JP7630392B2 - Method and equipment for repairing welded joints in steel decks - Google Patents

Description

The present invention relates to a method and device for repairing welds in a steel deck plate, which repairs weld penetration within a trough rib that is welded to the steel deck plate of a bridge.

Conventionally, a steel deck plate used in bridges is known, which is made by welding a reinforcing steel trough rib to the underside of a flat deck plate made of steel (see, for example, Patent Document 1).

The trough rib is formed in a roughly U-shape and is joined to the steel plate of the deck plate by fillet welding. When welding, a square groove is formed on the joining end surface of the trough rib, and welding is performed from the outside of the trough rib along the longitudinal direction of the trough rib.

JP 2008-307561 A

However, when fillet welding is performed from the outside of the trough rib, melt-through may occur in the weld. In such cases, the weld bead that has melted through remains on the inside of the trough rib, but because the trough rib has a sealed structure with partition walls at multiple locations along its length, it is not possible to visually check the weld bead from the outside during or after welding.

On the other hand, in recent years, steel decks that do not have a bulkhead inside the trough rib and use an air drying system to ventilate the inside of the trough rib have started to become popular. Since the inside of such a trough rib in a steel deck is not sealed with a bulkhead, it is thought possible to inspect the entire inside of the trough rib from an opening at one end in the longitudinal direction. However, the opening in the trough rib is not large enough for a person to enter, and the overall length is long (e.g. 25 m), so there is a problem that it is difficult to manually inspect and repair the welds inside the trough rib.

The present invention was made in consideration of the above problems, and its purpose is to provide a method and device for repairing welds in steel decks that can inspect and repair welds in trough ribs without the need for personnel to enter the trough ribs.

In order to achieve the above-mentioned object, the present invention provides a method for repairing welds in a steel deck, which inspects and repairs the penetration of welds in a trough rib welded to a deck plate of a steel deck, by running a self-propelled inspection device equipped with a camera inside the trough rib along the longitudinal direction of the trough rib, outputting an image of the weld in the trough rib captured by the camera to an external monitor, and measuring the distance from a predetermined longitudinal position of the trough rib to the inspection device, thereby measuring the position of the penetration part of the weld confirmed by the monitor, and moving a self-propelled scraping device to the position of the penetration part and scraping off the penetrated weld bead with the scraping device.

In addition, in order to achieve the above-mentioned object, the present invention provides a steel deck weld repair device that inspects and repairs weld penetration in a trough rib welded to a deck plate of a steel deck, the device comprising: a self-propelled inspection device equipped with a camera and running within the trough rib along the longitudinal direction of the trough rib; a monitor that is placed outside the trough rib and outputs an image of the weld in the trough rib captured by the camera; a position measuring means that measures the position of the penetration portion of the weld confirmed by the monitor by measuring the distance from a predetermined longitudinal position of the trough rib to the inspection device; and a self-propelled scraping device that moves to the position of the penetration portion measured by the position measuring means and scrapes off the penetrated weld bead.

As a result, the inspection device checks for the presence or absence of weld beads that have penetrated through the trough rib, and the weld beads that have penetrated through the trough rib are scraped off by the scraping device, making it possible to inspect and repair the welds in the trough rib for penetration without the need for personnel to enter the trough rib.

According to the present invention, it is possible to inspect and repair the penetration of welds in a trough rib without the need for personnel to enter the trough rib, so that inspection and repair of penetration of welds in a trough rib that does not have a bulkhead inside can be performed efficiently in a factory or on an existing bridge, thereby improving the quality and durability of the steel deck.

FIG. 1 is a partial perspective view of a steel deck showing one embodiment of the present invention. Partial perspective view of a steel deck with the underside facing upward Front view of the main part of the steel deck Front cross-sectional view of the main part of the steel deck Plan view of the inspection device Inspection device block diagram Plan view of scraping device Plan view of the rotary blade Enlarged side view of the main part of the rotary blade Block diagram of scraping device FIG. 2 is a plan view showing the operation of the inspection device; Diagram showing monitor screen FIG. 2 is a plan view showing the operation of the scraping device; Front cross-sectional view of the main part showing the weld bead cutting process Front cross-sectional view of the main part showing the weld bead cutting process Front cross-sectional view of the main part showing the weld bead cutting process FIG. 11 is a front cross-sectional view of a main part of another embodiment of the scraping device;

Figures 1 and 2 show one embodiment of the present invention, and show a weld repair method and an apparatus used for inspecting and repairing weld penetration in a trough rib of a steel deck.

