Patent Description:
Conventionally, in order to ensure the quality of metal plates, such as steel plates, as an inspection target, the steel plates or the like are inspected for surface defects or internal defects by ultrasonic flaw detection or the like. In the ultrasonic flaw detection, a plurality of ultrasonic flaw detection heads as inspection sensors arranged in parallel is brought into contact with a metal plate, such as a steel plate, conveyed on a feed roller of a production line via a water film, and then the metal plate is automatically inspected in on-line, for example. In off-line, the ultrasonic flaw detection heads are moved by a hand carriage or the like to be brought into contact with a stopped metal plate, such as a steel plate, via a water film, and then the metal plate is manually inspected.

In general, the ultrasonic flaw detection heads are connected to an ultrasonic flaw detector body with a flaw detection cable, outputs (results) obtained by the flaw detection by the ultrasonic flaw detection heads are input into the ultrasonic flaw detector body, and the outputs (result) are input into a data processing device to be processed, so that the metal plate is inspected for the presence or absence of internal defects. In the case of the ultrasonic flaw detection, water as a medium for passing ultrasonic waves is sprayed to an inspection surface (surface) of the metal plate, such as the steel plate, so that a water film is formed on the inspection surface (surface) of the metal plate. Therefore, when performing the ultrasonic flaw detection of the metal plate as the inspection target in off-line, the surface of the metal plate is wet with water to be slippery. The metal plate is placed on a skid or the like installed on the floor surface in many cases, and therefore an inspector moves on the wet metal plate with a level difference, which causes a risk that the inspector falls.

In order to perform highly accurate ultrasonic flaw detection, the ultrasonic flaw detection heads as the inspection sensors need to be accurately moved along a predetermined scanning line. However, a preparation to draw the scanning line on the metal plate requires time and labor and, at the same time, there is a limit to the accuracy of the manual movement of the ultrasonic flaw detection heads.

In order to eliminate such inconvenience caused by the manual operations, moving inspection devices for metal plate have been proposed in the past, and, for example, those illustrated in PTLS <NUM> and <NUM> have been proposed.

A moving inspection device for metal plate illustrated in PTL <NUM> is a moving inspection device for metal plate inspecting a metal plate using an indoor position measuring system performing self-position measurement in an indoor space based on the principle of triangulation. The moving inspection device for metal plate includes a carriage having: four wheels capable of rotating forward and backward; and a drive unit rotating and driving the wheels and individually and independently turning and driving the wheels, and traveling over the metal plate surface. The carriage is further mounted with a navigation signal transmitter or a navigation signal receiver constituting the indoor position measuring system and transmitting or receiving an indoor position measuring system signal and is provided with inspection sensors inspecting a metal plate for defects. A metal plate moving inspection device includes a control means of calculating a deviation from a self-position recognized using the indoor position measuring system signal and a target position, instructing the drive unit to rotate the wheels forward, rotate the wheels backward, stop the wheels, and turn each wheel according to the deviation, and causing the carriage to move laterally, obliquely, forward and backward, or turn on the spot to cause the carriage to autonomously travel to a predetermined target position.

A moving inspection device for metal plate illustrated in PTL <NUM> is a moving inspection device for metal plate moving over a metal plate based on information from a position measuring means and inspecting the metal plate for the presence or absence of defects present on the surface of the metal plate or inside the metal plate and including a carriage having at least two wheels capable of rotating forward and backward and a drive unit driving the wheels. The carriage is mounted with flaw detection heads each provided with an ultrasonic flaw detection probe inspecting the metal plate. The moving inspection device for metal plate includes a control unit calculating a deviation between the position of the inspection device recognized by the position measuring means and a target position, instructing the drive unit to rotate the wheels forward, rotate the wheels backward, and stop the wheels such that the deviation is minimized, and controlling the inspection device to autonomously travel to a predetermined target position. The control means has a function of detecting either or both of a weight change of the inspection device and sliding resistance between the metal plate and the flaw detection heads and feedbacking a correction value obtained from the detected values to the instruction.

<CIT>
discloses an inspection device falling under the preamble of claim <NUM>.

However, the conventional moving inspection devices for metal plate illustrated in PTLS <NUM> and <NUM> have had the following problems.

More specifically, in both the moving inspection devices for metal plate illustrated in PTLS <NUM> and <NUM>, a water tank for constantly supplying water between the inspection sensors (flaw detection heads) and the metal plate is mounted on the carriage and water is supplied between the inspection sensors (flaw detection heads) and the metal plate from the water tank through a water supply hose. Therefore, the weight of the carriage mounted with the inspection sensors (flaw detection heads) significantly increases, and thus a point to be improved has been found in the manual operability of the inspection device (carriage).

In contrast thereto, a case where the carriage itself is not mounted with a water tank and water is constantly supplied between the inspection sensors (flaw detection heads) and the metal plate from another place has posed a problem that water cannot be uniformly sprayed onto the surface of the metal plate depending on the surface state of the metal plate, which hinders the inspection of the metal plate for defects.

Therefore, the present invention has been made to solve the conventional problems. It is an object of the present invention to provide a moving inspection device capable of realizing significant size reduction/weight reduction without affecting the inspection performance for an inspection target, a moving inspection method, and a method for manufacturing a steel material.

In order to achieve the above-described object, a moving inspection device according to the present invention has the features of claim <NUM>.

A moving inspection method according to another aspect of the present invention has the features of claim <NUM>.

A method for manufacturing a steel material according to another aspect of the present invention has the features of claim <NUM>.

The present invention provides a moving inspection device capable of realizing significant size reduction/weight reduction without affecting the inspection performance for an inspection target, a moving inspection method, and a method for manufacturing a steel material.

Hereinafter, embodiments of the present invention will now be described with reference to the drawings. The following embodiments illustrate devices and methods for embodying the technical idea of the present invention. The technical idea of the present invention does not specify materials, shapes, structures, arrangement, and the like of constituent parts to the following embodiments. The drawings are schematic. Therefore, it should be noted that the relationship, ratio, and the like between the thickness and the planar dimension are different from the actual relationship, ratio, and the like. The drawings include portions different in mutual dimensional relationships and ratios.

First, the entire inspection system including a moving inspection device according to one embodiment of the present invention is described with reference to <FIG>.

