CN107576384B - Hoisting equipment crack Lamb wave online monitoring system and method - Google Patents
Hoisting equipment crack Lamb wave online monitoring system and method Download PDFInfo
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- CN107576384B CN107576384B CN201710795524.8A CN201710795524A CN107576384B CN 107576384 B CN107576384 B CN 107576384B CN 201710795524 A CN201710795524 A CN 201710795524A CN 107576384 B CN107576384 B CN 107576384B
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Abstract
The invention provides a hoisting equipment crack Lamb wave on-line monitoring system for hoisting equipment, which provides a means for hoisting equipment crack on-line monitoring, so that the damage quantification result is more accurate, and the system comprises a piezoelectric flexible sensing modular array, a multi-way change-over switch, a hardware excitation/acquisition module and system software. The hoisting equipment crack Lamb wave online monitoring system has the advantages of convenience in sensor installation, simplicity in wiring, small and portable system host, low power consumption and the like, is wider in application range, faster in structure scanning speed, and provides technical support for safe operation of hoisting equipment. The invention also discloses an online monitoring method for the crack Lamb wave of the hoisting equipment.
Description
Technical Field
The invention relates to a piezoelectric flexible sensing modular array which is used for monitoring fatigue crack evolution of a mechanical structure in real time. The invention also relates to a hoisting equipment crack Lamb wave online monitoring system comprising the piezoelectric flexible sensing modular array and an online monitoring method based on the hoisting equipment crack Lamb wave online monitoring system.
Background
The hoisting equipment is used as large-scale special equipment and is widely applied to industries with vital national economy, such as equipment manufacturing, port transportation, metallurgical power, building and the like. The hoisting equipment bears large load alternating stress for a long time during service, cracks are easy to generate under the corrosion action of air, rainwater and seawater, and safety accidents caused by crack defects are frequent. Meanwhile, many existing hoisting equipment are in the late stage of the design service life, even a part of the existing hoisting equipment is in service for a long time, microscopic or macroscopic cracks exist on the metal structure of the existing hoisting equipment, and the existing hoisting equipment has potential safety risks.
Non-destructive inspection methods that are conventional in engineering, such as: the method can be used for detecting and positioning cracks of the hoisting equipment, and has unique application fields and limitations. For example, magnetic particle inspection is limited by the particle size of the magnetic particles, and can only detect surface cracks with a certain opening width; the eddy current detection method can only detect surface and near-surface cracks and is not sensitive to deep-buried cracks; x-ray examination of objects is usually a volumetric type of lesion; ultrasonic echo detection needs to scan the structure, has low detection efficiency and low reliability when detecting closed cracks. In addition, the traditional nondestructive testing means has the problems of long testing period, inconvenient installation of instruments and equipment and the like in the crack detection application of hoisting equipment, often needs to be stopped production and shut down, and costs a large amount of manpower and financial resources.
Lamb waves are an ultrasonic guided wave that propagates in plate-like structures. When the transmitted Lamb wave encounters damage, effects such as reflection, scattering, mode conversion and energy absorption occur, so that the Lamb wave sensing signal is changed. Lamb waves have the advantages of small propagation attenuation, wide detection range, sensitivity to small damages such as cracks in plate structures and the like. A domestic research institution develops an integrated master control structure health monitoring system based on Lamb waves, the system has multiple functions of excitation signal output, sensing signal acquisition, multi-sensor channel polling scanning, damage monitoring and the like, and research and experiments of an active structure health monitoring technology of large-scale structural members can be realized.
The existing structural health monitoring system based on Lamb waves has the defects of large volume, heavier weight, large power consumption and the like, is suitable for scientific research and experimental research, and is not suitable for carrying out long-term online monitoring on cracks of hoisting equipment under actual working conditions.
The existing system generally adopts a piezoelectric wafer as a sensor, and adopts a plurality of piezoelectric sensors to form a network, so as to realize the monitoring of damage. When the piezoelectric ceramic chip is installed, a plurality of piezoelectric chips are pasted one by one and independently connected, and the method has the following problems when hoisting equipment cracks are monitored: a) the consistency of the performances of the sensors is difficult to ensure in a one-by-one pasting mode, and the stability, the electrical characteristics, the service life and the like of the sensors are difficult to control; b) each sensor requires 2 leads and the sensor operates at high frequency, necessitating the use of shielded wires. As a result, the number of leads of the sensors is large, and the weight is large; c) each sensor is pasted independently and wired respectively, and the arrangement efficiency of the piezoelectric sensor is low.
Disclosure of Invention
In order to overcome the defects, the invention realizes the real-time online monitoring of hoisting equipment cracks by utilizing a Lamb wave technology and develops a hoisting equipment crack Lamb wave online monitoring system.
