CN108195940B - Optical fiber acoustic emission sensor array device and mechanical crack evolution monitoring technology - Google Patents
Optical fiber acoustic emission sensor array device and mechanical crack evolution monitoring technology Download PDFInfo
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Abstract
The optical fiber acoustic emission sensing system comprises an optical fiber acoustic emission sensor array, an optical fiber acoustic emission preprocessing subsystem, an optical fiber acoustic emission transmission subsystem and an optical fiber acoustic emission monitoring software subsystem. The system provides a new technical method and means for developing fatigue crack evolution monitoring of the mechanical structure, and has an important technical support function for guaranteeing safe and reliable operation of the mechanical structure. Also discloses a method for monitoring the mechanical structure fatigue crack evolution of the optical fiber acoustic emission sensing system.
Description
Technical Field
The invention relates to an optical fiber acoustic emission sensor array which is used for monitoring fatigue crack evolution of a mechanical structure in real time. The invention also relates to an optical fiber acoustic emission sensing system comprising the optical fiber acoustic emission sensor array and a mechanical structure fatigue crack evolution monitoring technology based on the optical fiber acoustic emission sensing system.
Background
The mechanical structure is easy to generate fatigue cracks under the long-term repeated action of stress or strain in the service process, the expression form of the fatigue cracks is firstly the change of the microstructure and the elastoplasticity of a metal material, then the initiation of microcracks is carried out, finally the cracks are expanded until visible cracks are generated, and further the structure is suddenly failed, equipment is damaged in severe cases, and serious safety accidents such as casualties are brought.
Non-destructive inspection methods that are conventional in engineering, such as: the method can be used for detecting and positioning the fatigue crack of the metal structure by using penetration detection, magnetic powder detection, ray detection, ultrasonic detection, eddy current detection, acoustic emission detection and the like, but the detection methods also have 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, in the implementation process of the detection method, the external load of the part to be detected is mostly required to be released in advance, so that the normal operation of the equipment is influenced; on-line real-time monitoring is difficult, and is not beneficial to quickly finding out the structural state after an emergency.
Acoustic Emission (AE) is also called stress wave Emission, and is a phenomenon that a material deforms or breaks under the action of external force or internal force, and releases stress strain energy in the form of elastic waves, and most materials have Acoustic Emission when deforming and breaking. The macroscopic mechanisms that generate acoustic emissions are mainly plastic deformation of the object, the formation and propagation of cracks, fractures, etc., which are also the main manifestations of mechanical structure damage. Acoustic emission testing, in contrast to other non-destructive testing techniques, the energy detected is derived from the object under test itself, rather than being provided by a non-destructive testing machine, as is done with ultrasonic testing or radiographic testing. Meanwhile, acoustic emission detection is sensitive to active defects (such as fatigue crack evolution), and the acoustic emission detection can detect the active condition of the defects under the action of external loading.
Although the acoustic emission technology has many advantages, the acoustic emission technology also has application limitation, is influenced by inherent physical characteristics of a transmission cable, has short transmission distance of acoustic emission signals, is generally used for detection, cannot monitor a mechanical structure for a long time, cannot comprehensively master the health condition of the mechanical structure in real time, and cannot track fatigue crack evolution of the mechanical structure and perform early warning.
Disclosure of Invention
In order to overcome the defects, the invention integrates and innovates an acoustic emission technology and an optical fiber transmission technology, provides an optical fiber acoustic emission sensing technology, and develops an optical fiber acoustic emission sensing system for monitoring the fatigue crack evolution of a mechanical structure in real time. The system provides a new technical method and means for developing fatigue crack evolution monitoring of the mechanical structure, and has an important technical support function for guaranteeing safe and reliable operation of the mechanical structure.
The invention provides an optical fiber acoustic emission sensing system for monitoring fatigue crack evolution of a mechanical structure in real time, which comprises an optical fiber acoustic emission sensor array, an optical fiber acoustic emission preprocessing subsystem, an optical fiber acoustic emission transmission subsystem, an optical fiber acoustic emission monitoring software subsystem and the like, can realize real-time monitoring of fatigue crack evolution of the mechanical structure, and provides technical support for guaranteeing safe and reliable operation of the mechanical structure.
