CN100570316C - Fault detection instrument of rotary equipment based on acoustic emission - Google Patents
Fault detection instrument of rotary equipment based on acoustic emission Download PDFInfo
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- CN100570316C CN100570316C CNB2007100630881A CN200710063088A CN100570316C CN 100570316 C CN100570316 C CN 100570316C CN B2007100630881 A CNB2007100630881 A CN B2007100630881A CN 200710063088 A CN200710063088 A CN 200710063088A CN 100570316 C CN100570316 C CN 100570316C
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Abstract
The present invention is a kind of fault detection instrument of rotary equipment based on acoustic emission, belongs to a kind of fault detection instrument of rotary equipment.It is made up of calibrate AE sensor, signal condition and three parts such as automatic gain amplification module, digital signal processing module.Signal condition and automatic gain amplification module comprise Gain Automatic adjustment closed control loop that prime amplifier (1), digital regulation resistance (2), totalizer (3), single-chip microcomputer (5) and two-way comparer (6) constitute and trapper (7), low-pass filter several parts such as (8).Digital signal processing module comprises DSP digital signal processor (11), Flash data-carrier store (12), RAM data-carrier store (13), RS232 serial port chip (14), programmable logic controller (PLC) (15), keyboard (16), LCD display each several parts such as (17) composition.The anti-ambient noise interference ability of this instrument is strong, the instrument detecting real-time is good, obtain the equipment running status abundant information, be easy to realize miniaturization.
Description
Technical field
The present invention relates to a kind of fault detection instrument of rotary equipment, particularly a kind of equipment failure detector based on acoustic emission.
Background technology
Fault detection instrument of rotary equipment can be used for detecting the running status of slewing, for guaranteeing the slewing safe operation, avoiding substantial equipment accident and technology accident generation etc. to have tangible economic and social benefit.Existing fault detection instrument of rotary equipment adopts vibration transducer (acceleration, speed or displacement transducer) pick device vibration signal, utilize singlechip technology to carry out signal Processing exists certain deficiency: vibration transducer is equipped with the particular technology requirement, and installation accuracy is had relatively high expectations; The low-frequency excitation signal of environment can pick up by degree of being accelerated sensor, influence test result and cause erroneous judgement, and vibration analysis method is by the analyzing and processing of signals such as acceleration, displacement being come failure judgement, being equivalent to secondary singal and handling very difficult realization real-time detection truly; Single-chip microcomputer is that the data analysis disposal system arithmetic speed of core is slow, precision is low, function is simple relatively, does not also possess the requirement of acquired signal being carried out real-time check and analysis.
Summary of the invention
The purpose of this invention is to provide equipment failure detector based on acoustic emission, this instrument utilizes calibrate AE sensor to pick up the slewing acoustic emission signal, adopt high precision DSP and Digital Signal Processing to carry out signal Processing, instrument has signals collecting, signal analysis, signal storage, function such as wave shape memory and communication, it has overcome with vibration detection and singlechip technology fully is the shortcoming of the fault detection instrument of rotary equipment of core, and it is easy to install to have a sensor, acoustic emission signal is abundant, anti-ambient noise interference ability is strong, the detection real-time is good, be convenient to obtain characteristics such as equipment running status information.
Fault detection instrument of rotary equipment based on acoustic emission provided by the invention is made up of calibrate AE sensor, signal condition and three parts such as automatic gain amplification module, digital signal processing module.
Described signal condition and automatic gain amplification module is characterized in that: comprise prime amplifier 1, digital regulation resistance 2, totalizer 3 ,+1.8V reference power supply 4, single-chip microcomputer 5, two-way voltage comparator 6, trapper 7, low-pass filter 8 ,+2.5V reference power supply 9 ,+3.3V reference power supply 10; Totalizer 3 provides the output signal of prime amplifier 1 and+1.8V reference power supply 4+stack of 1.8V electromotive force, and the electromotive force after the stack is U
0Respectively as the input signal of trapper 7 and two-way voltage comparator 6, U
0Respectively with two-way voltage comparator 6+2.5V reference power supply 9 and+3.3V reference power supply 10 relatively, trigger single-chip microcomputer 5 respectively according to comparative result two-way voltage comparator 6 and produce interrupt INT 0 and interrupt INT 1, single-chip microcomputer 5 is carried out gain according to different interrupt instruction to be increased or the minimizing program, and the resistance that digital regulation resistance increases or reduce digital regulation resistance according to the instruction of single-chip microcomputer 5 reaches the purpose of prime amplifier 1 Gain Automatic adjustment; Signal potential U after prime amplifier 1 amplifies
0Maintain in the 0-3V scope, finish power frequency 50Hz and 150Hz signal trap, realize the 0-10kHz low-pass filtering through low-pass filter 8 again through trapper 7.
