CN118090079B - Air tightness test platform and test method for pneumatic conveying system - Google Patents
Air tightness test platform and test method for pneumatic conveying system Download PDFInfo
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- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M3/00—Investigating fluid-tightness of structures
- G01M3/02—Investigating fluid-tightness of structures by using fluid or vacuum
- G01M3/26—Investigating fluid-tightness of structures by using fluid or vacuum by measuring rate of loss or gain of fluid, e.g. by pressure-responsive devices, by flow detectors
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
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Abstract
The invention discloses an air tightness test platform and a test method for a pneumatic conveying system, which relate to the field of air tightness test and solve the problems that in the air tightness test of the pneumatic conveying system at the present stage, an integrity test is selected under most conditions and a standard element is not selected for synchronous test during the test at the present stage; the air tightness test module is used for carrying out air tightness test on the primary qualified element in the pneumatic conveying system, the air tightness test task of the pneumatic conveying system is subjected to the thinned sectional test, and test data of the standard element which is synchronously tested are used as references, so that test accuracy of the pneumatic conveying system in test is ensured.
Description
Technical Field
The invention belongs to the field of air tightness testing, and particularly relates to an air tightness testing platform and an air tightness testing method for a pneumatic conveying system.
Background
Pneumatic conveying systems are a common method of conveying materials that utilize a gas stream to convey powder, granular or particulate materials from one location to another. The pneumatic conveying system has wide application fields including industrial production, fly ash treatment, cement production, chemical technology and the like, and the traditional material conveying method, such as a screw conveyor, a bucket elevator and the like, has the problems of low speed, easy blockage, large occupied space and the like. While pneumatic conveying systems overcome these problems by utilizing the principle of compressed air or gas flow, it is necessary to ensure a high air tightness of the pneumatic conveying system, since the compressed air or gas is pushed and the leakage of the gas may lead to a reduced system performance, energy loss and possible safety problems.
However, in the prior art, when the air tightness test is performed on the pneumatic conveying system, in order to ensure the test efficiency of the pneumatic conveying system, the pneumatic conveying system is selected to be subjected to the integrity test in most cases, and the pneumatic conveying system is not split into single test elements to be subjected to the test, so that the leakage points in the pneumatic conveying system are difficult to accurately detect; meanwhile, the standard element is not selected for synchronous test and the test data after synchronous test of the standard element are used as references in the current test.
Therefore, we propose an airtight test platform and test method for pneumatic conveying system.
Disclosure of Invention
The invention aims at: the air tightness test platform and the air tightness test method for the pneumatic conveying system are provided to solve the problems that in the air tightness test of the pneumatic conveying system in the prior art, in most cases, an integrity test is selected and a standard element is not selected for synchronous test in the prior art.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
The air tightness test platform for the pneumatic conveying system comprises a data acquisition module, an appearance initial detection module, a scheme making module, a database, an air tightness test module and a display terminal;
The data acquisition module is used for acquiring the appearance information and the equivalent internal volume of the test element in the pneumatic conveying system, sending the appearance information of the test element in the pneumatic conveying system to the appearance primary detection module and sending the equivalent internal volume of the test element to the scheme making module;
the database is used for storing standard element information and element failure rates of test elements with different element models in the pneumatic conveying system;
the appearance primary detection module is used for carrying out primary detection on the appearance condition of the test element, sending the primary detection abnormal signal to the display terminal if the primary detection abnormal signal is generated, and sending the element model of the primary detection qualified element to the air tightness test module and the scheme making module if the primary detection qualified element is obtained through detection;
The scheme making module is used for making an air tightness test task for the primary qualified element in the pneumatic conveying system, obtaining an air tightness test grade corresponding to the primary qualified element and sending test parameters of the air tightness test task to the air tightness test module;
The air tightness test module is used for carrying out air tightness test on the primary qualified element in the pneumatic conveying system, and the test generated element abnormal signal or element normal signal is fed back to the display terminal; the display terminal is used for displaying the initial detection abnormal signal, the element abnormal signal or the element normal signal.
Preferably, the appearance information is specifically a real-time two-dimensional image of the test element at different viewing angles;
The standard element information is the element density of the test elements with different element models, and the element failure rate is the ratio of the failure number to the sales number of the test elements with different element models in the last quarter.
Preferably, the judging process of the test element is specifically as follows:
Step S1: identifying R, G and B components of a target pixel point in a real-time two-dimensional image of the test element at any view angle, and then carrying out graying treatment on the real-time two-dimensional image, namely converting the real-time two-dimensional image of the test element into a gray image;
Step S2: eliminating four or eight connected pixels in the gray image, adding and summing the gray values of adjacent target pixels to obtain an average value as the gray value of the corresponding target pixel;
Step S3: carrying out gray level binarization processing on the gray level image, namely converting the gray level image into a binary image, dividing the gray level image subjected to gray level binarization processing, marking a target pixel point with a gray level value larger than or equal to a gray level threshold value as 1, and marking a target pixel point with a gray level value smaller than the gray level threshold value as 0;
step S4: if a plurality of target pixel points with the binary value of 0 appear and the trend of the target pixel points with the binary value of 0 is a straight line, the continuous target pixel points are determined to be cracks, and the corresponding test element is marked as a primary detection abnormal element;
and S5, if the binary values of the target pixel points in the gray level image are 1, determining that no crack exists in the corresponding test element, and marking the test element as a primary qualified element.
