基于DSP的超声波检测仪的设计
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摘要
在工业部门中,各种机器和设备运行是否稳定,直接影响到企业的经济效益,一些关键性的设备甚至起着决定企业命运的作用。因此,如何避免设备发生故障,一直以来都是人们极为重视的问题。
为了检测设备的运行状态,本课题设计了一种结构简单、精度和实时性高、检测时无需拆卸设备、高速低噪声的利用旋转机械发出的超声波来检测机械故障的超声波检测仪。
本设计采用高速、低噪声的放大器LMC6482设计了前置放大器和带通滤波器,对超声波探头采集到的信号进行放大和滤波处理,并设计了IIR数字滤波程序;设计了超声包络检波降频电路,将超声信号降频转换为人耳能听到的声音;使用线性稳压器LP2985ITP-5.0作为系统的电源控制部分,大大提高了系统工作电压的稳定性,保证了信号采集系统的正常运行;选用10位并行模数转换器TLV1571,完成超声信号的高速采集,最大采集频率达625KHz;并通过DSP的UART设计了RS232接口。其硬件模块具体包括通过Proteus和Multisim 10电子电路仿真软件设计的信号放大器、带通滤波和包络检波电路;使用LabVIEW编程环境开发上位机程序。实验结果显示该系统可以有效将采集到的信号转换成数字信号。系统具有体积小、速度快、噪声低、可靠性高、成本低等优点,可广泛应用于基于超声检测的工业领域。
In the industrial sector, the stability of machines and equipment operating a direct impact on the economic efficiency of enterprises, and some critical equipment even play a role in deciding the fate of enterprises. Therefore, how to prevent equipment failure, especially catastrophic failure, has always been a problem that people attache great importance to.
In order to monitor the running status of devices,a ultrasonic testing equipment of simple structure,high precision and real-time detection without requiring removal equipment was designed with the advantages of high speed、low noise,it used the ultrasound issued by rotating machinery-device to detect mechanical failure。
In the system, high-speed, low-noise amplifier LMC6482 was used to design pre-amplifier and band-pass filter in order to enlarge and filter the signal collected on the ultrasonic probe, and IIR digital filter was also designed; An envelope detection circuit was designed as a frequency down converter to transform the ultrasonic signal into ordinary voices that human could hear. What’s more, a system of power control circuit was designed by using a linear voltage regulator LP2985ITP-5.0, that could greatly improving the stability of the system voltage and guarantee the system’s normal operation; The 10-bit parallel ADC TLV1571 was used to convert the collected high-speed ultrasonic analog signal into digital signal efficaciously, and the maximum sampling frequency could reach up to 625KHz.; and then the digital signal would be transported into computer through DSP's external connection UART interface. The hardware modules specifically included the signal amplifier, band-pass filter and envelope detector circuit designed by using the electronic circuit simulation software of Proteus and Multisim 10. LabVIEW programming environment was used to develop host computer program. Experimental results show that the system could effectively collect ultrasonic signal and convert the signal into digital signal. The system could be widely used in industries based on ultrasonic testing with the advantages of small in size, high speed, low noise, high reliability and low cost.
为了检测设备的运行状态,本课题设计了一种结构简单、精度和实时性高、检测时无需拆卸设备、高速低噪声的利用旋转机械发出的超声波来检测机械故障的超声波检测仪。
本设计采用高速、低噪声的放大器LMC6482设计了前置放大器和带通滤波器,对超声波探头采集到的信号进行放大和滤波处理,并设计了IIR数字滤波程序;设计了超声包络检波降频电路,将超声信号降频转换为人耳能听到的声音;使用线性稳压器LP2985ITP-5.0作为系统的电源控制部分,大大提高了系统工作电压的稳定性,保证了信号采集系统的正常运行;选用10位并行模数转换器TLV1571,完成超声信号的高速采集,最大采集频率达625KHz;并通过DSP的UART设计了RS232接口。其硬件模块具体包括通过Proteus和Multisim 10电子电路仿真软件设计的信号放大器、带通滤波和包络检波电路;使用LabVIEW编程环境开发上位机程序。实验结果显示该系统可以有效将采集到的信号转换成数字信号。系统具有体积小、速度快、噪声低、可靠性高、成本低等优点,可广泛应用于基于超声检测的工业领域。
In the industrial sector, the stability of machines and equipment operating a direct impact on the economic efficiency of enterprises, and some critical equipment even play a role in deciding the fate of enterprises. Therefore, how to prevent equipment failure, especially catastrophic failure, has always been a problem that people attache great importance to.
