基于FPGA的精密激光测径仪的开发
摘要
测量是机械工业生产中的一个必经过程,它作为质量控制的一个重要依据,关系着产品品质的提高和设备制造的发展。在机械产品的测量领域,尺寸的测量是最重要,也是最普遍的内容。而在尺寸测量里,轴类零件的直径测量应用最多,涉及的领域也最广泛,例如车床的丝杠、导轨、汽车的曲轴、转向阀的阀芯等等。目前常见的车床丝杠精度通常在20-50μm左右,汽车转向阀阀芯的精度甚至控制在7-10gm以内,可见,轴类零件的直径测量不仅普遍,而且测量精度也往往要求较其他零件高。
传统的测量方式由于其精度低,受人为因素影响较大,往往不能满足高精度轴类零件直径测量的要求。随着非接触测量技术的发展,尤其是激光测量技术的出现,结合CCD应用技术和EDA技术,将尺寸测量引入一个新的时代,激光测径仪越来越多地应用在轴类零件的直径测量领域。
本文首先规划了激光测径的方案,按照机械机构和硬件电路两个方向进行了布局。搭建了用于测量的光学机械结构,并对硬件测量的基本电路做了相关设计。
本文着重研究了基于FPGA的直径测量方法,通过使用硬件描述语言VerilogHDL完成了从CCD驱动、数据采集、处理、数制转化、显示等几个过程的模块设计。首先使用CCD驱动模块实现CCD视频信号的正常输出,通过片内的信号采集和处理模块控制外围电路的模数转化功能,并将结果送入片内进行处理、计算,获得的结果通过数据缓存、数制转换等一系列过程后送入显示模块,并最终控制液晶屏显示测量结果。
设计完成后,通过一系列的实验对激光测径仪的各个设计部分进行调试,并通过对标准试样的测量验证了激光测径仪的精度和可靠性。
Measurement is a necessary course in the production of the mechanical industry, it is an important basis of quality control that relate to the improvement of product quality and development of equipment manufacturing. In the field of the measurement of mechanical products, size measurement is the most important and popular content. And in size measurement, the diameter measurement of the axial parts is applied the most, the fields it involves the most widely also. For example the lathe screw, lead rail, crankshaft, trim of the steering valve, etc. The precision of the most common lathe screw in20to50μm or so, even the trim of the steering valve is controlled less than7～10μm. Thus, the diameter measurement of the axial parts is not only common, and also required higher measure precision than other parts.
Because of its low precision and influence by human, the traditional way to measure can't meet the high precision requirements of axial parts diameter measurement. With the development of non-contact measurement technology, especially the appears of the laser measurement technology, combined with CCD application technology and EDA technology, size measurement is coming to a new time, laser diameter gauge is more and more applied in the field of diameter measurement of axial parts.
This paper first planed the laser diameter gauge, and layout according to the two direction of mechanism and the hardware circuit. It build the optical measuring mechanical structure, and designed the relevant basic circuit of measuring.
This paper focuses on the diameter measurement method based on FPGA, by the use of hardware description language Verilog HDL, it accomplished the module design of process from the CCD drive to data acquisition, processing, transformation and display. Firstly using CCD driver module to realize CCD video signal output normally, through the signal acquisition and processing module to control the function of outer circuit, and send the the result to processing and calculating, the obtained results then sent into display module after a series of process of data cache and conversion, and controlled the measuring results to display on the LCD ultimately.
After the completion of the design, it debugged each part of the laser diameter gauge through a series of experiments, and verify the precision and reliability of the laser caliper gauge through standard sample measuring.
传统的测量方式由于其精度低,受人为因素影响较大,往往不能满足高精度轴类零件直径测量的要求。随着非接触测量技术的发展,尤其是激光测量技术的出现,结合CCD应用技术和EDA技术,将尺寸测量引入一个新的时代,激光测径仪越来越多地应用在轴类零件的直径测量领域。
本文首先规划了激光测径的方案,按照机械机构和硬件电路两个方向进行了布局。搭建了用于测量的光学机械结构,并对硬件测量的基本电路做了相关设计。
本文着重研究了基于FPGA的直径测量方法,通过使用硬件描述语言VerilogHDL完成了从CCD驱动、数据采集、处理、数制转化、显示等几个过程的模块设计。首先使用CCD驱动模块实现CCD视频信号的正常输出,通过片内的信号采集和处理模块控制外围电路的模数转化功能,并将结果送入片内进行处理、计算,获得的结果通过数据缓存、数制转换等一系列过程后送入显示模块,并最终控制液晶屏显示测量结果。
设计完成后,通过一系列的实验对激光测径仪的各个设计部分进行调试,并通过对标准试样的测量验证了激光测径仪的精度和可靠性。
Measurement is a necessary course in the production of the mechanical industry, it is an important basis of quality control that relate to the improvement of product quality and development of equipment manufacturing. In the field of the measurement of mechanical products, size measurement is the most important and popular content. And in size measurement, the diameter measurement of the axial parts is applied the most, the fields it involves the most widely also. For example the lathe screw, lead rail, crankshaft, trim of the steering valve, etc. The precision of the most common lathe screw in20to50μm or so, even the trim of the steering valve is controlled less than7～10μm. Thus, the diameter measurement of the axial parts is not only common, and also required higher measure precision than other parts.
