分布式实时振动监测系统设计
摘要
旋转机械是电力、石油化工、冶金、机械、航空以及一些军事工业部门的关键设备,对旋转机械状态的监测是保障大型机组安全高效运行、防止恶性事故的有效手段。传统的在线振动监测主要是单机监测模式,即每一台机器由一个监测系统来控制,它的缺点是工作效率低,浪费了大量的人力、物力,而且随着工厂规模的扩大,机器数的增加,这种模式的局限性日益突出。
本文设计了一种分布式振动监测系统,通过总线把分布于各现场的下位机连接起来,达到集中监测、管理、诊断的目的,成功地解决了测点数量多、分布广及监测、操作、管理、诊断困难的问题。它具有可靠性高、扩展灵活、网络互联能力强、系统构成成本低、系统功能强等特点。
系统主要由数据采集及处理模块、CAN总线的网络通信模块和上位机监控模块三部分组成。数据采集及处理模块以TI公司的DSP2407为核心处理器,充分利用其较快的处理速度和强大的外设功能以满足对于振动信号的采集和处理。与上位机的通信采用现场总线中的CAN总线技术,它具有突出的可靠性、实时性和灵活性,能有效地支持分布式系统。上位机与下位机的连接通过可同时操作两个独立的CAN网络的CAN接口卡,并能与上位机编程环境LabVIEW兼容。上位机采用可视化的开发平台LabVIEW,使得监控人机界面更加直观。
系统通过对振动信号进行时域、频域分析,包括实时振动波形,滤波后波形、功率谱、幅值谱、轴心轨迹,能够及时监测旋转机械的运行状况,并预报设备故障。利用LabVIEWSQL Toolkit和Report Generation工具包实现了与数据库的链接和自动生成报表的功能。
课题研究的内容主要有以下几个部分:
(1)基于DSP的数据采集模块设计
以TI公司的TMS320LF2407为下位机核心处理器,实现振动信号的采集与数字信号处理。包括数字滤波和快速傅立叶变换,并设计CAN接口与上位机实现通信。
(2)基于CAN总线的网络通信模块设计
利用现场总线技术的CAN总线构建分布式网络结构并与上位机进行数据传输,包括内部的通信接口程序及外部CAN通信接口程序。编写上位机CAN通信的接收和发送程序。用SQL Server建立网络数据库,存储采集数据。
(3)基于LabVIEW的上位机监控软件设计
利用LabVIEW可视化开发平台,分析处理振动信号并显示结果,包括振动波形、功率谱、幅值谱、轴心轨迹以及显示数据库数据和自动生成报表功能的实现。
Rotating machinery is the critical equipment for the electric power, petroleum and chemical, metallurgy, mechanism, aviation and military department. Monitoring for rotating machinery state is an effective strategy that can insure safe and highly effective running of large equipment as well as avoid malignant accident. The traditional on-line vibration monitoring is mostly single monitoring mode, i.e. one machine is controlled by one monitoring system. Its disadvantage is low efficiency, the wasting of many manpower and material resources and the extrusive limitations of this model with the enlargement of the scale of the factory as well as the increased number of machines.
The article designs a distributed vibration monitoring system which realized the centralizing of monitoring, management, diagnosis through link distributed lower computers by Bus and successfully resolved many problems, just as substantive and widely distributed measuring points, the difficulty of monitoring, operation, management and diagnosis. It has high security, flexibility in expansion, great network ability, low cost and strong functions.
The system is composed of the data acquisition and processing module, network communication module of CAN Bus and monitoring module of the upper computer. The data acquisition and processing module used the DSP2407 as core processor, which had high processing speed and powerful peripheral functions that can satisfied with the acquisition and processing of vibration signal. By using of CAN Bus as communication with upper computer, it has outstanding reliability, celerity as well as flexibility and can effectively support distributed system. The connection between the upper computer and the lower computer can synchronously operate two independent CAN network and CAN interface card and can compatible with LabVIEW. The graphical programmable language LabVIEW adopted by the upper computer can make the monitoring man-machine interface more intuitionistic.
Through the time domain and frequency domain analysis, including real-time vibration wave, wave after filtering, spectrum, amplitude and frequency curve, shaft centerline orbit, the system can timely monitor the operation state of the rotating machinery and forecast equipment failure. By using of LabVIEW SQL Toolkit and Report Generation Toolkit, the data-base interlinkage and auto-creating of report forms were realized.