The optical fiber acoustic emission sensing system comprises an optical fiber acoustic emission sensor array, an optical fiber acoustic emission preprocessing subsystem, an optical fiber acoustic emission transmission subsystem and an optical fiber acoustic emission monitoring software subsystem, wherein the optical fiber acoustic emission transmission subsystem adopts optical fiber for transmission.
Furthermore, the optical fiber acoustic emission sensor array is an optical fiber acoustic emission sensor array device and comprises acoustic emission sensing nodes and a guide rail device, wherein the acoustic emission sensing nodes comprise acoustic emission sensors and sensor fixing devices; the acoustic emission sensor is a piezoelectric acoustic emission sensor.
Furthermore, the optical fiber acoustic emission preprocessing subsystem comprises an optical fiber acoustic emission data acquisition module and an optical fiber acoustic emission data conversion module.
Furthermore, the optical fiber acoustic emission transmission subsystem is composed of an electro-optical/photoelectric conversion module, an optical fiber transmission module and the like, wherein the electro-optical/photoelectric conversion module is composed of an RJ45 interface, an isolation transformer, an optical dielectric circuit, an optical transceiver circuit, a power supply and a configuration part.
Furthermore, the optical fiber acoustic emission monitoring software subsystem comprises three modules of parameter setting, data acquisition and data analysis, and is used for processing, displaying and storing optical fiber acoustic emission monitoring signals, so that the acoustic emission condition and the real-time condition of the mechanical structure are displayed, and the fatigue crack evolution condition of the mechanical structure is early warned.
A method for monitoring the fatigue crack evolution of a mechanical structure of an optical fiber acoustic emission sensing system comprises the optical fiber acoustic emission sensing system for monitoring the fatigue crack evolution of the mechanical structure in real time, and comprises the following steps:
installation of optical fiber acoustic emission sensor array
a. Marking the installation position of the acoustic emission sensor on the surface of the detected mechanical structure;
b. polishing the surface of the mounting part of the acoustic emission sensor to remove paint, oxide skin or oil dirt and the like;
c. coating a proper amount of coupling agent on the contact surface of the acoustic emission sensor;
d. and adjusting the acoustic emission sensor in the optical fiber acoustic emission sensor array to a proper position, and pressing the sensor array to make the sensor array contact with the surface of the detected object, and mounting and fixing the sensor array.
Installation of photoelectric conversion module of optical fiber acoustic emission pretreatment subsystem and optical fiber acoustic emission transmission subsystem
In field application, signals output by the optical fiber acoustic emission sensor array are transmitted to the optical fiber acoustic emission preprocessing subsystem through a cable. Because the signal output by the sensor is weak, the cable between the sensor and the optical fiber acoustic emission preprocessing subsystem needs to shield electromagnetic interference, and the length is not too long, and generally should not exceed 2 meters. The optical fiber acoustic emission preprocessing subsystem is fixed on the mechanical structure through placement or magnetic adsorption, an output signal of the optical fiber acoustic emission preprocessing subsystem is connected to an electro-optical conversion module of the optical fiber acoustic emission transmission subsystem fixed on the mechanical structure, and after the electrical signal is converted into an optical signal, the optical fiber acoustic emission preprocessing subsystem is transmitted to a photoelectric conversion module of a monitoring room in a long distance through the optical fiber transmission module.
Mounting photoelectric conversion module of optical fiber acoustic emission transmission subsystem
The photoelectric conversion module is placed in a monitoring room, and is generally placed together with a monitoring computer. The module is used for restoring the optical signal transmitted by the optical fiber into an electric signal. The signals output by the photoelectric conversion subsystem are sent to a computer through a network cable for data analysis and processing.
