CN114878111A - Leakage detection method and device for air conditioner heat exchanger - Google Patents
Leakage detection method and device for air conditioner heat exchanger Download PDFInfo
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- 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
- G01M3/32—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 for containers, e.g. radiators
- G01M3/3236—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 for containers, e.g. radiators by monitoring the interior space of the containers
- G01M3/3272—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 for containers, e.g. radiators by monitoring the interior space of the containers for verifying the internal pressure of closed containers
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Abstract
本发明提供一种空调换热器的检漏方法及检漏装置。空调换热器的检漏方法包括封堵换热器的出气口，向换热器充入气体；当获取的第一内压数据是否到达预设值，继续向换热器充入气体并维持第一预设时长；当第二内压数据是否到达预设值停止充气；进行保压测试。检漏装置用于实现上述检漏方法；检漏装置包括进气机构、压力传感器和封堵机构；进气机构包括进气管道和阀体，进气管道的第一端用于与气源连通，进气管道的第二端与换热器的进气口连通，阀体用于控制进气管道的开度；压力传感器用于检测换热器的内压；本发明针对换热器的特殊性，保证保压前内压数据更具准确性，为后续保压测试、计算泄漏率以及判定工件是否合格更准确的依据，提升检漏准确度。
The invention provides a leak detection method and a leak detection device for an air conditioner heat exchanger. The leak detection method of the air-conditioning heat exchanger includes blocking the air outlet of the heat exchanger and filling the heat exchanger with gas; when the acquired first internal pressure data reaches a preset value, continue to fill the heat exchanger with gas and maintain The first preset duration; when the second internal pressure data reaches the preset value, stop inflation; carry out a pressure-holding test. The leak detection device is used to realize the above leak detection method; the leak detection device includes an air intake mechanism, a pressure sensor and a blocking mechanism; the air intake mechanism includes an intake pipe and a valve body, and the first end of the intake pipe is used for communicating with the air source , the second end of the intake pipe is communicated with the intake port of the heat exchanger, the valve body is used to control the opening of the intake pipe; the pressure sensor is used to detect the internal pressure of the heat exchanger; This ensures that the internal pressure data before pressure holding is more accurate, which is a more accurate basis for subsequent pressure holding tests, calculation of leak rates, and determination of whether the workpiece is qualified or not, and improves the accuracy of leak detection.
Description
Technical Field
The invention relates to the technical field of detection methods, in particular to a leak detection method and a leak detection device for an air conditioner heat exchanger.
Background
In the production process of two air conditioners (a condenser and an evaporator), in order to avoid quality accidents of air conditioner refrigerant leakage caused by poor compactness, leakage detection operation needs to be carried out on the two air conditioners.
The leak detection operation comprises a large leak detection operation and a small leak detection operation which are performed in sequence. The operation of detecting the micro leakage is to fill helium gas with a certain pressure into the workpiece, then place the workpiece into a vacuum box, and judge the compactness of the workpiece according to the helium leakage rate. But the leak detection method is mainly used for leak detection of workpieces with helium leakage rate of-6 and below. Workpieces with helium leakage rate of more than-6 cannot use the method for helium detection of the vacuum box, because helium leaked by the workpieces with helium leakage rate of more than-6 can pollute the vacuum box and the surrounding environment, the vacuum box is frequently alarmed by mistake.
The method comprises the following steps of screening a workpiece with helium leakage rate of more than-6 by a leak detection operation on the previous station of a vacuum box helium detection, wherein the leak detection operation is realized on the basis of a pressure difference principle, the common leak detection device mainly comprises an air inlet mechanism, a pressure sensor and a plug mechanism, the plug mechanism seals an air outlet pipeline of the workpiece, the air inlet mechanism is used for maintaining pressure for a period of time after a certain amount of high-pressure gas is filled into the workpiece from the air inlet pipeline of the workpiece, the pressure sensor records the pressure difference between the pressure before and after the pressure maintaining, and then whether the compactness of the workpiece is qualified or not is judged according to the pressure difference.
The existing large leakage detection method has the problems that although the internal pressure of the air conditioner two devices quickly rises to a preset value in the inflation process, and the pressure sensor detects that the internal pressure value reaches the preset value, the pressure sensor enters a pressure maintaining test, but actually, a plurality of bent capillary tubes are arranged in the air conditioner two devices, and the capillary tubes of the air conditioner two devices can be ensured to be filled with gas, so that the pressure detection result after pressure maintaining is influenced, false alarm is easy to occur, the large leakage detection method can only judge that a workpiece to be detected leaks or does not leak, the leakage rate of the workpiece cannot be accurately displayed, and the production quality is not convenient to control.
