数字式超声波探伤系统的研发
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摘要
超声探伤技术是无损检测中应用最为广泛的方法之一,它能精确的检测金属、非金属表面和内部的缺陷,在工业领域得到了广泛的应用。
本文首先介绍了超声波探伤技术在国内外的现状和发展趋势,阐述了超声波探伤的基本理论知识,针对飞机外场快速无损检测的需要,确定了论文的研究方向。根据超声波脉冲反射法基本原理,设计了以C8051F340高性能单片机为控制核心、采用PCI8001高速采集卡进行数据采集的四通道超声波无损检测硬件系统平台。为了实现对缺陷的有效评估,采用VC6.0开发了超声波无损检测信号分析系统,实现了对超声波波形的实时数据采集、显示和发现缺陷的自动报警。采用数字信号处理技术对回波波形进行分析,实现了对缺陷的埋藏深度和缺陷当量大小定量化评价。同时提出了在小信噪比的情况下,利用小波变换技术有效去除噪声干扰,实现了对缺陷回波信号的增强和提取,极大的减小了探伤过程中对缺陷的误判率和漏判率。利用小波模极值原理,实现了对缺陷埋藏深度的精确定位。本文最终完成了超声波探伤仪的样机的研制,搭建了实验平台。
通过大量的实验表明:本文设计的超声波探伤系统对缺陷的检测与加工的真实缺陷基本符合。
最后给出了全文的结论,并对于本文有关的进一步工作提出了建议。
Ultrasonic flaw detection is one of the most widespread technique in Non-Destructive Testing (NDT). It is widely used in industrial fields because it can detect the flaws in and on the metal and non-metal material.
In this paper, the status and the development of ultrasonic flaw detection technique at home and abroad are introduced and the basic principle of ultrasonic flaw detection is presented. In order to meet the need of the fast non-destructive examination on plane, the research direction of the paper is determined. The four-channel ultrasonic non-destructive testing system is introduced based on pulse ultrasonic detecting theory. With C8051F340 high performance processor as its control core unit, the system adopted PCI8001 to realize high speed data acquisition. In order to implement the effective evaluation of the flaws, the software of ultrasonic non-destructive testing system is designed based on VC6.0 environment. The system can realize real-time data acquisition and display of ultrasonic wave and can give an alarm automatically when the flaws exist. The digital signal process technique is adopted to analysis the flaw echo, which realized the evaluation of the depth and the size of the flaws successfully. At the same time, the wavelet technique is adopted to denoise in the situation of small signal-to-noise ratio, which enhance and extract the flaw echo successfully and reduce the ratio of misjudge and missing report during the detection. Besides, according to the principle of wavelet modular maximum, we realize the measure of the position of the flaws accurately.
We accomplish the design of prototype of ultrasonic flaw detector and build a good platform for ultrasonic non-destructive testing. According to a lot of experiments, it is indicated that the result of the test goes along with the true flaw on the specimen by and large.
In the end, the conclusions of this paper are given and the suggestions for further study are made.
本文首先介绍了超声波探伤技术在国内外的现状和发展趋势,阐述了超声波探伤的基本理论知识,针对飞机外场快速无损检测的需要,确定了论文的研究方向。根据超声波脉冲反射法基本原理,设计了以C8051F340高性能单片机为控制核心、采用PCI8001高速采集卡进行数据采集的四通道超声波无损检测硬件系统平台。为了实现对缺陷的有效评估,采用VC6.0开发了超声波无损检测信号分析系统,实现了对超声波波形的实时数据采集、显示和发现缺陷的自动报警。采用数字信号处理技术对回波波形进行分析,实现了对缺陷的埋藏深度和缺陷当量大小定量化评价。同时提出了在小信噪比的情况下,利用小波变换技术有效去除噪声干扰,实现了对缺陷回波信号的增强和提取,极大的减小了探伤过程中对缺陷的误判率和漏判率。利用小波模极值原理,实现了对缺陷埋藏深度的精确定位。本文最终完成了超声波探伤仪的样机的研制,搭建了实验平台。
通过大量的实验表明:本文设计的超声波探伤系统对缺陷的检测与加工的真实缺陷基本符合。
最后给出了全文的结论,并对于本文有关的进一步工作提出了建议。
Ultrasonic flaw detection is one of the most widespread technique in Non-Destructive Testing (NDT). It is widely used in industrial fields because it can detect the flaws in and on the metal and non-metal material.