Described signal condition and automatic gain amplification module, wherein prime amplifier 1, digital regulation resistance 2, totalizer 3, single-chip microcomputer 5 and two-way voltage comparator 6 have constituted Gain Automatic control closed-loop path.
Described prime amplifier is characterized by: be to be core devices with AD745, prime amplifier allows input impedance greater than 500M Ω, is fit to the conditioning of the calibrate AE sensor output signal of high output impedance.
Described digital signal processing module is primarily characterized in that: comprise DSP digital signal processor 11, Flash data-carrier store 12, RAM data-carrier store 13, RS232 serial port chip 14, programmable logic controller (PLC) 15, keyboard 16, LCD display 17 compositions.
Described DSP digital signal processor 11 has analog to digital converter on the sheet, and its effect is being converted to digital signal, initialization DSP digital signal processor from the analog electrical signal of signal condition and automatic gain amplification module, finishing function such as digital signal processing.
Described FPGA (Field Programmable Gate Array) control register 15 and keyboard 16 is characterized by: programmable logic controller (PLC) 15 is according to written program expansion DSP digital signal processor 11 external interrupt control registers, the button difference of keyboard 16 can make DSP digital signal processor 11 finish different interruptions, realizes user's man-machine conversation function.
Described Flash data-carrier store 12, it is characterized by data space is 512K * 16.
Described LCD display 17, it is characterized by the LCD display, the dot matrix resolution that need not negative pressure and controller is 320 * 240.
Described calibrate AE sensor is to propose on the basis of patent " piezoelectric acoustic sensor (patent No.: ZL200520103257.6) ", it is characterized in that: comprise permanent magnet 18, back sheet 19, piezoelectric element 20, insulation course 21, pickup head 22, intermediate 23, screw 24, lead fixed plate 25, gland bonnet 26, lead 27; Be inlaid with permanent magnet 18 in the inner annular groove of pickup head 22, pickup head 22 and intermediate 23 are used spiral marking connection, pickup head 22 is embedded with back sheet 19, piezoelectric element 20, insulation course 21, insulation course 21 usefulness insulating gels stick in the pickup head inner bottom surface, and piezoelectric element 20 is clipped between insulation course 21 and the back sheet 19.
Calibrate AE sensor leans on magnetic force can be adsorbed on the outside surface of slewing to be measured easily, and detected acoustic emission signal includes abundant slewing running state information.Adopted said structure, can make that the anti-ambient noise interference ability of calibrate AE sensor is strong, the instrument detecting real-time is good, obtain the equipment running status abundant information, be easy to realize miniaturization and portable equipment failure detector.The equipment failure detector that utilization is made has been realized the state-detection to slewing parts such as reciprocating compressor air valve, ram pump combination valve, rolling bearings, has reached the purpose that reduces the slewing accident, avoids disaster accident to take place.
Description of drawings
Fig. 1 is the fault detection instrument of rotary equipment structured flowchart based on acoustic emission;
Fig. 2 is signal condition and automatic gain amplification module structured flowchart;
Fig. 3 is the digital signal processing module structured flowchart;
Fig. 4 is for specifically to implement block diagram based on the fault detection instrument of rotary equipment signal condition and the automatic gain amplification module of acoustic emission;
Fig. 5 is a calibrate AE sensor;
Fig. 6 (a) U
0Singlechip interruption flow chart during＜2.5V;
Fig. 6 (b) U
0Singlechip interruption flow chart during＞3.3V;
Fig. 6 (c) 2.5V＜U
0Singlechip interruption flow chart during＜3.3V.
Embodiment
The invention will be further described below in conjunction with accompanying drawing.
As shown in Figure 1, fault detection instrument of rotary equipment is made up of calibrate AE sensor, signal condition and three parts such as automatic gain amplification module, digital signal processing module, and wherein calibrate AE sensor detects the acoustic emission signal of slewing; Functions such as the preposition amplification of signal condition and automatic gain amplification module realization calibrate AE sensor output signal, automatic gain control, power frequency trap, low-pass filtering, make the low output impedance that the high input impedance of calibrate AE sensor becomes and amplify faint electric signal, filtering interference signals and useless signal, the detection signal Control of Voltage of amplifying through signal condition and automatic gain between 0-3V, the extremely low requirement of satisfying the digital signal processing module input signal of impedance; Digital signal processing module is finished functions such as A/D analog to digital conversion, signal Processing, signal demonstration, signal storage and wave shape memory.
