CN115236174A - Sensor self-checking and self-adaptive adjusting method and system - Google Patents
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Abstract
The invention is suitable for the field of detection and flaw detection, and provides a sensor self-checking and self-adaptive adjusting method and system, which comprise the following steps: step S10: performing primary calculation; step S20: installing a sensor; step S30: collecting a non-invasive signal; step S40: judging whether adjustment is needed; step S50: the displacement and the angle of the sensor are adjusted through the displacement and angle adjusting mechanism. The method aims to solve the technical problem that the detection capability and the detection signal-to-noise ratio of equipment are reduced due to the installation error of a sensor or the adjustment of a detection environment and the limitation of the structure and the detection capability of the sensor in the prior art.
Description
Technical Field
The invention belongs to the field of detection and flaw detection, and particularly relates to a self-checking and self-adaptive adjusting method and system for a sensor.
Background
At present, most detection methods need to acquire signals through a sensor so as to analyze defect or damage information, and therefore the quality of the detection signals directly influences the detection capability of equipment and the signal-to-noise ratio of the detection signals. Because the signals are distributed differently in the space, the damaged signals can be detected only within a certain range, and the installation conditions of the sensors directly influence the quality of the detected signals due to the limitation of the structure and the detection capability of the sensors. The main influencing factors are the installation position and the installation angle of the sensor.
The detection capability of the sensor includes detection sensitivity and detection signal range. The detection sensitivity is the resolution of the detection signal, and in order to detect a smaller signal, the sensitivity of the sensor needs to be improved, but the improvement of the detection sensitivity increases the detection noise, especially the detection background noise. The increase in detection noise reduces the range of the sensor that detects the impairment signal, thereby reducing the detection capability of the device, and the increase in detection noise directly reduces the signal-to-noise ratio of the detection signal.
Different physical characteristics of different damages are different, the spatial distribution of the generated signals is also different, in order to detect better damage signals, enough sensors need to be arranged in the space to acquire signals of all positions in the space, so that better signals are selected, but due to the limitations of the structure, the volume and the detection space of the sensors, only a plurality of sensors or even one sensor can be installed, and better signals cannot be acquired.
Disclosure of Invention
The invention aims to provide a method and a system for self-checking and self-adaptive adjustment of a sensor, and aims to solve the technical problem that the detection capability and the signal-to-noise ratio of a detection signal of equipment are reduced due to the installation error of the sensor or the adjustment of the detection environment and the limitation of the structure and the detection capability of the sensor in the prior art.
The invention is realized in such a way that a sensor self-checking and self-adaptive adjusting method comprises the following steps:
step S10: analyzing or simulating by a magnetic flux leakage detection principle, calculating to obtain the position and the angle of the mounted sensor, and calculating to obtain the minimum magnetic flux leakage background noise according to the detection capability of the sensor;
step S20: installing the sensor according to the position and the angle of the installed sensor obtained by calculation;
step S30: collecting a non-damage magnetic leakage signal on a non-damaged detection object through magnetic leakage detection equipment;
step S40: judging whether the position and angle of the sensor need to be adjusted or not according to the non-damage magnetic leakage signal, executing the subsequent steps when the absolute value of the non-damage magnetic leakage signal is more than or equal to M, and meeting the detection requirement without adjustment when the absolute value of the non-damage magnetic leakage signal is less than M, wherein M is a preset error value;
step S50: the displacement and the angle of the sensor are adjusted through the displacement and angle adjusting mechanism, so that the nondestructive magnetic leakage signal meets the condition that D is less than M.
The further technical scheme of the invention is as follows: the specific step of step S10 is to analyze or simulate the magnetic leakage detection principle to obtain that the optimal position of the sensor is at the center of the excitation system, and the sensor should be parallel to the surface of the detected object, i.e. the angle with the X axis is 0 °, so that only the position of the X axis and the angle with the X axis need to be adjusted, and the minimum magnetic leakage background noise is calculated to be 0 Gs according to the detection capability of the sensor, i.e. the detection background signal is 0V in a non-damage state.