Investigation and study are made in the following sections:
(1) DSP-Based Data Acquisition and Processing module
By using of TI's TMS320LF2407 as core processor of lower computer, the vibration signal acquisition and digital signal processing were achieved, including digital filtering and fast Fourier transfer, as well as the communication between CAN interface and the upper computer.
(2) Based on CAN Bus network communication module
Using of fieldbus technology of the CAN Bus constructs distributed network and communicates with upper computer, including internal communication interface program and external CAN communication interface program, compiling receiving and sending program of CAN communication, building network database by SQL Server in order to storage acquisition data.
(3) Based on LabVIEW monitoring software design to upper computer
Using of LabVIEW development platform process and display analysis results of vibrationsignals, including power spectrum, amplitude spectrum, shaft centerline orbit and displayingdatabase data and auto-creating report forms.
本文设计了一种分布式振动监测系统,通过总线把分布于各现场的下位机连接起来,达到集中监测、管理、诊断的目的,成功地解决了测点数量多、分布广及监测、操作、管理、诊断困难的问题。它具有可靠性高、扩展灵活、网络互联能力强、系统构成成本低、系统功能强等特点。
系统主要由数据采集及处理模块、CAN总线的网络通信模块和上位机监控模块三部分组成。数据采集及处理模块以TI公司的DSP2407为核心处理器,充分利用其较快的处理速度和强大的外设功能以满足对于振动信号的采集和处理。与上位机的通信采用现场总线中的CAN总线技术,它具有突出的可靠性、实时性和灵活性,能有效地支持分布式系统。上位机与下位机的连接通过可同时操作两个独立的CAN网络的CAN接口卡,并能与上位机编程环境LabVIEW兼容。上位机采用可视化的开发平台LabVIEW,使得监控人机界面更加直观。
系统通过对振动信号进行时域、频域分析,包括实时振动波形,滤波后波形、功率谱、幅值谱、轴心轨迹,能够及时监测旋转机械的运行状况,并预报设备故障。利用LabVIEWSQL Toolkit和Report Generation工具包实现了与数据库的链接和自动生成报表的功能。
课题研究的内容主要有以下几个部分:
(1)基于DSP的数据采集模块设计
以TI公司的TMS320LF2407为下位机核心处理器,实现振动信号的采集与数字信号处理。包括数字滤波和快速傅立叶变换,并设计CAN接口与上位机实现通信。
(2)基于CAN总线的网络通信模块设计
利用现场总线技术的CAN总线构建分布式网络结构并与上位机进行数据传输,包括内部的通信接口程序及外部CAN通信接口程序。编写上位机CAN通信的接收和发送程序。用SQL Server建立网络数据库,存储采集数据。
(3)基于LabVIEW的上位机监控软件设计
利用LabVIEW可视化开发平台,分析处理振动信号并显示结果,包括振动波形、功率谱、幅值谱、轴心轨迹以及显示数据库数据和自动生成报表功能的实现。
Rotating machinery is the critical equipment for the electric power, petroleum and chemical, metallurgy, mechanism, aviation and military department. Monitoring for rotating machinery state is an effective strategy that can insure safe and highly effective running of large equipment as well as avoid malignant accident. The traditional on-line vibration monitoring is mostly single monitoring mode, i.e. one machine is controlled by one monitoring system. Its disadvantage is low efficiency, the wasting of many manpower and material resources and the extrusive limitations of this model with the enlargement of the scale of the factory as well as the increased number of machines.
The article designs a distributed vibration monitoring system which realized the centralizing of monitoring, management, diagnosis through link distributed lower computers by Bus and successfully resolved many problems, just as substantive and widely distributed measuring points, the difficulty of monitoring, operation, management and diagnosis. It has high security, flexibility in expansion, great network ability, low cost and strong functions.
The system is composed of the data acquisition and processing module, network communication module of CAN Bus and monitoring module of the upper computer. The data acquisition and processing module used the DSP2407 as core processor, which had high processing speed and powerful peripheral functions that can satisfied with the acquisition and processing of vibration signal. By using of CAN Bus as communication with upper computer, it has outstanding reliability, celerity as well as flexibility and can effectively support distributed system. The connection between the upper computer and the lower computer can synchronously operate two independent CAN network and CAN interface card and can compatible with LabVIEW. The graphical programmable language LabVIEW adopted by the upper computer can make the monitoring man-machine interface more intuitionistic.