The invention provides a piezoelectric flexible sensing modular array, which comprises a connector, a printed circuit, a piezoelectric wafer and a polyimide film, wherein the connector is welded at a reserved position at the top end of a polyimide film printed circuit board; the piezoelectric wafers are adhered to the reserved positions of the polyimide films through high-performance conductive adhesives and are sequentially arranged, so that the positive electrodes and the negative electrodes of the piezoelectric wafers are connected with one end of the printed circuit; the connector is connected with the other end of the printed circuit, and light and thin flexible materials for water resistance and corrosion resistance are respectively bonded on the upper side and the lower side of the polyimide film in consideration of the complexity of the field environment of the hoisting equipment.
A hoisting equipment crack Lamb wave on-line monitoring system comprises the piezoelectric flexible sensing modular array, a multi-way change-over switch, a hardware excitation/acquisition module and system software.
The multi-way change-over switch adopts a mixed design of a high-speed relay and a high-voltage analog switch, and realizes the quick switching between multi-way high-voltage excitation signals and low-voltage receiving signals.
The hardware excitation/acquisition module comprises a central processing unit, an excitation signal generation unit, a linear power amplification unit and an acquisition signal processing unit, wherein the central processing unit is used for logic control of each unit module and high-speed data communication with a computer; the excitation signal generating unit generates a sine modulation signal to be loaded to the excitation sensor; the linear power amplification unit is used for linearly amplifying the broadband low-voltage signal generated by the signal generation unit to a high-voltage signal required by exciting the piezoelectric flexible sensing modular array; the acquisition signal processing unit comprises a filter circuit, a pre-amplification circuit and an A/D sampling circuit and is used for acquiring an acquisition signal with a high signal-to-noise ratio.
The system software has a good man-machine interaction interface, the basic functions comprise measured structure definition, signal excitation/acquisition parameter setting, scanning path definition, acquired data visualization, characteristic parameter extraction and historical data query, and reliable online monitoring of the cracks of the hoisting equipment is realized.
A hoisting equipment crack Lamb wave online monitoring method adopts the hoisting equipment crack Lamb wave online monitoring system, and specifically comprises the following steps:
the first step is as follows: forming a piezoelectric flexible sensing modular array, and correspondingly fixing each piezoelectric wafer in the piezoelectric flexible sensing modular array on the tested hoisting equipment in an adhesion mode;
the second step is that: connecting and matching the modular arrays with a system, and arranging a connector matched with the piezoelectric flexible sensing modular array on system hardware, so that a male connector head at the top end of each piezoelectric flexible sensing modular array is connected with a female connector head matched with the hoisting equipment crack Lamb wave online monitoring system hardware;
the third step: the hoisting equipment crack Lamb wave monitoring system generates an excitation signal and loads the excitation signal onto the piezoelectric flexible sensing modular array, and simultaneously reads a monitoring signal of the piezoelectric flexible sensing modular array;
the fourth step: and analyzing and processing the monitoring signal by system software, extracting and displaying a crack signal.
The invention provides a piezoelectric flexible sensing array adopting a modular design, which overcomes the technical problems of one-by-one sticking and independent wiring of a plurality of piezoelectric wafers in the prior art, and integrates a connector, a printed circuit, the piezoelectric wafers, a polyimide film and the like into a modular array, so that in the online monitoring of cracks of hoisting equipment by using an active Lamb wave method, the monitoring stability can be realized by adopting a modular structure, the piezoelectric wafers are intensively arranged, the wiring among the piezoelectric wafers is simple, and the efficiency is higher. And the modular design is adopted, so that the whole sensing device has a simple structure and lighter weight, and the technical problem in the prior art is effectively solved.
The hoisting equipment crack Lamb wave online monitoring system based on the piezoelectric flexible sensing technology comprises a piezoelectric flexible sensing modular array, a multi-way switch, a hardware excitation/acquisition module and system software, and has the advantages of convenience in sensor installation, simplicity in wiring, small and portable system host, low power consumption and the like. The method provides a means for on-line monitoring of the cracks of the hoisting equipment and provides technical support for safe operation of the hoisting equipment.
Drawings
FIG. 1 is a composition block diagram of a hoisting equipment crack Lamb wave online monitoring system.
FIG. 2 is a schematic diagram of a piezoelectric flexible sensing modular array.
Detailed Description
Acoustic waves are excited at a certain point of the thin plate, and when the acoustic waves propagate to the upper and lower interfaces of the plate, waveform conversion occurs, and the waves formed after superposition are called Lamb waves. When Lamb waves propagate in the structure, various damages in the structure can cause stress concentration and crack propagation, and further cause scattering of Lamb wave signals propagating in the structure and absorption of energy, so that the Lamb waves can be used for monitoring the damages in the structure. The invention adopts an active Lamb wave method to carry out on-line monitoring on the cracks of the hoisting equipment.