<FIG> illustrates the schematic configuration of the entire inspection system including the moving inspection device according to one embodiment of the present invention. An inspection system <NUM> includes an indoor position measuring system <NUM> and a moving inspection device <NUM>.

The indoor position measuring system <NUM> measures the self-position indoors based on the principle of triangulation and uses an indoor global positioning system (IGPS) in this embodiment. Specifically, the indoor position measuring system <NUM> includes a plurality of navigation transmitters <NUM> arranged indoors, navigation receivers <NUM>, and a current position calculation unit <NUM> (see <FIG>) calculating the position of a moving inspection device body <NUM> by position calculation software.

The moving inspection device <NUM> includes the moving inspection device body <NUM> inspecting a steel plate S as an inspection target for internal defects of the steel plate S and surface defects of the rear surface side of the steel plate S while moving over the surface Sa of the steel plate S and water supply devices <NUM> suppling water W required for the inspection onto the surface Sa of the steel plate S. As the steel plate S as the inspection target, a thick steel plate (plate thickness of <NUM> or more) is targeted herein.

The moving inspection device body (hereinafter referred to as "inspection device body") <NUM> includes a carriage <NUM> having a predetermined plate thickness and extending in the right and left direction (right and left direction in <FIG>) and in the forward and backward direction (up and down direction in <FIG>) as illustrated in <FIG>. The carriage <NUM> is provided with a pair of right and left wheels <NUM> at both ends in the right and left direction on the front (upper side in <FIG>) side. The pair of right and left wheels <NUM> is individually and independently driven. Each wheel <NUM> has a rotation shaft 32a having first intersecting axis gears 32b at the tip as illustrated in <FIG>. The first intersecting axis gears 32b are meshed with second intersecting axis gears 33b provided at the tip of an output rotation shaft 33a of a speed reduction gear of a wheel driving motor <NUM>. Each wheel <NUM> can be rotated forward and backward by the wheel driving motor <NUM>. The carriage <NUM> is further installed with a driven wheel <NUM> capable of moving in all directions in a substantially center part in the right and left direction on the rear side of the undersurface side.

The carriage <NUM> is further provided with flaw detection heads <NUM> each including with an ultrasonic probe as inspection sensors detecting internal defects of the steel plate S and surface defects of the rear surface side of the steel plate S and an ultrasonic flaw detector body <NUM> into which outputs (results) from the flaw detection heads <NUM> are input and which data (calculation)-processes the outputs (results) and outputs the data processing results to an IO board <NUM> described below.

As illustrated in <FIG>, a first raised part <NUM> extending in the right and left direction is erected near the rear end of the upper surface of the carriage <NUM> and a second raised part <NUM> extending in the right and left direction is erected near the front end of the upper surface of the carriage <NUM>. As illustrated in <FIG>, a plurality of first plate members <NUM> extending in the right and left direction to project from the ends in the right and left direction of the carriage <NUM> is installed on the upper surface of the first raised part <NUM> and a plurality of second plate members <NUM> extending in the right and left direction is installed on the upper surface of the second raised part <NUM>. Further, a plurality of third plate members <NUM> extending in the forward and backward direction to bridge the first plate members <NUM> and the second plate members <NUM> are installed on the upper surfaces the first plate members <NUM> and the upper surfaces of the second plate members <NUM>. On the upper surfaces of the third plate members <NUM>, the above-described ultrasonic flaw detector body <NUM> is installed.

A pair of flaw detection heads <NUM> is installed on the rear end sides of the carriage <NUM> below the first plate members <NUM> projecting from the ends in the right and left direction end of the carriage <NUM> as illustrated in <FIG>. Each flaw detection head <NUM> is supported to the first plate members <NUM> by a follow-up mechanism <NUM> causing the flaw detection head <NUM> to follow the unevenness state of the surface Sa of the steel plate S as the inspection target. The follow-up mechanism <NUM> is described in detail later.

Further, a pair of navigation receivers <NUM> is erected near both the right and left ends on the second plate member <NUM> and an on-board computer <NUM> and an IO board <NUM> are provided in a control box <NUM> on the upper surface of the carriage <NUM>.

Each navigation transmitter <NUM> of the indoor position measuring system <NUM> emits rotating fan beams. Each navigation receiver <NUM> receives the rotating fan beams emitted from each navigation transmitter <NUM>. At this time, the rotating fan beams are deviated at a predetermined angle, and the three-dimensional coordinate values, i.e., the position or the height, of the navigation receivers <NUM> receiving the rotating fan beams can be measured. Reception information received by the navigation receivers <NUM> is transmitted to the on-board computer <NUM>, and the positions of the navigation receivers <NUM> are calculated by the on-board computer <NUM> according to the principle of triangulation. By the use of signals received from the plurality of navigation transmitters <NUM> and by repeating the calculation, position information of the traveling inspection device body <NUM> mounted with the navigation receivers <NUM> can be acquired in real time.

The On-board computer <NUM> is a computer system constituted to include a ROM, a RAM, a CPU, and the like and realizing each function described later on software by executing various dedicated programs stored in advance in the ROM and the like.

As illustrated in <FIG>, the on-board computer <NUM> includes the current position calculation unit <NUM> calculating the current position of each navigation receiver <NUM> based on the reception information received by each navigation receiver <NUM>. The on-board computer <NUM> further includes a setting/evaluation unit <NUM> setting a target inspection position and route information and evaluating inspection data and inspection position information from the IO board <NUM>. The on-board computer <NUM> further includes a position deviation calculation unit <NUM> calculating a deviation of the current position with respect to the target inspection position based on the current position of each navigation receiver <NUM> calculated by the current position calculation unit <NUM> and the target inspection position from the setting/evaluation unit <NUM>. The on-board computer <NUM> further includes a drive control unit <NUM> outputting a control signal, such as a speed command, to the wheel driving motor <NUM> such that the deviation calculated by the position deviation calculation unit <NUM> is <NUM> and performing feedback control of the speed (including the rotation direction) of the wheels <NUM>. The drive control unit <NUM> outputs a control signal, such as a speed command, to the wheel driving motor <NUM> such that the deviation is <NUM> and performs the feedback control of the speed (including the rotation direction) of the wheels <NUM>, so that the inspection device body <NUM> autonomously travels along the target travel route.

