Without the horizontal rotation body dynamic balance detection system of additional sensor
Technical field
The present invention relates to a kind of dynamic balance detection system, particularly relate to a kind of dynamic balance detection system without additional sensor.
Background technology
Contain a large amount of parts rotated in conventional machinery, such as various transmission shaft, main shaft, turntable and motor etc., be referred to as solid of revolution.In ideal conditions solid of revolution rotate time with non rotating time, to bearing produce pressure be the same, such solid of revolution be balance solid of revolution.But the various solid of revolution in engineering, because material is uneven or blank defect, processing and the error produced in assembling, even just there is the many factors such as asymmetrical geometric configuration during design, make solid of revolution when rotated, the centrifugal intertia force that on it, each small particle produces can not be cancelled out each other, centrifugal intertia force is applied on machinery and basis thereof by bearing, cause vibration, the amplitude of vibration is by the angular velocity with object, the effective mass of the unbalanced point of object, effective radius, and the rigidity of stilt is relevant, create noise, accelerate bearing wear, run shakiness etc., have a strong impact on the serviceable life of equipment, the precision of security and equipment, sexual behavior event can be damaged time serious.For this reason, equilibrium analysis and compensation must be carried out to solid of revolution, make it reach the balance accuracy grade of permission, or the mechanical vibration amplitude of generation is fallen in allowed limits.
The spot dynamic balance checkout equipment that some external manufacturers provide generally all adopts the method for acceleration transducer and speed probe to carry out balance detection calculating, so not only cost is high, and in some occasion inconvenient operation, so a kind of characteristic according to actual machine equipment, and develop one and be suitable in Application in numerical control (NC) System, carry out real-time transient equilibrium monitoring without additional sensor dynamic balance detection system, be very necessary.
Note: the patented technology that make use of another same period of the application of the applicant in system of the present invention, particular content is: dynamic balance analysis device as shown in Figure 1, comprise front end signal processing unit, be mainly used in gathering and change (the vibrative signal of external representation imbalance rotation because motor imbalance rotates the vibration signal produced, comprise the frequency of vibration, the information such as amplitude and phase place), carry out the operations such as AD sampling, to reach adjustment signal input range, the analog quantity of vibration signal is converted to digital quantity, ensure that FFT signal transacting has enough bandwidth.
FIFO, mainly as the buffer cell (namely rotating outside input motor imbalance causes vibration signal to cushion) of outer input data; By the data temporary storage of outside high-speed AD acquisition in FIFO, FIFO is disposable completely afterwards by the time delivers to data in two-port RAM storage element, calculates for fft processor; Control module: mainly as the controller of unit co-ordination.Control module is responsible for producing the enabling signal reading address, write address, enable signal and each correlation module.
Two-port RAM storage element, carries out buffer memory for the raw data inputted outside, and is used for keeping in the intermediate data after butterfly computation, and the inputoutput data of each butterfly row operation all will through the read-write operation of RAM.Therefore, the processing speed impact of frequent read-write operation speed on FFT of RAM is larger.In order to accelerate the arithmetic speed of FFT, need to construct the handling capacity that two-port RAM carrys out speeding up data transmission; The present embodiment adopts two two-port RAM storage unit (that is: dual port RAM 1 and dual port RAM 2).Display unit, the data of the vibration information that the data processing unit for sending data processing unit sends and compensated information show.
Fft processor, utilizes Fourier transform to be converted to frequency-region signal to the time-domain signal that high-speed a/d collects; Fft processor combines the requirement of FFT real time implementation and chip design flexibility, realize distributing rationally of parallel algorithm and hardware configuration, improve FFT processing speed, meet the requirement of the high speed of analysis of vibration signal process, high resolving power, high reliability.Fast fourier transform can accurately be purified to vibration frequency, and can obtain because solid of revolution imbalance revolves amplitude and the phase place that (namely motor imbalance rotates and causes vibration signal) transduction causes vibration performance frequency.