The further technical scheme of the invention is as follows: the step S50 includes the steps of:
step S501: the displacement and angle adjusting mechanism achieves positive direction movement of an X axis or anticlockwise angle rotation with the X axis by using different displacement devices A, B, C and D to extend or shorten different displacements, the displacement devices A and B are arranged at the upper and lower positions of two ends of the same side, the displacement devices C and D are arranged at two ends of the same side, the displacement devices C and B are opposite to the displacement devices B, and the displacement devices D and A are opposite to each other;
step S502: when D is less than 0, the adjustable unit voltage Vr is reduced for the voltages of the displacement device A and the displacement device C, meanwhile, the adjustable unit voltage Vr is increased for the voltages of the displacement device B and the displacement device D, the anticlockwise angle of the sensor is increased, namely D is increased, the step 502 is repeated, when | D | is less than M, the adjustment is stopped, when the adjustment angle reaches the adjustable maximum value during the adjustment, namely the adjustment voltages of the displacement devices A, B, C and D all reach the maximum voltage Vmax, and the | D | is still not satisfied and less than M, the subsequent steps are executed;
step S503: and increasing the adjustable unit voltage Vr for the voltages of the displacement device A and the displacement device B, and simultaneously decreasing the adjustable unit voltage Vr for the voltages of the displacement device C and the displacement device D, so that the positive displacement of the X axis of the sensor is increased, namely D is increased, and repeating the step 503 until the condition that | D | is less than M is met.
The further technical scheme of the invention is as follows: the step S50 further includes the steps of:
step S504: when D is larger than 0, increasing adjustable unit voltage Vr for the voltages of the displacement device A and the displacement device C, and simultaneously reducing the adjustable unit voltage Vr for the voltages of the displacement device B and the displacement device D, increasing the clockwise angle of the sensor, namely reducing D, repeating the step 504, when | D | is smaller than M, stopping adjustment, when adjusting, if the adjusting angle reaches the adjustable maximum value, namely the adjusting voltages of the displacement devices A, B, C and D all reach the maximum voltage Vmax, and still cannot meet the condition that | D | is smaller than M, executing subsequent steps;
step S505: and reducing the voltage of the displacement device A and the displacement device B by the adjustable unit voltage Vr, increasing the voltage of the displacement device C and the displacement device D by the adjustable unit voltage Vr, increasing the reverse displacement of the X axis of the sensor, namely reducing D, and repeating the step 505 until the condition that | D | is less than M is met.
The further technical scheme of the invention is as follows: the sensor is a bidirectional Hall sensor.
The further technical scheme of the invention is as follows: the displacement devices A, B, C and D are all piezoelectric ceramics.
Another objective of the present invention is to provide a sensor self-checking and self-adaptive adjusting system, which includes a displacement and angle adjusting mechanism disposed on a sensor for adjusting the displacement and angle of the sensor, a self-checking and self-adaptive adjusting unit connected to the displacement and angle adjusting mechanism for controlling the displacement and angle adjusting mechanism to operate, and a sensor detecting and collecting circuit connected to the sensor and the self-checking and self-adaptive adjusting unit for collecting the magnetic leakage damage-free signal of the sensor and transmitting the signal to the self-checking and self-adaptive adjusting unit, so that the self-checking and self-adaptive adjusting unit controls the displacement and angle adjusting mechanism to adjust the position and angle.
The further technical scheme of the invention is as follows: the displacement and angle adjusting mechanism comprises a displacement device A and a displacement device B which are arranged on the sensor and are arranged at the upper and lower positions at the two ends of the same side, and a displacement device C and a displacement device D which are arranged on the sensor and are arranged at the two ends of the same side, are opposite to the displacement device B, and are opposite to the displacement device A.
The further technical scheme of the invention is as follows: the displacement devices A, B, C and D are all piezoelectric ceramics.