Disclosure of Invention
The invention mainly aims to provide a leak detection method of an air conditioner heat exchanger aiming at two air conditioners to improve the leak detection accuracy.
The invention also aims to provide a leakage detection device for realizing the leakage detection method of the air conditioner heat exchanger.
The invention mainly aims to provide a leak detection method of an air-conditioning heat exchanger, which comprises the steps of plugging an air outlet of the heat exchanger, and then filling gas into the heat exchanger from an air inlet of the heat exchanger; acquiring first internal pressure data of the heat exchanger, judging whether the first internal pressure data reaches a preset value, if so, continuing to fill gas into the heat exchanger and maintaining the first preset time; acquiring second internal pressure data of the heat exchanger, judging whether the second internal pressure data reaches a preset value, and if so, stopping inflating the heat exchanger; and carrying out pressure maintaining test.
Compared with the universal differential pressure leak detection method in the prior art, the method has the advantages that aiming at the influence caused by the multi-bending structure of the heat exchanger, when the pressure sensor judges that the obtained first internal pressure data reaches the preset value for the first time, the inflation is not stopped at the first time, the pressure maintaining test stage is started, the inflation is kept continuously until the heat exchanger is actually filled with gas, the inflation is stopped, the obtained internal pressure data before the pressure maintaining is more accurate, and the method is a basis for the follow-up pressure maintaining test, the calculation of the leak rate and the judgment of whether a workpiece is qualified or not, so that the leak detection accuracy is improved.
The further scheme is that the step of carrying out pressure maintaining test comprises the steps of obtaining internal pressure data of the heat exchanger before pressure maintaining; obtaining internal pressure data of the heat exchanger after pressure maintaining for a second preset time; and generating leakage rate data according to the internal pressure data before pressure maintaining and the internal pressure data after pressure maintaining.
Therefore, the second internal pressure data and the third internal pressure data obtained after pressure maintaining are more accurate, and the leakage rate data generated by calculation through the second internal pressure data and the third internal pressure data are more accurate.
According to the further scheme, after the step of generating leakage rate data according to the internal pressure data before pressure maintaining and the internal pressure data after pressure maintaining, whether the heat exchanger is qualified in detection or not is judged according to the leakage rate data, and a detection result is generated; and displaying the leakage rate data and/or the detection result on an interface of the terminal equipment.
Therefore, after leakage detection is finished, the control system records the leakage detection result in the system memory, a visual data query interface can be provided, and testers and even users can query all historical detection records, so that quality control in the production process is realized, and the production quality can be traced.
According to the further scheme, after the step of judging whether the heat exchanger is qualified in detection and generating a detection result according to the leakage rate data, the heat exchanger is subjected to evacuation treatment.
From the above, after the leak detection is completed, the pressure release and the vacuum pumping treatment are required to be performed on the heat exchanger to ensure the quality of the heat exchanger and avoid pollution.
And further adopting the scheme that if the judgment result of the step of judging whether the second internal pressure data reaches the preset value is negative, the heat exchanger is evacuated.
Therefore, if the judgment result of the step of judging whether the second internal pressure data reaches the preset value is not, the workpiece of the heat exchanger has a large leakage problem, and the workpiece is judged to be a defective product, so that the pressure relief and vacuum pumping treatment can be directly carried out on the workpiece without carrying out the next pressure maintaining test.
Still further, the first preset time is determined according to the type of the heat exchanger.
As can be seen from the above, the first preset duration is related to the structure of the heat exchanger, and specifically, is related to parameters such as the degree of bending at each position in the heat exchanger, the length of the bent portion, and the size of the cross-sectional area of the bent portion, so that the optimal time value obtained after a limited number of tests for each heat exchanger of different types needs to be used as the first preset duration, thereby ensuring the effectiveness of the delayed inflation operation and avoiding the influence of insufficient inflation on the leak detection result.
