A multi-frequency excitation eddy current sensor comprehensive detection device

Abstract

The present application relates to the technical field of sensor, in particular to a multi-frequency excitation eddy current sensor comprehensive detection device, which comprises a multi-frequency eddy current sensor connected with a detection circuit, the eddy current signal obtained by the multi-frequency eddy current sensor is filtered and amplified by the detection circuit, and the obtained analog signal is sent to a DSP processing module; the DSP processing module converts the received analog signal into a digital signal, extracts the maximum value, integral value, three harmonic components and other characteristic values of the digitized eddy current signal, obtains five characteristic values of the rotating mechanical equipment, and identifies through analysis and comparison with a standard database; and the obtained identification result is sent to a terminal device through a serial communication port for display. The working state of the multi-frequency eddy current sensor can be quickly determined.

Description

Technical Field

[0001] The embodiments of the present invention belong to the field of sensor technology, specifically relating to a multi-frequency excitation eddy current sensor integrated detection device. Background Technology

[0002] Eddy current sensors can measure the distance between a measured metal conductor and the probe surface in a non-contact, highly linear, and high-resolution manner, both statically and dynamically. It is a non-contact, linearized metrological tool. Eddy current sensors accurately measure the static and dynamic relative displacement changes between the measured object (which must be a metal conductor) and the probe end face. The principle of eddy current sensors is based on the eddy current effect, accurately measuring the relative position between the measured object (which must be a metal conductor) and the probe end face. Its characteristics include high long-term reliability, high sensitivity, strong anti-interference ability, non-contact measurement, fast response speed, and immunity to the influence of media such as oil and water. It is often used for long-term real-time monitoring of parameters such as shaft displacement, shaft vibration, and shaft speed in large rotating machinery, enabling analysis of equipment operating conditions and fault causes, effectively protecting and preventing equipment failures.

[0003] However, in the actual application of rotating machinery, if phenomena such as coating on the surface of the shaft, magnetization of the shaft surface, mechanical defects on the shaft surface, and electromagnetication of the surrounding environment of the rotating machinery occur, they will interfere with the working state of the eddy current sensor, thus causing the eddy current sensor to be in an abnormal working state; however, it is difficult to determine whether the eddy current sensor is in an abnormal working state. Summary of the Invention

[0004] The purpose of this invention is to solve the problem in the prior art that when rotating machinery is used in practice, phenomena such as coating on the surface of the main shaft, magnetization of the main shaft surface, mechanical defects on the main shaft surface, and electromagnetication of the surrounding environment of the rotating machinery will interfere with the working state of the eddy current sensor, thereby causing the eddy current sensor to be in an abnormal working state, and at the same time it is difficult to determine whether the eddy current sensor is in an abnormal working state.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: An embodiment of the present invention provides a comprehensive detection device for a multi-frequency excitation eddy current sensor, characterized in that it includes a multi-frequency eddy current sensor, an excitation circuit, a detection circuit, and a DSP processing module; Multi-frequency eddy current sensors are installed along both sides of rotating machinery to detect the coating on the main shaft surface, magnetization on the main shaft surface, mechanical defects on the main shaft surface, and electromagnetic information of the surrounding environment of rotating machinery and generate different eddy current signals. The excitation circuit is connected to the DSP processing module. The input signal of the excitation circuit comes from the TTL control signal output by the DSP processing module. The output signal generated by the excitation circuit is sent to the multi-frequency eddy current sensor connected to it. The multi-frequency eddy current sensor is connected to the detection circuit. The eddy current signal obtained by the multi-frequency eddy current sensor is filtered and amplified by the detection circuit, and the resulting analog signal is sent to the DSP processing module. The DSP processing module converts the received analog signal into a digital signal and extracts the maximum value, integral value, and three harmonic components of the digital eddy current signal. After obtaining the five characteristic quantities of the rotating machinery, it identifies the equipment by analyzing and comparing them with a standard database. The obtained identification results are sent to the terminal device for display via a serial communication port, thereby obtaining the working status of the multi-frequency eddy current sensor.

[0006] Preferably, the multi-frequency eddy current sensor includes a reflective eddy current sensor and a transmissive eddy current sensor, wherein the reflective eddy current sensor obtains the eddy current signal based on the change of mechanical defect information on the surface of the shaft.

[0007] Preferably, the receiving coil and transmitting coil of the reflective eddy current sensor are made on the skeleton of a hollow cylinder. The receiving coil has an outer diameter of 30mm, is single-layer wound, and is located close to the rotating mechanical equipment. The transmitting coil has an outer diameter of 18mm and is wound with copper wire flat.

