Inspection tool and method for locating and removing obstructions in a sewer

Abstract

This disclosure describes inspection tools and methods for inspecting and maintaining the interior of vent gas manifold channels. A magnetically coupled probe (e.g., a sphere, cylinder, rectangular cube, or disk) is inserted into the vent gas manifold channel. A magnetically coupled head then magnetically pulls the magnetically coupled probe through the channels of the vent gas manifold. The inspection tool uses a sensor to monitor the position of the magnetically coupled probe within the channel. If an obstruction is encountered, the sensor monitors local changes in one or more physical or electrical properties of the inspection tool and alerts an operator. The magnetically coupled probe may be a steel spoon with sharp leading edges that detaches and picks up the obstruction.A programmed robot arm or an operator can move the head over the surface of the vent gas manifold parallel to the channel.

Description

INTRODUCTION

[0001] This disclosure relates to inspection tools and methods for inspecting ducts for obstructions located within the duct and for removing those obstructions after they have been detected. In particular, the disclosure relates to the inspection of vent gas distribution ducts in an electric vehicle battery pack.

[0002] Electric vehicle battery packs are made of multiple battery cells stacked in an array and enclosed by a structure that securely holds the batteries in place. Battery packs may have a venting gas distribution system (e.g., a series of parallel channels). Some of these battery packs may also be encapsulated with a polymer (e.g., silicone or polyurethane). DESCRIPTION

[0003] This disclosure describes inspection tools and methods for inspecting and maintaining the interior of vent gas distribution channels. A magnetically coupled probe (e.g., a ferrous steel or magnetic sphere, cylinder, rectangular cube, or disk) is inserted into the vent gas distribution channel. An external, magnetically coupled head is then used to magnetically pull the magnetically coupled probe through the vent gas distribution channels. The inspection tool uses a sensor to monitor the position of the magnetically coupled probe within the channel. If an obstruction is detected, the sensor monitors local changes in one or more physical, electrical, or magnetic properties of the inspection tool and alerts the operator of the obstruction.The magnetically coupled probe may comprise a steel scoop with upper and lower sharp leading edges that cuts, dislodges, and picks up the obstruction. The obstruction may be removed from the channel by removing the steel scoop. A human operator or a programmed robotic arm may move the magnetically coupled head over the surface of the vent gas manifold in a direction parallel to the channel.

[0004] In a first example, an inspection tool kit may include: a magnetically coupled probe sized to fit within 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 has encountered an obstruction located within 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 sufficient to pull the probe within the channel when the head is moved outside the channel.

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

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

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

[0008] In another example, the vent gas distribution channel may be disposed in a battery vent gas distribution system of an electric vehicle.

[0009] In another example, a method for inspecting a channel with an inspection tool may include: (a) providing an inspection tool comprising: 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 has encountered an obstruction located within 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 pull the probe within the channel when the head is moved outside the channel; then (b) inserting a magnetically coupled probe into the channel;then (c) placing the magnetically coupled head in close proximity to the channel and sliding the magnet or electromagnet along the channel, thereby applying a moving external magnetic field that draws the magnetically coupled probe along the channel; then (d) detecting one or more changes in a physical, electrical, and / or magnetic property of the inspection tool with the sensor when the magnetically coupled probe encounters the obstruction; and then (e) alerting a human operator that the obstruction has been detected.

[0010] In another example, the method may further include attaching a physical map or projecting a video screen onto an external surface of the battery pack displaying the positions of internal channels disposed within a battery pack, and using the map or screen to guide a human operator to move the magnetically coupled probe along the channel.

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

[0012] In another example, the method may further comprise measuring with the sensor: (a) a change in an electrical capacitance of the magnetically coupled probe / head pair; and / or (b) a change in an electrical inductance of an electromagnet disposed within the magnetically coupled head; when the obstacle is detected.

[0013] In another example, the inspection tool may be attached to a robotic manipulator arm; and the method further comprises moving the inspection tool and the magnetically coupled probe along the channel with the robotic manipulator arm.

[0014] In another example, the method may further comprise: (f) removing the obstruction from the channel after the magnetically coupled probe has located the obstruction; and (g) removing the magnetically coupled probe from the channel after the inspection is complete.

[0015] In another example, the method may further comprise holding the magnetically coupled probe at one end of the channel after completing the inspection.

[0016] In another example, the magnetically coupled probe may comprise ferrous steel or a magnet; and wherein the magnetically coupled head may comprise ferrous steel or a magnet.

[0017] In another example, removing the obstruction in step (f) may comprise: (1) magnetically moving a magnetically coupled bucket disposed within the channel having a magnetically coupled head, the magnetically coupled bucket having upper and lower sharp leading edges; (2) cutting and detaching the obstruction from a wall of the channel by advancing the magnetically coupled bucket into and past the obstruction, thereby cutting and creating a detachable obstruction; (3) retaining the detachable obstruction within the magnetically coupled bucket; and then (4) removing the magnetically coupled bucket with the detachable obstruction retained therein from the channel.