Although not illustrated, the carriage <NUM> is mounted with a battery as a power source.

Next, the follow-up mechanism <NUM> causing each flaw detection head <NUM> to follow the uneven state of the surface Sa of the steel plate S is described with reference to <FIG>.

Herein, the uneven state of the surface Sa of the steel plate S means not only a case where the surface Sa of the steel plate S has unevenness but all cases where the surface Sa of the steel plate S is uneven, also including a case where the surface Sa of the steel plate S has waviness.

The follow-up mechanism <NUM> includes a sensor holding mechanism <NUM> holding the flaw detection head <NUM> as the inspection sensor and a load adjustment mechanism <NUM> adjusting a load applied to the surface Sa of the steel plate S by the flaw detection head <NUM> held by the sensor holding mechanism <NUM>.

The sensor holding mechanism <NUM> includes a flat plate-like holder 53a holding the flaw detection head <NUM> to surround the periphery of the flaw detection head <NUM> as illustrated in <FIG>. As illustrated in <FIG>, the flaw detection head <NUM> is inserted into a through hole 53f formed in the center of the holder 53a, and the flaw detection head <NUM> is pressed from the outer periphery by a screw member 53e to be held by the holder 53a. The sensor holding mechanism <NUM> further includes a sensor holding frame member 53b fixing the holder 53a holding the flaw detection head <NUM> and surrounding the flaw detection head <NUM> from the periphery. The holder 53a is fixed to the sensor holding frame member 53b by a bolt 53c and a wing bolt 53d.

As illustrated in <FIG> and <FIG>, a first support member <NUM> is fixed to the upper surface of the sensor holding frame member 53b and the first support member <NUM> is rotatably supported around a first hinge <NUM> with respect to a second support member <NUM>. The first hinge <NUM> extends in the X-axis direction as illustrated in <FIG> and <FIG>. More specifically, the sensor holding frame member 53b holding the flaw detection head <NUM> is configured to rotate around the X-axis. The X-axis extends in parallel to and in the forward and backward (width) direction with respect to the surface Sa of the steel plate S.

As illustrated in <FIG>, the second support member <NUM> is rotatably supported around a second hinge <NUM> with respect to a third support member <NUM>. The second hinge <NUM> extends in the Y-axis direction as illustrated in <FIG> and <FIG>. More specifically, the sensor holding frame member 53b holding the flaw detection head <NUM> is configured to rotate around the Y-axis. The Y-axis extends in the right and left (longitudinal) direction parallel to the surface Sa of the steel plate S and orthogonal to the X-axis.

Each of the rotation around the X-axis and the rotation around the Y-axis of the sensor holding frame member 53b is regulated in some cases. Considering the cases, <FIG> illustrate members regulating each of the rotation around the X-axis and the rotation around the Y-axis of the sensor holding frame member 53b.

As illustrated in <FIG>, the third support member <NUM> is attached to the undersurface of a lower flat plate <NUM> having a predetermined plate thickness and extending in the right and left direction and in the forward and backward direction. An end part in the right and left direction of the lower flat plate <NUM> is attached with an attachment plate <NUM> and a rail member <NUM> extending in the Z-axis direction. Above the lower flat plates <NUM>, upper flat plates <NUM> having a predetermined plate thickness and extending in the right and left direction and in the forward and backward direction are provided. As illustrated in <FIG>, the upper flat plates <NUM> are attached to the undersurfaces of the first plate members <NUM> projecting from the ends in the right and left direction of the carriage <NUM>. To the undersurfaces of the upper flat plates <NUM>, attachment plate parts <NUM> each attached with a slider <NUM> at the tip are fixed. The slider <NUM> is configured to move along the rail member <NUM> attached to the lower flat plate <NUM>. More specifically, the slider <NUM> is fixed to the upper flat plate <NUM> fixed to the first plate member <NUM> fixed to the carriage <NUM>, and therefore the lower flat plate <NUM> moves up and down along a direction in which the rail member <NUM> extends. Therefore, the sensor holding frame member 53b holding the flaw detection head <NUM> is configured to move up and down along the Z-axis extending perpendicularly (up and down) to the surface Sa of the steel plate S.

Next, the load adjustment mechanism <NUM> adjusts a load applied to the surface Sa of the steel plate S by the flaw detection head <NUM> held by the sensor holding mechanism <NUM>. As described above, the sensor holding frame member 53b holding the flaw detection head <NUM> moves up and down along the Z-axis extending perpendicularly (up and down) to the surface Sa of the steel plate S. Therefore, when no load acts on the sensor holding frame member 53b, the self-weight of the entire configuration up to the lower flat plate <NUM> including the flaw detection head <NUM> and the sensor holding frame member 53b acts on the surface Sa of the steel plate S. When the self-weight of the entire configuration up to the lower flat plate <NUM> including the flaw detection head <NUM> and the sensor holding frame member 53b acts on the surface Sa of the steel plate S, the load is excessively large in the flaw detection by the flaw detection head <NUM>, which hinders the flaw detection. Therefore, in this embodiment, the load adjustment mechanism <NUM> adjusts the load applied to the surface Sa of the steel plate S by the flaw detection head <NUM>.

In the load adjustment mechanism <NUM>, bushes <NUM> each including a flange 62a at one end of a hollow pipe part are press-fitted and fixed to the vicinity of both ends in the forward and backward direction of the lower flat plate <NUM> such that the flange 62a is in contact with the upper surface of the lower flat plate <NUM> and the hollow pipe part is inserted through the lower flat plate <NUM> and projects downward from the lower flat plate <NUM> as illustrated in <FIG>. A shaft <NUM> inserted through each bush <NUM> is fixed to the upper flat plate <NUM>. Near the lower end of each shaft <NUM>, a male screw part is formed and a plurality of nuts <NUM> for load adjustment is screwed into the male screw part. A metal washer <NUM> is arranged above each nut <NUM>, a metal washer <NUM> is arranged below each bush <NUM>, and a compression coil spring <NUM> is arranged to surround each shaft <NUM> between both the metal washers <NUM>, <NUM>. The compression coil spring <NUM> acts to push the lower flat plate <NUM>, i. , the entire configuration up to the lower flat plate <NUM> including the flaw detection head <NUM> and the sensor holding frame member 53b, upward via the bush <NUM>. On the other hand, a metal washer <NUM> is arranged above the flange 62a of the bush <NUM> and a compression coil spring <NUM> is arranged to surround the shaft <NUM> between the metal washer <NUM> and the undersurface of upper flat plate <NUM>. The compression coil spring <NUM> acts to push the lower flat plate <NUM>, i.e., the entire configuration up to the lower flat plate <NUM> including the flaw detection head <NUM> and the sensor holding frame member 53b, downward via the bush <NUM>. By adjusting the push-up force by the compression coil spring <NUM> and the push-down force by the compression coil spring <NUM>, the load applied to the surface Sa of the steel plate S by the entire configuration up to the lower flat plate <NUM> including the flaw detection head <NUM> and the sensor holding frame member 53b is adjusted.