Preferably, the formulation process of the scheme formulation module is specifically as follows:
obtaining an element model of the primary qualified element, and obtaining an element failure rate XXL, element density YM and equivalent internal volume NRJ of the corresponding primary qualified element through the element model;
calculating a test grade value CDZ of the primary qualified element through a formula, wherein the formula is specifically as follows:
; wherein A1 and A2 are proportionality coefficients with fixed values, and the values of A1 and A2 are both larger than 0;
Comparing the test grade value of the primary qualified element with the test grade threshold value, and judging whether the airtight test grade of the primary qualified element corresponding to the airtight test task is a primary airtight test, a secondary airtight test or a tertiary airtight test;
and setting corresponding test parameters for the airtight test task of the primary qualified element according to the airtight test grade.
Preferably, the test strength of the airtight test task corresponding to the first-stage airtight test is smaller than the test strength of the airtight test task corresponding to the second-stage airtight test, and the test strength of the airtight test task corresponding to the second-stage airtight test is smaller than the test strength of the airtight test task corresponding to the third-stage airtight test.
Preferably, the test parameters include a standard test pressure, a first voltage stabilization period, and a second voltage stabilization period when performing the air tightness test task.
Preferably, the standard test pressure corresponding to the first-level airtight test is smaller than the standard test pressure corresponding to the second-level airtight test, and the standard test pressure corresponding to the second-level airtight test is smaller than the standard test pressure corresponding to the third-level airtight test;
The first voltage stabilizing time length corresponding to the primary air tightness test is smaller than the first voltage stabilizing time length corresponding to the secondary air tightness test, and the first voltage stabilizing time length corresponding to the secondary air tightness test is smaller than the first voltage stabilizing time length corresponding to the tertiary air tightness test;
The second voltage stabilizing time period corresponding to the primary air tightness test is smaller than the second voltage stabilizing time period corresponding to the secondary air tightness test, and the second voltage stabilizing time period corresponding to the secondary air tightness test is smaller than the second voltage stabilizing time period corresponding to the tertiary air tightness test.
Preferably, the testing process of the air tightness testing module is specifically as follows:
Step P1, obtaining a test task grade of a primary qualified element, and obtaining standard test pressure, first voltage stabilizing time and second voltage stabilizing time corresponding to the primary qualified element;
Step P2, obtaining the element model of the primary qualified element, selecting a standard element corresponding to the primary qualified element according to the element model, sealing the two ends of the standard element and the primary qualified element, pressurizing the interiors of the standard element and the primary qualified element, and standing for a specified period of time;
if the internal pressures of the standard element and the primary qualified element are different, generating an element abnormal signal;
If the internal pressures of the standard element and the primary qualified element are the same, entering the next step;
Step P3, setting a plurality of time points, and measuring the pressure inside the standard element and the primary qualified element at the time points;
If the difference value of the pressure in the standard element is in the fluctuation interval at all adjacent time points, judging that the pressure in the standard element is in a constant pressure state, adding and summing the pressures at a plurality of time points to obtain a standard constant pressure value in the standard element, and similarly, obtaining a primary detection constant pressure value in the primary detection qualified element, and entering the next step; if the pressure difference value at any adjacent time point is not in the fluctuation interval, judging that the inside of the standard element or the primary qualified element is not in a constant pressure state, and sealing the two ends of the standard element and the primary qualified element again;
step P4, placing the standard element in a standard bin without a connecting component and placing the primary qualified element in a test bin without a connecting component, keeping the standard bin and the test bin sealed, entering a pressurizing stage, opening a total valve, a valve 1 and a valve 2, pressurizing the filling areas of the standard bin and the test bin, and stopping pressurizing until the indication of the pressure sensor 1 reaches the standard test pressure P1;
And P5, synchronously closing the main valve, the valve 1 and the valve 2, entering a pressure stabilizing stage, wherein the pressure stabilizing time is a first pressure stabilizing time, using the pressure sensor 2 to collect the internal pressure of a standard element in a standard bin and using the pressure sensor 3 to collect the internal pressure of a primary qualified element in a test bin, calculating the difference between the pressure sensor 2 and the pressure sensor 3 and taking an absolute value to obtain a first pressure difference value, terminating the test and generating an element abnormal signal if the first pressure difference value is larger than a first pressure difference threshold, and generating an element normal signal if the first pressure difference value is smaller than or equal to the first pressure difference threshold.