Data processing unit, for asking modulus value computing and phase calculation to the complex domain data after FFT process, according to when rotating speed is certain, modulus value and the eccentric point quality of vibration are linearly proportional.By asking the scale-up factor of the modulus value of initializes quality and vibration signal, when rotating speed is constant, by modulus value and the phase place of measuring vibrations signal again, utilize this scale-up factor to determine quality (add or the cut down) M and relative position that need to compensate, current rotating speed is comprised to export, (namely obtain amplitude versus frequency characte and the phase propetry of vibration signal, the amplitude of fundamental frequency signal and phase place reflect the relative mass of eccentric point and the relation of relative position and vibration frequency to need the quality of compensation (add or cut down) and relative position result.)。
Fft processor comprises address control module, butterfly processing element, twiddle factor table storage unit and inverted order module as shown in Figure 2:
Address control module is used for producing enable signal, and plays the sequential control effect of each unit, and produces correct twiddle factor table and search address, and the read/write address of RAM, control effectively, ensure system worked well to the sequential of each module.
Described butterfly processing element, cause vibration signal to carry out butterfly computation for rotating the motor imbalance storing two-port RAM storage element, described butterfly computation can be divided into DIT-FFT (decimation in time) and DIF-FFT (decimation in frequency) algorithm according to the difference of the mode of extraction.According to the formation difference of butterfly computation can be divided into base 2, base 4, base 8 and arbitrarily the factor (2n, n be greater than 1 integer), and split-radix etc.For the course of work of clearer expression butterfly processing element, be described for base-2 loop structure that (this is also the optimum example of device of the present invention, compared with pipeline organization, arithmetic speed declines, but because it uses a butterfly processor, so the resource taken is minimum, the arithmetic speed of pipeline organization is the log of this loop structure
2n doubly.), model as shown in Figure 3: in base-2FFT, N is sampling number, N=2
m, total M level computing, every grade has N/2 2 FFT butterfly computations, therefore total (N/2) log of N point FFT
2n number of butterfly computation.1 base-2 butterfly computation is added with arithmetic element by 1 multiple multiplication unit and 2 and forms.Its formula is as follows:
Concrete operation process and Parametric Representation are:
p=0,1,2 ..., N/2-1; If sequence x (n) length is N, wherein N is FFT sampling number; Owing to altogether needing 256 twiddle factors in 512 every one-levels of FFT, and in every one-level, putting in order of twiddle factor is all regular governed, as: in the signal flow diagram of DIF-FFT, the twiddle factor of the first order is
,
the twiddle factor of the second level is
,
the twiddle factor of the third level is
the twiddle factor of the 9th grade is
,
visible, the twiddle factor of every one-level can extract according to different intervals from the twiddle factor of 256 of the first order, so only need store 256 twiddle factors of the first order in ROM.When calculating not at the same level, only need adopt corresponding addressing method according to arrangement regulation, therefore, the address-wire widths of ROM is also only with 8.
Described twiddle factor table storage unit, twiddle factor table is in fact a ROM, is used for storing the twiddle factor required for every one-level FFT computing, and in N point FFT computing flow graph, every grade has N/2 butterfly, and each butterfly will be multiplied by the factor
be called twiddle factor, wherein N is sampling number, and p is called the index of twiddle factor.But twiddle factor at different levels and recycle design are all different.In order to write calculation procedure, first twiddle factor should be found out
with the relation of computing progression.In order to improve arithmetic speed, by twiddle factor
be made into ROM table, be used for storing the twiddle factor required for every one-level FFT computing.
Described inverted order module, the operational data for being completed by butterfly processing element is carried out inverted sequence and is converted to positive sequence, realizes frequency spectrum normal sequence and outputs in data processing unit; It is order that FFT due to DIT form inputs data x (n) address, but owing to doing odd, even separating to x (n) in calculating process, causing exporting data address is no longer original order.If data address is by n bit representation, the rule of bit reversal is: (n-1)th and the 0th exchange, the n-th-2 and the 1st exchange, the n-th-3 and the 2nd exchange ..., the rest may be inferred just can be converted to positive sequence by inverted sequence.