[0018] In another example, the method may further comprise, after step (2), sucking up the dislodged obstruction with a suction tube attached to the rear end of the magnetically coupled bucket, thereby removing the dislodged obstruction from the channel.

[0019] In another example, the method may further include using a plurality of fixed or rotating blades or a pair of scissor jaws or a plurality of rotating gears that cut or grind the obstacle into a plurality of small pieces.

[0020] In another example, the channel may be disposed in a battery vent gas distribution system of an electric vehicle.

[0021] In another example, the method may further include, after completion of the inspection, holding the magnetically coupled probe at one end of the channel by rotating a one-way rotating post having a pair of arms that captures and holds the magnetically coupled probe at the end of the channel.

[0022] In another example, the method may further comprise retaining the magnetically coupled probe at an end of the channel after completion of the inspection by using a permanent magnet disposed at the end of the channel to capture and retain the magnetically coupled probe at the end of the channel.

[0023] In another example, a method for inspecting a channel with an inspection tool may include: (a) providing an inspection tool kit comprising: a magnetically coupled probe sized to fit into 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 magnetically coupled head; wherein the sensor is configured to detect when the magnetically coupled probe has encountered an obstruction located within the channel;and wherein the magnetically coupled head and the magnetically coupled probe are magnetically coupled to each other to form a magnetically coupled probe / head pair having a magnetic strength sufficient to pull the magnetically coupled probe within the channel when the magnetically coupled head is moved outside the channel, then; (b) inserting a magnetically coupled probe into the channel; then (c) placing the magnetically coupled head in close proximity to the channel and sliding the magnetically coupled head along the channel, thereby pulling the magnetically coupled probe along the channel, then; (d) sensing one or more changes in a physical, electrical, and / or magnetic property of the inspection tool with the sensor when the magnetically coupled probe encounters the obstruction; and then (e) alerting a human operator that the obstruction has been located;wherein the inspection tool further comprises a shaft attached to the magnet or the electromagnet; wherein the method further comprises measuring a lateral force, torque, and / or lateral deflection of the shaft generated when the magnetically coupled probe encounters the obstacle; wherein the inspection tool is attached to a robotic manipulator arm; and wherein the method further comprises moving the inspection tool and the magnetically coupled probe along a length of the channel with the robotic manipulator arm. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 shows a schematic view of a battery pack with three parallel vent gas distribution channels according to the present disclosure. Fig. 2A shows a schematic view of an example of an inspection tool and probe for inspecting a vent gas distribution channel according to the present disclosure. Fig. 2B shows a schematic view of an example of an inspection tool and probe inspecting a vent gas distribution channel and encountering an obstruction, according to the present disclosure. Fig. 3A shows a schematic top view of an example of a pair of vent gas distribution channels with a magnetically coupled probe and an endoscope hole penetrating a sidewall at one end of a channel, according to the present disclosure. Fig. 3B shows a schematic top view of an example of a vent gas distribution channel with a removed magnetically coupled probe and a plugged endoscope hole according to the present disclosure. Fig. 4 shows a schematic top view of an example of a vent gas manifold having multiple interconnected parallel channels with a magnetically coupled probe according to the present disclosure. Fig. 5A shows a schematic top view of an example of a vent gas distribution channel with a magnetically coupled probe and a rotatable mechanism acting as a trap, according to the present disclosure. Fig. 5B shows a schematic top view of an example of a vent gas distribution channel with a magnetically coupled probe and a rotatable mechanism that is rotated to a fixed position in accordance with the present disclosure. Fig. 6A shows a schematic top view of an example of a vent gas distribution channel with a magnetically coupled probe and a magnet at one end of the channel according to the present disclosure. Fig. 6B shows a schematic top view of an example of a vent gas distribution channel with a magnetically coupled probe attached to a magnet at one end of the channel, according to the present disclosure. Fig. 7A shows a schematic view of an example of a cylindrical magnet and a spherical probe according to the present disclosure. Fig. 7B shows a schematic view of an example of a cylindrical magnet and a cylindrical probe according to the present disclosure. Fig. Figure 7C shows a schematic view of a horseshoe-shaped magnet and a cylindrical probe according to the present disclosure. Fig. 7D shows a schematic view of an example of a cylindrical magnet and a disk-shaped probe according to the present disclosure. Fig. 7E shows a schematic perspective view of an example of a cylindrical magnet and a spoon-shaped probe according to the present disclosure. Fig. 8A shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution channel with an obstruction within the channel according to the present disclosure. Fig. 8B shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution channel with an obstruction within the channel according to the present disclosure. Fig. 9 shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution channel with an obstruction within the channel according to the present disclosure. Fig. 10 shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution channel with an obstruction within the channel according to the present disclosure. Fig. 11 shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution channel with an obstruction within the channel according to the present disclosure. Fig. 12A shows a schematic top view of an example of a magnetically coupled disk with four ball rollers arranged below the disk according to the present disclosure. Fig. 12B shows a cross-sectional view of an example of a magnetically coupled disk with four spherical rollers disposed beneath the disk in accordance with the present disclosure. Fig. Figure 13 shows an example of a process flow diagram illustrating a method for inspecting a vent gas distribution channel. Fig. 14 shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution channel with an obstruction and a laser disposed inside the channel, according to the present disclosure. Fig. 15 shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution channel with an obstruction and a snipping jaw endoscope disposed inside the channel, according to the present disclosure. DETAILED DESCRIPTION

