Ultrasonic impact equipment for U-rib weld joint of orthotropic steel bridge deck slab and use method of ultrasonic impact equipment

Abstract

The invention relates to ultrasonic impact equipment for a U-rib welding seam of an orthotropic steel bridge deck slab and a using method of the ultrasonic impact equipment. The equipment comprises an equipment shell, a transverse limiting device, a driving system, an ultrasonic impact gun, a power ultrasonic power supply, a display screen and a control knob. The transverse limiting device can be adjusted to adapt to U ribs of different sizes, the ultrasonic impact gun is of a miniaturized half-wavelength structure, and the power ultrasonic power supply is a self-excited oscillating circuit. The equipment using method comprises the operation steps of equipment preparation and installation, parameter setting and calibration, impact treatment, equipment inspection, limiting device and impact head adjustment, parameter setting, and impact and real-time fine adjustment on a welding seam in the equipment advancing process. The equipment is small in size, convenient to operate and efficient in treatment, residual stress can be reduced, the fatigue performance of the steel bridge deck is improved, and the equipment has important application value in the field of steel bridge construction and maintenance.

Description

Technical Field

[0001] This invention relates to an ultrasonic impact device, and more particularly to an ultrasonic impact device for the U-rib weld of orthotropic steel bridge deck and its method of use. Background Technology

[0002] As a landmark innovation in modern bridge engineering, orthotropic steel bridge decks have become the preferred bridge deck structure for long-span steel bridges. However, due to the difficulty in rolling the plates and the complexity of their construction and welding processes, residual stress and welding deformation are severe after extensive welding and assembly. Under the combined action of residual stress and repeated alternating vehicle loads, localized stress concentration areas in the orthotropic steel bridge deck plasticize, accelerating structural fatigue damage and significantly reducing its fatigue life. Reducing residual stress, minimizing localized plasticization areas, and effectively improving fatigue life to ensure traffic safety within its design lifespan are important research topics in the fatigue problem of orthotropic steel bridge decks. Ultrasonic impact testing is an effective method for reducing residual stress and stress concentration.

[0003] In recent years, a large number of studies on the application of high-power ultrasonic technology in industry, especially ultrasonic impact technology, have been carried out in Ukraine, Russia, and the United States. The various applications of ultrasonic impact in industry have gradually gained attention, and research results in related fields are increasing. Preliminary applications of ultrasonic impact in engineering have also yielded good results. Researchers in the United States and Ukraine have used ultrasonic impact treatment to repair highway bridges with fatigue cracks. The results show that ultrasonic impact treatment is a novel and highly efficient method for restoring and repairing welded components and structures. Post-treatment of load-bearing components can achieve the same good effect on improving fatigue strength as treatment during construction. Tests on large-size components show that the fatigue strength of structures treated with ultrasonic impact is the highest compared to other post-weld treatment methods. Existing ultrasonic impact designs can be used for the restoration and repair of highway and railway bridges.

[0004] The application of ultrasonic impact testing is gaining popularity, but its limitations are becoming increasingly apparent due to insufficient research and development capabilities. For example, regarding the double-sided welding of steel box girder panels and U-ribs, the limited space inside the U-ribs prevents ultrasonic impact testing of the inner weld seams, inevitably leading to a significant reduction in the fatigue performance of the steel bridge. Therefore, developing a miniaturized ultrasonic impact testing device suitable for double-sided welding of U-ribs is essential. Summary of the Invention

[0005] The main objective of this invention is to provide an ultrasonic impact device for the weld seam of the U-rib of orthotropic steel bridge deck, which can automatically, intelligently and efficiently perform ultrasonic impact on the weld seams on the inner and outer sides of the U-rib.

