JP7215450B2 - Air gap inspection device, air gap inspection method, and structure manufacturing method - Google Patents

Description

The present invention relates to a gap inspection device, a gap inspection method, and a structure manufacturing method.

BACKGROUND ART In a structure (for example, a coke oven) constructed by arranging construction materials such as bricks, mortar is filled in the gaps (hereinafter also referred to as "joints") between the construction materials.

JP 2016-169376 A

If there are voids in the mortar, there is a risk of hindering the use of the structure.
For example, a brickwork structure, such as a coke oven, has hot gases flowing through it.
Therefore, if there are gaps in the mortar filled in the joints between the bricks, gas may leak through the gaps. In this case, problems such as occurrence of abnormal combustion and deterioration of coke quality may occur.
Furthermore, if the mortar dries with the voids included, the strength of those portions will be reduced, which may adversely affect the earthquake resistance of the structure.

Conventionally, in order to avoid the situation where voids exist in the mortar filled in the joints, the voids are removed by pushing the mortar into the joints, or the construction materials are extracted and peeled off after the mortar is filled into the joints to remove the voids. Visually check for the presence of
Since such work requires time and effort, the construction work (construction) of the structure may take a long time.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a gap inspection device and a gap inspection method capable of appropriately inspecting the presence or absence of voids inside mortar filled in joints of construction materials. do.
A further object of the present invention is to provide a structure manufacturing method using the above-described void inspection method.

As a result of intensive studies, the inventors of the present invention have found that the above object can be achieved by adopting the following configuration, and completed the present invention.

That is, the present invention provides the following [1] to [7].
[1] A void inspection device for inspecting the presence or absence of voids inside mortar filled in joints of construction materials arranged side by side, comprising a probe inserted into the mortar, and a probe inserted into the mortar. A gap inspection apparatus comprising: a moving part for moving in a direction; and a detecting part for detecting a resistance force received when the tip of the probe moves inside the mortar.
[2] A determination unit that determines whether or not there is a gap based on the resistance detected by the detection unit, and the determination unit determines, when the resistance becomes equal to or less than a specified value, the probe at that time. The gap inspection device according to the above [1], which determines that the gap is present at the position of the tip of the.
[3] A void inspection method for inspecting the presence or absence of voids inside mortar filled in joints of construction materials arranged side by side, wherein a probe is inserted into the mortar, and the probe is inserted into the mortar. and detecting the resistance force received by the tip of the probe as it moves inside the mortar.
[4] The gap inspection method according to [3] above, wherein when the resistance becomes equal to or less than a specified value, it is determined that the gap exists at the position of the tip of the probe at that time.
[5] A method of manufacturing a structure by arranging construction materials side by side, wherein each time a joint is formed by arranging the construction materials, the mortar filled in the joint is: A method for manufacturing a structure, wherein the presence or absence of voids is inspected according to the method described in [3] or [4] above.
[6] The method of manufacturing a structure according to [5] above, wherein the construction material is a brick, and the structure is a furnace having a furnace wall formed by arranging the bricks side by side.
[7] The method for manufacturing a structure according to [6] above, wherein the furnace is a coke oven.

According to the present invention, it is possible to appropriately inspect the presence or absence of voids inside mortar filled in joints of construction materials.

1 is a perspective view showing a void inspection device of a first embodiment; FIG. It is an XY cross-sectional view of the air gap inspection device. It is an XY cross section of the joint mortar. FIG. 4 is a graph showing the resistance force experienced by the tip of the probe at position A in FIG. 3; FIG. FIG. 4 is a graph showing the resistance force experienced by the tip of the probe at position B of FIG. 3; FIG. FIG. 4 is a graph showing the resistance force experienced by the tip of the probe at position C of FIG. 3; FIG. It is a mapping image of voids. It is a perspective view which shows the space|gap inspection apparatus of 2nd Embodiment. It is a perspective view which shows the space|gap inspection apparatus of 3rd Embodiment. It is a perspective view which shows the space|gap inspection apparatus of 4th Embodiment.

A preferred embodiment of the air gap inspection device will be described below. The following explanation also serves as an explanation of the void inspection method and the structure manufacturing method.

In the following description, "mortar" means mortar before drying.
Specifically, for example, it means a mortar having a water content ratio (water content) of 10% or more to the total mass, more specifically, a mortar having a water content of 10 to 30%.

