CN104007171B - A kind of real-time high-precision ACFM crackle condition monitoring system - Google Patents
A kind of real-time high-precision ACFM crackle condition monitoring system Download PDFInfo
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- CN104007171B CN104007171B CN201410227673.0A CN201410227673A CN104007171B CN 104007171 B CN104007171 B CN 104007171B CN 201410227673 A CN201410227673 A CN 201410227673A CN 104007171 B CN104007171 B CN 104007171B
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Abstract
The invention discloses a kind of real-time high-precision ACFM crackle condition monitoring system, comprise rotating magnetic field signal driving source, ACFM monitors mobile platform, platform driving power module, displacement transducer, monitoring probe, Signal-regulated kinase, lock-in amplify module, PLC slave computer, system control subsystem and defect Intelligent Recognition subsystem.Rotating magnetic field signal driving source goes out electromagnetic field at workpiece for measurement surface induction, monitoring probe obtains distorted signal, Signal-regulated kinase carries out pre-service to distorted signal, lock-in amplify module carries out vector detection to distorted signal, PLC slave computer controls automatic monitoring platform, system control subsystem realizes data exchange, and defect Intelligent Recognition subsystem crack defect carries out intellectual analysis and identification.Energy Real-Time Monitoring steel knot state of the present invention, achieves the detection of fault of construction, Intelligent Recognition, supervision and early warning, effectively improves reliability and the engineering practicability of monitoring, have stronger propagation and employment and be worth.
Description
Technical field
The invention belongs to ac magnetic field monitoring technical field, particularly relate to a kind of real-time high-precision ACFM crackle condition monitoring system.
Background technology
Often can produce the surfaces externally and internally defects such as burn into crackle in production and use ferrous materials, repeatedly occur to cause the major accidents such as air crash, pipeline breaking and the bursting of boilers because of defects such as mechanical crackles.In Offshore Engineering field, the equipment such as ocean platform and submarine pipeline is on active service for a long time in severe marine environment, more easily occurs the structural failure such as corrosion and fatigue, fracture.Current electromagnetic nondestructive testing solves the problem of quite most structural failure because of defect in the structural application of this kind of steel-based Infrastructure, such as: alternating current field measurement (ACFM) technology.But, depend merely on artificial cycle detection architecture, not only by arrangement works environmental limit, and fully can not use the mission life of structure, even may occur detecting not exclusively, thus the problem of artificial error in judgement, make detection efficiency and reliability on the low side, the requirement in modern large scale industry epoch can not be met.
The status monitoring of ACFM structural crack and diagnostic techniques, integrated computer technology, by installing on the mobile apparatus or being directly installed on tested structural sensor, the signal that instant acquisition various kinds of sensors gathers, such as displacement, field signal etc., continuous print monitoring can be carried out to structure, be characterized in monitoring and the shaping of inverting crackle, and its expansion situation of real time monitoring, evaluation structure safety in advance, realize automatic diagnosis and real-time early warning, reliable maintenance efficiently or replacement damaged structure, avoid because of corrosion, tired, the major disaster that the structural failures such as fracture cause, ensure the structural safety of steel infrastructure, build structural safety on-line monitoring system.
ACFM structural crack status monitoring analytical technology comprises discovery and inspection, crack-type and the diagnosis at position, the analysis of crack form and the development trend of anomaly detection signal; And comprise detection technique, signal transacting and recognition technology, Ethernet or Serial Communication, forecasting techniques simultaneously.
Summary of the invention
The object of the present invention is to provide a kind of real-time high-precision ACFM crackle condition monitoring system, be intended to solve and depend merely on artificial cycle alternating current field measurement structure of steel product at present, not only by arrangement works environmental limit, and fully can not use the mission life of structure, even may occur detecting not exclusively, thus the problem of artificial error in judgement, make detection efficiency and reliability on the low side, the requirement in modern large scale industry epoch can not be met.
