金属板厚度电磁超声检测与数据处理技术研究
|
摘要
电磁超声技术以其非接触、可以产生各种波形、能够在恶劣环境中工作、能对移动物体进行准确检测等优点成为工业生产中重要的检测手段之一。厚度的测量是检测物体的重要指标之一,尤其在金属板材检测方面,知晓板材的精确壁厚对于保障其质量与安全至关重要。
本文从理论及实验两方面研究了电磁超声波金属板厚度测量问题,并对电磁超声采集信号进行软件上的处理。理论方面,本文通过研究电磁超声检测的基本原理,选取横波作为测厚的波的类型,确定了产生横波的测厚换能器结构形式。利用ANSYS有限元分析软件对确定形式的金属板测厚换能器进行了仿真分析。对于非铁磁性材料,仿真采用电磁结构耦合分析方法,分别得出了试件所受洛伦兹力及试件上的质点位移。通过分析多个质点位移值得出超声波在被测试件中主要传播角度。针对参数改变对超声波传播的影响问题,分析了在改变频率、线圈间距、线圈提离距等情况下金属板质点位移的变化。对于铁磁性材料,介绍了压磁—压电比拟法。实验方面,利用电磁超声检测平台对铝板进行了实际测量,测量结果证实了理论分析内容。针对电磁超声采集信号具有信号微弱、噪声大、干扰强、信噪比高的缺点,本文采用软件的方法对电磁超声采集信号进行了滤波去噪。比较了不同处理算法的原理及特点,选择了平均算法及小波去噪算法。结果表明,处理后信号质量明显提高。
搭建了电磁超声测厚系统实验平台,并对板材进行了测厚实验。实验平台实现了对金属板的厚度测量。实验结果有效验证了理论及仿真分析正确性。
Electromagnetic ultrasonic technique has become one of the important means of detection in industrial production. Because it not only can detect objects without contact or moving objects in various environments, but also can produce a variety of waveforms. Thickness measurement is an important indicator of object detection, especially in the metal plate detection, it is essential to ensure quality and safety of plate.
This article studies the electromagnetic ultrasonic metal plate thickness measurement from the experimental and theoretical aspects, and processing the signal collected using software. In theory, this paper studies the basic principle of electromagnetic ultrasonic detection, select transverse wave as the wave type and the transducer structure is determined. The simulation is established using finite element software. For non-ferromag- netic material, the force and displacement of specimen suffered can be obtained from the electromagnetic structure coupling analysis. The analysis shows the main transmission angle. Simulation analyzes the effect on particle displacement by changing frequency, spaced coil and coil lift-off. For the ferromagnetic material, paper introduces an analogy method between magnetic analysis and piezoelectric analysis. In experiment, aluminum plate is measured using the electromagnetic ultrasonic testing platform and the results show that the theoretical analysis is content. In this paper, the weak signal collected with noise and interference is filtered. Comparing to the principle and characteristics of different processing algorithms, this paper chose the average algorithm and wavelet algorithm. The results show that, after processing the signal is improved.
The experiment system of thickness measurement is set up and it is used to detect plate. The experiment results can verify the theoretical analysis and simulation effectively, and can measure thickness of metal plate.
本文从理论及实验两方面研究了电磁超声波金属板厚度测量问题,并对电磁超声采集信号进行软件上的处理。理论方面,本文通过研究电磁超声检测的基本原理,选取横波作为测厚的波的类型,确定了产生横波的测厚换能器结构形式。利用ANSYS有限元分析软件对确定形式的金属板测厚换能器进行了仿真分析。对于非铁磁性材料,仿真采用电磁结构耦合分析方法,分别得出了试件所受洛伦兹力及试件上的质点位移。通过分析多个质点位移值得出超声波在被测试件中主要传播角度。针对参数改变对超声波传播的影响问题,分析了在改变频率、线圈间距、线圈提离距等情况下金属板质点位移的变化。对于铁磁性材料,介绍了压磁—压电比拟法。实验方面,利用电磁超声检测平台对铝板进行了实际测量,测量结果证实了理论分析内容。针对电磁超声采集信号具有信号微弱、噪声大、干扰强、信噪比高的缺点,本文采用软件的方法对电磁超声采集信号进行了滤波去噪。比较了不同处理算法的原理及特点,选择了平均算法及小波去噪算法。结果表明,处理后信号质量明显提高。
搭建了电磁超声测厚系统实验平台,并对板材进行了测厚实验。实验平台实现了对金属板的厚度测量。实验结果有效验证了理论及仿真分析正确性。
Electromagnetic ultrasonic technique has become one of the important means of detection in industrial production. Because it not only can detect objects without contact or moving objects in various environments, but also can produce a variety of waveforms. Thickness measurement is an important indicator of object detection, especially in the metal plate detection, it is essential to ensure quality and safety of plate.