The leakage detection device of the air-conditioning heat exchanger provided by the invention is used for realizing the leakage detection method of the air-conditioning heat exchanger; the leakage detection device comprises an air inlet mechanism, a pressure sensor and a plugging mechanism; the air inlet mechanism comprises an air inlet pipeline and a valve body arranged on the air inlet pipeline, the first end of the air inlet pipeline is used for being communicated with an air source, the second end of the air inlet pipeline is used for being communicated with an air inlet of the heat exchanger, and the valve body is used for controlling the opening degree of the air inlet pipeline; the pressure sensor is used for detecting the internal pressure of the heat exchanger; the plugging mechanism is used for plugging the air outlet of the heat exchanger.
According to the leak detection device, when the pressure sensor judges that the acquired first internal pressure data reach the preset value for the first time, inflation is not stopped at the first time to enter a pressure maintaining test stage, inflation is kept continuously until the heat exchanger is actually filled with gas, inflation is stopped, and then the acquired second internal pressure data have higher accuracy, so that a more accurate calculation basis is provided for the subsequent judgment of whether a workpiece is qualified or not and the calculation of the leak rate, and the leak detection accuracy is improved.
The leakage detection device further comprises an evacuation mechanism, wherein the evacuation mechanism comprises a pressure release pipeline and a vacuum pumping pipeline; the pressure relief pipeline is provided with a pressure relief valve, and the vacuumizing pipeline is provided with a vacuumizing valve and a vacuum pump; the pressure release pipeline is communicated with the air inlet pipeline, and the vacuumizing pipeline is communicated with the air inlet pipeline.
Therefore, the evacuation mechanism can effectively release pressure and evacuate the vacuum pipeline and the interior of the workpiece to be detected.
The further scheme is that from the first end to the second end of the air inlet pipeline, the valve body and the pressure sensor are sequentially arranged on the air inlet pipeline.
The further proposal is that the pressure sensor is arranged on the air inlet pipeline close to the air inlet of the heat exchanger.
It can be seen from above that, because the second end of admission line and the air inlet intercommunication that is detected the heat exchanger, the pressure of the second end of admission line equals with the heat exchanger internal pressure, consequently, pressure sensor's the position of setting is close to the second end as far as possible and can be guaranteed the accuracy of detecting the heat exchanger internal pressure.
Drawings
Fig. 1 is a schematic connection diagram of an embodiment of the leak detection device for the air-conditioning heat exchanger and a heat exchanger to be tested.
Fig. 2 is a flow chart of an embodiment of the leak detection method of the air conditioner heat exchanger of the invention.
Detailed Description
Leakage detection device embodiment of air conditioner heat exchanger
Referring to fig. 1, the leak detection device is used for implementing the leak detection method of the air conditioner heat exchanger based on the pressure difference principle. The leakage detection device comprises an air inlet mechanism, a pressure sensor 3, a plugging mechanism and an evacuation mechanism, wherein the air inlet mechanism comprises an air inlet pipeline 1 and an inflation pneumatic valve 2, the plugging mechanism mainly comprises a plugging head (not shown in the figure), and the evacuation mechanism comprises a pressure release pipeline and an evacuation pipeline; the pressure release pipeline is provided with a pressure release pneumatic valve 7, and the vacuumizing pipeline is provided with a vacuumizing pneumatic valve 5 and a vacuum pump 6, wherein the inflating pneumatic valve 2 is a valve body of the vacuum pump, the vacuumizing pneumatic valve 5 is a vacuumizing valve 5 of the vacuum pump, and the pressure release pneumatic valve 7 is a pressure release valve 7 of the vacuum pump.
The first end of the air inlet pipeline 1 is used for being communicated with an air source (not shown in the figure), the air source is a high-pressure air storage tank, the second end of the air inlet pipeline is used for being communicated with an air inlet of the heat exchanger 4, the valve body 2 and the pressure sensor 3 are sequentially arranged on the air inlet pipeline 1 from the first end to the second end of the air inlet pipeline 1, the inflation pneumatic valve 2 is used for controlling the opening degree of the air inlet pipeline 1, the inflation pneumatic valve 2 can realize that constant-pressure air is filled into the heat exchanger 4, the pressure sensor 3 is used for detecting the internal pressure of the heat exchanger 4, the pressure sensor 3 is arranged on the air inlet pipeline 1 and is close to the air inlet of the heat exchanger 4, because the second end of the air inlet pipeline 1 is communicated with the air inlet of the detected heat exchanger 4, the pressure of the second end of the air inlet pipeline 1 is equal to the internal pressure of the heat exchanger 4, therefore, the pressure sensor 3 is disposed as close to the second end as possible, so that the accuracy of detecting the internal pressure of the heat exchanger 4 can be ensured.