Because of its low precision and influence by human, the traditional way to measure can't meet the high precision requirements of axial parts diameter measurement. With the development of non-contact measurement technology, especially the appears of the laser measurement technology, combined with CCD application technology and EDA technology, size measurement is coming to a new time, laser diameter gauge is more and more applied in the field of diameter measurement of axial parts.
This paper first planed the laser diameter gauge, and layout according to the two direction of mechanism and the hardware circuit. It build the optical measuring mechanical structure, and designed the relevant basic circuit of measuring.
This paper focuses on the diameter measurement method based on FPGA, by the use of hardware description language Verilog HDL, it accomplished the module design of process from the CCD drive to data acquisition, processing, transformation and display. Firstly using CCD driver module to realize CCD video signal output normally, through the signal acquisition and processing module to control the function of outer circuit, and send the the result to processing and calculating, the obtained results then sent into display module after a series of process of data cache and conversion, and controlled the measuring results to display on the LCD ultimately.
After the completion of the design, it debugged each part of the laser diameter gauge through a series of experiments, and verify the precision and reliability of the laser caliper gauge through standard sample measuring.
引文
[1]花国梁,李岩.精密测量技术[M].北京：中国计量出版社,2001.
[2]尹中会,李春.CCD技术在工业非接触测量中的应用[J].煤矿机电,2011,(2)：112-113.
[3]Kazuhiko Ishikawa, Hitomi Yamanob, Katsuhiko Asada, etal. Real-time measurement of a thickness of a thin coating by means of sheet laser. Optics and Lasers in Engineering.2004, (41):730-742.
[4]Alvarez, Israel. Length measurement of plates using CCD's[C]. IEEE Instrumentation and Measurement Technology Conference, May2001:941-944.
[5]http://www.betalasermike.com.
[6]http://www.zumbach.com.
[7]http://china.keyence.com/products/measure/micrometer/ls7000/ls7000.php.
[8]马宏,宋路,车英等.钢管内径光电检测装置[J].半导体光电,1996,9:261-266.
[9]高爱华,田爱玲,赵贵波.基于线阵CCD的尺寸测量装置[J].西安工业学院学报,2003,9：189-193.
[10]http://www.mrkj.net/cp_show.asp?id=191.
[11]http://www.cdsplendor.com.
[12]孙艳玲.降低电感接触式测量仪系统误差的方法研究[J].中国仪器仪表,2006,9:48-51.
[13]谭海艳.基于激光三角法的零件表面粗糙度在线测量[J].工具技术,2009,43:103-105.
[14]李晓天,张铁强等.基于激光三角法的小物体尺寸测量及三维重构系统[J].光学仪器,2008,6(12)：21-26.
[15]孙钊等.线阵CCD测径装置的设计[J].应用光学,2003,24(2)：31-33.
[16]王晓嘉,高隽,王磊.激光三角法综述[J].仪器仪表学报,2004,4(8):601-608.
[17]李书强.基于DSP的线阵CCD管螺纹梳刀刀片测量仪的研究[D].西华大学硕十学位论文,2007.
[18]代鑫,关维国.基于FPGA的高速数据采集系统设计[J].黑龙江科技信息,2010,3:70-71.
[19]陈家璧,彭润玲.激光原理及应用[M].北京：电子工业出版社,2008.
[20]蓝信钜等.激光技术[M].北京：科学出版社,2005.
[21]孙长库,叶声华.激光测量技术[M].天津：天津大学出版社,2008.
[22]朱若谷.激光应用技术[M].北京：国防工业出版社,2006.
[23]周广宽,葛国库,赵亚辉.激光器件[M].西安：西安电子科技大学出版社,2011.
[24]杜宝勋.半导体激光器理论基础[M].北京：科学出版社,2011.
[25]王庆有.光电传感器应用技术[M].北京：机械工业出版社,2007.
[26]Toshiba Corporation. CCD linear image sensor CCD TCD1501 D[J]. Japan. Toshiba Corporation.1999,6.
[27]张庆玲,杨勇编FPGA原理与实践[M].北京：北京航空航天大学出版社,2006.
[28]褚振勇,翁木云FPGA设计及应用[M].西安：西安电子科技大学出版社,2002.