Technology contents of the present invention is: a kind of real-time high-precision ACFM crackle condition monitoring system, and this ACFM crackle condition monitoring system comprises:
For inducing the rotating magnetic field signal driving source of at the uniform velocity rotation, all strong-electromagnetic field at steel structure surface to be monitored;
For controlling monitoring probe motion and monitoring mode thereof, the ACFM realizing automatic monitoring steel structure surface monitors mobile platform;
For the platform driving power module driving ACFM to monitor mobile platform;
For obtaining the real-time displacement signal of monitoring probe, and to the displacement transducer that obtained displacement signal exports;
For carrying out scanning and stationary monitoring at steel structure surface to be monitored, the rotating magnetic field distorted signal that the surface imperfection obtaining structure to be monitored causes, and to the monitoring probe that obtained rotating magnetic field distorted signal exports;
Being connected with described monitoring probe, for receiving the rotating magnetic field distorted signal that described monitoring probe exports, rotating magnetic field distorted signal being amplified and filter preprocessing, and to the Signal-regulated kinase that pretreated rotating magnetic field distorted signal exports;
Be connected with described Signal-regulated kinase, for receiving the pretreated rotating magnetic field distorted signal of described Signal-regulated kinase, cross-correlation vector computing is carried out to the rotating magnetic field distorted signal after process, and to the lock-in amplify module that the rotating magnetic field distorted signal amplitude of gained after operation exports with corresponding phase mode analog quantity;
Be connected with institute displacement sensors, lock-in amplify module, the rotating magnetic field distorted signal that the displacement signal that displacement sensors exports for receiving, described lock-in amplify module export, digital-to-analog conversion, collection, storage are carried out to these signals, for receiving mechanism for monitoring control module output signal, and by this signal transmission to the PLC slave computer of motor driver;
Be connected with described PLC slave computer, the rotating magnetic field exported for receiving described PLC slave computer distorts and displacement signal, rotating magnetic field distortion and displacement digital signal are gathered, and according to mechanism for monitoring control module to the system control subsystem of PLC slave computer instruction;
Be connected with described system control subsystem, the rotating magnetic field gathered for receiving described system control subsystem distorts and displacement digital signal, rotating magnetic field distortion and displacement digital signal are processed, and the crackle state treating monitoring of structures surface carries out the defect Intelligent Recognition subsystem of real-time oversight, intellectual analysis, identification and defect early warning.
Described rotating magnetic field signal driving source adopts two groups of orthogonal first drive coils and the second drive coil to be wound on above orthogonal double-U-shaped magnetic core, the first drive coil and the second drive coil passes into amplitude, frequency is identical, the sinusoidal ac signal that phase is 90 degree is given respectively by signal generator, power amplification circuit, phase-shift circuit; Described platform driving power module comprises, S-250-24 Switching Power Supply, for receive the mechanism for monitoring control module output signal of PLC slave computer transmission motor driver, through motor starting device, short circuit current fuse protecting device and the first drive motor and the second drive motor of electric current, tach signal being exported to monitoring mobile platform.
Described double-U-shaped magnetic core adopts double-U-shaped manganese-zinc ferrite core; The sinusoidal ac signal of described signal generator adopts accurate function generator ICL8038 to produce; Described phase-shift circuit adopts RC phase-shift circuit, by changing resistance value, obtains identical with input signal size, frequency, but the sinusoidal ac signal of phase 90 degree.
Described motor driver adopts DCM8055/8028, receives the motor driving parameter signal that PLC slave computer exports; Described motor starting device adopts the single contactor of Lc1D09...C, short circuit current fuse protecting device to adopt RT28N-32x low-tension fuse, receives the electric current that described motor driver exports, and starter motor, protects short circuit.
Institute's displacement sensors adopts NS-WY06, and its structure is that two stay-supported type displacement sensors are separately fixed at immediately below two stepper motors; Described first drive motor and the second drive motor are arranged in mutually vertical and on screw rod in parallel water plane, with rotation planar each autokinesis of screw rod, and the positional information of Real-time Obtaining monitoring probe; Described monitoring probe comprises scanning monitoring probe and stationary monitoring probe, all adopt 2 dimension array structures, wherein scan monitoring probe and adopt nx1 dimensional pattern, stationary monitoring probe adopts nxm dimensional pattern, n, m are each independent detection probe, for being more than or equal to the integer of 1, each detection probe comprises the magnetic field levels of pair of orthogonal and the magnetic test coil of vertical component.
Described Signal-regulated kinase adopts prime amplifier AD620 to carry out signal amplification to rotating magnetic field distortion simulation signal, adopts 2 rank Butterworth filters to carry out low-pass filtering.
Described PLC slave computer adopts XCM-32T4-E and XC-E8AD, this independently PLC slave computer can realize I/O expansion easily and be connected with same host computer PC, have the independently equipment such as CPU and control circuit, program storage, I/O interface, communication interface, power supply; This PLC slave computer supports Modbus communication, according to the setting of host computer PC parameter, read rotating magnetic field distortion simulation signal least significant bit (LSB) data LSB, and be converted to magnitude of voltage, displacement, rotating magnetic field distortion amplitude and phase mode analog signal are converted to digital signal, complete a data acquisition, storage; According to the instruction of host computer PC, control ACFM monitors mobile platform motion path.