[0024] This disclosure describes inspection tools and methods for inspecting and maintaining the interior of vent gas manifold channels. A ferrous or magnetic probe (e.g., a steel ball, cylinder, rectangular cube, or disk) is inserted into the channel of the vent gas manifold. Then, an external magnetic field from a magnetically coupled head is used to magnetically pull the probe through the channels of the vent gas manifold. The inspection tool uses a sensor to monitor the position of the magnetically coupled probe within the channel. If an obstruction is detected, the sensor monitors local changes in one or more physical, electrical, or magnetic properties of the inspection tool and alerts the operator of the obstruction.The magnetically coupled probe can be a steel bucket with sharp upper and lower leading edges that cuts, dislodges, and picks up the obstruction. It can be removed from the channel by removing the magnetically coupled bucket. A human operator or a programmed robotic arm can move the magnetically coupled head over the surface of the vent gas manifold in a direction parallel to the channel.

[0025] The term “magnet” as used herein may include permanent magnets, electromagnets, or combinations thereof.

[0026] Fig. 1 shows a schematic view of an example of a battery pack with three parallel vent gas distribution channels according to the present disclosure. The passages 8, 8', and 8'' connect the vent gases of the battery cells 60, 60', and 60'' to the vent gas distribution channels 20, 20', and 20'', respectively. The encapsulation layers (e.g., silicone or polyurethane) 34, 34', 34'', 34''', and 35 surround and support the battery cells 20, 20', and 20'', respectively. The horizontal cell support tray 64 is disposed above and transverse to the battery cells 20, 20', and 20''. The bottom wall 24 extends horizontally across the bottom of the vent gas distribution channels 20, 20', and 20''. The TP shell 22 is disposed horizontally above the upper portion of the vent gas distribution channels 20, 20', and 20''. The upper shear plate 68 is disposed horizontally above the TP shell 22, with the potting layer 66 disposed between the TP shell 22 and the horizontal upper shear plate 68.

[0027] Fig. 2A shows a schematic view of an inspection tool 15 and a magnetically coupled probe 28 for inspecting a vent gas distribution channel 20 according to the present disclosure. The inspection tool 15 includes a magnetically coupled head 10 that can be attached to the shaft 12. The shaft 12 is attached to the sensor 14. The sensor 14 can optionally be attached to a robotic arm 18 via a rotatable joint 16. Alternatively, the sensor 14 can be handheld and guided by a human operator (not shown) following a template attached to the battery pack that visually indicates the location of the parallel vent gas distribution channels located within the structure that houses the battery pack (see Fig. 1). The inspection tool 15 may include electronic and visual and / or audible warning means (not shown) to wirelessly alert a human operator or a monitoring computer that an obstruction has been detected. The sensor 14 may be located inside the magnetically coupled head 10.

[0028] With further reference to Fig. 1, the magnetically coupled probe 28 is inserted into the vent gas distribution channel 20, where it is drawn against the upper channel wall 22 by magnetic attraction. The channel wall 22 may be made of a non-magnetic material (e.g., a polymer or aluminum). The magnetically coupled probe 28 may be made of a ferrous material, steel, low-carbon steel, or a magnet. The magnetically coupled head 10 may be a magnet, in which case the magnetically coupled probe 28 may be a ferrous steel part or a magnet. Alternatively, the magnetically coupled head 10 may also be made of 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 to form a magnetically coupled probe / head pair.The lateral movement of the inspection tool 15 draws the magnetically coupled probe 28 laterally into the channel 20. The obstruction 26 may be a lump of potting compound that has penetrated the channel 20 through a small opening or hole (not shown) in the upper channel wall 22. In . Fig. 2A, the magnetically coupled probe 28 has not yet encountered the obstacle 26. The magnetically coupled probe 28 may have the shape of a sphere, a cylinder, a rectangular cube, a disk, or a U-shaped spoon / scoop.