In usual, the load is adjusted such that a value obtained by subtracting the push-down force by the compression coil spring <NUM> from the push-up force by the compression coil spring <NUM> is positive. Thus, the entire configuration up to the lower flat plate <NUM> including the flaw detection head <NUM> and the sensor holding frame member 53b is pushed upward, so that the self-weight of the entire configuration up to the lower flat plate <NUM> including the flaw detection head <NUM> and the sensor holding frame member 53b acting on the surface Sa of the steel plate S is subtracted.

Thus, the load applied to the surface Sa of the steel plate S by the flaw detection head <NUM> is adjusted.

As described above, the follow-up mechanism <NUM> includes the sensor holding mechanism <NUM> holding the flaw detection head <NUM> as the inspection sensor and the load adjustment mechanism <NUM> adjusting the load applied to the surface Sa of the steel plate S by the flaw detection head <NUM> held by the sensor holding mechanism <NUM>. The sensor holding mechanism <NUM> rotates around the X-axis extending in parallel to the surface Sa of the steel plate S and the Y-axis extending in a direction parallel to the surface Sa of the steel plate S and orthogonal to the X-axis, and moves up and down along the Z-axis extending perpendicularly to the surface Sa of the steel plate S.

Thus, as illustrated in <FIG>, when the flaw detection head <NUM> scans (moves over) the surface Sa of the steel plate S, the flaw detection head <NUM> held by the sensor holding mechanism <NUM> rotates around the X-axis and the Y-axis in a state where a predetermined load is applied to the surface Sa of the steel plate S according to the uneven state of the surface Sa of the steel plate S. Further, the flaw detection head <NUM> can move up and down along the Z-axis, and thus the flaw detection head <NUM> can follow the uneven state of the surface Sa of the steel plate S with an appropriate pressing force.

Next, the water supply devices <NUM> are described. The inspection device body <NUM> inspects the steel plate S for internal defects of the steel plate S and surface defects of the rear surface side of the steel plate S by ultrasonic the flaw detection, and therefore the surface (inspection surface) Sa of the steel plate S requires water as a medium for passing ultrasonic waves. To spray this water onto the surface Sa of the steel plate S, the moving inspection device <NUM> includes the water supply devices <NUM> supplying the water W required for the inspection onto the surface Sa of the steel plate S as illustrated in <FIG> and <FIG>.

The water supply devices <NUM> are provided separately from the inspection device body <NUM>. In this embodiment, as illustrated in <FIG>, a pair of water supply devices <NUM> is installed on the end surfaces on the long-side sides facing each other of the steel plate S formed in a rectangular shape.

Each water supply device <NUM> includes a nozzle <NUM> supplying the water W onto the surface Sa of the steel plate S as illustrated in <FIG> and <FIG>. The nozzle <NUM> includes a flat spray nozzle, and the water W is jetted from the nozzle <NUM> to spread in a fan shape.

Herein, the nozzle <NUM> is attached by a fixing member 82a onto an attachment plate <NUM> of a rectangular flat plate shape fixed to a magnet-type attachment base <NUM> such that the upper surface is flush with the attachment base <NUM>, the attachment base <NUM> being detachably attached to the end surface of the steel plate S such that the upper surface is flush with the surface Sa of the steel plate S. The nozzle <NUM> is installed at a position separated from the end surface of the steel plate S by a predetermined distance such that the tip of the nozzle <NUM> does not abut on the flaw detection head <NUM> which has moved to the end surface side of the steel plate S as illustrated in <FIG> and <FIG>.

A water supply hose <NUM> is connected to each nozzle <NUM>, and the two water supply hoses <NUM> are connected to a hose <NUM> connected to a water supply source (not illustrated) by a joint <NUM>.

When the water W is supplied from the water supply source to the nozzles <NUM> via the hose <NUM> and the water supply hoses <NUM>, the water W is jetted from the nozzles <NUM> in a fan shape and supplied onto the surface Sa of the steel plate S through the upper surface of the attachment plate <NUM> and the upper surface of the attachment base <NUM>. Thus, the water W is sprayed onto the surface Sa of the steel plate S.

As described above, in the moving inspection device <NUM> according to this embodiment, the water supply devices <NUM> supplying the water W required for the inspection onto the surface Sa of the steel plate S as the inspection target are installed separately from the inspection device body <NUM>, and therefore the inspection device body <NUM> itself is reduced in size and weight, so that the moving inspection device <NUM> capable of realizing significant size reduction/weight reduction can be achieved. One in which a water tank is installed in the inspection device body <NUM> itself requires, when the water W is used up, labor of supplying the water W to the water tank again. However, the moving inspection device <NUM> according to this embodiment has eliminated a fear of using up water.

On the other hand, when the water W is supplied onto the surface Sa of the steel plate S from the water supply devices <NUM> provided separately from the inspection device body <NUM>, the water cannot be uniformly sprayed onto the surface Sa of the steel plate S depending on the state of the surface Sa of the steel plate S, which hinders the inspection of the steel plate S for defects by the ultrasonic flaw detection in some cases. For example, when the surface Sa (inspection surface) of the steel plate S is slightly tilted or when the surface Sa has small waviness, unevenness, or the like, unevenness arises in water film formation on the surface Sa, so that a water film is insufficient in the flaw detection heads <NUM> in some cases. In that case, measurement is performed such that a defect is present even though no defects are present inside the steel plate S (pseudo-detection) in some cases, and therefore water needs to be surely supplied to parts of the flaw detection heads <NUM>.