[0008] Preferably, the transmission-type eddy current sensor obtains eddy current signals based on changes in the coating on the shaft surface, the magnetization of the shaft surface, and the electromagnetic information of the surrounding environment of the rotating machinery. The coil frame of the transmission-type eddy current sensor is a hollow cylinder with a rectangular cross-section.

[0009] Preferably, the transmitting coil and receiving coil of the transmission-type eddy current sensor are made of copper wire wound flat, and the two coils are arranged on both sides of the rotating mechanical equipment.

[0010] Preferably, to further improve the accuracy and reliability of the detection device, the present invention also employs advanced signal processing technology. The DSP processing module incorporates advanced algorithms capable of fast and accurate analysis of eddy current signals. These algorithms include, but are not limited to, Fast Fourier Transform (FFT) and wavelet transform, which can effectively extract useful feature information from complex signals.

[0011] In addition, the DSP processing module also has an adaptive filtering function, which can automatically adjust the filtering parameters according to changes in environmental noise, thereby ensuring the stability and accuracy of signal processing.

[0012] Preferably, in order to adapt to the testing needs of different types of rotating machinery, the DSP processing module can also adapt to new rotating machinery characteristics through software updates, ensuring that the testing device can work continuously and effectively.

[0013] In practical applications, the multi-frequency excitation eddy current sensor integrated detection device of the present invention can achieve high-speed detection of rotating machinery. The device has an extremely short response time, thanks to the efficient computing power of the DSP processing module and the optimized signal processing flow.

[0014] Preferably, the device also has a self-diagnostic function, capable of periodically checking its own working status to ensure high-precision detection capabilities during long-term operation. When an abnormality is detected in the rotating machinery, the device will immediately send an alarm signal to the terminal device via the communication interface and display it. This rapid response mechanism is crucial for maintaining the safe operation of rotating machinery.

[0015] Preferably, in designing the multi-frequency excitation eddy current sensor integrated detection device of the present invention, its adaptability and robustness under different environments were also specifically considered. The hardware design of the device uses high-precision, low-noise electronic components to ensure stable performance under various temperature and humidity conditions.

[0016] Meanwhile, to cope with potential electromagnetic interference, the internal circuit design of the device employs shielding and isolation technologies, effectively reducing the impact of external electromagnetic interference on the test results.

[0017] Preferably, the device's software system also has a self-calibration function, which can automatically adjust the detection parameters according to environmental changes to ensure that the accuracy of the detection results is not affected.

[0018] Preferably, the detection device of the present invention also demonstrates great convenience in terms of maintenance and upgrades. The DSP processing module supports remote upgrades, which means that users can download the latest software updates directly from the manufacturer via a network connection, thereby quickly improving the functionality and performance of the detection device.

[0019] Meanwhile, the device's hardware modules are designed with a modular structure, facilitating rapid replacement and maintenance. When a module malfunctions, technicians can quickly replace the corresponding module without requiring extensive repairs to the entire device, significantly reducing downtime and improving equipment efficiency.

[0020] Preferably, the device is also equipped with a detailed usage log recording function, which can record detailed information for each test, providing valuable data support for subsequent troubleshooting and performance analysis.

[0021] In practical deployment and use, the multi-frequency excitation eddy current sensor integrated detection device of the present invention has demonstrated extremely high flexibility and scalability. The device design allows users to customize the configuration according to actual needs; for example, the number of eddy current sensors can be increased or decreased to adapt to the detection of rotating machinery of different sizes and types.

[0022] Furthermore, the device features a user-friendly software interface that is easy to operate, allowing even non-professionals to quickly get started. The DSP processing module's user interface provides intuitive data display and control options, enabling users to easily monitor the detection process and results.

[0023] Preferably, to further enhance the user experience, the device also supports multiple language interfaces to meet the needs of users in different countries and regions.

[0024] Preferably, the detection device of the present invention also performs excellently in terms of safety. The device incorporates multiple safety protection mechanisms, including overload protection, short circuit protection, and abnormal voltage protection, to ensure that the equipment can be safely shut down under any abnormal circumstances, preventing potential damage.

[0025] In addition, the device also has data encryption capabilities to ensure the security of all transmitted and stored data and prevent data leakage or unauthorized access.

[0026] Preferably, in order to further improve the reliability of the system, the device is also designed with a redundancy backup mechanism. Key components such as the DSP processing module and power supply are equipped with backups to ensure that the system can seamlessly switch to the backup components when the main components fail, thus ensuring the continuity of the detection work.