As shown in fig. 1, the hoisting equipment crack Lamb wave online monitoring system comprises a piezoelectric flexible sensing modular array, a multi-way switch, a hardware excitation/acquisition module and system software.
The multi-way change-over switch adopts a mixed design of a high-speed relay and a high-voltage analog switch, and realizes the quick switching between multi-way high-voltage excitation signals and low-voltage receiving signals.
The hardware excitation/acquisition module comprises a central processing unit, an excitation signal generation unit, a linear power amplification unit, an acquisition signal processing unit and the like. The central processing unit is used for logic control of each unit module and high-speed data communication with the computer; the excitation signal generating unit generates a sine modulation signal to be loaded to the excitation sensor; the linear power amplification unit is used for linearly amplifying the broadband low-voltage signal generated by the signal generation unit to a high-voltage signal required by exciting the piezoelectric flexible sensing modular array; the acquisition signal processing unit comprises a filter circuit, a pre-amplification circuit, an A/D sampling circuit and the like and is used for acquiring an acquisition signal with a high signal-to-noise ratio.
The system software has a good man-machine interaction interface, the basic functions comprise measured structure definition, signal excitation/acquisition parameter setting, scanning path definition, acquired data visualization, characteristic parameter extraction, historical data query and the like, and reliable online monitoring of the cracks of the hoisting equipment is realized.
As shown in fig. 2, the piezoelectric flexible sensing modular array comprises a connector 1, a printed circuit 2, 6 piezoelectric wafers 3 and a polyimide film 4. The 12-core connector 1 is welded at a reserved position at the top end of the polyimide film printed circuit board, and the printed circuit 2 is printed on the polyimide film 4 in a printed circuit board mode; the piezoelectric wafer 3 is adhered to the reserved position of the polyimide film 4 through high-performance conductive adhesive, such as high-performance epoxy resin adhesive, 6 piezoelectric wafers 3 are arranged, and the piezoelectric wafers 3 are sequentially arranged, so that the positive electrode and the negative electrode of the piezoelectric wafer 3 are connected with one end of the printed circuit 2; the 12-core connector 1 is connected to the other end of the printed circuit 2, and light and thin flexible materials for water resistance and corrosion resistance are respectively bonded to the upper and lower sides of the polyimide film in consideration of the complexity of the field environment of the lifting equipment, and the number of the piezoelectric wafers may be arranged as required, so that an appropriate connector is constructed according to the conditions of the piezoelectric wafers.
Compared with the prior art, the piezoelectric wafers are in a modularized design, the technical problems that a plurality of piezoelectric wafers are pasted one by one and are connected independently in the prior art are solved, and the connectors, the printed circuits, the piezoelectric wafers, the polyimide films and the like are integrated in a modularized array, so that in the process of carrying out online monitoring on cracks of hoisting equipment by using an active Lamb wave method, the modularized structure is adopted, the monitoring stability can be realized, the piezoelectric wafers are arranged in a centralized mode, the wiring among the piezoelectric wafers is simple, and the efficiency is high. And the modular design is adopted, so that the whole sensing device has a simple structure and lighter weight, and the technical problem in the prior art is effectively solved.
The method for on-line monitoring of the crack Lamb wave of the hoisting equipment comprises the following steps:
the first step is as follows: forming a piezoelectric flexible sensing modular array, and correspondingly fixing each piezoelectric wafer in the piezoelectric flexible sensing modular array on the tested hoisting equipment in an adhesion mode;
the second step is that: connecting and matching the modular arrays with a system, and arranging a connector matched with the piezoelectric flexible sensing modular array on system hardware, so that a male connector head at the top end of each piezoelectric flexible sensing modular array is connected with a female connector head matched with the hoisting equipment crack Lamb wave online monitoring system hardware;
the third step: the hoisting equipment crack Lamb wave monitoring system generates an excitation signal and loads the excitation signal onto the piezoelectric flexible sensing modular array, and simultaneously reads a monitoring signal of the piezoelectric flexible sensing modular array;
the fourth step: and analyzing and processing the monitoring signal by system software, extracting and displaying a crack signal.
By the system and the monitoring method, the online monitoring of the large-area plate structure cracks can be realized, and the system and the method have important significance in the aspects of ensuring the safety and reliability of hoisting equipment, reducing the probability of disasters, avoiding major safety accidents, reducing the operation and maintenance cost and the like.
