基于FPGA和DSP的数字式超声检测系统的研究
|
摘要
随着我国铁路高速重载战略的实施,铁路运输速度和能力稳步提升,铁道机车车辆在肩负着新的历史责任和任务的同时也面临着更加严峻的行车安全考验。机车车辆零部件性能的稳定是列车安全运行的重要保证,这些零部件在长期运营的情况下极易出现不同程度的损伤,对铁路安全运输构成威胁,严重时甚至引起重大的行车事故。因此,采用先进的检测技术和仪器对机车车辆在役零部件进行及时的检修,对于保证行车安全和铁路发展战略的加速实施具有重要的现实意义。
论文针对目前铁道机车车辆超声检测领域模拟式检测系统的问题与不足,提出了一套以FPGA和DSP为核心的数字式超声检测系统方案,实现了高频率、低幅值的超声模拟信号的采集、处理、存储和传输。
论文完成了检测系统的硬件电路设计工作。系统选用高速宽带放大器AD8099和AD603对超声回波信号进行了调理,并采用采样频率达40MHz的8位高速模数转换器TLC5540对调理后的信号进行采样量化；系统以FPGA器件EP1C3T144C8和DSP器件TMS320F2812为控制模块核心,解决了超声回波高速数据流的处理问题；此外,系统采用USB控制器CY7C68013作为与上位机通讯的接口完成采集数据的传输。
论文在FPGA开发软件QuartusⅡ中完成了系统逻辑控制和数据缓存等功能模块的设计和仿真,验证了软件设计的有效性；系统采用C语言在DSP集成开发环境CCS中完成了系统的采集控制软件开发工作；另外,系统在Keil环境下进行了USB固件程序的编写与调试。
论文在完成系统软硬件设计的基础上,在车辆实验室对所设计的数字式超声检测系统进行了功能测试。测试结果证明,该检测系统能够满足超声检测所需的高速数据采集、处理和传输的要求,提高了超声检测系统的自动化和智能化的程度,对于完善和发展超声检测具有很强的理论意义和现实意义。
With the implementation of high-speed and overload strategy,the national transportation speed and capability have increased steadyly,and the railway locomotives vehicles are undertaking new responsibility and mission,and at the same time facing a more severe test of driving safty.The stability of Locomotive vehicle key parts is an important guarantee for the safe operation of train,however,these components will suffer various damage in different degree, or cause a series of serious traffic accident under the condition of long-term operation, which has been a great threaten to the transportation.Therefore,a timely maintenance for the in-sever vehicle parts with the use of advanced detection technology and equipment is of important practical significance to the assurance of driving safty and development strategy implemention.
Aiming at the disadvantages and shortcomings of analog ultrasonic inspection equipment currently used in the railway locomotives and car field, a digital ultrasonic inspection system based on FPGA and DSP was put forword,which enable the acqusition,processing, storage and transmission of high-frequency,low amplitude ultrasonic analog signal.
The hardware circuit of the digital inspection system was designed.High speed,wide bandwidth devices AD8099 and AD603 were adopted as the system amplifier,and a 8bit analog-to-digital conventor TLC5540 was used as the system ADC,whose sampling rate is up to 40MHz. Besides,the problem of high speed data flow processing was well solved,using FPGA device EP1C3T144C8 and DSP device TMS320F2812 as the core of system control module; in addition,the system choosed USB controllor device CY7C68013 as the communication interface between system and the host computer.
The paper designed the FPGA software,such as the function module of logic control and data cache, as well as simulated to verify the effectiveness in QuartusⅡ;besides,the system acqusition and control software development is finished in CCS based on C language;at last, the USB firmware was finished in Keil enviroment.
The digital ultrasonic inspection system was tested in the vehicle laboratory on the basis of hardware and software completion.The result showed that the system can meet the needs of the high-speed data acquisition, processing and transmission of ultrasonic signal,and made a great improvement in the aspects of automation and intelligent,being of great significance for the ultrasonic inspection development both in practice and theory.