[0027] Compared with the prior art, the beneficial effect of the present invention is that by acquiring five characteristic quantities of rotating mechanical equipment and comparing them with a standard database for identification, the working state of the eddy current sensor can be determined. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the multi-frequency excitation eddy current sensor integrated detection device of the present invention. Detailed Implementation

[0029] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0030] Reference Figure 1A multi-frequency excitation eddy current sensor integrated detection device is disclosed. This device mainly consists of a multi-frequency eddy current sensor, an excitation circuit, a detection circuit, and a DSP processing module. The multi-frequency eddy current sensor is carefully arranged on both sides of the rotating machinery to detect the coating on the shaft surface, the magnetization of the shaft surface, mechanical defects on the shaft surface, and the electromagnetic information of the surrounding environment of the rotating machinery, generating different eddy current signals. These signals are then used to determine the operating status of the multi-frequency eddy current sensor.

[0031] The excitation circuit is closely connected to the DSP processing module. The excitation circuit receives the TTL control signal from the DSP processing module as an input signal and transmits the generated output signal to the connected multi-frequency eddy current sensor. The multi-frequency eddy current sensor is connected to the detection circuit. The eddy current signal it receives is filtered and amplified by the detection circuit, and the analog signal is sent to the DSP processing module. The DSP processing module is responsible for converting the received analog signal into a digital signal and extracting key characteristic values ​​such as the maximum value, integral value, and three harmonic components of the digital eddy current signal.

[0032] By acquiring five characteristic quantities of rotating machinery, the DSP processing module can analyze and compare them with a standard database to identify the working status of the rotating machinery. The identification results are sent to the terminal device via a serial communication port for display. This allows the determination of the operating status of the eddy current sensor.

[0033] Furthermore, multi-frequency eddy current sensors include reflective eddy current sensors and transmissive eddy current sensors. Reflective eddy current sensors can obtain eddy current signals based on changes in mechanical defects on the surface of a large shaft. Their receiving and transmitting coils are mounted on a hollow cylindrical frame. The receiving coil has an outer diameter of 30mm, uses a single-layer winding method, and is placed close to the rotating machinery. The transmitting coil has an outer diameter of 18mm and is wound with flat copper wire.

[0034] Transmission-type eddy current sensors obtain eddy current signals based on changes in the coating on the surface of the shaft, the magnetization of the shaft surface, and the electromagnetic information of the surrounding environment of the rotating machinery. The coil frame is a hollow cylinder with a rectangular cross-section, and the transmitting coil and receiving coil are made of copper wire wound flat, with the two coils located on both sides of the rotating machinery.

[0035] The working principle of this invention is as follows: When using this invention, eddy current signals are first acquired, and these signals are then filtered and amplified. The processed signals are then sent to a DSP processor, which is responsible for extracting and identifying multi-frequency and time-domain features. The detection results are sent to the controller of the terminal device via the communication port, and the controller displays an alarm. In this way, it can be determined whether the eddy current sensor is operating normally.

[0036] To further improve the accuracy and reliability of the detection device, this invention also employs advanced signal processing technology. The DSP processing module incorporates advanced algorithms capable of fast and accurate analysis of eddy current signals. These algorithms include, but are not limited to, Fast Fourier Transform (FFT) and wavelet transform, which can effectively extract useful feature information from complex signals.

[0037] In addition, the DSP processing module also has an adaptive filtering function, which can automatically adjust the filtering parameters according to changes in environmental noise, thereby ensuring the stability and accuracy of signal processing.

[0038] To meet the testing needs of different types of rotating machinery, the DSP processing module can also adapt to new rotating machinery characteristics through software updates, ensuring that the testing device can continue to work effectively.

[0039] In practical applications, the multi-frequency excitation eddy current sensor integrated detection device of the present invention can achieve high-speed detection of rotating machinery. The device has an extremely short response time, thanks to the efficient computing power of the DSP processing module and the optimized signal processing flow.

[0040] In addition, the device has a self-diagnostic function, which can periodically check its own working status to ensure that it maintains high-precision detection capabilities during long-term operation.

[0041] When an anomaly is detected in the rotating machinery, the device immediately sends an alarm signal to the terminal device via the communication interface and displays the alarm. This rapid response mechanism is crucial for maintaining the safe operation of rotating machinery.

[0042] In designing the multi-frequency excitation eddy current sensor integrated detection device of the present invention, special consideration was given to its adaptability and robustness in different environments.

[0043] The device's hardware design employs high-precision, low-noise electronic components to ensure stable performance under various temperature and humidity conditions. Furthermore, to address potential electromagnetic interference, the internal circuitry utilizes shielding and isolation techniques, effectively reducing the impact of external electromagnetic interference on the test results.

[0044] In addition, the device's software system also has a self-calibration function, which can automatically adjust the detection parameters according to environmental changes to ensure that the accuracy of the detection results is not affected.

[0045] In terms of maintenance and upgrades, the detection device of this invention also demonstrates great convenience. The DSP processing module supports remote upgrades, meaning that users can download the latest software updates directly from the manufacturer via a network connection, thereby quickly improving the functionality and performance of the detection device.