[0006] To achieve the above objectives, this invention provides an ultrasonic impact testing device for U-rib welds in orthotropic steel bridge decks, comprising a housing, a lateral limiting device, a drive system, an ultrasonic impact gun, a power ultrasonic power supply, a display screen, and a control knob. The lateral limiting device is located symmetrically on both sides of the housing and includes an upper support plate, a lower support plate, a connecting rod, a telescopic knob, a telescopic rod, and a fixed support. The upper and lower support plates are connected by the connecting rod. By adjusting the length of the telescopic rod, the support can be fitted to the U-rib, allowing the lateral limiting device to adapt to U-ribs of different sizes. The ultrasonic impact gun adopts a miniaturized half-wavelength structure. The power ultrasonic power supply uses a self-excited oscillation circuit. The display screen displays the ultrasonic frequency, impact duration, ultrasonic impact needle vibration frequency, and power ultrasonic power supply.

[0007] Furthermore, the ultrasonic impact gun includes an ultrasonic impact gun housing, a replacement knob, a replaceable impact head, a connecting rod, and a telescopic knob; the two ultrasonic impact gun housings are connected by the connecting rod; the telescopic knob is mounted on the connecting rod; adjusting the telescopic knob can adjust the distance between the two ultrasonic impact guns and the angle of the impact head; the replaceable impact head is connected to the ultrasonic impact gun housing via the replacement knob; different replaceable impact heads can be replaced by adjusting the replacement knob.

[0008] Furthermore, the replaceable impact head can be replaced with a single or multiple straight-line high-speed steel replaceable impact head.

[0009] Furthermore, the drive system includes a rubber track and a drive wheel; the drive wheel is connected to the rubber track by meshing, and each drive wheel consists of two coaxial rollers with a certain axial distance.

[0010] Furthermore, the control knobs include a knob for adjusting the duration of ultrasonic frequency impact, a knob for adjusting the vibration frequency of ultrasonic impact needle, and a telescopic knob for adjusting the extension and retraction of the rod; the knobs for adjusting the duration of ultrasonic frequency impact and the knobs for adjusting the vibration frequency of ultrasonic impact head are located on the back of the other end of the device and the device on which the ultrasonic impact gun is mounted.

[0011] A method for using an ultrasonic impact testing device for U-rib welds in orthotropic steel bridge decks, characterized by comprising the following steps:

[0012] (1) Equipment preparation and installation: Check the equipment housing, rubber tracks, drive wheels, ultrasonic impact gun, replaceable impact head and power ultrasonic power supply circuit to ensure that the equipment is in good condition; adjust the distance between the upper and lower support plates of the lateral limit device by the telescopic knob to fit the U-rib, and adjust the length of the telescopic rod to match the width of the U-rib; select the type of impact head according to the weld position and fix it by the replacement knob, and adjust the telescopic knob to make the ultrasonic impact gun distance and impact head angle perpendicular to the weld surface;

[0013] (2) Parameter setting and calibration: Turn on the power ultrasonic power supply and preheat to a stable state. Observe the display screen to confirm that the power supply power and frequency parameters are normal. Set the ultrasonic frequency, impact duration, impact pin vibration frequency, and telescopic rod length using the control knob. Adjust the ultrasonic frequency to 15-40kHz and the impact pressure to 0.5-2N / mm according to the U-rib material, weld size, and processing requirements. 2 ;

[0014] (3) Impact treatment operation: Place the equipment inside or outside the U-rib, start the drive system to make the equipment move at a constant speed of 50-200mm / min along the weld direction, and ensure that the transverse limiting device always fits the U-rib; the ultrasonic impact gun automatically performs high-frequency impact on the weld and heat-affected zone, focusing on the weld toe area, and observe the display screen parameters in real time and make fine adjustments; if the weld is long, it is processed in sections, with each section overlapping ≥10mm. For the narrow space inside the U-rib, the angle is flexibly adjusted using a miniaturized impact gun for processing.

[0015] Furthermore, in the equipment preparation and installation steps, checking whether the rubber tracks and drive wheels are normal is done by observing their surface wear and whether there is any jamming during the transmission process.

[0016] Furthermore, in the parameter setting and calibration steps, the parameters displayed on the screen in real time include power supply, frequency, ultrasonic frequency, impact duration, impact needle vibration frequency, and telescopic rod length.