Signal condition provided by the invention and automatic gain amplification module: see Fig. 2, Fig. 4, comprise with AD745 being the prime amplifier 1 of core devices, with AD5200 is the digital regulation resistance 2 of core devices, with AD8642 is the totalizer 3 of core devices, with AD318 be core devices+1.8V reference power supply 4, model is the single-chip microcomputer 5 of AT89S8253, with AD8612 is the two-way voltage comparator 6 of core devices, model is the trapper 7 of LMF90, model is the low-pass filter 8 of MAX291, with ADR421 be core devices+2.5V reference power supply 9, with ADR366 be core devices+3.3V reference power supply 10, prime amplifier 1, digital regulation resistance 2, totalizer 3, single-chip microcomputer 5 and two-way voltage comparator 6 etc. are formed a closed-loop control system, and the principle of its closed-loop control is: totalizer 3 is with the electric signal of prime amplifier 1 output and+1.8V reference power supply 4 output positive potentials stacks becoming unipolarity output electric signal U
0, two-way voltage comparator 6 utilization+2.5V reference power supplies 9 and+3.3V reference power supply 10 forms a voltage window comparer, the window comparator upper voltage limit be+3.3V, lower voltage limit are+2.5V to work as U
0Crest voltage when surpassing upper voltage limit, two-way voltage comparator 6 triggers single-chip microcomputers 5 and produces external interrupt 0, single-chip microcomputer 5 makes that the resistance of digital regulation resistance 2 reduces, the gain of amplifier 1 reduces in interrupt routine; Work as U
0Crest voltage when being lower than lower voltage limit, single-chip microcomputer 5 increases the resistance of digital regulation resistance 2, amplifier 1 gain becomes big.The detection signal that amplifies through gain carries out power frequency 50Hz trap and 150Hz trap through trapper 7, and then realizes the 0-10kHz low-pass filtering through low-pass filter (Max291) 8.
Signal condition provided by the invention and automatic gain amplification module technical scheme are: the detected electric signal of calibrate AE sensor is from the port IN input of prime amplifier 1, and digital regulation resistance 2 is determined the gain amplifier of prime amplifier 1 according to the gain adjustment instruction of single-chip microcomputer 5; The port CSI of digital regulation resistance 2 is connected with the MISO port with the SCK of single-chip microcomputer 5 respectively with MOSI; The OUT port of prime amplifier 1 links to each other with the IN port of totalizer 3, and+1.8V reference power supply 4 provides+the output signal stack of 1.8V voltage and prime amplifier 1, the signal after the stack is from the OUT port output of totalizer 3; Electric signal after the stack is divided into two-way, and one the tunnel links to each other with the IN input port of two-way voltage comparator 6, and one the tunnel links to each other with the IN input port of trapper 7; Signal after the stack in two-way voltage comparator 6 respectively with+2.5V reference power supply 9 and+VL and VH voltage that 3.3V reference power supply 10 provides compares, make single-chip microcomputer 5 produce INT0 and INT1 interruption respectively according to comparative result, and then make the change in gain of digital regulation resistance 2; The INT0 of two-way voltage comparator 6 links to each other with the INT1 port with the INT0 of single-chip microcomputer 5 respectively with the INT1 port; Signal after gain is amplified carries out power frequency 50Hz and 150Hz trap through trapper 7, and the OUT port of trapper 7 links to each other with the IN port of low-pass filter 8; Signal after the low-pass filtering is from the OUT port output of low-pass filter 8.
Single-chip microcomputer gain control program block diagram: see Fig. 6 (a) and (b), (c), master routine and interrupt routine connect by zone bit Flag, an interrupt latency is arranged in master routine, just check subsequently whether Flag is set to 1 in interrupt routine 1, if on behalf of the output signal peak value, 0 do not reach set lower voltage limit, the gain that single-chip microcomputer increases amplifier 1 by the value that increases register RDAC; If on behalf of the output signal peak value, 1 reached lower voltage limit, Amplifier Gain is more suitable this moment, do not need to adjust, so master routine is not done any operation, and the detection of a beginning new round after the Flag zero clearing; In case just entering the value of interrupting reducing in 0 the interrupt routine register RDAC, the upper voltage limit that the peak value of output signal surpass to be set, program reach the purpose that reduces amplifier gain.