The invention further adopts the technical scheme that: the sensor is a bidirectional Hall sensor.
The beneficial effects of the invention are: the method and the system can solve the problems of reduction of detection capability and signal to noise ratio of detection signals and the like due to installation errors of the sensors or adjustment of detection environments, can perform self-detection aiming at the sensors of different detection methods, different detection environments and different detection objects, eliminate the installation errors and select a better detection position through the self-detection and self-adaptive control unit, thereby improving the detection capability and the signal to noise ratio of the detection signals, effectively and better using the detection capability of the sensors and enabling the sensors to be in an optimal detection mode.
Drawings
Fig. 1 is a flowchart of a method for self-checking and self-adaptive adjusting a sensor according to an embodiment of the present invention;
fig. 2 is a schematic diagram of a magnetic flux leakage detection device of a sensor self-inspection and self-adaptive adjustment method according to an embodiment of the present invention;
fig. 3 is a sensor and a displacement and angle adjusting mechanism of a magnetic flux leakage detecting device according to a sensor self-testing and self-adaptive adjusting method provided by an embodiment of the present invention;
fig. 4 is a diagram illustrating a displacement and angle adjusting mechanism for a sensor self-checking and self-adaptive adjusting method according to an embodiment of the present invention to adjust an angle of a sensor;
FIG. 5 is a diagram illustrating an embodiment of a displacement and angle adjustment mechanism for a self-checking and self-adaptive adjustment method of a sensor to adjust the position of the X axis of the sensor;
fig. 6 is a damage signal of a magnetic flux leakage detection device with a sensor at a theoretically optimal position according to a sensor self-inspection and self-adaptive adjustment method provided by an embodiment of the present invention;
fig. 7 shows an actually detected damage signal and an optimized damage signal of a sensor self-detection and adaptive adjustment system according to an embodiment of the present invention;
fig. 8 is a structural diagram of a sensor self-checking and adaptive adjusting system according to an embodiment of the present invention.
Detailed Description
Reference numerals: 1-sensor 2-displacement and angle adjusting mechanism 3-self-checking and self-adaptive control unit.
Fig. 1 to 7 show a sensor self-checking and self-adaptive adjusting method provided by the present invention, which includes the following steps:
step S10: analyzing or simulating by a magnetic flux leakage detection principle, calculating to obtain the position and the angle of the mounted sensor, and calculating to obtain the minimum magnetic flux leakage background noise according to the detection capability of the sensor; the method comprises the specific steps of analyzing or simulating through a magnetic flux leakage detection principle to obtain that the optimal position of a sensor is in the center of an excitation system, and the sensor is parallel to the surface of a detected object, namely the angle between the sensor and an X axis is 0 degree, so that the position of the X axis and the angle between the X axis are only required to be adjusted, and the minimum magnetic flux leakage background noise is calculated to be 0 Gs according to the detection capability of the sensor, namely the detection background signal is 0V under a non-damage state; the sensor is a bidirectional Hall sensor.
Step S20: installing the sensor according to the position and the angle of the installed sensor obtained by calculation; since the sensor is mounted at a position deviated from the optimum position due to adverse factors such as mounting errors and detection jitter, the sensor is mounted at the center of the excitation system as much as possible and mounted above the object to be detected as much as possible in parallel.
Step S30: collecting a non-damage magnetic leakage signal on a non-damaged detection object through magnetic leakage detection equipment; and (3) enabling the magnetic leakage detection equipment to be positioned on a detection object without damage, and acquiring a magnetic leakage signal at the moment through a sensor.
Step S40: and judging whether the position and angle of the sensor need to be adjusted or not according to the non-damage magnetic leakage signal, executing the subsequent steps when the absolute value of the non-damage magnetic leakage signal is more than or equal to M, and meeting the detection requirement without adjustment when the absolute value of the non-damage magnetic leakage signal is less than M, wherein M is a preset error value.