In the following description, a joint is a gap between construction materials.
Construction materials include, for example, block-shaped construction materials such as bricks.
Joints include horizontal joints extending in the horizontal direction and vertical joints extending in the vertical direction, but hereinafter, the horizontal joints are simply referred to as "joints" unless otherwise specified.
The mortar filled in the joint is used as a binder for binding construction materials positioned on both sides of the joint (upper and lower sides of the joint), and is hereinafter referred to as "joint mortar".

In the following, an example will be described in which the presence or absence of voids inside joint mortar is inspected in the construction (manufacturing) process of a structure. That is, in the following description, the presence or absence of voids in the mortar filled in the horizontal joints is inspected. However, the presence or absence of voids in the mortar filled in the vertical joints may be inspected.

The structure has walls constructed by arranging construction materials such as bricks vertically and horizontally, respectively. The structure may further have a space (internal space) surrounded by its walls.
Examples of such structures include furnaces such as firing furnaces such as coke ovens; heating furnaces; smelting furnaces; fireplaces; The structure is not limited to a furnace, and may be another structure (for example, an outer wall of a building, etc.).

[First embodiment]
A first embodiment will be described based on FIGS. 1 to 5. FIG.

FIG. 1 is a perspective view showing the air gap inspection device 10 of the first embodiment.
In FIG. 1, the air gap inspection device 10 faces a furnace wall 9 constructed by stacking a plurality of bricks 8 . The oven wall 9 constitutes an oven such as a coke oven, for example. A joint mortar 4 is filled in gaps (joints) between bricks 8 as a building material.
In FIG. 1, the X direction is the longitudinal direction (left and right horizontal direction) of the furnace wall 9 . The Y direction is the depth direction of the furnace wall 9 (horizontal direction toward the back side or front side of the furnace wall 9). The Z direction is the height direction (vertical direction) of the furnace wall 9 .

The air gap inspection apparatus 10 is mainly composed of an apparatus body 10H and a monitor 16. As shown in FIG.
The apparatus body 10H incorporates an actuator 15 as a moving section, a load cell 22 as a detecting section, and a processing device 30 as a determining section (see FIG. 2 for all).
Although the monitor 16 is connected to the device body 10H by wire in FIG. 1, it may be connected wirelessly. In the latter case, the monitor 16 can be installed at a location farther from the device body 10H. The monitor 16 may be integrated with the apparatus main body 10H without being separated from the apparatus main body 10H.

FIG. 2 is an XY cross-sectional view of the air gap inspection device 10. As shown in FIG. In FIG. 2, each part is illustrated in a simplified manner.
A gap inspection device 10 has a probe 11 , a load cell 22 and an actuator 15 . A portion of the probe 11 including the tip 13 protrudes outside the apparatus body 10H.
The other end of probe 11 is attached to actuator 15 via load cell 22 .

The probe 11 is, for example, a rod-shaped (for example, quadrangular prism-shaped) member.
As will be described later, the tip 13 of the probe 11 is inserted into the joint mortar 4 and is required to receive a certain amount of resistance.
For this reason, the tip 13 of the probe 11 is preferably a flat surface, and more specifically, a rectangular surface elongated in the Y direction, for example.
For the same reason, the material of the probe 11 preferably has a certain degree of hardness, and examples thereof include resin, glass, and metal.

Actuator 15 is, for example, a single-axis actuator.
The actuator 15 moves the probe 11 elongated in one direction linearly (for example, intermittently by a fixed amount) along its longitudinal direction. That is, the probe 11 can move back and forth along the Y direction by the actuator 15 .

The load cell 22 detects the resistance force applied to the tip 13 of the probe 11 moved in the Y direction by the actuator 15 toward the back side (upper side in FIG. 2), and detects the detection result (specifically, the magnitude of the resistance force). ) to output a signal corresponding to
The load cell 22 is not particularly limited, and includes, for example, a general compression load cell; a beam type load cell that is compact and can be used by being integrated with another structure; and the like.

A processing device 30 is further incorporated inside the device body 10H. The processing device 30 is configured by, for example, a processor such as a microcomputer or an ASIC (Application specific integrated circuit).
The processing device 30 is electrically connected to the actuator 15, the load cell 22, the monitor 16 (not shown in FIG. 2), and the like. For example, processor 30 controls actuator 15 to move probe 11 in the Y direction.