Idiographic flow is as shown in Figure 4: first, wait for that inputted vibration analyzes enabling signal, then the vibratory output (namely inputting the rotation of motor imbalance to outside causes vibration signal to cushion) carrying out being caused by the rotation of rotating object imbalance is through front end signal processing unit processes (namely AD samples), analog quantity is converted to digital quantity, be input in FIFO (First Input First Output), carry out data buffer storage, by judging whether data get out control the unlatching of fft processor.Data, by after fft processor, can convert frequency-region signal to time-domain signal.Sent by controller and start fft processor signal, start FFT home address control module, first RAM write address is produced, data in FIFO are written in dual port RAM 1, then butterfly processing element is sent the data that first order butterfly computation needs in the address of reading producing RAM1, what produce twiddle factor table reads address, the twiddle factor needed for first order butterfly computation simultaneously
be sent to butterfly processing element, produce the enabling signal of butterfly processing element simultaneously.After first order butterfly computation terminates, address control unit produces the write address of RAM2, and data are deposited in RAM2.Entered log
2after the butterfly computation of N (wherein N is FFT sampling number) level, complete a FFT computing.Export after data processing, return simultaneously and wait for that vibration analysis starts next time.Data in working storage RAM2 are exactly the data of the plural form after FFT computing, through asking modulus value computing to it and asking phase bit arithmetic, just can obtain the amplitude versus frequency characte after FFT and phase-frequency characteristic.Amplitude versus frequency characte has reacted the relative mass of eccentric point and the relation of vibration frequency, and phase-frequency characteristic has reacted the relative position of eccentric point and the relation of vibration frequency.
(such as FPGA in transient equilibrium detection and vibration analysis device accessible site chip.) also special chip can be set, Miltilayer wiring structure can be adopted at chip internal, lower core voltage, abundanter I/O pin, capacity can reach an about 20k logical block (LES), built-in embedded RAM resource, inner integrated multiple digital phase-locked loop, the hardware multiplier of multiple embedding, in conjunction with building of this chip internal embedded software CPU and inner peripheral hardware thereof, all these make this chip demonstrate oneself distinctive advantage in transient equilibrium detection and vibration analysis field.
This is also for the realization without the horizontal rotation body dynamic balance detection system of additional sensor becomes possibility.
Summary of the invention
The present invention is directed to the proposition of above problem, and develop a kind of horizontal rotation body dynamic balance detection system without additional sensor.Concrete technical scheme of the present invention is as follows:
1) private current sensor being connected to the drive motor of horizontal rotation body takes on driver;
2) current value is read after taking driver by private, namely the vibratory output that the rotation of rotating object imbalance causes represents electric current, analog quantity is converted to digital quantity, is input in cell fifo, carry out data buffer storage, by judging whether data get out control the unlatching of fft processor;
3), after the unlatching of fft processor, data convert frequency-region signal by fft processor to time-domain signal, specific as follows:
A, to be sent by controller and start fft processor signal, start fft processor home address control module, first RAM write address is produced, data in FIFO are written in dual port RAM 1, then butterfly processing element is sent the data that first order butterfly computation needs in the address of reading producing RAM1, what produce twiddle factor table reads address, the twiddle factor W needed for first order butterfly computation simultaneously
nbe sent to butterfly processing element, produce the enabling signal of butterfly processing element simultaneously;
After b, first order butterfly computation terminate, address control unit produces the write address of RAM2, data is deposited in RAM2, entered log
2after the butterfly computation of N level, fft processor completes once-through operation, exports after data processing, returns simultaneously and waits for that vibration analysis starts next time;
Data in c, working storage RAM2 are exactly the data of the plural form after fft processor computing, through asking modulus value computing to it and asking phase bit arithmetic, just can obtain corresponding amplitude versus frequency characte and phase-frequency characteristic;
4) amplitude versus frequency characte has reacted the relative mass of eccentric point and the relation of vibration frequency, and phase-frequency characteristic has reacted the relative position of eccentric point and the relation of vibration frequency, just obtains horizontal rotation body transient equilibrium situation.
Carry out the horizontal rotation body dynamic balance detecting device without additional sensor according to said method, comprising:
Front end signal processing unit, causes vibration signal to convert digital quantity to for the analog signals collected and motor imbalance being rotated;
FIFO, causes the digital quantity of vibration signal to cushion for rotating outside input motor imbalance;
Control module, for generation of reading address, write address, the enabling signal of enable signal and each correlation module and control signal;
Two-port RAM storage element, carries out buffer memory for the raw data inputted outside, and is used for keeping in the intermediate data after butterfly computation;
Display unit, the data of the vibration information that the data processing unit for sending data processing unit sends and compensated information show;
Fft processor, utilizes Fourier transform to cause the frequency of vibration signal to purify to because motor imbalance rotates, frequency inverted corresponding for motor speed is become solid of revolution imbalance to rotate the amplitude and the phase place that cause vibration performance frequency;
Data processing unit, for asking modulus value computing and phase calculation to the complex domain data after FFT process, being analyzed transient equilibrium vibration data by the modulus value of vibration and the relation of eccentric point quality, exporting the quality and relative position that compensate;
Described fft processor comprises address control module, butterfly processing element, twiddle factor table storage unit and inverted order module;
Described address control module, searches the read/write address of address and two-port RAM storage element, and controls the sequential of each unit for generation of enable signal, twiddle factor table;
Described butterfly processing element, causes vibration signal to carry out butterfly computation for rotating the motor imbalance storing two-port RAM storage element;
Described twiddle factor table storage unit, for storing the twiddle factor needed for butterfly processing element
wherein N is sampling number, and P is twiddle factor index;
Described inverted order module, the operational data for being completed by butterfly processing element is carried out inverted sequence and is converted to positive sequence, realizes frequency spectrum normal sequence and outputs in data processing unit;
It is characterized in that: front end signal processing unit is connected to the drive motor of horizontal rotation body private by current sensor takes on driver and obtains driving current value.
