Inspection tool and method for positioning and removing obstacles from channel

Abstract

Inspection tools and methods of inspecting and maintaining the interior of a ventilated gas manifold channel are described. Magnetic coupling probes (e.g., spheres, cylinders, rectangular cubes, or discs) are inserted inside the ventilation gas manifold channels. The magnetic coupling head then magnetically drags the magnetic coupling probe through the passage of the ventilation gas manifold. The inspection tool uses a sensor to monitor the position of the magnetically coupled probe inside the channel. If an obstacle is encountered, the sensor monitors local changes in one or more physical or electrical properties of the inspection tool and alerts the operator. The magnetically coupled probe may be a steel scooping member having a sharp leading edge that separates and scoops obstacles. A programmed robotic arm or manual operator may move the head across a surface of the ventilation gas manifold parallel to the channels.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to inspection tools and methods for inspecting channels for obstructions located inside the channels and removing them after identification. In particular, the present disclosure relates to the inspection of vent gas manifold channels in electric vehicle battery packs. BACKGROUND

[0002] Electric vehicle battery packs are constructed of multiple battery cells stacked in an array and encapsulated in a structure that firmly secures the batteries in place. The battery packs can have a vent gas manifold system (e.g., a series of parallel channels). Some of these battery packs can also be filled with a polymer (e.g., silicone or polyurethane). SUMMARY

[0003] The present disclosure describes inspection tools and methods for inspecting and maintaining the interior of vent gas manifold channels. A magnetically coupled probe (e.g., a ferrous steel or magnetic sphere, cylinder, rectangular cube, or disc) is inserted into the interior of a vent gas manifold channel. Subsequently, an external magnetically coupled head is used to magnetically drag the magnetically coupled probe through the channel of the vent gas manifold. The inspection tool uses a sensor to monitor the position of the magnetically coupled probe inside the channel. If an obstruction is encountered, the sensor monitors a local change in one or more physical, electrical, or magnetic properties of the inspection tool and alerts an operator of the obstruction. The magnetically coupled probe can include a steel bucket with upper and lower sharp leading edges that cut, separate, and scoop up the obstruction, which can be removed by removing the steel bucket from the channel. A human operator or a programmed robotic arm can move the magnetically coupled head across the surface of the vent gas manifold in a direction parallel to the channel.

[0004] In a first example, an inspection tool kit can include: a magnetically coupled probe sized to fit within a channel and slide along the channel; an inspection tool including a magnetically coupled head disposed outside the channel; and a sensor attached to or disposed within the magnetically coupled head; wherein the sensor is configured to detect when the magnetically coupled probe encounters an obstruction located inside the channel; and wherein the magnetically coupled head and the magnetically coupled probe are magnetically coupled together to form a magnetically coupled probe / head pair having a magnetic strength strong enough to drag the probe inside the channel when the head is moved outside the channel.

[0005] In another example, the inspection tool kit can also include: a shaft attached to the magnetically coupled head and the sensor, disposed between the magnetically coupled head and the sensor; and wherein the sensor is configured to sense an increase in lateral force, torque, and / or lateral deflection of the shaft when the magnetically coupled probe encounters an obstruction located inside the channel.

[0006] In another example, the sensor can sense: (a) a change in capacitance of the magnetically coupled probe, and / or (b) a change in inductance of an electromagnet disposed inside the magnetically coupled head, when the magnetically coupled probe encounters an obstruction.

[0007] In another example, the inspection tool can be attached to and operated by a robotic manipulator arm; or operated by a human operator.

[0008] In another example, the vent gas manifold channel can be disposed within a battery vent gas manifold system of an electric vehicle.

[0009] In another example, a method of inspecting a channel using an inspection tool can include: (a) providing an inspection tool, the inspection tool including: a magnetically coupled probe sized to fit within and slide along the channel; an inspection tool including a head disposed outside the channel; and a sensor attached to or disposed within the head; wherein the sensor is configured to detect when the magnetically coupled probe encounters an obstruction located inside the channel; and wherein the head and the magnetically coupled probe are magnetically coupled together to form a magnetically coupled probe / head pair coupled together with a magnetic strength strong enough to drag the probe inside the channel when the head is moved outside the channel; then, (b) inserting the magnetically coupled probe into the channel; then, (c) placing the magnetically coupled head proximate to the channel and sliding the magnet or electromagnet along the channel, thereby exerting an external magnetic field that drags the magnetically coupled probe along the channel; then, (d) using the sensor to detect one or more changes in physical, electrical, and / or magnetic properties of the inspection tool when the magnetically coupled probe encounters an obstruction; and then, (e) alerting a human operator that an obstruction has been detected.

[0010] In another example, the method can further include: applying a physical map or projecting a video display to an exterior surface of the battery pack showing locations of internal channels disposed within the battery pack, and using the map or display to guide a human operator to move the magnetically coupled probe along the channel.

[0011] In another example, the inspection tool can further include a shaft attached to the magnetically coupled head; and the method can further include measuring lateral force, torque, and / or lateral deflection of the shaft produced when the magnetically coupled probe encounters an obstruction located inside the channel.

[0012] In another example, the method can further include using the sensor to measure: (a) a change in capacitance of the magnetically coupled probe / head pair, and / or (b) a change in inductance of an electromagnet disposed within the magnetically coupled head, when an obstruction is encountered.

[0013] In another example, the inspection tool can be attached to a robotic operating arm; and the method further comprises using the robotic operating arm to move the inspection tool and the magnetic coupling probe along the passageway.

[0014] In another example, the method can further comprise: (f) removing the obstruction from the passageway after the magnetic coupling probe has located the obstruction; and (g) removing the magnetic coupling probe from the passageway after the inspection is completed.

[0015] In another example, the method can further comprise retaining the magnetic coupling probe at one end of the passageway after the inspection is completed.

[0016] In another example, the magnetic coupling probe can comprise ferrous steel or a magnet; and wherein the magnetic coupling head can comprise ferrous steel or a magnet.