[0017] Furthermore, in the impact treatment operation steps, when fine-tuning the parameters on the real-time display screen, if the ultrasonic frequency deviates from the set value by ±10%, it is adjusted by controlling the knob.

[0018] Furthermore, the rubber tracks, drive wheels, and lateral limiting devices ensure the smooth movement of the equipment; the ultrasonic impact gun uses a miniaturized half-wavelength structure instead of the traditional full-wavelength gun body structure, which can impact welds in some narrow and inconvenient locations.

[0019] Compared with the prior art, the present invention has the following advantages:

[0020] (1) The ultrasonic impact equipment for the U-rib weld of orthotropic steel bridge deck is small in size and light in weight. It can enter and adapt to the narrow space inside the U-rib of various sizes, and can also work on the outside of the U-rib, realizing automatic, intelligent and efficient ultrasonic impact.

[0021] (2) The ultrasonic impact equipment for the U-rib weld of orthotropic steel bridge deck can adjust the duration of ultrasonic impact and the vibration frequency of ultrasonic impact needle, making it convenient to adjust the output power and control the impact effect on site.

[0022] (3) The ultrasonic impact equipment for the U-rib weld of orthotropic steel bridge deck has a fast processing speed, stable and reliable results, low cost and good economic benefits.

[0023] (4) The ultrasonic impact test equipment for the U-rib weld of orthotropic steel bridge deck can significantly reduce residual stress, reduce stress concentration, improve the fatigue performance of steel bridge deck, and reduce the serious damage and loss caused by fatigue cracks. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 , 2 This is a schematic diagram of the ultrasonic impact testing device for the U-rib weld of orthotropic steel bridge deck provided by the present invention.

[0026] Figure 3 This is a schematic diagram of the lateral limiting device in the ultrasonic impact device for the U-rib weld of orthotropic steel bridge deck provided by the present invention.

[0027] Figure 4 This is a schematic diagram of the drive system in the ultrasonic impact device for U-rib welds of orthotropic steel bridge decks provided by the present invention.

[0028] Figure 5 This is a schematic diagram of the ultrasonic impact gun in the ultrasonic impact device for the U-rib weld of orthotropic steel bridge deck provided by the present invention.

[0029] The reference numerals in the accompanying drawings include:

[0030] 1: Equipment housing; 2: Lateral limiting device; 21: Upper support plate; 22: Lower support plate; 23: Connecting rod; 24: Telescopic knob; 25: Telescopic rod; 26: Fixed support; 3: Drive system; 31: Rubber track; 32: Drive wheel; 4: Ultrasonic impact gun; 41: Ultrasonic impact gun housing; 42: Replacement knob; 43: Replaceable impact head; 44: Connecting rod; 45: Telescopic knob; 5: Power ultrasonic power supply; 6: Knob for adjusting ultrasonic frequency and impact duration; 7: Display screen; 8: Knob for adjusting the vibration frequency of the ultrasonic impact needle. Detailed Implementation

[0031] The present invention will now be clearly and completely described in conjunction with the accompanying drawings. Those skilled in the art will be able to implement the present invention based on these descriptions. Before describing the present invention in conjunction with the accompanying drawings, it should be particularly noted that:

[0032] The technical solutions and features provided in the various parts of this invention, including the following description, can be combined with each other without conflict.

[0033] Furthermore, the embodiments of the present invention described below are generally only some, not all, of the embodiments of the present invention. Therefore, all other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

[0034] Regarding the terminology and units used in this invention: The terms "comprising," "having," and any variations thereof in the specification, claims, and related parts of this invention are intended to cover non-exclusive inclusion.

