Abstract:
A performance testing method of air conditioner, adapted to simultaneously test performance of indoor units and outdoor units on a production line for concurrently assembling the indoor units and outdoor units, the method comprising the steps of: firstly testing operability of indoor unit and leakage of outdoor units; connecting a communication line between the indoor unit and the outdoor unit; connecting a pipe between the outdoor unit and a dummy indoor unit; secondly testing a communicative operation between the indoor unit and the outdoor unit and operability of the outdoor unit; and comprehensively discriminating performances of the indoor unit and outdoor unit according to test data disclosed from the first and second testing procedures.

Description:
CLAIM OF PRIORITY 
     This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application for Performance Testing Method of Air Conditioner earlier filed in the Korean Industrial Property Office on Aug. 5 th  1999 and there duly assigned Ser. No. 32128/1999. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a separation-type air conditioner, and more particularly to a performance testing method of air conditioner adapted to simultaneously test performance of indoor units and outdoor units on a production line for simultaneously assembling the indoor units and outdoor units. 
     2. Description of the Prior Art 
     Generally, a separation-type air conditioner includes an indoor unit and an outdoor unit, where, between the indoor unit and the outdoor unit, there is a communication line for reciprocally receiving and transmitting data of operation state (temperature, humidity, outside temperature, operational frequency, motor revolutions per minute of each indoor unit, etc) and a refrigerant pipe for infusing and discharging refrigerant. 
     A conventional production line for assembling a separation-type air conditioner having a separate indoor unit and outdoor unit is separately equipped with an indoor unit line for assembling the indoor unit and an outdoor unit line for assembling the outdoor unit, and the indoor and outdoor unit lines are respectively mounted with testing systems for checking whether the quality of each set is good or bad. 
     In the conventional production line where the indoor units and outdoor units are separately assembled, a test system of the indoor unit line sequentially performs each test of an indoor unit and comprehensively analyzes the data therefrom to inspect the performance (good or bad quality) of the indoor unit, while a test system of the outdoor unit line sequentially performs each test of the outdoor unit and comprehensively analyzes the data therefrom to inspect the performance (good or bad quality) of the outdoor unit. 
     However, there is a problem in the performance test method of separation-type air conditioner according to the prior art thus described in that production lines are separately installed for the indoor units and the outdoor units, inevitably forcing tests to be done separately for the indoor units and the outdoor units, thereby prolonging an operation time. There is another problem in that investment cost is increased due to overlapped systems. There is still another problem in that in separate testing of indoor units and outdoor units, it is difficult to correctly discriminate the capacity of cooling and heating which results from circulation of coolant flowing between the indoor unit and the outdoor unit. 
     Examples of separation-type air conditioners of the conventional art are seen, for example, in the following U.S. Patents. U.S. Pat. No. 4,526,010, to Sato et al., entitled Separation Type Air Conditioner, describes an air conditioner with indoor, outer and remote controller units at different locations. 
     U.S. Pat. No. 5,191,770, to Kim, entitled Mounting Assembly Of A Separate Type Air-Conditioner, describes an air conditioner with separate indoor and outdoor units affixed to opposite sides of a building wall. 
     U.S. Pat. No. 5,203,178, to Shyu, entitled Noise Control Of Air Conditioner, describes an air conditioning apparatus which performs a test to determine optimum speeds of the motors of the apparatus, to minimize vibration. 
     U.S. Pat. No. 5,824,921, to Kanai, entitled Method And System For Testing Performance Of Refrigeration Units, describes an assembly line having a test line capable of operating an air conditioner in a simulation mode and measuring a physical quantity in this simulation mode. The patent describes testing of the outdoor unit of a separate type air conditioner. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide an improved performance testing method of a separation-type air conditioner. 
     It is a further object of the present invention to provide a more rapid performance testing method of a separation-type air conditioner. 
     A yet further object of the present invention to provide a performance testing apparatus of a separation-type air conditioner, of lower capital cost. 
     A still further object of the present invention is to provide a performance testing apparatus and method which can correctly discriminate the cooling and heating capacity of indoor and outdoor units of the air conditioner. 
     The present invention is disclosed to achieve the above and other objects of the present invention by providing a performance testing method of an air conditioner adapted to simultaneously test performances of indoor units and outdoor units on a production line for simultaneous assembly of the indoor units and the outdoor units, thereby shortening operation time. The present invention reduces investment cost by using a single system. The present invention simultaneously tests the indoor units and outdoor units to thereby increase discrimination capacity. 
