基于锁相放大器的喷丸检测系统设计
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中北大学极限环境光电动态测试技术与仪器全国重点实验室 太原 046500

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TN722

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国家自然科学基金面上项目(52275550)资助


Design of lock-in amplifier based shot peening inspection system
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National Key Laboratory of Extreme Environment Optoelectronic Dynamic Testing Technology and Instrumentation, North China University of Technology,Taiyuan 046500, China

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    摘要:

    为精准解决细长管件内部喷丸残留这一影响高端装备服役安全的关键问题,满足航空航天、精密医疗器械等领域对核心零部件全周期质量保障的严苛需求,克服现有无损检测技术的局限,本研究首次在细长管件内部残留喷丸检测场景下提出将涡流检测技术与锁相放大器相结合,并设计了一种基于现场可编程门阵列(field programmable gate array,FPGA)与锁相放大器的集成化喷丸残留检测系统,以电涡流传感器为探测手段,伸入管件内部捕获喷丸残留产生的电磁响应;基于互相关理论,通过锁相放大器实现对微弱相位信号的精准提取,经FPGA控制的高精度数据采集模块完成信号量化,最终通过相位变化特征实现喷丸的残留识别与位置定位。该系统突破了传统超声波检测、射线检测及单一涡流检测的应用局限,可以通过多频段激励频率适配不同检测场景,检测精度从厘米级提升至毫米级,可有效检测不同尺寸的残留喷丸,无需依赖耦合剂,不受管件几何结构、喷丸附着状态影响。同时,系统具备检测速度快、效率高的优势,且体积小巧、成本较低,无辐射污染,对检测环境要求宽松,便于现场部署。通过搭建实际测试平台,在不同频段激励频率下对铝合金细长管件内不同尺寸钢质喷丸残留的情况进行检测验证,结果表明,检测系统可以在不同激励频率下有效识别管件内残留的不同尺寸的喷丸,对喷丸位置检测结果的平均误差仅为2.38 mm,标准差为1.35 mm,信噪比相较于传统涡流检测方法也有所提升。

    Abstract:

    To precisely address the critical issue of internal shot peening residue in slender tubes, which affects the service safety of high-end equipment, and to meet the stringent requirements for full-cycle quality assurance of core components in fields such as aerospace and precision medical devices, this study overcomes the limitations of existing nondestructive testing technologies. For the first time in the context of detecting shot peening residue inside slender tubes, this paper proposes combining eddy current testing technology with a lock-in amplifier and designs an integrated shot peening residue detection system based on field programmable gate array (FPGA) and a lock-in amplifier. Using an eddy current sensor as the probing tool, the system is inserted into the tube to capture the electromagnetic response generated by the residual shot. Based on cross-correlation theory, the lock-in amplifier enables precise extraction of weak phase signals. These signals are then quantified by a high-precision data acquisition module controlled by an FPGA, and finally, residue identification and location of the shot are achieved through phase variation characteristics. The system overcomes the application limitations of conventional ultrasonic testing, radiographic testing and single-mode eddy current testing. It can adapt to different detection scenarios through multi-frequency excitation, improving detection accuracy from the centimeter level to the millimeter level. It effectively detects residual shot of different sizes, requires no coupling agent and is unaffected by tube geometry or shot adhesion conditions. Additionally, the system offers fast detection speed, high efficiency, compact size, low cost, no radiation pollution, relaxed environmental requirements and ease of on-site deployment. A practical test platform was built to validate the detection of steel shot residue of various sizes inside aluminum-alloy slender tubes under different excitation frequencies. The results show that the detection system can effectively identify residual shots inside the tubes under different excitation frequencies. The average error in shot location detection is only 2.38 mm, with a standard deviation of 1.35 mm, and the signal-to-noise ratio is also improved compared to traditional eddy current testing methods.

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徐浩东,张志杰.基于锁相放大器的喷丸检测系统设计[J].电子测量技术,2026,49(15):45-59

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  • 在线发布日期: 2026-10-23
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