In order to ensure the pressure balance inside the fuel tank and avoid oil leakage, gasoline-electric hybrid new energy vehicles need to conduct a sealing test on their fuel tank caps. However, due to the special shape of the fuel tank caps of new energy vehicles, sealing testing becomes a difficult problem.This time, Hairis Technology will demonstrate a new fuel tank cap sealing tester, which has performed well in testing the fuel tank cap sealing of new energy vehicles. The following is an application example of the tester.
1. Analysis of the appearance of new energy vehicle fuel tank caps
The picture above is the new energy vehicle fuel tank cap that Hairuis Technology needs to inspect this time. It has a disc structure as a whole, with a raised corner, and both upper and lower sides are uneven and have edge grooves.There are 90-degree zigzag vents on the upper part, which mainly adjust the air pressure of the fuel tank. Therefore, the fuel tank cap is not fully sealed. We need to seal the vents during inspection.The lower part is sealed, which is the focus of inspection. However, the fuel tank cap with a single-sided structure cannot be directly inspected, which is a difficulty in the inspection plan.
2. Sealing requirements and key points of new energy vehicle fuel tank caps
1. Ensure that the products during testing are not contaminated, damaged, or blocked in pores, etc.
2. The product has an irregular shape and a disc structure. It focuses on testing the sealing performance of the lower part of the fuel tank cap. Therefore, direct testing cannot be used and indirect testing is required.
3. Realize detection data monitoring and statistics, provide scientific basis for later production adjustments, and achieve effective monitoring and improvement of defective products.
4. The customer required dual-station tooling inspection. One operator can operate two products for inspection at the same time to improve inspection efficiency and boost production capacity.
3. Breakthrough in the sealing of new energy vehicle fuel tank caps
In order not to cause damage and pollution to new energy vehicle fuel tank caps during testing, Hairis Technology integrated indirect detection methods and customized specific molds for new energy vehicle fuel tank caps to assist in non-destructive testing.Below is a real photo of the mold.
Hairis Technology Co., Ltd.The detector is divided into three parts: tester, air source, and tooling.Because the tester, air source, and tooling are independent entities, in order to achieve dual-station testing, Hairis Technology equipped it with two sealing testers, and we designed the tester in a cabinet shape to scientifically design the instrument space, reduce the floor space, and facilitate operation.
This instrument can be equipped with molds and corresponding tooling according to different product shapes or details to meet the needs for testing different products.It can not only improve the use value of the sealing tester, but also facilitate the manufacturer's equipment deployment and reduce the investment in testing equipment.The following isHairis TechnologyNew energy vehicle fuel tank cap sealing dual-station detector.
4. Operation steps of new energy vehicle fuel tank cap sealing tester
The first step in testing is to set the instrument's data. After setting once, the data can be used, which simplifies the testing process.Because of this dual-station detector, we need to set relevant detection parameters for the two instruments respectively.The instrument has"Positive, negative"two pressure forms, and8There are three basic test modes, which can be selected individually or combined.use24BitA/Dconversion,32BitCPUComputing, and completely independently developed industrial control operating system, with full touch human-computer interaction interface.built-inRS232serial port,RJ45network port,USBcommunication interface,LTPexternalI/OThe control port supports multiple communication protocols, which enhances the operability of the equipment and improves the manufacturer’s detection efficiency.
The second step is to put the new energy vehicle fuel tank caps that need to be tested into two molds respectively. After the tester is started, the upper and lower molds will be closed, and then the air source will inflate the new energy vehicle fuel tank cap mold. The precision pressure sensor of the new energy vehicle fuel tank cap sealing detection equipment senses the change in air pressure in the mold, and will transmit the value of the air pressure change to the detection system and display it. We can clearly see the change in the air pressure value on the instrument.
The third step is to enter the pressure stabilization stage. At this stage, we do not need to operate. We can just wait for the air pressure to stabilize on its own. The pressure sensor can calculate the gas leakage value through a series of calculations according to the changes in air pressure. According to the leakage value, the gas leakage value can be detected.GPSRadar locator anti-performance andIPWaterproof level, the following is a detailed picture of the test.
The above content is the application demonstration of Hairis Technology's new energy vehicle fuel tank cap sealing tester. This instrument has realized dual-station and multi-station detection and can be customized according to user needs.The instrument can not only test the sealing of new energy fuel tank caps, but also has applications in testing the sealing, waterproofness and air tightness of charging guns, car lights, wiring harnesses, spare parts, etc. See the application solutions in previous cases.
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