基于DSP的便携式轮对探伤装置的研究
摘要
随着世界铁路交通的蓬勃发展,我国铁路交通也进入跨越式发展时代。铁道部先后进行的六次大提速,大大缓解了我国运能与需求的矛盾,铁路运输具有良好的发展前景。但我国铁路安全技术装备水平与发达国家相比仍有较大的差距,设备质量不良的问题仍比较突出。对机车轮对进行探伤,是铁道运输安全非常关注的问题。目前,使用的轮对检测设备系统庞大、工位固定、检测效率低、操作复杂、工人劳动强度大、价格昂贵,难以及时准确的发现轮对存在的问题。
基于声发射技术和DSP数字信号处理技术的便携式轮对探伤装置,一方面可以识别运行状态不良的车辆,进而进行相应车辆检修保障行车安全,为列车事故的防范和预警起到重要作用;另一方面可以规范车辆检修人员对轮对故障的判断,减少人为因素的影响;同时,在诊断可靠性不降低的情况下,可以简化作业,降低成本,具有重要的理论和实际意义。本文对基于DSP的便携式轮对探伤装置进行了开发和应用研究,具体包括以下工作:
1.学习并了解声发射传感器原理,选用一种合适的PVDF声发射传感器;
2.基于DSP技术研制了轮对探伤装置,主要完成声发射信号的采样、调理、存储和分析等功能。
(1)设计了适合PVDF声发射传感器的高阻抗(＞500MΩ)、小电荷量输出的信号调理电路,主要完成模拟信号前置放大、工频陷波、低通滤波和自动增益调节等功能。
(2)采用高精度数字信号处理器TMS320F2812进行程序开发,使之完成数据采样、信号分析及与计算机的串口通讯等功能。
3.基于VC编制设备管理软件,使计算机能够获取、保存、分析信号,实现设备数字化管理。
4.研究DSP的基本原理和数字信号处理算法,尤其是FFT的实现;
5.进行轮对探伤装置的抗干扰设计。
研究结果表明:采用声发射技术和数字信号处理方法,轮对探伤装置一定程度上能够辨别轮对的状态,从而验证了系统的可行性。
With the fast development of railway transport over the world, our railway transport enters into an era of development with great strides. The 6th train speed increasement conducted by Ministry of Railways which greatly abated the contradiction between the transmission demand and the actual transmission capacity. The railway transport foresees a good prospect. But there is still a big ifference on the safety technique and equipment in railway transport, between the developed countries and our country. The quality issue of the device is still an outstanding problem. Crack detection of locomotive wheel-sets is the main point of safety issues in railway transport. The present wheel-sets measurement equipment, which is usually expensive, has huge system, fixed structure, low efficiency, complicated operation method and heavy work for the operator. It is difficult to find the problem of wheel-sets immediately and precisely using such equipment.
The portable wheel-sets detection device is developed on the basis of acoustic emission technology and digital signal processing technology. On one hand, it can identify the vehicle which is in bad running condition, provide reference to relevant maintenance work to assure the running safety and play an important role on the prevention and warning of train accident. On the other hand, it can standardize the definition of fault of different people so as to reduce the personal mistake and at the same time, it can simplify the work, reduce the cost without reducing the reliability, which has important theoretical and practical meaning. This article is about the development of the portable wheel-sets crack detection device based on DSP including the following work:
Firstly, learn the principle of acoustic emission sensors and choose a proper PVDF acoustic emission sensor.
Secondly, a wheel-sets detection device was developed based on the DSP technology which can realize analog signal regulation, data acquisition, digital signal processing and anlysis. A signal regulation circuit was designed, with high impedence, low electricity output to realize the preamplification of the analog signal, industrial frequency pitch, lowpass filter, and automatic amplitude regulation. The application software was designed based on the high precise digital signal processor TMS320F2812, to realize data acquisition, signal analysis and save, wave save and serial communication with computer. Design the device management software in VC, to allow the computer to obtain, save and analyze datas and realize the ditigalized management.
Thirdly, study principle of DSP and digital signal processing arithmetic, expecially the realization of FFT.
At last, do the anti-interference design of the wheel-sets detection device.
The analysis results indicated that by using AE technology and DSP methods, the wheel-sets etection equipment can distinguish the wheel-sets condition in certain degree, thus has confirmed the system feasibility.
