基于AVR单片机和曲轴角振动信号的内燃机诊断仪研制
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摘要
发展内燃机测试诊断设备,监测内燃机工作状况,对于确保内燃机运行安全、合理维修、降低成本是非常必要的。目前内燃机曲轴角振动测试诊断设备大多无法长期运行监测内燃机的工作且由于其专业性强而不能满足一般工人的使用要求。为了解决上述问题,本文在研究了目前国内外基于内燃机曲轴角振动故障诊断仪的特点及测试诊断方法的基础上,成功开发了内燃机停缸故障诊断仪器。该仪器集数据采集、数据分析、液晶显示为一体,操作简单并可脱离计算机独立运作,既可手工操作也可制成内置仪表长期监测内燃机状态。主要研究内容和结论如下:
1.根据系统的检测要求和功能需求,提出了基于传感器技术、单片机控制技术的设计策略,确定了仪器的总体设计方案。阐述了利用AVR单片机ATmegal28L实现的曲轴角振动诊断仪的开发方法和开发步骤,其中分析了使用AVR单片机进行角振动信号测量的原理和基于内燃机曲轴角振动信号的故障诊断技术的应用,其中重点研究了齿数对波形分析法的影响。
2.基于模块化的设计思想,完成仪器硬件的开发与设计。仪器以AVR单片机ATmegal28L为核心,由信号采集、信号调理、数据处理以及液晶显示、数据通信等功能模块组成。硬件设计时介绍了主要功能模块的具体设计方案,并给出了主要部分的电路原理图,分析了所用芯片的特点、作用以及模块电路的工作原理。硬件设计遵循测控系统可靠性原则,提出了系统可靠性设计的具体措施,保证系统运行的可靠性。
3.软件程序采用模块化设计思想。在GCC-AVR的编译环境下,完成了系统各模块的软件设计,包括主程序、数据采集程序及通讯程序等功能模块的设计,同时给出了软件流程和编程实现的方法。
4.为了验证仪器的正确性、可靠性及精度,本文进行了实验研究。将仪器与西南交通大学内燃机实验室开发的角振动测量分析系统(PTVM)进行了实验对比。通过实验验证,该仪器对角振动信号的测量分析以及故障诊断是准确可靠的,在内燃机曲轴扭振测量分析和故障诊断等方面具有一定的应用价值。
Development of the testing and diagnostic equipment of I.C. Engine, monitoring working conditions of the I.C. Engine, to ensure the safe operation, reasonable maintenance, reduce costs is essential. Presently the crank angular oscillation test and diagnostic instrument for I.C.Engine is unable the long-term run to monitor the I.C.Engine,and can not satisfy the non-professinal's operation requirement as a result of its specialization. To sove the problem of the current diagnosis system,the text based on the analysis of characteristics of the current and international diagnosis instrument of I.C. Engine and the testing methods, successfully develop a cylinder deactivation instrument. The system integrates data acquisition, data analysis, and liquid crystal displays, it can operate simple and independently from the computer. It can been not only manual operatied but also can been made the built-in instrument for long-term monitor the I.C.Engine.Major study contents and conclusions are as follows:
1.According to the detection system requirements and functional requirements, the strategy based on sensor technology and the single-chip microcomputer control technology has been proposed, and determined the instrument's design project. Elaborated realized the method of exploitation and the development step of the crank angular oscillation diagnostic equipment using AVR monolithic integrated circuit ATmegal28L,selectivly analysis and study the principle of the angular oscillation signal measurement using the AVR monolithic integrated circuit and application of the signal failure diagnosis technology based on the I.C. Engine crank angular oscillation,and study the influence of the number of teeth to the profile analytic method.
2.The instrument hardware development and design has been completed based on the modular design concept. The instrument as the core of ATmega128L,and it is made up of signal acquisition, signal conditioning, signal processing and liquid crystal display, data communications, and other functions module.It introduced the design proposal of the major function module,and has given the main part electric circuit schematic diagram when hardware design. It analysis the characteristics and the role of the main chip and the working principle of circuit modules. The hardware design follows the observation system reliable principle, propose the specific measures of the system reliable design, guarantee the system movement reliability.
3.The software routine uses the modulation design concept.It has been completed, including the main program, data collection procedures and communication procedures, and other functional modules design with the compiler of AVR-GCC.It gives the software flow and the program method.
4. In order to confirm instrument's accuracy, the reliability and the precision, this article has conducted the experimental study.The experiment has been carried on the experiment contrast the instrument with the demarcation angular oscillation survey analysis system(PTVM). The experimental results show that measurement analysis of the vibration signal and fault diagnosis is accurate and reliable and it has a certain value in the measurement and fault diagnosis of I.C. Engine.