Preferably, the testing process of the air tightness testing module further comprises:
Q1, respectively connecting a standard bin with a connecting component, a test bin with the connecting component and a group of future test bins with the connecting component at the tail end of a test pipeline, assembling a test element in the test bin and the standard element in the standard bin through the connecting component, and simultaneously, putting the test element, the standard element and the test pipeline in a communication state;
q2, pressurizing filling areas of the standard bin and the test bin, and standing for a specified period of time;
if the internal pressures of the filling areas in the standard bin and the test bin are different, generating element abnormal signals;
if the internal pressure of the filling areas in the standard bin and the test bin is the same, entering the next step;
q3, setting a plurality of time points, and measuring the pressure of the filling areas in the standard bin and the test bin at the time points;
If the difference value of the pressure in the filling area corresponding to the standard bin at all adjacent time points is in a fluctuation range, judging that the filling area corresponding to the standard bin is in a constant pressure state, adding the pressures at a plurality of time points, summing and averaging to obtain a standard constant pressure value of the filling area corresponding to the standard bin, and similarly, obtaining a standard constant pressure value of the filling area corresponding to the test bin, and then entering the next step; if the difference value of the pressure in the filling area corresponding to the standard bin is not in a fluctuation interval at any adjacent time point, judging that the filling area corresponding to the standard bin or the test bin is not in a constant pressure state, and measuring or resealing the pressure in the filling area corresponding to the standard bin or the test bin;
Step Q4, entering a pressurizing stage, opening a main valve, a valve 1 and a valve 2, pressurizing filling areas of a standard bin and a test bin, and stopping pressurizing until the indication of the pressure sensor 1 reaches the standard test pressure P1;
And Q5, synchronously closing the main valve, the valve 1 and the valve 2, entering a pressure stabilizing stage, wherein the pressure stabilizing time is a second pressure stabilizing time, measuring the pressure of a filling area in a standard bin by using the pressure sensor 2 and the pressure of the filling area in a test bin by using the pressure sensor 3, calculating the difference value between the pressure sensor 2 and the pressure sensor 3, taking an absolute value to obtain a second pressure difference value, terminating the test and generating an element abnormal signal if the second pressure difference value is larger than a second pressure difference threshold, and generating an element normal signal if the second pressure difference value is smaller than or equal to the second pressure difference threshold.
The invention also adopts the following technical scheme:
the air tightness test method for the pneumatic conveying system comprises the following steps of:
s101, collecting appearance information and equivalent internal volume of a test element in a pneumatic conveying system;
Step S102, an appearance primary detection module carries out primary detection on the appearance condition of a test element, and a primary detection abnormal signal is generated or a primary detection qualified element is obtained through detection;
Step S103, formulating an airtight test task of the primary qualified element in the pneumatic conveying system, and obtaining an airtight test grade corresponding to the primary qualified element and test parameters of the airtight test task;
Step S104, performing air tightness test on the primary qualified element in the pneumatic conveying system, and generating an element abnormal signal or an element normal signal through the test;
Step S105, the initial detection abnormal signal, the element abnormal signal or the element normal signal is displayed.
In summary, due to the adoption of the technical scheme, the beneficial effects of the invention are as follows:
According to the invention, the appearance condition of the test element is primarily detected by utilizing the appearance primary detection module, if the primary detection qualified element is obtained, the element model is sent to the air tightness test module and the scheme making module, then the air tightness test task is made for the primary detection qualified element in the pneumatic conveying system by utilizing the scheme making module, the air tightness test grade corresponding to the primary detection qualified element and the test parameters of the air tightness test task are made and obtained, the air tightness test is carried out on the primary detection qualified element in the pneumatic conveying system by the air tightness test module, the abnormal signal of the element or the normal signal of the element is generated by the test, the air tightness test task of the pneumatic conveying system is subjected to the detailed sectional test, and the test data of the standard element which is synchronously tested are used as references, so that the test accuracy of the pneumatic conveying system in the test is ensured.
Drawings
The present invention is further described below with reference to the accompanying drawings for the convenience of understanding by those skilled in the art.
Fig. 1 is an overall system block diagram of the present invention.
Fig. 2 is a schematic structural diagram of four-connected pixels and eight-connected pixels in the present invention.
FIG. 3 is a schematic illustration of the test of the present invention.
Fig. 4 is a schematic diagram of another test of the present invention.
