Weld scanner for real-life bridge and scanning method thereof

Abstract

A weld scanner for a real-life bridge and scanning method thereof is disclosed. The weld scanner includes a running portion and a scanning portion mounted on a scanner chassis. A front end and a tail end of the scanner chassis are both provided with a laser range finder. A magnet is arranged at a bottom portion of the scanner chassis. The scanning portion includes a probe slider, a bendable metal pipe and a probe connected in sequence. A gear is arranged on the probe slider, and the gear is meshed with a rack inside a scanner chassis chute. The weld scanner scans while the running portion moves forward along a weld, and scans a suspected defect position more carefully when a magnetic field change is detected.

Claims

1. A weld scanner for a real-life bridge, comprising a running portion and a scanning portion mounted on a scanner chassis, wherein a front end and a tail end of the scanner chassis are both provided with a laser range finder, a magnet is arranged at a bottom portion of the scanner chassis, the scanning portion and the running portion are connected by a chute, the scanning portion comprises a probe slider, a bendable metal pipe and a probe connected in sequence, a gear is arranged on the probe slider, and the gear is meshed with a rack in the chute, and the probe comprises a fixed sleeve, a magnet, a magnetic resistance sensor and a camera, the magnet is mounted in the fixed sleeve, the magnetic resistance sensor is mount at an end of the magnet, and the camera is fixedly mounted on an outer wall of the sleeve.

2. The weld scanner for a real-life bridge according to claim 1, wherein the magnet is an artificial permanent magnet.

3. The weld scanner for a real-life bridge according to claim 1, wherein the scanner chassis is internally provided with a power supply and a control device.

4. The weld scanner for a real-life bridge according to claim 3, wherein the control device is connected to a wireless transceiver.

5. A weld scanner for a real-life bridge, comprising a running portion and a scanning portion mounted on a scanner chassis, wherein a front end and a tail end of the scanner chassis are both provided with a laser range finder, a magnet is arranged at a bottom portion of the scanner chassis, the scanning portion and the running portion are connected by a chute wherein a wheel of the running portion is wrapped with a rubber pad, a wall of the scanner chassis is provided with a wire through hole, the scanner chassis and a probe slider of the scanning portion are provided with a USB interface, and an end portion of the scanner chassis chute is provided with a detachable fixing baffle.

6. A scanning method of a weld scanner for a real-life bridge, the weld scanner including: a running portion and a scanning portion mounted on a scanner chassis, wherein a front end an a tail end of the scanner chassis are both provided with a laser range finder, a magnet is arranged at a bottom portion of the scanner chassis, the scanning portion and the running portion are connected by a chute. wherein the scanning method comprises: the weld scanner scans along a weld direction and gathers signals of all members to a control device; the control device controls the running portion and the scanning portion, and sends the signals to a client; and the client analyzes the signals, further obtains a coordinate and a macroscopic image of a suspected defect position according to initially set coordinate positions, and controls an advancing speed of the weld scanner by controlling a frequency converter of the weld scanner, so that the weld scanner can scan the suspected defect position more carefully when a magnetic field change is detected.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a front external diagram of a scanner;

(2) FIG. 2 is a rear external diagram of the scanner;

(3) FIG. 3 is a sectional view of a circuit board position of the scanner;

(4) FIG. 4 is a diagram illustrating cooperation between a probe motor and a rack of the scanner;

(5) FIG. 5 is a sectional view of the rack in a chute of the scanner;

(6) FIG. 6 is a sectional view of an internal structure of a probe slider of the scanner;

(7) FIG. 7 is a sectional view of internal structures of a magnet fixing sleeve and a camera fixing sleeve of the scanner;

(8) FIG. 8 is an implementation diagram of the scanner;

(9) FIG. 9 is a diagram illustrating movement of a probe portion of the scanner;

(10) FIG. 10 is a diagram illustrating coordinate setting of the scanner; and

(11) FIG. 11 is a diagram illustrating a signal change principle of a magnetic resistance sensor of the scanner.