基于声发射技术和DSP数字信号处理技术的便携式轮对探伤装置,一方面可以识别运行状态不良的车辆,进而进行相应车辆检修保障行车安全,为列车事故的防范和预警起到重要作用;另一方面可以规范车辆检修人员对轮对故障的判断,减少人为因素的影响;同时,在诊断可靠性不降低的情况下,可以简化作业,降低成本,具有重要的理论和实际意义。本文对基于DSP的便携式轮对探伤装置进行了开发和应用研究,具体包括以下工作:
1.学习并了解声发射传感器原理,选用一种合适的PVDF声发射传感器;
2.基于DSP技术研制了轮对探伤装置,主要完成声发射信号的采样、调理、存储和分析等功能。
(1)设计了适合PVDF声发射传感器的高阻抗(＞500MΩ)、小电荷量输出的信号调理电路,主要完成模拟信号前置放大、工频陷波、低通滤波和自动增益调节等功能。
(2)采用高精度数字信号处理器TMS320F2812进行程序开发,使之完成数据采样、信号分析及与计算机的串口通讯等功能。
3.基于VC编制设备管理软件,使计算机能够获取、保存、分析信号,实现设备数字化管理。
4.研究DSP的基本原理和数字信号处理算法,尤其是FFT的实现;
5.进行轮对探伤装置的抗干扰设计。
研究结果表明:采用声发射技术和数字信号处理方法,轮对探伤装置一定程度上能够辨别轮对的状态,从而验证了系统的可行性。
With the fast development of railway transport over the world, our railway transport enters into an era of development with great strides. The 6th train speed increasement conducted by Ministry of Railways which greatly abated the contradiction between the transmission demand and the actual transmission capacity. The railway transport foresees a good prospect. But there is still a big ifference on the safety technique and equipment in railway transport, between the developed countries and our country. The quality issue of the device is still an outstanding problem. Crack detection of locomotive wheel-sets is the main point of safety issues in railway transport. The present wheel-sets measurement equipment, which is usually expensive, has huge system, fixed structure, low efficiency, complicated operation method and heavy work for the operator. It is difficult to find the problem of wheel-sets immediately and precisely using such equipment.
The portable wheel-sets detection device is developed on the basis of acoustic emission technology and digital signal processing technology. On one hand, it can identify the vehicle which is in bad running condition, provide reference to relevant maintenance work to assure the running safety and play an important role on the prevention and warning of train accident. On the other hand, it can standardize the definition of fault of different people so as to reduce the personal mistake and at the same time, it can simplify the work, reduce the cost without reducing the reliability, which has important theoretical and practical meaning. This article is about the development of the portable wheel-sets crack detection device based on DSP including the following work:
Firstly, learn the principle of acoustic emission sensors and choose a proper PVDF acoustic emission sensor.
Secondly, a wheel-sets detection device was developed based on the DSP technology which can realize analog signal regulation, data acquisition, digital signal processing and anlysis. A signal regulation circuit was designed, with high impedence, low electricity output to realize the preamplification of the analog signal, industrial frequency pitch, lowpass filter, and automatic amplitude regulation. The application software was designed based on the high precise digital signal processor TMS320F2812, to realize data acquisition, signal analysis and save, wave save and serial communication with computer. Design the device management software in VC, to allow the computer to obtain, save and analyze datas and realize the ditigalized management.
Thirdly, study principle of DSP and digital signal processing arithmetic, expecially the realization of FFT.
At last, do the anti-interference design of the wheel-sets detection device.
The analysis results indicated that by using AE technology and DSP methods, the wheel-sets etection equipment can distinguish the wheel-sets condition in certain degree, thus has confirmed the system feasibility.
引文
铩颷1]孙国平,沈志坚.国外机车车辆走行部件无损检测的现状和发展[J].国外机车车辆工艺,1998,(6):1-5.
[2]养祖次郎等.采用表面SH波的车轴超声波探伤法[J].国外机车车辆工艺,2003,9(5):34-39.
[3]H.Wustenberg等.铁路车轮车轴超声波探伤的最新进展[J].国外机车车辆工艺,2002,3(2):1-3.
[4]张黎椿.基于DSP的轮箍表面裂纹电涡流检测系统[D].西安理工大学硕士学位论文,2005.