The pressure release pipeline provided with the pressure release pneumatic valve 7 is communicated with the air inlet pipeline 1, the vacuumizing pipeline provided with the vacuumizing pneumatic valve 5 and the vacuum pump 6 is communicated with the air inlet pipeline 1, and the air inlet pipeline 1, the vacuumizing pneumatic valve 5 and the vacuum pump 6 are sequentially communicated.
Embodiment of leak detection method of air conditioner heat exchanger
The leakage detection method of the invention utilizes the leakage detection device and is used for carrying out leakage detection work on the air conditioner heat exchanger. The leak detection method mainly comprises a connecting step, an air inflation leak detection step and a workpiece evacuation step which are sequentially carried out.
Referring to fig. 1, firstly, the connection step is mainly to connect the heat exchanger 4 to be detected with the leak detection device, the air outlet of the heat exchanger 4 is blocked by a blocking head, and the air inlet of the heat exchanger 4 is communicated with the second end of the air inlet pipeline 1.
Referring to fig. 1 and 2, in the inflation detection step, step S1 is first executed, the inflation pneumatic valve 2 is opened, and the air source, the air inlet pipe 1 and the detected heat exchanger 4 are sequentially communicated. During the charging process, the internal pressure of the heat exchanger 4 rapidly rises as seen from the degree of the pressure sensor 3. Thereafter, the system performs step S2 to obtain real-time first internal pressure data of the heat exchanger 4 through the pressure sensor 3 and determine that the first internal pressure data is greater than or equal to a preset value, for example, the preset value is 2.8 MPa. If not, the heat exchanger 4 continues to be kept charged and the process continues to decision step S2. On the other hand, if the determination result in step S2 is yes, it indicates that the pressure sensor 3 detects that the internal pressure of the heat exchanger 4 at that time has reached the preset value. In practice, the heat exchanger 4 is not filled with gas at this time.
At this time, the system performs step S3, and keeps charging the heat exchanger 4 for the next 6 seconds without turning off the charging air-operated valve 2. After the 6-second inflation maintaining period is finished, the system performs a determination step S4 to acquire the second internal pressure data of the heat exchanger 4 at that time via the pressure sensor 3 and determine that the first internal pressure data is greater than or equal to the preset value. If the determination result is no, this indicates that the detected heat exchanger 4 still cannot reach the preset pressure value even after the time delay inflation, and the leakage rate of the detected heat exchanger 4 is high, so step S15 is executed, and the system determines that the detection is not qualified and records the detection result.
If the determination result in the step S4 is yes, it indicates that the inside of the heat exchanger 4 including the plurality of bent capillaries is filled with gas and reaches the preset pressure value, and then step S5 is executed to close the charge air-operated valve 2 to stop charging the heat exchanger 4.
The pressure holding test step was then performed: after the step S5 is completed, the charge air valve 2 is closed, the step S6 is executed, and after the pressure sensor 3 acquires the internal pressure data before pressure holding at this time of the heat exchanger 4, the step S7 is executed for 6 seconds, in which the current internal air pressure is maintained, and the pressure is not applied and the pressure is not released. After the pressure holding process is completed for 6 seconds, step S8 is executed to acquire post-pressure-holding internal pressure data of the heat exchanger 4 by the pressure sensor 3.
The system then executes step S9 to calculate a generated leak rate from the difference between the acquired pre-dwell internal pressure data and post-dwell internal pressure data. Further, the leakage amount V is calculated according to the following formula L ：
Wherein, V L Is the leakage amount to be solved (unit: cc/s); delta P is the pressure difference (unit: mmH) generated during the dwell time 2 O), namely the difference value of the internal pressure data before pressure maintaining and the internal pressure data after pressure maintaining; v is the internal volume (unit: cc) of the heat exchanger 4, T is the dwell time length (unit: s), the dwell time length in this example is 6 seconds, P 0 Is atmospheric pressure (unit: mmH) 2 O). Can then be based on the leakage V L The leak rate is converted.