[29]陈月强,刘星.基于Xilinx XC3 S500E的FPGA最小开发板的制作[J].电子元器件应用,2007,9(2)：22-28.
[30]周子昂,吴定允,徐坤,张利红.一种基于CMOS工艺的电平转换芯片[J].电子与封装,2011,11(3)：22-24.
[31]郭付才,王洪涛,刘志华.基于AT89C51单片机的RS232串行数据截取器设计[J].现代电子技术,2012,35(7)：95-97.
[32]陈新华.EDA技术与应用[M].北京：机械工业出版社,2008.
[33]柳春锋.电子设计自动化(EDA)教程[M].北京：北京理工大学出版社,2005.
[34]杜慧敏,李宥谋,赵全良.基于Verilog的FPGA设计基础[M].西安：西安电子科技大学出版社,2006.
[35]王书志.基于Quartus II的数字逻辑电路设计技术基础[M].兰州：兰州大学出版社,2011.
[36]赵震方,刘治华,李建鹏.一种新型CCD的驱动时序产生方法[J].机床与液压,2010,38(22)：92-94.
[37]王茹,王翠亚,李金.基于CPLD的TCD150ID型线阵CCD自适应驱动电路波计[J].2008,14：23-24.
[38]徐卫,黄惟公,李书强.基于 XC9572和线阵CCD TCD1501D的数据采集系统的设计[J].仪表技术,2007,4:12-14.
[39]王庆有,孙雪珠.CCD应用技术[M].天津：天津大学出版社,2002.
[40]葛鹏,刘涛等.基于FPGA+ADSP的线阵CCD非接触测量系统[J].光学仪器,2008,30(5):1-4.
[41]黄建亮.基于FPGA的自适应滤波器设计与实现[D].西安电子科技大学硕士学位论文,2006.
[42]韩西宁，许晖,焦留芳.基于FPGA的同步数据采集处理系统的设计与实现[J].电子应用技术,2009,1：89-91.
[43]郑宝华,基于FPGA的高速数据采集及处理系统设计[J].吉林化工学院学报,2008,4:36-39.
[44]赵雅兴FPGA原理、设计与应用[M].天津：天津大学出版社,1999.
[45]朱明程.现场可编程逻辑门阵列器件FPGA原理及应用设计[M].北京:电子工业出版社1994.
[46]夏宇闻Verilog数字系统设计教程[M].北京：北京航天航空大学出版社,2008.
[47]Jingwen Tian, Hao Wu, Meijuan Gao. Tension measurement system of oil based on embedded system [J].2008 International Conference on Computer Science and Software Engineering, 2008,4:972-975.
[48]Skuratov A U, Povernov E S, etc. Design and research of the optical gauge of a rigid pavement quality control[J]. Electro Devices and Materials,2008:117-119.
[49]Li Mingwei, Yang Guangwei. On Precise Photoelectric Measurement Device for Dimension[J]. Control Conference,2007:435-437.
[50]浦昭邦,王宝光.测控仪器设计[M].北京：机械工业出版社,2007.
[51]Harris S J, Jones D P. A Fast Pupillometer Using High Resolution Linear CCD Arrays and a 16-bit Microprocessor [J]. Engineering in Medicine and Biology Society,1992,14: 1562-1563.
[2]尹中会,李春.CCD技术在工业非接触测量中的应用[J].煤矿机电,2011,(2)：112-113.
[3]Kazuhiko Ishikawa, Hitomi Yamanob, Katsuhiko Asada, etal. Real-time measurement of a thickness of a thin coating by means of sheet laser. Optics and Lasers in Engineering.2004, (41):730-742.
[4]Alvarez, Israel. Length measurement of plates using CCD's[C]. IEEE Instrumentation and Measurement Technology Conference, May2001:941-944.
[5]http://www.betalasermike.com.
[6]http://www.zumbach.com.
[7]http://china.keyence.com/products/measure/micrometer/ls7000/ls7000.php.
[8]马宏,宋路,车英等.钢管内径光电检测装置[J].半导体光电,1996,9:261-266.
[9]高爱华,田爱玲,赵贵波.基于线阵CCD的尺寸测量装置[J].西安工业学院学报,2003,9：189-193.
[10]http://www.mrkj.net/cp_show.asp?id=191.
[11]http://www.cdsplendor.com.
[12]孙艳玲.降低电感接触式测量仪系统误差的方法研究[J].中国仪器仪表,2006,9:48-51.
[13]谭海艳.基于激光三角法的零件表面粗糙度在线测量[J].工具技术,2009,43:103-105.
[14]李晓天,张铁强等.基于激光三角法的小物体尺寸测量及三维重构系统[J].光学仪器,2008,6(12)：21-26.
