CN103423877B - The pulse detection system of inner container of electric water heater and low consumption detection method - Google Patents
The pulse detection system of inner container of electric water heater and low consumption detection method Download PDFInfo
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Abstract
本发明公开了一种电热水器内胆的脉冲压力检测系统和低耗检测方法,脉冲压力检测系统包括变频电机水泵,溢流阀、附加遥控口串接溢流电磁铁的溢流阀、第一电磁阀、第二电磁阀、第三电磁阀、电液比例阀、止回阀,第一压力传感变送器、第二压力传感变送器,加压蓄能器、保压蓄能器,储水式电热水器内胆,水箱,控制器以及连接管路组成,加压蓄能器和保压蓄能器均为充气式蓄能器。脉冲压力检测系统采用加压蓄能器、保压蓄能器的双蓄能器结构,降低了系统的能耗,减少了水泵输出端承受的高低压循环脉冲压力及“回压”对水泵的损害;采用模拟量比例阀PID调节电热水器内胆注入的水量,缓解了因开关阀造成的“水击现象”对检测系统的危害。
The invention discloses a pulse pressure detection system and a low-consumption detection method for an inner tank of an electric water heater. Solenoid valve, second solenoid valve, third solenoid valve, electro-hydraulic proportional valve, check valve, first pressure sensing transmitter, second pressure sensing transmitter, pressurized accumulator, pressure-holding energy storage It is composed of a water storage type electric water heater liner, a water tank, a controller and connecting pipelines. Both the pressurized accumulator and the pressure-holding accumulator are gas-filled accumulators. The pulse pressure detection system adopts a double accumulator structure of a pressurized accumulator and a pressure-holding accumulator, which reduces the energy consumption of the system and reduces the impact of the high and low pressure cycle pulse pressure and "back pressure" on the pump output end. Damage; the analog proportional valve PID is used to adjust the water volume injected into the inner tank of the electric water heater, which alleviates the damage to the detection system caused by the "water hammer phenomenon" caused by the switch valve.
Description
技术领域 technical field
本发明属电热水器的脉冲压力检测技术范畴,尤其涉及一种电热水器内胆的脉冲压力检测系统和低耗检测方法。 The invention belongs to the technical category of pulse pressure detection for electric water heaters, and in particular relates to a pulse pressure detection system and a low-consumption detection method for an inner tank of an electric water heater.
背景技术 Background technique
我国电热水器的年销量约1300万台,为规范电热水器行业有序的健康发展、保护使用者的人身安全,国家和行业主管部门先后引进、制定和颁布了一系列的技术规范和标准:GB4706.1《家用和类似用途电器的安全通用要求》、GB4706.12《家用和类似用途电器的安全储水式热水器的特殊要求》、GB/T20289-2006《储水式电热水器》、IEC60379《热水器性能试验方法》、QB/T 4101-2010《储水式电热水器内胆》。技术规范和标准明确界定了储水式电热水器的额定容量、加热效率、24小时固有能耗、热水输出率、刻度回差、温度回差、安全参数和电热水器内胆脉冲压力的技术指标。现有技术条件下,储水式电热水器前7项指标的检测装置和检测方法已相当成熟有效;时至今日唯独脉冲压力检测项目仍差強人意,亟待改进。储水式电热水器内胆脉冲压力检测的国标技术要点如下: The annual sales volume of electric water heaters in my country is about 13 million units. In order to regulate the orderly and healthy development of the electric water heater industry and protect the personal safety of users, the state and industry authorities have successively introduced, formulated and promulgated a series of technical specifications and standards: GB4706 .1 "General Requirements for Safety of Household and Similar Electrical Appliances", GB4706.12 "Special Requirements for Safe Water Storage Water Heaters for Household and Similar Electrical Appliances", GB/T20289-2006 "Water Storage Electric Water Heaters", IEC60379 "Water Heaters Performance Test Method", QB/T 4101-2010 "Water Storage Electric Water Heater Liner". The technical specifications and standards clearly define the rated capacity, heating efficiency, 24-hour inherent energy consumption, hot water output rate, scale hysteresis, temperature hysteresis, safety parameters and technical indicators of electric water heater liner pulse pressure for water storage electric water heaters. . Under the existing technical conditions, the detection devices and detection methods for the first 7 indicators of water storage electric water heaters are quite mature and effective; up to now, only the pulse pressure detection items are still unsatisfactory and need to be improved urgently. The key technical points of the national standard for pulse pressure detection of the inner tank of the water storage electric water heater are as follows:
·试验压力:额定压力的15%~100±5%,可调范围0~1Mpa; ·Test pressure: 15%~100±5% of rated pressure, adjustable range 0~1Mpa;
·冲击计数范围: 0~999999次; Impact counting range: 0~999999 times;
·工作电压:AC220V; ·Working voltage: AC220V;
·工作温度:0℃~+50℃; ·Working temperature: 0℃~+50℃;
·工作湿度:10%~90%RH; ·Working humidity: 10%~90%RH;
·冲击频率:25~60次/min; ·Impact frequency: 25~60 times/min;
·工作周期:每10000次冲击后停止10min,目测容器无明显变形,再继续下一个工作周期,循环总次数≥80000。 ·Working cycle: Stop for 10 minutes after every 10,000 impacts, visually inspect the container for no obvious deformation, and then continue to the next working cycle, the total number of cycles is ≥80,000.
显然,脉冲压力检测的技术难点是可调压力(额定压力的15%~100±5%)水源的高冲击频率指标;如采用低冲击频率的可调压力水源,则检测效率低下、更偏离了国标,实不可取。 Obviously, the technical difficulty of pulse pressure detection is the high impact frequency index of the water source with adjustable pressure (15%~100±5% of the rated pressure); if the adjustable pressure water source with low impact frequency is used, the detection efficiency will be low, and it will deviate further. The national standard is not advisable.