Step S50: the displacement and the angle of the sensor are adjusted through the displacement and angle adjusting mechanism, so that the nondestructive magnetic leakage signal meets the condition that D is less than M.
The method specifically comprises the following steps:
step S501: displacement and angle adjustment mechanism are through using different displacement device A, B, C, D extension or shorten different displacements and reach X axle positive direction and remove or with X axle anticlockwise angle rotation, thereby make the not damaged magnetic leakage signal that gathers meet the demands, stop the adjustment, position about the homonymy both ends are arranged in to displacement device A and B, it is relative with B that homonymy both ends and C are arranged in to displacement device C and D, D is relative with A, it increases to assume that X axle positive direction removes or with X axle anticlockwise angle rotation sensor's magnetic leakage signal, otherwise reduce, displacement device A, B, C, D are piezoceramics.
Now specifically explaining through the magnetic leakage detection device, as shown in fig. 2, which is a schematic view of the magnetic leakage detection device, according to the analysis of the magnetic leakage detection principle, the displacement and angle adjustment mechanism includes four displacement devices (piezoelectric ceramics are selected) of a, B, C, and D, as shown in fig. 3.
Step S502: when D is less than 0, the adjustable unit voltage Vr is reduced for the voltages of the displacement device A and the displacement device C, meanwhile, the adjustable unit voltage Vr is increased for the voltages of the displacement device B and the displacement device D, the anticlockwise angle of the sensor is increased, as shown in FIG. 4, namely D is increased, the step 502 is repeated, when | D | < M, the adjustment is stopped, when in adjustment, if the adjustment angle reaches the adjustable maximum value, namely the adjustment voltages of the displacement devices A, B, C and D all reach the maximum voltage Vmax, and still can not meet | D | < M, the subsequent steps are executed.
Step S503: increasing the voltage of the displacement device A and the displacement device B by the adjustable unit voltage Vr, and simultaneously decreasing the voltage of the displacement device C and the displacement device D by the adjustable unit voltage Vr, the positive displacement of the X axis of the sensor is increased, as shown in FIG. 5, namely, D is increased, and the step 503 is repeated until the condition that | D | < M is satisfied.
Further comprising the steps of:
step S504: and when D is larger than 0, increasing the adjustable unit voltage Vr for the voltages of the displacement device A and the displacement device C, and simultaneously reducing the adjustable unit voltage Vr for the voltages of the displacement device B and the displacement device D, increasing the clockwise angle of the sensor, namely reducing D, repeating the step 504, stopping adjustment when | D | is smaller than M, and executing subsequent steps if the adjustment angle reaches the adjustable maximum value when the adjustment angle reaches the adjustable maximum value, namely the adjustment voltages of the displacement devices A, B, C and D all reach the maximum voltage Vmax and cannot meet the condition that | D | is smaller than M.
Step S505: and reducing the voltage of the displacement device A and the displacement device B by the adjustable unit voltage Vr, increasing the voltage of the displacement device C and the displacement device D by the adjustable unit voltage Vr, increasing the reverse displacement of the X axis of the sensor, namely reducing D, and repeating the step 505 until the condition that | D | is less than M is met.
Fig. 6 shows a damage signal of the magnetic flux leakage detection device sensor at the theoretically optimal position, and fig. 7 shows a damage signal actually detected by the magnetic flux leakage detection device sensor and a damage signal optimized by the sensor self-inspection and adaptive adjustment system.
Fig. 8 shows a sensor self-checking and self-adaptive adjusting system provided by the present invention, which includes a displacement and angle adjusting mechanism disposed on a sensor for adjusting the displacement and angle of the sensor, a self-checking and self-adaptive control unit connected to the displacement and angle adjusting mechanism for controlling the displacement and angle adjusting mechanism to operate, and a sensor detection and acquisition circuit connected to the sensor and the self-checking and self-adaptive control unit for acquiring a magnetic leakage signal of the sensor without damage and transmitting the magnetic leakage signal to the self-checking and self-adaptive control unit, so that the self-checking and self-adaptive control unit controls the displacement and angle adjusting mechanism to adjust the position and angle.