[0017] In another example, removing the obstruction in step (f) can comprise: (1) magnetically moving a magnetic coupling scoop disposed inside the passageway using the magnetic coupling head, wherein the magnetic coupling scoop comprises an upper portion and a lower sharp leading edge; (2) cutting and creating the separated obstruction by pushing the magnetic coupling scoop forward into and through the obstruction, thereby cutting and separating the obstruction from the walls of the passageway; (3) retaining the separated obstruction in the magnetic coupling scoop; and subsequently, (4) removing the magnetic coupling scoop with the separated obstruction retained inside it from the passageway.

[0018] In another example, the method can further comprise: after step (2), vacuuming the separated obstruction using a vacuum tube attached to a rear end of the magnetic coupling scoop; thereby removing the separated obstruction from the passageway.

[0019] In another example, the method can further comprise: using a plurality of fixed or rotating blades; or a pair of snipper jaws, or a plurality of rotating gears that cut or grind the obstruction into a plurality of small individual pieces.

[0020] In another example, the passageway can be disposed within a battery ventilation manifold system of an electric vehicle.

[0021] In another example, the method can further comprise retaining the magnetic coupling probe at an end of the passageway after the inspection is completed comprises using a pair of arms to rotate a one-way turning post that grabs and captures the magnetic coupling probe at the end of the passageway.

[0022] In another example, the method can further comprise retaining the magnetic coupling probe at an end of the passageway after the inspection is completed comprises using a permanent magnet disposed at the end of the passageway to grab and retain the magnetic coupling probe at the end of the passageway.

[0023] In another example, a method of inspecting a passageway using an inspection tool can include: (a) providing an inspection tool kit including: a magnetically coupled probe sized to fit within and slide along the passageway; an inspection tool including a magnetically coupled head disposed outside the passageway; and a sensor attached to or disposed within the magnetically coupled head; wherein the sensor is configured to detect when the magnetically coupled probe encounters an obstruction located inside the passageway; and wherein the magnetically coupled head and the magnetically coupled probe magnetically couple together to form a magnetically coupled probe / head pair having a magnetic strength strong enough to drag the magnetically coupled probe inside the passageway when the magnetically coupled head is moved outside the passageway, followed by: (b) inserting the magnetically coupled probe into the passageway; followed by (c) placing the magnetically coupled head proximate the passageway and sliding the magnetically coupled head along the passageway, thereby dragging the magnetically coupled probe along the passageway, followed by: (d) using the sensor to detect one or more changes in physical, electrical, and / or magnetic properties of the inspection tool when the magnetically coupled probe encounters the obstruction; and followed by, (e) alerting a human operator that the obstruction has been located; wherein the inspection tool further includes a shaft attached to the magnet or electromagnet; wherein the method further includes measuring the lateral force, torque, and / or lateral deflection of the shaft generated when the magnetically coupled probe encounters the obstruction; wherein the inspection tool is attached to a robotic operating arm; and wherein the method further includes using the robotic operating arm to move the inspection tool and the magnetically coupled probe along the length of the passageway. Scheme 1. An inspection tool kit, comprising: a magnetically coupled probe sized to fit within and slide along the passageway; an inspection tool including a magnetically coupled head disposed outside the passageway; and a sensor attached to or disposed within the magnetically coupled head; wherein the sensor is configured to detect when the magnetically coupled probe encounters an obstruction located inside the passageway; and wherein the magnetically coupled head and the magnetically coupled probe magnetically couple together to form a magnetically coupled probe / head pair having a magnetic strength strong enough to drag the magnetically coupled probe inside the passageway when the magnetically coupled head is moved outside the passageway. Scheme 2. The inspection tool kit of Scheme 1, further comprising: a shaft attached to the head and the sensor, disposed between the head and the sensor; and wherein the sensor is configured to sense an increase in lateral force, torque, and / or lateral deflection of the shaft when the magnetically coupled probe encounters the obstruction located inside the passageway. Scheme 3. The inspection tool kit of Scheme 1, wherein the sensor senses: an increase in the magnetic field strength of the magnetically coupled probe / head pair when the magnetically coupled probe encounters the obstruction. (a) a change in capacitance of the magnetically coupled probe / head pair, and / or (b) a change in inductance of an electromagnet disposed inside the magnetically coupled head. Scheme 4. The inspection tool kit of Scheme 1, wherein the inspection tool is attached to and operated by a robotic manipulator arm; or is operated by a human operator. Scheme 5. The inspection tool kit of Scheme 1, wherein the passageway is disposed within a battery ventilation gas manifold system of an electric vehicle. Scheme 6. A method of inspecting a passageway using an inspection tool kit, the method comprising: (a) providing an inspection tool kit, the inspection tool kit comprising: a magnetically coupled probe sized to fit within and slide along the passageway; an inspection tool comprising a magnetically coupled head disposed outside the passageway; and a sensor attached to or disposed within the magnetically coupled head; wherein the sensor is configured to detect when the magnetically coupled probe encounters an obstruction located inside the passageway; and wherein the magnetically coupled head and the magnetically coupled probe are magnetically coupled together to form a magnetically coupled probe / head pair having a magnetic strength strong enough to drag the magnetically coupled probe inside the passageway when the magnetically coupled head is moved outside the passageway; (b) inserting the magnetically coupled probe into the passageway; (c) placing the magnetically coupled head proximate to the passageway and sliding the magnetically coupled head along the passageway, thereby dragging the magnetically coupled probe along the passageway; (d) using the sensor to detect a change in one or more of the physical, electrical, and / or magnetic properties of the inspection tool when the magnetically coupled probe encounters the obstruction; and (e) alerting a computer or a human operator that the obstruction has been detected. Scheme 7. The method of Scheme 6, further comprising: applying a physical map or projecting a video display to an exterior surface of the battery pack showing the location of the internal passageway disposed within the battery pack, and using the map or display to guide a human operator to move the magnetically coupled probe along the passageway. Scheme 8. The method of Scheme 6, wherein the inspection tool further comprises a shaft attached to the magnetically coupled head; and wherein the method further comprises measuring the lateral force, torque, and / or lateral deflection of the shaft produced when the magnetically coupled probe encounters the obstruction located inside the passageway. Scheme 9. The method of Scheme 6, further comprising using the sensor to measure: the lateral force, torque, and / or lateral deflection of the shaft produced when the magnetically coupled probe encounters the obstruction, (a) a change in capacitance of the magnetically coupled probe / head pair; and / or (b) a change in inductance of an electromagnet disposed within the magnetically coupled head. Scheme 10. The method of Scheme 6, wherein the inspection tool is attached to the robotic manipulator arm; and wherein the method further comprises using the robotic manipulator arm to move the inspection tool and the magnetically coupled probe along the passageway. Scheme 11. The method of Scheme 6, further comprising: (f) removing the obstruction from the passageway after the magnetically coupled probe has located the obstruction; and (g) removing the magnetically coupled probe from the passageway after the inspection is complete. Scheme 12. The method of Scheme 11, wherein the magnetically coupled probe comprises ferrous steel or a magnet; and wherein the magnetically coupled head comprises ferrous steel or a magnet. Scheme 13. The method of Scheme 11, further comprising retaining or capturing the magnetically coupled probe at one end of the passageway after the inspection is complete. Scheme 14. The method of Scheme 11, wherein removing the obstruction in step (f) comprises: (1) magnetically moving a magnetically coupled scoop disposed inside the passageway using the magnetically coupled head, wherein the magnetically coupled scoop comprises an upper and lower sharp leading edge; (2) severing and separating the obstruction from the walls of the passageway by pushing the magnetically coupled scoop forward into and past the obstruction, thereby severing and creating a separated obstruction; (3) retaining the separated obstruction in the magnetically coupled scoop; and (4) removing the magnetically coupled scoop with the separated obstruction retained inside it from the passageway. Scheme 15. The method of Scheme 14, further comprising: vacuuming the separated obstruction after step (2) using a vacuum tube attached to a rear end of the magnetically coupled scoop; thereby removing the separated obstruction from the passageway. Scheme 16. The method of Scheme 14, further comprising: using a plurality of fixed or rotating blades; or a pair of shears, or a plurality of rotating gears that cut or grind the obstruction into a plurality of small individual pieces. Scheme 17. The method of Scheme 14, wherein the passageway is disposed within a battery ventilation manifold system of an electric vehicle. Scheme 18. The method of Scheme 13, wherein retaining the magnetically coupled probe at the end of the passageway after the inspection is complete comprises: using a pair of arms to rotate a one-way turning post that grabs and captures the magnetically coupled probe at the end of the passageway. Scheme 19. The method according to Scheme 13, wherein the sensor comprises an ultrasonic sensor or a Hall magnetic sensor. Scheme 20. A method of inspecting a passageway using an inspection tool kit, the method comprising: (a) providing an inspection tool kit, the inspection tool kit comprising: a magnetically coupled probe sized to fit within the passageway and slide along the passageway; an inspection tool comprising a magnetically coupled head disposed outside the passageway; and a sensor attached to or disposed within the magnetically coupled head; wherein the sensor is configured to detect when the magnetically coupled probe encounters an obstruction located inside the passageway; and wherein the magnetically coupled head and the magnetically coupled probe magnetically couple together to form a magnetically coupled probe / head pair having a magnetic strength strong enough to drag the magnetically coupled probe inside the passageway when the magnetically coupled head is moved outside the passageway; (b) inserting the magnetically coupled probe into the passageway; (c) placing the magnetically coupled head proximate to the passageway and sliding the magnetically coupled head along the passageway, thereby dragging the magnetically coupled probe along the passageway; (d) using the sensor to detect a change in one or more of the physical, electrical, and / or magnetic properties of the inspection tool when the magnetically coupled probe encounters the obstruction; and (e) alerting a computer or human operator that the obstruction has been located; wherein the inspection tool further comprises a shaft attached to the magnetically coupled head; wherein the method further comprises measuring the lateral force, torque, and / or lateral deflection of the shaft produced when the magnetically coupled probe encounters the obstruction; wherein the inspection tool is attached to a robotic manipulator arm; and wherein the method further comprises using the robotic manipulator arm to move the inspection tool and the magnetically coupled probe along the length of the passageway. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 shows a schematic elevation view of an example of a battery pack according to the present disclosure, with 3 parallel vent gas manifold passageways.