This article studies the electromagnetic ultrasonic metal plate thickness measurement from the experimental and theoretical aspects, and processing the signal collected using software. In theory, this paper studies the basic principle of electromagnetic ultrasonic detection, select transverse wave as the wave type and the transducer structure is determined. The simulation is established using finite element software. For non-ferromag- netic material, the force and displacement of specimen suffered can be obtained from the electromagnetic structure coupling analysis. The analysis shows the main transmission angle. Simulation analyzes the effect on particle displacement by changing frequency, spaced coil and coil lift-off. For the ferromagnetic material, paper introduces an analogy method between magnetic analysis and piezoelectric analysis. In experiment, aluminum plate is measured using the electromagnetic ultrasonic testing platform and the results show that the theoretical analysis is content. In this paper, the weak signal collected with noise and interference is filtered. Comparing to the principle and characteristics of different processing algorithms, this paper chose the average algorithm and wavelet algorithm. The results show that, after processing the signal is improved.
The experiment system of thickness measurement is set up and it is used to detect plate. The experiment results can verify the theoretical analysis and simulation effectively, and can measure thickness of metal plate.
引文
[1]吴鑫,李方奇,石坤.脉冲涡流测厚技术理论与应用.北京交通大学学报,2009,33(1):20~31.
[2]程松波,郭顺生,李嘉宁等.电涡流式钢板在线测厚系统设计.机械研究与应用,2005, 18(3):61~62.
[3]崔遇功,海潮智.铝及铝合金中厚板在线激光测厚新技术.轻合金加工技术,1999,27(1):21~24.
[4]孙渝生.一种激光测厚装置.应用激光.2003,2:104~106.
[5]张庆社,任晋军.石油钻杆管壁及附件的超声波测厚.无损探伤,2010,34(4):44~49.
[6]张晓春,刘春生,李海宝.电磁超声无损检测技术及其应用.煤矿机械,2002,2:69~70.
[7]贾宝贤,边文凤,赵万生等.压电超声换能器的应用与发展.压电与声光,2005,27(2):131~135.
[8]曹建海,严拱标,韩晓枫.电磁超声测厚原理及其应用——一种新型超声测厚法.浙江大学学报(工学版) 2002,36(1):88~91.
[9]朱红秀,吴淼,范弘等.钢管的电磁超声无损检测技术.煤炭科学技术,2003,31(12):51~53.
[10]马恺,戴朝辉.电磁超声技术在管端探伤中的应用.2005中国钢铁年会论文集,2005:434~435.
[11]刘天华,乔学亮等.EMAT测距测厚的系统设计及实现.测控技术,2005,24(4):20~21.
[12]李振才.电磁超声(EMA)技术的发展与应用.无损探伤,2006,30(6):13~14.
[13]王淑娟,康磊,翟国富.电磁声超声换能器优化设计综述.仪器仪表学报:2007,28(8):93~99.
[14] R.Jafari-Shapoorabadi, A.Konrad. Improved Finite Element Method for EMAT Analysis and Design. TRANSACTIONS ON MAGNETICS, 2001, 37(4):2821~2823.
[15] Liang Jin, Qingxin Yang, Suzhen Liu et al. Electromagnetic Stimulation of the Acoustic Emission for Fatigue Crack Detection of the Sheet Metal. TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, 2010, 20(3):1848~1851.