The optical fiber sensing technology and the acoustic emission technology are integrated and innovated to realize the real-time monitoring of the fatigue crack evolution of the mechanical structure, and the developed optical fiber acoustic emission sensing system for the real-time monitoring of the fatigue crack evolution of the mechanical structure overcomes the defects of the traditional acoustic emission system, realizes the long-distance transmission of acoustic emission signals, and has the characteristics of strong anti-interference capability, long signal transmission distance and the like. The system provides a means for monitoring the fatigue crack evolution of the mechanical structure, and lays a technical foundation for establishing a long-acting mechanism and a safety regulation standard system for the dynamic supervision of the operation safety of the mechanical structure, which are suitable for the national conditions of China.
Drawings
FIG. 1 is a schematic diagram of a fiber acoustic emission sensing system for real-time monitoring of fatigue crack evolution of a mechanical structure.
Fig. 2a is a perspective view of a sensor array suitable for in-plane monitoring.
Fig. 2b is a perspective view of a sensor array suitable for surface monitoring.
FIG. 3 is a block diagram of a fiber acoustic emission data conversion module.
FIG. 4 is a block diagram of an electro-optic/electro-optic conversion module of the fiber optic acoustic emission transmission subsystem.
FIG. 5 is a software block diagram of a fiber acoustic emission sensing system for real-time monitoring of fatigue crack evolution of a mechanical structure.
FIG. 6 is a real-time monitoring interface of the fiber acoustic emission sensing system software for real-time monitoring of fatigue crack evolution of the mechanical structure.
FIG. 7 is a parameter setting interface of the fiber acoustic emission sensing system software for real-time monitoring of fatigue crack evolution of the mechanical structure.
Detailed Description
The optical fiber acoustic emission sensing system for monitoring the fatigue crack evolution of the mechanical structure in real time comprises an optical fiber acoustic emission sensor array 2, an optical fiber acoustic emission preprocessing subsystem 3, an optical fiber acoustic emission transmission subsystem 4, an optical fiber acoustic emission monitoring software subsystem 7 and the like, wherein as shown in figure 1, the optical fiber acoustic emission sensor array 2 receives signals transmitted by an acoustic emission source 1, the signals are processed and converted by the optical fiber acoustic emission preprocessing subsystem 3 and then transmitted to the optical fiber acoustic emission monitoring software subsystem 7 through an optical fiber acoustic emission transmission subsystem 5, the transmission mode is an optical fiber transmission mode 6, and the optical fiber acoustic emission software monitoring subsystem 7 runs through a computer 6.
As shown in fig. 1, the signal acquisition of the optical fiber acoustic emission sensing system for monitoring the fatigue crack evolution of the mechanical structure in real time is realized by the acoustic emission sensor array 2, and the high-efficiency and reliable sensor is the premise of ensuring the health monitoring quality. The piezoelectric acoustic emission sensor has the advantages of simple and compact structure, small size, portability, large linear high-range and the like, has mature technology, stable and reliable work and easy replacement compared with an optical fiber acoustic emission sensor, and adopts the piezoelectric sensor to collect fatigue crack evolution signals.
When fatigue crack evolution monitoring is carried out on a mechanical structure, if a single acoustic emission sensor is adopted for monitoring, misjudgment can be caused by noise interference. Therefore, 2 or 3 acoustic emission sensors are typically used for monitoring. At present, a plurality of acoustic emission sensors are generally installed in a mode of respectively fixing the acoustic emission sensors, the mode is complex to install, and if one of the acoustic emission sensors is not well coupled with a tested mechanical structure, the sensor is difficult to judge which acoustic emission sensor has a problem. The optical fiber acoustic emission sensor array is designed and developed for the purpose of the invention, as shown in fig. 2a and 2b, wherein fig. 2a is the optical fiber acoustic emission sensor array for plane monitoring, and fig. 2b is the optical fiber acoustic emission sensor array for curved surface monitoring.