论文针对目前铁道机车车辆超声检测领域模拟式检测系统的问题与不足,提出了一套以FPGA和DSP为核心的数字式超声检测系统方案,实现了高频率、低幅值的超声模拟信号的采集、处理、存储和传输。
论文完成了检测系统的硬件电路设计工作。系统选用高速宽带放大器AD8099和AD603对超声回波信号进行了调理,并采用采样频率达40MHz的8位高速模数转换器TLC5540对调理后的信号进行采样量化；系统以FPGA器件EP1C3T144C8和DSP器件TMS320F2812为控制模块核心,解决了超声回波高速数据流的处理问题；此外,系统采用USB控制器CY7C68013作为与上位机通讯的接口完成采集数据的传输。
论文在FPGA开发软件QuartusⅡ中完成了系统逻辑控制和数据缓存等功能模块的设计和仿真,验证了软件设计的有效性；系统采用C语言在DSP集成开发环境CCS中完成了系统的采集控制软件开发工作；另外,系统在Keil环境下进行了USB固件程序的编写与调试。
论文在完成系统软硬件设计的基础上,在车辆实验室对所设计的数字式超声检测系统进行了功能测试。测试结果证明,该检测系统能够满足超声检测所需的高速数据采集、处理和传输的要求,提高了超声检测系统的自动化和智能化的程度,对于完善和发展超声检测具有很强的理论意义和现实意义。
With the implementation of high-speed and overload strategy,the national transportation speed and capability have increased steadyly,and the railway locomotives vehicles are undertaking new responsibility and mission,and at the same time facing a more severe test of driving safty.The stability of Locomotive vehicle key parts is an important guarantee for the safe operation of train,however,these components will suffer various damage in different degree, or cause a series of serious traffic accident under the condition of long-term operation, which has been a great threaten to the transportation.Therefore,a timely maintenance for the in-sever vehicle parts with the use of advanced detection technology and equipment is of important practical significance to the assurance of driving safty and development strategy implemention.
Aiming at the disadvantages and shortcomings of analog ultrasonic inspection equipment currently used in the railway locomotives and car field, a digital ultrasonic inspection system based on FPGA and DSP was put forword,which enable the acqusition,processing, storage and transmission of high-frequency,low amplitude ultrasonic analog signal.
The hardware circuit of the digital inspection system was designed.High speed,wide bandwidth devices AD8099 and AD603 were adopted as the system amplifier,and a 8bit analog-to-digital conventor TLC5540 was used as the system ADC,whose sampling rate is up to 40MHz. Besides,the problem of high speed data flow processing was well solved,using FPGA device EP1C3T144C8 and DSP device TMS320F2812 as the core of system control module; in addition,the system choosed USB controllor device CY7C68013 as the communication interface between system and the host computer.
The paper designed the FPGA software,such as the function module of logic control and data cache, as well as simulated to verify the effectiveness in QuartusⅡ;besides,the system acqusition and control software development is finished in CCS based on C language;at last, the USB firmware was finished in Keil enviroment.
The digital ultrasonic inspection system was tested in the vehicle laboratory on the basis of hardware and software completion.The result showed that the system can meet the needs of the high-speed data acquisition, processing and transmission of ultrasonic signal,and made a great improvement in the aspects of automation and intelligent,being of great significance for the ultrasonic inspection development both in practice and theory.
引文
[1]何绍圻.德国战后最严重的铁路事故.铁道知识.1998(6)
[2]铁道部运输局装备部.铁路货车典型故障汇编.北京：中国铁道出版社,2006
[3]王雪梅.无损检测技术及其在轨道交通中的应用.四川：西南交通大学出版社,2010
[4]傅八路.日本高速列车及检修基地综述.国外铁道车辆.1998(4)
[5]王仲生,万小朋.无损检测诊断现场实用技术.北京：机械工业出版社,2002
[6]中国机械工业标准汇编：金属无损检测与探伤卷(下).北京：中国标准出版社,2005
[7]司马强.机车车轴超声波探伤工艺浅析.装备制造技术.2009(10)
[8]范弘.火车车轮超声探伤技术研究与开发.钢铁.2000,35(12)
[9]戴立新,王泽勇.电磁超声在车轮踏面探伤中的应用研究.铁道技术监督.2008(12)
[10]UTE TESSARO, THOMAS HECKEL, RAINER BOEHM. Ultrasonic Testing Of Railway Axles From Aborehole In Axial Direction. ECDENT 2006-Fr.1.3.3
[11]陈海.日本新干线的检修设备.国外铁道车辆.2009,46(2)
[12]王家玉.东风4D型机车车轴的超声波探伤.无损检测.2009(5)
[13]沈明珠,陈昌华.车轮超声波数字化探伤系统.无损检测.1999(9)
[14]耿荣生.更快、更可靠和更直观-第16届世界无损检测会议综述.无损检测.2004,26(11)
[15]单宝华.超声相控阵检测技术及其应用.无损检测.2004(26)
[16]W Kappes, B Rockstroh, W Bahr, M Kroning. Applicationof New Front-End Electronics For Non-Destructive Testing Of Railroad Wheel Set, Berlin, German, ECNDT,2006
[17]ERNESTO GARCIA ARES, JOSE LUIS GARCIA ALONSO, JUAN A. Automatic In-Service Train Axle Inspectin System. The 8th European Conference On Nondestructive Testing, September25-29,2006, Berlin, German
[18]王一名.钢轨超声波探伤方法.北京：铁道出版社,1981
[19]刘洋,项占琴.激光超声技术在钢轨探伤中的应用研究.机械设计与制造.2009(10)
[20]付希卓.浅析超声波探伤技术在货车制动梁端轴探伤中的应用.铁道技术监督.2005(11)
[21]万升云.无损检测在机车车辆工艺上的应用(四)-超声波检测.铁道机车车辆工人.2007(9)
[22]蒋危平.超声波探伤仪发展简史.无损检测.1997(1)
[23]陈文革.超声无损检测的应用研究与进展.无损探伤.2001(25)
[24]周荣.一种新型数字化超声波探伤系统的研制.南京航空航天大学硕士学位论文.2007
[25]ROCKSTROH B, WALTE F,KAPPES W, etal. New Ultrasound Testing System For The Production Testing Of Rail Wheel. ECNDT 2006-Th.4.5.3
[26]http://www.jebsen-ndt.com
[27]http://www. tayasaf.com
[28]http://www.testmart.cn
[29]http://www.ceshi 17.com
[30]蒋危平.数字化超声波探伤仪十五年技术进展.无损检测.2004,26(3)
[31]Bourne S. Novel Solid Contact Ultrasonic Couplants Based On Hydrophilic Polymers. proc Of 15th WCNDT. Rome:2000.406.