1.根据系统的检测要求和功能需求,提出了基于传感器技术、单片机控制技术的设计策略,确定了仪器的总体设计方案。阐述了利用AVR单片机ATmegal28L实现的曲轴角振动诊断仪的开发方法和开发步骤,其中分析了使用AVR单片机进行角振动信号测量的原理和基于内燃机曲轴角振动信号的故障诊断技术的应用,其中重点研究了齿数对波形分析法的影响。
2.基于模块化的设计思想,完成仪器硬件的开发与设计。仪器以AVR单片机ATmegal28L为核心,由信号采集、信号调理、数据处理以及液晶显示、数据通信等功能模块组成。硬件设计时介绍了主要功能模块的具体设计方案,并给出了主要部分的电路原理图,分析了所用芯片的特点、作用以及模块电路的工作原理。硬件设计遵循测控系统可靠性原则,提出了系统可靠性设计的具体措施,保证系统运行的可靠性。
3.软件程序采用模块化设计思想。在GCC-AVR的编译环境下,完成了系统各模块的软件设计,包括主程序、数据采集程序及通讯程序等功能模块的设计,同时给出了软件流程和编程实现的方法。
4.为了验证仪器的正确性、可靠性及精度,本文进行了实验研究。将仪器与西南交通大学内燃机实验室开发的角振动测量分析系统(PTVM)进行了实验对比。通过实验验证,该仪器对角振动信号的测量分析以及故障诊断是准确可靠的,在内燃机曲轴扭振测量分析和故障诊断等方面具有一定的应用价值。
Development of the testing and diagnostic equipment of I.C. Engine, monitoring working conditions of the I.C. Engine, to ensure the safe operation, reasonable maintenance, reduce costs is essential. Presently the crank angular oscillation test and diagnostic instrument for I.C.Engine is unable the long-term run to monitor the I.C.Engine,and can not satisfy the non-professinal's operation requirement as a result of its specialization. To sove the problem of the current diagnosis system,the text based on the analysis of characteristics of the current and international diagnosis instrument of I.C. Engine and the testing methods, successfully develop a cylinder deactivation instrument. The system integrates data acquisition, data analysis, and liquid crystal displays, it can operate simple and independently from the computer. It can been not only manual operatied but also can been made the built-in instrument for long-term monitor the I.C.Engine.Major study contents and conclusions are as follows:
1.According to the detection system requirements and functional requirements, the strategy based on sensor technology and the single-chip microcomputer control technology has been proposed, and determined the instrument's design project. Elaborated realized the method of exploitation and the development step of the crank angular oscillation diagnostic equipment using AVR monolithic integrated circuit ATmegal28L,selectivly analysis and study the principle of the angular oscillation signal measurement using the AVR monolithic integrated circuit and application of the signal failure diagnosis technology based on the I.C. Engine crank angular oscillation,and study the influence of the number of teeth to the profile analytic method.
2.The instrument hardware development and design has been completed based on the modular design concept. The instrument as the core of ATmega128L,and it is made up of signal acquisition, signal conditioning, signal processing and liquid crystal display, data communications, and other functions module.It introduced the design proposal of the major function module,and has given the main part electric circuit schematic diagram when hardware design. It analysis the characteristics and the role of the main chip and the working principle of circuit modules. The hardware design follows the observation system reliable principle, propose the specific measures of the system reliable design, guarantee the system movement reliability.
3.The software routine uses the modulation design concept.It has been completed, including the main program, data collection procedures and communication procedures, and other functional modules design with the compiler of AVR-GCC.It gives the software flow and the program method.
4. In order to confirm instrument's accuracy, the reliability and the precision, this article has conducted the experimental study.The experiment has been carried on the experiment contrast the instrument with the demarcation angular oscillation survey analysis system(PTVM). The experimental results show that measurement analysis of the vibration signal and fault diagnosis is accurate and reliable and it has a certain value in the measurement and fault diagnosis of I.C. Engine.
引文
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[4]徐涛.基于无载测功和转速波动的发动机故障诊断系统.硕士学位论文,大连:大连理工大学.2005,5-6
[5]郭成壁.Geiger扭振记录的分析.国外内燃机车.1973(4):14-27
[6]李善祯,程鹏,辛德杰等.利用AVL657内燃机数据分析系统测量内燃机曲轴的扭转振动.内燃机工程.1994(4):1-5
[7]王吉华.单片机在内燃机瞬态转速测量中的应用.小型内燃机.1997(6)28-31
[8]Halliwell N A,Pickering C T D,Eastwood P G.The Laser Torsional Vibrometer a New Instrument Journal of Sound and Vibration,1984(4):588
[9]向守兵.基于USB的便携式内燃机曲轴角振动信号测量仪器的开发[M].硕士学位论文,成都:西南交通大学.2006,7-9
[10]崔岩,周广仁.瞬时转速测量及求瞬时转速方法浅析.世界海运.1998
[11]齐长远,王爱明等.一种非接触高精度的转速测量方法.微型机与应用.2000.19(12)
[12]伍学奎,陈进,周秩尘内燃机瞬时转速的研究.内燃机学报,1999,17(3)
[13]宋喜奎.测量动态转速的一种方法.内燃机,1998,(5)
[14]胡玉平,吴波.内燃机瞬时转速的波动规律分析.山东工业大学学报.2001(4)
[15]郭文勇,朴甲哲,张永祥.基于瞬时转速的内燃机故障诊断方法.海军工程大学学报.2001,13(6)
[16]姚志斌,沈玉娣.柴油机扭转振动诊断综述.汽车工程.2004,26(2)
[17]Yang Janguo.Fault Detection in a Diesel Engine by Analysing the Instantaneous Angular Speed.Mechanical Systems and Signal Processing,2001,15(3)
[18]刘世元,杜润生,杨叔子.利用转速波动信号诊断内燃机失火故障的研究(2)——波形分析法.内燃机学报.2000(3)
[19]Brown T S,et al.Determination of Engine Cylinder Pressure from Crankshaft Speed Fluctuation.SAE 920463
[20]Rezeka S F,Henein N A.A Diagnostic Technique for the Identification of Misfiring Cylinder(s).SAE 870546
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