[5]邱晨.机车轮对超声波智能探伤系统[D].大连铁道学院硕士学位论文,2003.
[6]刘卫华,郁永章,昂海松.气阀故障诊断的实验研究[J].压缩机技术,2001,(2):3-5.
[7]祖淑芝.便携式设备状态监测与诊断系统的研究[D].天津大学硕士学位论文,2004.
[8]Texas Instruments.TMS320F28x DSP Serial Communication Interface(SCI)ReferenceGuide.Literature Number:SPRU051A.
[9]王双维,刘秀环,郝乃澜.以MCS-8098单片机为核心的声发射实验系统的研制[J].物理实验,1997,(6):1-4.
[10]李家伟,陈积懋.无损检测手册[M].机械工业出版社,2002.
[11]刘卫华,郁永章,昂海松.气阀故障诊断的实验研究[J].压缩机技术,2001,(2):3-5.
[12]文常保,卢文科.基于神经网络的压缩机故障诊断[J].压缩机技术,2002,(5):1-4.
[13]王庆锋.基于声发射技术的设备故障检测仪的研制[D].北京工业大学硕士学位论文,2007.
[14]张卫民,王信义,王克勇等.声发射技术在压缩机故障检测中的应用[J].仪表技术与传感器,1999,(6):31-33.
[15]村松博芝,新荻正隆,仲村隆.压电传感器,压电传感器的制造方法和脉搏检测器[P].日本发明专利:专利号,02150498.9,2003-5.
[16]J.L.罗斯.固体中的超声波[M].何存富,吴斌,王秀彦等译.科学出版社,2004:43-65.
[17]Analog Devices.Ultralow Noise,High Speed,BiFET Op Amp AD745.2002.
[18]National Semiconductor Corporation.LMF90 4th-Order Elliptic Filter.1995.
[19]Maxim.8th-Order,Lowpass,Switched-Capacitor Filters.1996.
[20]Texas Instruments.TMS320F2810,TMS320F2812 Digital Signal Processors Data Manual.Literature Number:SPRS1741.
[21]Texas Instruments.TMS320F28x DSP Analog-to-Digital Converter(ADC)ReferenceGuide.Literature Number:SPRU060A.
[22]Analog Devices.256-Position and 33-Position Digital Potentionmeters.2001.
[23]Analog Devices.Low Power,Rail-to-Rail Output Precision JFET Amplifier.2005.
[24]Analog Devices.Ultrafast 4ns Single Supply Comparators.2000.
[25]苏奎峰,吕强等.TMS320F2812原理与开发[M].电子工业出版社,2005.
[26]徐科军,张瀚,陈智渊.TMS320X281x原理与应用[M].北京航空航天大学出版社,2006.
[27]曹军军,陈小勤,吴超.TMS320F2812型数字信号处理器与PC的串行通信[J].国外电子元器件,2005,(8):38-40.
铩颷28]阳宪惠.现场总线技术及应用[M].北京航空航天大学出版社,1999.
[29]杨辉前.基于TMS320F2812的CAN总线通信的设计与实现[J].自动化仪表,2006,(5):28-32.
[30]李宏,张家田.液晶显示器件应用技术[M].机械工业出版社,2004.
[31]刘冬生,曾晓雁.液晶显示控制器SED1330/SED1335/SED1336/E1330的应用[J].电子技术应用,2004(2):71-76.
[32]左韬,艾勇.DSP与液晶接口电路的分析与实现[J].集成电路应用,2005,(1):47-49.
[33]杨保亮,蒲琪,代祥俊.基于TMS320F2812控制的液晶显示屏的设计和实现LJ].山东理工大学学报,2007,21(3):87-89.
[34]陈真诚.MCS-8098与液晶显示控制嚣SED1330的软硬件连接与实现[J].医疗卫生装备,1999,(1):11-13.
[35]张云安,冯志华,王晓峰.双路输出低压差电压调整器TPS767D301及其应用[J].中国电子元器件应用,2006,(7):112-114.
[36]SANYO.Sanyo Lithium Rechargeable Batteries,2002.
[37]Texas Instruments.TPS3305-33 Dual Processor Supervisors.1998.
[38]李驹光,聂雪媛.ARM应用系统开发详解--基于S3CA510B的系统设计[M].清华大学出版社,2003.