(12) In the drawings: 1 refers to scanner chassis, 2 refers to probe slider, 2a refers to placement hole of probe slider circuit board, 2b and 2c refer to probe slider circuit holes, 3 refers to probe motor, 3a refers to transmission gear, 4 refers to bendable metal pipe, 5 refers to magnet fixing sleeve, 5a refers to magnet mounting hole, 6 refers to camera fixing sleeve, 6a refers to camera mounting hole, 7 refers to rack, 8 refers to chute, 9 refers to laser range finder, 9a refers to laser transmitting hole, 9b refers to laser receiving hole, 10 refers to scanner wheel, 10a refers to rubber coat, 11 refers to first artificial magnet, 16 refers to second artificial magnet, 11a refers to artificial magnet embedding hole, 12 refers to fixing baffle, 13 refers to rotational rod, 14 refers to fixing bolt, 15 refers to round hole, 17 refers to magnetic resistance sensor, 18 refers to wire through hole, 19 refers to first USB interface, 20 refers to second USB interface, 21 refers to power switch, 22 refers to power interface, 23 refers to circuit board, 24 refers to Bluetooth signal transceiver, and 25 refers to probe circuit hole.

DETAILED DESCRIPTION

First Embodiment

(13) Taking the scanning to a weld between a top plate of a bin of a steel box girder and a U-rib as an example, as shown in FIG. 1, FIG. 2, FIG. 5, FIG. 6 and FIG. 7, a weld scanner for real-life bridge comprises a scanner chassis 1, a probe slider 2, a placement hole of probe slider circuit board 2a, probe slider circuit holes 2b and 2c, a probe motor 3, a transmission gear 3a, a bendable metal pipe 4, a magnet fixing sleeve 5, a magnet mounting hole 5a, a camera fixing sleeve 6, a camera mounting hole 6a, a rack 7, a chute 8, a laser range finder 9, a laser transmitting hole 9a, a laser receiving hole 9b, a scanner wheel 10, a rubber coat 10a, a first artificial magnet 11, a second artificial magnet 16, an artificial magnet embedding hole 11a, a fixing baffle 12, a rotational rod 13, a fixing bolt 14, a round hole 15, a magnetic resistance sensor 17, a wire through hole 18, a first USB interface 19, a second USB interface 20, a power switch 21, a power interface 22, a circuit board 23, a Bluetooth signal transceiver 24, and a probe circuit hole 25. The artificial magnet 11 may be embedded into a bottom portion of the scanner chassis 1, and the scanner smoothly runs on a top portion and an inner wall of the steel box girder through an attraction between the artificial magnet and the inner wall of the steel box girder. The probe slider 2 may slide in the chute 8 through the interaction between the probe motor 3 and the rack 7. The fixing baffle 12 may fix the probe slider 2 through the rotational rod 13 and the fixing bolt 14 to prevent the probe slider 2 from falling out of the chute 8. The laser range finder 9 may check a position of the scanner chassis 1 to ensure that an advancing direction thereof is parallel to the weld.

(14) As shown in FIG. 1, FIG. 2, FIG. 8, FIG. 9 and FIG. 10, all members of the weld scanner are mounted, the laser range finder 9 close to the magnetic resistance sensor is pushed to the inner wall of the steel box girder, the corresponding position thereof is used as a starting position for the scanner to move forward, and a coordinate in a temporary coordinate system is set as A (0, 0). Since the bendable metal pipe 4 of the scanning portion may be bent, a position of the magnetic resistance sensor 17 may be adjusted according to actual needs. After adjustment, a distance between a probe of the magnetic resistance sensor and an origin of coordinates (i.e. the laser range finder) is measured to be d.sub.1, and a coordinate (d.sub.1, 0) of a scanning start may be obtained by inputting d.sub.1 into a client program. An external power supply is connected to the scanner through the power interface 22. The power switch 21 of the weld scanner is turned on, and if the power supply is normal, the weld scanner may send a signal s.sub.g of normal power supply to a client through the Bluetooth signal transceiver 24. The client judges a received Bluetooth signal and displays a result:

(15) TABLE-US-00001 If s.sub.g=1, then Text1= normal power supply Else Text1= normal power supply End