目前,获取可调压力水源的通行技术是借助变频电机水泵的转速变化;电机、水泵具有固有的转动惯量,因此变频电机水泵转速的变化率根本无法达到可调压力水源所期望的压力变化率,即脉冲压力检测的冲击频率受限于变频电机水泵转速所能实现的变化速率;目前,检验机构和生产企业均提出“高压变频水泵+管路切换”的解决方案(参阅专利“电热水器容器脉冲压力寿命试验装置”、专利号ZL201120240605.X;王东浩,热水器内胆压力试验装置,家电科技[J],2007.11)。“高压变频水泵+管路切换”解决方案的基本原理是:在脉冲压力检测全程,变频器控制的变频电机和水泵始终处于高速状态;脉冲压力检测中的卸压、卸压后的低压保压过程则通过相应管路上阀的启闭,即通过脉冲压力检测系统的管路切换实现;脉冲压力检测中的加压、加压后的高压保压过程,仍有赖于阀启闭实现的管路切换;由于变频电机水泵始终处于高速状态,从而消除了加/卸压过程对应的、变频电机水泵从低/高速至高/低速所需的时间--达到了脉冲压力检测系统可调压力水源所期望的压力变化速度。“高压变频水泵+管路切换”解决方案可行,但缺陷甚多,有待改进;“高压变频水泵+管路切换”解决方案的缺陷、缺陷的原因和改进举措逐一列举如下: At present, the current technology to obtain adjustable pressure water source is to use the speed change of frequency conversion motor water pump; motor and water pump have inherent moment of inertia, so the change rate of frequency conversion motor water pump speed cannot reach the expected pressure change rate of adjustable pressure water source at all. That is, the impact frequency of pulse pressure detection is limited by the rate of change that can be achieved by the speed of the variable frequency motor water pump; at present, both inspection agencies and manufacturers have proposed a solution of "high-voltage variable frequency water pump + pipeline switching" (see the patent "Electric Water Heater Container Pulse Pressure Life Test Device", Patent No. ZL201120240605.X; Wang Donghao, Water Heater Tank Pressure Test Device, Home Appliance Technology [J], 2007.11). The basic principle of the "high-voltage frequency conversion water pump + pipeline switching" solution is: during the whole process of pulse pressure detection, the frequency conversion motor and water pump controlled by the frequency converter are always in a high-speed state; The process is realized by the opening and closing of the valve on the corresponding pipeline, that is, through the pipeline switching of the pulse pressure detection system; the process of pressurization in the pulse pressure detection and the high pressure holding process after pressurization still depends on the pipeline realized by valve opening and closing. Switching; since the variable frequency motor water pump is always in a high-speed state, it eliminates the time required for the variable frequency motor water pump to change from low/high speed to high/low speed corresponding to the process of adding/relieving pressure—meeting the expectations of the adjustable pressure water source of the pulse pressure detection system rate of pressure change. The solution of "high-voltage variable-frequency water pump + pipeline switching" is feasible, but there are many defects that need to be improved; the defects, causes and improvement measures of the solution of "high-voltage frequency-variable water pump + pipeline switching" are listed as follows:
1、脉冲压力检测系统的能耗大。脉冲压力检测的冲击主循环流程涉及:加压、加压后的高压保压过程,卸压、卸压后的低压保压过程;需变频电机水泵输入能量的只有冲击主循环流程的加压过程,维持高/低压保压过程的变频电机水泵输入能量微不足道、仅用于补偿待检测容器和相关管路的泄漏损耗,卸压过程则是待检测容器内高压水的能量释放。“高压变频水泵+管路切换”解决方案的变频电机水泵始终处于高速状态,高/低压保压和卸压过程的变频电机水泵输入能量处于空耗状态,故导致脉冲压力检测系统的能耗过大。以检验机构和生产企业常备的脉冲压力检测系统为例,变频电机水泵的功率在4000W左右,储水式电热水器内胆脉冲压力检测(频率取50次/min、脉冲循环总次数=80000)消耗电能:(80000÷50)÷60×4 +(80000÷10000)×10÷60×4=112(度);鉴于加压过程只占冲击主循环时间片的一小部分,112度电能的绝大部分白白浪费。在保证脉冲压力检测系统稳定可靠运行的前提下,如能充分利用高/低压保压和卸压过程的变频电机水泵输入能量,将降低脉冲压力检测系统的过高能耗。 1. The pulse pressure detection system consumes a lot of energy. The impact main cycle process of pulse pressure detection involves: pressurization, high pressure holding process after pressurization, pressure relief, low pressure holding process after pressure relief; only the pressurization process of the impact main cycle process needs the input energy of frequency conversion motor water pump , the input energy of the variable frequency motor water pump to maintain the high/low pressure holding process is negligible, and it is only used to compensate the leakage loss of the container to be tested and related pipelines. The pressure relief process is the energy release of the high-pressure water in the container to be tested. The variable-frequency motor water pump in the solution of "high-voltage variable-frequency water pump + pipeline switching" is always in a high-speed state, and the input energy of the variable-frequency motor water pump in the process of high/low pressure holding and pressure relief is in a state of empty consumption, which leads to excessive energy consumption of the pulse pressure detection system . Taking the pulse pressure detection system that inspection institutions and production enterprises always have as an example, the power of the frequency conversion motor water pump is about 4000W, and the pulse pressure detection of the tank of the water storage electric water heater (the frequency is 50 times/min, the total number of pulse cycles = 80000) consumes Electric energy: (80000÷50)÷60×4 + (80000÷10000)×10÷60×4=112 (degrees); in view of the fact that the pressurization process only accounts for a small part of the time slice of the main impact cycle, the absolute power of 112 degrees Most of it goes to waste. On the premise of ensuring the stable and reliable operation of the pulse pressure detection system, if the input energy of the frequency conversion motor water pump in the process of high/low pressure holding and pressure relief can be fully utilized, the excessive energy consumption of the pulse pressure detection system will be reduced.