Fig. 5 is a flow chart of the method of the present invention.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in connection with the embodiments, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Example 1: referring to fig. 1-4, the invention provides an air tightness test platform for a pneumatic conveying system, which comprises a data acquisition module, an appearance initial detection module, a scheme making module, a database, an air tightness test module and a display terminal;
When the air tightness test is carried out on the pneumatic conveying system, the air tightness test is carried out on each element in the pneumatic conveying system, so that the air tightness of the pneumatic conveying system is judged, the elements of the pneumatic conveying system specifically comprise conveying pipelines, conveying fans, filters, receivers and the like, and the air tightness of the pneumatic conveying system is less influenced by the conveying fans, the filters, the receivers and the like;
The data acquisition module is used for acquiring the appearance information and the equivalent internal volume of the test element in the pneumatic conveying system, sending the appearance information of the test element in the pneumatic conveying system to the appearance primary detection module and sending the equivalent internal volume of the test element to the scheme making module;
the method comprises the steps that when the real-time two-dimensional images of the test element at different visual angles are actually obtained, the test element is placed under a constant light source, and then the image acquisition equipment is used for acquiring the real-time two-dimensional images of the test element at a plurality of visual angles under the constant light source; because the shapes of the test elements are different, when the equivalent internal volume of the test elements is collected, the opening of the test element is sealed until only one of the test elements remains, then water is injected into the test element until the water in the test element just overflows, the water in the test element is introduced into the measuring cylinder, and the volume of the water is measured as the equivalent internal volume of the test element;
The database is used for storing standard element information and element failure rates of test elements with different element models in the pneumatic conveying system; the standard element information is element density of test elements with different element models, and the element failure rate refers to the ratio of the failure number to the sales number of the test elements with different element models in the last quarter;
The appearance primary detection module is used for carrying out primary detection on the appearance condition of the test element, and the primary detection process is specifically as follows:
Obtaining appearance information of a test element in the pneumatic conveying system, and obtaining real-time two-dimensional images of the test element in the pneumatic conveying system under different visual angles;
Judging whether a crack exists in the real-time two-dimensional image of the test element in the pneumatic conveying system under different visual angles through a crack identification model;
If the real-time two-dimensional image of the test element at any visual angle has cracks, marking the corresponding test element as a primary detection abnormal element and generating a primary detection abnormal signal;
If the real-time two-dimensional images of the test element under all view angles have no cracks, marking the corresponding test element as a primary qualified element, and simultaneously comparing the appearance information of the primary qualified element with standard element information stored in a database to obtain the element model corresponding to the primary qualified element;
the appearance primary detection module sends the element model of the primary detection qualified element to the air tightness test module and the scheme making module, and the appearance primary detection module sends a primary detection abnormal signal to the display terminal;
specifically, the working process of the crack recognition model is specifically as follows:
Step S1: firstly, identifying R, G and B components of a target pixel point in a real-time two-dimensional image of a test element at any view angle, and then carrying out graying treatment on the real-time two-dimensional image, namely converting the real-time two-dimensional image of the test element into a gray image; the preferred processing method in the invention is to select the weighted average of R, G, B components of the target pixel points (xi, yi) as the gray value HD (xi, yi) of the corresponding target pixel point, i is the number of the target pixel point in the real-time two-dimensional image;
optionally, the graying processing method of the RGB image specifically includes:
(1) Selecting a certain value in R, G, B components of the target pixel point (xi, yi) as a gray value of the corresponding target pixel point, namely HD (xi, yi) = { X|X epsilon [ R (xi, yi) G (xi, yi) B (xi, yi) ]};
(2) Selecting the maximum value in R, G, B components of the target pixel point (xi, yi) as a gray value of the corresponding target pixel point, namely HD (xi, yi) =max { R (xi, yi) G (xi, yi) B (xi, yi) };
(3) Selecting the average value of R, G, B components of the target pixel points (xi, yi) as the gray value of the corresponding target pixel points, namely, HDi (xi, yi) = [ R (xi, yi) +G (xi, yi) +B (xi, yi) ]/3;
(4) The weighted average of R, G, B components of the target pixel points (xi, yi) is selected as the gray value of the corresponding target pixel point, and the human eyes have higher sensitivity to the green component and lower sensitivity to the blue component in visual subjectivity, so that the common calculation formula is as follows: HD (xi, yi) =0.2126×r (xi, yi) +0.7152×g (xi, yi) +0.0722×b (xi, yi);
step S2: eliminating four or eight connected pixels in the gray level image, adding and summing the gray level values of adjacent target pixels to obtain an average value as the gray level value of the corresponding target pixel, referring to fig. 2, the four connected pixels refer to the target pixels and the adjacent target pixels being different in color, the adjacent target pixels of the target pixels are the same in color, and the eight connected pixels are the same;
Step S3: the gray level image is subjected to gray level binarization processing, namely the gray level image is converted into a binary image, the gray level image after gray level binarization processing is divided, a target pixel point with a gray level value larger than or equal to a gray level threshold value is marked as 1, and a target pixel point with a gray level value smaller than the gray level threshold value is marked as 0, namely:
; wherein YZ is a gray threshold value, which is obtained by calculating gray change characteristics of a target pixel point (xi, yi) and an adjacent target pixel point, and optionally, a gray value mean value HDJ and a standard deviation BZC of the adjacent target pixel point can be calculated, and HDJ+ZBC or HDJ-BZC can be used as YZ;