A pair of positioning portions 26 are provided on the outside of the device body 10H with the probe 11 interposed therebetween. The positioning part 26 is a member projecting from the apparatus main body 10H to the outside, and is a member for keeping the distance between the apparatus main body 10H and the furnace wall 9 constant.

A guide portion (not shown) that restricts the movement of the probe 11 in the X direction and/or the Z direction may be provided inside or outside the device body 10H. This allows the probe 11 to move more linearly along the Y direction.
As such a guide portion, for example, a roller provided at a position sandwiching the probe 11 and assisting the movement of the probe 11 in the Y direction can be used.

In such a configuration, the presence or absence of voids inside the joint mortar 4 is inspected (hereinafter referred to as "void inspection" for convenience).
Void inspections are performed during the construction process of structures such as furnaces. For example, every time a joint is formed by stacking (arranging) bricks for one stage, the mortar filled in the joint is inspected for voids. However, the present invention is not limited to this, and for example, a void inspection may be performed each time a new brick is stacked one by one.

In the void inspection described below, the joint formed immediately before (hereinafter referred to as "target joint 2") is targeted, and the presence or absence of voids inside the joint mortar 4 is inspected in real time along the X direction. .

First, an inspector (not shown) who is a user of the air gap inspection apparatus 10 holds the apparatus main body 10H, and positions the tip 13 of the probe 11 facing the joint mortar 4 of the target joint 2. The face is brought into contact with the furnace wall 9 (the surface of the bricks 8 laid up at that time).

Next, the actuator 15 is driven to move the probe 11 toward the back side (upper side in FIG. 2) in the Y direction. As a result, the tip 13 of the probe 11 is inserted into the joint mortar 4 of the target joint 2, and then proceeds in the inserted direction. Thus, the insertion amount of the tip 13 of the probe 11 changes.
The amount of insertion is the distance that the tip 13 of the probe 11 has moved from the surface of the joint mortar 4 (indicated by symbol L in FIG. 2).
When the tip 13 of the probe 11 is inserted up to a predetermined insertion amount (hereinafter referred to as "maximum insertion amount"), the actuator 15 retracts the probe 11 to remove the tip 13 of the probe 11 from the joint mortar 4. Pull out.
The maximum insertion amount is, for example, a distance slightly shorter than the distance of the target joint 2 in the Y direction. In this case, the tip 13 of the probe 11 does not penetrate the joint mortar 4 .
However, the maximum insertion amount may be a distance longer than the distance of the target joint 2 in the Y direction. That is, the tip 13 of the probe 11 may pass through the joint mortar 4 .

By the way, the tip 13 of the probe 11 receives a resistance force from the joint mortar 4 while the probe 11 is moving in the Y-direction back side (upward in FIG. 2) inside the joint mortar 4 .
However, when the tip 13 of the probe 11 enters the gap inside the joint mortar 4, the resistance force applied to the tip 13 of the probe 11 decreases (below the specified value).
A load cell 22 successively detects a change in the resisting force according to the presence or absence of voids in the joint mortar 4 . Based on the detection result of the load cell 22 (that is, change in resistance), it is determined whether or not there is a gap.

At this time, the processing device 30 may perform the above-described insertion amount adjustment and determination.
Specifically, for example, the processing device 30 controls the actuator 15 to move the probe 11 forward and backward along the Y direction to adjust the amount of insertion. The processing device 30 specifies the insertion amount of the tip 13 of the probe 11 each time the actuator 15 moves the probe 11 along the Y direction.
A detection result (change in resistance) of the load cell 22 is output to the processor 30 . The processing device 30 determines that there is a gap at the position of the tip 13 of the probe 11 at that time when the resistance becomes equal to or less than the specified value.

In this way, by detecting a change in the resistance in association with the amount of insertion of the tip 13 of the probe 11, it is possible to determine whether or not there is a gap in the Y direction.

After that, the air gap inspection device 10 is moved along the X direction, and the same operation as described above is repeated while changing the position of the tip 13 of the probe 11 to a plurality of positions in the X direction.
At this time, by specifying the position of the tip 13 of the probe 11 in the X direction, it is possible to inspect whether there is a gap in each of the X direction and the Y direction. Additionally, the location, shape and size of the voids can be determined.
A method for identifying the positions of voids existing inside the joint mortar 4 will be described with reference to FIGS. 3 to 5. FIG.