2、“回压”和“水击现象”对脉冲压力检测系统寿命的负面影响。“高压变频水泵+管路切换”解决方案中,变频电机水泵输出端需承受高低压循环的脉冲压力,输出端出现的“回压”将缩短水泵(压力检测系统)的寿命。另一方面,脉冲压力检测中的卸压、卸压后的低压保压过程,加压、加压后的高压保压过程,均采用开关阀的启闭和多管路切换实现;阀和多管路的切换形成液压撞击产生水击(water hammer),“水击现象”对电热水器,检测系统的器件、管路和连结件均会带来损伤;此外,管路切换因管路数目有限,检测系统可供检测的范围也将受限。如果变频电机水泵输出端承受的水压能保持基本不变,将有效克服“回压”的消极因素;如能设置液压缓冲装置并减少管路切换数量,将有望减少“水击现象”的损伤;此外,注入储水式电热水器内胆的水受模拟量而非开关量控制,必将大大延拓检测系统可供检测的范围。 2. The negative impact of "back pressure" and "water hammer" on the life of the pulse pressure detection system. In the solution of "high-voltage frequency conversion water pump + pipeline switching", the output end of the frequency conversion motor water pump needs to withstand the pulse pressure of high and low pressure cycles, and the "back pressure" at the output end will shorten the life of the water pump (pressure detection system). On the other hand, the pressure relief in the pulse pressure detection, the low-pressure pressure holding process after pressure relief, and the high-pressure pressure holding process after pressurization and pressurization are all realized by the opening and closing of switch valves and multi-pipe switching; valves and multi-pipelines The switching of pipelines will cause hydraulic impact to produce water hammer. The "water hammer phenomenon" will cause damage to electric water heaters, components, pipelines and connectors of the detection system; in addition, pipeline switching is limited due to the limited number of pipelines , the detection range of the detection system will also be limited. If the water pressure at the output end of the variable frequency motor water pump can remain basically unchanged, the negative factor of "back pressure" will be effectively overcome; if the hydraulic buffer device can be installed and the number of pipeline switching can be reduced, it is expected to reduce the damage of "water hammer phenomenon" ; In addition, the water injected into the tank of the water storage electric water heater is controlled by the analog quantity instead of the switch quantity, which will greatly extend the detection range of the detection system.
3、冲击主循环周期内加压、高压保压、卸压和低压保压过程的定性时间不利于检测结果的一致性。 3. The qualitative time of pressurization, high pressure holding, pressure relief and low pressure holding in the shock main cycle is not conducive to the consistency of test results.
针对储水式电热水器内胆的脉冲压力检测系统和检测方法存在的缺陷,本发明逐一提出改进措施:首先,变频电机水泵的输出端安装充气式蓄能器,卸压、高/低压保压过程时蓄能器吸收变频电机水泵输出的能量,加压过程时蓄能器和变频电机水泵共同输出能量;既降低了检测系统的能耗,又消除了变频电机水泵输出端的“回压”。其次,采用模拟量比例阀PID调节电热水器内胆注入的水量;不仅缓解了“水击现象”的危害,而且延拓了检测系统可供检测的范围。第三,量化冲击主循环周期内加压、高压保压、卸压和低压保压过程的时间,有助于提升脉冲压力检测系统检测结果的一致性。 Aiming at the defects of the pulse pressure detection system and detection method of the water storage type electric water heater liner, the present invention proposes improvement measures one by one: first, the output end of the frequency conversion motor water pump is installed with an air-filled accumulator, and the pressure is relieved and the high/low pressure is maintained. During the process, the accumulator absorbs the energy output by the frequency conversion motor water pump, and during the pressurization process, the accumulator and the frequency conversion motor water pump jointly output energy; it not only reduces the energy consumption of the detection system, but also eliminates the "back pressure" at the output end of the frequency conversion motor water pump. Secondly, the analog proportional valve PID is used to adjust the amount of water injected into the inner tank of the electric water heater; it not only alleviates the harm of "water hammer phenomenon", but also extends the detection range of the detection system. Third, quantifying the time of pressurization, high-pressure holding, pressure relief and low-pressure holding in the main shock cycle will help improve the consistency of the detection results of the pulse pressure detection system.
发明内容 Contents of the invention
本发明的目的是克服现有技术的不足,提供一种电热水器内胆的脉冲压力检测系统和低耗检测方法。 The purpose of the present invention is to overcome the deficiencies of the prior art, and provide a pulse pressure detection system and a low-consumption detection method for the inner tank of an electric water heater.