The steel deck 1 shown in the figure has a flat deck plate 2 made of steel plate, and multiple reinforcing trough ribs 3 are welded to the underside of the deck plate 2. The trough ribs 3 are made of steel material formed into an approximately U-shape, and as shown in Figures 2 and 3, they are welded to the deck plate 2 with the steel deck 1 turned upside down in a factory or the like. At that time, a square groove is formed on the joint end surface of the trough rib 3, and the trough rib 3 is welded along the longitudinal direction from the outside.

When fillet welding is performed from the outside of the trough rib 3, the weld 4 may melt through to the inside of the trough rib 3. In such a case, the weld bead 4a that has melted through remains on the inside of the trough rib 3, as shown in Figure 4.

The repair device of this embodiment is composed of a self-propelled inspection device 10 for inspecting the presence or absence of weld beads 4a that have penetrated through the trough rib 3, and a self-propelled scraping device 20 for scraping off the weld beads 4a in the trough rib 3.

The inspection device 10 includes a device body 11 that can enter the trough rib 3, a traveling device 12 that moves the device body 11, an operation unit 13 that remotely controls the traveling device 12, a camera 14 mounted on the device body 11, a monitor 15 that outputs the image from the camera 14, and a measuring tool 16 that serves as a position measuring means for measuring the position of the device body 11.

The traveling device 12 is composed of a drive mechanism, a steering mechanism, a battery, etc. (not shown), and drives the wheels 11a attached to the device body 11 to make the device body 11 travel.

The operation unit 13 is connected to the traveling device 12 wirelessly or by wire, and allows the operator to operate the traveling device 12, such as moving the device main body 11 forward, backward, and steering.

The camera 14 is a well-known high-definition camera that captures images in front of the device body 11 and has the function of recording the captured images.

The monitor 15 is connected to the camera 14 wirelessly or via a wired connection, and is placed on the operator's side together with the operation unit 13.

The measuring tool 16 is a strip-shaped measuring tape used in well-known tape measures, with one end connected to the rear end of the device body 11 and the other end positioned outside the trough rib 3.

The scraping device 20 includes a device body 21 that can enter the trough rib 3, a traveling device 22 that drives the device body 21, a holding device 23 that can hold the device body 21 in the trough rib 3, a cutting machine 24 that scrapes off the weld bead 4a that has penetrated through the trough rib 3, an operating unit 25 that remotely controls the traveling device 22, the holding device 23, and the cutting machine 24, a camera 26 mounted on the cutting machine 24, and a monitor 27 that outputs the image from the camera 26.

The traveling device 22 is composed of a drive mechanism, a steering mechanism, a battery, etc. (not shown), and drives the wheels 21a attached to the device body 21 to make the device body 21 travel.

The holding device 23 has a pair of holding parts 23a provided on both sides of the device body 21, and each holding part 23a is movable in the width direction of the device body 21 by a driving mechanism such as a cylinder (not shown). In addition, each holding part 23a is provided with a guide roller 23b that abuts against the inner surface of the trough rib 3.

The cutting machine 24 includes an arm 24a rotatably mounted on the device body 21, a cutting head 24b mounted on the tip of the arm 24a, and a rotary blade 24c attached to the cutting head 24b. The arm 24a moves the cutting head 24b to the cutting position, and the rotary blade 24c cuts off the cutting object. The rotary blades 24c are provided at equal intervals at four locations around the rotation shaft 24d as shown in FIG. 8, and rotate horizontally around the rotation shaft 24d by a driving mechanism such as a motor (not shown). In addition, the rotary blade 24c is formed so that the cutting edge angle θ is equal to the angle between the inner surface of the trough rib 3 and the deck plate 2 as shown in FIG. 9. A guide portion 24e that abuts against the inner surface of the trough rib 3 is provided above the rotary blade 24c, and the abutment surface of the guide portion 24e and the rotary blade 24c are formed to be flush with each other with respect to the inner surface of the trough rib 3.

The operating unit 25 is connected wirelessly or by wire to the traveling device 22, the holding device 23, and the cutting machine 24, and allows the operator to operate the traveling device 12, such as moving the device body 21 forward, backward, and steering, and to operate the holding device 23, such as moving each holding part 23a, and to operate the cutting machine 24, such as rotating the arm 24a and rotating the rotary blade 24c.

The camera 26 is a well-known high-definition camera that captures images of the cutting position of the cutting machine 24.

The monitor 27 is connected to the camera 26 wirelessly or via a wired connection, and is located on the operator's side together with the operation unit 25.