Step S4: if a plurality of target pixel points with binary value of 0 appear and the trend of the target pixel points with binary value of 0 is approximately a straight line, then the continuous target pixel points are considered to be cracks, the corresponding test elements are marked as initial detection abnormal elements, when the trend of the target pixel points is judged, the slope of the pixel straight line is formed by the corresponding target pixel points through the coordinates of the plurality of target pixel points, then the standard deviation of the slope of the pixel straight line is calculated, if the standard deviation is smaller than or equal to a first threshold value, the trend of the corresponding target pixel points is considered to be approximately a straight line, if the standard deviation is larger than the first threshold value, the trend of the corresponding target pixel points is not considered to be approximately a straight line, wherein the first threshold value is set by a tester according to experience, and the smaller the first threshold value is, the higher the accuracy of crack judgment is;
Step S5, if the binary values of the target pixel points in the gray level image are 1, the corresponding test element is determined to have no crack, and the test element is marked as a primary qualified element;
the scheme making module is used for making an air tightness test task for the primary inspection qualified element in the pneumatic conveying system, and the making process is specifically as follows:
obtaining an element model of the primary qualified element, and obtaining an element failure rate XXL, element density YM and equivalent internal volume NRJ of the corresponding primary qualified element through the element model;
calculating a test grade value CDZ of the primary qualified element through a formula, wherein the formula is specifically as follows:
; wherein A1 and A2 are proportionality coefficients of fixed values, the values of A1 and A2 are both larger than 0, and it is to be explained that if the failure rate of the element is higher, the testing force of the primary qualified element is improved, if the equivalent internal volume is larger, the volume of the primary qualified element is larger, the internal space of the primary qualified element is larger, the possibility of leakage is far higher than that of the primary qualified element with small volume and small internal space, and meanwhile, if the density of the element is higher, the structural strength of the primary qualified element is higher, and the testing force of the primary qualified element is correspondingly reduced;
If CDZ is less than X1, the airtight test grade of the qualified element corresponding to the airtight test task is a primary airtight test;
if X1 is less than or equal to CDZ and less than X2, the airtight test grade of the primary qualified element corresponding to the airtight test task is a secondary airtight test;
If X2 is less than or equal to CDZ, the airtight test grade of the primary qualified element corresponding to the airtight test task is three-level airtight test; wherein X1 is more than 0 and less than X2, the testing strength of the airtight testing task corresponding to the primary airtight test is smaller than the testing strength of the airtight testing task corresponding to the secondary airtight test, and the testing strength of the airtight testing task corresponding to the secondary airtight test is smaller than the testing strength of the airtight testing task corresponding to the tertiary airtight test;
Setting corresponding test parameters for an airtight test task of the primary qualified element according to the airtight test grade, wherein the test parameters comprise standard test pressure, first voltage stabilizing time and second voltage stabilizing time when the airtight test task is carried out;
For example, the first-stage airtight test sets a standard test pressure P1 to Pa1, a first voltage-stabilizing period T1 to Ta1, and a second voltage-stabilizing period T2 to Ta2; setting standard test pressure P1 as Pb1, setting first voltage stabilizing time period T1 as Tb1 and setting second voltage stabilizing time period T2 as Tb2 in the second-level airtight test; setting standard test pressure P1 as Pc1, setting first voltage stabilizing time period T1 as Tc1, setting second voltage stabilizing time period T2 as Tc2, wherein Pa1 is more than 0 and less than Pc1, ta1 is more than 0 and less than Tb1 and Tc1, and Ta2 is more than 0 and less than Tb2 and Tc2;
The scheme making module sends the air tightness test grade corresponding to the primary qualified element and the test parameter of the air tightness test task to the air tightness test module;
referring to fig. 3-4, the air tightness testing module is configured to perform an air tightness test on a primary qualified component in a pneumatic conveying system, where the primary qualified component corresponding testing device includes a testing pipeline, a group of pressure sources, three groups of valves, three groups of pressure sensors, a group of standard bins with connecting components, a group of standard bins without connecting components, a group of testing bins with connecting components, a group of testing bins without connecting components, and the like, and the testing process is specifically as follows:
Step P1, obtaining a test task grade of a primary qualified element, and obtaining standard test pressure, first voltage stabilizing time and second voltage stabilizing time corresponding to the primary qualified element;
Step P2, obtaining the element model of the primary qualified element, selecting a standard element corresponding to the primary qualified element according to the element model, sealing two ends of the standard element and the primary qualified element, pressurizing the interiors of the standard element and the primary qualified element, standing for a specified period of time, entering the next step if the internal pressures of the standard element and the primary qualified element are the same, and generating an element abnormal signal if the internal pressures of the standard element and the primary qualified element are different;
Wherein, the standard element refers to a test element with the characteristics and parameters confirmed through accurate calibration and verification;
Step P3, setting a plurality of time points, and measuring the pressure inside the standard element and the primary qualified element at the time points;
If the difference value of the pressure in the standard element is in the fluctuation interval at all adjacent time points, judging that the pressure in the standard element is in a constant pressure state, adding and summing the pressures at a plurality of time points to obtain a standard constant pressure value in the standard element, and similarly, obtaining a primary detection constant pressure value in the primary detection qualified element, and entering the next step; if the pressure difference value at any adjacent time point is not in the fluctuation interval, judging that the inside of the standard element or the primary qualified element is not in a constant pressure state, and sealing the two ends of the standard element and the primary qualified element again;
Step P4, as shown in FIG. 3, placing the standard element in a standard bin without a connecting component and placing the primary qualified element in a test bin without a connecting component, keeping the standard bin and the test bin sealed, entering a pressurizing stage, opening a total valve, a valve 1 and a valve 2, pressurizing the filling areas of the standard bin and the test bin, and stopping pressurizing until the indication of the pressure sensor 1 reaches the standard test pressure P1;