[16] Yi Liu, Tianhong Cui. Power consumption analysis of surface acoustic wave sensor systems using ANSYS and PSPICE. Microsyst Technol, 2007, 13:97~101.
[17] S. Thomas, S. S. A. Obayya, R. Taneja et al. A Coupled Electromagnetic and Mechanical Analysis of Electromagnetic Acoustic Transducers. International Journal for Computational Methods in Engineering Science and Mechanics, 2009, 10:124~133.
[18] Koorosh Mirkhani, Chris Chaggares, Chris Mastersona et al. Optimal design of EMAT transmitters. NDT&E International, 2004, 37:181~193.
[19] Julie G. EMAT generation of horizontally polarized guided shear waves for ultrasonic pipe inspection. International Pipeline conference, 1998, 1:327~334.
[20] Gori M, Giamboni S. Guided waves by EMAT transducers for rapid defect location on heat exchanger and boiler tubes. Ultrasonic, 1996, 34:311~314.
[21] Masashi Yoshida, Tetsuo Asano. A New Method to Measure the Oxide Layer Thickness on Steels Using Electromagnetic Acoustic Resonance. Joumal of Nondestructive Evaluation, 2003(22):11~19.
[22]李冰.钢管电磁超声探伤方法的研究.沈阳:沈阳工业大学,2009.
[23]邢志忠,张广纯,刘鑫禾.电磁声检测带钢应力的实验研究.钢铁研究总院学报,1988,8:77~82.
[24]徐维灏,陆原,李希英等.铁磁性钢板电磁声兰姆波探伤技术的研究.钢铁研究总院学报, 1988,8(2):59~64.
[25]李莺莺,靳世久,曹丽娜.油气管道电磁超声法检测的信号处理石油学报.2006,27(3):112~119.
[26]段伟亮,康磊等.基于FPGA的电磁超声测厚仪.仪表技术与传感器,2010(4):14~16.
[27]苏日亮,康磊,冯剑钊等.基于电磁超声斜入射SV波的厚壁管道裂纹检测系统.仪器研制,2010,32(8):641~644.
[28]吴山标.电磁超声检测中激磁场的有限元模拟.物理测试,2009,27(3):42~46.
[29]蒯淑君.电磁超声测厚方法与系统的研究.合肥:合肥工业大学,2010.
[30]孙明礼,胡仁喜,崔海蓉等.ANSYS10.0电磁学有限元分析实例指导教程.北京:机械工业出版社,2007:1~16.
[31]维基百科.http://zh.wikipedia.org/zh/%E6%B3%A2%E5%8A%A8%E6%96%B9%E7%A8 %8B,2006.
[32]王世山,王德林,李彦明.大型有限元软件ANSYS在电磁领域的使用.高压电器,2002,38(3):27~33.
[33]邓凡平.ANSYS10.0有限元分析自学手册.北京:人民邮电出版社,2007.23~46.
[34] ANSYS耦合场分析指南.http://wenku.baidu.com/view/86ab93370b4c2e3f572763b0.html.
[35] ANSYS单元手册.http://wenku.baidu.com/view/7fc0037b168884868762d6de.html.
[36] Lei Huaming, Que Peiwen, Zhang Zhigang, Huang Jing.Mechanism. Study on electromag netic acoustic transducer for ultrasonic generation in ferromagnetic material. Journal of Southeast Universi, 2004, 20(3):309~313.
[37]莫喜平,朱厚卿,刘建国等.Terfenol-D超磁致伸缩换能器的有限元模拟.应用声学,1990,19(4):5~8.
[38] Physicotechnical Institute, Ural Division, Russian Academy of Sciences, ul. On the Possibility of Estimating the Elasticity Limit and Residual Deformations in Ferromagnetic Metals Using the Parameters of Electromagnetic Acoustic Transformation. Russian Journal of Nondestructive Testing, 2010, 46(1):83~89.
[39]汪开灿.基于电磁超声的钢轨缺陷检测系统.哈尔滨:哈尔滨工业大学,2010.
[40]李锐,何辅云,夏玉宝.相关检测原理及其应用.合肥工业大学学报(自然科学版),2008,31(4):573~579.