[0029] Fig. Figure 2B shows a schematic view of an example of an inspection tool 15 and a magnetically coupled probe 28 inspecting a vent gas distribution duct 20 and encountering an obstruction 26, as described in the present disclosure. In this figure, the magnetically coupled probe 28 has contacted the obstruction 26, which displaces the magnetically coupled probe 28 downward from the ceiling of the duct 20 by a distance = d. This displaces the magnetically coupled probe 28 from the magnetically coupled head 10 by a horizontal distance = X, which in turn increases the angle q of the magnetic field lines (shown in dashed lines). The increase in the angle q of the magnetic field lines and / or the displacements (d, X) of the magnetically coupled probe 28 from its normal (undeflected) position can be detected by the sensor 14 in various physical or electrical ways.In one example, a strain gauge 17 may be mounted vertically on one side of the shaft 12, which responds to the bending of the shaft 12 when a lateral magnetic force F is applied due to the impact of an obstacle 26. The force F, or bending moment (torque T), may be calculated from the sensor 14 and strain gauge 17. A sudden increase in this force F indicates that the magnetically coupled probe 28 has contacted the obstacle 26.

[0030] In another example, the magnetically coupled head 10 may include a capacitance sensor that monitors the capacitance of the separation between the magnetically coupled probe 28 and the magnetically coupled head 10. The incremental increase in distances d and X as the magnetically coupled probe 28 contacts the obstacle 26 increases the capacitance of the inspection tool 15. In another example, the electrical inductance of an electromagnetically coupled head 10 may be monitored for sudden changes in inductance when an obstacle 26 is detected. In another example, a magnetic field sensor (e.g., a Hall sensor) may be used to monitor changes in magnetic strength and direction (angle, q) when an obstacle 26 is detected.In another example, the magnetically coupled head 10 may include an ultrasonic sensor that monitors the distances (d, x) between the magnetically coupled probe 28 and the magnetically coupled head 10 when an obstacle 26 is detected. In a final example, the magnetically coupled head 10 may include an eddy current sensor that monitors changes in the eddy currents due to changes in the distances (d, x) between the magnetically coupled probe 28 and the magnetically coupled head 10 when an obstacle 26 is detected.

[0031] Fig. Figure 3A shows a schematic top view of an example of a pair of vent gas distribution channels 20 and 20' with a magnetically coupled probe 28 and an endoscope hole 32 penetrating a sidewall 30 at one end of the channel 20, according to the present disclosure. The purpose of the hole (which can be any type of hole) is to allow the magnetically coupled probe 28 to be removed from the vent gas distribution channel 20 after the inspection is complete.

[0032] Fig. Figure 3B shows a schematic top view of an example of a vent gas distribution channel 20 with a removed magnetically coupled probe 28 and an endoscope hole 32 closed with a plug 40 according to the present disclosure. The hole 32 is closed with the plug 40 after the magnetically coupled probe 28 has been removed from the channel 20.

[0033] Fig. 4 shows a schematic top view of an example of a vent gas manifold 42 having a plurality of interconnected parallel channels 20, 20', 20'', etc., and a magnetically coupled probe 28 according to the present disclosure. The magnetically coupled probe 28 enters at a corner of the vent gas manifold 42 and is pulled by the moving inspection tool 15 (not shown) along the length of the interconnected vent gas manifold channels 20, 20', 20'', etc., thereby searching for one or more obstructions (not shown) that may be located within the channels 20, 20', 20'', etc. A plurality of vent gas manifold channels 20, 20', 20'', etc. form a serpentine pattern of interconnected paths 44 separated by a plurality of parallel interior walls 34, 34', etc. When the magnetically coupled probe 28 reaches the end of the interconnected channels 20, 20', 20'', etc.Once the gas reaches the desired level, it can either (1) be removed through a temporary hole or opening in a side wall of the vent gas manifold 42 (the hole will be closed later), or (2) be caught / captured / held / retained inside the manifold 42 by the trap 46. The trap 46 may, for example, comprise a rotating mechanism (see . Fig. 5A and Fig. 5B). Alternatively, the trap 46 may comprise a permanent magnet (see Fig. 6A and Fig. 6B). Alternatively, the trap 46 may also comprise a sticky, self-adhesive pad (not shown).

[0034] Fig. Figure 5A shows a schematic top view of an example of a vent gas distribution channel with a magnetically coupled probe and a rotatable mechanism acting as a trap, according to the present disclosure. The rotating mechanism 48 includes first and second short arms (i.e., wings) 50 and 52 arranged at right angles to each other and attached to a vertical post 48 that is rotatable. The magnetically coupled probe 28 is magnetically coupled and rests on the second arm 52 in Fig. 5A.