After the step S9 is completed, step S14 is executed to record the calculated leakage rate of the heat exchanger 4 and store the calculated leakage rate in the data table corresponding to the heat exchanger 4; in addition, after the step S9 is completed, a step S10 is executed to determine whether the calculated leakage rate is smaller than a preset value, if so, the leakage rate of the heat exchanger 4 is low, and thus, the step S11 is executed to determine that the heat exchanger 4 is qualified for detection; if not, it indicates that the leakage rate of the heat exchanger 4 is high, so step S15 is executed to determine that the heat exchanger 4 is not qualified. After the determination of whether or not the heat exchanger 4 to be detected is acceptable in step S11 or step S15, step S12 is executed to record the detection result of the heat exchanger 4. When the determination result of step S4 is negative and step S15 is executed, step S12 is also continued.
In addition, after the system records the leakage rate of each heat exchanger 4 through the step S14 and records and stores the detection result of each heat exchanger 4 through the step S12, the system edits and arranges the leakage rate data and the detection result data related to each heat exchanger 4 into a form or a graph which is beneficial to visualization and is displayed on a screen interface of a terminal device used by a leak detector for monitoring or controlling the leak detection system, such as a tablet computer, a computer or a mobile phone, and the like, in addition, the leakage rate data and the detection result data can also be stored in a data list under the air conditioner number, and when a user inputs an air conditioner code through an official query interface to query various detection data of the air conditioner, the leakage rate data and the detection result related to the heat exchanger 4 can be searched. Therefore, the quality control in the production process can be realized, and the traceability of the production quality can also be realized.
After completion of step S12, it is necessary to perform evacuation processing on the detection heat exchanger 4, the evacuation processing including pressure release processing and evacuation processing performed in this order. Pressure relief treatment: the pressure release pneumatic valve 7 is opened to discharge the high-pressure gas in the heat exchanger 4 and the intake pipe 1 to the air, and the pressure release process can be completed in a short time because the high-pressure compressed gas is charged. Vacuumizing treatment: in the pressure relief processing process, the pressure sensor 3 acquires real-time internal pressure data, when the real-time internal pressure data is lower than a preset threshold value, the vacuum pump 6 is started, the vacuumizing pneumatic valve 5 is opened at the same time, and the air inlet pipeline, the pressure relief pipeline, the vacuumizing pipeline and the heat exchanger 4 are vacuumized.
The following table 1 shows data obtained after a group of tested heat exchangers with different leakage degrees are tested in the leakage detection device by the leakage detection method. The equivalent internal volumes of the plurality of heat exchangers are all 5L, the pressure maintaining time is all 6S, and the pressure difference in the following table refers to the difference value between the internal pressure data before pressure maintaining and the internal pressure data after pressure maintaining.
| Dwell time | Pressure difference | Leakage rate |
| 6S | 1KPa | 8.07E-6 |
| 6S | 5KPa | 4.03E-5 |
| 6S | 12KPa | 9.68E-5 |
| 6S | 20KPa | 1.61E-4 |
TABLE 1 leak Rate conversion record Table
Compared with the prior art for detecting the leakage of the conventional inner contour workpiece by using the pressure difference, the method disclosed by the invention has the advantages that aiming at the influence caused by the multi-bending structure of the heat exchanger, when the pressure sensor judges that the obtained first internal pressure data reaches the preset value for the first time, the inflation is not stopped at the first time, the inflation is stopped until the heat exchanger is actually filled with gas, the inflation is stopped, the obtained internal pressure data before the pressure maintaining is more accurate, and the method is a more accurate basis for subsequent pressure maintaining test, calculation of the leakage rate and judgment of whether the workpiece is qualified or not, so that the leakage detection accuracy is improved.
Finally, it should be emphasized that the above-described preferred embodiments of the present invention are merely examples of implementations, rather than limitations, and that many variations and modifications of the invention are possible to those skilled in the art, without departing from the spirit and scope of the invention.
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| CN118464316A (en) * | 2024-07-10 | 2024-08-09 | 烟台至公生物医药科技有限公司 | Leak detection method and system based on helium mass spectrometer leak detector |
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Denomination of invention: Air conditioning heat exchanger leak detection methods and leak detection devices Granted publication date: 20230818 Pledgee: Bank of Communications Ltd. Zhuhai branch Pledgor: GREE ELECTRIC APPLIANCES,Inc.OF ZHUHAI Registration number: Y2025980062030 |