[0035] like Figure 1 and Figure 2 As shown, this invention provides an ultrasonic impact testing device for U-rib welds in orthotropic steel bridge decks, comprising a housing 1, a lateral limiting device 2, a drive system 3, an ultrasonic impact gun 4, a power ultrasonic power supply 5, a display screen 7, and control knobs. The housing 1 is made of fiberglass, possessing good corrosion resistance and capable of continuous operation under high heat and strong radiation conditions, while also providing excellent protection for the internal components. The ultrasonic impact gun 4 is an energy conversion mechanism, employing a miniaturized half-wavelength structure instead of the traditional full-wavelength gun structure, enabling impact treatment of welds in confined spaces that are difficult to access. The control knobs include a knob 6 for adjusting the ultrasonic frequency and impact duration, a knob 8 for adjusting the ultrasonic impact needle vibration frequency, and a telescopic knob 24 for adjusting the extension and retraction of the rod. The knobs 6 and 8 for adjusting the ultrasonic frequency and impact duration are located on the back of the device and the other end where the ultrasonic impact gun 4 is mounted. The ultrasonic frequency and impact duration, the ultrasonic impact head vibration frequency, and the power ultrasonic power supply are all displayed on the display screen 7. The display screen 7 can display the ultrasonic frequency impact duration, ultrasonic impact needle vibration frequency, and ultrasonic power supply power; the ultrasonic power supply 5 is a self-excited oscillation circuit, which has the advantages of simple circuit form, few components, and convenient maintenance and debugging.

[0036] like Figure 3As shown, the lateral limiting device 2 is located symmetrically on both sides of the equipment housing; it includes an upper support plate 21, a lower support plate 22, a connecting rod 23, a telescopic knob 24, a telescopic rod 25, and fixed supports 26. The upper support plate 21 and the lower support plate 22 are connected by the connecting rod 23, which can be extended or retracted using the telescopic knob 24 to adjust the distance between the upper support plate 21 and the lower support plate 22. Each side of the lateral limiting device 2 is connected to the equipment housing 1 via four fixed supports 26, forming a single unit. The length of the telescopic rod 25 can be adjusted, allowing the supports of the lateral limiting device 2 to conform to the webs on both sides of the U-rib, ensuring the equipment moves straight forward. Furthermore, by adjusting the length of the telescopic rod 25, the supports 26 can be fitted to the U-rib, enabling the lateral limiting device to adapt to U-ribs of different sizes.

[0037] like Figure 4 As shown, the drive system 3 includes a rubber track 31 and a drive wheel 32. The drive wheel 32 is connected to the rubber track 31 by meshing. Each drive wheel consists of two coaxial rollers with a certain axial distance, which enables the equipment to move forward smoothly.

[0038] like Figure 5 As shown, the ultrasonic impact gun 4 includes an ultrasonic impact gun housing 41, a replacement knob 42, a replaceable impact head 43, a connecting rod 44, and a telescopic knob 45. The two ultrasonic impact gun housings 41 are connected by the connecting rod 44. The telescopic knob 45 is located on the connecting rod 44. To accommodate different U-rib widths, adjusting the telescopic knob 45 adjusts the distance between the two ultrasonic impact guns and the angle of the impact head, ensuring the impact head is perpendicular to the weld seam for optimal impact effect. The symmetrical arrangement of the two ultrasonic impact guns allows for simultaneous ultrasonic treatment of the U-ribs on both sides, avoiding the asymmetric effects caused by ultrasonic treatment of the weld seam on one side. The replaceable impact head 43 is connected to the ultrasonic impact gun housing 41 via the replacement knob 42. Adjusting the replacement knob 42 allows for the replacement of different replaceable impact heads 43, which can be replaced with single or multiple straight high-speed steel replaceable impact heads 43, depending on the actual situation. The replacement knob 42 also serves to connect the replaceable impact head 43 to the ultrasonic impact gun housing 41.

[0039] The method for using ultrasonic impact testing equipment for U-rib welds in orthotropic steel bridge decks is as follows:

[0040] 1. Equipment preparation and installation

[0041] (1) Equipment inspection:

[0042] 1) Confirm the equipment casing is intact. 2) Check the rubber tracks and drive wheels for proper functioning, ensuring smooth transmission. 3) Verify the ultrasonic impact gun and replaceable impact head are securely connected. 4) Ensure the ultrasonic power supply circuit is functioning correctly, and the control knobs and display screen are working properly.