Compared with the existing technology advantage of the present invention is apparent, is detected by the balance of carrying out horizontal rotation body without additional sensor dynamic, the trouble brought when so just having evaded the error and sensor installation that sensor brings.In addition because its use uses same disposal system with dynamic balance analysis device, be so not only convenient to produce, and cost is very cheap is suitable for extensive popularization.
Accompanying drawing explanation
Fig. 1 is the structured flowchart of equilibrium analysis device described in background technology of the present invention;
Fig. 2 is the structured flowchart of fft processor in equilibrium analysis device described in background technology of the present invention;
Fig. 3 is butterfly processing element flow graph in equilibrium analysis device described in background technology of the present invention;
Fig. 4 is the process flow diagram of equilibrium analysis device described in background technology of the present invention;
Fig. 5 is basic principle schematic of the present invention;
Fig. 6 is corresponding relation schematic diagram of the present invention.
Embodiment
Ultimate principle as shown in Figure 5,
When object rotates with angular velocity omega, any particle is respectively in the component velocity of XY coordinate system:
V
X=ω*R*cosθ①
V
y=ω*R*sinθ②
Wherein θ is the angle of particle M and X-axis
To 1. 2. formula ask first order derivative to obtain:
③
④
Therefore for particle M, the stress in XY direction is
F
X=ω*R*sinθ*M⑤
F
y=ω*R*cosθ*M⑥
5. 6. can be found out when object at the uniform velocity rotates by formula, be a sine value at the centripetal-stress of X and Y-direction.Any rigid support thing can think an elastic model, namely meets
F=k*X⑦
Wherein F is acting force, and X represents deformation efficient deformation amount, and k represents the stiffness factor of different elastic model.Therefore meet on XY direction as follows
k*X
x=F
x=ω*R*sinθ*M⑨
k*X
y=F
y=ω*R*cosθ*M⑩
As can be seen from 9. 10., the displacement in XY direction is the displacement that a kind of satisfied sine accelerates equally, and the acceleration that is by measuring stilt just indirectly can measure the amount of unbalance of rotating part.
According to the formula M=FL of moment;
Power brachium * power=resistance brachium * resistance, now for equalising torque state is when Objects around A stationary shaft rotates, moment only has two kinds of possible directions, so can represent by sign.General provision: the moment that object is rotated in the counterclockwise direction is just; The moment that object is rotated along clockwise direction is negative.Therefore the resultant moment acting on the several moments on the article for rotation of stationary shaft just equals their algebraic sum.If the algebraic sum of the resultant moment of the power suffered by an object is 0, so just say that this object is in equalising torque state; If resultant moment algebraic sum is not 0, so illustrate that this object is in moment nonequilibrium condition.
As shown in Figure 6: owing to giving the drive current I of permanent magnet synchronous torque motor larger, the torque T of motor is larger, I and T direct proportionality, and T=K1*I, K1 are the moment coefficient of motor.
When turntable rotates with angular velocity omega imbalance, due to can not cancelling out each other of centrifugal force, the centrifugal force in Fig. 3 X-direction can constantly change, and turntable can be made to produce vibration, cause X-axis motor also can change the torque T that turntable applies, the drive current I of motor also changes thereupon thereupon.So by detecting the drive current I of X-axis motor, calculate T further, and the component of the centrifugal force of eccentric point M in X-axis can be F
x=ω * Rsin θ * M, angle θ is the angle of particle M and X-axis, directly can be read by the angular encoder under turntable.