储水式电热水器内胆的脉冲压力检测系统包括变频电机水泵,溢流阀、附加遥控口串接溢流电磁铁的溢流阀、第一电磁阀、第二电磁阀、第三电磁阀、电液比例阀、止回阀,第一压力传感变送器、第二压力传感变送器,加压蓄能器、保压蓄能器,储水式电热水器内胆,水箱,控制器以及连接管路组成,加压蓄能器和保压蓄能器均为充气式蓄能器; The pulse pressure detection system of the storage type electric water heater includes a frequency conversion motor water pump, an overflow valve, an overflow valve with an additional remote control port connected in series with an overflow electromagnet, the first solenoid valve, the second solenoid valve, the third solenoid valve, Electro-hydraulic proportional valve, check valve, first pressure sensing transmitter, second pressure sensing transmitter, pressurized accumulator, pressure-holding accumulator, water storage type electric water heater liner, water tank, control The pressurized accumulator and the pressure-holding accumulator are all gas-filled accumulators;
控制器包括CPU224XP DC/DC/DC模块、CPU模块自带的开入开出模块、CPU模块自带的模入模出模块、电源NES-75-24模块、CPU模块自带的通信模块、触摸屏MT8070iH模块; The controller includes CPU224XP DC/DC/DC module, the input and output module of the CPU module, the mold input and output module of the CPU module, the power supply NES-75-24 module, the communication module of the CPU module, and the touch screen MT8070iH module;
变频电机水泵的进水口通过进水管与水箱相连,变频电机水泵的第一路出水口经过溢流阀与水箱相连,变频电机水泵的第二路出水口经过止回阀、附加遥控口串接溢流电磁铁的溢流阀与水箱相连,变频电机水泵的第三路出水口依次通过止回阀、加压蓄能器、第一压力传感变送器、第一电磁阀、电液比例阀、第二压力传感变送器、储水式电热水器内胆、第三电磁阀与水箱相连,第二电磁阀的进水口接在第一电磁阀与电液比例阀之间的管路上、第二电磁阀的出水口与保压蓄能器相连; The water inlet of the frequency conversion motor water pump is connected to the water tank through the water inlet pipe, the first water outlet of the frequency conversion motor water pump is connected to the water tank through the overflow valve, and the second water outlet of the frequency conversion motor water pump is connected to the overflow through a check valve and an additional remote control port in series. The overflow valve of the flow electromagnet is connected with the water tank, and the third water outlet of the variable frequency motor water pump passes through the check valve, the pressurized accumulator, the first pressure sensor transmitter, the first solenoid valve, and the electro-hydraulic proportional valve in sequence. , the second pressure sensor transmitter, the tank of the water storage electric water heater, the third solenoid valve connected to the water tank, the water inlet of the second solenoid valve connected to the pipeline between the first solenoid valve and the electro-hydraulic proportional valve, The water outlet of the second electromagnetic valve is connected with the pressure maintaining accumulator;
控制器的CPU224XP DC/DC/DC模块通过通信模块与触摸屏MT8070iH模块进行数据传输,市电一路接入变频电机、市电另一路接入电源NES-75-24模块,开入开出模块输出的4路开关量DO1、DO2、DO3、DO4分别与附加遥控口串接溢流电磁铁的溢流阀、第一电磁阀、第二电磁阀、第三电磁阀相连,模入模出模块的两个模入口分别接入第一压力传感变送器、第二压力传感变送器输出的AI1和AI2模拟量,模入模出模块的模出口输出的模拟控制量AO与电液比例阀相连。 The CPU224XP DC/DC/DC module of the controller performs data transmission with the touch screen MT8070iH module through the communication module. The 4-way switching value DO 1 , DO 2 , DO 3 , DO 4 are respectively connected with the overflow valve, the first solenoid valve, the second solenoid valve, and the third solenoid valve connected in series with the overflow electromagnet at the additional remote control port, and the mold is inserted into the mold. The two mold inlets of the outlet module are respectively connected to the AI 1 and AI 2 analog quantities output by the first pressure sensor transmitter and the second pressure sensor transmitter, and the analog control quantity output by the mold outlet of the mold-in and mold-out module AO is connected with electro-hydraulic proportional valve.
脉冲压力检测系统的低耗检测方法包括检测准备流程、冲击主循环流程和万次冲击主循环后的10分钟保压流程; The low-consumption detection method of the pulse pressure detection system includes the detection preparation process, the impact main cycle process and the 10-minute pressure holding process after the main impact cycle of 10,000 times;
检测准备流程:在触摸屏人机交互界面上输入试验压力P0、脉冲压力检测的冲击主循环总次数N、冲击主循环频率f0即冲击主循环周期T0、工作周期T、工作周期的间隔时间、冲击主循环周期内的加压t1/高压保压t2/卸压t3/低压保压t4过程时间, Test preparation process: Input the test pressure P 0 on the touch screen human-computer interaction interface, the total number of impact main cycles N of pulse pressure detection, the frequency f 0 of the main impact cycle, that is, the main impact cycle T 0 , the working cycle T, and the interval of the working cycle Time, pressurization t 1 / high pressure holding t 2 / pressure relief t 3 / low pressure holding t 4 process time in the main impact cycle,
确定溢流阀的动作压力阀值P1,在触摸屏人机交互界面上输入溢流阀的动作压力阀值P2、P1>P2>P0, Determine the operating pressure threshold P 1 of the relief valve, and input the operating pressure threshold P 2 of the relief valve on the touch screen human-computer interaction interface, P 1 >P 2 >P 0 ,
关闭第三电磁阀,开启第一电磁阀、第二电磁阀、电液比例阀,储水式电热水器内胆注满水、关闭电液比例阀,启动变频电机水泵、当压力模拟量AI1>P2时控制器的开关量DO1开启溢流阀、当变频电机水泵的出口压大于P1时溢流阀溢流、加压蓄能器和保压蓄能器完成蓄能,进入冲击主循环流程加压过程的条件就绪; Close the third solenoid valve, open the first solenoid valve, the second solenoid valve, and the electro-hydraulic proportional valve, fill the tank of the water storage electric water heater with water, close the electro-hydraulic proportional valve, start the variable frequency motor water pump, when the pressure analog AI 1 When >P 2 , the switching value DO 1 of the controller opens the overflow valve, when the outlet pressure of the variable frequency motor water pump is greater than P 1 , the overflow valve overflows, the pressurized accumulator and the pressure-holding accumulator complete energy storage, and enter the impact The conditions for the pressurization process of the main circulation process are ready;
冲击主循环流程由加压、高压保压、卸压和低压保压过程组成: The main impact cycle process consists of pressurization, high pressure holding, pressure relief and low pressure holding:
·加压过程--变频电机水泵运行,关闭第三电磁阀、开启第一电磁阀和第二电磁阀,根据偏差P0-AI2,PID控制电液比例阀的开度、使AI2=P0,若t1<0.15T0或t1>0.2T0、则冲击主循环流程结束时调低或调高变频电机水泵的频率、否则变频电机水泵的频率不变, Pressurization process - the frequency conversion motor water pump is running, close the third solenoid valve, open the first solenoid valve and the second solenoid valve, according to the deviation P 0 -AI 2 , PID controls the opening of the electro-hydraulic proportional valve, so that AI 2 = P 0 , if t 1 <0.15T 0 or t 1 >0.2T 0 , then reduce or increase the frequency of the variable frequency motor water pump at the end of the main impact cycle, otherwise the frequency of the variable frequency motor water pump remains unchanged.