(16) As shown in FIG. 3, FIG. 8 and FIG. 11, the weld scanner scans along a weld direction, i.e., a direction of a vector i, collects signals of all members on the circuit board 23, and sends the signals to the client through the Bluetooth signal transceiver 24. The signals collected by the circuit board comprise: a power supply signal s.sub.g, a magnetic resistance sensor signal s.sub.c, a rotation speed s.sub.x1 of a scanner drive motor, a rotation speed s.sub.x2 of the probe motor, and a photographic picture signal s.sub.t of a camera, wherein the power supply signal s.sub.g, the magnetic resistance sensor signal s.sub.c, the rotation speed s.sub.x1 of the scanner drive motor and the rotation speed s.sub.x2 of the probe motor constitute a signal matrix A={s.sub.g,s.sub.C,s.sub.x1,s.sub.x2}, and the client multiplies A with a unit matrix

(17) $B=\left[\begin{array}{c}1,0,0,0\\ 0,1,0,0\\ 0,0,1,0\\ 0,0,0,1\end{array}\right],$
i.e., A.Math.B, to obtain a received signal digital matrix C={a, b, c, d}, so that the client may process information in the C matrix. For example:

(18) (1) Obtaining a Coordinate of a Suspected Defect Position F

(19) The client program processes the received magnetic resistance sensor signal s.sub.c, if the signal s.sub.c is changed, b=1, and a running distance of the scanner may be calculated from the formula x=d.sub.1+c.Math.t.Math. to obtain a coordinate (d.sub.1+c.Math.t.Math.,0) of the defect position, wherein c is the rotation speed of the scanner drive motor, which may be controlled by a frequency converter on the circuit board 23; t is advancing time of the weld scanner; and is a conversion coefficient, and represents an advancing distance of the scanner when the transmission gear of the scanner drive motor rotates by one circle, which depends on specific parameters of the transmission gear of the scanner drive motor.

(20) (2) Obtaining a Macroscopic Photo of the Suspected Defect Position

(21) The client program processes the received signal, if the magnetic resistance sensor detects a magnetic field change at the moment, the client program sends an instruction, the circuit board in the scanner chassis recognizes the instruction at the moment and executes the instruction, and the camera conducts a photographing operation after executing the instruction, and sends obtained picture signal s.sub.t to the client. The client program processes the received signal s.sub.t to obtain a macroscopic image of a suspected defect area.

(22) As shown in FIG. 4, FIG. 8 and FIG. 9, when the weld scanner reaches an end of the weld, since the scanner chassis itself has a certain size, a scanning probe may complete the scanning to the remaining weld through moving left and right at the moment. The client program may automatically determine whether the scanner reaches the end of the weld:

(23) TABLE-US-00002 If d.sub.1 + c .Math. t .Math. = L D, then s.sub.stop = 1 s.sub.x2 = 1 Else s.sub.stop = 0 End
where L is a length of the chamber of the steel box girder (i.e., a full length of the weld); and D is a length of the weld scanner. The client sends a judgment result to the scanner chassis, the scanner chassis controls a movement state of the weld scanner according to the received signal s.sub.stop, wherein s.sub.stop=1 indicates stop, and s.sub.stop=0 indicates advancing. s.sub.x2=1 indicates that the probe motor starts to work at the moment and feeds back rotation speed information to the client program. A length of the rack 8 is set as l.sub.c, and the client program may automatically control a distance that the probe slider 2 moves left and right, i.e.:

(24) TABLE-US-00003 If d .Math. t.sub.1 .Math. = l.sub.c, then s.sub.stop = 0 s.sub.x2 = 0 Else s.sub.stop = 0 s.sub.x2 = 1 End
where d is a value in the signal matrix C={a, b, c, d}; t.sub.1 is time for the probe motor 2 to rotate; is a conversion coefficient, and indicates a movement distance of the probe slider when the probe motor 2 rotates by one circle; is a ratio between the length of the remaining weld and the length of the rack, and the value may be obtained as follows: n is a length of the laser range finder, and m is a distance from a center of the magnetic resistance sensor to the origin of coordinates:

(25) $=\frac{l_c+n-2m}{l_c}$

(26) After scanning, the power supply of the weld scanner is turned off, the fixing bolt 14 is pulled out, the scanning probe portion is removed, the USB data line and power line are put away, and the weld scanner is stored; and the weld scanner may also be put into the start of the next scanning to continue the scanning work. At the moment, the client program may be used to store the data during the scanning process, so as to facilitate subsequent comparative analysis.