[0035] Fig. Figure 5B shows a schematic top view of an example of a vent gas distribution duct with a magnetically coupled probe 28 and a rotatable mechanism 48 that is rotated into a locked position according to the present disclosure. Here, the rotatable post 48 has rotated 90 degrees counterclockwise, causing the first arm 50 to trap and retain the magnetically coupled probe 28 between the first arm 50 and the second arm 52, and against the partition wall 34 and the bottom wall segment 37 (creating a box-shaped trap). Fig. Figure 6A shows a schematic top view of an example of a vent gas distribution channel 20I with a magnetically coupled probe 28 and a magnet 54 at one end of the channel according to the present disclosure. The magnetically coupled probe 28 is attracted to the magnet 54 at the end of the channel 20.

[0036] Fig. Figure 6B shows a schematic top view of an example of a vent gas distribution channel 20 with a magnetically coupled probe 28 attached to a magnet 54 at one end of the channel 20, according to the present disclosure. The magnet 54 holds the magnetically coupled probe 28 at the end of the channel 20.

[0037] Fig. Figure 7A shows a schematic view of an example of a cylindrical magnetically coupled head 10 and a spherical magnetically coupled probe 28 according to the present disclosure. The magnetically coupled head 10 may be made of a rare earth magnetic material, ferrite, or other magnetic material (e.g., NdFe 35 ). The magnetically coupled probe 28 can be made of steel, low-carbon steel, or a magnet. In this configuration, the magnetic force can be approximately 7 N.

[0038] Fig. Figure 7B shows a schematic view of an example of a cylindrical magnetically coupled head 10 and a cylindrical magnetically coupled probe 28 according to the present disclosure. The magnetically coupled head 10 may be made of a rare earth magnetic material, ferrite, or other magnetic material (e.g., NdFe 35 ). The magnetically coupled probe 28 can be made of steel, low-carbon steel, or a magnet. In this configuration, the magnetic force can be approximately 21 N.

[0039] Fig. Figure 7C shows a schematic view of a horseshoe-shaped magnetically coupled head 10 and a cylindrical magnetically coupled probe 28 according to the present disclosure. The magnetically coupled head 10 may be made of a rare earth magnetic material, ferrite, or other magnetic material (e.g., NdFe 35). The magnetically coupled probe 28 can be made of steel, low-carbon steel, steel 1010, or a magnet. The diameter of the cylindrical, magnetically coupled probe 28 can be approximately 12 mm, with a length of approximately 20 mm. In this configuration, the magnetic force can be approximately 45 N.

[0040] Fig. Figure 7D shows a schematic view of an example of a cylindrical, magnetically coupled head 10 and a disk-shaped, magnetically coupled probe 28 according to the present disclosure. The magnetically coupled head 10 may be made of a rare earth magnetic material, ferrite, or other magnetic material (e.g., NdFe 35). The magnetically coupled probe 28 can be made of steel, low-carbon steel, 1010 steel, or a magnet. The diameter of the disc-shaped, magnetically coupled probe 28 can be approximately 20 mm, with a thickness of approximately 12 mm. In this configuration, the magnetic force can be approximately 40 N.

[0041] Fig. Figure 7E shows a schematic perspective view of an example of a U-shaped magnetically coupled probe 28 having upper and lower sharp leading edges 66 and 63, respectively, according to the present disclosure. The magnetically coupled probe 28 may also be referred to as a "spoon probe 62." The U-shaped magnetically coupled probe 28 may be sized to fit within a vent gas distribution channel, being small enough to easily traverse and move through a 180-degree turnaround portion of the ends of a pair of parallel, adjacent vent gas distribution channels (see Fig. 4). The U-shaped spoon probe 62 can function as a magnetically coupled probe 28, or it can simply function as a spoon to cut off and hold a lump of intruded grout (e.g., obstruction 26); in this case, a separate magnetically coupled probe 28 would be used during the inspection steps.

[0042] Fig. 8A shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60'' and a vent gas distribution channel 20 with an obstruction 26 within the channel according to the present disclosure. The obstruction 26 may be a lump of potting compound that has entered the channel 20. The steel scoop 62 is a U-shaped "scoop" that can be magnetically drawn into the channel 20 by moving the external, magnetically coupled head 10 horizontally over the upper shear plate 68. The external, magnetically coupled head 10 has a vertical shaft / extension 11 that can serve as a handle for a human operator or a robotic arm (not shown) to hold and move. The steel scoops 62 may include a pair of lower and upper sharpened tips / blades 63 and 65, respectively, that can cut the protruding obstruction 26 from the bottom wall 24.The magnetically coupled head 10 pulls the steel bucket 62 horizontally through the channel 20 until it encounters an obstacle 26. At this point, the steel bucket 62 cuts off the protruding obstacle 26 (e.g., from the bottom wall 24). The severed obstacle 26' is then retained inside the steel bucket 62 (see . Fig. 8B), whereby the steel bucket 62 can later be removed from the channel 20. The lower sharpened tip / blade 63 extends horizontally farther to the right than the upper sharpened tip / blade 65 of the steel bucket 62, so that the cut-off obstruction 26' falls onto the longer lower sharpened tip / blade 63 and is caught by the steel bucket 62 when the obstruction 26 has penetrated from the upper TP shell 22. It should be noted that the outer dimensions and shape of the steel bucket 62 should be sufficiently narrow to allow the magnetically coupled steel bucket 62 to successfully complete the 180-degree turn at the turnaround point 45 of the parallel channels 20' and 20'' in the vent gas manifold 42 without becoming stuck at the turnaround point 45 (see Fig. 4).

