基于虚拟仪器技术的摩擦焊机参数检测及分析系统
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摘要
本论文对CT-25特种摩擦焊机的参数检测系统进行了开发和研究。在摩擦焊过程中,摩擦压力、主轴转速、摩擦烧损位移量等都是影响摩擦焊接头质量的重要参数。因此,研制一套先进的、功能较强的摩擦焊机参数检测及分析系统,对于提高焊接质量、研究新的焊接工艺和提高生产管理水平都具有十分重要的意义。
文中详细介绍了参数检测与分析系统的总体设计思路及软硬件的设计。系统硬件主要由工控机、PCI2013多功能数据采集卡以及压力、转速和位移传感器以及数显表等组成。其中转速传感器采用LEC-50BM-G05E增量式光电旋转编码器,压力传感器采用ST2001压力传感器,位移传感器和数显表分别采用SGC系列光栅尺和GS4204光栅数显表。系统软件采用NI公司的虚拟仪器编程软件LabVIEW来实现。虚拟仪器(Virtual Instruments,简称VI)技术是测控技术与计算机技术相结合的产物,它的出现标志着测控技术进入了一个新的时代。LabVIEW作为虚拟仪器技术的代表性开发软件,采用模块化、图形化的编程方式,开发出的测控系统具有友好的人机交互界面,并且当用户的测试要求变化时,可以方便地由用户自己来增减硬、软件模块,或重新配置现有系统以满足新的测试要求。本文采用LabVIEW7.1编程,实现了摩擦焊过程各级转速、压力和摩擦烧损位移量等参数的检测、曲线实时显示、保存和焊后数据回放以及产品原始资料档案记录等功能。
本文对于在软件开发过程中采用的动态库连接、多线程、多任务处理、串口通信以及数字滤波等技术进行了详细的介绍。对如何解决采集数据的延时问题以及采集数据串道等问题也分别进行了论述。文中还对实际工作环境中的干扰源进行了分析并采取了相应的防干扰措施。
最后论文对测控系统进行了模拟验证试验。通过试验进一步验证了系统的有效性和良好的操作性。
It has been developed and researched deeply to the parameter detection system of CT-25 special friction welder in this paper.During the course of friction welding,the frictional pressure, the rotational speed of the main shaft and the burned displacement amount etc.are the very important parameters who can influence the welded joints’quality.So developing a set of advanced friction welder parameter detection and analyticl system with stronger function has important meanings for improving the quality of welding, studying the new welding craft and improving the management level etc.
In the paper,it has been introduced detailedly to the overall ideas of the design and How to design In software and hardware to the parameter detection and analyticl system. The systematic hardware is mainly made up of Industrial Personal Computer, PCI2013 multi-functional data acquisition card and pressure, rotational speed and displacement sensors. Among them the rotating speed sensor adopts LEC-50BM-G05E incremental photoelectric rotary encoder, the pressure sensor adopts the pressure sensor of ST2001, the displacement sensor and the digital display meter adopt SGC series grating scale and the GS4204 grating digital readout-instrument separately.The software part can be realized with the the programming software LabVIEW of NI corp. Virtual Instruments(abbreviated as VI) technology is the result which is combined with the technology of measuring control and the computer technology. Its appearance indicates the technology of measuring control enters a new era . As the representative development software of the VI technology LabVIEW adopts the module, figure programming way. the measurement and control systems witch have been developed with LabVIEW have the human-computer interaction interface with friendship. When users’testing requirements change, it can easily change their hardware and software modules or re-allocation of existing systems by the users to meet new testing requirements. In this paper, it has realized these functions such as the detection of the parameter of rotational speed, pressure at all levels and the burned displacement amount in the course of the friction welding, the curve real time display ,the date preservation ,the Playback of the data after welding and the firsthand information dossier of the products and so on by writing the programme with LabVIEW7.1 software. In this paper, It has realized the functions such as the detection of the parameters of the rotational speed, pressure at all levels during the friction welding process and the burned displacement amount, the curve real-time display,the date storage, the playback of data after welding and the products’firsthand information archival records etc.