[0025] Figure 2A shows a schematic elevation view of an example of an inspection tool and probe according to the present disclosure, inspecting a vent gas manifold passageway.

[0026] Figure 2BA schematic elevation view showing an example of an inspection tool and probe according to the present disclosure, inspecting a vent gas manifold channel and encountering an obstruction.

[0027] Figure 3A A schematic plan view showing an example of a pair of vent gas manifold channels according to the present disclosure, with a magnetically coupled probe and a borescope hole through the side wall at the end of the channel.

[0028] Figure 3B A schematic plan view showing an example of a vent gas manifold channel according to the present disclosure, with a magnetically coupled probe removed and a borescope hole plugged.

[0029] Figure 4 A schematic plan view showing an example of a vent gas manifold according to the present disclosure, with multiple interconnected parallel channels and a magnetically coupled probe.

[0030] Figure 5A A schematic plan view showing an example of a vent gas manifold channel according to the present disclosure, with a magnetically coupled probe and a turn-style mechanism serving as a capture.

[0031] Figure 5B A schematic plan view showing an example of a vent gas manifold channel according to the present disclosure, with a magnetically coupled probe and a turn-style mechanism rotated to a capture position.

[0032] Figure 6A A schematic plan view showing an example of a vent gas manifold channel according to the present disclosure, with a magnetically coupled probe and a magnet at the end of the channel.

[0033] Figure 6B A schematic plan view showing an example of a vent gas manifold channel according to the present disclosure, with a magnetically coupled probe attached to a magnet at the end of the channel.

[0034] Figure 7A A schematic elevation view showing an example of a cylindrical magnet and a spherical probe according to the present disclosure.

[0035] Figure 7B A schematic elevation view showing an example of a cylindrical magnet and a cylindrical probe according to the present disclosure.

[0036] Figure 7C A schematic elevation view showing an example of a horseshoe magnet and a cylindrical probe according to the present disclosure.

[0037] Figure 7D A schematic elevation view showing an example of a cylindrical magnet and a disc-shaped probe according to the present disclosure.