step P5, synchronously closing the main valve, the valve 1 and the valve 2, entering a pressure stabilizing stage, wherein the pressure stabilizing time is a first pressure stabilizing time, using the pressure sensor 2 to collect the internal pressure of a standard element in a standard bin and using the pressure sensor 3 to collect the internal pressure of a primary qualified element in a test bin, calculating the difference between the pressure sensor 2 and the pressure sensor 3 and taking an absolute value to obtain a first pressure difference value, terminating the test and generating an element abnormal signal if the first pressure difference value is larger than a first pressure difference threshold, and generating an element normal signal if the first pressure difference value is smaller than or equal to the first pressure difference threshold;
It should be explained that after the gas is injected into the filling area, if the test element has a leakage condition, the pressure in the filling area will enter the test element, and then the pressure in the filling area will decrease, and in practice, the pressure sensor 2 may be configured on the standard element, and the pressure sensor 3 may be configured on the primary qualified element;
as shown in fig. 4, as a further aspect of the present invention, the testing process of the air tightness testing module further includes:
Q1, replacing a standard bin and a test bin, wherein the tail end of a test pipeline is respectively connected with a group of standard bins with connecting components and a group of test bins with connecting components, a test element is assembled in the test bin and the standard element is assembled in the standard bin through the connecting components, and meanwhile, the test element, the standard element and the test pipeline are in a communication state;
Step Q2, pressurizing the filling areas of the standard bin and the test bin, standing for a specified period of time, entering the next step if the internal pressures of the filling areas in the standard bin and the test bin are the same, and generating element abnormal signals if the internal pressures of the filling areas in the standard bin and the test bin are different;
q3, setting a plurality of time points, and measuring the pressure of the filling areas in the standard bin and the test bin at the time points;
If the difference value of the pressure in the filling area corresponding to the standard bin at all adjacent time points is in a fluctuation range, judging that the filling area corresponding to the standard bin is in a constant pressure state, adding the pressures at a plurality of time points, summing and averaging to obtain a standard constant pressure value of the filling area corresponding to the standard bin, and similarly, obtaining a standard constant pressure value of the filling area corresponding to the test bin, and then entering the next step; if the difference value of the pressure in the filling area corresponding to the standard bin is not in a fluctuation interval at any adjacent time point, judging that the filling area corresponding to the standard bin or the test bin is not in a constant pressure state, and measuring or resealing the pressure in the filling area corresponding to the standard bin or the test bin;
Step Q4, entering a pressurizing stage, opening a main valve, a valve 1 and a valve 2, pressurizing filling areas of a standard bin and a test bin, and stopping pressurizing until the indication of the pressure sensor 1 reaches the standard test pressure P1;
Step Q5, synchronously closing the main valve, the valve 1 and the valve 2, entering a pressure stabilizing stage, wherein the pressure stabilizing time is a second pressure stabilizing time, measuring the pressure of a filling area in a standard bin by using the pressure sensor 2 and the pressure of the filling area in a test bin by using the pressure sensor 3, calculating the difference value between the pressure sensor 2 and the pressure sensor 3, taking an absolute value to obtain a second pressure difference value, terminating the test and generating an element abnormal signal if the second pressure difference value is larger than a second pressure difference threshold, and generating an element normal signal if the second pressure difference value is smaller than or equal to the second pressure difference threshold;
It should be explained that, pressurization is performed in the standard element and the primary qualified element, if a leakage condition exists in the test element, the pressures in the standard element and the primary qualified element will enter the corresponding filling area, and then the pressures in the filling area will increase, in practice, the pressure sensor 2 may be configured in the standard bin, and the pressure sensor 3 may be configured in the test bin;
the air tightness test module feeds back an element abnormal signal or an element normal signal to the display terminal;
the display terminal is used for acquiring a primary detection abnormal signal, an element abnormal signal or an element normal signal, prompting a user that the corresponding test element has cracks if the primary detection abnormal signal is received, prompting the user that the test element can leak if the element abnormal signal is received, and prompting the user that the air tightness test of the corresponding test element is qualified if the element normal signal is received;
In the application, if a corresponding calculation formula appears, the calculation formulas are all dimensionality-removed and numerical calculation, and the weight coefficient, the proportion coefficient and other coefficients in the formulas are set to be a result value obtained by quantizing each parameter, so long as the proportion relation between the parameter and the result value is not influenced.
Example 2: based on another concept of the same invention, referring to fig. 5, a method for testing air tightness of a pneumatic conveying system is provided, and the testing method comprises the following steps:
Step S101, a data acquisition module acquires appearance information and equivalent internal volume of a test element in a pneumatic conveying system, sends the appearance information of the test element in the pneumatic conveying system to an appearance primary detection module and sends the equivalent internal volume of the test element to a scheme making module;
Step S102, the appearance initial detection module carries out initial detection on the appearance condition of the test element, if the initial detection abnormal signal is generated, the appearance initial detection module sends the appearance condition to the display terminal, and if the initial detection qualified element is obtained, the element model is sent to the scheme making module;
Step S103, a scheme making module makes an air tightness test task for the primary qualified element in the pneumatic conveying system, and makes an air tightness test grade corresponding to the primary qualified element and test parameters of the air tightness test task to be sent to the air tightness test module;
step S104, the air tightness test module carries out air tightness test on the primary qualified element in the pneumatic conveying system, and the test generates element abnormal signals or element normal signals and feeds the element abnormal signals back to the display terminal;
in step S105, the display terminal displays the initial detection abnormal signal, the element abnormal signal or the element normal signal.