Through the time domain and frequency domain analysis, including real-time vibration wave, wave after filtering, spectrum, amplitude and frequency curve, shaft centerline orbit, the system can timely monitor the operation state of the rotating machinery and forecast equipment failure. By using of LabVIEW SQL Toolkit and Report Generation Toolkit, the data-base interlinkage and auto-creating of report forms were realized.
Investigation and study are made in the following sections:
(1) DSP-Based Data Acquisition and Processing module
By using of TI's TMS320LF2407 as core processor of lower computer, the vibration signal acquisition and digital signal processing were achieved, including digital filtering and fast Fourier transfer, as well as the communication between CAN interface and the upper computer.
(2) Based on CAN Bus network communication module
Using of fieldbus technology of the CAN Bus constructs distributed network and communicates with upper computer, including internal communication interface program and external CAN communication interface program, compiling receiving and sending program of CAN communication, building network database by SQL Server in order to storage acquisition data.
(3) Based on LabVIEW monitoring software design to upper computer
Using of LabVIEW development platform process and display analysis results of vibrationsignals, including power spectrum, amplitude spectrum, shaft centerline orbit and displayingdatabase data and auto-creating report forms.
引文
[1]李大庆.旋转机械振动监测系统的设计与实现[D].北京:北京工业大学,2006
[2]雷凯.旋转机械状态监测系统[D].成都:电子科技大学,2005
[3]王义.分布式在线振动监测网络系统中数据处理技术的应用[D].天津:天津大学,2005
[4]孙双花.分布式在线振动监测网络系统及其通讯接口的设计[D].天津:天津大学,2004
[5]Yang Zhi-Juan,Liang Ye-Wei.Digital system-level diagnosis based on practice[J].Chinese Journal of Computers,1997,20(9):845-848
[6]魏立东.大型旋转机械状态监测故障诊断及网络系统设计[D].大连:大连理工大学,2002
[7]薛婷.分布式在线振动监测网络系统研究及DSP应用[D].天津:天津大学,2003
[8]佟德纯,李华彪.振动监测与诊断[M].上海:上海科学技术文献出版社,1997
[9]周祖德,陈幼平.现代机械制造系统的监控与故障诊断[M].武汉:华中理工大学,1998
[10]盛兆顺,尹琦岭.设备状态监测与故障诊断技术及应用[M].北京:化学工业出版社,2003
[11]陈阳.基于DSP数据采集系统的设计[D].武汉:武汉理工大学,2006
[12]邬宽明.CAN总线原理和应用系统设计[M].北京:北京航空航天大学出版社,1996
[13]Gary.W,Johnson,Richerd Jennings:LabVIEW Graphical programming[M].McGraw Hill Companies,2001
[14]刘雄.转子监测和诊断系统[M].西安:西安交通大学,1991
[15]扈宏杰.DSP控制系统的设计与实现[M].北京:机械工业出版社,2004
[16]张雄伟,曹铁勇.DSP芯片的原理与开发应用[M].北京:电子工业出版社,2001
[17]徐科军,黄云志.定点DSP的原理、开发与应用.北京:清华大学出版社,2002
[18]尹勇,欧光军,关荣锋.DSP集成开发环境CCS使用指南[M].北京:北京航空航天大学出版社,2003
[19]彭启琼,管庆等.DSP集成开发环境CCS及DSPIBIOS的原理与应用[M].北京:电子工业出版社,2004
[20]张雄伟,陈亮.DSP集成开发与应用实例[M].北京:电子工业出版,2002
[21]朱铭皓,赵勇,甘泉.DSP应用系统设计[M].北京:电子工业出版社,2002
[22]彭启琼,李玉柏,管庆.DSP技术的发展与应用[M].北京:高等教育出版社,2002
[23]刘和平,王维俊,江渝.TMS320LF240X DSPC语言开发应用[M].北京:北京航空航天出版社,2003