In order to solve this problem, the inspection device body <NUM> is installed with a flow adjustment plate <NUM> as illustrated in <FIG> and <FIG> to <FIG> in this embodiment.

The flow adjustment plate <NUM> is installed with a flow adjustment plate attachment member <NUM> on the undersurface of the carriage <NUM> to project from the carriage <NUM> in the advancing direction (backward direction, downward direction in <FIG>) in an inspection path of the inspection device body <NUM> as illustrated in <FIG>.

The inspection device body <NUM> advances toward the backward side of the carriage <NUM> in the inspection path and advances to the front side of the carriage <NUM> in a movement path, which is described later.

The flow adjustment plate attachment member <NUM> includes a pair of right and left support leg parts 74a extending downward from the undersurface of the carriage <NUM> and an arc-shaped attachment plate part 74b attached to the rear ends of both the support leg parts 74a to be bridged therebetween and having a projecting and arc-shaped rear side.

As illustrated in <FIG>, the flow adjustment plate <NUM> has a first arc surface 73a and a second arc surface 73b having a slightly smaller diameter than the diameter of the first arc surface 73a, has an arc shape formed into a predetermined plate thickness, and is attached to the rear surface of the arc-shaped attachment plate part 74b such that the first arc surface 73a projects toward the advancing direction (lower side and rear side in <FIG>) in the inspection path of the inspection device body <NUM>. The flow adjustment plate <NUM> is attached to the arc-shaped attachment plate part 74b to form a gap such that a water film is formed between the flow adjustment plate <NUM> and the surface Sa of the steel plate S.

As illustrated in <FIG>, the flow adjustment plate <NUM> pushes out the water W supplied onto the surface Sa of the steel plate S from the water supply devices <NUM> in the advancing direction and forms streamlines for supplying the water between the flaw detection heads <NUM> and the surface Sa of the steel plate S simultaneously with the movement of the inspection device body <NUM> (in <FIG>, the inspection device body <NUM> moves upward (backward) in the inspection path described later as illustrated by a thick arrow).

The flow adjustment plate <NUM> pushes out the water W supplied onto the surface Sa of the steel plate S from the water supply devices <NUM> in the advancing direction simultaneously with the movement of the inspection device body <NUM> (movement in the inspection path). Thus, in the ultrasonic flaw detection by the inspection device body <NUM>, the water W can be uniformly supplied even to places where the surface Sa (inspection surface) of the steel plate S is slightly tilted or the surface Sa has small waviness, unevenness, or the like, so that the water can be uniformly sprayed onto the surface Sa of the steel plate S.

The flow adjustment plate <NUM> forms the streamlines for supplying the water between the flaw detection heads <NUM> and the surface Sa of the steel plate S simultaneously with the movement of the inspection device body <NUM>. Therefore, in the ultrasonic flaw detection by the inspection device body <NUM>, the water W required for the inspection can be efficiently supplied between the flaw detection heads <NUM> and the surface Sa of the steel plate S.

Thus, in the moving inspection device <NUM> according to this embodiment, the measurement such that a defect is present even though no defects are present inside the steel plate S (pseudo-detection) can be avoided and the inspection device body <NUM> itself can be reduced in size and weight, so that significant size reduction/weight reduction can be realized without affecting the inspection performance for the steel plate S.

As illustrated in <FIG>, the flow adjustment plate <NUM> may be formed in a triangular shape and the flow adjustment plate may be arranged such that the apex projects toward the advancing (inspection) direction (upper side in <FIG>) of the inspection device body.

However, in this case, the streamlines for supplying the water between the flaw detection heads <NUM> and the surface Sa of the steel plate S are formed simultaneously with the movement of the inspection device body <NUM>, but a function of pushing out the water W supplied onto the surface Sa of the steel plate S from the water supply devices <NUM> in the advancing direction is slightly poor. Therefore, in the ultrasonic flaw detection by the inspection device body <NUM>, the water W cannot be uniformly supplied in some cases to places where the surface Sa (inspection surface) of the steel plate S is slightly tilted or the surface Sa has small waviness, unevenness, or the like.

Therefore, as illustrated in <FIG>, it is preferable that the flow adjustment plate <NUM> is formed in an arc shape and is arranged such that the first arc surface (arc surface) 73a projects toward the advancing direction of the inspection device body <NUM>.

Next, a moving inspection method using the moving inspection device <NUM> illustrated in <FIG> is described with reference to <FIG> is a view for explaining a movement pattern of a moving inspection device body when detecting flaws inside a steel plate. <FIG> is a view illustrating an example of an inspection pattern according to JIS G0801: Ultrasonic testing of steel plates for pressure vessels, in which the moving inspection device body moves in the movement pattern illustrated in <FIG> to detect flaws inside the steel plate.

First, in the moving inspection of the steel plate S using the moving inspection device <NUM>, the water W is supplied onto the surface Sa of the steel plate S as the inspection target from the water supply devices <NUM>, so that the water W is uniformly sprayed onto the surface Sa of the steel plate S. The supply of the water W by the water supply devices <NUM> is constantly performed during the inspection of the steel plate S.

Subsequently, the inspection device body <NUM> of the moving inspection device <NUM> is moved over the surface Sa of the steel plate S in the movement pattern illustrated in <FIG> to detect flaws inside the steel plate S.

Herein, the current position calculation unit <NUM> of the on-board computer <NUM> mounted in the inspection device body <NUM> calculates the current positions of the navigation receivers <NUM> based on the reception information received by the navigation receivers <NUM>. The position deviation calculation unit <NUM> calculates a deviation of the current position with respect to the target inspection position based on the current positions of the navigation receivers <NUM> calculated by the current position calculation unit <NUM> and the target inspection position from the setting/evaluation unit <NUM>. The drive control unit <NUM> outputs a control signal, such as a speed command, to the wheel driving motor <NUM> such that the deviation calculated by the position deviation calculation unit <NUM> is <NUM> and performs feedback control of the speed (including the rotation direction) of the wheels <NUM>, so that the inspection device body <NUM> autonomously travels along the target travel route.