[0038] Figure 7E A schematic perspective view showing an example of a cylindrical magnet and a scoop-shaped probe according to the present disclosure.

[0039] Figure 8A Schematic elevational cross-sectional view showing an example of three battery cells and a ventilation gas manifold channel with an obstruction inside the channel according to the present disclosure.

[0040] Figure 8B Schematic elevational cross-sectional view showing an example of three battery cells and a ventilation gas manifold channel with an obstruction inside the channel according to the present disclosure.

[0041] Figure 9 Schematic elevational cross-sectional view showing an example of three battery cells and a ventilation gas manifold channel with an obstruction inside the channel according to the present disclosure.

[0042] Figure 10 Schematic elevational cross-sectional view showing an example of three battery cells and a ventilation gas manifold channel with an obstruction inside the channel according to the present disclosure.

[0043] Figure 11 Schematic elevational cross-sectional view showing an example of three battery cells and a ventilation gas manifold channel with an obstruction inside the channel according to the present disclosure.

[0044] Figure 12A A schematic plan view showing an example of a magnetically coupled disk according to the present disclosure, with four spherical rollers disposed beneath the disk.

[0045] Figure 12B Shown is a front cross-sectional view of an example of a magnetically coupled disk according to the present disclosure, with four spherical rollers disposed beneath the disk.

[0046] Figure 13 An example of a process flow diagram is shown illustrating a method of inspecting ventilation gas manifold passages.

[0047] Figure 14 Schematic elevational cross-sectional view showing an example of three battery cells and a ventilation gas manifold channel with an obstruction and a laser positioned inside the channel according to the present disclosure.

[0048] Figure 15 A schematic elevational cross-sectional view of an example of three battery cells and a ventilation gas manifold channel according to the present disclosure is shown with an obstruction and a borescope with a scissor head positioned inside the channel. DETAILED DESCRIPTION

[0049] The present disclosure describes an inspection tool and method for inspecting and maintaining the interior of a plenum gas manifold channel. A ferrous or magnetic probe (e.g., a steel sphere, cylinder, rectangular cube, or disc) is inserted into the interior of a plenum gas manifold channel. An external magnetic field from a magnetic coupling head is then used to magnetically drag the probe through the channel of the plenum gas manifold. The inspection tool uses a sensor to monitor the position of the magnetically coupled probe inside the channel. If an obstruction is encountered, the sensor monitors local changes in one or more physical, electrical, or magnetic properties of the inspection tool and alerts an operator of the obstruction. The magnetically coupled probe can be a steel spade piece with upper and lower sharp leading edges that cut, separate, and spade up the obstruction, which can be removed by removing the magnetically coupled spade piece from the channel. A human operator or a programmed robotic manipulator arm can move the magnetic coupling head in a direction parallel to the channel across the surface of the plenum gas manifold.

[0050] As used herein, the term "magnet" can include a permanent magnet, an electromagnet, or a combination thereof.

[0051] Figure 1 A schematic elevation view showing an example of a battery pack 4 according to the present disclosure, with 3 parallel plenum gas manifold channels 20, 20' and 20". Passages 8, 8' and 8" fluidly communicate plenum gas from battery cells 60, 60' and 60" to respective plenum gas manifold channels 20, 20' and 20". Potting layers (e.g., silicone or polyurethane) 34, 34', 34", 34"' and 35 surround and support respective battery cells 20, 20' and 20". A horizontal cell support tray 64 is disposed above and across battery cells 20, 20' and 20". A lower wall 24 extends horizontally across the bottom of plenum gas manifold channels 20, 20' and 20". A TP tray 22 is disposed horizontally across an upper portion of plenum gas manifold channels 20, 20' and 20". An upper shear plate 68 is disposed horizontally above TP tray 22, with a potting layer 66 disposed between TP tray 22 and horizontal upper shear plate 68.

[0052] Figure 2A A schematic elevation view showing an example of an inspection tool 15 and magnetically coupled probe 28 according to the present disclosure, which inspects plenum gas manifold channel 20. Inspection tool 15 includes a magnetically coupled head 10 that can be attached to a shaft 12. Shaft 12 is attached to a sensor 14. Sensor 14 can be optionally attached to a robotic manipulator arm 18 via a rotatable joint 16. Alternatively, sensor 14 can be handheld and guided by a human operator (not shown), who can follow a visually illustrated path disposed on a holding battery pack (see Figure 1template of the location of the parallel vent gas manifold channel within the structure. The inspection tool 15 can include electronic and visual and / or audio alarm means (not shown) for alarming a human operator or for wireless alarming a monitoring computer that an obstruction has been detected. The sensor 14 can be disposed inside the magnetically coupled head 10.

[0053] Still referring to Figure 1 , the magnetically coupled probe 28 is inserted inside the vent gas manifold channel 20 where it is pulled upward by magnetic attraction against the upper channel wall 22. The channel wall 22 can be made of a non-magnetic material (e.g., polymer or aluminum). The magnetically coupled probe 28 can be made of ferrous material, steel, mild steel, or a magnet. The magnetically coupled head 10 can be a magnet, in which case the magnetically coupled probe 28 can be a ferrous steel part or a magnet. Alternatively, the magnetically coupled head 10 can be a ferrous steel part, in which case the magnetically coupled probe 28 is a magnet. In all of these options, the magnetically coupled head 10 and the magnetically coupled probe 28 are magnetically coupled together to form a magnetically coupled probe / head pair. The lateral movement inspection tool 15 causes the magnetically coupled probe 28 to be laterally dragged inside the channel 20. The obstruction 26 can be a blob of fill compound that has intruded into the channel 20 at a small opening or hole (not shown) in the upper channel wall 22. In Figure 2A , the magnetically coupled probe 28 has not yet encountered the obstruction 26. The magnetically coupled probe 28 can have the shape of a sphere, a cylinder, a rectangular cube, a disc, or a U-shaped scoop.