[39]尹勇.DSP集成开发环境CCS开发指南[M].北京航空航天大学出版社,2003.
[40]牛景涛.基于DSP实现的数字语音信号处理技术研究[D].西北工业大学硕士学位论文,2003.
[41]SST.2Mbit/4Mbit/8Mbit(×16)Multi-Purpose Flash,SST39VF400A Data Sheet.
[42]胡汉才.单片机原理及其接口技术[M].清华大学出版社,1996.183-192.
[43]姚静毅.基于DSP的数据采集系统的研究和实验声发射信号的检测[D].广西大学硕士学位论文,2005.
[43]刘易平.便携式铁路车辆走行部故障在线诊断系统研究与开发[D].湖南大学硕士学位论文,2005.
[44]应怀樵.波形与频谱分析与随机信号处理[M].中国铁道出版社,1983.65-67.
[45]胡广书.数字信号处理--理论、算法与实现[M].清华大学出版社,2003.
[46]勒希.信号处理原理与应用[M].清华大学出版社,2004.
[47]侯朝焕.实用FFT信号处理技术[M].海洋出版社,1990.
[48]汪晓强.基于DSP的高精度实时电力谐波测量装置的研究[D].福州大学硕士沦文,2004.
[49]吕武.基于浮点DSP的FFT算法的研究和应用[D].北京交通大学硕士学位论文,2005.
[50]陈群阳,戴曙光,穆平安等.DSP系统抗干扰技术的研究[J].仪表技术,2004,(4):60-61.
[51]余祖俊.微机检测与控制应用系统设计[M].北方交通大学出版社,2001.
[52]毛楠.电子电路抗干扰使用技术[M].国防工业出版社,1996.
[53]张松春等.电子控制设备抗干扰技术及其应用[M].机械工业出版社,1995.
[54]黄曙光.铁路车辆轮对参数自动检测技术的研究[D].广东工业大学硕士学位论文,2002.
[2]养祖次郎等.采用表面SH波的车轴超声波探伤法[J].国外机车车辆工艺,2003,9(5):34-39.
[3]H.Wustenberg等.铁路车轮车轴超声波探伤的最新进展[J].国外机车车辆工艺,2002,3(2):1-3.
[4]张黎椿.基于DSP的轮箍表面裂纹电涡流检测系统[D].西安理工大学硕士学位论文,2005.
[5]邱晨.机车轮对超声波智能探伤系统[D].大连铁道学院硕士学位论文,2003.
[6]刘卫华,郁永章,昂海松.气阀故障诊断的实验研究[J].压缩机技术,2001,(2):3-5.
[7]祖淑芝.便携式设备状态监测与诊断系统的研究[D].天津大学硕士学位论文,2004.
[8]Texas Instruments.TMS320F28x DSP Serial Communication Interface(SCI)ReferenceGuide.Literature Number:SPRU051A.
[9]王双维,刘秀环,郝乃澜.以MCS-8098单片机为核心的声发射实验系统的研制[J].物理实验,1997,(6):1-4.
[10]李家伟,陈积懋.无损检测手册[M].机械工业出版社,2002.
[11]刘卫华,郁永章,昂海松.气阀故障诊断的实验研究[J].压缩机技术,2001,(2):3-5.
[12]文常保,卢文科.基于神经网络的压缩机故障诊断[J].压缩机技术,2002,(5):1-4.
[13]王庆锋.基于声发射技术的设备故障检测仪的研制[D].北京工业大学硕士学位论文,2007.
[14]张卫民,王信义,王克勇等.声发射技术在压缩机故障检测中的应用[J].仪表技术与传感器,1999,(6):31-33.
[15]村松博芝,新荻正隆,仲村隆.压电传感器,压电传感器的制造方法和脉搏检测器[P].日本发明专利:专利号,02150498.9,2003-5.
[16]J.L.罗斯.固体中的超声波[M].何存富,吴斌,王秀彦等译.科学出版社,2004:43-65.
[17]Analog Devices.Ultralow Noise,High Speed,BiFET Op Amp AD745.2002.
[18]National Semiconductor Corporation.LMF90 4th-Order Elliptic Filter.1995.
[19]Maxim.8th-Order,Lowpass,Switched-Capacitor Filters.1996.