Herein, the target travel route of the inspection device body <NUM>, i.e., the movement pattern of the inspection device body, is as illustrated in <FIG>. First, the surface Sa (inspection surface) of the steel plate S as the inspection target is virtually divided into a front half and a rear half with a center line CL in the width direction of the steel plate S as the center.

Then, in the front half, the inspection device body <NUM> repeats the inspection path and the movement path described later from one end side in the longitudinal direction of the steel plate S (left end side of the steel plate S in <FIG>) to the other end side in the longitudinal direction of the steel plate S (right end side of the steel plate S in <FIG>), thereby detecting flaws inside the steel plate S.

Herein, in the front half, the inspection device body <NUM> starts the movement from a position where the center as viewed from the plane is located at a point P1 where the flaw detection heads <NUM> are located on the center line CL with the backward of the carriage <NUM> as the advancing direction and, simultaneously therewith, the flaw detection heads <NUM> move in the width direction of the steel plate S while detecting flaws. Then, the inspection device body <NUM> reaches a position where the center as viewed from the plane is located at a point P2 where the flaw detection heads <NUM> are located on the side edge of the steel plate S, and then stops. In this embodiment, the movement of the inspection device body <NUM> from the point P1 to the point P2 is referred to as the inspection path. The movement of the inspection device body <NUM> in the inspection path is a straight-ahead movement in which the same rotation speed is applied to the right and left wheels <NUM>.

Thereafter, the inspection device body <NUM> rotates each wheel <NUM> backward while applying different rotation speeds to the right and left wheels <NUM>, so that the inspection device body <NUM> moves from the position where the center as viewed from the plane is located at the point P2 where the flaw detection heads <NUM> are located on the side edge of the steel plate S with the front of the carriage <NUM> as the advancing direction, reaches a position where the center as viewed from the plane is located at a point P3 where the flaw detection heads <NUM> are located on the center line CL in the width direction of the steel plate S, and then stops. The point P1 and the point P3 are separated by one pitch D along the longitudinal direction of the steel plate S. In the present embodiment, the movement of the inspection device body <NUM> from the point P2 to the point P3 is referred to as the movement path. In this movement path, the flaw detection is simultaneously performed by the flaw detection heads <NUM> but the inspection data is erased in the setting/evaluation unit <NUM> described later. The movement of the inspection device body <NUM> in the movement path is a curvilinear movement in which different rotation speeds are applied to the right and left wheels <NUM>.

Thereafter, in the front half, the inspection device body <NUM> repeats the inspection path and the movement path to the other end side in the longitudinal direction of the steel plate S, thereby completing the inspection in the front half.

Then, when the inspection in the front half is completed, the inspection device body <NUM> rotates the right and left wheels <NUM> forward and backward to perform pivotal turn to turn <NUM>°. Thus, the flaw detection heads <NUM> are directed in the opposite direction in the width direction of the steel plate S.

Then, in the rear half, the inspection device body <NUM> repeats an inspection path and a movement path similar to those in the front half of the inspection from the other end side in the longitudinal direction of the steel plate S (right end side of the steel plate S in <FIG>) to the one end side in the longitudinal direction of the steel plate S (left end side of the steel plate S in <FIG>), thereby detecting flaws inside the steel plate S.

Thus, as in the example of the inspection pattern according to JIS G0801: Ultrasonic testing of steel plates for pressure vessels illustrated in <FIG>, the flaw detection inside the steel plate S is carried out at the pitch D along the longitudinal direction of the steel plate S.

As illustrated in <FIG>, the inspection data obtained by the flaw detection heads <NUM> is transmitted to the setting/evaluation unit <NUM> of the on-board computer <NUM> via the ultrasonic flaw detector body <NUM> and the IO board <NUM> for evaluation.

As described above, the moving inspection device <NUM> according to the present embodiment includes the inspection device body <NUM> inspecting the steel plate S for defects while moving over the surface Sa of the steel plate S as the inspection target and the water supply devices <NUM> provided separately from the inspection device body <NUM> and supplying the water W required for the inspection onto the surface Sa of the steel plate S.

Thus, the inspection device body <NUM> itself is reduced in size and weight, and thus the moving inspection device <NUM> capable of realizing significant size reduction/weight reduction can be achieved. One in which a water tank is installed in the inspection device body <NUM> itself requires, when the water W is used up, labor of supplying the water W to the water tank again. However, the moving inspection device <NUM> according to this embodiment has eliminated a fear of using up water.

The inspection device body <NUM> is further installed with the flow adjustment plate <NUM> pushing out the water W supplied onto the surface Sa of the steel plate S from the water supply devices <NUM> in the advancing direction and forming the streamlines for supplying the water W between the flaw detection heads <NUM> as the inspection sensors inspecting the steel plate S for defects and the surface Sa of the steel plate S simultaneously with the movement of the inspection device body <NUM> (movement in the inspection path).

Thus, in the ultrasonic flaw detection by the inspection device body <NUM>, the water W can be uniformly supplied even to places where the surface Sa (inspection surface) of the steel plate S is slightly tilted or the surface Sa has small waviness, unevenness, or the like, so that the water can be uniformly sprayed onto the surface Sa of the steel plate S. The flow adjustment plate <NUM> forms the streamlines for supplying the water between the flaw detection heads <NUM> and the surface Sa of the steel plate S simultaneously with the movement of the inspection device body <NUM>. Therefore, in the ultrasonic flaw detection by the inspection device body <NUM>, the water W required for the inspection can be efficiently supplied between the flaw detection heads <NUM> and the surface Sa of the steel plate S.

The flow adjustment plate <NUM> is formed in an arc shape having the first arc surface 73a and is arranged such that the first arc surface 73a projects toward the advancing direction in the inspection path of the inspection device body <NUM>.

Thus, the flow adjustment plate <NUM> can push out the water W supplied onto the surface Sa of the steel plate S from the water supply devices <NUM> in the advancing direction and appropriately form a flow for supplying the water W between the flaw detection heads <NUM> inspecting the steel plate S for defects and the surface Sa of the steel plate S simultaneously with the movement of the inspection device body <NUM>.

Further, according to the moving inspection device <NUM> of this embodiment, the inspection device body <NUM> includes the follow-up mechanism <NUM> of causing the flaw detection heads <NUM> as the inspection sensors to follow the uneven state of the surface Sa of the steel plate S as the inspection target.