[0054] Figure 2B A schematic elevation view showing an example of the inspection tool 15 and the magnetically coupled probe 28 according to the present disclosure, inspecting the vent gas manifold channel 20 and encountering the obstruction 26. In this figure, the magnetically coupled probe 28 has contacted the obstruction 26, which causes the magnetically coupled probe 28 to be displaced downward by a distance = d from the top of the channel 20. This causes the magnetically coupled probe 28 to be offset horizontally by a distance = X from the magnetically coupled head 10, which in turn increases the angle q of the magnetic field lines (shown as dashed lines). The increase in the angle q of the magnetic field lines and / or the displacement (d, X) of the magnetically coupled probe 28 from its normal (un-deflected) position can be sensed by the sensor 14 in different physical or electrical ways. In one example, a strain gauge 17 can be mounted vertically on one side of the shaft 12 that responds to the bending of the shaft 12 when a lateral magnetic force F is applied due to encountering the obstruction 26. The force F or the bending moment (torque, T) can be calculated by the sensor 14 and the strain gauge 17. A step increase in this force F indicates that the magnetically coupled probe 28 has contacted the obstruction 26.

[0055] In another example, the magnetic coupling head 10 can include a capacitive sensor that monitors the capacitance of the separation between the magnetic coupling probe 28 and the magnetic coupling head 10. The capacitance of the inspection tool 15 increases in a stepwise manner as the distance d and the step increase in X increase when the magnetic coupling probe 28 comes into contact with the obstacle 26. In another example, the inductance of the magnetic coupling head 10 can be monitored for a sudden change in inductance when an obstacle 26 is encountered. In another example, a magnetic field sensor (e.g., a Hall sensor) can be used to monitor the change in magnetic strength and direction (angle, q) when an obstacle 26 is encountered. In another example, the magnetic coupling head 10 can include an ultrasonic sensor that monitors the separation distance (d, x) between the magnetic coupling probe 28 and the magnetic coupling head 10 when an obstacle 26 is encountered. In a final example, the magnetic coupling head 10 can include an eddy current sensor that monitors the change in eddy currents when an obstacle 26 is encountered due to the change in separation distance (d, x) between the magnetic coupling probe 28 and the magnetic coupling head 10.

[0056] Figure 3A A schematic plan view showing an example of a pair of vent gas manifold channels 20 and 20' according to the present disclosure, with a magnetic coupling probe 28 and a borescope hole 32 through the sidewall 30 at the end of the channel 20. The purpose of the borescope hole (which can be any type of hole) is to allow the magnetic coupling probe 28 to be removed from the vent gas manifold channel 20 after the inspection is complete.

[0057] Figure 3B A schematic plan view showing an example of a vent gas manifold channel 20 according to the present disclosure, with the magnetic coupling probe 28 removed and the borescope hole 32 sealed using a plug 40. After the magnetic coupling probe 28 is removed from the channel 20, the hole 32 is plugged using the plug 40.

[0058] Figure 4A schematic plan view showing an example of a vent gas manifold 42 according to the present disclosure, with multiple interconnected parallel channels 20, 20', 20", etc. and a magnetically coupled probe 28. The magnetically coupled probe 28 enters at a corner of the vent gas manifold 42 and is remotely (magnetically) dragged by moving the inspection tool 15 (not shown) along the length of the interconnected vent gas manifold channels 20, 20', 20", etc. to search / probe for one or more obstructions (not shown) that can be located inside the channels 20, 20', 20", etc. The multiple vent gas manifold channels 20, 20', 20", etc. form a serpentine pattern of interconnected paths 44 that are separated by multiple parallel interior walls 34, 34', etc. When the magnetically coupled probe 28 reaches the end of the interconnected channels 20, 20', 20", etc. it can be (1) removed through a temporary hole or opening in the side wall of the vent gas manifold 42 (the hole is subsequently plugged), or (2) captured / grabbed / retained / maintained inside the manifold 42 by a catch 46. The catch 46 can include, for example, a flipper mechanism (see Figure 5A and 5B ). Alternatively, the catch 46 can include a permanent magnet (see Figure 6A and 6B ). Alternatively, the catch 46 can include a sticky adhesive board (not shown).

[0059] Figure 5A A schematic plan view showing an example of a vent gas manifold channel 20 according to the present disclosure, with a magnetically coupled probe 28 and a flipper mechanism 48 that is used as a catch 46. The flipper mechanism 48 includes first and second short arms (i.e., flippers) 50 and 52 that are disposed at right angles to each other, the short arms being attached to a rotatable vertical post 48. In Figure 5A , the magnetically coupled probe 28 is magnetically coupled against the second arm 52.

[0060] Figure 5B A schematic plan view showing an example of a vent gas manifold channel 20 according to the present disclosure, with a magnetically coupled probe 28 and a flipper mechanism 48 that is rotated to a grab position. Here, the rotatable post 48 is rotated 90 degrees counterclockwise, which causes the first arm 50 to capture and retain the magnetically coupled probe 28 between the first arm 50 and the second arm 52, and against the divider 34 and the lower wall segment 37 (thus forming a box-shaped catch).

[0061] Figure 6A A schematic plan view showing an example of a vent gas manifold channel 201 according to the present disclosure, with a magnetically coupled probe 28 and a magnet 54 at the end of the channel. The magnetically coupled probe 28 is dragged toward the magnet 54 at the end of the channel 20.

[0062] Figure 6BA schematic plan view showing an example of a vent gas manifold channel 20 according to the present disclosure, with a magnetic coupling probe 28 attached to a magnet 54 at an end of the channel 20. The magnet 54 captures the magnetic coupling probe 28 at the end of the channel 20.

[0063] Figure 7A A schematic front view showing an example of a cylindrical magnetic coupling head 10 and a spherical magnetic coupling probe 28 according to the present disclosure. The magnetic coupling head 10 can be made of a rare earth magnetic material, Ferrite, or other magnetic material (e.g. NdFe 35 ). The magnetic coupling probe 28 can be made of steel, mild steel, or a magnet. In this configuration, the magnetic force can be approximately equal to 7 N.

[0064] Figure 7B A schematic front view showing an example of a cylindrical magnetic coupling head 10 and a cylindrical magnetic coupling probe 28 according to the present disclosure. The magnetic coupling head 10 can be made of a rare earth magnetic material, Ferrite, or other magnetic material (e.g. NdFe 35 ). The magnetic coupling probe 28 can be made of steel, mild steel, or a magnet. In this configuration, the magnetic force can be approximately equal to 21 N.