FIG. 3 is an XY cross section of the joint mortar 4. As shown in FIG. A void W exists inside the joint mortar 4 shown in FIG.
At each position in the X direction (Position A, Position B and Position C in FIG. 3), the tip 13 of the probe 11 is inserted into the joint mortar 4 and moved along the Y direction. Along with this, the resistance force that the tip 13 of the probe 11 receives changes.

FIGS. 4A, 4B and 4C are graphs showing the resistance forces experienced by tip 13 of probe 11 at positions A, B and C of FIG. 3, respectively.
In FIGS. 4A to 4C, the horizontal axis represents the amount of insertion of the tip 13 of the probe 11 in the Y direction (unit: "mm", etc.). The vertical axis indicates the resistance force F received by the tip 13 of the probe 11 .
As shown in FIGS. 4A to 4C, when the tip 13 of the probe 11 enters the gap W, the resistive force F sharply decreases to a specified value _TF or less. When the tip 13 of the probe 11 exits the gap W and enters the joint mortar 4 again, the resistance F increases and exceeds the specified value _TF . By visualizing such a tendency, the range of the gap W (that is, the edge of the gap W) can be specified.

At each of a plurality of inspection positions (including positions A, B, and C in FIG. 3) set at a constant pitch ΔX along the X direction, changes in resistance are detected in the above-described procedure.
The accuracy of specifying the position of the gap W depends on the pitch ΔX. As ΔX is made smaller, accuracy improves, but inspection takes longer. Therefore, in actual operation, for example, it is preferable to determine in advance the minimum size of the void to be detected, and set ΔX accordingly.

The amount of insertion (the position of the tip 13 of the probe 11 in the Y direction) when the resistance becomes equal to or less than a specified value is recorded as the resistance changes at each inspection position in the X direction.
The recorded insertion amount is plotted in correspondence with each inspection position on the XY plane, and a curve passing through each plot is drawn. Thereby, as shown in FIG. 5 described later, the position, shape and size of the gap W can be represented as a mapping image.

FIG. 5 is a mapping image of the gap W. FIG. In FIG. 5, the three axes perpendicular to each other indicate the position in the X direction, the position in the Y direction, and the resistance force F, respectively.
In FIG. 5, changes in the resistance force F at positions A, B, and C in FIG.

A mapping image of the gap W is displayed on the monitor 16 .
By looking at the mapping image of the gap W displayed on the monitor 16, the inspector can notice the presence of the gap W inside the joint mortar 4, and further grasp the position, shape and size of the gap W.

At this time, specifically, for example, the processing device 30 creates a mapping image of the gap and causes the monitor 16 to display the created mapping image.
The processing device 30 analyzes the mapping image of the gap W, calculates the area of the gap W, and further calculates the ratio of the area of the gap W to the cross-sectional area of the target joint 2 (the area of the XY cross section). good too.
For example, when this ratio exceeds a threshold, it can be determined that the construction is defective. In addition, it may be determined that the construction is defective simply when the area of the gap W exceeds a predetermined value or when the gap W penetrates the joint mortar 4 .
The processing device 30 may make this determination and further display the determination result on the monitor 16 together with the mapping image. At this time, for example, it may be displayed on the monitor 16 that the bricks need to be restacked due to poor construction.

If a gap is found in the gap inspection and it is determined that the construction is defective, the bricks piled up immediately before will be removed, and the mortar will be applied again and the bricks will be restacked.

[Second embodiment]
Next, a second embodiment will be described based on FIG. The same reference numerals are given to the same parts as those shown in the first embodiment, and the description thereof is omitted.
FIG. 6 is a perspective view showing the air gap inspection device 10 of the second embodiment.
In the second embodiment, as shown in FIG. 6, multiple probes 11 are arranged at regular intervals along the X direction. Therefore, the position of the tip 13 of each probe 11 in the X direction can be identified. The processing device 30 may memorize the distance between the probes 11 . Then, the tip 13 of each probe 11 is inserted into the joint mortar 4, and the resistance is detected.
The number of probes 11 is not particularly limited as long as it is two or more. For example, an actuator 15 is provided for each of the plurality of probes 11 and each actuator 15 moves the corresponding probe 11 .