·高压保压过程--变频电机水泵运行,关闭第一电磁阀、根据偏差P0-AI2,PID控制电液比例阀的开度、保压蓄能器向储水式电热水器内胆输出能量,变频电机水泵向加压蓄能器输出能量,直至t1+t2=0.5T0, ·High pressure holding process--the variable frequency motor water pump is running, the first solenoid valve is closed, and the opening of the electro-hydraulic proportional valve is controlled by PID according to the deviation P 0 -AI 2 , and the pressure holding accumulator is output to the inner tank of the water storage electric water heater energy, the variable frequency motor water pump outputs energy to the pressurized accumulator until t 1 +t 2 =0.5T 0 ,
·卸压过程--变频电机水泵运行,关闭第二电磁阀和电液比例阀、开启第三电磁阀,当AI2=0.15P0时关闭第三电磁阀、变频电机水泵向加压蓄能器输出能量, ·Pressure relief process--the frequency conversion motor water pump is running, close the second solenoid valve and electro-hydraulic proportional valve, open the third solenoid valve, when AI 2 =0.15P 0 , close the third solenoid valve, and the frequency conversion motor water pump will pressurize and store energy device output energy,
·低压保压过程--变频电机水泵运行,开启第二电磁阀和电液比例阀、根据偏差0.15P0-AI2,PID控制电液比例阀的开度、保压蓄能器向储水式电热水器内胆输出能量,变频电机水泵向加压蓄能器输出能量,直至t3+t4=0.5T0; ·Low pressure maintenance process--the frequency conversion motor water pump is running, open the second solenoid valve and electro-hydraulic proportional valve, according to the deviation of 0.15P 0 -AI 2 , PID controls the opening of the electro-hydraulic proportional valve, and the pressure-maintaining accumulator to the water storage The tank of the electric water heater outputs energy, and the water pump of the variable frequency motor outputs energy to the pressurized accumulator until t 3 +t 4 =0.5T 0 ;
万次冲击主循环后的10分钟保压流程:首先完成冲击主循环流程的加压过程,关闭第三电磁阀、降低变频电机水泵的频率、开启第一电磁阀第二电磁阀和电液比例阀、根据偏差P0-AI2,PID控制电液比例阀的开度、加压蓄能器和保压蓄能器向储水式电热水器内胆输出能量使AI2=P0,延时10min; 10-minute pressure-holding process after 10,000 impacts on the main cycle: first complete the pressurization process of the impacting main cycle, close the third solenoid valve, reduce the frequency of the variable frequency motor water pump, open the first solenoid valve, the second solenoid valve and the electro-hydraulic proportional The valve, according to the deviation P 0 -AI 2 , PID controls the opening of the electro-hydraulic proportional valve, the pressurized accumulator and the pressure-holding accumulator output energy to the inner tank of the water storage electric water heater so that AI 2 =P 0 , time delay 10min;
·AI2<P0且连接管路无问题、储水式电热水器内胆不合格则中止检测, · If AI 2 < P 0 and there is no problem with the connecting pipeline, and the tank of the water storage electric water heater is unqualified, the inspection will be terminated.
·目测储水式电热水器内胆明显变形、不合格则中止检测, Visual inspection of the water storage type electric water heater liner is obviously deformed, if it is unqualified, the inspection will be suspended.
·目测储水式电热水器内胆无明显变形、冲击主循环数<冲击总数N则执行新工作周期, ·Visual inspection of the storage type electric water heater has no obvious deformation, and the number of main shock cycles is less than the total number of shocks N, then a new work cycle will be executed.
·目测储水式电热水器内胆无明显变形、冲击主循环数=冲击总数N则合格则中止检测。 ·Visual inspection of the inner tank of the water storage electric water heater has no obvious deformation, and the number of main impact cycles = the total number of impacts N, if it is qualified, the test will be terminated.
本发明与背景技术相比,具有的有益效果是: Compared with the background technology, the present invention has the beneficial effects of:
借助加/保压双蓄能器,充分利用高/低压保压和卸压过程的变频电机水泵输入能量,降低了脉冲压力检测系统的过高能耗; With the help of dual accumulators for adding/holding pressure, the input energy of the frequency conversion motor water pump in the process of high/low pressure holding and pressure relief is fully utilized, reducing the excessive energy consumption of the pulse pressure detection system;
借助加/保压双蓄能器,减小了变频电机水泵输出端承受的高低压循环脉冲压力,降低了水泵输出端“回压”对水泵的损害; With the help of adding/holding double accumulators, the high and low pressure cycle pulse pressure on the output end of the variable frequency motor water pump is reduced, and the damage to the water pump caused by the "back pressure" at the output end of the water pump is reduced;
采用模拟量比例阀PID调节电热水器内胆注入的水量,缓解了因开关阀造成的“水击现象”对检测系统的危害,而且延拓了检测系统可供检测的范围。 The analog proportional valve PID is used to adjust the amount of water injected into the inner tank of the electric water heater, which alleviates the damage to the detection system caused by the "water hammer phenomenon" caused by the switch valve, and extends the detection range of the detection system.