In this paper, the status and the development of ultrasonic flaw detection technique at home and abroad are introduced and the basic principle of ultrasonic flaw detection is presented. In order to meet the need of the fast non-destructive examination on plane, the research direction of the paper is determined. The four-channel ultrasonic non-destructive testing system is introduced based on pulse ultrasonic detecting theory. With C8051F340 high performance processor as its control core unit, the system adopted PCI8001 to realize high speed data acquisition. In order to implement the effective evaluation of the flaws, the software of ultrasonic non-destructive testing system is designed based on VC6.0 environment. The system can realize real-time data acquisition and display of ultrasonic wave and can give an alarm automatically when the flaws exist. The digital signal process technique is adopted to analysis the flaw echo, which realized the evaluation of the depth and the size of the flaws successfully. At the same time, the wavelet technique is adopted to denoise in the situation of small signal-to-noise ratio, which enhance and extract the flaw echo successfully and reduce the ratio of misjudge and missing report during the detection. Besides, according to the principle of wavelet modular maximum, we realize the measure of the position of the flaws accurately.
We accomplish the design of prototype of ultrasonic flaw detector and build a good platform for ultrasonic non-destructive testing. According to a lot of experiments, it is indicated that the result of the test goes along with the true flaw on the specimen by and large.
In the end, the conclusions of this paper are given and the suggestions for further study are made.
引文
[1]国防科技工业无损检测人员资格鉴定与认证培训教材编审委员会编,超声波检测,机械工业出版社,2005
[2]王仲生编,无损检测诊断现场实用技术,机械工业出版社2002
[3]潘仲明,王跃科,杨俊编,现代测控理论基础,国防科技大学出版社,2004
[4]潘琢金译,C8051F340全速USB FLASH微控制器数据手册,2006
[5]沈(?)亚,郑中兴,超声波探伤原理及其应用,北京市技术交流站,1982
[6]冯若,姚锦种编,超声手册,南京大学出版社,1999
[7]超声波探伤编写组编,超声波探伤,电力工业出版社,1980
[8]美国无损检测学会编,美国无损检测手册(超声卷),上海世界图书出版社,1996
[9]超声波探伤技术与探伤仪编写组,超声波探伤技术及探伤仪,国防工业出版社,1977
[10]孙金立编,无损检测及在航空维修中的应用,国防工业出版社,2004
[11]胡昌华,张军波编,基于MATLAB的系统分析与设计小波分析,西安电子科技大学出版社,1999
[12]刘春生,张晓春编,实用小波分析,中国矿业大学出版社,2002
[13]郑治真,小波变换及其MATLAB工具的应用,北京地震出版社,2001
[14]Albert Boggess Francis J.Narcowich 著,A First Course in Wavelets with Fourier Analysis,电子工业出版社,2004
[15]Eugene Olafen,Kenn Scribner等著,MFC Visual C++6编程技术内幕,机械工业出版社,2000
[16]郝文化,Windows多线程编程技术与实例,2002
[17]张志涌,精通MATLAB6.5,北京航空航天大学出版社,2000
[18]张贤达,现代信号处理,清华大学出版社,2002
[19]M.H.海因斯,数字信号处理,科学出版社,2002
[20]王幸之,单片机应用系统抗干扰技术,北京航空航天大学出版社,2000
[21]蔺大元,多通道超声波探伤仪及其在自动化探伤中的应用,无损探伤,97
[22]蒋危平等,便携式超声探伤仪,国外无损检测,Vol.2,No.1,pp.44-45,1992
[23]陈昌华,车轮轮箍超声波探伤计算机检测技术,马钢科研,2001
[24]高松巍,陈晓民,多通道高速智能超声波探伤仪的研制,沈阳工业大学学报,99
[25]徐红建,高精度数字式超声波检测和成像处理系统的研究与实现,上海交通大学,2002
[26]郭海鸥,飞机某型发动机压缩机一级叶片裂纹检测研究,无损探伤NDT,2004
[27]宋建萍,超声波探伤仪收发电路研究,电子工程师,Vol 30,No.6,2004
[28]周渭,于建国,刘海霞,测试于计量技术基础,西安电子科技大学出版社,2004
[29]Liao TW,Li DM,Two manufacturing application of the fuzzy KNN algorithm,Fuzzy Sets Syst 1997;92:289-303
[30]Liao TW,Li DM,Li YM,Detection of welding flaws from radiographic images with fuzzy clustering methods,Fuzzy Sets Syst 1999,108:145-58
[31]Santos JB,Perdigao F.Automatic defects classification--a contribution,NDT&E int 2001,34:313-8
[32]Song YW,Udpa SS.A new morphological algorithm for fusing ultrasonic and eddy current images,IEEE Symp Ultrason 1996:649-52
[33]Simone G,Morabito FC,NDT image fusion using eddy current and ultrasonic data,Int J Comput Math Electr Electron Eng 2001;20(3):857-868(12)
[34]Penrose R.The emperor's new mind.Oxford:Oxford University Press;1989.