In order to monitor the running status of devices,a ultrasonic testing equipment of simple structure,high precision and real-time detection without requiring removal equipment was designed with the advantages of high speed、low noise,it used the ultrasound issued by rotating machinery-device to detect mechanical failure。
In the system, high-speed, low-noise amplifier LMC6482 was used to design pre-amplifier and band-pass filter in order to enlarge and filter the signal collected on the ultrasonic probe, and IIR digital filter was also designed; An envelope detection circuit was designed as a frequency down converter to transform the ultrasonic signal into ordinary voices that human could hear. What’s more, a system of power control circuit was designed by using a linear voltage regulator LP2985ITP-5.0, that could greatly improving the stability of the system voltage and guarantee the system’s normal operation; The 10-bit parallel ADC TLV1571 was used to convert the collected high-speed ultrasonic analog signal into digital signal efficaciously, and the maximum sampling frequency could reach up to 625KHz.; and then the digital signal would be transported into computer through DSP's external connection UART interface. The hardware modules specifically included the signal amplifier, band-pass filter and envelope detector circuit designed by using the electronic circuit simulation software of Proteus and Multisim 10. LabVIEW programming environment was used to develop host computer program. Experimental results show that the system could effectively collect ultrasonic signal and convert the signal into digital signal. The system could be widely used in industries based on ultrasonic testing with the advantages of small in size, high speed, low noise, high reliability and low cost.
引文
1无损检测学会.超声波探伤A.南京:江苏科学技术出版社, 1980:2-10
2姚来凤,冯益华,王丽.超声波及超声检测.山东轻工业学院学报,2007, 21(2):67-69
3罗津别尔格著,周元培译.超声波及其应用.北京:人民邮电大学出版社, 1963:73-122
4张燕芳.设备状态检测和故障诊断.科技信息, 2008, 7:83-84
5 P.Harper, B.Hollingsworth, R.Dwyer-Joyce, etc. Journal Bearing Oil Film Measurement Using Ultrasonic Reflection. Tribology and Interface Engineering Series, 2003, 41:469-476
6 F.Deneuville, M.Duquennoy, Ouaftouh, M.Ourak,etc. High Frequency Ultrasonic Detection of C-crack Defects in Silicon Nitride Bearing Balls. Ultrasonics, 2009, 49(1): 89-93
7理华,徐春广.滚动轴承声发射检测技术.轴承, 2002, 7:24-26
8禇静,骆英,万雄.超声波检测的AE传感器设计与实现.计算机测量与控制, 2008, 16(4):464-466
9 G.W. Stachowiak, T.B. Kirk, G.B. Stachowiak. Ferrography and Fractal Analysis of Contamination Particles in Unused Lubricating Oils. Tribology International, 1991, 24 (6):329-334
10 David N. Anderson, Christopher J. Hubert, John H. Johnson.Advances in Quantitative Analytical Ferrography and the Evaluation of A High Gradient Magnetic Separator for the Study of Diesel Engine Wear. Wear. 1983, 90(2):297-333
11 Ultraprobe超声波探测仪的典型应用.北京新宇胜利仪器有限责任公司,技术资料
12王海,阙沛文.超声信号采集模块的设计.计算机测量与控制,2007, 15(6):816-819
13杜功焕.声学基础.南京:南京大学出版社, 2001:182-192
14 Tang Tzu-Chiang, Chian C. EMI Suppression For High-speed PCB. 2009 International Waveform Diversity and Design Conference Proceedings, 2009: 168-172