Described system control subsystem comprises further: digital communication module, mechanism for monitoring control module, systematic conservation module, historical data playback module, threshold value update module;
Wherein digital communication module utilizes RS232 type cable to be connected to by PLC slave computer on the serial ports of the PC host computer that LabVIEW is housed, based on the ModbusASCII communication modes of LabVIEW, utilize VISA technology, serial ports parameter is set, pack data to be sent and instruction by the form of PLC command frame, send command frame to writing serial ports, time delay is waited for that the acknowledgement frame of PLC arrives and is read serial ports, read and unpack the acknowledgement frame of PLC, obtain displacement, rotating magnetic field distortion amplitude and phase data, complete an exchanges data.
Described defect Intelligent Recognition subsystem comprises further:
Being connected with described digital communication module, for receiving rotating magnetic field distortion, the displacement digital signal of the output of described digital communication module, rotating magnetic field distortion digital signal being carried out to the digital signal processing module of digital IIR filtering;
Being connected with described digital signal processing module, is the threshold value setting module of following automatic diagnosis module intelligent set monitoring threshold;
Be connected with described threshold value setting module, for receiving the rotating magnetic field distortion digital signal that described digital signal processing module exports, the monitoring threshold based on threshold value setting module carries out N continuous time to rotating magnetic field distortion digital signal and differentiates and export the automatic diagnosis module of preserving satisfactory rotating magnetic field distortion digital signal;
Be connected with described automatic diagnosis module, for receiving the satisfactory rotating magnetic field distortion digital signal that described automatic diagnosis module exports, the defect intelligent identification module that the carrying out for the treatment of the surface imperfection of monitoring of structures according to rotating magnetic field distortion digital signal identifies;
Be connected with described defect intelligent identification module, the defect for the information preservation that accept defect intelligent identification module preserves module;
Preserve module with described defect to be connected, according to damage tolerance design thought, the crack length of module output is preserved for accepting defect, according to the residual intensity of crack length computation structure, determine the proof cycle of structure to be monitored, crack warning parameter is set: Gao Gaobao, high report, low report, low report, the fluctuation upper limit, the defect warning module of real-time graded early warning.
Described digital signal processing module selects 8 rank Butterworth filters to carry out filtering process to rotating magnetic field distortion digital signal; Described threshold value setting module adopts false-alarm probability determination monitoring threshold, adopts LabVIEW designing user graphical interfaces and interface, and MATLAB provides threshold setting algorithm program to call for LabVIEW on backstage, method of calling selects MATLABScript node mode; Described automatic diagnosis module is according to N continuous time criterion: N number of data compare with monitoring threshold, and N continuous is secondary within the scope of monitoring threshold; Automatic detection defect position at the whole story, synchronous data of preserving in threshold range, the data signal waveforms figure of Real-time Two-dimensional cromogram real-time graph display defect information and collection shows; In described defect intelligent identification module, the intelligent visual defect inverting of ACFM monitoring adopts the method for LabVIEW and MATLAB hybrid programming to realize, analyze the extremal features point extracted in described automatic diagnosis module synchronization preservation data, adopt LabVIEW designing user graphical interfaces and interface, MATLAB provides defect intelligent quantization and visualized algorithm program to call for LabVIEW on backstage, method of calling selects MATLABScript node mode.
Beneficial effect of the present invention is: the real-time high-precision ACFM crackle condition monitoring system provided can carry out Real-Time Monitoring to any iron structure surface crack, achieve disengaging manually, to be continuously or periodically shaped and the monitoring of expansion process to crackle, effectively improve monitoring efficiency and reliability, there is stronger propagation and employment and be worth.
Accompanying drawing explanation
Fig. 1 is the structured flowchart of the real-time high-precision ACFM crackle condition monitoring system that the embodiment of the present invention provides.
Fig. 2 be the embodiment of the present invention provide rotating magnetic field signal driving source time be engraved in the rotating magnetic field distribution plan produced in workpiece for measurement.
Fig. 3 is the key wiring diagram of the phase-shift circuit that the embodiment of the present invention provides.
Fig. 4 is the test crackle Dependence Results that provides of the embodiment of the present invention and warning exemplary plot.
Fig. 5 is the software design block diagram that the embodiment of the present invention provides.
Fig. 6 is the automatic diagnosis block flow diagram that the embodiment of the present invention provides.
Fig. 7 is the monitoring mobile platform structural drawing that the embodiment of the present invention provides.
Fig. 8 is the monitoring mobile platform moving structure figure that the embodiment of the present invention provides.
