基于光纤微位移测量的轧辊磨损度在线检测技术的研究
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摘要
21世纪世界钢铁工业竞争的焦点是钢材的质量高而成本低,主要体现在要求钢材尺寸精度高、板形好。轧制钢材的轧辊长时间工作后,表面受到不同程度的磨损,其形状发生变化,导致钢材的板形和板厚难以控制,进而使产品质量下降。因此,及时、准确地检测出轧辊的磨损度是目前轧制生产的迫切要求。对于合理选择磨辊时间、减少换辊次数、保证钢材质量、实现在线磨辊都具有重要意义,成为提高生产效率和经济效益的重要技术之一。
由于光纤传感技术具有灵敏度高、稳定可靠、抗电磁干扰,易与计算机连接实现智能化等特点受到国内外研究者广泛关注。本文在研究了国内外多种检测方法的基础上,进行基于光纤微位移测量的轧辊磨损度在线检测技术的理论和实验研究。主要研究工作如下:
(1)基于光纤微位移测量原理,研究了将轧辊磨损度转化为位移量实现在线精确测量的机理。对轧辊磨损度的大小与光纤探头到轧辊表面距离之间的定量关系进行分析,建立了检测系统的数学模型。
(2)对光纤在线检测系统进行设计,并对系统的关键技术进行研究。研制了可实现自动补偿功能的光纤探头;利用相敏检波和比值处理技术保证光源光强的稳定;采用差动相消法抑制电路的温度及零点漂移;设计可沿轧辊径向、轴向运动的三自由度精密传感器运动机构;采用VC++ 6.0编程工具对检测数据采集和处理软件系统进行设计。
(3)在对影响轧辊磨损度在线检测精度各种因素分析的基础上,对轧辊磨损度在线检测误差分离与补偿方法进行研究。主要包括:利用设立参考通道的方法补偿光纤传感器的工作误差;采用最小二乘圆法对轧辊偏心、圆度、回转误差进行补偿;应用基于海明窗函数的有限冲击响应数字滤波器对检测数据进行滤波,补偿轧辊振动产生的误差等。
(4)基于神经网络和小波分析理论寻找对检测信号进行数据处理的新方法,提高检测系统的灵敏度和精度。
(5)采用快速数据采集芯片ADuC812,保证实时准确的显示检测数据,使之适于在实际现场进行高精度检测。
(6)对检测系统进行实验研究。主要包括:光纤传感器实验、轧辊磨损度在线检测中轧辊自身状态及周围环境因素对检测结果的影响实验、检测系统分析控制软件仿真实验等。
In 21st century the competitive focus of the world iron and steel industry is good quality and low cost of the product. And the main requests are precise size and right shape of the steel boards. After long time working, the surface of a roller will wear. So the shape of the roller will be changed. And the roller wear will result in difficult controlling the shape and the thickness of the board. Further more it can lead to the decline of the product quality of a rolling mill. So it is very urgent to detect the roller wear exactly and real time. Examining the profile of a working roller between the intervals of rolling is called online testing for roller wear. The study of online testing roller wear is very important for selecting the grinding time in reason; reducing the exchanging roller times, improving the quality of the product and realizing online grinding rollers. It has become one of the key technologies to improve the producing efficiency and economic benefits.
Because of high sensitivity, stabilization and credibility, no electromagnetic interference and easily realized intelligent with the computer optical fiber sensor has get a broad attention by domestic and overseas investigators. In this paper, after summarizing the experience of the detecting methods inside and outside we carry on the theoretic and experimental studying of roller wear online detecting system based on optical fiber tiny displacement measurement. The main research contents are as follows:
(1)Based on optical fiber tiny displacement measurement principle, the mechanism of converting roller wear to displacement for online precisely detecting was studied. The ration relation of roller wear and the distance between the probe and the roller surface was analyzed. Also the mathematics model of the system was set up.
(2)The whole online optical fiber detecting system was designed. And the key technologies of the detecting system were studied. The optical fiber probe that can realize compensating automatically was designed. By using the technology of PSD and ratio disposal the light intensity stabilization can be ensured. Zero and temperature excursion can be restrained by using differential circuit. A three freedom of motion organ which can move along the radial axle and axial direction of the sensor were designed. By using programming software VC++6.0 the data collecting and processing system was designed.
(3)Through analyzing the diversified factors which affect the precision of the detecting system, the principle of error separation and compensation was studied. The main contents are: working error of optical fiber sensor can be compensated by setting up reference channel; by using LSC the circular and rotator errors of the detected roller can be compensated; librations error can be compensated by using FIR digit filter based on Hamming window.
(4)Based on artificial neural network and wavelet analysis, a new processing method for detecting data was found. So the sensitivity and measuring precision of the detecting system can be improved.
(5)By using high speed data acquisition chip ADuC812, detecting data can be output in real time and accurately. And this can make the detecting system appropriate for working in rolling locale and detecting with high precision.
(6)Experimental research and analysis have been completed. The main experiments include optical fiber sensor characteristics, the effect of the roller’s states and ambience, and simulation of the analysis control software for the detecting system.