15周月琴,行鸿彦.超声波远距离振动信号检测系统的设计.机械科学与技术, 2008, 27(6):819-821
16严钟豪,谭祖根.非电量电测技术.北京:机械工业出版社, 2001:128-131
17龚其春,叶骞,刘成良,王永红等.新型气体泄漏超声检测系统的研究与设计.电子技术应用,2005, 31(3):36-39
18何希才,任力颖,杨静.实用传感器接口电路实例.北京:中国电力出版社, 2007:186-193
19刘修文.实用电子电路设计制作300例.北京:中国电力出版社, 2005:208-210
20鲁顺昌.开关电容带通滤波器设计原理.西华大学学报, 2006, 25(5):51-53
21南静,刘艳萍,刘昕.超声无损检测技术中的高速数据采集系统设计.研究与开发,2007, 26(11):38-41
22钱忠.多功能超声波检测系统的信号采集及放大电路模块的研制.昆明理工大学学报, 2006, 31(3):42-45
23 [日]松井邦彦著,邓学译. OP放大器应用技巧100例.北京:科学出版社, 2006:120-123
24 Vratislav Michal, Geoffroy Klisnick, Gérard Sou, Michel Redon, Alain J.Kreisler, etc. Fixed-gain CMOS differential amplifiers with no external feedback for a wide temperature range. Cryogenics, 2009, 49(11):615-619
25 J. Gubelmann, P.A. Dal Fabbro, M. Pastre, etc.High-efficiency dynamic supply CMOS audio power amplifier for low-power applications.Microelectronics Journal, 2009, 40(8):1175-1183
26 Stuart Lawson, Martin Anderson.The design of 2-D approximately linear phase filters using a direct approach. Signal Processing, 1997, 57(3):205-221
27 Giuseppe Di Cataldo, Rosario Mita, Salvatore Pennisi. High-speed CMOS unity-gain current amplifier. Microelectronics Journal, 2006, 37(10):1086-1091
28 Newton C.Braga著,毕树生译.仿生电子制作.北京:科学出版社, 2007:206-208
29 P.E艾伦, D.R霍尔伯格著,王正华,叶小琳译. CMOS模拟电路设计.北京:科学出版社, 1995:571-578
30阎石.数字电子技术基础.北京:高等教育出版社, 1983:486-493
31王晔,赵兴群.基于DSP的超声检测系统高速数据采集压缩卡设计.工业控制计算机, 2007, 20(10):24-25
32李映颖,王海军,孟祥谦.串行AD转换器TLC2543与51系列单片机的接口设计.仪表技术, 2004, (1):22-23
33孙世君.串行及并行AD转换器在高速数据采集中的采样差别性分析.国外电子元器件, 2006, 10:54-56
34刘向宇. DSP嵌入式常用模块与综合系统设计实例精讲.北京:电子工业出版社, 2009:290-300
35简远鸣,晏福平,刘念.基于DSP的高速数据采集与处理系统.微计算机信息, 2009, 25(1-2): 130-132
36尹勇. DSP集成开发环境CCS使用指南.北京:北京航空航天大学出版社, 2003:1-11
37刘会灯. MATLAB编程基础与典型应用.北京:人民邮电出版社, 2008:316-336
38 S.A. Samad, A. Hussain, D. Isa.Wave digital filters with minimum multiplier for discrete Hilbert transformer realization. Signal Processing, 2006, 86(12):3761-3768
39蔡旭晖. MATLAB基础与应用教程.北京:人民邮电出版社, 2009:1-11
40潘松. EDA技术实用教程.北京:科学出版社, 2002:160-240
41 Thomas Bangemann, Xavier Rebeuf, Denis Reboul, etc. PROTEUS—Creating distributed maintenance systems through an integration platform.Computers in Industry, 2006,57(6):539-551
42 J. Hayes.Good mix of industrial and academic papers: Electronic Design Automation 1987 Conference and exhibition.Wembley Conference Centre,1988,20(2):107
43马刚,李向仓.用Proteus与Keil整合构建单片机虚拟仿真平台.现代电子技术, 2006, 29(24):129-131
44 M. J. Corbin, G. F. Butler. Multisim: An object-based distributed framework for mission simulation.Simulation Practice and Theory, 1996,3(6):383-399
45从宏寿,程卫群,李绍铭. Multisim 8仿真与应用实例开发.北京:清华大学出版社, 2007:7-27
46石嘉顺.基于Multisim环境下的电路设计与仿真.计算机仿真, 2007,24(12):306-308
47段玉生,李钊年.在Multisim中创建任意函数信号源.电气电子教学学报, 2003, 25(5):50-53
48 Nasser Kehtarnavaz, Namjin Kim.LabVIEW Programming Environment. Digital Signal Processing System-Level Design Using LabVIEW, 2005:5-14
49 Chance Elliott, Vipin Vijayakumar, Wesley Zink. National Instruments LabVIEW: A Programming Environment for Laboratory Automation and Measurement.Journal of the Association for Laboratory Automation, 2007, 12(1):17-24