[32]蒋危平.超声波探伤仪发展简史.无损检测.1997(1)
[33]http://www.siui.com
[34]http://www.zkcx.com
[35]王鑫,陈健,傅丰林.数据采集系统应用的高速并行A/D转换器.电子产品世界,2003(8)
[36]刘贵民.无损检测技术.北京：国防工业出版社,2006
[37]李国华,吴淼,现代无损检测与评价.北京：化学工业出版社,2009
[38]胡建恺,张谦琳.超声检测原理和方法.安徽：中国科学技术大学出版社,1993
[39]应崇福.超声学.北京：科技出版社,1993
[40]超声波探伤技术及探伤仪编写组.超声波探伤技术及探伤仪.北京：国防工业出版社,2009
[41]赵斌.超声检测信息处理系统的研究.大连理工大学硕士学位论文,2000
[42]中国机械工业标准汇编：金属无损检测与探伤卷(下).北京：中国标准出版社,2005
[43]马伟.计算机USB系统原理及其主从机设计.北京：北京航空航天出版社,2004
[44]ICL7660 Data Sheet. Intersil.File No.3072.4.1999.4
[45]TPS767D318 User Manual. TI.2000
[46]王昊.集成运放应用电路设计360例.北京：电子工业出版社,2007
[47]Ultralow Distortion,High Speed Op Amp AD8099. User Manual[R], Revision 1, Analog Devices,2007
[48]Low Cost,High Speed Op Amps ADA4851-2 User Manual[R], Revision 1, Analog Devices,2007
[49]冯若.超声手册.南京：南京大学出版社,1999
[50]8-Bit High-Speed Analog-To-Digital Converter TLC5540 User Manual[R], Revision 1, TI,2004
[51]褚振勇,齐亮.FPGA设计及应用(第二版).西安：西安电子科技大学出版社,2006
[52]王诚,吴继华.Altear FPGA/CPLD设计.北京：人民邮电出版社,2005
[53]Cy7c68013 USB Microcontroller. Cypress
[54]尹勇,欧光军等.DSP集成开发环境CCS开发指南.北京：北京航空航天大学出版社,2003
[55]胡建恺,张谦琳编著.超声检测原理和方法.合肥：中国科学技术大学出版社,1993
[56]EZ-USB FX2 Technical Reference Manual. Cypress Semiconductor
[57]全国钢标准化技术委员会.中华人民共和国黑色冶金超声信号探伤信号幅度测量误差标准.YBT144-1998.1998
[2]铁道部运输局装备部.铁路货车典型故障汇编.北京：中国铁道出版社,2006
[3]王雪梅.无损检测技术及其在轨道交通中的应用.四川：西南交通大学出版社,2010
[4]傅八路.日本高速列车及检修基地综述.国外铁道车辆.1998(4)
[5]王仲生,万小朋.无损检测诊断现场实用技术.北京：机械工业出版社,2002
[6]中国机械工业标准汇编：金属无损检测与探伤卷(下).北京：中国标准出版社,2005
[7]司马强.机车车轴超声波探伤工艺浅析.装备制造技术.2009(10)
[8]范弘.火车车轮超声探伤技术研究与开发.钢铁.2000,35(12)
[9]戴立新,王泽勇.电磁超声在车轮踏面探伤中的应用研究.铁道技术监督.2008(12)
[10]UTE TESSARO, THOMAS HECKEL, RAINER BOEHM. Ultrasonic Testing Of Railway Axles From Aborehole In Axial Direction. ECDENT 2006-Fr.1.3.3
[11]陈海.日本新干线的检修设备.国外铁道车辆.2009,46(2)
[12]王家玉.东风4D型机车车轴的超声波探伤.无损检测.2009(5)
[13]沈明珠,陈昌华.车轮超声波数字化探伤系统.无损检测.1999(9)
[14]耿荣生.更快、更可靠和更直观-第16届世界无损检测会议综述.无损检测.2004,26(11)
[15]单宝华.超声相控阵检测技术及其应用.无损检测.2004(26)
[16]W Kappes, B Rockstroh, W Bahr, M Kroning. Applicationof New Front-End Electronics For Non-Destructive Testing Of Railroad Wheel Set, Berlin, German, ECNDT,2006