[35]Shah S,Levine MD,Visual information processing in primate cone pathways-Part Ⅰ:a model.IEEE Trans SMC--B:Cybernet 1996;26(2):259-74
[36]Shah S,Levine MD,Visual information processing in primate cone pathways-Part Ⅱ:experiments,IEEE Trans SMC--B:Cybernet 1996;26(2):275-89
[37]Mostafawy S,Kermani O,Lubatschowski H.Virtual eye:retinal image visualization of the human eye,IEEE Comput Graphics Appl 1997;17(1):8-12
[38]Levine MD,Vision and machine,New York:McGraw Hill Co.;1985
[39]Hoppner F,Klawonn F,Kruse R,Runkler T.Fuzzy cluster analysis,New York:John Wiley and Sons;1999
[40]Gath I,Geva AB,Unsupervised optimal fuzzy clustering,IEEE Trans Pattern Anal Mach Intell 1989;11:773-81
[41]Duda R,Hart P.,Pattern classification and scene analysis,New York:Wiley;1973
[42]Gros XE,Bousigue J,Takahashi K,NDT data fusion at pixel level.NDT&E Int 1999;32:283-92
[43]刘镇清,陈广,超声无损检测中的谱分析技术[J],无损检测,2001,23(2):85-88
[44]屠耀元,超声检测中的信号分析技术[F],无损检测,1993.15(5):15-17.
[45]刘镇清,超声共振法金属厚度测量的谱估计技术[I],无损检测,1993.15(11):301-303
[46]刘镇清等,脉冲超声波幅度谱测厚技术[U],计量技术,1999.43(5):6-9
[47]谢远遐,刘镇清.板中超声传播的几何分析及应用[J],无损检测,1999.21(12):536-540
[48]李萍,李喜孟,王来,超声回波射频(RF)信号的特征值提取[J],数理统计与管理.2003,23(4):24-27
[49]潘泉,小波滤波方法及应用,清华大学出版社,2005
[2]王仲生编,无损检测诊断现场实用技术,机械工业出版社2002
[3]潘仲明,王跃科,杨俊编,现代测控理论基础,国防科技大学出版社,2004
[4]潘琢金译,C8051F340全速USB FLASH微控制器数据手册,2006
[5]沈(?)亚,郑中兴,超声波探伤原理及其应用,北京市技术交流站,1982
[6]冯若,姚锦种编,超声手册,南京大学出版社,1999
[7]超声波探伤编写组编,超声波探伤,电力工业出版社,1980
[8]美国无损检测学会编,美国无损检测手册(超声卷),上海世界图书出版社,1996
[9]超声波探伤技术与探伤仪编写组,超声波探伤技术及探伤仪,国防工业出版社,1977
[10]孙金立编,无损检测及在航空维修中的应用,国防工业出版社,2004
[11]胡昌华,张军波编,基于MATLAB的系统分析与设计小波分析,西安电子科技大学出版社,1999
[12]刘春生,张晓春编,实用小波分析,中国矿业大学出版社,2002
[13]郑治真,小波变换及其MATLAB工具的应用,北京地震出版社,2001
[14]Albert Boggess Francis J.Narcowich 著,A First Course in Wavelets with Fourier Analysis,电子工业出版社,2004
[15]Eugene Olafen,Kenn Scribner等著,MFC Visual C++6编程技术内幕,机械工业出版社,2000
[16]郝文化,Windows多线程编程技术与实例,2002
[17]张志涌,精通MATLAB6.5,北京航空航天大学出版社,2000
[18]张贤达,现代信号处理,清华大学出版社,2002
[19]M.H.海因斯,数字信号处理,科学出版社,2002
[20]王幸之,单片机应用系统抗干扰技术,北京航空航天大学出版社,2000
[21]蔺大元,多通道超声波探伤仪及其在自动化探伤中的应用,无损探伤,97
[22]蒋危平等,便携式超声探伤仪,国外无损检测,Vol.2,No.1,pp.44-45,1992
[23]陈昌华,车轮轮箍超声波探伤计算机检测技术,马钢科研,2001