Wherein: 11, rotating magnetic field signal driving source; 111, signal generator; 112, power amplification circuit; 113, phase-shift circuit; 114, the first drive coil; 115, the second drive coil; 116, double-U-shaped magnetic core; 12, monitoring probe; 13, displacement transducer; 14, Signal-regulated kinase; 15, lock-in amplify module; 16, PLC slave computer; 161, PLC and capture card communication module; 162, PLC mobile platform control module; 17, system control subsystem; 171, digital communication module; 172, systematic conservation module; 173, historical data playback module; 174 threshold value update module; 175 mechanism for monitoring control modules; 18 defect Intelligent Recognition subsystems; 181, digital signal processing module; 182, threshold value setting module; 183, automatic diagnosis module; 184, defect intelligent identification module; 185, defect preserves module; 186 defect warning modules; 19, mobile platform is monitored; 20, platform driving power module; 201, Switching Power Supply; 202, motor driver; 203, motor starting device; 204, short circuit current fuse protecting device; 1, the first drive motor; 2, the first displacement transducer; 3, screw rod; 4, moving guide rail; 5, the first lower guideway supporting construction; 6, the second lower guideway supporting construction; 7, the second drive motor; 8, second displacement sensor; 9, the first contiguous block 10, second contiguous block; 22, monitoring device support.
Embodiment
In order to make object of the present invention, technical scheme and advantage clearly understand, below in conjunction with drawings and Examples, the present invention is described in further detail.Should be appreciated that specific embodiment described herein only in order to explain the present invention, and be not used in restriction invention.
Fig. 1 shows the structure of the real-time high-precision ACFM crackle condition monitoring system that the embodiment of the present invention provides.For convenience of explanation, illustrate only part related to the present invention.
Below in conjunction with drawings and the specific embodiments, application principle of the present invention is further described.
The object of this invention is to provide a kind of real-time high-precision ACFM crackle condition monitoring system, can realize carrying out Real-Time Monitoring and early warning to the crackle of steel structure surface, and provide for Systematical control, the Software Module Design of defect intelligent distinguishing, orthogonal first drive coil 114 and second drive coil 115 vertical in double-U-shaped magnetic core 116 top coiling two groups, pass into amplitude respectively, frequency is identical, the sinusoidal ac signal that phase is 90 degree, the equal strong-electromagnetic field at the uniform velocity rotated is induced at steel structure surface to be measured, when there is defect in steel structure surface, monitoring probe 12 can both effectively pick up distorted magnetic field signal, through signal condition and collection, and extract phase information by lock-in amplify module 15, by PLC slave computer 16, the simulating signal that monitoring probe 12 and displacement transducer 13 gather is converted into digital signal input system control subsystem 17, enter defect Intelligent Recognition subsystem 18, and carry out real time discriminating by defect intelligent identification module 184 pairs of defects, thus the shaping of Real-Time Monitoring steel structure surface crackle and expansion carry out intelligent early-warning, reach the unmanned automatic monitoring of steel large scale structure, improve steel construction defect inspection efficiency, reliability and engineering practicability.
The present invention is based on real-time high-precision ACFM crackle condition monitoring system structure as shown in Figure 1, mainly comprise rotating magnetic field driving source 11, monitoring probe 12, displacement transducer 13, Signal-regulated kinase 14, lock-in amplify module 15, PLC slave computer 16, signal generator 111 in rotating magnetic field driving source adopts accurate function generator ICL8038 to produce the sinusoidal ac signal of certain amplitude frequency, two-way amplitude is formed through power amplification circuit 112 and phase-shift circuit 113, frequency is identical, the sinusoidal ac signal of phase 90, pass into two groups of orthogonal first drive coil 114 and second drive coils 115 be wound on above orthogonal double-U-shaped magnetic core 116 respectively, thus the uniform induction magnetic field that generation direction at the uniform velocity rotates, overcome the restriction of inductive current direction to flaw angle, certain moment rotating magnetic field distribution as shown in Figure 2.The design of phase-shift circuit 113 be based on RC phase-shift circuit 113 under certain frequency, the change of resistance value directly affects the feature of the phase differential of input and output signal, concrete circuit diagram as shown in Figure 3, monitoring probe 12 adopts two-dimensional array, extract the field signal of surface of the work crackle annex, and export in the form of a voltage, the pre-service in early stage such as amplification and filtering is carried out through Signal-regulated kinase 14, complete field signal is extracted by lock-in amplify module 15, by PLC and capture card communication module 161, simulating signal is converted into digital signal and sends into system control subsystem 17, defect Intelligent Recognition subsystem 18 carries out Treatment Analysis, according to the steel construction state monitored by system control information to platform driving power module 20, thus control monitoring mobile platform 19.
System control subsystem 17 under being based upon LabVIEW environment, realizes signals collecting, system defect library storage, and historical data is adjusted back, and monitoring threshold upgrades and ACFM monitors the functions such as mobile platform control, mainly comprises following components:
A, digital communication module 171: utilize RS232 type cable to be connected to by PLC slave computer on the serial ports of the PC host computer that LabVIEW is housed, based on the ModbusASCII communication modes of LabVIEW, utilize VISA technology, serial ports parameter is set, pack data to be sent and instruction by the form of PLC command frame, send command frame to writing serial ports, time delay is waited for that the acknowledgement frame of PLC arrives and is read serial ports, read and unpack the acknowledgement frame of PLC, obtain displacement, rotating magnetic field distortion amplitude and phase data, complete an exchanges data.