附图说明 Description of drawings
图1是储水式电热水器内胆的脉冲压力检测系统结构图; Figure 1 is a structural diagram of the pulse pressure detection system for the tank of the water storage electric water heater;
图2(a)是脉冲压力检测系统的低耗检测法流程图; Fig. 2 (a) is the flow chart of the low-consumption detection method of the pulse pressure detection system;
图2(b)是脉冲压力检测系统的检测系统准备流程; Figure 2(b) is the detection system preparation process of the pulse pressure detection system;
图2(c)是脉冲压力检测系统的冲击主循环流程; Fig. 2 (c) is the impact main circulation process of the pulse pressure detection system;
图2(d)是脉冲压力检测系统的10分钟保压流程。 Figure 2(d) is the 10-minute pressure-holding process of the pulse pressure detection system.
具体实施方式 Detailed ways
如图1所示,储水式电热水器内胆的脉冲压力检测系统包括变频电机水泵10,溢流阀20、附加遥控口串接溢流电磁铁的溢流阀21、第一电磁阀22、第二电磁阀23、第三电磁阀24、电液比例阀25、止回阀26,第一压力传感变送器31、第二压力传感变送器32,加压蓄能器41、保压蓄能器42,储水式电热水器内胆50,水箱60,控制器70以及连接管路组成,加压蓄能器和保压蓄能器均为充气式蓄能器; As shown in Figure 1, the pulse pressure detection system of the tank of the water storage electric water heater includes a variable frequency motor water pump 10, an overflow valve 20, an additional remote control port connected in series with an overflow electromagnet overflow valve 21, a first electromagnetic valve 22, Second solenoid valve 23, third solenoid valve 24, electro-hydraulic proportional valve 25, check valve 26, first pressure sensing transmitter 31, second pressure sensing transmitter 32, pressurized accumulator 41, The pressure-maintaining accumulator 42 is composed of a storage-type electric water heater liner 50, a water tank 60, a controller 70 and connecting pipelines. Both the pressurized accumulator and the pressure-maintaining accumulator are gas-filled accumulators;
控制器70包括CPU224XP DC/DC/DC模块71、CPU模块自带的开入开出模块72、CPU模块自带的模入模出模块73、电源NES-75-24模块74、CPU模块自带的通信模块75、触摸屏MT8070iH模块76; The controller 70 includes a CPU224XP DC/DC/DC module 71, a built-in input and output module 72 of the CPU module, a mold-in and mold-out module 73 of the CPU module, a power supply NES-75-24 module 74, and a built-in CPU module Communication module 75, touch screen MT8070iH module 76;
变频电机水泵10的进水口通过进水管与水箱60相连,变频电机水泵10的第一路出水口经过溢流阀20与水箱60相连,变频电机水泵10的第二路出水口经过止回阀26、附加遥控口串接溢流电磁铁的溢流阀21与水箱60相连,变频电机水泵10的第三路出水口依次通过止回阀26、加压蓄能器41、第一压力传感变送器31、第一电磁阀22、电液比例阀25、第二压力传感变送器32、储水式电热水器内胆50、第三电磁阀24与水箱60相连,第二电磁阀23的进水口接在第一电磁阀22与电液比例阀25之间的管路上、第二电磁阀23的出水口与保压蓄能器42相连; The water inlet of the frequency conversion motor water pump 10 is connected to the water tank 60 through the water inlet pipe, the first water outlet of the frequency conversion motor water pump 10 is connected to the water tank 60 through the overflow valve 20, and the second water outlet of the frequency conversion motor water pump 10 passes through the check valve 26 The overflow valve 21 connected in series with the overflow electromagnet with the additional remote control port is connected with the water tank 60, and the third water outlet of the frequency conversion motor water pump 10 passes through the check valve 26, the pressurized accumulator 41, the first pressure sensor variable Transmitter 31, first electromagnetic valve 22, electro-hydraulic proportional valve 25, second pressure sensor transmitter 32, water storage type electric water heater liner 50, third electromagnetic valve 24 is connected with water tank 60, second electromagnetic valve 23 The water inlet of the first solenoid valve 22 is connected to the pipeline between the electro-hydraulic proportional valve 25, and the water outlet of the second solenoid valve 23 is connected with the pressure maintaining accumulator 42;
控制器70的CPU224XP DC/DC/DC模块71通过通信模块75与触摸屏MT8070iH模块76进行数据传输,市电一路接入变频电机、市电另一路接入电源NES-75-24模块74,开入开出模块72输出的4路开关量DO1、DO2、DO3、DO4分别与附加遥控口串接溢流电磁铁的溢流阀21、第一电磁阀22、第二电磁阀23、第三电磁阀24相连,模入模出模块73的两个模入口分别接入第一压力传感变送器31、第二压力传感变送器32输出的AI1和AI2模拟量,模入模出模块73的模出口输出的模拟控制量AO与电液比例阀25相连。 The CPU224XP DC/DC/DC module 71 of the controller 70 performs data transmission with the touch screen MT8070iH module 76 through the communication module 75. The 4-way switching values DO 1 , DO 2 , DO 3 , and DO 4 output by the output module 72 are respectively connected to the additional remote control port in series with the overflow valve 21 of the overflow electromagnet, the first solenoid valve 22, the second solenoid valve 23, The third solenoid valve 24 is connected, and the two mold inlets of the mold-in and mold-out module 73 are respectively connected to the AI 1 and AI 2 analog quantities output by the first pressure sensor transmitter 31 and the second pressure sensor transmitter 32, The analog control quantity AO output by the mold outlet of the mold-in mold-out module 73 is connected with the electro-hydraulic proportional valve 25 .