[0046] Meanwhile, the device's hardware modules are designed with a modular structure, facilitating quick replacement and maintenance.

[0047] When a module malfunctions, technicians can quickly replace the corresponding module without having to carry out large-scale repairs on the entire device, greatly reducing downtime and improving equipment efficiency.

[0048] In addition, the device is equipped with a detailed usage log recording function, which can record detailed information for each test, providing valuable data support for subsequent troubleshooting and performance analysis.

[0049] In actual deployment and use, the multi-frequency excitation eddy current sensor integrated detection device of the present invention has demonstrated extremely high flexibility and scalability.

[0050] The device is designed to allow users to customize the configuration according to their actual needs. For example, the number of eddy current sensors can be increased or decreased to accommodate the detection of rotating machinery of different sizes and types.

[0051] Furthermore, the device features a user-friendly software interface that is easy to operate, allowing even non-professionals to quickly get started. The DSP processing module's user interface provides intuitive data display and control options, enabling users to easily monitor the detection process and results.

[0052] To further enhance the user experience, the device also supports multiple language interfaces, meeting the needs of users in different countries and regions.

[0053] In terms of safety, the detection device of the present invention also performs excellently.

[0054] The device incorporates multiple safety protection mechanisms, including overload protection, short circuit protection, and abnormal voltage protection, to ensure that the equipment can be safely shut down under any abnormal circumstances and to prevent potential damage.

[0055] In addition, the device also has data encryption capabilities to ensure the security of all transmitted and stored data and prevent data leakage or unauthorized access.

[0056] To further improve the reliability of the system, the device is also designed with a redundancy backup mechanism. Key components such as the DSP processing module and power supply are equipped with backups to ensure that the system can seamlessly switch to the backup components when the main components fail, thus ensuring the continuity of the detection work.

[0057] It is understood that the above embodiments are merely exemplary implementations used to illustrate the principles of the present invention, and the present invention is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and essence of the present invention, and these modifications and improvements are also considered to be within the scope of protection of the present invention.

Claims

1. A multi-frequency excitation eddy current sensor integrated detection device, characterized in that, It includes a multi-frequency eddy current sensor, excitation circuit, detection circuit, and DSP processing module; Multi-frequency eddy current sensors are installed along both sides of rotating machinery to detect the coating on the main shaft surface, magnetization on the main shaft surface, mechanical defects on the main shaft surface, and electromagnetic information of the surrounding environment of rotating machinery and generate different eddy current signals. The excitation circuit is connected to the DSP processing module. The input signal of the excitation circuit comes from the TTL control signal output by the DSP processing module. The output signal generated by the excitation circuit is sent to the multi-frequency eddy current sensor connected to it. The multi-frequency eddy current sensor is connected to the detection circuit. The eddy current signal obtained by the multi-frequency eddy current sensor is filtered and amplified by the detection circuit, and the resulting analog signal is sent to the DSP processing module. The DSP processing module converts the received analog signal into a digital signal and extracts the maximum value, integral value, and three harmonic components of the digital eddy current signal. After obtaining the five characteristic quantities of the rotating machinery, it identifies the equipment by analyzing and comparing them with a standard database. The obtained identification results are sent to the terminal device for display via a serial communication port, thereby obtaining the working status of the multi-frequency eddy current sensor.

2. The multi-frequency excitation eddy current sensor integrated detection device according to claim 1, characterized in that, The multi-frequency eddy current sensor includes a reflective eddy current sensor and a transmissive eddy current sensor. The reflective eddy current sensor obtains the eddy current signal based on the changes in mechanical defect information on the surface of the shaft.

3. The multi-frequency excitation eddy current sensor integrated detection device according to claim 2, characterized in that, The receiving coil and transmitting coil of the reflective eddy current sensor are made on the skeleton of a hollow cylinder. The receiving coil has an outer diameter of 30mm, is single-layer wound, and is located close to the rotating mechanical equipment. The transmitting coil has an outer diameter of 18mm and is wound with copper wire flat.

4. The multi-frequency excitation eddy current sensor integrated detection device according to claim 2, characterized in that, The transmission-type eddy current sensor obtains eddy current signals based on changes in the coating on the surface of the shaft, the magnetization of the shaft surface, and the electromagnetic information of the surrounding environment of the rotating machinery. The coil frame of the transmission-type eddy current sensor is a hollow cylinder with a rectangular cross-section.

5. The multi-frequency excitation eddy current sensor integrated detection device according to claim 2, characterized in that, The transmitting and receiving coils of the transmission-type eddy current sensor are made of copper wire wound flat, and the two coils are arranged on both sides of the rotating mechanical equipment.

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