     In accordance with the objects of the present invention, there is provided a performance testing method of air conditioner, the method comprising the steps of: 
     firstly testing operability of indoor unit and leakage of outdoor units; 
     connecting a communication line between the indoor unit and the outdoor unit; 
     connecting a pipe between the outdoor unit and a dummy indoor unit; 
     secondly testing a communicative operation between the indoor unit and the outdoor unit and operability of the outdoor unit; and 
     comprehensively discriminating performances of the indoor unit and outdoor unit according to test data disclosed from the first and second testing procedures. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For fuller understanding of the nature and objects of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which: 
     FIG. 1 is a schematic diagram of indoor unit and outdoor unit of a general separation-type air conditioner; 
     FIG. 2 is a block diagram for illustrating a performance testing device of air conditioner according to an embodiment of the present invention; and 
     FIGS. 3 a  and  3   b  are flow charts for respectively illustrating a performance test control operational procedure of air conditioner according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Turning now to the drawings, the general separation-type air conditioner described above includes, as illustrated in FIG. 1, an indoor unit  10  and an outdoor unit  20 , where, between the indoor unit  10  and the outdoor unit  20 , there is a communication line  30  for reciprocally receiving and transmitting data of operation state (temperature, humidity, outside temperature, operational frequency, motor revolutions per minute of each indoor unit, etc) and a refrigerant pipe  40  for infusing and discharging refrigerant. 
     A conventional production line for assembling a separation-type air conditioner having a separate indoor unit  10  and outdoor unit  20  is separately equipped with an indoor unit line for assembling the indoor unit  10  and an outdoor unit line for assembling the outdoor unit  20 , and the indoor and outdoor unit lines are respectively mounted with testing systems for checking whether the quality of each set is good or bad. 
     In the conventional production line where the indoor units  10  and outdoor units  20  are separately assembled, a test system of the indoor unit line sequentially performs each test of an indoor unit  10  and comprehensively analyzes the data therefrom to inspect the performance (good or bad quality) of the indoor unit  10 , while a test system of the outdoor unit line sequentially performs each test of the outdoor unit  10  and comprehensively analyzes the data therefrom to inspect the performance (good or bad quality) of the outdoor unit  20 . 
     However, there is a problem in the performance test method of separation-type air conditioner according to the prior art thus described in that production lines are separately installed for indoor units  10  and the outdoor units  20  inevitably forcing tests to be done separately for the indoor units  10  and the outdoor units  20 , thereby prolonging an operation time. There is another problem in that investment cost is increased due to overlapped systems. There is still another problem in that in separate testing of indoor units  10  and outdoor units  20 , it is difficult to correctly discriminate the capacity of cooling and heating which results from circulation of coolant flowing between the indoor unit and the outdoor unit. 
     A preferred embodiment of the present invention will now be described in detail with reference to the accompanying drawings. Throughout the drawings, like reference numerals and terms are used for designation of like or equivalent parts or portions for simplicity of illustration and explanation. 
     A performance testing device of air conditioner for testing performance of indoor units  10  and outdoor units  20  simultaneously put into testing procedure at a production line for concurrently assembling the indoor units  10  and outdoor units  20  includes, as illustrated in FIG. 2, a bar code reader  100  for reading a bar code of a set (an indoor unit and an outdoor unit) put into the testing procedure, first test procedure means  110  for testing operability of the indoor unit  10  and gas leakage of the outdoor unit  20 , second test procedure means  120  for connecting a communication line between the indoor unit  10  and the outdoor unit  20  and connecting a pipe between the outdoor unit  20  and a dummy indoor unit for testing cooling, heating, communication and operability of the outdoor unit  20 , and performance discriminating means  140  for analyzing data of test set (indoor unit+outdoor unit) as identified by the bar code input from the bar code reader  100  and receiving a test signal output from the first test procedure means  110  or second test procedure means  120  to sequentially process each test of the test set and to comprehensively analyze and discriminate the data, thereby discriminating a good quality or bad quality of the test set, where display means  150  is additionally mounted thereto for displaying good quality or bad quality of the test set according to control signal output from the performance discriminating means  140 , thereby allowing a worker to easily discriminate performance of the indoor unit  10  and the outdoor unit  20 . 
     The first test procedure means  110  includes a gas detector  111  for detecting refrigerant gas of the outdoor unit  20 , an indoor RPM measurer  112  for measuring the revolution rate (RPM) of a motor in the indoor unit  10 , a gas leakage switch, or input device,  113  for manual input of a signal indicating leakage by a worker to checking leakage of gas detected by the gas detector  111 , an operation switch, or input unit,  114  for manual input of an abnormal (bad) operational signal by a worker checking the operational state of the indoor unit  10  (fan, louver, lamp, buzzer and the like), an abnormal room noise switch, or input unit,  115  for manual input of bad noise signal by a worker checking the noise state of the indoor unit  10 , and start/end switches  116  and  117  for allowing a worker to manually input signals of test start and test completion of the first test procedure means  110 . These input units may be, for example, an input unit or key board electrically connected to performance means  140 . 