Thus, when the flaw detection heads <NUM> scan (move over) the surface Sa of the steel plate S, the flaw detection heads <NUM> can follow the uneven state of the surface Sa of the steel plate S and appropriately inspect the steel plate S for defects regardless of the uneven state of the surface Sa of the steel plate S.

The follow-up mechanism <NUM> includes the sensor holding mechanism <NUM> holding the flaw detection head <NUM> as the inspection sensor and the load adjustment mechanism <NUM> adjusting the load applied to the surface Sa of the steel plate S by the flaw detection head <NUM> held by the sensor holding mechanism <NUM>. The sensor holding mechanism <NUM> rotates around the X-axis extending in parallel to the surface Sa of the steel plate S and the Y-axis extending in a direction parallel to the surface Sa of the steel plate S and orthogonal to the X-axis, and moves up and down along the Z-axis extending perpendicularly to the surface Sa of the steel plate S.

Thus, as illustrated in <FIG>, when the flaw detection heads <NUM> scan (move over) the surface Sa of the steel plate S, the flaw detection heads <NUM> held by the sensor holding mechanisms <NUM> rotate around the X-axis and the Y-axis in a state where a predetermined load is applied to the surface Sa of the steel plate S according to the uneven state of the surface Sa of the steel plate S. Further, the flaw detection head <NUM> can move up and down along the Z-axis, and the flaw detection head <NUM> can follow the uneven state of the surface Sa of the steel plate S with an appropriate pressing force.

Further, according to the moving inspection method of this embodiment, the steel plate S as the inspection target is inspected for defects using the above-described moving inspection device <NUM>, and therefore the inspection device body <NUM> itself is reduced in size and weight, so that the steel plate S as the inspection target can be inspected for defects using the moving inspection device capable of realizing significant size reduction/weight reduction without affecting the inspection performance for the steel plate S.

The steel plate S as a steel material is manufactured through an inspection step of implementing the moving inspection method.

The embodiments of the present invention are described above but the present invention is not limited thereto and can be variously altered or modified.

For example, the inspection target to be inspected by the moving inspection device <NUM> is not limited to the steel plate S.

The inspection of the steel plate S for defects by the moving inspection device <NUM> may also include inspecting the steel plate S for all defects including internal defects and surface defects of the front surface side and the rear surface side of the steel plate S without being limited to the inspection of the steel plate S for internal defects and surface defects of the rear surface side by the ultrasonic flaw detection.

The inspection device body <NUM> is not limited to one having the structure illustrated in <FIG> and <FIG> to <FIG> and may be any one inspecting the steel plate S for defects while moving over the surface Sa of the steel plate S as the inspection target and installed with the flow adjustment plate <NUM>. For example, the wheels <NUM> are not limited to two wheels and may be three or four wheels.

The flow adjustment plate <NUM> is not limited to the arc shape having the first arc surface and may be any one pushing out the water W supplied onto the surface Sa of the steel plate S from the water supply devices <NUM> in the advancing direction and forming the streamlines for supplying the water W between the flaw detection heads <NUM> as the inspection sensors and the surface Sa of the steel plate S simultaneously with the movement of the inspection device body <NUM>.

The flow adjustment plate <NUM> may be installed in the carriage <NUM> by devising the shape such that the water W supplied onto surface Sa of the steel plate S from the water supply devices <NUM> is pushed out in the advancing direction and the streamlines for supplying the water W are formed between the flaw detection heads <NUM> as the inspection sensors and the surface Sa of the steel plate S simultaneously with not only in the movement of the inspection device body <NUM> in the inspection path but in the movement of the inspection device body <NUM> in the movement path.

The arc shape of the flow adjustment plate <NUM> may have the first arc surface 73a and may not necessarily have the second arc surface 73b.

The flow adjustment plate <NUM> may be formed in a triangular shape. In that case, the flow adjustment plate <NUM> is preferably arranged such that the apex projects toward the advancing direction in the inspection path of the inspection device body <NUM>.

The follow-up mechanism <NUM> is not limited to one having the sensor holding mechanism <NUM> and the load adjustment mechanism <NUM>. The sensor holding mechanism <NUM> holds the flaw detection head <NUM> as the inspection sensor, rotates around the X-axis extending in parallel to the surface Sa of the steel plate S and the Y-axis extending in a direction parallel to the surface Sa of the steel plate S and orthogonal to the X-axis, and moves up and down along the Z-axis extending perpendicularly to the surface Sa of the steel plate S. The load adjustment mechanism <NUM> adjusts the load applied by the flaw detection head <NUM> held by the sensor holding mechanism <NUM> to the surface Sa of the steel plate S.

For example, as illustrated in <FIG>, the follow-up mechanism <NUM> may include an actuator <NUM>, a distance meter <NUM>, and an actuator control device <NUM>. The actuator <NUM> moves up and down the flaw detection head <NUM> as the inspection sensor along the Z-axis extending perpendicularly to the surface Sa of the steel plate S as the inspection target. The distance meter <NUM> measures a distance δ along the Z-axis between the flaw detection head <NUM> and the surface Sa of the steel plate S. The actuator control device <NUM> controls the actuator <NUM> to move up and down the flaw detection head <NUM> according to the above-described distance δ measured by the distance meter <NUM> to adjust the above-described distance δ. In <FIG>, the distance meter <NUM> is attached to the upper surface of the flaw detection head <NUM> and the distance meter <NUM> measures a height h between the upper surface of the flaw detection head <NUM> and the surface Sa of the steel plate S. Since a height hh of the flaw detection head <NUM> is known in advance, the distance meter <NUM> measures the height h between the upper surface of the flaw detection head <NUM> and the surface Sa of the steel plate S, and then subtracts the height hh of the flaw detection head <NUM> from the measured height h to calculate the distance δ along the Z-axis between flaw detection head <NUM> and the surface Sa of the steel plate S.

This enables the follow-up mechanism <NUM> to actively and appropriately cause the flaw detection head <NUM> to follow the uneven state of the surface Sa of the steel plate S.