[20]Texas Instruments.TMS320F2810,TMS320F2812 Digital Signal Processors Data Manual.Literature Number:SPRS1741.
[21]Texas Instruments.TMS320F28x DSP Analog-to-Digital Converter(ADC)ReferenceGuide.Literature Number:SPRU060A.
[22]Analog Devices.256-Position and 33-Position Digital Potentionmeters.2001.
[23]Analog Devices.Low Power,Rail-to-Rail Output Precision JFET Amplifier.2005.
[24]Analog Devices.Ultrafast 4ns Single Supply Comparators.2000.
[25]苏奎峰,吕强等.TMS320F2812原理与开发[M].电子工业出版社,2005.
[26]徐科军,张瀚,陈智渊.TMS320X281x原理与应用[M].北京航空航天大学出版社,2006.
[27]曹军军,陈小勤,吴超.TMS320F2812型数字信号处理器与PC的串行通信[J].国外电子元器件,2005,(8):38-40.
铩颷28]阳宪惠.现场总线技术及应用[M].北京航空航天大学出版社,1999.
[29]杨辉前.基于TMS320F2812的CAN总线通信的设计与实现[J].自动化仪表,2006,(5):28-32.
[30]李宏,张家田.液晶显示器件应用技术[M].机械工业出版社,2004.
[31]刘冬生,曾晓雁.液晶显示控制器SED1330/SED1335/SED1336/E1330的应用[J].电子技术应用,2004(2):71-76.
[32]左韬,艾勇.DSP与液晶接口电路的分析与实现[J].集成电路应用,2005,(1):47-49.
[33]杨保亮,蒲琪,代祥俊.基于TMS320F2812控制的液晶显示屏的设计和实现LJ].山东理工大学学报,2007,21(3):87-89.
[34]陈真诚.MCS-8098与液晶显示控制嚣SED1330的软硬件连接与实现[J].医疗卫生装备,1999,(1):11-13.
[35]张云安,冯志华,王晓峰.双路输出低压差电压调整器TPS767D301及其应用[J].中国电子元器件应用,2006,(7):112-114.
[36]SANYO.Sanyo Lithium Rechargeable Batteries,2002.
[37]Texas Instruments.TPS3305-33 Dual Processor Supervisors.1998.
[38]李驹光,聂雪媛.ARM应用系统开发详解--基于S3CA510B的系统设计[M].清华大学出版社,2003.
[39]尹勇.DSP集成开发环境CCS开发指南[M].北京航空航天大学出版社,2003.
[40]牛景涛.基于DSP实现的数字语音信号处理技术研究[D].西北工业大学硕士学位论文,2003.
[41]SST.2Mbit/4Mbit/8Mbit(×16)Multi-Purpose Flash,SST39VF400A Data Sheet.
[42]胡汉才.单片机原理及其接口技术[M].清华大学出版社,1996.183-192.
[43]姚静毅.基于DSP的数据采集系统的研究和实验声发射信号的检测[D].广西大学硕士学位论文,2005.
[43]刘易平.便携式铁路车辆走行部故障在线诊断系统研究与开发[D].湖南大学硕士学位论文,2005.
[44]应怀樵.波形与频谱分析与随机信号处理[M].中国铁道出版社,1983.65-67.
[45]胡广书.数字信号处理--理论、算法与实现[M].清华大学出版社,2003.
[46]勒希.信号处理原理与应用[M].清华大学出版社,2004.
[47]侯朝焕.实用FFT信号处理技术[M].海洋出版社,1990.
[48]汪晓强.基于DSP的高精度实时电力谐波测量装置的研究[D].福州大学硕士沦文,2004.
[49]吕武.基于浮点DSP的FFT算法的研究和应用[D].北京交通大学硕士学位论文,2005.
[50]陈群阳,戴曙光,穆平安等.DSP系统抗干扰技术的研究[J].仪表技术,2004,(4):60-61.
[51]余祖俊.微机检测与控制应用系统设计[M].北方交通大学出版社,2001.
[52]毛楠.电子电路抗干扰使用技术[M].国防工业出版社,1996.
[53]张松春等.电子控制设备抗干扰技术及其应用[M].机械工业出版社,1995.
[54]黄曙光.铁路车辆轮对参数自动检测技术的研究[D].广东工业大学硕士学位论文,2002.