The preferred embodiments of the invention disclosed above are intended only to assist in the explanation of the invention. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best understand and utilize the invention. The invention is limited only by the claims and the full scope and equivalents thereof.
Claims (4)
1. The air tightness test platform for the pneumatic conveying system is characterized by comprising a data acquisition module, an appearance initial detection module, a scheme making module, a database, an air tightness test module and a display terminal;
The data acquisition module is used for acquiring the appearance information and the equivalent internal volume of the test element in the pneumatic conveying system, sending the appearance information of the test element in the pneumatic conveying system to the appearance primary detection module and sending the equivalent internal volume of the test element to the scheme making module, wherein the appearance information is a real-time two-dimensional image of the test element at different visual angles;
the database is used for storing standard element information and element fault rate of test elements with different element models in the pneumatic conveying system, wherein the standard element information is element density of the test elements with different element models, and the element fault rate is the ratio of the fault number to the sales number of the test elements with different element models in the last quarter; the appearance primary detection module is used for carrying out primary detection on the appearance condition of the test element, sending the primary detection abnormal signal to the display terminal if the primary detection abnormal signal is generated, and sending the element model of the primary detection qualified element to the air tightness test module and the scheme making module if the primary detection qualified element is obtained through detection;
The scheme making module is used for making an air tightness test task for the primary qualified element in the pneumatic conveying system, obtaining an air tightness test grade corresponding to the primary qualified element and sending test parameters of the air tightness test task to the air tightness test module;
the scheme making module is specifically arranged as follows:
obtaining an element model of the primary qualified element, and obtaining an element failure rate, element density and equivalent internal volume of the element corresponding to the primary qualified element through the element model;
Calculating a test grade value of the primary qualified element;
Comparing the test grade value of the primary qualified element with the test grade threshold value, and judging whether the airtight test grade of the primary qualified element corresponding to the airtight test task is a primary airtight test, a secondary airtight test or a tertiary airtight test;
Setting corresponding test parameters for an airtight test task of the primary qualified element according to the airtight test grade, wherein the test parameters comprise standard test pressure, first voltage stabilizing time and second voltage stabilizing time when the airtight test task is carried out;
the test strength of the first-level airtight test corresponding to the airtight test task is smaller than the test strength of the second-level airtight test corresponding to the airtight test task, and the test strength of the second-level airtight test corresponding to the airtight test task is smaller than the test strength of the third-level airtight test corresponding to the airtight test task, specifically:
the standard test pressure corresponding to the primary air tightness test is smaller than the standard test pressure corresponding to the secondary air tightness test, and the standard test pressure corresponding to the secondary air tightness test is smaller than the standard test pressure corresponding to the tertiary air tightness test;
The first voltage stabilizing time length corresponding to the primary air tightness test is smaller than the first voltage stabilizing time length corresponding to the secondary air tightness test, and the first voltage stabilizing time length corresponding to the secondary air tightness test is smaller than the first voltage stabilizing time length corresponding to the tertiary air tightness test;
The second voltage stabilizing time length corresponding to the first-stage airtight test is smaller than the second voltage stabilizing time length corresponding to the second-stage airtight test, and the second voltage stabilizing time length corresponding to the second-stage airtight test is smaller than the second voltage stabilizing time length corresponding to the third-stage airtight test;
The air tightness test module is used for carrying out air tightness test on the primary qualified element in the pneumatic conveying system, and the test generated element abnormal signal or element normal signal is fed back to the display terminal; the display terminal is used for displaying the initial detection abnormal signal, the element abnormal signal or the element normal signal;
The test process of the air tightness test module is specifically as follows:
Step P1, obtaining a test task grade of a primary qualified element, and obtaining standard test pressure, first voltage stabilizing time and second voltage stabilizing time corresponding to the primary qualified element;
Step P2, obtaining the element model of the primary qualified element, selecting a standard element corresponding to the primary qualified element according to the element model, sealing the two ends of the standard element and the primary qualified element, pressurizing the interiors of the standard element and the primary qualified element, and standing for a specified period of time;
if the internal pressures of the standard element and the primary qualified element are different, generating an element abnormal signal;
If the internal pressures of the standard element and the primary qualified element are the same, entering the next step;
Step P3, setting a plurality of time points, and measuring the pressure inside the standard element and the primary qualified element at the time points;
If the difference value of the pressure in the standard element is in the fluctuation interval at all adjacent time points, judging that the pressure in the standard element is in a constant pressure state, adding and summing the pressures at a plurality of time points to obtain a standard constant pressure value in the standard element, and similarly, obtaining a primary detection constant pressure value in the primary detection qualified element, and entering the next step; if the pressure difference value at any adjacent time point is not in the fluctuation interval, judging that the inside of the standard element or the primary qualified element is not in a constant pressure state, and sealing the two ends of the standard element and the primary qualified element again;
step P4, placing the standard element in a standard bin without a connecting component and placing the primary qualified element in a test bin without a connecting component, keeping the standard bin and the test bin sealed, entering a pressurizing stage, opening a total valve, a valve 1 and a valve 2, pressurizing the filling areas of the standard bin and the test bin, and stopping pressurizing until the indication of the pressure sensor 1 reaches the standard test pressure P1;
And P5, synchronously closing the main valve, the valve 1 and the valve 2, entering a pressure stabilizing stage, wherein the pressure stabilizing time is a first pressure stabilizing time, using the pressure sensor 2 to collect the internal pressure of a standard element in a standard bin and using the pressure sensor 3 to collect the internal pressure of a primary qualified element in a test bin, calculating the difference between the pressure sensor 2 and the pressure sensor 3 and taking an absolute value to obtain a first pressure difference value, terminating the test and generating an element abnormal signal if the first pressure difference value is larger than a first pressure difference threshold, and generating an element normal signal if the first pressure difference value is smaller than or equal to the first pressure difference threshold.
