滚珠丝杠副论文：基于DSP便携式滚珠丝杠副故障检测仪设计.doc

滚珠丝杠副论文：基于DSP便携式滚珠丝杠副故障检测仪设计

【中文摘要】滚珠丝杠副是数控加工机床中最重要的部件之一,它是数控加工机床主要的传动、定位装置,因其具有传动效率高、定位精度准、刚度强等特点,在数控机床领域得到了广泛应用。数控机床滚珠丝杠副的使用寿命一般规定在1-1.5万小时,但是很多数控机床横向滚珠丝杠副达不到这个运行时间就会发生故障。当滚珠丝杠副出现故障,如果不能及时发现,将会对所加工产品的精度造成严重的误差,从而导致产品合格率下降。这会使数控加工生产企业的经济效益大幅度降低。同时由于目前国内数控机床的加工技术远不能满足高精度的需求,许多企业只能依靠进口高精度数控机床进行产品的加工生产。一旦发现滚珠丝杠副出现问题,再向国外厂家订购,会大大增加数控加工企业的停工时间。这也将很大降低数控加工企业的经济效益。近年来,国内对滚珠丝杠副故障诊断系统也有一定的研究,但是绝大多数故障诊断系统的文献都是基于PC机形式来实现的。这大大增加了数控加工企业的成本,也限制了现场的实际应用的价值。国外也有研究基于便携式的滚珠丝杠副故障诊断仪,但是由于其价格过于昂贵,难以在国内数控加工企业普及。针对上述情况本文提出一种基于DSP便携式滚珠丝杠副故障测试仪。实现了低成本、高运算能力、高数据传输速度等优点。论文完成了滚珠丝杠副故障检测系统的硬件电路设计工作。系统采用了高共模抑制比前置放大器MAX492进行信号的前置放大处理,并采用LMF90构成50Hz陷波电路滤去工频干扰信号,同时采用MAX7424开关电容滤波芯片构成低通滤波器,由TMS320VC5502控制其时钟信号,从而达到可自调整截止频率的,最后由DAC0832和运算放大器构成程控放大器,达到放大倍数可调,为12位串行A/D转换器MAX1246提供适合转换的模拟信号。经过A/D转换器MAX1246后的得到的数字信号通过TMS320VC5502的多通道缓冲串口,利用DMA控制器将数据搬移到DSP内部存储器。同时,论文完成了人机交互硬件模块,使系统能更便于的操作。论文还完成了TMS320VC5502的自加载程序设计。通过对Boot表设计,使系统程序能顺利烧写到Flash中,并在系统上电后能完成自加载任务。此外,论文在DSP的CCS2.0开发环境中用C语言和汇编语言完成了系统软件的开发和快速傅里叶算法的编写。论文在完成软硬件系统的基础上,在数控加工企业以CNCNNATIV5-3000加工中心的滚珠丝杠副作为实验对象进行功能测试。测试结果证明,该检测仪能够满足滚珠丝杠副的故障检测要求。这对提高数控加工企业的工作效率和经济效益有着重大的现实意义,也对故障检测在滚珠丝杠副的应用有着很强的理论意义。
【英文摘要】The ball screw is one of the most important components in CNC machine, which mainly is the transmission and position device of CNC machine. And it’s used widely in the area of CNC machine, because of its high transmission efficiency, precision positioning, and high stiffness. The using life of ball screw in CNC machine is about 10-15 thousand hours. But many ball screws of CNC machine can’t achieve the running time.If not found the malfunction of the ball screw immediately, it will cause serious errors of the product, so it will make the qualified of product decline. This will reduce the benefits of CNC enterprise. At the same time, the CNC processing technology can’t satisfy the high precision demand, so many enterprises only rely on the import CNC to produce production. Once the ball screw appears problems, then order the products, it will increase the downtime of CNC enterprise and reduce the benefits of CNC enterprise. In recent years, lots of fault diagnosis research about ball screw has been developed. However, most fault diagnosis system based on PC machine. This great increase the cost of the CNC enterprise, and it also limits the value of practical application. There are some researches about portable ball screw fault diagnostic instrument, but due to its expensive price, it can’t be equipped in domestic CNC enterprise popularly.In view of this situation, this paper presents a kind of portable ball screw fault diagnostic instrument based on DSP. It realizes some advantages such as low cost, high operation ability, and high data transmission speed.This paper completed the design of hardware of the ball screw fault diagnostic system. The system uses a high CMRR preamplifier IC MAX492 in signal processing, then it uses LMF90 to constitute the circuit of 50Hz trapped wave filter to filtering the power frequency signal. And it adopts MAX7424 to constitute the circuit of low pass filter. TMS320VC5502 controls its clock signal to adjust the cut-off frequency. Finally, it uses DAC0832 and OP to constitute the program-controlled amplifier, which provides suitable analog signals to 12 serial A/D converter MAX 1246. The digital signals which are converted by MAX 1246 are received by TMS320VC5502 by McBSP, and then the data are moved by DMA controller to RAM. And the paper completed the hardware of human-computer interaction, which makes the system better to be operated.This paper completed the boot loader of TMS320VC5502. The boot table makes Flash Burn successful, therefore the system can run after power up. In addition this paper completed the software and FFT algorithm based on DSP in CCS2.0. This paper completed hardware and software system, then makes tests on CNCNNATIV5—3000 machining center. The test results show that this diagnostic system can satisfy the fault detection requirements. This will make great benefits to NC processing enterprise, and also make great theoretical significance on fault detection.
【关键词】滚珠丝杠副 故障检测 DSP 便携式
【英文关键词】ball screw fault detection DSP portable
【目录】基于DSP便携式滚珠丝杠副故障检测仪设计