A pair of water supply devices <NUM> is installed on each of the end surfaces on the long-side sides facing each other of the steel plate S formed in a rectangular shape, but the installation number thereof may be one or three or more. The water supply device <NUM> can be installed at any position with respect to the steel plate S insofar as the water W can be supplied onto the surface Sa of the steel plate S.

The water supply device <NUM> may also be modified as illustrated in <FIG> illustrate a modification of the water supply device <NUM>, in which <FIG> is a side view and <FIG> is a perspective view.

The nozzle <NUM> of the water supply device <NUM> illustrated in <FIG> described above is detachably attached to the end surface of the steel plate S by the magnet-type attachment base <NUM>. In this case, the water supply device <NUM> is inevitably installed at a position around the end surface of the steel plate S and, depending on the shape of the steel plate S, the water supply device <NUM> cannot be installed.

In contrast thereto, the water supply device <NUM> according to the modification illustrated in <FIG> includes two kinds: the water supply device <NUM> for large plate thickness and the water supply device <NUM> for small plate thickness. The water supply device <NUM> for large plate thickness is supported in an upper part of a bar-shaped support <NUM> provided in a stand <NUM> placed on a floor surface F and the water supply device <NUM> for small plate thickness is supported in a lower part of the support <NUM>.

The nozzle <NUM> connected to the tip of the water supply hose <NUM> in each water supply device <NUM> is supported by a support clamp <NUM> to be movable up and down with respect to the support <NUM> (Y-direction indicated by the arrow in <FIG>), such that the installation height of the nozzle <NUM> can be changed according to the height of the surface Sa of the steel plate S. Further, the nozzle <NUM> is supported by the support clamp <NUM> to be rotatable in the horizontal rotation direction with respect to the support <NUM> (X-direction indicated by the arrow in <FIG>), such that the direction of the nozzle <NUM> can be changed. More specifically, the nozzle <NUM> in each water supply device <NUM> is provided with the support clamp <NUM>. Each nozzle <NUM> is then moved in the up and down direction with respect to the support <NUM> such that the installation height of each nozzle <NUM> is flush with the surface Sa of the steel plate S, and, simultaneously therewith, each nozzle <NUM> is rotated with respect to the support <NUM> such that the direction of the nozzle <NUM> is located at a desired position, and then the support clamp <NUM> is tightened in this state, so that each nozzle <NUM> is supported.

Thus, each nozzle <NUM> is supported by the support <NUM> with the installation height and the direction adjusted with respect to the surface Sa of the steel plate S.

According to the water supply device <NUM> of this modification, each nozzle <NUM> is supported by the support <NUM> provided in the stand <NUM> placed on the floor surface F. Therefore, each nozzle <NUM> can be arranged as desired around the steel plate S without being constrained by the end surfaces of the steel plate S. Each nozzle <NUM> is supported by the support <NUM> with the installation height and the direction adjusted with respect to the surface Sa of the steel plate S. As a result, there is an advantage that each nozzle <NUM> can be sometimes predominantly arranged in a place where flaw detection water is likely to dry depending on the surface characteristics of the steel plate S and the tilt of the steel plate S, which enables more stable and reliable flaw detection.

Each nozzle <NUM> in the water supply device <NUM> according to the modification includes a flow rate adjustment member 90a adjusting the flow rate of the water W supplied from each nozzle <NUM>. Therefore, the flow rate adjustment member 90a can adjust the passage area of a water supply passage in each nozzle <NUM> to adjust the flow rate of the water W to the surface Sa of the steel plate S from each nozzle <NUM>. As illustrated in <FIG>, each nozzle <NUM> is provided with an unsealing plug 90b. When the water W is supplied to the surface Sa of the steel plate S from each nozzle <NUM>, the unsealing plug 90b may be opened after the flow rate is adjusted by the flow rate adjustment member 90a.

In the water supply device <NUM> according to the modification illustrated in <FIG> , the water supply devices <NUM> of the two kinds of the water supply device <NUM> for large plate thickness and the water supply device <NUM> for small plate thickness are supported by the support <NUM>, but the present invention is not limited thereto and the water supply device <NUM> of one kind may be supported or the water supply devices <NUM> of a plurality (two kinds or more) of kinds may be supported. The number of the stands <NUM> each having the support <NUM> is not limited to one. Two or more of the stands <NUM> may be prepared and each support <NUM> may support the water supply device <NUM>.

The installation number of the water supply devices <NUM> is preferably determined according to the surface area of the steel plate S to be supplied with the water W. Thus, the flaw detection can be appropriately performed according to the surface area of the steel plate S.

A steel plate provided with artificial defects (∘, Δ, □) was inspected using the moving inspection device <NUM> illustrated in <FIG> as a moving inspection device according to Examples. An inspection map therefor is illustrated in <FIG>. The inspection map was created by associating the position of the inspection device body <NUM> with inspection data at that position.

The positions and the shapes of the artificial defects (∘, Δ, □) provided on the steel plate were accurately known in advance, and thus it was able to be confirmed that the inspection by the moving inspection device according to Examples had sufficient accuracy.

The mass of conventional moving inspection devices (moving inspection devices having a configuration similar to that illustrated in PTL <NUM> or PTL <NUM>) is about <NUM> (exceeds <NUM> when filled with water) because a water tank was provided, and thus the conventional moving inspection devices were very heavy. Therefore, a lifter or the like was used in the movement between steel plates of the moving inspection devices, and thus there was room for improvement.

Claim 1:
A moving inspection device (<NUM>) comprising:
a moving inspection device body (<NUM>) configured to inspect an inspection target (S) for a defect while moving over a surface (Sa) of the inspection target (S) and provided with an inspection sensor (<NUM>) configured to inspect the inspection target (S) for a defect; and
a water supply device (<NUM>) provided separately from the moving inspection device body (<NUM>) and configured to supply water (W) required for the inspection onto the surface (Sa) of the inspection target (S), characterized in that
the moving inspection device body (<NUM>) is installed with a flow adjustment plate (<NUM>) configured to push out the water (W) supplied onto the surface (Sa) of the inspection target (S) from the water supply device (<NUM>) in an advancing direction of the moving inspection device body (<NUM>) and form a streamline for supplying the water between the inspection sensor (<NUM>) and the surface (Sa) of the inspection target (S) simultaneously with the movement of the moving inspection device body (<NUM>).