During the course of the program development,it introduced the dynamic link library technology, multithread technology, multi-task processing technology,serial port communication technology and digital filtering technology and derived a mathematical model to solve the problem of acquisition data delay.It also analyzed the interference source and toke the corresponding defending measure to the interference source in the real working environment in the paper.
Eventually the paper has also carried on the simulation verification test to measurement and control system. Has further confirmed system's validity and the good operationality through the test.
文中详细介绍了参数检测与分析系统的总体设计思路及软硬件的设计。系统硬件主要由工控机、PCI2013多功能数据采集卡以及压力、转速和位移传感器以及数显表等组成。其中转速传感器采用LEC-50BM-G05E增量式光电旋转编码器,压力传感器采用ST2001压力传感器,位移传感器和数显表分别采用SGC系列光栅尺和GS4204光栅数显表。系统软件采用NI公司的虚拟仪器编程软件LabVIEW来实现。虚拟仪器(Virtual Instruments,简称VI)技术是测控技术与计算机技术相结合的产物,它的出现标志着测控技术进入了一个新的时代。LabVIEW作为虚拟仪器技术的代表性开发软件,采用模块化、图形化的编程方式,开发出的测控系统具有友好的人机交互界面,并且当用户的测试要求变化时,可以方便地由用户自己来增减硬、软件模块,或重新配置现有系统以满足新的测试要求。本文采用LabVIEW7.1编程,实现了摩擦焊过程各级转速、压力和摩擦烧损位移量等参数的检测、曲线实时显示、保存和焊后数据回放以及产品原始资料档案记录等功能。
本文对于在软件开发过程中采用的动态库连接、多线程、多任务处理、串口通信以及数字滤波等技术进行了详细的介绍。对如何解决采集数据的延时问题以及采集数据串道等问题也分别进行了论述。文中还对实际工作环境中的干扰源进行了分析并采取了相应的防干扰措施。
最后论文对测控系统进行了模拟验证试验。通过试验进一步验证了系统的有效性和良好的操作性。
It has been developed and researched deeply to the parameter detection system of CT-25 special friction welder in this paper.During the course of friction welding,the frictional pressure, the rotational speed of the main shaft and the burned displacement amount etc.are the very important parameters who can influence the welded joints’quality.So developing a set of advanced friction welder parameter detection and analyticl system with stronger function has important meanings for improving the quality of welding, studying the new welding craft and improving the management level etc.
In the paper,it has been introduced detailedly to the overall ideas of the design and How to design In software and hardware to the parameter detection and analyticl system. The systematic hardware is mainly made up of Industrial Personal Computer, PCI2013 multi-functional data acquisition card and pressure, rotational speed and displacement sensors. Among them the rotating speed sensor adopts LEC-50BM-G05E incremental photoelectric rotary encoder, the pressure sensor adopts the pressure sensor of ST2001, the displacement sensor and the digital display meter adopt SGC series grating scale and the GS4204 grating digital readout-instrument separately.The software part can be realized with the the programming software LabVIEW of NI corp. Virtual Instruments(abbreviated as VI) technology is the result which is combined with the technology of measuring control and the computer technology. Its appearance indicates the technology of measuring control enters a new era . As the representative development software of the VI technology LabVIEW adopts the module, figure programming way. the measurement and control systems witch have been developed with LabVIEW have the human-computer interaction interface with friendship. When users’testing requirements change, it can easily change their hardware and software modules or re-allocation of existing systems by the users to meet new testing requirements. In this paper, it has realized these functions such as the detection of the parameter of rotational speed, pressure at all levels and the burned displacement amount in the course of the friction welding, the curve real time display ,the date preservation ,the Playback of the data after welding and the firsthand information dossier of the products and so on by writing the programme with LabVIEW7.1 software. In this paper, It has realized the functions such as the detection of the parameters of the rotational speed, pressure at all levels during the friction welding process and the burned displacement amount, the curve real-time display,the date storage, the playback of data after welding and the products’firsthand information archival records etc.