B, systematic conservation module 172: preserve module 185 with defect and be connected, preserve the information of module 185 for connecing defect, and defect is preserved module 185 information and deposit into system defect according to storehouse.
C, historical data playback module 173: be connected with systematic conservation module 172, recall the data of desired structure monitoring information with txt format system according to peripheral hardware input instruction.
D, threshold value update module 174: be connected with threshold value setting module 182, for accepting the information of systematic conservation module 172, timing upgrades monitoring threshold.
E, mechanism for monitoring control module 175: be connected with defect warning module 186, for accepting the early-warning parameters of defect warning module 186, judging monitoring mobile platform operator scheme according to early-warning parameters, and steering order passed to digital communication module 171.Monitoring policy is: last time monitoring result using as determine next time monitoring differentiate foundation.According to early warning signal, judge monitoring mobile platform operator scheme: scanning monitoring, stationary monitoring.Propose the method determining the priority scanning monitoring velocity (startup interval) and stationary monitoring position according to configuration state, that is: the position that early-warning parameters is high will have higher priority, preferentially will be processed when bus " multi-master competition ", realized the emphasis monitoring of keypoint part.
Defect Intelligent Recognition subsystem 18 is under being based upon LabVIEW environment, and embed Matlab language program node, realize digital signal processing, monitoring threshold sets, and the functions such as the automatic diagnosis of ACFM defect, Intelligent Recognition and early warning, mainly comprise following components:
A, digital signal processing module 181: digital signal processing module 181 comprises digital IIR filtering, according to theoretical and experimental study, 8 rank Butterworth filters selected by digital filter.
B, threshold value setting module 182: threshold value setting module adopts false-alarm probability determination monitoring threshold, adopt LabVIEW designing user graphical interfaces and interface, MATLAB provides threshold setting algorithm program to call for LabVIEW on backstage, method of calling selects MATLABScript node mode (Bx power spectrum <10; Bz power spectrum <0).
C, automatic diagnosis module 183, as shown in Figure 6: according to N continuous time criterion: N number of data compare with monitoring threshold, N continuous is secondary within the scope of monitoring threshold.Automatic detection defect position at the whole story, data in synchronous preservation threshold range, the data signal waveforms figure of Real-time Two-dimensional cromogram real-time graph display defect information and collection shows (when X conforms to Cleaning Principle with the Magnetic field strength curve figure of Z-direction, could identify this position existing defects).
D, defect intelligent identification module 184: in view of the unique advantage of MATLAB language in numerical evaluation and analysis, in module, the intelligent visual defect inverting of ACFM monitoring adopts the method for LabVIEW and MATLAB hybrid programming to realize, give full play to bilingual advantage separately, analyze the extremal features point extracted in described automatic diagnosis module synchronization preservation data, adopt LabVIEW designing user graphical interfaces and interface, MATLAB provides defect intelligent quantization and visualized algorithm program to call for LabVIEW on backstage, method of calling selects MATLABScript node mode.
E, defect preserve module 185: be connected with defect intelligent identification module 184, for accepting the information of defect intelligent identification module 184 and preserving.
F, defect warning module 186: preserve module 185 with defect and be connected, according to damage tolerance design thought, the crack length of module 185 output is preserved for accepting defect, according to the residual intensity of crack length computation structure, determine the proof cycle of structure to be monitored, crack warning parameter is set: Gao Gaobao, high report, low report, low report, the fluctuation upper limit, real-time graded early warning.5, the first lower guideway supporting construction; 6, the second lower guideway supporting construction; 7, the second drive motor; 8, second displacement sensor; 9, the first contiguous block 10, second contiguous block;
Real-time high-precision ACFM crackle condition monitoring system is utilized to monitor the crackle of mild-steel sheet surface random site, scanning monitoring probe is arranged on the monitoring device support 22 of Fig. 7, slave computer PLC16 is according to two stay-supported first displacement transducers 2, second displacement sensor 8 gives the first drive motor 1 of its corresponding top respectively, second drive motor 7 operation instruction, thus drive two mutually vertical and screw rods 3 in parallel water plane respectively, and then monitoring device support carries out scanning monitoring by preset path along the orthogonal moving guide rail 4 of two shown in accompanying drawing 8: upper rail and monitoring mobile platform frame welding, lower guideway is by first, second lower guideway supporting construction is fixed it and is being monitored the upright position on mobile platform framework, second lower guideway supporting construction 6 is a column type steel pipe, it is embedded in monitoring mobile platform framework, the center cylindrical hole of the first lower guideway supporting construction 5 can be slided along the second lower guideway supporting construction 6, two guide rail sides all have the groove of certain length, in order to assemble corresponding contiguous block 10, monitoring device support moves along lower guideway by the second contiguous block 10, lower guideway moves along upper rail by the first contiguous block 9, first contiguous block 9 is fixed with lower guideway spiral marking connection, to verify that native system surveys ability to the Real-Time Monitoring of steel structure surface crackle, this is set forth for 25 ° and 60 °.