[Third embodiment]
Next, a third embodiment will be described based on FIG. The same reference numerals are given to the same parts as those shown in the first embodiment, and the description thereof is omitted.
FIG. 7 is a perspective view showing the air gap inspection device 10 of the third embodiment.
In the third embodiment, as shown in FIG. 7, a wheel 41 having a rotary encoder is attached to an apparatus main body 10H.
The wheels 41 rotate while being in contact with the furnace wall 9 when the apparatus main body 10H is conveyed along the X direction. A rotary encoder mounted on the wheel 41 outputs a signal according to the amount of rotation of the wheel 41 . Specifically, for example, a pulse signal is output each time the wheel 41 rotates by a predetermined amount.
For example, the processing device 30 identifies the position of the probe 11 in the X direction based on the signal output by the rotary encoder.
Each time the probe 11 is transported from one inspection position (for example, position A in FIG. 3) to the next inspection position (for example, position B in FIG. 3) along the X direction, the procedure described above The post-transfer position of the probe 11 in the X direction is specified.

[Fourth embodiment]
Next, a fourth embodiment will be described based on FIG. The same reference numerals are given to the same parts as those shown in the first embodiment, and the description thereof is omitted.
FIG. 8 is a perspective view showing the air gap inspection device 10 of the fourth embodiment.
In the fourth embodiment, an indoor GPS (iGPS: Indoor Global Positioning System) is used. More specifically, an iGPS position sensor 42 is mounted on the device body 10H.
The position sensor 42 has an antenna (not shown) and receives a signal (radio signal) periodically transmitted from the base station 43 . Upon receiving the radio signal from the base station 43, the position sensor 42 specifies its own three-dimensional position based on the received signal, and outputs a signal corresponding to the specified three-dimensional position.
Based on the output signal of the position sensor 42, for example, the processing device 30 identifies the three-dimensional position of the device main body 10H (that is, the position in each of the XYZ directions), and uses the identification result to move the probe 11 in the X direction. Identify the location of

According to the embodiment described above, the presence or absence of voids inside the joint mortar 4 can be easily and appropriately inspected.

In the above-described embodiment, the apparatus body 10H is transported by an inspector (that is, manually), but the present invention is not limited to this.
For example, the device body 10H may be transported by a robot or self-propelled mechanism.
The device main body 10H may be mounted on an unmanned aerial vehicle such as a drone, and the device main body 10H may be transported by remotely operating the unmanned aerial vehicle.

2: Target joint 4: Joint mortar 8: Brick (building material)
9: Furnace wall 10: Gap inspection device 10H: Device body 11: Probe 13: Probe tip 15: Actuator (moving part)
16: Monitor 22: Load cell (detector)
26: Positioning unit 30: Processing device (determining unit)
41: Wheel 42: Position sensor 43: Base station W: Air gap

Claims (7)

A void inspection device for inspecting the presence or absence of voids inside mortar filled in joints of construction materials arranged side by side,
a probe inserted into the mortar;
a moving unit that moves the probe in a direction in which it is inserted into the mortar;
and a detection unit for detecting a resistance force received when the tip of the probe moves inside the mortar in the direction in which the probe is inserted into the mortar at the position where the probe is inserted . A determination unit that determines the presence or absence of the void based on the resistance detected by the detection unit,
2. The gap inspection apparatus according to claim 1, wherein when said resistance becomes equal to or less than a specified value, said determination unit determines that said gap exists at the position of the tip of said probe at that time. A void inspection method for inspecting the presence or absence of voids inside mortar filled in joints of construction materials arranged side by side,
Insert the probe into the mortar,
moving the probe in the direction in which it is inserted into the mortar;
A void inspection method , wherein, at a position where the probe is inserted, a resistance force received when the tip of the probe moves inside the mortar in a direction in which it is inserted into the mortar is detected. 4. The gap inspection method according to claim 3, wherein when the resistance becomes equal to or less than a specified value, it is determined that the gap exists at the position of the tip of the probe at that time. A method of manufacturing a structure by arranging construction materials side by side, comprising:
When joints are formed by arranging the construction materials, the mortar filled in the joints is inspected for the presence or absence of voids according to the method according to claim 3 or 4 each time. Production method. The construction material is a brick,
6. The method of manufacturing a structure according to claim 5, wherein said structure is a furnace having a furnace wall formed by arranging said bricks side by side. 7. The method of manufacturing a structure according to claim 6, wherein said oven is a coke oven.

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