50 Jason H.Moore. Artificial intelligence programming with LabVIEW: genetic algorithms for instrumentation control and optimization.Computer Methods and Programs in Biomedicine, 1995, 47(1):73-79
51 Chance Elliott, Vipin Vijayakumar, Wesley Zink.etc.National Instruments LabVIEW: A Programming Environment for Laboratory Automation and Measurement.Journal of the Association for Laboratory Automation, 2007,12(1):17-24
52 Nasser Kehtarnavaz, Namjin Kim. LabVIEW Programming Environment. Digital Signal Processing System-Level Design Using LabVIEW, 2005:5-14
53 Kirsten N. Whitley, Laura R. Novick, etc.Evidence in favor of visual representation for the dataflow paradigm: An experiment testing LabVIEW's comprehensibility. International Journal of Human-Computer Studies,2006, 64(4):281-303
54 K. Dastoori, B. Makin, M. Chye,etc.Adhesion measurements for electrostatic powder coatings using a vertical drop test rig and LabVIEW software. Journal of Electrostatics, 2005,63(10): 551-557
2姚来凤,冯益华,王丽.超声波及超声检测.山东轻工业学院学报,2007, 21(2):67-69
3罗津别尔格著,周元培译.超声波及其应用.北京:人民邮电大学出版社, 1963:73-122
4张燕芳.设备状态检测和故障诊断.科技信息, 2008, 7:83-84
5 P.Harper, B.Hollingsworth, R.Dwyer-Joyce, etc. Journal Bearing Oil Film Measurement Using Ultrasonic Reflection. Tribology and Interface Engineering Series, 2003, 41:469-476
6 F.Deneuville, M.Duquennoy, Ouaftouh, M.Ourak,etc. High Frequency Ultrasonic Detection of C-crack Defects in Silicon Nitride Bearing Balls. Ultrasonics, 2009, 49(1): 89-93
7理华,徐春广.滚动轴承声发射检测技术.轴承, 2002, 7:24-26
8禇静,骆英,万雄.超声波检测的AE传感器设计与实现.计算机测量与控制, 2008, 16(4):464-466
9 G.W. Stachowiak, T.B. Kirk, G.B. Stachowiak. Ferrography and Fractal Analysis of Contamination Particles in Unused Lubricating Oils. Tribology International, 1991, 24 (6):329-334
10 David N. Anderson, Christopher J. Hubert, John H. Johnson.Advances in Quantitative Analytical Ferrography and the Evaluation of A High Gradient Magnetic Separator for the Study of Diesel Engine Wear. Wear. 1983, 90(2):297-333
11 Ultraprobe超声波探测仪的典型应用.北京新宇胜利仪器有限责任公司,技术资料
12王海,阙沛文.超声信号采集模块的设计.计算机测量与控制,2007, 15(6):816-819
13杜功焕.声学基础.南京:南京大学出版社, 2001:182-192
14 Tang Tzu-Chiang, Chian C. EMI Suppression For High-speed PCB. 2009 International Waveform Diversity and Design Conference Proceedings, 2009: 168-172
15周月琴,行鸿彦.超声波远距离振动信号检测系统的设计.机械科学与技术, 2008, 27(6):819-821
16严钟豪,谭祖根.非电量电测技术.北京:机械工业出版社, 2001:128-131
17龚其春,叶骞,刘成良,王永红等.新型气体泄漏超声检测系统的研究与设计.电子技术应用,2005, 31(3):36-39
18何希才,任力颖,杨静.实用传感器接口电路实例.北京:中国电力出版社, 2007:186-193
19刘修文.实用电子电路设计制作300例.北京:中国电力出版社, 2005:208-210
20鲁顺昌.开关电容带通滤波器设计原理.西华大学学报, 2006, 25(5):51-53
21南静,刘艳萍,刘昕.超声无损检测技术中的高速数据采集系统设计.研究与开发,2007, 26(11):38-41
22钱忠.多功能超声波检测系统的信号采集及放大电路模块的研制.昆明理工大学学报, 2006, 31(3):42-45
23 [日]松井邦彦著,邓学译. OP放大器应用技巧100例.北京:科学出版社, 2006:120-123
24 Vratislav Michal, Geoffroy Klisnick, Gérard Sou, Michel Redon, Alain J.Kreisler, etc. Fixed-gain CMOS differential amplifiers with no external feedback for a wide temperature range. Cryogenics, 2009, 49(11):615-619
25 J. Gubelmann, P.A. Dal Fabbro, M. Pastre, etc.High-efficiency dynamic supply CMOS audio power amplifier for low-power applications.Microelectronics Journal, 2009, 40(8):1175-1183