During the course of the program development,it introduced the dynamic link library technology, multithread technology, multi-task processing technology,serial port communication technology and digital filtering technology and derived a mathematical model to solve the problem of acquisition data delay.It also analyzed the interference source and toke the corresponding defending measure to the interference source in the real working environment in the paper.
Eventually the paper has also carried on the simulation verification test to measurement and control system. Has further confirmed system's validity and the good operationality through the test.
引文
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[7] C.J.Dowes etc.Friction Stir Process Welds Aluminum Alloys[J].Welding Journal.March 1996,75 (3): 41-45.
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[12]杜随更,王喜锋等.摩擦焊接过程测控软件开发[J].第十次全国焊接会议论文集,2001.
[13]陈世攀,胡波等.钻杆摩擦焊接参数实时检测系统的研制[J].电气传动自动化. 2006, 28(3): 36-37.
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[20]厚国屏,王坤等. LabVIEW编程与虚拟仪器设计[M].北京:清华大学出版社, 2005.
[21]孙传友,孙晓斌等.测控系统原理与设计[M].北京:北京航空航天大学出版社, 2002.
[22]戴鹏飞,王胜开等.测试工程与labVIEW应用[M].北京:电子工业出版社, 2006.
[23] Mconuel E. Future of virtual instrumentation[J]. Sensory,1997,14(7): 22-24.
[24]汪忠士,刘利,陈明等.两种滤波算法在液压数据采集系统中的应用与研究[J].机床与液压, 2005, ( l ): 103-104.
[25]王先培,王全德.测控系统通信与网络教程[M].武汉:武汉大学出版社,2003.
[26]韩毅,邢忠宝.高速高可靠性并行通信接口设计[J].光学精密工程,1995,(4):115-118.
[27] Rowe,Richard R.The transformation of scholarly communications and the future of serials[J]. Serials Review,1996,22 (2) :33-43.
[28]杨乐平,李海涛,杨磊. LabVIEW程序设计与应用(第二版)[M].北京:电子工业出版社,2005.
[29]雷霖著.微机自动检测与系统设计[M].北京:电子工业出版社,2003.
[30]曹向群,黄维石,金彤.光栅计量技术[M].杭州:浙江大学出版社,1992.
[31]徐晓菱,申捷.轴向摩擦焊机上的径向摩擦焊[J].电焊机,1995,(5):30-31.
[32]邓焱,王磊等. LabVIEW7.1测试技术与仪器应用[M].北京:机械工业出版社,2004.
[33]白凤山,潘而立.动态连接库(DLL)在虚拟仪器中的应用[J].自动化与仪表, 2001,16(1):21-22.
[34]穆群英.动态链接库(DLL)的应用[J].石油仪器,2001,(4):49-51.
[35] Vankeerberghen, P etc. Dynamic link libraries I[J]. Introduction.Trends in Analytical Chemistry. 1996, 15(6): 206-208.
[36]陈茂爱,吕云飞,武传松.基于LabVIEW的熔滴过渡过程参数检测系统的方案设计[J].山东大学学报,2005,35(6):104-105.
[37]谢启,方玉.基于LabVIEW软件开发测试系统的关键技术研究[J].机床与液压,2005,(10):151-152.
[38] Kodosky J, MacCrisken J,Rymar G. Visual Programming Using Structured Date Flow[J],IEEE Workshops on Visual Language,Kobe,Japan,1991:260.
[39] National Instruments. LabVIEW Help, 2004(3).
[2]孙勇等.摩擦焊新技术及发展趋势[J].机械工艺师, 1996, (12):34 -35.
[3] Anon. Friction Welding Redefine Design Guidelines[J]. Welding&Metal Fabrication. 1996,64 (9): 21-22.
[4] LabVIEW Data Storage,National Instruments Application Note,2000.
[5] Kevin J Grewe. Friction Welding Takes on New Applieations[J].WeldingJournal,1997,(9):39-40.
[6] Dunkerton S B. Toughness properties of friction welds in steels[J].Welding Journal,1986,8: 193-202.
[7] C.J.Dowes etc.Friction Stir Process Welds Aluminum Alloys[J].Welding Journal.March 1996,75 (3): 41-45.