[0043] Fig. 8A shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60'' and a vent gas distribution channel 20 with an obstruction 26 within the channel according to the present disclosure. In this view, the steel bucket 62 holds the severed obstruction 26'. The steel bucket 62, in which the severed obstruction 26' is held, can later be removed from the channel 20, thereby clearing the channel 20 of obstructions. Note: Multiple obstructions (not shown) can be individually cut and captured by the steel bucket 62 before the steel bucket 62 is removed from the channel 20.

[0044] Fig. Figure 9 shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60" and a vent gas distribution channel 20 with an obstruction 26 within the channel 20 according to the present disclosure. This figure is identical to Fig. 8A, except that a flexible vacuum tube 70 has been added to the rear end of the steel bucket 62. This allows the cut-off obstruction 26 to be vacuumed from within the steel bucket 62 and permanently removed, particularly when the obstruction 26 is liquid or semi-liquid. The flexible vacuum tube 70 may have a sufficiently large diameter to guide a solidified, cut-off obstruction 26' through the tube 70.

[0045] Fig. Figure 10 shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60" and a vent gas distribution channel 20 with an obstruction 26 within the channel 20 according to the present disclosure. This figure is identical to Fig. 9, except for the addition of a sharp net (“array”) 72 of several sharp blades at the front / front end of the steel spoon 62. The sharp net 72 breaks the obstacle 26 into several smaller pieces that can be more easily vacuumed through the flexible vacuum tube 70.

[0046] Fig. Figure 11 shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60" and a vent gas distribution channel 20 with an obstruction 26 within the channel 20 according to the present disclosure. This figure is identical to Fig. 9, except that a horizontal shaft 73 (attached to the steel spoon 62) has been added with one or two rotating sharp blades 74 rotatably mounted on the distal end of the horizontal shaft 73. Sharp, rotating blades 74 cut the obstruction 26 into several smaller pieces / fragments that can be more easily vacuumed through the flexible vacuum tube 70. The rotating blades 74 can be driven by a battery-powered motor (not shown) or by vacuum.

[0047] Fig. 12A shows a schematic top view of an example of a magnetically coupled disk 28 having four spherical rollers 76, 76', etc., disposed beneath the disk 28, in accordance with the present disclosure.

[0048] Fig. 12B shows a cross-sectional view of an example of a magnetically coupled disk 28 with four spherical rollers 76, 76', etc., disposed beneath the disk 28, according to the present disclosure. In some cases, cylindrical rollers may be used. The number of rollers may be three, four, five, or six, selected to enable omnidirectional movement with reduced friction when sliding along the channel 20.

[0049] Fig. Figure 13 shows an example process flow diagram illustrating a method for inspecting a vent gas distribution duct. The example process flow diagram includes the following steps: Step 100: Provision of an inspection tool kit; Step 102: Inserting a magnetically coupled probe into a channel; Step 104: Place a magnetically coupled head in close proximity to the channel; Step 106: Pushing the magnetically coupled head and pulling the magnetically coupled probe into the canal; Step 108: Detecting a change in a physical, electrical and / or magnetic property with the sensor when the magnetically coupled probe encounters an obstacle; and Step 110: Alert a computer or human operator that the obstacle has been detected.

[0050] Fig. 14 shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60'' and a vent gas distribution channel 20 with an obstruction 26 and a magnetically coupled laser 80 disposed within the channel 20, according to the present disclosure. The magnetically coupled laser 80 may be inserted into the channel 20 after the magnetically coupled probe 28 (not shown) has located the obstruction 26 and alerted an operator (not shown). The magnetically coupled laser 80, with the power cable 84 attached thereto, may be constructed with a steel housing and may be moved (i.e., pulled) into a suitable position by the magnetically coupled head 10. Alternatively, the magnetically coupled laser 80 may also function as a magnetically coupled probe 28 and be pulled along the channel 20 by the magnetically coupled head 10 until it encounters the obstacle 26 and alerts a computer or an operator.Once the magnetically coupled laser 80 is positioned close enough to the obstacle 26, it can irradiate the obstacle 26 with a laser beam 82 of sufficient power (and suitable wavelength) to heat and completely vaporize the obstacle 26.