Claims (6)
1. A piezoelectric flexible sensing modular array comprises a connector, a printed circuit, a piezoelectric wafer and a polyimide film, wherein the upper side and the lower side of the polyimide film are respectively bonded with a waterproof and anti-corrosion light and thin flexible material in consideration of the complexity of the field environment of hoisting equipment; the piezoelectric wafers are adhered to the reserved positions of the polyimide films through high-performance conductive adhesives and are sequentially arranged, so that the positive electrodes and the negative electrodes of the piezoelectric wafers are connected with one end of the printed circuit; the connector is connected with the other end of the printed circuit.
2. A hoisting equipment crack Lamb wave on-line monitoring system, comprising the piezoelectric flexible sensing modular array, a multi-way switch, a hardware excitation/acquisition module and system software as claimed in claim 1.
3. The hoisting equipment crack Lamb wave on-line monitoring system of claim 2, wherein: the multi-way change-over switch adopts a mixed design of a high-speed relay and a high-voltage analog switch, and realizes the quick switching between multi-way high-voltage excitation signals and low-voltage receiving signals.
4. The hoisting equipment crack Lamb wave on-line monitoring system of claim 2, wherein: the hardware excitation/acquisition module comprises a central processing unit, an excitation signal generation unit, a linear power amplification unit and an acquisition signal processing unit, wherein the central processing unit is used for logic control of each unit module and high-speed data communication with a computer; the excitation signal generating unit generates a sine modulation signal to be loaded to the excitation sensor; the linear power amplification unit is used for linearly amplifying the broadband low-voltage signal generated by the signal generation unit to a high-voltage signal required by exciting the piezoelectric flexible sensing modular array; the acquisition signal processing unit comprises a filter circuit, a pre-amplification circuit and an A/D sampling circuit and is used for acquiring an acquisition signal with a high signal-to-noise ratio.
5. The hoisting equipment crack Lamb wave on-line monitoring system of claim 2, wherein: the system software has a good man-machine interaction interface, the basic functions comprise measured structure definition, signal excitation/acquisition parameter setting, scanning path definition, acquired data visualization, characteristic parameter extraction and historical data query, and reliable online monitoring of the cracks of the hoisting equipment is realized.
6. A hoisting equipment crack Lamb wave online monitoring method adopts the hoisting equipment crack Lamb wave online monitoring system as claimed in any one of claims 2-5, and specifically comprises the following steps:
the first step is as follows: forming a piezoelectric flexible sensing modular array, and correspondingly fixing each piezoelectric wafer in the piezoelectric flexible sensing modular array on the tested hoisting equipment in an adhesion mode;
the second step is that: connecting and matching the modular arrays with a system, and arranging a connector matched with the piezoelectric flexible sensing modular array on system hardware, so that a male connector head at the top end of each piezoelectric flexible sensing modular array is connected with a female connector head matched with the hoisting equipment crack Lamb wave online monitoring system hardware;
the third step: the hoisting equipment crack Lamb wave monitoring system generates an excitation signal and loads the excitation signal onto the piezoelectric flexible sensing modular array, and simultaneously reads a monitoring signal of the piezoelectric flexible sensing modular array;
the fourth step: and analyzing and processing the monitoring signal by system software, extracting and displaying a crack signal.
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| CN109738105B (en) * | 2018-12-17 | 2022-06-03 | 浙江清华柔性电子技术研究院 | Skin electronic device for monitoring shock wave intensity |
| CN109655493A (en) * | 2019-01-21 | 2019-04-19 | 广东省特种设备检测研究院珠海检测院 | A kind of crane crack Propagation monitoring device and method |
| CN110108402B (en) | 2019-05-20 | 2021-08-06 | 北京工业大学 | Nonlinear Lamb wave frequency mixing method for measuring stress distribution in metal sheet |
| CN110729395A (en) * | 2019-10-31 | 2020-01-24 | 华东交通大学 | Flexible sensing device and method for active flaw detection of train bogie |
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Effective date of registration: 20211207 Address after: Room 710, block a, building 2, Xiyuan, Heping Street, Chaoyang District, Beijing 100020 Patentee after: BEIJING ZHONGJIAN HOPES TECHNOLOGY CO.,LTD. Address before: 100029 No.2 Xiyuan, Heping Street, Chaoyang District, Beijing Patentee before: CHINA SPECIAL EQUIPMENT INSPECTION AND Research Institute Patentee before: Beijing Zhongjian hope Technology Co., Ltd |
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Address after: Room 710, block a, building 2, Xiyuan, Heping Street, Chaoyang District, Beijing 100020 Patentee after: China Merchants zhongtezhi inspection (Beijing) Technology Co.,Ltd. Address before: Room 710, block a, building 2, Xiyuan, Heping Street, Chaoyang District, Beijing 100020 Patentee before: BEIJING ZHONGJIAN HOPES TECHNOLOGY CO.,LTD. |
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