[0065] Figure 7C A schematic front view showing an example of a horseshoe magnetic coupling head 10 and a cylindrical magnetic coupling probe 28 according to the present disclosure. The magnetic coupling head 10 can be made of a rare earth magnetic material, Ferrite, or other magnetic material (e.g. NdFe 35 ). The magnetic coupling probe 28 can be made of steel, mild steel, steel 1010, or a magnet. The diameter of the cylindrical magnetic coupling probe 28 can be approximately 12 mm, and the length approximately 20 mm. In this configuration, the magnetic force can be approximately equal to 45 N.

[0066] Figure 7D A schematic front view showing an example of a cylindrical magnetic coupling head 10 and a disc-shaped magnetic coupling probe 28 according to the present disclosure. The magnetic coupling head 10 can be made of a rare earth magnetic material, Ferrite, or other magnetic material (e.g. NdFe 35 ). The magnetic coupling probe 28 can be made of steel, mild steel, steel 1010, or a magnet. The diameter of the disc-shaped magnetic coupling probe 28 can be approximately 20 mm, and the thickness approximately 12 mm. In this configuration, the magnetic force can be approximately equal to 40 N.

[0067] Figure 7EA schematic perspective view showing an example of a U-shaped magnetic coupling probe 28 having respective upper and lower sharp leading edges 66 and 63 according to the present disclosure is shown. The magnetic coupling probe 28 can also be referred to as a "shovel probe 62". The U-shaped magnetic coupling probe 28 can be sized to fit within a vent gas manifold channel, small enough so that it can easily traverse and move through a 180 degree turn section of the ends of a pair of parallel, adjacent vent gas manifold channels (see Figure 4 ). The U-shaped shovel probe 62 can be used as the magnetic coupling probe 28, or it can simply be used as a shovel to cut and hold a mass of encroaching potting compound (e.g., the obstruction 26), in which case a separate magnetic coupling probe 28 would be used during the inspection step.

[0068] Figure 8A A schematic front cross-sectional view showing an example of 3 battery cells 60, 60', 60" and a vent gas manifold channel 20 with an obstruction 26 inside the channel according to the present disclosure is shown. The obstruction 26 can be a mass of potting compound that has encroached inside the channel 20. A steel shovel 62 is a U-shaped "shovel" that can be magnetically dragged inside the channel 20 by moving an external magnetic coupling head 10 horizontally across an upper shear plate 68. The external magnetic coupling head 10 has a vertical shaft / extension 11 that can be used as a handle for a human operator or a robotic manipulator arm (not shown) to hold and move. The steel shovel 62 can include a pair of respective lower and upper sharp tips / blades 63 and 65 that can cut through the protruding obstruction 26, for example, from the lower wall 24. The magnetic coupling head 10 drags the steel shovel 62 horizontally through the channel 20 until it encounters the obstruction 26, at which point the steel shovel 62 then cuts and severs the protruding obstruction 26 (see Figure 8B ) from, for example, the lower wall 24 inside the steel shovel 62, where it can then be removed from the channel 20. The lower sharp tip / blade 63 extends horizontally further to the right than the upper sharp tip / blade 65 of the steel shovel 62, so that when the obstruction 26 encroaches from the upper TP tray 22, the severed obstruction 26' falls onto the longer lower sharp tip / blade 63 and is captured by the steel shovel 62. Note that the outer dimensions and shape of the steel shovel 62 should be narrow enough so that the magnetically coupled steel shovel 62 can successfully navigate a 180 degree turn at the turn point 45 of the parallel channels 20' and 20" in the vent gas manifold 42 without getting stuck at the turn point 45 (see Figure 4 ).

[0069] Figure 8BA schematic front cross-sectional view showing an example of 3 battery cells 60, 60', 60" and a vent gas manifold channel 20 according to the present disclosure, with an obstruction 26 inside the channel 20. In this view, a steel scoop piece 62 holds the severed obstruction 26'. The steel scoop piece 62 with the severed obstruction 26' held inside it can be later removed from the channel 20, thus clearing the channel 20 of obstructions. Note that multiple obstructions (not shown) can be individually severed and collected by the steel scoop piece 62 before it is removed from the channel 20.

[0070] Figure 9 A schematic front cross-sectional view showing an example of 3 battery cells 60, 60', 60" and a vent gas manifold channel 20 according to the present disclosure, with an obstruction 26 inside the channel 20. This view is identical to the view in Figure 1, except that a flexible vacuum tube 70 has been added to the rear end of the steel scoop piece 62. This provides the ability to suck out and permanently remove the severed obstruction 26 from the interior of the steel scoop piece 62, especially if the obstruction 26 is a liquid or semi-liquid. The flexible vacuum tube 70 can have a diameter large enough for the solidified, severed obstruction 26' to pass through the tube 70. Figure 8A

[0071] Figure 10 A schematic front cross-sectional view showing an example of 3 battery cells 60, 60', 60" and a vent gas manifold channel 20 according to the present disclosure, with an obstruction 26 inside the channel 20. This view is identical to the view in Figure 1, except that a sharp grid (array) 72 of multiple sharp blades has been added in front of / to the front end of the steel scoop piece 62. The sharp grid 72 minces (chops up) the obstruction 26 into multiple smaller pieces / fragments, which are more easily vacuumed out by the flexible vacuum tube 70. Figure 9

[0072] Figure 11 A schematic front cross-sectional view showing an example of 3 battery cells 60, 60', 60" and a vent gas manifold channel 20 according to the present disclosure, with an obstruction 26 inside the channel 20. This view is identical to the view in Figure 1, except that a sharp grid (array) 72 of multiple sharp blades has been added in front of / to the front end of the steel scoop piece 62. The sharp grid 72 minces (chops up) the obstruction 26 into multiple smaller pieces / fragments, which are more easily vacuumed out by the flexible vacuum tube 70. Figure 9

[0073] Figure 12A A schematic plan view showing an example of a magnetic coupling puck 28 according to the present disclosure, with 4 spherical rollers 76, 76' etc. disposed underneath the puck 28. ​​​

[0074] Figure 12B A front cross-sectional view showing an example of a magnetic coupling puck 28 according to the present disclosure, with 4 spherical rollers 76, 76' etc. disposed underneath the puck 28. In some embodiments, cylindrical rollers can be used. The number of rollers can be 3, 4, 5, or 6, chosen to provide omnidirectional motion with reduced friction along the channel 20.

