated (the pressure is controlled at 4-6 bar) to further enhance the sealing of the manifold injector 5 in the fixed fixture 4.

[0036] Then, start the gas source 1 and adjust the gas pressure through the pressure regulating gas circuit 2 to maintain the gas pressure through the leak tester 3 and into the manifold injector 5 at the test pressure of 10 bar, and perform a pressure holding test.

[0037] Finally, after the test is completed, the entire sub-high pressure leakage test device is depressurized (including the two sealing rings), and the upper fixture 41 is raised to release the fixed limit on the manifold injector 5. The operator then removes the manifold injector 5 to complete the test.

[0038] The above description of the embodiments is provided to enable those skilled in the art to understand and use the utility model. It will be apparent to those skilled in the art that various modifications can be easily made to these embodiments, and the general principles described herein can be applied to other embodiments without inventive effort. Therefore, the present utility model is not limited to the above embodiments, and any improvements and modifications made by those skilled in the art based on the disclosure of the present utility model without departing from its scope should be within the protection scope of the present utility model.

Claims

1. A sub-high pressure leakage testing device for manifold injectors, characterized in that, include: Gas source (1); The pressure regulating air path (2) is used to regulate the air pressure output by the air source (1) to the sub-high pressure range; the first end of the pressure regulating air path (2) is connected to the air source (1). Leakage tester (3); the first interface of the leakage tester (3) is connected to the second end of the pressure regulating gas circuit (2); A fixed fixture (4) is used to assemble a manifold injector (5); the air inlet of the fixed fixture (4) is connected to the second interface of the leak tester (3) through a test air path, and the exhaust port of the fixed fixture (4) is connected to the third interface of the leak tester (3) through a test air path. Control module; the control module is electrically connected to the pressure regulating gas circuit (2), the leak tester (3) and the fixed fixture (4) respectively.

2. The sub-high pressure leakage testing device for manifold injectors according to claim 1, characterized in that, The pressure regulating air circuit (2) includes at least one pressure regulating valve and a pressure sensor (23); The control module is electrically connected to the pressure regulating valve and the pressure sensor (23) respectively.

3. The sub-high pressure leakage testing device for a manifold injector according to claim 2, characterized in that, The pressure regulating valve includes a coarse pressure regulating valve (21) and a fine pressure regulating valve (22) arranged in series along the airflow direction.

4. The sub-high pressure leakage testing device for a manifold injector according to claim 1, characterized in that, The leakage tester (3) mentioned above is an Ateq tester.

5. The sub-high pressure leakage testing device for a manifold injector according to claim 1, characterized in that, The fixed fixture (4) includes an upper fixture (41) and a lower fixture (42). The upper tooling (41) is provided with an air inlet that is connected to the second interface of the leak tester (3); The lower tooling (42) is provided with an exhaust port that is connected to the third interface of the leak tester (3); The manifold injector (5) is assembled between the upper tooling (41) and the lower tooling (42), and the air inlet end of the manifold injector (5) is connected to the air inlet of the upper tooling (41), and the exhaust end of the manifold injector (5) is connected to the exhaust port of the lower tooling (42).

6. The sub-high pressure leakage testing device for a manifold injector according to claim 5, characterized in that, The upper tooling (41) is provided with a first air-filled sealing ring (43) in the groove for assembling the manifold injector (5). The first air-filled sealing ring (43) is used to perform air-filled sealing after the air inlet end of the manifold injector (5) is connected to the air inlet of the upper tooling (41) for assembly.

7. The sub-high pressure leakage testing device for a manifold injector according to claim 5, characterized in that, The lower tooling (42) is provided with a second air-filled sealing ring (44) in the groove for assembling the manifold injector (5). The second air-filled sealing ring (44) is used to perform air-filled sealing after the exhaust end of the manifold injector (5) is connected to the exhaust port of the lower tooling (42) for assembly.

8. The sub-high pressure leakage testing device for a manifold injector according to claim 5, characterized in that, The fixed fixture (4) also includes a fixture body; The upper tooling (41) is connected to the tooling body via a lifting module; The lower tooling (42) is fixedly assembled on the tooling body.

9. A sub-high pressure leakage testing device for a manifold injector according to claim 1, characterized in that, The control module is a PLC controller, a microcontroller, or an industrial computer.

10. A sub-high pressure leakage testing device for a manifold injector according to claim 1, characterized in that, The aforementioned sub-high pressure leakage testing device also includes an identification module; The identification module is positioned toward the manifold injector (5) assembled inside the fixed fixture (4) and is used to identify the manifold injector (5); the identification module is electrically connected to the control module.

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