This ACFM monitoring system composition as shown in Figure 1, primarily of rotating magnetic field excitation source signal generator 111, power amplification circuit 112, phase-shift circuit 113, double-U-shaped magnetic core 116, first drive coil 114, second drive coil 115, monitoring probe 12, displacement transducer 13, Signal-regulated kinase 14, lock-in amplify module 15, PLC slave computer 16PLC and capture card communication module 161, PLC mobile platform control module 162, system control subsystem 17, defect Intelligent Recognition subsystem 18, monitoring mobile platform 19 and platform driving power module 20 Switching Power Supply 201, motor driver 202, motor starting device 203, short circuit current fuse protecting device 204 forms.
The generation of rotating magnetic field: utilize stabilized voltage supply to power for accurate function generator ICL8038, generation amplitude is 1V, frequency is the sinusoidal ac signal of 6KHz, this signal is after power amplification circuit 112 and phase-shift circuit 113, form two-way phase 90 degree, the sinusoidal signal that amplitude is identical with frequency, pass into respectively be wound on orthogonal double-U-shaped magnetic core 116 the first drive coil 114 and the second drive coil 115 on, thus on steel structure surface, induce the uniform magnetic field at the uniform velocity rotated, rotating magnetic field has magnetic direction and becomes Periodic Rotating in time, but the time-independent advantage of magnetic field intensity.
Flaw indication extracts and pre-treatment: by monitoring probe 12 by preset path scanning, monitoring probe 12 is utilized to extract the field signal of steel structure surface defect annex respectively, and export in the form of a voltage, carry out amplifying and filtering in access signal conditioning circuit, complete the pre-treatment of simulating signal in early stage, magnetic phase information is extracted again through lock-in amplify module 15, by PLC slave computer 16, simulating signal is converted into digital signal input system control subsystem 17, analyzing in defect Intelligent Recognition subsystem 18, automatic real-time intelligent differentiates defect and supervises the extended mode of defect.
Automatic diagnosis: after defect digital signal enters defect Intelligent Recognition subsystem 18, first digital IIR filtering is carried out by digital signal processing module 181, threshold value setting module 182 is utilized data to be carried out N continuous criterion diagnosis, automatic detection defect position at the whole story, data in synchronous preservation threshold range, Real-time Two-dimensional cromogram real-time graph display defect information, the data signal waveforms figure gathered shows, magnetic density curve and butterfly diagram, when N continuous secondary data then surperficial existing defects within the scope of monitoring threshold, so just realize the automatic diagnosis to defect, test crackle Dependence Results and warning signal are as shown in Figure 4.
Found by a large amount of monitoring experiment, real-time high-precision ACFM crackle condition monitoring system of the present invention, can the shaping of real-time oversight steel structure surface crackle and expansion carry out intelligent early-warning, reach the unmanned automatic monitoring of steel large scale structure, improve steel construction defect inspection efficiency and engineering practicability.
The real-time high-precision ACFM crackle condition monitoring system that the embodiment of the present invention provides, rotating magnetic field signal driving source 11 induces at steel structure surface to be measured and at the uniform velocity rotates, equal strong-electromagnetic field, monitoring probe 12 carries out scanner uni stationary monitoring on the surface of steel construction to be measured, the rotating magnetic field distorted signal that the surface imperfection obtaining steel construction to be measured causes, and obtained rotating magnetic field distorted signal is exported, Signal-regulated kinase 14 receives the rotating magnetic field distorted signal that monitoring probe 12 exports, rotating magnetic field distorted signal is amplified and filter preprocessing, and pretreated rotating magnetic field distorted signal is exported, magnetic phase information is extracted again through lock-in amplify module 15, by PLC slave computer 16, the simulating signal that monitoring probe 12 and displacement transducer 13 gather is converted into digital signal input system control subsystem 17, processing through defect Intelligent Recognition subsystem 18 pairs of rotating magnetic field distortion digital signals, and real time discriminating and intellectual analysis are carried out to the crack defect of steel structure surface to be measured, identify, according to the steel construction state monitored by system control information to platform driving power module 20, and then control monitoring mobile platform 19, automatic real-time intelligent differentiates defect and supervises the extended mode of defect.