26 Stuart Lawson, Martin Anderson.The design of 2-D approximately linear phase filters using a direct approach. Signal Processing, 1997, 57(3):205-221
27 Giuseppe Di Cataldo, Rosario Mita, Salvatore Pennisi. High-speed CMOS unity-gain current amplifier. Microelectronics Journal, 2006, 37(10):1086-1091
28 Newton C.Braga著,毕树生译.仿生电子制作.北京:科学出版社, 2007:206-208
29 P.E艾伦, D.R霍尔伯格著,王正华,叶小琳译. CMOS模拟电路设计.北京:科学出版社, 1995:571-578
30阎石.数字电子技术基础.北京:高等教育出版社, 1983:486-493
31王晔,赵兴群.基于DSP的超声检测系统高速数据采集压缩卡设计.工业控制计算机, 2007, 20(10):24-25
32李映颖,王海军,孟祥谦.串行AD转换器TLC2543与51系列单片机的接口设计.仪表技术, 2004, (1):22-23
33孙世君.串行及并行AD转换器在高速数据采集中的采样差别性分析.国外电子元器件, 2006, 10:54-56
34刘向宇. DSP嵌入式常用模块与综合系统设计实例精讲.北京:电子工业出版社, 2009:290-300
35简远鸣,晏福平,刘念.基于DSP的高速数据采集与处理系统.微计算机信息, 2009, 25(1-2): 130-132
36尹勇. DSP集成开发环境CCS使用指南.北京:北京航空航天大学出版社, 2003:1-11
37刘会灯. MATLAB编程基础与典型应用.北京:人民邮电出版社, 2008:316-336
38 S.A. Samad, A. Hussain, D. Isa.Wave digital filters with minimum multiplier for discrete Hilbert transformer realization. Signal Processing, 2006, 86(12):3761-3768
39蔡旭晖. MATLAB基础与应用教程.北京:人民邮电出版社, 2009:1-11
40潘松. EDA技术实用教程.北京:科学出版社, 2002:160-240
41 Thomas Bangemann, Xavier Rebeuf, Denis Reboul, etc. PROTEUS—Creating distributed maintenance systems through an integration platform.Computers in Industry, 2006,57(6):539-551
42 J. Hayes.Good mix of industrial and academic papers: Electronic Design Automation 1987 Conference and exhibition.Wembley Conference Centre,1988,20(2):107
43马刚,李向仓.用Proteus与Keil整合构建单片机虚拟仿真平台.现代电子技术, 2006, 29(24):129-131
44 M. J. Corbin, G. F. Butler. Multisim: An object-based distributed framework for mission simulation.Simulation Practice and Theory, 1996,3(6):383-399
45从宏寿,程卫群,李绍铭. Multisim 8仿真与应用实例开发.北京:清华大学出版社, 2007:7-27
46石嘉顺.基于Multisim环境下的电路设计与仿真.计算机仿真, 2007,24(12):306-308
47段玉生,李钊年.在Multisim中创建任意函数信号源.电气电子教学学报, 2003, 25(5):50-53
48 Nasser Kehtarnavaz, Namjin Kim.LabVIEW Programming Environment. Digital Signal Processing System-Level Design Using LabVIEW, 2005:5-14
49 Chance Elliott, Vipin Vijayakumar, Wesley Zink. National Instruments LabVIEW: A Programming Environment for Laboratory Automation and Measurement.Journal of the Association for Laboratory Automation, 2007, 12(1):17-24
50 Jason H.Moore. Artificial intelligence programming with LabVIEW: genetic algorithms for instrumentation control and optimization.Computer Methods and Programs in Biomedicine, 1995, 47(1):73-79
51 Chance Elliott, Vipin Vijayakumar, Wesley Zink.etc.National Instruments LabVIEW: A Programming Environment for Laboratory Automation and Measurement.Journal of the Association for Laboratory Automation, 2007,12(1):17-24
52 Nasser Kehtarnavaz, Namjin Kim. LabVIEW Programming Environment. Digital Signal Processing System-Level Design Using LabVIEW, 2005:5-14
53 Kirsten N. Whitley, Laura R. Novick, etc.Evidence in favor of visual representation for the dataflow paradigm: An experiment testing LabVIEW's comprehensibility. International Journal of Human-Computer Studies,2006, 64(4):281-303
54 K. Dastoori, B. Makin, M. Chye,etc.Adhesion measurements for electrostatic powder coatings using a vertical drop test rig and LabVIEW software. Journal of Electrostatics, 2005,63(10): 551-557