[0075] Figure 13 An example of a process flow diagram showing a method of inspecting a vent gas manifold channel is shown. The example of a process flow diagram includes the following steps:

[0076] Step 100 : providing an inspection tool kit;

[0077] Step 102 : inserting a magnetic coupling probe into the channel;

[0078] Step 104 : placing a magnetic coupling head proximate to the channel;

[0079] Step 106 : sliding the magnetic coupling head and dragging the magnetic coupling probe in the channel;

[0080] Step 108 : using a sensor to detect a change in physical, electrical, and / or magnetic properties when the magnetic coupling probe encounters an obstruction; and

[0081] Step 110: alerting a computer or human operator that an obstruction has been detected.

[0082] Figure 14 A schematic front cross-sectional view showing an example of 3 battery cells 60, 60', 60" and a vent gas manifold channel 20 according to the present disclosure, with an obstruction 26 and a magnetic coupling laser 80 disposed inside the channel 20. After the magnetic coupling probe 28 (not shown) locates the obstruction 26 and alerts an operator (not shown), the magnetic coupling laser 80 can be inserted into the channel 20. The magnetic coupling laser 80, with attached power cord 84, can be manufactured with a steel outer shell and can be moved (i.e., dragged) into place by the magnetic coupling head 10. Alternatively, the magnetic coupling laser 80 can be used as the magnetic coupling probe 28 and dragged along the channel 20 by the magnetic coupling head 10 until it encounters the obstruction 26 and alerts a computer or operator. Once located sufficiently close to the obstruction 26, the magnetic coupling laser 80 can irradiate the obstruction 26 with a laser beam 82 of sufficient power (and appropriate wavelength) to heat and completely vaporize the obstruction 26.

[0083] Figure 15A schematic front cross-sectional view showing an example of 3 battery cells 60, 60', 60" and a ventilation gas manifold channel 20 according to the present disclosure, with an obstruction 26 and a borescope 90 with a pair of shears heads 92, 92' disposed inside the channel 20. Once the location of the obstruction 26 inside the channel 20 has been identified by the inspection tool 15, the magnetically coupled probe 28 can be removed. Subsequently, the borescope 90 (with a pair of shears heads 92, 92') can be subsequently inserted into the channel 20, adjacent to the location of the obstruction 26. Finally, the shears heads 92, 92' can shear and cut the obstruction 26 into smaller pieces or fragments (not shown), which can be vacuumed out afterwards using a vacuum hose (not shown).

[0084] In some embodiments, the magnetically coupled probe 28 can be configured to grind the obstruction 26 using one or more rotating roller or gear elements (not shown), which can be driven by a battery-powered motor (not shown).

[0085] In some embodiments, a computer algorithm can be used to control the robotic arm, which guides the magnetically coupled probe 28 through the series of interconnected parallel ventilation gas manifold channels 20, 20', 20", etc. inside the ventilation gas manifold 42.

[0086] In some embodiments, the ventilation gas manifold channels 20, 20', 20", etc. and the manifold 42 itself can be made of non-magnetic materials (e.g., aluminum, polymer, or fiber-reinforced polymer composites).

[0087] In some embodiments, the magnetically coupled probe 28 can be a spade-shaped shovel 62 with respective upper and lower sharp front edges 65 and 63 and made of steel or a magnetic material.

[0088] In some embodiments, the ventilation gas manifold channels 20 can be rectangular tubular channels.

[0089] In some embodiments, the ventilation gas manifold channels 20 can be integral parts of a battery pack in an electric vehicle, an electric airplane, an electric boat or submarine, or an electric drone.

[0090] In some embodiments, the obstruction 26 can include a blob of a potting compound that intrudes inside the channel 20.

[0091] In some embodiments, the inspection tool 25 can further include a shaft 12 attached to the magnetically coupled head 10.

[0092] In some embodiments, the method further includes measuring the lateral force, torque, and / or lateral deflection of the shaft 12 when the magnetically coupled probe 28 encounters an obstruction 26 located inside the channel 20.

[0093] In some embodiments, the method further includes using the sensor 14 to measure: (a) a change in capacitance of the probe / magnet combination, and / or (b) a change in inductance of the magnetically coupled head 10, when encountering the obstruction 26.

[0094] In some embodiments, the inspection tool can be attached to a robotic manipulator arm 18; and the method further includes using the robotic manipulator arm 18 to move the inspection tool 15 and the magnetically coupled probe 28 along the passageway.

[0095] In some embodiments, the method can further include removing the obstruction 26 from the passageway 20 after the magnetically coupled probe 28 is positioned and detached and / or pulverized the obstruction 26.

[0096] In some embodiments, the method can further include removing the magnetically coupled probe 28 from the passageway after the inspection is completed.

[0097] In some embodiments, the method can further include retaining and / or capturing the magnetically coupled probe 28 at one end of the passageway 20 after the inspection is completed.

[0098] In some embodiments, removing the obstruction 26 can include: (1) magnetically driving the magnetically coupled head 10 and a magnetically coupled scoop 62 disposed inside the passageway, wherein the magnetically coupled scoop 62 includes respective upper and lower sharp leading edges 63, 65; (2) severing and detaching the obstruction 26 from the walls of the passageway 20 by pushing the magnetically coupled scoop 26 forward into and through the obstruction, thereby cutting and creating a detached obstruction 26'; (3) retaining the detached obstruction 26' in the magnetically coupled scoop 62; and subsequently, (4) removing the magnetically coupled scoop 62 with the detached obstruction retained inside it from the passageway 20.

[0099] In some embodiments, the method can further include vacuuming up the detached obstruction 26' using a vacuum tube 70 attached to a rear end of the magnetically coupled scoop 62; thereby removing the detached obstruction 26' from the passageway 20.