[17]ERNESTO GARCIA ARES, JOSE LUIS GARCIA ALONSO, JUAN A. Automatic In-Service Train Axle Inspectin System. The 8th European Conference On Nondestructive Testing, September25-29,2006, Berlin, German
[18]王一名.钢轨超声波探伤方法.北京：铁道出版社,1981
[19]刘洋,项占琴.激光超声技术在钢轨探伤中的应用研究.机械设计与制造.2009(10)
[20]付希卓.浅析超声波探伤技术在货车制动梁端轴探伤中的应用.铁道技术监督.2005(11)
[21]万升云.无损检测在机车车辆工艺上的应用(四)-超声波检测.铁道机车车辆工人.2007(9)
[22]蒋危平.超声波探伤仪发展简史.无损检测.1997(1)
[23]陈文革.超声无损检测的应用研究与进展.无损探伤.2001(25)
[24]周荣.一种新型数字化超声波探伤系统的研制.南京航空航天大学硕士学位论文.2007
[25]ROCKSTROH B, WALTE F,KAPPES W, etal. New Ultrasound Testing System For The Production Testing Of Rail Wheel. ECNDT 2006-Th.4.5.3
[26]http://www.jebsen-ndt.com
[27]http://www. tayasaf.com
[28]http://www.testmart.cn
[29]http://www.ceshi 17.com
[30]蒋危平.数字化超声波探伤仪十五年技术进展.无损检测.2004,26(3)
[31]Bourne S. Novel Solid Contact Ultrasonic Couplants Based On Hydrophilic Polymers. proc Of 15th WCNDT. Rome:2000.406.
[32]蒋危平.超声波探伤仪发展简史.无损检测.1997(1)
[33]http://www.siui.com
[34]http://www.zkcx.com
[35]王鑫,陈健,傅丰林.数据采集系统应用的高速并行A/D转换器.电子产品世界,2003(8)
[36]刘贵民.无损检测技术.北京：国防工业出版社,2006
[37]李国华,吴淼,现代无损检测与评价.北京：化学工业出版社,2009
[38]胡建恺,张谦琳.超声检测原理和方法.安徽：中国科学技术大学出版社,1993
[39]应崇福.超声学.北京：科技出版社,1993
[40]超声波探伤技术及探伤仪编写组.超声波探伤技术及探伤仪.北京：国防工业出版社,2009
[41]赵斌.超声检测信息处理系统的研究.大连理工大学硕士学位论文,2000
[42]中国机械工业标准汇编：金属无损检测与探伤卷(下).北京：中国标准出版社,2005
[43]马伟.计算机USB系统原理及其主从机设计.北京：北京航空航天出版社,2004
[44]ICL7660 Data Sheet. Intersil.File No.3072.4.1999.4
[45]TPS767D318 User Manual. TI.2000
[46]王昊.集成运放应用电路设计360例.北京：电子工业出版社,2007
[47]Ultralow Distortion,High Speed Op Amp AD8099. User Manual[R], Revision 1, Analog Devices,2007
[48]Low Cost,High Speed Op Amps ADA4851-2 User Manual[R], Revision 1, Analog Devices,2007
[49]冯若.超声手册.南京：南京大学出版社,1999
[50]8-Bit High-Speed Analog-To-Digital Converter TLC5540 User Manual[R], Revision 1, TI,2004
[51]褚振勇,齐亮.FPGA设计及应用(第二版).西安：西安电子科技大学出版社,2006
[52]王诚,吴继华.Altear FPGA/CPLD设计.北京：人民邮电出版社,2005
[53]Cy7c68013 USB Microcontroller. Cypress
[54]尹勇,欧光军等.DSP集成开发环境CCS开发指南.北京：北京航空航天大学出版社,2003
[55]胡建恺,张谦琳编著.超声检测原理和方法.合肥：中国科学技术大学出版社,1993
[56]EZ-USB FX2 Technical Reference Manual. Cypress Semiconductor
[57]全国钢标准化技术委员会.中华人民共和国黑色冶金超声信号探伤信号幅度测量误差标准.YBT144-1998.1998