[0043] (2) Adjustment of the lateral limiting device

[0044] 1) Adjust the distance between the upper and lower support plates of the lateral limiting device by using the telescopic knob to make it fit the U-rib.

[0045] 2) Adjust the length of the telescopic rod to ensure that the equipment matches the width of the U-rib and keep the equipment moving in a straight line.

[0046] (3) Impact head installation and angle adjustment

[0047] 1) Select the impact head type according to the weld location (inner or outer side) and fix it by changing the knob.

[0048] 2) Adjust the telescopic knob to adjust the ultrasonic impact gun spacing and impact head angle to ensure that the impact head is perpendicular to the weld surface.

[0049] 2. Parameter Setting and Calibration

[0050] (1) Power start-up and preheating

[0051] 1) Turn on the ultrasonic power supply and preheat the equipment to a stable state. 2) Observe the display screen to confirm that the power and frequency parameters are normal.

[0052] (2) Parameter adjustment

[0053] 1) Set the following parameters via the control knob: ultrasonic frequency, impact duration, impact pin vibration frequency, and telescopic rod length. 2) Adjust the parameter range according to the U-rib material, weld size, and processing requirements: ultrasonic frequency: 15–40 kHz; impact pressure: 0.5–2 N / mm². 2 .

[0054] 3. Impact treatment operation

[0055] (1) Equipment positioning and startup

[0056] 1) Place the equipment inside or outside the U-rib, start the drive system (rubber track + drive wheel), and the equipment moves at a constant speed (50-200 mm / min) along the weld direction.

[0057] 2) Ensure that the lateral limiting device always fits the U-rib to prevent displacement.

[0058] (2) Impact treatment execution

[0059] 1) The ultrasonic impact gun automatically performs high-frequency impact on the weld and heat-affected zone, with a focus on the weld toe area.

[0060] 2) Observe the parameters on the display screen in real time, and fine-tune the frequency, duration or vibration intensity by turning the knob if necessary.

[0061] (3) Multi-regional coverage

[0062] 1) If the weld is long, it should be processed in sections, with each section overlapping by ≥10mm to ensure complete impact coverage.

[0063] 2) For the narrow space inside the U-rib, use a miniaturized impact gun to flexibly adjust the angle to avoid missing any areas.

[0064] This equipment, through its miniaturized design, lateral limiting, and intelligent adjustment functions, achieves efficient impact treatment of the welds on both the inner and outer sides of the U-rib, significantly improving the fatigue life of the steel bridge deck. In practical applications, operational details need to be flexibly adjusted according to on-site conditions.

[0065] The foregoing has described the relevant content of the present invention. Those skilled in the art will be able to implement the present invention based on these descriptions. All other embodiments obtained by those skilled in the art based on the above description of the present invention without inventive effort should fall within the scope of protection of the present invention.

Claims

1. An ultrasonic impact testing device for the U-rib weld of orthotropic steel bridge deck, characterized in that, The device includes a housing, a lateral limiting device, a drive system, an ultrasonic impact gun, a high-power ultrasonic power supply, a display screen, and a control knob. The lateral limiting device is located symmetrically on both sides of the housing. It includes an upper support plate, a lower support plate, a connecting rod, a telescopic knob, a telescopic rod, and a fixed support. The upper and lower support plates are connected by the connecting rod. By adjusting the length of the telescopic rod, the support fits against the U-rib, allowing the lateral limiting device to adapt to U-ribs of different sizes. The ultrasonic impact gun uses a miniaturized half-wavelength structure. The high-power ultrasonic power supply uses a self-excited oscillation circuit. The display screen displays the ultrasonic frequency, impact duration, ultrasonic impact needle vibration frequency, and high-power ultrasonic power supply power.