[41]吴斌,邓菲,何存富.超声导波无损检测中的信号处理研究进展.北京工业大学学报,2007,33(4):342~348.
[42]李燕南,伍逸枫,刘欣等.基于MATLAB微弱信号的相关检测设计与仿真.中国高新技术企业,2010,(1):25~35.
[43]王浩,王黎,高晓蓉.车轮电磁超声探伤技术及探伤信号的处理.机车车辆工艺,2004,(6):34~36.
[44]孙日明.电磁超声应用于钢轨应力检测的研究和分析.南京:南京航空航天大学,2011.
[45]朱习军,隋思涟,张宾等.MATLAB在信号处与图像处理中的应用.北京:电子工业出版社,2009,150~174.
[46]潘伟才.基于FPGA的电磁超声检测系统的研究.哈尔滨:哈尔滨工业大学,2008.
[47]戴立新.电磁超声系统强噪声干扰抑制算法研究.四川:西南交通大学,2007.
[2]程松波,郭顺生,李嘉宁等.电涡流式钢板在线测厚系统设计.机械研究与应用,2005, 18(3):61~62.
[3]崔遇功,海潮智.铝及铝合金中厚板在线激光测厚新技术.轻合金加工技术,1999,27(1):21~24.
[4]孙渝生.一种激光测厚装置.应用激光.2003,2:104~106.
[5]张庆社,任晋军.石油钻杆管壁及附件的超声波测厚.无损探伤,2010,34(4):44~49.
[6]张晓春,刘春生,李海宝.电磁超声无损检测技术及其应用.煤矿机械,2002,2:69~70.
[7]贾宝贤,边文凤,赵万生等.压电超声换能器的应用与发展.压电与声光,2005,27(2):131~135.
[8]曹建海,严拱标,韩晓枫.电磁超声测厚原理及其应用——一种新型超声测厚法.浙江大学学报(工学版) 2002,36(1):88~91.
[9]朱红秀,吴淼,范弘等.钢管的电磁超声无损检测技术.煤炭科学技术,2003,31(12):51~53.
[10]马恺,戴朝辉.电磁超声技术在管端探伤中的应用.2005中国钢铁年会论文集,2005:434~435.
[11]刘天华,乔学亮等.EMAT测距测厚的系统设计及实现.测控技术,2005,24(4):20~21.
[12]李振才.电磁超声(EMA)技术的发展与应用.无损探伤,2006,30(6):13~14.
[13]王淑娟,康磊,翟国富.电磁声超声换能器优化设计综述.仪器仪表学报:2007,28(8):93~99.
[14] R.Jafari-Shapoorabadi, A.Konrad. Improved Finite Element Method for EMAT Analysis and Design. TRANSACTIONS ON MAGNETICS, 2001, 37(4):2821~2823.
[15] Liang Jin, Qingxin Yang, Suzhen Liu et al. Electromagnetic Stimulation of the Acoustic Emission for Fatigue Crack Detection of the Sheet Metal. TRANSACTIONS ON APPLIED SUPERCONDUCTIVITY, 2010, 20(3):1848~1851.
[16] Yi Liu, Tianhong Cui. Power consumption analysis of surface acoustic wave sensor systems using ANSYS and PSPICE. Microsyst Technol, 2007, 13:97~101.
[17] S. Thomas, S. S. A. Obayya, R. Taneja et al. A Coupled Electromagnetic and Mechanical Analysis of Electromagnetic Acoustic Transducers. International Journal for Computational Methods in Engineering Science and Mechanics, 2009, 10:124~133.
[18] Koorosh Mirkhani, Chris Chaggares, Chris Mastersona et al. Optimal design of EMAT transmitters. NDT&E International, 2004, 37:181~193.
[19] Julie G. EMAT generation of horizontally polarized guided shear waves for ultrasonic pipe inspection. International Pipeline conference, 1998, 1:327~334.
[20] Gori M, Giamboni S. Guided waves by EMAT transducers for rapid defect location on heat exchanger and boiler tubes. Ultrasonic, 1996, 34:311~314.