如图2所示,脉冲压力检测系统的低耗检测方法包括检测准备流程、冲击主循环流程和万次冲击主循环后的10分钟保压流程; As shown in Figure 2, the low-consumption detection method of the pulse pressure detection system includes the detection preparation process, the main impact cycle process and the 10-minute pressure holding process after the main impact cycle for 10,000 times;
检测准备流程:在触摸屏人机交互界面上输入试验压力P0(缺省值1MPa)、脉冲压力检测的冲击主循环总次数N(缺省值80000次)、冲击主循环频率f0(缺省值60次/min)即冲击主循环周期T0(缺省值1S)、工作周期T(缺省值10000次冲击主循环时间=10000S)、工作周期的间隔时间(缺省值10min)、冲击主循环周期内的加压t1/高压保压t2/卸压t3/低压保压t4过程时间(缺省值0.15T0≤t1≤0.2T0、t1+t2=0.5T0、t3≤0.2T0、t3+t4=0.5T0), Test preparation process: Input the test pressure P 0 (default value 1MPa), the total number of impact main cycles N (default value 80,000 times) of the pulse pressure test, and the main impact cycle frequency f 0 (default value 60 times/min), that is, the shock main cycle period T 0 (default value 1S), work cycle T (default value 10000 shock main cycle time = 10000S), work cycle interval time (default value 10min), shock Pressurization t 1 /high pressure holding t 2 /pressure relief t 3 /low pressure holding t 4 process time in the main cycle (default value 0.15T 0 ≤t 1 ≤0.2T 0 , t 1 +t 2 =0.5 T 0 , t 3 ≤0.2T 0 , t 3 +t 4 =0.5T 0 ),
确定溢流阀20的动作压力阀值P1、并手工设定之,在触摸屏人机交互界面上输入溢流阀21的动作压力阀值P2、P1>P2>P0, Determine the operating pressure threshold P 1 of the overflow valve 20 and manually set it, and input the operating pressure threshold P 2 of the overflow valve 21 on the touch screen human-computer interaction interface, P 1 >P 2 >P 0 ,
关闭第三电磁阀24,开启第一电磁阀22、第二电磁阀23、电液比例阀25,储水式电热水器内胆50注满水、关闭电液比例阀25,启动变频电机水泵10、当压力模拟量AI1>P2时控制器70的开关量DO1开启溢流阀21、当变频电机水泵10的出口压大于P1时溢流阀20溢流、加压蓄能器41和保压蓄能器42完成蓄能,进入冲击主循环流程加压过程的条件就绪; Close the third solenoid valve 24, open the first solenoid valve 22, the second solenoid valve 23, and the electro-hydraulic proportional valve 25, fill the tank 50 of the water storage electric water heater with water, close the electro-hydraulic proportional valve 25, and start the variable frequency motor water pump 10 . When the pressure analog quantity AI 1 >P 2 , the switching value DO 1 of the controller 70 opens the overflow valve 21. When the outlet pressure of the variable frequency motor water pump 10 is greater than P 1 , the overflow valve 20 overflows and pressurizes the accumulator 41 Complete the energy storage with the pressure-holding accumulator 42, and the conditions for entering the pressurization process of the impact main circulation process are ready;
冲击主循环流程由加压、高压保压、卸压和低压保压过程组成: The main impact cycle process consists of pressurization, high pressure holding, pressure relief and low pressure holding:
·加压过程--变频电机水泵10运行,关闭第三电磁阀24、开启第一电磁阀22和第二电磁阀23,根据偏差P0-AI2,PID控制电液比例阀25的开度、使AI2=P0,若t1<0.15T0或t1>0.2T0、则冲击主循环流程结束时调低或调高变频电机水泵10的频率、否则变频电机水泵10的频率不变, Pressurization process - the frequency conversion motor water pump 10 is running, the third solenoid valve 24 is closed, the first solenoid valve 22 and the second solenoid valve 23 are opened, and the opening of the electro-hydraulic proportional valve 25 is controlled by PID according to the deviation P 0 -AI 2 , Make AI 2 =P 0 , if t 1 <0.15T 0 or t 1 >0.2T 0 , then lower or increase the frequency of the variable frequency motor water pump 10 at the end of the main impact cycle, otherwise the frequency of the variable frequency motor water pump 10 will not Change,
·高压保压过程--变频电机水泵10运行,关闭第一电磁阀22、根据偏差P0-AI2,PID控制电液比例阀25的开度、保压蓄能器42向储水式电热水器内胆50输出能量,变频电机水泵10向加压蓄能器41输出能量,直至t1+t2=0.5T0, ·High pressure holding process--the variable frequency motor water pump 10 is running, the first solenoid valve 22 is closed, the opening of the electro-hydraulic proportional valve 25 is controlled by PID according to the deviation P 0 -AI 2 , and the pressure holding accumulator 42 is turned to the water storage type electric valve. The water heater liner 50 outputs energy, and the variable frequency motor water pump 10 outputs energy to the pressurized accumulator 41 until t 1 +t 2 =0.5T 0 ,
·卸压过程--变频电机水泵10运行,关闭第二电磁阀23和电液比例阀25、开启第三电磁阀24,当AI2=0.15P0时关闭第三电磁阀24、变频电机水泵10向加压蓄能器41输出能量, ·Pressure relief process--the frequency conversion motor water pump 10 is running, close the second solenoid valve 23 and electro-hydraulic proportional valve 25, open the third solenoid valve 24, when AI 2 =0.15P 0 , close the third solenoid valve 24, frequency conversion motor water pump 10 output energy to the pressurized accumulator 41,