[0051] Fig.15 shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60'' and a vent gas distribution channel 20 with an obstruction 26 and an endoscope 90 with a pair of scissor jaws 92, 92' disposed within the channel 20, according to the present disclosure. Once the position of an obstruction 26 in the channel 20 has been identified by the inspection tool 15, the magnetically coupled probe 28 can be removed. Subsequently, the endoscope 90 (with a pair of scissor jaws 92, 92') can be inserted into the channel 20, proximate the location of the obstruction 26. Finally, the scissor jaws 92, 92' can cut the obstruction 26 into smaller pieces or fragments (not shown), which can later be vacuumed away with a suction hose (not shown).

[0052] In some embodiments, the magnetically coupled probe 28 may be configured to abrade the obstacle 26 with one or more rotating rollers or gear members (not shown) that may be driven by a battery-powered motor (not shown).

[0053] In some embodiments, a computer-based algorithm may be used to control a robotic arm that guides the magnetically coupled probe 28 through the interconnected series of parallel vent gas distribution channels 20, 20', 20'', etc. within the vent gas distribution manifold 42.

[0054] In some embodiments, the vent gas distribution channels 20, 20', 20'', etc., and the distributor 42 itself may be made of a non-magnetic material (e.g., aluminum, a polymer, or fiber-reinforced polymer composite).

[0055] In some embodiments, the magnetically coupled probe 28 may be a spoon-shaped scoop 62 having upper and lower sharp leading edges 65 and 63, respectively, made of steel or a magnetic material.

[0056] In some embodiments, the vent gas distribution channel 20 may be a rectangular, tubular channel.

[0057] In some embodiments, the vent gas distribution channel 20 may be an integral part of a battery pack in an electric vehicle, an electric aircraft, an electric boat or submarine, or an electric drone.

[0058] In some embodiments, the obstacle 26 may comprise a lump of potting compound that has penetrated into the channel 20.

[0059] In some embodiments, the inspection tool 25 may further include a shaft 12 attached to the magnetically coupled head 10.

[0060] In some embodiments, the method may further include measuring a lateral force, torque, and / or lateral deflection of the shaft 12 generated when the magnetically coupled probe 28 encounters an obstacle 26 within the channel 20.

[0061] In some embodiments, the method may further include measuring (a) a change in the electrical capacitance of a probe-magnet combination and / or (b) a change in the electrical inductance of the magnetically coupled head 10 to the sensor 14 when the obstacle 26 is detected.

[0062] In some embodiments, the inspection tool may be attached to a robotic manipulator arm 18; and the method may further include moving the inspection tool 15 and the magnetically coupled probe 28 along the channel with the robotic manipulator arm 18.

[0063] In some embodiments, the method may further include removing the obstruction 26 from the channel 20 after the magnetically coupled probe 28 has located and dislodged and / or abraded the obstruction 26.

[0064] In some embodiments, the method may further include removing the magnetically coupled probe 28 from the channel after the inspection is completed.

[0065] In some embodiments, the method may further include holding and / or enclosing the magnetically coupled probe 28 at one end of the channel 20 after the inspection is completed.

[0066] In some embodiments, removing the obstruction 26 may comprise: (1) magnetically driving the magnetically coupled head 10 and a magnetically coupled bucket 62 disposed within the channel, the magnetically coupled bucket 62 including lower and upper sharp leading edges 63 and 65, respectively; (2) cutting and detaching the obstruction 26 from a wall of the channel 20 by advancing the magnetically coupled bucket 62 into and past the obstruction, thereby cutting and creating a severed obstruction 26'; (3) retaining the severed obstruction 26' within the magnetically coupled bucket 62; and then (4) removing the magnetically coupled bucket 62 with the severed obstruction retained therein from the channel 20.

[0067] In some embodiments, the method may further include vacuuming the dislodged obstruction 26' with a vacuum tube 70 attached to the rear end of the magnetically coupled spoon 62, thereby removing the dislodged obstruction 26' from the channel 20.

[0068] In some embodiments, the magnetically coupled spoon 62 may include a plurality of fixed or rotating blades 74 that cut the obstruction into a plurality of small, individual fragments that are more easily removed (e.g., by suction).

[0069] In some embodiments, the channel 20 may be disposed within a battery vent gas distribution system 42 of an electric vehicle.

[0070] In some embodiments, retaining the magnetically coupled probe 28 at one end of the channel 20 after completion of the inspection may include rotating a unidirectional post 48 having a pair of arms 50, 52 that captures and retains the magnetically coupled probe 28 at the end of the channel 20.

[0071] In some embodiments, retaining the magnetically coupled probe 28 at one end of the channel 20 after completion of the inspection may include using a permanent magnet 54 disposed at the end of the channel 20 to capture and retain the magnetically coupled probe 28 at the end of the channel 20.