2. The air tightness test platform for a pneumatic conveying system according to claim 1, wherein the judging process of the test element is specifically as follows:
Step S1: identifying R, G and B components of a target pixel point in a real-time two-dimensional image of the test element at any view angle, and then carrying out graying treatment on the real-time two-dimensional image, namely converting the real-time two-dimensional image of the test element into a gray image;
Step S2: eliminating four or eight connected pixels in the gray image, adding and summing the gray values of adjacent target pixels to obtain an average value as the gray value of the corresponding target pixel;
Step S3: carrying out gray level binarization processing on the gray level image, namely converting the gray level image into a binary image, dividing the gray level image subjected to gray level binarization processing, marking a target pixel point with a gray level value larger than or equal to a gray level threshold value as 1, and marking a target pixel point with a gray level value smaller than the gray level threshold value as 0;
step S4: if a plurality of target pixel points with the binary value of 0 appear and the trend of the target pixel points with the binary value of 0 is a straight line, the continuous target pixel points are determined to be cracks, and the corresponding test element is marked as a primary detection abnormal element;
and S5, if the binary values of the target pixel points in the gray level image are 1, determining that no crack exists in the corresponding test element, and marking the test element as a primary qualified element.
3. A gas tightness test platform for a pneumatic conveying system as set forth in claim 1 wherein said testing process of said gas tightness test module further comprises:
q1, connecting a standard bin with a connecting component and a test bin with a connecting component at the tail end of a test pipeline respectively, assembling a test element in the test bin and the standard element in the standard bin through the connecting component, and simultaneously, enabling the test element, the standard element and the test pipeline to be in a communication state;
q2, pressurizing filling areas of the standard bin and the test bin, and standing for a specified period of time;
if the internal pressures of the filling areas in the standard bin and the test bin are different, generating element abnormal signals;
if the internal pressure of the filling areas in the standard bin and the test bin is the same, entering the next step;
q3, setting a plurality of time points, and measuring the pressure of the filling areas in the standard bin and the test bin at the time points;
If the difference value of the pressure in the filling area corresponding to the standard bin at all adjacent time points is in a fluctuation range, judging that the filling area corresponding to the standard bin is in a constant pressure state, adding the pressures at a plurality of time points, summing and averaging to obtain a standard constant pressure value of the filling area corresponding to the standard bin, and similarly, obtaining a standard constant pressure value of the filling area corresponding to the test bin, and then entering the next step; if the difference value of the pressure in the filling area corresponding to the standard bin is not in a fluctuation interval at any adjacent time point, judging that the filling area corresponding to the standard bin or the test bin is not in a constant pressure state, and measuring or resealing the pressure in the filling area corresponding to the standard bin or the test bin;
Step Q4, entering a pressurizing stage, opening a main valve, a valve 1 and a valve 2, pressurizing filling areas of a standard bin and a test bin, and stopping pressurizing until the indication of the pressure sensor 1 reaches the standard test pressure P1;
And Q5, synchronously closing the main valve, the valve 1 and the valve 2, entering a pressure stabilizing stage, wherein the pressure stabilizing time is a second pressure stabilizing time, measuring the pressure of a filling area in a standard bin by using the pressure sensor 2 and the pressure of the filling area in a test bin by using the pressure sensor 3, calculating the difference value between the pressure sensor 2 and the pressure sensor 3, taking an absolute value to obtain a second pressure difference value, terminating the test and generating an element abnormal signal if the second pressure difference value is larger than a second pressure difference threshold, and generating an element normal signal if the second pressure difference value is smaller than or equal to the second pressure difference threshold.
4. An air tightness test method for a pneumatic conveying system, which is characterized by comprising the following steps of:
s101, collecting appearance information and equivalent internal volume of a test element in a pneumatic conveying system;
Step S102, an appearance primary detection module carries out primary detection on the appearance condition of a test element, and a primary detection abnormal signal is generated or a primary detection qualified element is obtained through detection;
Step S103, formulating an airtight test task of the primary qualified element in the pneumatic conveying system, and obtaining an airtight test grade corresponding to the primary qualified element and test parameters of the airtight test task;
Step S104, performing air tightness test on the primary qualified element in the pneumatic conveying system, and generating an element abnormal signal or an element normal signal through the test;
Step S105, the initial detection abnormal signal, the element abnormal signal or the element normal signal is displayed.
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