[21] Masashi Yoshida, Tetsuo Asano. A New Method to Measure the Oxide Layer Thickness on Steels Using Electromagnetic Acoustic Resonance. Joumal of Nondestructive Evaluation, 2003(22):11~19.
[22]李冰.钢管电磁超声探伤方法的研究.沈阳:沈阳工业大学,2009.
[23]邢志忠,张广纯,刘鑫禾.电磁声检测带钢应力的实验研究.钢铁研究总院学报,1988,8:77~82.
[24]徐维灏,陆原,李希英等.铁磁性钢板电磁声兰姆波探伤技术的研究.钢铁研究总院学报, 1988,8(2):59~64.
[25]李莺莺,靳世久,曹丽娜.油气管道电磁超声法检测的信号处理石油学报.2006,27(3):112~119.
[26]段伟亮,康磊等.基于FPGA的电磁超声测厚仪.仪表技术与传感器,2010(4):14~16.
[27]苏日亮,康磊,冯剑钊等.基于电磁超声斜入射SV波的厚壁管道裂纹检测系统.仪器研制,2010,32(8):641~644.
[28]吴山标.电磁超声检测中激磁场的有限元模拟.物理测试,2009,27(3):42~46.
[29]蒯淑君.电磁超声测厚方法与系统的研究.合肥:合肥工业大学,2010.
[30]孙明礼,胡仁喜,崔海蓉等.ANSYS10.0电磁学有限元分析实例指导教程.北京:机械工业出版社,2007:1~16.
[31]维基百科.http://zh.wikipedia.org/zh/%E6%B3%A2%E5%8A%A8%E6%96%B9%E7%A8 %8B,2006.
[32]王世山,王德林,李彦明.大型有限元软件ANSYS在电磁领域的使用.高压电器,2002,38(3):27~33.
[33]邓凡平.ANSYS10.0有限元分析自学手册.北京:人民邮电出版社,2007.23~46.
[34] ANSYS耦合场分析指南.http://wenku.baidu.com/view/86ab93370b4c2e3f572763b0.html.
[35] ANSYS单元手册.http://wenku.baidu.com/view/7fc0037b168884868762d6de.html.
[36] Lei Huaming, Que Peiwen, Zhang Zhigang, Huang Jing.Mechanism. Study on electromag netic acoustic transducer for ultrasonic generation in ferromagnetic material. Journal of Southeast Universi, 2004, 20(3):309~313.
[37]莫喜平,朱厚卿,刘建国等.Terfenol-D超磁致伸缩换能器的有限元模拟.应用声学,1990,19(4):5~8.
[38] Physicotechnical Institute, Ural Division, Russian Academy of Sciences, ul. On the Possibility of Estimating the Elasticity Limit and Residual Deformations in Ferromagnetic Metals Using the Parameters of Electromagnetic Acoustic Transformation. Russian Journal of Nondestructive Testing, 2010, 46(1):83~89.
[39]汪开灿.基于电磁超声的钢轨缺陷检测系统.哈尔滨:哈尔滨工业大学,2010.
[40]李锐,何辅云,夏玉宝.相关检测原理及其应用.合肥工业大学学报(自然科学版),2008,31(4):573~579.
[41]吴斌,邓菲,何存富.超声导波无损检测中的信号处理研究进展.北京工业大学学报,2007,33(4):342~348.
[42]李燕南,伍逸枫,刘欣等.基于MATLAB微弱信号的相关检测设计与仿真.中国高新技术企业,2010,(1):25~35.
[43]王浩,王黎,高晓蓉.车轮电磁超声探伤技术及探伤信号的处理.机车车辆工艺,2004,(6):34~36.
[44]孙日明.电磁超声应用于钢轨应力检测的研究和分析.南京:南京航空航天大学,2011.
[45]朱习军,隋思涟,张宾等.MATLAB在信号处与图像处理中的应用.北京:电子工业出版社,2009,150~174.
[46]潘伟才.基于FPGA的电磁超声检测系统的研究.哈尔滨:哈尔滨工业大学,2008.
[47]戴立新.电磁超声系统强噪声干扰抑制算法研究.四川:西南交通大学,2007.