     The second test procedure means  120  includes an automatic voltage regulator  121  for restricting the changes of power voltage to generate static voltage and low voltage. An automatic voltage regulator is a device for preventing damage to equipment by load due to the generation of overvoltage or low voltage, and for maintaining stability by way of constant voltage. Second test procedure means  120  also includes a power meter  122  for measuring input voltage, current and consumed electricity, a tester  123  for testing voltage resistance, insulation resistance and earthing (grounding) resistance, an outdoor RPM tester  124  for measuring revolutions per minute of a motor in the outdoor unit  20 , a temperature recorder  125  for measuring a temperature difference between an inlet and outlet of dummy indoor unit  135 , a pressure tester  126  for measuring pipe pressure, cooling/heating remote controllers  127  and  128  for cooling or heating the test set, a bad heating switch  129  for manually inputting an “abnormal/bad heating” signal when a worker checks a heating condition when turning on the heating remote controller  128 , an abnormal outdoor noise switch  130  for manual input of an abnormal noise signal by a worker checking a noise condition of the outdoor unit  20 , a bad communication switch  131  for manual input of an abnormal (bad) communication signal by a worker checking a communication condition between the indoor unit  10  and the outdoor unit  20 , and start/end switches  132  and  133  for allowing a worker to manually input signals of test start/end of the second test procedure means  120 . 
     Now, the operational effect of the performance test method of air conditioner thus constructed according to the present invention will be described. FIGS. 3 a  and  3   b  are flow charts for illustrating operation procedures of performance test control for an air conditioner according to the present invention, where reference symbol S indicates step. 
     First of all, when an indoor unit  10  and an outdoor unit  20  are concurrently assembled and put into test procedure, at step S 1 , the bar code reader  100  reads a bar code of a set (indoor unit+outdoor unit) put to the test procedure to thereafter input the bar code data to the performance discriminating means  140 , which in turn analyzes the data of the test set (indoor unit+outdoor unit) as identified by the bar code input from the bar code reader  100 . 
     Successively, at step S 2 , a worker manually manipulates the start switch  116  of the first test procedure means  110  to allow the performance discriminating means  140  to discriminate whether a first test start signal is input, and if the first test start signal is not input (that is, NO at step S 2 ), the method repeatedly performs step S 2 . As a result of the discrimination at step S 2 , if the first test start signal is input (YES at S 2 ), flow of the method advances to step S 3  to start each test of the first test procedure means  110 , where the gas detector  111  at the first test procedure means  110  detects the refrigerant gas of the outdoor unit  20  and the indoor RPM measurer  112  measures the revolution rate of a motor in the indoor unit  10  to input the measured data to the performance discriminating means  140 . 
     Successively, at step S 4 , the performance discriminating means  140  compares the revolution rate of the motor of indoor unit  10  measured by the indoor RPM measurer  112  with the established revolutions per minute of test set identified by bar code to discriminate whether the revolution rate of the motor in the indoor unit  10  is within the allowable range, and if the revolution rate is not within the allowable range (NO at S 41 ), flow of the method advances to step S 41 , where the performance discriminating means  140  discriminates that the revolution rate of the motor in the indoor unit  10  is bad and causes the display means  150  to indicate that the revolution rate of the motor in the indoor unit  10  is bad, thereby terminating the operation (discharge of the set). 
     As a result of the discrimination at step S 4 , if the revolution rate of the motor in the indoor unit  10  is within the allowable range (that is, YES at step S 4 ), flow of the method proceeds to step S 5 , where a worker checks if there is any leakage of gas from the gas detector  111  and the performance discriminating means discriminates whether the gas leakage switch  113  has been manually turned on as a result of the discrimination at step S 5 , and if the gas leakage switch  113  is turned on (YES at step S 5 ), flow of the method advances to step S 51 , where the performance discriminating means  140  discriminates that gas is leaking, and causes the display means  150  to indicate “the gas is leaking” to terminate the operation. 