[24]Mitty C.Plummer.,A New Approach to Balancing[J],South and Vibration,2000,11(4):15-18
[25]TI Co..TMS320LF2407A DSP CONTROLLERS datasheet[OL].http://datasheet.ednchina.com/0/SSSAHSEVSHIAA/Detail.aspx,2003-9
[26]张贤达.现代数字信号处理[M].北京:清华大学出版社,1996
[27]周利清.数字信号处理基础[M].北京:北京邮电大学出版社,2005
[28]和卫星,许波.信号与系统分析[M].西安:西安电子科技大学出版社,2007
[29]杜尚丰,曹晓钟,徐津.CAN总线测控技术及其应用[M].北京:电子工业出版社,2006
[30]Richard Piggin,Ken Young.Machine safety with fieldbus[J].Process engineering,2000,81(5):41-42
[31]侯朝帧.分布式计算机控制系统[M].北京:北京理工大学出版壮,1997
[32]Microchip corporation,Data Sheet MCP2510[OL],http://www.alldatasheet.cn/down/Microchip/201.html,1994-11
[33]Philips Semiconductors,Data Sheet PCA82C250[OL],http://www.ednchina.com/download/327/52935/DownDetail.aspx,1994-11
[34]Reberto Oboe,Paolo Fiorini.A Design and Control Environment for Internet-Based Telerobotics[J].The International Journal of Robotics Research,1998,17(4):433-449
[35]祁晓英.旋转机械虚拟振动测试分析系统研究与开发[D].南京:东南大学,2003
[36]徐超.LabVIEW在实时测控系统中的应用研究[D].重庆:重庆大学,2005
[37]周毅.基于虚拟仪器技术的分布式测控技术研究[D].武汉:华中科技大学,2005
[38]雷振山.LabVIEW 7 EXPRESS实用教程[M].北京:中国铁道出版社,2004
[39]杨乐平.LabVIEW高级程序设计[M].北京:清华大学出版社,2003
[40]J.Y.Z Wang.LabVIEW in engineering laboratory courses[J].Frontiers in Education,2003,(2):5-8
[41]林凯等.基于LabVIEW的多通道振动测试与分析系统[J].清华大学学报,2003,43(5)23-26
[42]吴国新.基于LabVIEW的虚拟振动测试系统[J].北京机械工业学院学报,2000,15(4):30-33
[43]Dr.Peter Athanas,Dr.Mark Jones,Dr.Cameron Patterson.Design and Implementation of an FPGA-based Partially Reconfigurable Network Controller[M],2004
[44]K.A.Lilienkamp,D.L.Trumper:Dynamic Signal Analyzer for Dspace[M],1995
[45]Rbert J.Nibbero:Microprocessers in Instruments and Control[M],1986
[46]韩捷,张瑞林等.旋转机械故障机理及诊断技术[M].北京:机械土业出版社,1998
[47]钟秉林,黄仁.机械故障诊断[M].北京:机械土业出版社,2000
[48]F.LIN,M.P.SCHOEN,U.A.KORDE.Numerical Investigation with rub-Related Vibration in Rotating Machinery[J].Vibration and Control,2001,7(11):32-36
[49]Mitty.C.Plunmer.A Now Approach to Balancing sound and Vibration[J].University of Norse Texas.Denton.Texas.2000,11(9):25-27
[50]张思.振动测试与分析技术[M].北京:清华大学出版社,1992
[51]W.Elsner.A diagnosis scheme for vibration monitoring of steamturbor generators[J].Machine Vibration,1995,4(12):12-15
[2]雷凯.旋转机械状态监测系统[D].成都:电子科技大学,2005
[3]王义.分布式在线振动监测网络系统中数据处理技术的应用[D].天津:天津大学,2005
[4]孙双花.分布式在线振动监测网络系统及其通讯接口的设计[D].天津:天津大学,2004
[5]Yang Zhi-Juan,Liang Ye-Wei.Digital system-level diagnosis based on practice[J].Chinese Journal of Computers,1997,20(9):845-848
[6]魏立东.大型旋转机械状态监测故障诊断及网络系统设计[D].大连:大连理工大学,2002
[7]薛婷.分布式在线振动监测网络系统研究及DSP应用[D].天津:天津大学,2003
[8]佟德纯,李华彪.振动监测与诊断[M].上海:上海科学技术文献出版社,1997
[9]周祖德,陈幼平.现代机械制造系统的监控与故障诊断[M].武汉:华中理工大学,1998
[10]盛兆顺,尹琦岭.设备状态监测与故障诊断技术及应用[M].北京:化学工业出版社,2003
[11]陈阳.基于DSP数据采集系统的设计[D].武汉:武汉理工大学,2006
[12]邬宽明.CAN总线原理和应用系统设计[M].北京:北京航空航天大学出版社,1996