As shown in fig. 2a, monitoring of local crack evolution in planar structures is typically performed using two or three acoustic emission sensors 23, wherein two sensors may perform line positioning and three sensors may perform planar positioning. For this purpose, two sensor arrays suitable for planar monitoring have been designed. The optical fiber acoustic emission sensor array for plane monitoring comprises two (or three) acoustic emission sensing nodes and a guide rail device 21. The acoustic emission node consists of an acoustic emission sensor 23 and a sensor fixing device 22, and the sensor fixing device 22 fixes the acoustic emission sensor 23 on the measured structure in a magnetic adsorption mode; the guide rail device 21 is also called a rail type bracket, and the process is to process a kidney-shaped hole on a rectangular or triangular bracket. The acoustic emission sensing node is fixed on the track type support through screws, and the sensing node can move and monitor in the range of the kidney-shaped hole of the track type support.
As shown in fig. 2b, the optical fiber acoustic emission sensor array for curved surface monitoring is similar to the sensor array for planar monitoring, but the difference is that the joint can be adjusted perpendicular to the surface to be measured, and when the part to be measured is a curved surface, the array can couple the plurality of sensors with the object to be measured well by adjusting the joint, thereby realizing the monitoring of the object to be measured with a curved surface. Meanwhile, the sensor array reserves an active area for each sensor, and the position of the acoustic emission sensor can be adjusted relatively during monitoring.
The optical fiber acoustic emission preprocessing subsystem realizes the data processing function of the acquired signals and comprises an optical fiber acoustic emission data acquisition module and an optical fiber acoustic emission data conversion module.
Optical fiber acoustic emission data acquisition module
The optical fiber acoustic emission data acquisition module is mainly used for performing related conditioning on signals sensed by the acoustic emission sensor. The data acquisition module comprises signal amplification, filtering, analog-to-digital conversion, characteristic parameter extraction and the like. Because the signals collected by the sensor array are weak, the signals are firstly amplified, and then the analog signals are conditioned into standard signals which can be received by the A/D chip. The analog-to-digital conversion part converts the analog signals into digital signals, and finally the FPGA controls and finishes the extraction of real-time acoustic emission characteristics and the acquisition of acoustic emission waveforms.
Optical fiber acoustic emission data conversion module
The data output by the optical fiber acoustic emission data acquisition module is in a USB protocol, and needs to be converted into a RJ45 protocol and then modulated into an optical signal. The optical fiber acoustic emission data conversion module completes protocol conversion of the USB-Ethernet. According to the requirements of optical fiber transmission and data acquisition, a network conversion interface based on an AVR series single chip microcomputer Tmega64 as a master controller is designed, and the structural block diagram of the system is shown in FIG. 3.
The traditional method for transmitting signals by adopting cables has the defects of limited transmission distance, easiness in interference and the like, while the optical fiber transmission has the advantages of low loss, strong anti-interference capability, reliable performance and the like. The optical fiber acoustic emission transmission subsystem comprises an electro-optical/photoelectric conversion module, an optical fiber transmission module and the like, mainly realizes the functions of electro-optical conversion, optical fiber long-distance transmission, photoelectric demodulation and the like of acoustic emission sensing signals, and realizes the optical fiber transmission of the signals.
The electro-optical/photoelectric conversion module mainly comprises an RJ45 interface, an isolation transformer, an optical-electrical medium circuit, an optical transceiver circuit, a power supply and a configuration part, and realizes the electro-optical conversion and the optical-electrical conversion, and the system structure is shown in fig. 4. The working principle of the electro-optical conversion is as follows: the data introduced into the Ethernet from the 3 and 6 pins of the RJ45 unshielded twisted pair copper cable connector is filtered by the coupling filter circuit, then the signal is sent to the photoelectric medium circuit, the photoelectric medium circuit translates or reformats the data to complete a level conversion, and the level conversion is sent to the optical transceiver circuit, and then the optical transceiver circuit sends the data to the optical fiber transmission module. The photo-electric conversion is opposite to the above-described operation.
The optical fiber transmission module mainly refers to a transmission optical fiber which is used for transmitting an optical signal output by the electro-optical conversion module in a long distance.
The fiber acoustic emission monitoring software subsystem for monitoring the fatigue crack evolution of the mechanical structure in real time has the functions of processing, displaying and storing acoustic emission monitoring signals, visually displaying the acoustic emission condition and the real-time condition of the mechanical structure, and early warning the fatigue crack evolution condition of the mechanical structure, wherein the system comprises three modules, namely parameter setting module, data acquisition module and data analysis module, the system block diagram is shown in figure 5, and the software interfaces are shown in figures 6 and 7.