[15]孙钊等.线阵CCD测径装置的设计[J].应用光学,2003,24(2)：31-33.
[16]王晓嘉,高隽,王磊.激光三角法综述[J].仪器仪表学报,2004,4(8):601-608.
[17]李书强.基于DSP的线阵CCD管螺纹梳刀刀片测量仪的研究[D].西华大学硕十学位论文,2007.
[18]代鑫,关维国.基于FPGA的高速数据采集系统设计[J].黑龙江科技信息,2010,3:70-71.
[19]陈家璧,彭润玲.激光原理及应用[M].北京：电子工业出版社,2008.
[20]蓝信钜等.激光技术[M].北京：科学出版社,2005.
[21]孙长库,叶声华.激光测量技术[M].天津：天津大学出版社,2008.
[22]朱若谷.激光应用技术[M].北京：国防工业出版社,2006.
[23]周广宽,葛国库,赵亚辉.激光器件[M].西安：西安电子科技大学出版社,2011.
[24]杜宝勋.半导体激光器理论基础[M].北京：科学出版社,2011.
[25]王庆有.光电传感器应用技术[M].北京：机械工业出版社,2007.
[26]Toshiba Corporation. CCD linear image sensor CCD TCD1501 D[J]. Japan. Toshiba Corporation.1999,6.
[27]张庆玲,杨勇编FPGA原理与实践[M].北京：北京航空航天大学出版社,2006.
[28]褚振勇,翁木云FPGA设计及应用[M].西安：西安电子科技大学出版社,2002.
[29]陈月强,刘星.基于Xilinx XC3 S500E的FPGA最小开发板的制作[J].电子元器件应用,2007,9(2)：22-28.
[30]周子昂,吴定允,徐坤,张利红.一种基于CMOS工艺的电平转换芯片[J].电子与封装,2011,11(3)：22-24.
[31]郭付才,王洪涛,刘志华.基于AT89C51单片机的RS232串行数据截取器设计[J].现代电子技术,2012,35(7)：95-97.
[32]陈新华.EDA技术与应用[M].北京：机械工业出版社,2008.
[33]柳春锋.电子设计自动化(EDA)教程[M].北京：北京理工大学出版社,2005.
[34]杜慧敏,李宥谋,赵全良.基于Verilog的FPGA设计基础[M].西安：西安电子科技大学出版社,2006.
[35]王书志.基于Quartus II的数字逻辑电路设计技术基础[M].兰州：兰州大学出版社,2011.
[36]赵震方,刘治华,李建鹏.一种新型CCD的驱动时序产生方法[J].机床与液压,2010,38(22)：92-94.
[37]王茹,王翠亚,李金.基于CPLD的TCD150ID型线阵CCD自适应驱动电路波计[J].2008,14：23-24.
[38]徐卫,黄惟公,李书强.基于 XC9572和线阵CCD TCD1501D的数据采集系统的设计[J].仪表技术,2007,4:12-14.
[39]王庆有,孙雪珠.CCD应用技术[M].天津：天津大学出版社,2002.
[40]葛鹏,刘涛等.基于FPGA+ADSP的线阵CCD非接触测量系统[J].光学仪器,2008,30(5):1-4.
[41]黄建亮.基于FPGA的自适应滤波器设计与实现[D].西安电子科技大学硕士学位论文,2006.
[42]韩西宁，许晖,焦留芳.基于FPGA的同步数据采集处理系统的设计与实现[J].电子应用技术,2009,1：89-91.
[43]郑宝华,基于FPGA的高速数据采集及处理系统设计[J].吉林化工学院学报,2008,4:36-39.
[44]赵雅兴FPGA原理、设计与应用[M].天津：天津大学出版社,1999.
[45]朱明程.现场可编程逻辑门阵列器件FPGA原理及应用设计[M].北京:电子工业出版社1994.
[46]夏宇闻Verilog数字系统设计教程[M].北京：北京航天航空大学出版社,2008.
[47]Jingwen Tian, Hao Wu, Meijuan Gao. Tension measurement system of oil based on embedded system [J].2008 International Conference on Computer Science and Software Engineering, 2008,4:972-975.
[48]Skuratov A U, Povernov E S, etc. Design and research of the optical gauge of a rigid pavement quality control[J]. Electro Devices and Materials,2008:117-119.
[49]Li Mingwei, Yang Guangwei. On Precise Photoelectric Measurement Device for Dimension[J]. Control Conference,2007:435-437.
[50]浦昭邦,王宝光.测控仪器设计[M].北京：机械工业出版社,2007.
[51]Harris S J, Jones D P. A Fast Pupillometer Using High Resolution Linear CCD Arrays and a 16-bit Microprocessor [J]. Engineering in Medicine and Biology Society,1992,14: 1562-1563.