Pass through formula below again:
V
X=ω*R*cosθ
F=Ma
T1=F·r
Wherein T1 is centrifugal force moment.
The relation of the angle value θ that the mass M of the eccentric point of turntable and the drive current I of relative position and X-axis motor and scrambler read can be derived.
Transient equilibrium detection without additional sensor and vibration analysis function can be realized to the rotation functional block such as large-scale turntable by said method.
Design without additional sensor transient equilibrium detection scheme
The design's Complex programmable logic device FPGA system devises a portable solution without additional sensor transient equilibrium detection and vibration analysis.
Digital processes divides core to adopt FPGA design, uses the parallel processing technique of hardware, and comprise building of embedded software CPU and inner peripheral hardware thereof, the display card of TFT liquid crystal is built, building and the exploitation of historical data backup and USB interface of fft processor.To the SRAM of several power down protection be hung in addition on cpu bus, for storing the data of testing, comprising compensated information and targeted message.USB part is used for uploading detecting information.Idiographic flow is as follows:
First, etc. the enabling signal of dynamic balance analysis to be entered, the vibratory output (driving the electric current I of the motor rotated) caused is rotated by rotating object imbalance, current value is read after taking driver by private, analog quantity is converted to digital quantity, be input in FIFO (First Input First Output), carry out data buffer storage, by judging whether data get out control the unlatching of fft processor.
Data, by after FFT, can convert frequency-region signal to time-domain signal.
Sent by controller and start fft processor signal, start FFT home address control module, first RAM write address is produced, data in FIFO are written in dual port RAM 1, then butterfly processing element is sent the data that first order butterfly computation needs in the address of reading producing RAM1, what produce twiddle factor table reads address, the twiddle factor W needed for first order butterfly computation simultaneously
nbe sent to butterfly processing element, produce the enabling signal of butterfly processing element simultaneously.After first order butterfly computation terminates, address control unit produces the write address of RAM2, and data are deposited in RAM2.Entered log
2after the butterfly computation of N (wherein N is counting of FFT change) level, complete a FFT computing.Export after data processing, return simultaneously and wait for that vibration analysis starts next time.Data in working storage RAM2 are exactly the data of the plural form after FFT computing, through asking modulus value computing to it and asking phase bit arithmetic, just can obtain the amplitude versus frequency characte after FFT and phase-frequency characteristic.Amplitude versus frequency characte has reacted the relative mass of eccentric point and the relation of vibration frequency, and phase-frequency characteristic has reacted the relative position of eccentric point and the relation of vibration frequency.
The portable solution without additional sensor transient equilibrium detection and vibration analysis of the design's Complex programmable logic device FPGA and AVR single chip Dual System Design one.
(1) front end signal processing unit mainly carries out the operation such as gain-adjusted, bandpass filtering to input signal, to reach adjustment signal input range;
(2) signal acquisition module is with high-speed AD converter AD9220 for core, ensures that spectrum analyzer has enough bandwidth;
(3) fft processor carries out 256 base 2FFT computing to time-domain sampling point, calculates the frequency spectrum of time-domain signal; :
(4) address control module is responsible for producing and is read address, write address, the startup of enable signal and correlation module, control signal, is the core of this module; Dual port RAM is responsible for carrying out buffer memory to the raw data of outside input; Butterfly processing element completes 2 DFT computings; Twiddle factor table is in fact a ROM, is used for storing the twiddle factor required for every one-level FFT computing; Working storage RAM is used for keeping in the intermediate data after butterfly computation; Inverted order module realizes frequency spectrum normal sequence and exports; Operation result due to FFT is plural number, so also need to ask modulus value computing and phase calculation to data.The sequential of control module to each module control effectively, and ensures system worked well;
(5) digital processes divides core to adopt FPGA design, use the parallel processing technique of hardware, comprise building of embedded software CPU and inner peripheral hardware thereof, the display card of TFT liquid crystal is built, building and the exploitation of historical data backup and USB interface of FFT code.To the SRAM of several power down protection be hung in addition on cpu bus, for storing the data of testing, comprising compensated information and targeted message.USB part is used for uploading detecting information, for upper structure database construction.
The above; be only the present invention's preferably embodiment; but protection scope of the present invention is not limited thereto; anyly be familiar with those skilled in the art in the technical scope that the present invention discloses; be equal to according to technical scheme of the present invention and inventive concept thereof and replace or change, all should be encompassed within protection scope of the present invention.