These are only preferred embodiment of the present invention, not in order to limit the present invention, all any amendments done within the spirit and principles in the present invention, equivalent replacement and improvement etc., all should be included within protection scope of the present invention.
Claims (2)
1. a real-time high-precision ACFM crackle condition monitoring system, is characterized in that: this ACFM crackle condition monitoring system comprises:
For inducing the rotating magnetic field signal driving source (11) of at the uniform velocity rotation, all strong-electromagnetic field at steel structure surface to be monitored;
For controlling monitoring probe motion and monitoring mode thereof, the ACFM realizing automatic monitoring steel structure surface monitors mobile platform (19);
For the platform driving power module (20) driving ACFM to monitor mobile platform;
For obtaining the real-time displacement signal of monitoring probe, and to the displacement transducer (13) that obtained displacement signal exports;
For carrying out scanning and stationary monitoring at steel structure surface to be monitored, the rotating magnetic field distorted signal that the surface imperfection obtaining structure to be monitored causes, and to the monitoring probe (12) that obtained rotating magnetic field distorted signal exports;
Be connected with described monitoring probe (12), for receiving the rotating magnetic field distorted signal that described monitoring probe (12) exports, rotating magnetic field distorted signal is amplified and filter preprocessing, and to the Signal-regulated kinase (14) that pretreated rotating magnetic field distorted signal exports;
Be connected with described Signal-regulated kinase (14), for receiving the pretreated rotating magnetic field distorted signal of described Signal-regulated kinase (14), cross-correlation vector computing is carried out to the rotating magnetic field distorted signal after process, and to the lock-in amplify module (15) that the rotating magnetic field distorted signal amplitude of gained after operation exports with corresponding phase mode analog quantity;
Be connected with institute's displacement sensors (13), lock-in amplify module (15), the rotating magnetic field distorted signal that the displacement signal that displacement sensors (13) exports for receiving, described lock-in amplify module (15) export, digital-to-analog conversion, collection, storage are carried out to these signals, for receiving mechanism for monitoring control module (175) output signal, and by this signal transmission to the PLC slave computer (16) of motor driver (202);
Be connected with described PLC slave computer (16), the rotating magnetic field exported for receiving described PLC slave computer (16) distorts and displacement signal, rotating magnetic field distortion and displacement digital signal are gathered, and according to mechanism for monitoring control module (175) to the system control subsystem (17) of PLC slave computer (16) instruction;
Be connected with described system control subsystem (17), the rotating magnetic field gathered for receiving described system control subsystem (17) distorts and displacement digital signal, rotating magnetic field distortion and displacement digital signal are processed, and the crackle state treating monitoring of structures surface carries out the defect Intelligent Recognition subsystem (18) of real-time oversight, intellectual analysis, identification and defect early warning;
Institute's displacement sensors (13) adopts NS-WY06, and its structure is that two stay-supported type displacement sensors are separately fixed at immediately below two stepper motors; Described first drive motor (1) and the second drive motor (7) are arranged in mutually vertical and on screw rod (3) in parallel water plane, with rotation planar each autokinesis of screw rod (3), the positional information of Real-time Obtaining monitoring probe (12); Described monitoring probe (12) comprises scanning monitoring probe and stationary monitoring probe, all adopt 2 dimension array structures, wherein scan monitoring probe and adopt nx1 dimensional pattern, stationary monitoring probe adopts nxm dimensional pattern, n, m are each independent detection probe, for being more than or equal to the integer of 1, each detection probe comprises the magnetic field levels of pair of orthogonal and the magnetic test coil of vertical component;
Described Signal-regulated kinase (14) adopts prime amplifier AD620 to carry out signal amplification to rotating magnetic field distortion simulation signal, adopts 2 rank Butterworth filters to carry out low-pass filtering;
Described PLC slave computer (16) adopts XCM-32T4-E and XC-E8AD, this independently PLC slave computer (16) can realize easily I/O expansion be connected with same host computer PC, have the independently equipment such as CPU and control circuit, program storage, I/O interface, communication interface, power supply; This PLC slave computer (16) supports Modbus communication, according to the setting of host computer PC parameter, read rotating magnetic field distortion simulation signal least significant bit (LSB) data LSB, and be converted to magnitude of voltage, displacement, rotating magnetic field distortion amplitude and phase mode analog signal are converted to digital signal, complete a data acquisition, storage; According to the instruction of host computer PC, control ACFM monitors mobile platform (19) motion path;
Described system control subsystem comprises further: digital communication module (171), mechanism for monitoring control module (175), systematic conservation module (172), historical data playback module (173), threshold value update module (174); Wherein digital communication module (171) utilizes RS232 type cable to be connected on the serial ports of the PC host computer that LabVIEW is housed by PLC slave computer (16), based on the ModbusASCII communication modes of LabVIEW, utilize VISA technology, serial ports parameter is set, pack data to be sent and instruction by the form of PLC command frame, send command frame to writing serial ports, time delay is waited for that the acknowledgement frame of PLC arrives and is read serial ports, read and unpack the acknowledgement frame of PLC, obtain displacement, rotating magnetic field distortion amplitude and phase data, complete an exchanges data;