[8] Xu Xiaoling,Wu Wei,Xu Yuanze.The research of radial friction welding[J].Welding in the World,2005,49 (1/2): 12-15.
[9] Dunkerton S B. Radial Friction Welding for off shore Pipelines. Welding Journal .1987,(7):40-47.
[10] Prosser K.Alternative Welding Systems for Pipelines[J]. Welding Research Abroad,1991,(4):17-27.
[11]樊留群,王文彬等.新型摩擦焊接机床液压及测控系统的研究[J].机床与液压, 1998,(6): 58.
[12]杜随更,王喜锋等.摩擦焊接过程测控软件开发[J].第十次全国焊接会议论文集,2001.
[13]陈世攀,胡波等.钻杆摩擦焊接参数实时检测系统的研制[J].电气传动自动化. 2006, 28(3): 36-37.
[14]李岳流.摩擦焊的现状及其发展动向[J].广州电机, 1989, (1):22-23.
[15]秦树人.虚拟仪器[M].北京:中国计量出版社,2004.
[16]张毅,周绍磊等.虚拟仪器技术分析与应用[M].北京:机械工业出版社,2004.
[17]王朝英,冯新喜.信号处理原理[M].北京:清华大学出版社,北方交通大学出版社, 2005.
[18]汤宝平.数据采集与处理(课堂讲义),2001.
[19]范云霄,刘桦.测试技术与信号处理[M].北京:中国计量出版社, 2002.
[20]厚国屏,王坤等. LabVIEW编程与虚拟仪器设计[M].北京:清华大学出版社, 2005.
[21]孙传友,孙晓斌等.测控系统原理与设计[M].北京:北京航空航天大学出版社, 2002.
[22]戴鹏飞,王胜开等.测试工程与labVIEW应用[M].北京:电子工业出版社, 2006.
[23] Mconuel E. Future of virtual instrumentation[J]. Sensory,1997,14(7): 22-24.
[24]汪忠士,刘利,陈明等.两种滤波算法在液压数据采集系统中的应用与研究[J].机床与液压, 2005, ( l ): 103-104.
[25]王先培,王全德.测控系统通信与网络教程[M].武汉:武汉大学出版社,2003.
[26]韩毅,邢忠宝.高速高可靠性并行通信接口设计[J].光学精密工程,1995,(4):115-118.
[27] Rowe,Richard R.The transformation of scholarly communications and the future of serials[J]. Serials Review,1996,22 (2) :33-43.
[28]杨乐平,李海涛,杨磊. LabVIEW程序设计与应用(第二版)[M].北京:电子工业出版社,2005.
[29]雷霖著.微机自动检测与系统设计[M].北京:电子工业出版社,2003.
[30]曹向群,黄维石,金彤.光栅计量技术[M].杭州:浙江大学出版社,1992.
[31]徐晓菱,申捷.轴向摩擦焊机上的径向摩擦焊[J].电焊机,1995,(5):30-31.
[32]邓焱,王磊等. LabVIEW7.1测试技术与仪器应用[M].北京:机械工业出版社,2004.
[33]白凤山,潘而立.动态连接库(DLL)在虚拟仪器中的应用[J].自动化与仪表, 2001,16(1):21-22.
[34]穆群英.动态链接库(DLL)的应用[J].石油仪器,2001,(4):49-51.
[35] Vankeerberghen, P etc. Dynamic link libraries I[J]. Introduction.Trends in Analytical Chemistry. 1996, 15(6): 206-208.
[36]陈茂爱,吕云飞,武传松.基于LabVIEW的熔滴过渡过程参数检测系统的方案设计[J].山东大学学报,2005,35(6):104-105.
[37]谢启,方玉.基于LabVIEW软件开发测试系统的关键技术研究[J].机床与液压,2005,(10):151-152.
[38] Kodosky J, MacCrisken J,Rymar G. Visual Programming Using Structured Date Flow[J],IEEE Workshops on Visual Language,Kobe,Japan,1991:260.
[39] National Instruments. LabVIEW Help, 2004(3).