The following describes the method for repairing welds in this embodiment, including the inspection process using the inspection device 10 and the scraping process using the scraping device 20.

First, in the inspection process, the main body 11 of the inspection device 10 is placed at one end of the trough rib 3 and is moved toward the other end of the trough rib 3 as shown in FIG. 11. During this, the main body 11 is moved while capturing an image of the area in front of it with the camera 14, and the image is output to the monitor 15 and also recorded as a video in a storage device (not shown). The monitor 15 displays the deck plate 2 and the inner surface of the trough rib 3 on the screen 15a as shown in FIG. 12, and the operator moves the main body 11 while watching the image on the monitor 15. In addition, the measuring tool 16 is advanced into the trough rib 3 along with the moving main body 11.

When the operator confirms from the image on the monitor 15 that a weld bead 4a has appeared at the boundary between the deck plate 2 and the trough rib 3, the device body 11 is stopped at the position of the weld bead 4a, and the position of the weld bead 4a is measured by the measuring tool 16. In this case, as shown in FIG. 11, the distance L from the device body 11 to one end of the trough rib 3 is measured by reading the scale on the measuring tool 16, and the measured distance is recorded as the position of the weld bead 4a.

Next, in the scraping process, the device body 21 of the scraping device 20 is placed at one end side of the trough rib 3, and the device body 21 is moved toward the other end side of the trough rib 3 to the position of the weld bead 4a. At that time, since the measured distance L from one end of the trough rib 3 to the weld bead 4a is recorded in the inspection process, the device body 21 is moved to the position of the weld bead 4a based on that distance L. In addition, the position and state of the weld bead 4a are confirmed using the image recorded by the camera 14. After the device body 21 is moved to the cutting work position as shown in FIG. 13, each holding portion 23a of the holding device 23 is moved toward the outside in the width direction to abut against the inner side surface of the trough rib 3, and the device body 21 is held so as not to move in the width direction. At that time, each holding portion 23a of the device body 21 abuts against the inner side surface of the trough rib 3 via the guide roller 23b, so that the device body 21 is held in a state in which it can move in the front-rear direction (the longitudinal direction of the trough rib 3).

Next, the weld bead 4a is scraped off by the cutting machine 24 of the scraping device 20. That is, as shown in FIG. 14, the cutting head 24b is moved to the cutting position by the arm 24a, and as shown in FIG. 15, the rotating blade 24c is pressed against the weld bead 4a while rotating, thereby cutting the weld bead 4a. At that time, the traveling device 22 moves the device body 21 in the forward and backward directions to cut the weld bead 4a along the boundary between the deck plate 2 and the trough rib 3. In addition, since the cutting edge angle θ of the rotating blade 24c has an angle equivalent to the angle between the inner surface of the trough rib 3 and the deck plate 2, the weld bead 4a is cut so as to be flush with the inner surface of the trough rib 3, and the guide portion 24e abuts against the inner surface of the trough rib 3 during cutting, so that the movement of the cutting edge of the rotating blade 24c is restricted at the inner surface position of the trough rib 3. In this type of cutting work, the cutting area is displayed on the monitor 27 by the camera 26, and the operator performs the cutting work by operating the cutting machine 24 and the traveling device 22 while watching the image. By cutting away the weld bead 4a in this way, the through-hole on the inner surface of the trough rib 3 is repaired so that it is flush with the other parts, as shown in FIG. 16.

In this way, according to this embodiment, the self-propelled inspection device 10 equipped with the camera 14 is moved inside the trough rib 3 along the longitudinal direction of the trough rib 3, and the image of the weld in the trough rib 3 captured by the camera of the inspection device 10 is output to the external monitor 15, the position of the weld penetration confirmed by the monitor 15 is measured, and the self-propelled scraping device 20 is moved to the position of the penetration, and the weld bead 4a that has penetrated through is scraped off by the scraping device 20. This makes it possible to inspect and repair the penetration of the weld in the trough rib 3 without a person entering the trough rib 3. This allows efficient inspection and repair of the penetration of the weld in the trough rib 3 that does not have a bulkhead inside to be performed in a factory or an existing bridge, improving the quality and durability of the steel deck.

In addition, a measuring tool 16, one end of which is connected to the main body 11 of the inspection device 10, is used to measure the distance L from a predetermined longitudinal position (one end) of the trough rib 3 to the main body 11, thereby measuring the position of the welded portion through the weld. This makes it possible to easily measure the position of the welded portion through the weld without using a complex structure.