[24]高松巍,陈晓民,多通道高速智能超声波探伤仪的研制,沈阳工业大学学报,99
[25]徐红建,高精度数字式超声波检测和成像处理系统的研究与实现,上海交通大学,2002
[26]郭海鸥,飞机某型发动机压缩机一级叶片裂纹检测研究,无损探伤NDT,2004
[27]宋建萍,超声波探伤仪收发电路研究,电子工程师,Vol 30,No.6,2004
[28]周渭,于建国,刘海霞,测试于计量技术基础,西安电子科技大学出版社,2004
[29]Liao TW,Li DM,Two manufacturing application of the fuzzy KNN algorithm,Fuzzy Sets Syst 1997;92:289-303
[30]Liao TW,Li DM,Li YM,Detection of welding flaws from radiographic images with fuzzy clustering methods,Fuzzy Sets Syst 1999,108:145-58
[31]Santos JB,Perdigao F.Automatic defects classification--a contribution,NDT&E int 2001,34:313-8
[32]Song YW,Udpa SS.A new morphological algorithm for fusing ultrasonic and eddy current images,IEEE Symp Ultrason 1996:649-52
[33]Simone G,Morabito FC,NDT image fusion using eddy current and ultrasonic data,Int J Comput Math Electr Electron Eng 2001;20(3):857-868(12)
[34]Penrose R.The emperor's new mind.Oxford:Oxford University Press;1989.
[35]Shah S,Levine MD,Visual information processing in primate cone pathways-Part Ⅰ:a model.IEEE Trans SMC--B:Cybernet 1996;26(2):259-74
[36]Shah S,Levine MD,Visual information processing in primate cone pathways-Part Ⅱ:experiments,IEEE Trans SMC--B:Cybernet 1996;26(2):275-89
[37]Mostafawy S,Kermani O,Lubatschowski H.Virtual eye:retinal image visualization of the human eye,IEEE Comput Graphics Appl 1997;17(1):8-12
[38]Levine MD,Vision and machine,New York:McGraw Hill Co.;1985
[39]Hoppner F,Klawonn F,Kruse R,Runkler T.Fuzzy cluster analysis,New York:John Wiley and Sons;1999
[40]Gath I,Geva AB,Unsupervised optimal fuzzy clustering,IEEE Trans Pattern Anal Mach Intell 1989;11:773-81
[41]Duda R,Hart P.,Pattern classification and scene analysis,New York:Wiley;1973
[42]Gros XE,Bousigue J,Takahashi K,NDT data fusion at pixel level.NDT&E Int 1999;32:283-92
[43]刘镇清,陈广,超声无损检测中的谱分析技术[J],无损检测,2001,23(2):85-88
[44]屠耀元,超声检测中的信号分析技术[F],无损检测,1993.15(5):15-17.
[45]刘镇清,超声共振法金属厚度测量的谱估计技术[I],无损检测,1993.15(11):301-303
[46]刘镇清等,脉冲超声波幅度谱测厚技术[U],计量技术,1999.43(5):6-9
[47]谢远遐,刘镇清.板中超声传播的几何分析及应用[J],无损检测,1999.21(12):536-540
[48]李萍,李喜孟,王来,超声回波射频(RF)信号的特征值提取[J],数理统计与管理.2003,23(4):24-27
[49]潘泉,小波滤波方法及应用,清华大学出版社,2005