Installation of optical fiber acoustic emission sensor array
a. Marking the installation position of the acoustic emission sensor on the surface of the detected mechanical structure;
b. polishing the surface of the mounting part of the acoustic emission sensor to remove paint, oxide skin or oil dirt and the like;
c. coating a proper amount of coupling agent on the contact surface of the acoustic emission sensor;
d. and adjusting the acoustic emission sensor in the optical fiber acoustic emission sensor array to a proper position, and pressing the sensor array to make the sensor array contact with the surface of the detected object, and mounting and fixing the sensor array.
The acoustic emission sensor is connected with the structure to be measured through a coupling agent, and the coupling agent has the following functions: firstly, filling micro gaps between contact surfaces; secondly, the acoustic impedance difference between the sensor and the detection surface is reduced through the transition effect of the coupling agent, so that the reflection loss of energy at the interface is reduced. In addition, the lubricating device also has the function of lubrication, and reduces the friction between contact surfaces.
Installation of photoelectric conversion module of optical fiber acoustic emission pretreatment subsystem and optical fiber acoustic emission transmission subsystem
In field application, signals output by the optical fiber acoustic emission sensor array are transmitted to the optical fiber acoustic emission preprocessing subsystem through a cable. Because the signal output by the sensor is weak, the cable between the sensor and the optical fiber acoustic emission preprocessing subsystem needs to shield electromagnetic interference, and the length is not too long, and generally should not exceed 2 meters. The optical fiber acoustic emission preprocessing subsystem is fixed on the mechanical structure through placement or magnetic adsorption, an output signal of the optical fiber acoustic emission preprocessing subsystem is connected to an electro-optical conversion module of the optical fiber acoustic emission transmission subsystem fixed on the mechanical structure, and after the electrical signal is converted into an optical signal, the optical fiber acoustic emission preprocessing subsystem is transmitted to a photoelectric conversion module of a monitoring room in a long distance through the optical fiber transmission module.
Mounting photoelectric conversion module of optical fiber acoustic emission transmission subsystem
The photoelectric conversion module is placed in a monitoring room, and is generally placed together with a monitoring computer. The module is used for restoring the optical signal transmitted by the optical fiber into an electric signal. The signals output by the photoelectric conversion subsystem are sent to a computer through a network cable for data analysis and processing.
It should be understood by those skilled in the art that the present invention is not limited to the details of the foregoing exemplary embodiments, that the scope of the invention is defined by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Claims (6)
1. An optical fiber acoustic emission sensing system for monitoring fatigue crack evolution of a mechanical structure in real time comprises an optical fiber acoustic emission sensor array, an optical fiber acoustic emission preprocessing subsystem, an optical fiber acoustic emission transmission subsystem and an optical fiber acoustic emission monitoring software subsystem, wherein the optical fiber acoustic emission transmission subsystem adopts optical fiber for transmission; the optical fiber acoustic emission sensor array comprises a guide rail device and two or three acoustic emission sensing nodes, wherein the acoustic emission sensing nodes comprise acoustic emission sensors, sensor fixing devices and screws, the sensor fixing devices fix the acoustic emission sensors on a measured structure in a magnetic adsorption mode, the guide rail device is a rail type support, kidney-shaped holes are formed in the rail type support, the screws penetrate through the kidney-shaped holes of the rail type support and are connected with the sensor fixing devices, and the acoustic emission sensing nodes can move in the kidney-shaped holes of the rail type support; the optical fiber acoustic emission sensor array further comprises a connector, wherein the connector is connected with the guide rail device, and the connection position of the connector and the guide rail device can be adjusted in a way of being vertical to the measured surface; and a coupling agent is coated between the optical fiber acoustic emission sensor and the contact surface.
2. The fiber acoustic emission sensing system for real-time monitoring of fatigue crack evolution of a mechanical structure as claimed in claim 1, wherein: the acoustic emission sensor is a piezoelectric acoustic emission sensor.