[0072] In some embodiments, the inspection tool 15 may be attached to a robotic manipulator arm 18; and the method may further include moving the inspection tool 15 and the magnetically coupled probe 28 along a length of the channel with the robotic manipulator arm 18.

[0073] In some embodiments, a paper or plastic "map" of the interconnected channels 20, 20', 20'', etc. may be affixed or glued to the exterior surface of the battery pack to indicate the location of the internal channels. This may assist a human operator in manually moving the inspection probe 15 along the turns of the interconnected channels 20, 20', 20'', etc. Alternatively, a video projector may project the "map" of the channels 20, 20', 20'', etc. onto the exterior surface of the battery pack.

[0074] In some embodiments, a magnetically coupled laser 80 having a steel housing may be inserted into the channel 20, magnetically attracted to a location on the obstacle 26 by the magnetically coupled head 10, and then irradiate the obstacle 26, thereby heating and vaporizing it.

[0075] In another example, the laser 80 may function as a magnetically coupled probe 28 and be magnetically pulled along the channel 20 by the magnetically coupled head 10 until it encounters the obstacle 26 and warns an operator before vaporizing the obstacle 26 with the laser.

[0076] In another example, an endoscope with cutting jaws can be inserted into the canal, and the cutting jaws can cut the obstruction into small fragments that can be suctioned out with a separate suction device.

[0077] The detailed description and the drawings or figures support and describe the present teachings, but the scope of the present teachings is defined solely by the claims. While some of the best modes and other embodiments for carrying out the present teachings have been described in detail, various alternative designs and embodiments exist for practicing the present teachings, as defined in the appended claims.

Claims

[1] An inspection tool kit comprising: a magnetically coupled probe sized to fit and slide into a channel; an inspection tool with a magnetically coupled head arranged 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 has encountered an obstacle located within the channel; and wherein the magnetically coupled head and the magnetically coupled probe are magnetically coupled to each other to form a magnetically coupled probe / head pair having a magnetic strength sufficient to attract the magnetically coupled probe within the channel when the magnetically coupled head is moved outside the channel. [2] The inspection tool kit of claim 1, further comprising: a shaft attached to the head and the sensor and disposed between the head and the sensor; and wherein the sensor is configured to detect an increase in a lateral force, a torque and / or a lateral deflection of the shaft when the magnetically coupled probe encounters the obstacle located inside the channel. [3] The inspection tool kit of claim 1, wherein the sensor detects: (a) a change in the electrical capacitance of the magnetically coupled probe / head pair and / or (b) a change in the electrical inductance of an electromagnet located inside the magnetically coupled head when the magnetically coupled probe encounters the obstacle. [4] The inspection tool kit of claim 1, wherein the inspection tool is mounted on and manipulated by a robot manipulator arm; or manipulated by a human operator. [5] The inspection tool kit of claim 1, wherein the channel is disposed in a battery vent gas distribution system of an electric vehicle. [6] A method for inspecting a channel using an inspection tool kit, the method comprising: (a) Provision of an inspection tool kit comprising: a magnetically coupled probe sized to fit and slide into the canal; an inspection tool with a magnetically coupled head arranged 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 has encountered an obstacle located within the channel; and wherein the magnetically coupled head and the magnetically coupled probe are magnetically coupled to each other to form a magnetically coupled probe / head pair having a magnetic strength sufficient to attract the magnetically coupled probe within the channel when the magnetically coupled head is moved outside the channel. (b) Inserting the magnetically coupled probe into the canal; (c) placing the magnetically coupled head in close proximity to the channel and sliding the magnetically coupled head along the channel, thereby pulling the magnetically coupled probe along the channel; (d) detecting one or more changes in a physical, electrical and / or magnetic property of the inspection tool with the sensor when the magnetically coupled probe encounters the obstacle; and (e) alerting a computer or human operator that the obstacle has been detected. [7] The method of claim 6 further comprising applying a physical map or projecting a video display onto an external surface of a battery pack showing the positions of internal channels within a battery pack, and using the map or display to guide a human operator to move the magnetically coupled probe along the channel. [8] Method according to claim 6, wherein the inspection tool further comprises a shaft attached to the magnetically coupled head; and wherein the method further comprises measuring a lateral force, a torque and / or a lateral deflection of the shaft generated when the magnetically coupled probe encounters the obstacle located within the channel. [9] The method according to claim 6 further comprising measuring with the sensor: (a) a change in the electrical capacitance of the magnetically coupled probe / head pair and / or (b) a change in the electrical inductance of an electromagnet arranged in the magnetically coupled head; when the obstacle is detected. [10] Method according to claim 6, wherein the inspection tool is attached to a robot manipulator arm; and the method further comprising moving the inspection tool and the magnetically coupled probe along the channel with the robotic manipulator arm.

Images