Described defect Intelligent Recognition subsystem (18) comprises further: be connected with described digital communication module (171), the rotating magnetic field exported for receiving described digital communication module (171) distorts, displacement digital signal, rotating magnetic field distortion digital signal is carried out to the digital signal processing module (181) of digital IIR filtering; Being connected with described digital signal processing module (181), is the threshold value setting module (182) of following automatic diagnosis module (183) intelligent set monitoring threshold; Be connected with described threshold value setting module (182), for receiving the rotating magnetic field distortion digital signal that described digital signal processing module (181) exports, the monitoring threshold based on threshold value setting module (182) carries out N continuous time to rotating magnetic field distortion digital signal and differentiates and export the automatic diagnosis module (183) of preserving satisfactory rotating magnetic field distortion digital signal; Be connected with described automatic diagnosis module (183), for receiving the satisfactory rotating magnetic field distortion digital signal that described automatic diagnosis module (183) exports, the defect intelligent identification module (184) that the carrying out for the treatment of the surface imperfection of monitoring of structures according to rotating magnetic field distortion digital signal identifies; Be connected with described defect intelligent identification module (184), the defect for the information preservation that accept defect intelligent identification module (184) preserves module (185); Preserve module (185) with described defect to be connected, according to damage tolerance design thought, for accepting the crack length that defect preservation module (185) exports, according to the residual intensity of crack length computation structure, determine the proof cycle of structure to be monitored, crack warning parameter is set: Gao Gaobao, high report, low report, low report, the fluctuation upper limit, the defect warning module (186) of real-time graded early warning;
Described digital signal processing module (181) selects 8 rank Butterworth filters to carry out filtering process to rotating magnetic field distortion digital signal; Described threshold value setting module (182) adopts false-alarm probability determination monitoring threshold, adopt LabVIEW designing user graphical interfaces and interface, MATLAB provides threshold setting algorithm program to call for LabVIEW on backstage, method of calling selects MATLABScript node mode; Described automatic diagnosis module (183) is according to N continuous time criterion: N number of data compare with monitoring threshold, and N continuous is secondary within the scope of monitoring threshold; Automatic detection defect position at the whole story, synchronous data of preserving in threshold range, the data signal waveforms figure of Real-time Two-dimensional cromogram real-time graph display defect information and collection shows; In described defect intelligent identification module (184), the intelligent visual defect inverting of ACFM monitoring adopts the method for LabVIEW and MATLAB hybrid programming to realize, analyze the extremal features point extracted in described automatic diagnosis module synchronization preservation data, adopt LabVIEW designing user graphical interfaces and interface, MATLAB provides defect intelligent quantization and visualized algorithm program to call for LabVIEW on backstage, method of calling selects MATLABScript node mode.
2. real-time high-precision ACFM crackle condition monitoring system as claimed in claim 1, it is characterized in that: described rotating magnetic field signal driving source (11) adopts two groups of orthogonal first drive coils (114) and the second drive coil (115) to be wound on above orthogonal double-U-shaped magnetic core, the first drive coil (114) and the second drive coil (115) passes into amplitude, frequency is identical, the sinusoidal ac signal that phase is 90 degree is given respectively by signal generator (111), power amplification circuit (112), phase-shift circuit (113); Described platform driving power module (20) comprises, the motor driver (202) that S-250-24 Switching Power Supply (201), the mechanism for monitoring control module (175) transmitted for receiving PLC slave computer (16) output signal, through motor starting device (203), short circuit current fuse protecting device (204) and the first drive motor (1) and the second drive motor (7) of electric current, tach signal being exported to monitoring mobile platform (19); Described double-U-shaped magnetic core adopts double-U-shaped manganese-zinc ferrite core; The sinusoidal ac signal of described signal generator (111) adopts accurate function generator ICL8038 to produce; Described phase-shift circuit (113) adopts RC phase-shift circuit, by changing resistance value, obtains identical with input signal size, frequency, but the sinusoidal ac signal of phase 90 degree; Described motor driver (202) adopts DCM8055/8028, receives the motor driving parameter signal that PLC slave computer (16) exports; Described motor starting device (203) adopts the single contactor of Lc1D09...C, short circuit current fuse protecting device (204) to adopt RT28N-32x low-tension fuse; receive the electric current that described motor driver (202) exports, starter motor, short circuit to be protected.
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