3. The fiber acoustic emission sensing system for real-time monitoring of fatigue crack evolution of a mechanical structure as claimed in claim 1, wherein the fiber acoustic emission preprocessing subsystem comprises a fiber acoustic emission data acquisition module and a fiber acoustic emission data conversion module.
4. The fiber acoustic emission sensing system for real-time monitoring of fatigue crack evolution of a mechanical structure as claimed in claim 1, wherein the fiber acoustic emission transmission subsystem is composed of an electro-optical/photoelectric conversion module and a fiber transmission module, the electro-optical/photoelectric conversion module is composed of an RJ45 interface and an isolation transformer, an optical dielectric circuit, an optical transceiver circuit, a power supply and a configuration.
5. The fiber acoustic emission sensing system for real-time monitoring of fatigue crack evolution of a mechanical structure as claimed in claim 1, wherein the fiber acoustic emission monitoring software subsystem comprises three modules of parameter setting, data acquisition and data analysis, and is used for processing, displaying and storing fiber acoustic emission monitoring signals, thereby showing acoustic emission conditions and real-time conditions of the mechanical structure, and early warning fatigue crack evolution conditions of the mechanical structure.
6. A method for monitoring fatigue crack evolution of a mechanical structure of an optical fiber acoustic emission sensing system, comprising the optical fiber acoustic emission sensing system for monitoring fatigue crack evolution of a mechanical structure in real time according to claim 1, the method comprising the steps of:
installation of optical fiber acoustic emission sensor array
a. Marking the installation position of the acoustic emission sensor on the surface of the detected mechanical structure;
b. polishing the surface of the mounting part of the acoustic emission sensor to remove paint, oxide skin or oil dirt;
c. coating a proper amount of coupling agent on the contact surface of the acoustic emission sensor;
d. adjusting an acoustic emission sensor in the optical fiber acoustic emission sensor array to a proper position, pressing the sensor array to enable the sensor array to be in contact with the surface of the detected object, and installing and fixing the sensor array;
installation of photoelectric conversion module of optical fiber acoustic emission pretreatment subsystem and optical fiber acoustic emission transmission subsystem
The optical fiber acoustic emission sensor array is characterized in that signals output by the optical fiber acoustic emission sensor array are transmitted to an optical fiber acoustic emission preprocessing subsystem through cables, the optical fiber acoustic emission preprocessing subsystem is fixed on a mechanical structure through placement or magnetic adsorption, output signals of the optical fiber acoustic emission preprocessing subsystem are connected to an electro-optical conversion module of the optical fiber acoustic emission transmission subsystem fixed on the mechanical structure, and after the electrical signals are converted into optical signals, the optical signals are transmitted to a photoelectric conversion module of a monitoring room in a long distance through the optical fiber transmission module;
and thirdly, installing a photoelectric conversion module of the optical fiber acoustic emission transmission subsystem, wherein the photoelectric conversion module is placed in a monitoring room and is placed together with a monitoring computer, and signals output by the photoelectric conversion subsystem are sent to the computer through a network cable for data analysis and processing.
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| CN111103359B (en) * | 2018-10-25 | 2022-05-17 | 中国计量大学 | 316L stainless steel early fatigue crack detection method based on critical refraction longitudinal wave and vibration sound modulation technology |
| CN113552223B (en) * | 2021-07-21 | 2023-09-26 | 北京航空航天大学 | Torsion shaft multichannel acoustic emission detection system and defect detection method based on optical fiber interferometer |
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| CN102323338B (en) * | 2011-08-19 | 2013-02-20 | 北京航空航天大学 | Acoustic emission based detection method for damage position of fastener |
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| CN103308604B (en) * | 2012-03-15 | 2016-05-18 | 中国特种设备检测研究院 | Spherical tank health monitoring systems based on optical fiber acoustic emission |
| CN203572806U (en) * | 2013-09-30 | 2014-04-30 | 天津工程机械研究院 | On-line fatigue crack detection system |
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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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