Digital signal processing module provided by the invention: see Fig. 3, it is that the DSP digital signal processor 11 of TMS320F2812 carries out signal Processing that the electric signal that amplifies through signal condition and gain is delivered to model, and digital signal processor 11 has AD switching controller on 12 bit slices; DSP digital signal processor 11 is finished being provided with etc. of initialization, interrupt service routine entry address of initialization, the system peripheral of initialization, the PIE interrupt vector table of self system by instruction repertorie; Utilize model for the FPGA (Field Programmable Gate Array) control register 15 of EPM7128A extends out external interrupt I/O composition keyboard 16, make instrument realize functions such as corresponding sampling, time-domain analysis, frequency-domain analysis, correlation analysis, data preservation, data communication by interrupt function; Adopting model is that the Flash data-carrier store 12 of SST39VF400A is preserved the data hold function that data that DSP digital signal processors 11 send here realize instrument; DSP digital signal processor 11 also can call the wave shape memory function of the data realization instrument in the Flash data-carrier store; Model is that the RS232 serial port chip 14 of MAX3232 is to realize that DSP digital signal processor 11 and outer computer carry out the hardware device of serial communication, and DSP digital signal processor 11 is realized and the computer by serial communication according to corresponding interrupt instruction function; Model is the random data storer of the RAM data-carrier store 13 of 61LV25616AL as DSP digital signal processor 11; The employing signal is that the LCD display 17 of AT-320240Q1FIEB-33H realizes functions such as waveform demonstrations, the dialogue of instrument man-machine interface.
Adopt this rotary equipment failure detector that the acoustic emission signal of centrifugal pump rolling bearing and reciprocating compressor air valve is detected, the fault detection instrument of rotary equipment that facts have proved development has characteristics such as man-machine interface close friend, anti-ambient noise interference ability be strong, easy to use, it can be used safely in the state-detection of slewing, realizes functions such as signals collecting, signal storage, time-domain waveform analysis, frequency-region signal analysis, root mean square analysis, mean deviation analysis, wave shape memory and RS232 serial communication.
Claims (5)
1, based on the fault detection instrument of rotary equipment of acoustic emission, it is characterized in that: comprise calibrate AE sensor, signal condition and automatic gain amplification module, digital signal processing module;
Described signal condition and automatic gain amplification module, comprise prime amplifier (1), digital regulation resistance (2), totalizer (3) ,+1.8V reference power supply (4), single-chip microcomputer (5), two-way voltage comparator (6), trapper (7), low-pass filter (8) ,+2.5V reference power supply (9) ,+3.3V reference power supply (10); Totalizer (3) provides the output signal of prime amplifier (1) and+1.8V reference power supply (4)+stack of 1.8V electromotive force, and the electromotive force after the stack is U
0Respectively as the input signal of trapper (7) and two-way voltage comparator (6), U
0Respectively with two-way voltage comparator (6)+2.5V reference power supply (9) and+3.3V reference power supply (10) relatively, trigger single-chip microcomputer (5) according to comparative result two-way voltage comparator (6), single-chip microcomputer (5) produces interrupt INT 0 and interrupt INT 1, single-chip microcomputer (5) is carried out gain according to interrupt INT O respectively with interrupt INT 1 different interrupt instruction to be increased or the minimizing program, and then the resistance that makes digital regulation resistance (2) increases or reduces, and reaches the purpose of the Gain Automatic adjustment of prime amplifier (1); The output signal of prime amplifier (1) is finished power frequency 50Hz and 150Hz signal trap through trapper (7), realizes the 0-10kHz low-pass filtering through low-pass filter (8) again;
Described signal condition and automatic gain amplification module, its prime amplifier (1), digital regulation resistance (2), totalizer (3), single-chip microcomputer (5) and two-way voltage comparator (6) have constituted automatic gain control closed-loop path;
Described prime amplifier (1) is a core devices with AD745, allows input impedance greater than 500M Ω, is fit to the conditioning of the calibrate AE sensor output signal of high output impedance;
Described digital signal processing module comprises DSP digital signal processor (11), Flash data-carrier store (12), RAM data-carrier store (13), RS232 serial port chip (14), programmable logic controller (PLC) (15), keyboard (16), LCD display (17).