2. The ultrasonic impact testing equipment for the U-rib weld of orthotropic steel bridge deck as described in claim 1, characterized in that, The ultrasonic impact gun includes an ultrasonic impact gun housing, a replacement knob, a replaceable impact head, a connecting rod, and a telescopic knob; two ultrasonic impact gun housings are symmetrically arranged and connected by the connecting rod; the telescopic knob is located on the connecting rod; adjusting the telescopic knob adjusts the distance between the two ultrasonic impact guns and the angle of the impact head; the replaceable impact head is connected to the ultrasonic impact gun housing via the replacement knob; different replaceable impact heads can be replaced by adjusting the replacement knob.

3. The ultrasonic impact testing equipment for the U-rib weld of orthotropic steel bridge deck according to claim 2, characterized in that, The replaceable impact head can be replaced with a single or multiple straight-line high-speed steel replaceable impact head.

4. The ultrasonic impact testing equipment for the U-rib weld of orthotropic steel bridge deck according to claim 1, characterized in that, The drive system includes a rubber track and a drive wheel; the drive wheel is connected to the rubber track by meshing, and each drive wheel consists of two coaxial rollers with a certain axial distance.

5. The ultrasonic impact testing equipment for the U-rib weld of orthotropic steel bridge deck according to claim 1, characterized in that, The control knobs include a knob for adjusting the duration of ultrasonic frequency impact, a knob for adjusting the vibration frequency of ultrasonic impact needle, and a telescopic knob for adjusting the extension and retraction of the rod; the knobs for adjusting the duration of ultrasonic frequency impact and the knobs for adjusting the vibration frequency of ultrasonic impact head are located on the back of the other end of the device and the device on which the ultrasonic impact gun is installed.

6. A method of using an ultrasonic impact testing device for the U-rib weld of orthotropic steel bridge deck according to any one of claims 1-5, characterized in that, Includes the following steps: (1) Equipment preparation and installation: Check the equipment housing, rubber tracks, drive wheels, ultrasonic impact gun, replaceable impact head and power ultrasonic power supply circuit to ensure that the equipment is in good condition; adjust the distance between the upper and lower support plates of the lateral limit device by the telescopic knob to fit the U-rib, and adjust the length of the telescopic rod to match the width of the U-rib; select the type of impact head according to the weld position and fix it by the replacement knob, and adjust the telescopic knob to make the ultrasonic impact gun distance and impact head angle perpendicular to the weld surface; (2) Parameter setting and calibration: Turn on the power ultrasonic power supply and preheat to a stable state. Observe the display screen to confirm that the power supply power and frequency parameters are normal. Set the ultrasonic frequency, impact duration, impact pin vibration frequency, and telescopic rod length using the control knob. Adjust the ultrasonic frequency to 15-40kHz and the impact pressure to 0.5-2N / mm according to the U-rib material, weld size, and processing requirements. 2 ; (3) Impact treatment operation: Place the equipment inside or outside the U-rib, start the drive system to make the equipment move at a constant speed of 50-200mm / min along the weld direction, and ensure that the transverse limiting device always fits the U-rib; the ultrasonic impact gun automatically performs high-frequency impact on the weld and heat-affected zone, focusing on the weld toe area, and observe the display screen parameters in real time and make fine adjustments; if the weld is long, it is processed in sections, with each section overlapping ≥10mm. For the narrow space inside the U-rib, the angle is flexibly adjusted using a miniaturized impact gun for processing.

7. The method of use according to claim 6, characterized in that, In the equipment preparation and installation steps, checking whether the rubber tracks and drive wheels are normal is done by observing their surface wear and whether there is any jamming during the transmission process.

8. The method of use according to claim 6, characterized in that, In the parameter setting and calibration steps, the parameters displayed on the screen in real time include power supply, frequency, ultrasonic frequency, impact duration, impact needle vibration frequency, and telescopic rod length.

9. The method of use according to claim 6, characterized in that, In the impact treatment operation, when fine-tuning the parameters on the display screen in real time, if the ultrasonic frequency deviates from the set value by ±10%, it is adjusted by controlling the knob.

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