The displacement and angle adjusting mechanism comprises a displacement device A and a displacement device B which are arranged on the sensor and are arranged at the upper and lower positions of the two ends of the same side, a displacement device C which is arranged at the two ends of the same side on the sensor and is opposite to the displacement device B, and a displacement device D which is opposite to the displacement device A; the displacement devices A, B, C and D are all piezoelectric ceramics; the sensor is a bidirectional Hall sensor.
The sensor 1 as shown in fig. 8 is typically an integrated device; the displacement and angle adjusting mechanism 2 is provided with a plurality of displacement devices (controllable displacement devices such as piezoelectric ceramics and the like can be used) on six surfaces of the sensor 1, so that the displacement and the angle of the sensor space on three axes can be adjusted, and the displacement devices can be increased or decreased according to actual requirements; the sensor detection acquisition circuit and the self-checking and self-adapting control unit 3 are used for acquiring signals of the sensor 1 and outputting operation and control signals of a self-checking and self-adapting adjusting program of the sensor 1, and generally comprise an AD chip, a CPU (central processing unit) or MCU (micro control unit) processing controller, a DA (digital-analog) chip and the like, wherein the AD chip inputs detection signals of the sensor 1 into the processing controller, and the processing controller operates the self-checking and self-adapting adjusting program and outputs the control signals to the displacement and angle adjusting mechanism through the DA chip.
The method and the system can solve the problems of reduction of detection capability and signal to noise ratio of detection signals and the like due to installation errors of the sensors or adjustment of detection environments, can perform self-detection aiming at the sensors of different detection methods, different detection environments and different detection objects, eliminate the installation errors and select a better detection position through the self-detection and self-adaptive control unit, thereby improving the detection capability and the signal to noise ratio of the detection signals, effectively and better using the detection capability of the sensors and enabling the sensors to be in an optimal detection mode.
The above description is intended to be illustrative of the preferred embodiment of the present invention and should not be taken as limiting the invention, but rather, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
Claims (10)
1. A self-checking and self-adaptive adjusting method of a sensor is characterized by comprising the following steps:
step S10: analyzing or simulating according to a magnetic flux leakage detection principle, calculating to obtain the position and the angle of the installed sensor, and calculating to obtain the minimum magnetic flux leakage background noise according to the detection capability of the sensor;
step S20: installing the sensor according to the position and the angle of the installed sensor obtained by calculation;
step S30: collecting a non-damage magnetic leakage signal on a non-damaged detection object through magnetic leakage detection equipment;
step S40: judging whether the position and angle of the sensor need to be adjusted or not according to the non-damage magnetic leakage signal, executing the subsequent steps when the absolute value of the non-damage magnetic leakage signal is more than or equal to M, and meeting the detection requirement without adjustment when the absolute value of the non-damage magnetic leakage signal is less than M, wherein M is a preset error value;
step S50: the displacement and the angle of the sensor are adjusted through the displacement and angle adjusting mechanism, so that the nondestructive magnetic leakage signal meets the condition that D is less than M.
2. The self-detecting and self-adapting adjusting method of the sensor according to claim 1, wherein the step S10 is specifically performed by analyzing or simulating through a magnetic leakage detection principle to obtain that the optimal position of the sensor is at the center of the excitation system, and the sensor should be parallel to the surface of the object to be detected, i.e. the angle with the X-axis is 0 °, so that only the position with the X-axis and the angle with the X-axis need to be adjusted, and the minimum magnetic leakage background noise is calculated to be 0 Gs according to the detection capability of the sensor, i.e. the detection background signal is 0V in a non-damage state.