2, the fault detection instrument of rotary equipment based on acoustic emission according to claim 1 is characterized in that: DSP digital signal processor (11) has analog to digital converter on the sheet.
3, the equipment failure detector based on acoustic emission according to claim 1 is characterized in that: Flash data-carrier store (12) storage space is 512K * 16Bit.
4, the fault detection instrument of rotary equipment based on acoustic emission according to claim 1 is characterized in that: LCD display (17) is for need not the LCD display of negative pressure and controller, and its dot matrix resolution is 320 * 240.
5, the fault detection instrument of rotary equipment based on acoustic emission according to claim 1, it is characterized in that: described calibrate AE sensor comprises permanent magnet (18), back sheet (19), piezoelectric element (20), insulation course (21), pickup head (22), intermediate (23), screw (24), lead fixed plate (25), gland bonnet (26), lead (27); Be inlaid with permanent magnet (18) in the inner annular groove of pickup head (22), pickup head (22) and intermediate (23) are used spiral marking connection; Pickup head (22) is embedded with back sheet (19), piezoelectric element (20), insulation course (21), and insulation course (21) sticks in the pickup head inner bottom surface with insulating gel, and piezoelectric element (20) is clipped between insulation course (21) and the back sheet (19).
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| Application Number | Priority Date | Filing Date | Title |
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| CNB2007100630881A CN100570316C (en) | 2007-01-26 | 2007-01-26 | Fault detection instrument of rotary equipment based on acoustic emission |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB2007100630881A CN100570316C (en) | 2007-01-26 | 2007-01-26 | Fault detection instrument of rotary equipment based on acoustic emission |
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| CN101008589A CN101008589A (en) | 2007-08-01 |
| CN100570316C true CN100570316C (en) | 2009-12-16 |
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Families Citing this family (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102155988B (en) * | 2010-02-11 | 2012-10-10 | 中国钢铁股份有限公司 | Equipment monitoring and diagnosing method |
| CN101943682B (en) * | 2010-09-07 | 2012-02-01 | 中国矿业大学 | Distributed mechanical failures real time monitoring device based on array sound transmitter and method therefor |
| CN102072829B (en) * | 2010-11-04 | 2013-09-04 | 同济大学 | Iron and steel continuous casting equipment oriented method and device for forecasting faults |
| CN102507170B (en) * | 2011-10-20 | 2014-09-17 | 中国人民解放军装甲兵工程学院 | Contact fatigue life prediction testing machine |
| CN105227158B (en) * | 2015-11-13 | 2017-12-15 | 中国空气动力研究与发展中心低速空气动力研究所 | A kind of high-precision signal real time filter |
| CN105716865B (en) * | 2016-02-14 | 2018-09-28 | 成都柏森松传感技术有限公司 | A kind of foundation and application method for detecting the database of bearing running abnormal sound |
| CN105527104B (en) * | 2016-02-14 | 2018-06-05 | 成都柏森松传感技术有限公司 | A kind of bearing running abnormal sound detecting system |
| CN106017932B (en) * | 2016-08-02 | 2020-01-03 | 哈尔滨理工大学 | Motor bearing on-line monitoring and intelligent early warning system |
| CN108981896A (en) * | 2018-07-12 | 2018-12-11 | 清诚声发射研究（广州）有限公司 | A kind of acoustic emission sensor |
| CN109387279B (en) * | 2018-12-19 | 2020-10-16 | 南京工程学院 | Detection circuit for detecting final-stage vibration signal of steam turbine generator |
| CN110132591B (en) * | 2019-06-11 | 2020-12-08 | 任才银 | High-precision rotating shaft fault detection positioning device |
| CN110469782B (en) * | 2019-07-31 | 2020-07-17 | 中国科学院声学研究所 | Pipeline leakage positioning device based on self-adaptive filter |
| CN111227820A (en) * | 2020-02-21 | 2020-06-05 | 孙磊 | Fetal heart detection sensor matrix of multidimensional channel sensor and fetal heart detection equipment |
| CN113639853A (en) * | 2021-08-30 | 2021-11-12 | 广东亿讯电子有限公司 | Fault detection device and fault detection circuit of stamping die |
| CN116626171B (en) * | 2023-07-24 | 2023-12-19 | 之江实验室 | Acoustic emission signal detection system, acoustic emission signal detection method and fault diagnosis equipment |
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