     Meanwhile, as a result of the discrimination at step S 5 , if the gas leakage switch  113  is not turned on (that is, NO at step S 5 ), flow of the method proceeds to step S 6  to allow a worker to check an operational status of the indoor unit  10  (fan, louver, lamp, buzzer, etc) and performance discriminating means  140  discriminates whether the operation switch  114  is manually turned on. As a result of the discrimination at step S 6 , if the operation switch  114  is turned on (YES at step S 6 ), flow of the method advances to step S 61 , where the performance discriminating means  140  discriminates that the indoor unit  10  is inoperable and causes the display means  150  to indicate that the indoor unit  10  is inoperable and to terminate the operation. 
     Meanwhile, as a result of the discrimination at step S 6 , if the operation switch  114  is not turned on (NO at step S 6 ), flow of the method proceeds to step S 7 , where a worker checks noise state of the indoor unit  10  to decide whether to manually operate the abnormal room noise switch  115 . As a result of the discrimination at step S 7 , if the abnormal room noise switch  115  is turned on (YES in step S 7 ), flow of the method proceeds to step S 71 , where the performance discriminating means  140  discriminates that the indoor unit  10  is bad in terms of noise state and thereby causes the display means  150  to indicate that the indoor unit  10  is bad in noise state, and terminates the operation. 
     Meanwhile, as a result of the discrimination at step S 7 , if the abnormal room noise switch  115  is not turned on (in case of NO), flow of the method advances to step S 8 , where a worker manually manipulates the end switch  117  of the first test procedure means  110  to determine whether a first test end signal is input to the performance discriminating means  140 , and if the signal is not input (that is, in case of NO), step S 8  is repeated. 
     As a result of the discrimination at step S 8 , if the first test end signal is input (in case of YES), flow of the method advances to step S 9  because each test at the first test procedure means  110  has been sequentially progressed through and completed. At step S 9  a worker connects a communication cable between the indoor unit  10  put into the second test procedure means  120  and the outdoor unit  20 . Flow of the method now advances to step S 10  where a pipe is connected between the outdoor unit  20  and the dummy indoor unit  135 . 
     Successively, at step S 11 , a worker decides whether to manually turn on the start switch  132  of the second test procedure means  120  and performance discriminating means  140  discriminates whether a second test start signal has been input, and if the second test start signal is not input (NO in S 11 ), step S 11  is repeated. 
     As a result of discrimination at step S 11 , if the second test start signal is input (YES in step S 11 ), flow of the method proceeds to step S 12  because each test of the second test procedure means  120  should be started, where the tester  123  at the second test procedure means  120  tests voltage resistance, insulation resistance, earthing resistance to input the test values to the performance discriminating means  140 . 
     Successively, at step S 13 , the performance discriminating means  140  compares the voltage resistance, insulation resistance and earthing resistance detected by the tester  123  with the voltage resistance, insulation resistance and earthing resistance set-up value identified by the bar code to discriminate whether the voltage resistance, insulation resistance and earthing resistance are within the allowable limit. 
     As a result of the discrimination at step S 13 , if the voltage resistance, insulation resistance and earthing resistance are not in the allowable range (NO in step S 13 ), flow of the method proceeds to step S 131 , where the performance discriminating means  140  discriminates that the voltage resistance, insulation resistance and earthing resistance are bad to allow the display means  150  to indicate that the voltage resistance, insulation resistance and earthing resistance are bad, thereby terminating the operation. 
     Meanwhile, as a result of the discrimination at step S 13 , if the voltage resistance, insulation resistance and earthing resistances are good (YES at step S 13 ), flow of the method advances to step S 14 , where the worker discriminates whether the cooling remote controller  128  is manually turned on, and if the heating remote controller  128  is not turned on (in case of NO), step S 14  is repeatedly performed. 
     As a result of the discrimination at step S 14 , if the heating remote controller  128  is turned on (in case of YES), flow of the method proceeds to step S 15 , where the performance discriminating means  140  tests a low voltage generated from the automatic voltage regulator  121  at the second test procedure means  120  during the heating operation. 
     Successively, at step S 16 , the performance discriminating means  140  compares the tested low voltage with the low voltage set-up value analyzed by the bar code to discriminate whether the low voltage is within the allowable limit. If the low voltage is not within the allowable range (in case of NO), flow of the method advances to step S 161 , where the performance discriminating means  140  discriminates that the low voltage is bad to cause the display means  150  to indicate that the low voltage is bad, thereby terminating operation. 
     As a result of the discrimination at step S 16 , if the low voltage is within the allowable range (YES at step S 16 ), flow of the method proceeds to step S 17 , where the worker discriminates whether the cooling remote controller  127  is manually turned on, and if the cooling remote controller  127  is not turned on (in case of NO), step S 17  is repeatedly performed. 
