Cooperative Salt Spray and Humidity Control in Environmental Test Equipment
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Solution Overview
Problem
Existing salt spray test equipment fails to cooperatively control salt spray concentration and relative humidity, leading to unrealistic simulation of actual service environments and inability to reproduce potential faults in electrical equipment.
Innovation Solution
An environmental test equipment with a dry salt spray generation system, air conditioning system, mixing chamber, and control cabinet, which adjusts salt spray concentration and relative humidity to simulate actual service conditions by regulating temperature and humidity, using adjustable air supply devices and sensors to maintain dynamic equilibrium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If compressed air is used to break the solution into fine spray for salt spray test, then salt spray concentration and relative humidity are high, but this causes rapid acceleration effect leading to serious corrosion and failure of electrical equipment, making it impossible to reproduce actual service faults
Solution Approach 1:
The patent divides the salt spray generation process into two separate systems: a dry salt spray generation system that produces only salt particles without moisture, and a separate humidity control system. This segmentation allows independent control of salt spray concentration and relative humidity, eliminating the coupled high concentration-high humidity condition that causes excessive corrosion.
Solution Approach 2:
The patent changes the physical state of salt spray from wet aerosol to dry particles, and independently adjusts the humidity parameter. By controlling the dry salt spray concentration and relative humidity as separate parameters, the system can achieve realistic service environment simulation with appropriate acceleration factors, preventing unrealistic rapid corrosion.
2Quantity of substance
If high relative humidity is maintained during salt spray test, then salt spray test can be conducted, but salt spray and humidity cannot be cooperative controlled, resulting in significant differences from actual service environment
Solution Approach 1:
The patent separates salt spray generation from humidity generation into two independent systems, enabling cooperative control of both parameters. The dry salt spray generation system controls salt particle concentration while the air conditioning system controls humidity, allowing the test environment to accurately simulate actual service conditions with programmable acceleration factors.
3Quantity of substance
If dry salt spray generation system is used to produce micron sized dry salt aerosol particles, then salt spray concentration can be controlled, but additional temperature and humidity regulation modules are required
Solution Approach 1:
The air conditioning system serves multiple functions: it regulates the humidity of the environment, cools the dry salt spray particles to condensation temperature, and provides the carrier air for transporting salt particles to the test chamber. This multi-functionality reduces overall system complexity despite the specialized dry salt spray generation process.
4Adaptability or versatility
If mixing chamber is used to mix dry salt aerosol particles with regulated air, then cooperative control of salt spray and humidity is achieved, but flow rate regulation devices are required for precise control
Solution Approach 1:
The system incorporates sensors to detect salt spray concentration and relative humidity in the test chamber, with control circuits that receive these signals and automatically adjust the flow rates of dry salt spray and regulated air through the mixing chamber. This feedback control achieves precise cooperative parameter control while automating the process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The equipment effectively simulates the actual service environment, allowing for accurate reproduction of potential faults and improving the relevance of environmental adaptability testing for electrical equipment.
Implementation Method 1
the dry spray generator grinds salt particles into micron sized dry salt aerosol particles
Implementation Method 2
The mixing chamber is used to mix the dry salt aerosol particles inside and the introduced regulated air evenly
Data Source
AI summary
Environmental test equipment for the cooperative control of salt spray concentration and relative humidity, comprising: a dry salt spray generation system, an air conditioning system, a mixing chamber, a test chamber and an electric control cabinet; in accordance with the principle of conserving salt content and moisture content before and after mixing, the environmental test equipment obtains a salt spray concentration relationship formula and a relative humidity relationship formula between: environmental parameters in the test chamber, dry salt spray environmental parameters in the dry salt spray generation system, and air conditioning environmental parameters in the air conditioning system; after determining environmental test parameters required in the test chamber, the salt spray concentration relationship formula and the relative humidity relationship formula are used to obtain: temperature parameters and relative humidity parameters required to be set in the dry salt spray generation system, and temperature parameters and relative humidity parameters required to be set in the air conditioning system.