基于DSP便携式滚珠丝杠副故障检测仪设计

发布时间：2018-11-21 06:46

【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目的,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。
[Abstract]:Ball screw pair is one of the most important parts in NC machining machine tools. It is the main transmission and positioning device of NC machine tools, because of its high transmission efficiency, accurate positioning accuracy, strong stiffness and so on. It has been widely used in the field of NC machine tools. The service life of the ball screw pair of CNC machine tools is generally in the range of 10 to 15, 000 hours, but many CNC machine tool horizontal ball screw pairs will fail if they fail to reach this running time. If the ball screw pair fails, if it can not be found in time, it will cause serious error to the precision of the processed product, which will lead to the decline of the qualified rate of the product. This will greatly reduce the economic benefits of NC manufacturing enterprises. At the same time, because the machining technology of domestic NC machine tools is far from meeting the demand of high precision, many enterprises can only rely on imported high-precision NC machine tools to process and produce products. Once found the ball screw pair problems, and then ordered from foreign manufacturers, will greatly increase the shutdown time of CNC processing enterprises. This will also greatly reduce the economic benefits of NC processing enterprises. In recent years, the ball screw fault diagnosis system has also been studied in China, but most of the documents of the fault diagnosis system are based on the form of PC machine. This greatly increases the cost of NC processing enterprises and limits the practical value of field applications. There are also researches in foreign countries based on portable ball screw fault diagnosis instrument, but because its price is too expensive, it is difficult to be popularized in domestic NC processing enterprises. This paper presents a portable ball screw fault tester based on DSP. It has the advantages of low cost, high computing capacity and high data transmission speed. The hardware circuit design of the ball screw fault detection system is completed in this paper. A high common-mode rejection ratio preamplifier (MAX492) is used to preamplify the signal. The 50Hz notch circuit is used to filter the power frequency interference signal and the MAX7424 switch capacitor filter chip is used to filter the low-pass filter. The clock signal is controlled by TMS320VC5502 to achieve the purpose of self-adjusting cutoff frequency. At last, the programmable amplifier is composed of DAC0832 and operational amplifier, and the amplification ratio is adjustable. The analog signal suitable for conversion is provided for 12-bit serial A / D converter MAX1246. The digital signal obtained by the MAX1246 of the A / D converter is moved to the internal memory of the DSP by using the DMA controller through the multi-channel buffer serial port of the TMS320VC5502. At the same time, the hardware module of man-machine interaction is completed, which makes the system more convenient to operate. The thesis also completes the self-loading program design of TMS320VC5502. Through the design of Boot table, the system program can be burned into the Flash smoothly, and the self-loading task can be completed after the system is powered on. In addition, in the CCS2.0 development environment of DSP, the system software and fast Fourier algorithm are developed with C language and assembly language. On the basis of the software and hardware system, the paper takes the ball screw pair of CNCNNATIV5-3000 machining center as the experimental object to test its function. The test results show that the tester can meet the fault detection requirements of ball screw pair. It is of great practical significance to improve the working efficiency and economic benefit of NC machining enterprises, and it is also of great theoretical significance to the application of fault detection in ball screw pairs.
【学位授予单位】：西南交通大学
【学位级别】：硕士
【学位授予年份】：2011
【分类号】：TG659;TH165.3

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