     As a result of discrimination at step S 17 , if the cooling remote controller  127  is turned on (in case of YES), flow of the method proceeds to step S 18 , where the performance discriminating means  140  performs a normal cooling operation. At this time, at step S 19 , the outdoor RPM measurer  124  of the second test procedure means  120  measures the revolutions per minute of the motor in the outdoor unit  20 , and the power meter  122  measures consumed power, while the temperature recorder  125  measures a temperature difference between inlet and outlet of the dummy indoor unit  135  disposed in the second test procedure means  120  to record same. 
     Successively, at step S 20 , the performance discriminating means  140  compares the consumed power measured by the power meter  122  with consumed power set-up value recorded for this bar code value, while the temperature recorder  125  compares the temperature difference between inlet and outlet of the dummy indoor unit measured by the temperature recorder  125  with the temperature difference set-up value recorded for this bar code value, to discriminate whether the cooling electricity characteristic is within an allowable range. 
     As a result of the discrimination at step S 20 , if the cooling electricity characteristic is not within the allowable range (in case of NO), flow of the method proceeds to step S 201 , where the performance discriminating means  140  discriminates that cooling is bad to cause the display means  150  to indicate that the cooling is bad and to stop operation. 
     Meanwhile, as a result of the discrimination at step S 20 , if the cooling electricity characteristic is within the allowable range (in case of YES), flow of the method advances to step S 21 , where the worker checks the heating status to discriminate whether the bad heating switch  129  is manually turned on. 
     As a result of the discrimination at step S 21 , if the bad heating switch  129  is turned on (YES at step S 21 ), flow of the method proceeds to step S 211 , where the performance discriminating means  140  discriminates that the heating is bad to cause the display means  150  to indicate that the heating is bad and to terminate the operation. 
     As a result of discrimination at step S 21 , if the bad heating switch  129  is not turned on (NO at step S 21 ), flow of the method proceeds to step S 22 , where the worker checks the noise status of the outdoor unit  20  to determine whether to manually turn on the abnormal outdoor noise switch  130 . 
     As a result of the discrimination at step S 22 , if the abnormal outdoor noise switch  130  is turned on (YES in step S 22 ), flow of the method proceeds to step S 221 , where the performance discriminating means  140  discriminates that the noise status of the outdoor unit  20  is bad to cause the display means  150  to indicate that the noise of the outdoor unit is bad and to terminate the operation. 
     Meanwhile, as a result of the discrimination at step S 22 , if the abnormal outdoor noise switch  130  is not turned on (NO at step S 22 ), flow of the method advances to step S 23 , where the worker checks the communication between the indoor unit  10  and the outdoor unit  20  to thereafter determine whether to manually turn on communication switch  130 . 
     As a result of the discrimination at step S 23 , if the bad communication switch  131  is turned on (YES at step S 23 ), flow of the method proceeds to step S 231 , where the performance discriminating means  140  discriminates that the communication is bad to cause the display means  150  to indicate that the communication is bad and to thereafter terminate the operation. 
     Meanwhile, as a result of the discrimination at step S 23 , if the bad communication switch  131  is not turned on (NO at S 23 ), flow of the method advances to step S 24 , where the worker manually manipulates the end switch  133  at the second test procedure means  120  to determine whether second test end signal is input to the performance discriminating means  140 , and if the signal is not input (NO at S 24 ), step S 24  is repeatedly performed. 
     As a result of the discrimination at step S 24 , if the second test end signal is input (YES at S 24 ), flow of the method advances to step S 25  because each test at the second test procedure means  120  has been sequentially processed and completed. At S 25 , the performance discriminating means  140  discriminates that the set (indoor+outdoor) put to the test process is good in quality thereof to cause the display means  150  to indicate that the set is of good quality and to terminate the operation. 
     Meanwhile, although the preferred embodiment of the present invention has been described with reference to sequential progress of each test at the first test procedure means  110  and the second test procedure means  120 , the present invention is not intended to be restricted to the above embodiment disclosed, which is considered to be purely exemplary. 
     It should be understood that the production line for simultaneously assembling the indoor units  10  and the outdoor units  20  can include other test procedures for testing performances of the indoor units  10  and the outdoor units  20  in addition to the first and second test procedure means  110 ,  120 . 
     As apparent from the foregoing, there is an advantage in the performance testing method of air conditioner thus described according to the present invention in that a production line for simultaneously assembling indoor units and outdoor units and simultaneously testing same performs the testing of the indoor units and outdoor units at the same time, thereby shortening the working hours. 
     There is another advantage in that investment cost is reduced to a unified system. There is still another advantage in that detecting capability is improved because the indoor units and outdoor units are concurrently tested.