3. The method for self-checking and self-adapting adjustment of a sensor according to any one of claims 1-2, wherein the step S50 comprises the steps of:
step S501: the displacement and angle adjusting mechanism extends or shortens different displacements by using different displacement devices A, B, C and D to achieve positive direction movement of an X axis or anticlockwise angle rotation with the X axis, the displacement devices A and B are arranged at the upper and lower positions of two ends of the same side, the displacement devices C and D are arranged at two ends of the same side, C is opposite to B, and D is opposite to A;
step S502: when D is less than 0, the adjustable unit voltage Vr is reduced for the voltages of the displacement device A and the displacement device C, meanwhile, the adjustable unit voltage Vr is increased for the voltages of the displacement device B and the displacement device D, the anticlockwise angle of the sensor is increased, namely D is increased, the step 502 is repeated, when | D | is less than M, the adjustment is stopped, when the adjustment angle reaches the adjustable maximum value during the adjustment, namely the adjustment voltages of the displacement devices A, B, C and D all reach the maximum voltage Vmax, and the | D | is still not satisfied and less than M, the subsequent steps are executed;
step S503: and increasing the adjustable unit voltage Vr for the voltages of the displacement device A and the displacement device B, and simultaneously decreasing the adjustable unit voltage Vr for the voltages of the displacement device C and the displacement device D, so that the positive displacement of the X axis of the sensor is increased, namely D is increased, and the step 503 is repeated until | D | < M is satisfied.
4. The method for self-checking and self-adaptive adjusting of sensors according to claim 3, wherein the step S50 further comprises the steps of:
step S504: when D is larger than 0, increasing adjustable unit voltage Vr for the voltages of the displacement device A and the displacement device C, and simultaneously reducing the adjustable unit voltage Vr for the voltages of the displacement device B and the displacement device D, increasing the clockwise angle of the sensor, namely reducing D, repeating the step 504, when | D | is smaller than M, stopping adjustment, when adjusting, if the adjusting angle reaches the adjustable maximum value, namely the adjusting voltages of the displacement devices A, B, C and D all reach the maximum voltage Vmax, and still cannot meet the condition that | D | is smaller than M, executing subsequent steps;
step S505: and reducing the voltage of the displacement device A and the displacement device B by the adjustable unit voltage Vr, increasing the voltage of the displacement device C and the displacement device D by the adjustable unit voltage Vr, increasing the reverse displacement of the X axis of the sensor, namely reducing D, and repeating the step 505 until the absolute value of D < M is met.
5. The sensor self-checking and self-adaptive adjusting method according to claim 4, wherein the sensor is a bidirectional Hall sensor.
6. The self-checking and self-adaptive adjusting method of the sensor according to claim 5, wherein the displacement devices A, B, C and D are all piezoelectric ceramics.
7. The utility model provides a sensor self-checking and self-adaptation adjustment system, its characterized in that, sensor self-checking and self-adaptation adjustment system is used for including setting up on the sensor displacement and angle adjustment's displacement and angle adjustment mechanism connect displacement and angle adjustment mechanism are used for controlling displacement and angle adjustment mechanism carry out the self-checking and the self-adaptation control unit of work, and connect the sensor reaches self-checking and self-adaptation control unit are used for gathering sensor not damaged magnetic leakage signal gives self-checking and self-adaptation control unit, make self-checking and self-adaptation control unit control the sensor that displacement and angle adjustment mechanism carry out position and angle adjustment detects the acquisition circuit.
8. The self-inspection and self-adaptation adjusting system of the sensor according to claim 7, wherein the displacement and angle adjusting mechanism includes a displacement device A and a displacement device B which are disposed on the sensor and are disposed at upper and lower positions of both ends of the same side, a displacement device C which is disposed at both ends of the same side on the sensor and is disposed opposite to the displacement device B, and a displacement device D which is disposed opposite to the displacement device A.
9. The sensor self-testing and self-adaptive adjusting system of claim 8, wherein the displacement devices A, B, C, D are all piezoelectric ceramics.
10. The system for self-checking and self-adaptive adjustment of sensors according to any one of claims 7-9, wherein the sensors are bi-directional hall sensors.
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