·低压保压过程--变频电机水泵10运行,开启第二电磁阀23和电液比例阀25、根据偏差0.15P0-AI2,PID控制电液比例阀25的开度、保压蓄能器42向储水式电热水器内胆50输出能量,变频电机水泵10向加压蓄能器41输出能量,直至t3+t4=0.5T0; ·Low pressure maintenance process--the frequency conversion motor water pump 10 is running, the second solenoid valve 23 and the electro-hydraulic proportional valve 25 are opened, and according to the deviation of 0.15P 0 -AI 2 , the PID controls the opening of the electro-hydraulic proportional valve 25, pressure maintenance and energy storage The device 42 outputs energy to the tank 50 of the water storage type electric water heater, and the variable frequency motor water pump 10 outputs energy to the pressurized accumulator 41 until t 3 +t 4 =0.5T 0 ;
万次冲击主循环后的10分钟保压流程:首先完成冲击主循环流程的加压过程,关闭第三电磁阀24、降低变频电机水泵10的频率、开启第一电磁阀22第二电磁阀23和电液比例阀25、根据偏差P0-AI2,PID控制电液比例阀25的开度、加压蓄能器41和保压蓄能器42向储水式电热水器内胆50输出能量使AI2=P0,延时10min; The 10-minute pressure-holding process after 10,000 impacts on the main cycle: first complete the pressurization process of the impact on the main cycle, close the third solenoid valve 24, reduce the frequency of the variable frequency motor water pump 10, and open the first solenoid valve 22 and the second solenoid valve 23 And the electro-hydraulic proportional valve 25, according to the deviation P 0 -AI 2 , PID controls the opening of the electro-hydraulic proportional valve 25, the pressurized accumulator 41 and the pressure-holding accumulator 42 output energy to the water storage type electric water heater inner tank 50 Make AI 2 =P 0 and delay for 10 minutes;
·AI2<P0且连接管路无问题、储水式电热水器内胆不合格则中止检测, · If AI 2 < P 0 and there is no problem with the connecting pipeline, and the tank of the water storage electric water heater is unqualified, the inspection will be terminated.
·目测储水式电热水器内胆明显变形、不合格则中止检测, Visual inspection of the water storage type electric water heater liner is obviously deformed, if it is unqualified, the inspection will be suspended.
·目测储水式电热水器内胆无明显变形、冲击主循环数<冲击总数N则执行新工作周期, ·Visual inspection of the storage type electric water heater has no obvious deformation, and the number of main shock cycles is less than the total number of shocks N, then a new work cycle will be executed.
·目测储水式电热水器内胆无明显变形、冲击主循环数=冲击总数N则合格则中止检测。 ·Visual inspection of the inner tank of the water storage electric water heater has no obvious deformation, and the number of main impact cycles = the total number of impacts N, if it is qualified, the test will be terminated.
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CN109612668B (en) * | 2017-09-30 | 2021-01-19 | 宁波方太厨具有限公司 | Water hammer test system and test method |
CN110940602B (en) * | 2019-12-13 | 2020-11-06 | 四川大学 | Synchronous measurement device and method for pulse electromagnetic force and discharge inductance of RLC (radio Link control) discharge circuit |
CN113325250B (en) * | 2021-04-22 | 2024-12-06 | 青岛经济技术开发区海尔热水器有限公司 | Energy consumption test method and test device for storage type electric water heater |
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DE4034500C1 (en) * | 1990-10-30 | 1992-03-12 | Schmidt, Kranz & Co Gmbh Zweigniederlassung Zorge, 3421 Zorge, De | Pulse testing arrangement for component subjected to hydraulic fluid - has connection blocks in closed test liquid circuit and having heating elements controlled by pressure resistant temp. sensors |
CN1657893A (en) * | 2004-02-19 | 2005-08-24 | 通用电气公司 | Apparatus and methods for dynamically pressure testing an article |
CN201221474Y (en) * | 2007-12-18 | 2009-04-15 | 台州市耀达工贸有限公司 | Water pump electronic pressure controller |
CN102445391A (en) * | 2011-10-09 | 2012-05-09 | 东南大学 | Pressure pulse fatigue testing device for directly generating pulses with plunger pump |
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JP2804893B2 (en) * | 1994-10-19 | 1998-09-30 | 明光産業株式会社 | Water level difference measuring device in automatic pressure measuring device for cylinders |
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DE4034500C1 (en) * | 1990-10-30 | 1992-03-12 | Schmidt, Kranz & Co Gmbh Zweigniederlassung Zorge, 3421 Zorge, De | Pulse testing arrangement for component subjected to hydraulic fluid - has connection blocks in closed test liquid circuit and having heating elements controlled by pressure resistant temp. sensors |
CN1657893A (en) * | 2004-02-19 | 2005-08-24 | 通用电气公司 | Apparatus and methods for dynamically pressure testing an article |
CN201221474Y (en) * | 2007-12-18 | 2009-04-15 | 台州市耀达工贸有限公司 | Water pump electronic pressure controller |
CN102445391A (en) * | 2011-10-09 | 2012-05-09 | 东南大学 | Pressure pulse fatigue testing device for directly generating pulses with plunger pump |
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