由于光纤传感技术具有灵敏度高、稳定可靠、抗电磁干扰,易与计算机连接实现智能化等特点受到国内外研究者广泛关注。本文在研究了国内外多种检测方法的基础上,进行基于光纤微位移测量的轧辊磨损度在线检测技术的理论和实验研究。主要研究工作如下:
(1)基于光纤微位移测量原理,研究了将轧辊磨损度转化为位移量实现在线精确测量的机理。对轧辊磨损度的大小与光纤探头到轧辊表面距离之间的定量关系进行分析,建立了检测系统的数学模型。
(2)对光纤在线检测系统进行设计,并对系统的关键技术进行研究。研制了可实现自动补偿功能的光纤探头;利用相敏检波和比值处理技术保证光源光强的稳定;采用差动相消法抑制电路的温度及零点漂移;设计可沿轧辊径向、轴向运动的三自由度精密传感器运动机构;采用VC++ 6.0编程工具对检测数据采集和处理软件系统进行设计。
(3)在对影响轧辊磨损度在线检测精度各种因素分析的基础上,对轧辊磨损度在线检测误差分离与补偿方法进行研究。主要包括:利用设立参考通道的方法补偿光纤传感器的工作误差;采用最小二乘圆法对轧辊偏心、圆度、回转误差进行补偿;应用基于海明窗函数的有限冲击响应数字滤波器对检测数据进行滤波,补偿轧辊振动产生的误差等。
(4)基于神经网络和小波分析理论寻找对检测信号进行数据处理的新方法,提高检测系统的灵敏度和精度。
(5)采用快速数据采集芯片ADuC812,保证实时准确的显示检测数据,使之适于在实际现场进行高精度检测。
(6)对检测系统进行实验研究。主要包括:光纤传感器实验、轧辊磨损度在线检测中轧辊自身状态及周围环境因素对检测结果的影响实验、检测系统分析控制软件仿真实验等。
In 21st century the competitive focus of the world iron and steel industry is good quality and low cost of the product. And the main requests are precise size and right shape of the steel boards. After long time working, the surface of a roller will wear. So the shape of the roller will be changed. And the roller wear will result in difficult controlling the shape and the thickness of the board. Further more it can lead to the decline of the product quality of a rolling mill. So it is very urgent to detect the roller wear exactly and real time. Examining the profile of a working roller between the intervals of rolling is called online testing for roller wear. The study of online testing roller wear is very important for selecting the grinding time in reason; reducing the exchanging roller times, improving the quality of the product and realizing online grinding rollers. It has become one of the key technologies to improve the producing efficiency and economic benefits.
Because of high sensitivity, stabilization and credibility, no electromagnetic interference and easily realized intelligent with the computer optical fiber sensor has get a broad attention by domestic and overseas investigators. In this paper, after summarizing the experience of the detecting methods inside and outside we carry on the theoretic and experimental studying of roller wear online detecting system based on optical fiber tiny displacement measurement. The main research contents are as follows:
(1)Based on optical fiber tiny displacement measurement principle, the mechanism of converting roller wear to displacement for online precisely detecting was studied. The ration relation of roller wear and the distance between the probe and the roller surface was analyzed. Also the mathematics model of the system was set up.
(2)The whole online optical fiber detecting system was designed. And the key technologies of the detecting system were studied. The optical fiber probe that can realize compensating automatically was designed. By using the technology of PSD and ratio disposal the light intensity stabilization can be ensured. Zero and temperature excursion can be restrained by using differential circuit. A three freedom of motion organ which can move along the radial axle and axial direction of the sensor were designed. By using programming software VC++6.0 the data collecting and processing system was designed.
(3)Through analyzing the diversified factors which affect the precision of the detecting system, the principle of error separation and compensation was studied. The main contents are: working error of optical fiber sensor can be compensated by setting up reference channel; by using LSC the circular and rotator errors of the detected roller can be compensated; librations error can be compensated by using FIR digit filter based on Hamming window.
(4)Based on artificial neural network and wavelet analysis, a new processing method for detecting data was found. So the sensitivity and measuring precision of the detecting system can be improved.
(5)By using high speed data acquisition chip ADuC812, detecting data can be output in real time and accurately. And this can make the detecting system appropriate for working in rolling locale and detecting with high precision.
(6)Experimental research and analysis have been completed. The main experiments include optical fiber sensor characteristics, the effect of the roller’s states and ambience, and simulation of the analysis control software for the detecting system.
引文
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109 Tan Yihua, Tian Jinwen, Liu Jian.Adaptively wavelet-based image denoising algorithm with edge preserving. CHINESE OPTICS LETTERS,2006,4(2):80-83
110 Ma Qiming, Wang Xuanjin. Method and application of wavelet shrinkage denoising based on genetic algorithm. JOURNAL OF ZHEJIANG UNIVERSITY SCIENCE,2006,7(3):361-367
111 FEIP ei-yan, GUO Bao-long. Infrared Image Denoising Based on Single-wavelet and Multiwavelets. INFRARED TECHNOLOGY,2005,27(3):235-239
112 Liu Pin. Wavelet and Signal Processing. Journal of South-Central University for Nationalities, 2001,20:23-26
113 S.Jarrett, J.M.Allwood. Fast model of thermal camber evolution in metal rolling for online use. Ironmaking and Steelmaking,1999,26(6):439-407
114 Li C James, Li Sheng Yi, Yu Jiang Ming. High resolution error separation technique for in-situ straightness measurement of machine tools and workpieces. Mechatronics, 1996, 6(3):337-347