摘要

6-7

Abstract

7-8

第1章 绪论

11-15

1.1 滚珠丝杠副简介

11-12

1.2 滚珠丝杠副故障检测系统研究现状

12-13

1.3 本文研究意义

13-14

1.4 本文研究任务

14-15

第2章 检测仪方案设计

15-19

2.1 便携式设计原则

15

2.2 检测仪设计主要内容

15-16

2.3 检测仪硬件设计

16-17

2.4 检测仪软件设计

17-18

2.5 本章小结

18-19

第3章 检测仪硬件设计

19-35

3.1 振动传感信号测试方法

19

3.2 信号调理电路设计

19-25

3.2.1 信号前置放大电路

20

3.2.2 50Hz陷波电路设计

20-22

3.2.3 抗混叠滤波器设计

22-23

3.2.4 程控放大器设计

23-25

3.3 DSP系统设计

25-28

3.3.1 DSP概述

25-26

3.3.2 存储器扩展

26-28

3.4 人机交互设计

28-30

3.4.1 液晶显示

28-29

3.4.2 键盘设计

29-30

3.5 A/D转换电路接口设计

30-32

3.5.1 多通道缓冲串口概述

30-31

3.5.2 电路接口设计

31-32

3.6 电源设计

32-34

3.6.1 系统对电源的要求

32

3.6.2 电源转换模块设计

32-34

3.7 本章小结

34-35

第4章 Bootloader引导设计

35-41

4.1 Bootloader的基本原理和模式

35-36

4.2 Boot表的建立

36-38

4.3 在线Flsah的烧写

38-40

4.4 本章小结

40-41

第5章 系统软件设计

41-50

5.1 集成开发环境CCS2.0

41-43

5.2 DSP软件编程步骤

43-44

5.3 系统功能软件

44-49

5.3.1 系统初始化

44-45

5.3.2 A/D转换程序设计

45-47

5.3.3 人机交互程序设计

47-49

5.4 本章小结

49-50

第6章 DSP实现快速傅里叶算法

50-60

6.1 数字信号处理典型算法

50-52

6.1.1 时域分析方法

50-51

6.1.2 频域分析方法

51-52

6.2 FFT数学理论及其算法

52-57

6.2.1 离散傅里叶变换原理

52-53

6.2.2 快速傅里叶变换原理

53

6.2.3 基-2FFT算法

53-57

6.3 FFT算法的DSP实现

57-59

6.4 本章小结

59-60

结论

60-61

致谢

61-62

参考文献

62-65

攻读硕士学位期间发表论文

65-66

附录

66