[0100] In some embodiments, the magnetically coupled scoop 62 can include a plurality of fixed or rotating blades 74 that cut the obstruction into a plurality of small individual pieces or fragments that are easier to remove (e.g., vacuum up).

[0101] In some embodiments, the passageway 20 can be disposed within a battery ventilation manifold system 42 of an electric vehicle.

[0102] In some embodiments, retaining the magnetically coupled probe 28 at an end of the passageway 20 after the inspection is completed can include using a pair of arms 50, 52 to rotate a one-way ratcheting post 48 that grabs and captures the magnetically coupled probe 28 at an end of the passageway 20.

[0103] In some embodiments, retaining the magnetic coupling probe 28 at the end of the passageway 20 after completing the inspection can include capturing and retaining the magnetic coupling probe 28 at the end of the passageway 20 using a permanent magnet 54 disposed at the end of the passageway 20.

[0104] In some embodiments, the inspection tool 15 can be attached to the robotic manipulator arm 18; and the method can further include moving the inspection tool 15 and the magnetic coupling probe 28 along the length of the passageway using the robotic manipulator arm 18.

[0105] In some embodiments, a paper or plastic "map" of the interconnected passageways 20, 20', 20", etc. can be placed or adhesively attached on the exterior surface of the battery pack to indicate the location of the internal passageways located inside. This can assist a human operator when manually moving the inspection probe 15 along the curves and turns of the interconnected passageways 20, 20', 20", etc. Alternatively, a video projector can project a "map" of the passageways 20, 20', 20", etc. on the exterior surface of the battery pack.

[0106] In some embodiments, a magnetic coupling laser 80 with a steel outer shell can be inserted into the passageway 20, magnetically dragged to the location of the obstruction 26 by the magnetic coupling head 10, and subsequently irradiate the obstruction 26, thereby heating it and causing it to vaporize.

[0107] In another example, the laser 80 can be used as the magnetic coupling probe 28 and magnetically dragged along the passageway 20 by the magnetic coupling head 10 until it encounters the obstruction 26 and alerts the operator before using the laser to vaporize the obstruction 26.

[0108] In another example, a borescope with a shears head can be inserted into the passageway and the shears head can cut the obstruction into small pieces that can be vacuumed out using a separate vacuum tool.

[0109] The detailed description and the accompanying drawings or diagrams provide support for the teachings of the present teachings, but the scope of the present teachings is limited only by the claims. While there have been described herein the best mode and other embodiments for the practice of the present teachings, various modifications and changes can be made to these best mode and other embodiments without departing from the teachings of the present teachings which are intended to be defined by the scope of the appended claims.

Claims

1. An inspection tool kit comprising: a magnetically coupled probe sized to fit within and slide along the channel; an inspection tool comprising a magnetically coupled head disposed outside the channel; as well as a sensor attached to or disposed within the magnetic coupling head; wherein the sensor is configured to detect when the magnetic coupling probe encounters an obstacle located inside the channel; and The magnetic coupling head and the magnetic coupling probe are magnetically coupled together to form a magnetic coupling probe / head pair, which has a magnetic strength strong enough to drag the magnetic coupling probe inside the channel when the magnetic coupling head moves outside the channel.

2. The inspection tool kit according to claim 1, further comprising: a shaft attached to the head and the sensor, disposed between the head and the sensor; as well as Therein, the sensor is configured to sense an increase in lateral force, torque, and / or lateral deflection of the shaft when the magnetically coupled probe encounters an obstacle located within the channel.

3. The inspection tool kit according to claim 1, wherein: Sensor sensing: When the magnetic coupling probe encounters an obstacle, (a) changes in the capacitance of the magnetically coupled probe / head pair, and / or (b) Changes in the inductance of the electromagnet provided inside the magnetic coupling head.

4. The inspection tool kit according to claim 1, wherein: The inspection tool is attached to and operated by a robotic manipulator arm; or by a human operator.

5. The inspection tool kit according to claim 1, wherein: The passage is disposed within a battery ventilation gas manifold system of an electric vehicle.

6. A method of inspecting a channel using an inspection tool kit, the method comprising: (a) providing an inspection tool kit, the inspection tool kit comprising: a magnetically coupled probe sized to fit within and slide along the channel; an inspection tool comprising a magnetically coupled head disposed outside the channel; and a sensor attached to or disposed within the magnetic coupling head; wherein the sensor is configured to detect when the magnetic coupling probe encounters an obstacle located inside the channel; and wherein the magnetic coupling head and the magnetic coupling probe are magnetically coupled together to form a magnetic coupling probe / head pair, wherein the magnetic coupling probe / head pair has a sufficiently strong magnetic strength to drag the magnetic coupling probe inside the channel when the magnetic coupling head moves outside the channel; (b) Inserting the magnetic coupling probe into the channel; (c) placing the magnetic coupling head adjacent to the channel and sliding the magnetic coupling head along the channel, thereby dragging the magnetic coupling probe along the channel; (d) using sensors to detect one or more changes in physical, electrical, and / or magnetic properties of the inspection tool when the magnetically coupled probe encounters an obstruction; and (e) Alert the computer or human operator that an obstruction has been detected.

7. The method according to claim 6, further comprising: A physical map is applied or a video display is projected onto the exterior surface of the battery pack showing the locations of internal passages disposed within the battery pack, and the map or display is used to guide a human operator in moving the magnetically coupled probe along the passages.

8. The method according to claim 6, in, The inspection tool also includes a shaft attached to the magnetically coupled head; and The method further includes measuring a lateral force, torque, and / or lateral deflection of the shaft generated when the magnetically coupled probe encounters an obstacle located within the channel.

9. The method according to claim 6, further comprising using a sensor to measure: when encountering an obstacle, (a) a change in the capacitance of the magnetically coupled probe / head pair; and / or (b) Changes in the inductance of the electromagnet provided in the magnetic coupling head.

10. The method according to claim 6, in, The inspection tool is attached to the robotic manipulator arm; and The method further includes using a robotic manipulator to move the inspection tool and the magnetically coupled probe along the channel.

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