Furthermore, the device is equipped with a holding device 23 that holds the device body 21 of the scraping device 20 inside the trough rib 3 by abutting against the inner surface of the trough rib 3, so that the device body 21 is held inside the trough rib 3 during cutting, allowing cutting work to be performed stably.

The scraping device 20 also has a rotary blade 24c with a cutting edge angle θ equal to the angle between the inner surface of the trough rib 3 and the deck plate 2, so the weld bead 4a can be cut so that it is flush with the inner surface of the trough rib 3, and the weld bead 4a that has penetrated through the trough can be almost completely removed.

Furthermore, a guide portion 24e that abuts against the inner surface of the trough rib 3 is provided near the rotary blade 24c, and by abutting the guide portion 24e against the inner surface of the trough rib 3 during cutting, the movement of the cutting edge of the rotary blade 24c is restricted at the position of the inner surface of the trough rib 3, so excessive cutting by the rotary blade 24c can be prevented and the weld bead 4a that has been cut through can be cut accurately.

In the above embodiment, the weld bead 4a that has been cut through is scraped off by cutting with the rotary blade 24c. However, instead of the cutting machine 24 of the scraping device 20, a grinder 28 may be used as in another embodiment shown in FIG. 17, and the spherical grinding wheel 28a at the tip of the grinder 28 may be rotated and pressed against the weld bead 4a to grind and scrape off the weld bead 4a that has been cut through.

The above embodiment is merely an example of the present invention, and the configurations of the inspection device 10 and scraping device 20 are not limited to those described in the above embodiment.

Reference Signs List 1...steel deck, 2...deck plate, 3...trough rib, 4...welded portion, 4a...weld bead, 10...inspection device, 11...device main body, 12...traveling device, 13...operation unit, 14...camera, 15...monitor, 20...scraping device, 21...device main body, 22...traveling device, 23...holding device, 24...cutting machine, 25...operation unit, 26...camera, 27...monitor, 28...grinder.

Claims (8)

A method for repairing welds in a steel deck, which inspects and repairs weld penetration in a trough rib welded to a deck plate of a steel deck, comprising:
A self-propelled inspection device equipped with a camera is moved inside the trough rib along the longitudinal direction of the trough rib,
An image of the welded portion in the trough rib captured by the camera is output to an external monitor;
By measuring the distance from a predetermined position in the longitudinal direction of the trough rib to the inspection device, the position of the penetration part of the weld confirmed by the monitor is measured, and
A method for repairing a welded portion of a steel deck, comprising: moving a self-propelled scraping device to the position of the welded portion and scraping off the welded bead that has been scraped off by the scraping device. The method for repairing a welded portion of a steel deck as described in claim 1, characterized in that a measuring tool having one end connected to the inspection device is used to measure the position of the weld penetration portion by measuring the distance from a predetermined longitudinal position of the trough rib to the inspection device with the measuring tool. 3. The method for repairing a welded portion of a steel deck according to claim 1, further comprising the step of scraping off the weld bead with a scraping device while the scraping device is held within the trough rib by a holding device that abuts against the inner surface of the trough rib. 4. The method for repairing a welded portion of a steel deck according to claim 1, 2 or 3, characterized in that the weld bead is scraped off using a rotary blade having a blade angle equal to the angle between the inner surface of the trough rib and the deck plate. A steel deck weld repair device that inspects and repairs weld penetration in a trough rib welded to a deck plate of a steel deck,
A self-propelled inspection device equipped with a camera that travels inside the trough rib along the longitudinal direction of the trough rib;
a monitor that is disposed outside the trough rib and outputs an image of the welded portion inside the trough rib captured by the camera;
a position measuring means for measuring a distance from a predetermined position in the longitudinal direction of the trough rib to an inspection device, thereby measuring a position of a penetration portion of the weld confirmed by a monitor;
and a self-propelled scraping device that moves to the position of the strike-through portion measured by the position measuring means and scrapes off the weld bead that has been struck through. The steel deck weld repair device according to claim 5, characterized in that the position measuring means comprises a measuring tool having one end connected to the inspection device, and measures the position of the penetration portion of the weld by measuring the distance from a predetermined longitudinal position of the trough rib to the inspection device using the measuring tool. The steel deck weld repair device according to claim 5 or 6, further comprising a holding device that holds the scraping device within the trough rib by abutting against an inner surface of the trough rib. 8. The steel deck weld repair device according to claim 5, 6 or 7, wherein the scraping device has a rotary blade having a blade angle equal to an angle between the inner surface of the trough rib and the deck plate.

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