[13]Gary.W,Johnson,Richerd Jennings:LabVIEW Graphical programming[M].McGraw Hill Companies,2001
[14]刘雄.转子监测和诊断系统[M].西安:西安交通大学,1991
[15]扈宏杰.DSP控制系统的设计与实现[M].北京:机械工业出版社,2004
[16]张雄伟,曹铁勇.DSP芯片的原理与开发应用[M].北京:电子工业出版社,2001
[17]徐科军,黄云志.定点DSP的原理、开发与应用.北京:清华大学出版社,2002
[18]尹勇,欧光军,关荣锋.DSP集成开发环境CCS使用指南[M].北京:北京航空航天大学出版社,2003
[19]彭启琼,管庆等.DSP集成开发环境CCS及DSPIBIOS的原理与应用[M].北京:电子工业出版社,2004
[20]张雄伟,陈亮.DSP集成开发与应用实例[M].北京:电子工业出版,2002
[21]朱铭皓,赵勇,甘泉.DSP应用系统设计[M].北京:电子工业出版社,2002
[22]彭启琼,李玉柏,管庆.DSP技术的发展与应用[M].北京:高等教育出版社,2002
[23]刘和平,王维俊,江渝.TMS320LF240X DSPC语言开发应用[M].北京:北京航空航天出版社,2003
[24]Mitty C.Plummer.,A New Approach to Balancing[J],South and Vibration,2000,11(4):15-18
[25]TI Co..TMS320LF2407A DSP CONTROLLERS datasheet[OL].http://datasheet.ednchina.com/0/SSSAHSEVSHIAA/Detail.aspx,2003-9
[26]张贤达.现代数字信号处理[M].北京:清华大学出版社,1996
[27]周利清.数字信号处理基础[M].北京:北京邮电大学出版社,2005
[28]和卫星,许波.信号与系统分析[M].西安:西安电子科技大学出版社,2007
[29]杜尚丰,曹晓钟,徐津.CAN总线测控技术及其应用[M].北京:电子工业出版社,2006
[30]Richard Piggin,Ken Young.Machine safety with fieldbus[J].Process engineering,2000,81(5):41-42
[31]侯朝帧.分布式计算机控制系统[M].北京:北京理工大学出版壮,1997
[32]Microchip corporation,Data Sheet MCP2510[OL],http://www.alldatasheet.cn/down/Microchip/201.html,1994-11
[33]Philips Semiconductors,Data Sheet PCA82C250[OL],http://www.ednchina.com/download/327/52935/DownDetail.aspx,1994-11
[34]Reberto Oboe,Paolo Fiorini.A Design and Control Environment for Internet-Based Telerobotics[J].The International Journal of Robotics Research,1998,17(4):433-449
[35]祁晓英.旋转机械虚拟振动测试分析系统研究与开发[D].南京:东南大学,2003
[36]徐超.LabVIEW在实时测控系统中的应用研究[D].重庆:重庆大学,2005
[37]周毅.基于虚拟仪器技术的分布式测控技术研究[D].武汉:华中科技大学,2005
[38]雷振山.LabVIEW 7 EXPRESS实用教程[M].北京:中国铁道出版社,2004
[39]杨乐平.LabVIEW高级程序设计[M].北京:清华大学出版社,2003
[40]J.Y.Z Wang.LabVIEW in engineering laboratory courses[J].Frontiers in Education,2003,(2):5-8
[41]林凯等.基于LabVIEW的多通道振动测试与分析系统[J].清华大学学报,2003,43(5)23-26
[42]吴国新.基于LabVIEW的虚拟振动测试系统[J].北京机械工业学院学报,2000,15(4):30-33
[43]Dr.Peter Athanas,Dr.Mark Jones,Dr.Cameron Patterson.Design and Implementation of an FPGA-based Partially Reconfigurable Network Controller[M],2004
[44]K.A.Lilienkamp,D.L.Trumper:Dynamic Signal Analyzer for Dspace[M],1995
[45]Rbert J.Nibbero:Microprocessers in Instruments and Control[M],1986
[46]韩捷,张瑞林等.旋转机械故障机理及诊断技术[M].北京:机械土业出版社,1998
[47]钟秉林,黄仁.机械故障诊断[M].北京:机械土业出版社,2000
[48]F.LIN,M.P.SCHOEN,U.A.KORDE.Numerical Investigation with rub-Related Vibration in Rotating Machinery[J].Vibration and Control,2001,7(11):32-36
[49]Mitty.C.Plunmer.A Now Approach to Balancing sound and Vibration[J].University of Norse Texas.Denton.Texas.2000,11(9):25-27
[50]张思.振动测试与分析技术[M].北京:清华大学出版社,1992
[51]W.Elsner.A diagnosis scheme for vibration monitoring of steamturbor generators[J].Machine Vibration,1995,4(12):12-15