Inspection tool and method for inspecting a channel using an inspection tool set

Abstract

Inspection tool set, including: a magnetically coupled probe (28) dimensioned to fit into a channel (20) and slide along it; an inspection tool (15) with a magnetically coupled head (10) arranged outside the channel (20); and a sensor (14) which is attached to or arranged in the magnetically coupled head (10); wherein the sensor (14) is configured to detect when the magnetically coupled probe (28) has encountered an obstacle (26) located within the channel (20); and wherein the magnetically coupled head (10) and the magnetically coupled probe (28) are magnetically coupled to form a magnetically coupled probe / head pair having a magnetic strength sufficient to pull the magnetically coupled probe (28) inside the channel (20) when the magnetically coupled head (10) is moved outside the channel (20); a shaft (12) attached to the head (10) and the sensor (14), which is arranged between the head (10) and the sensor (14); and wherein the sensor (14) is configured to detect an increase in a lateral force, torque and / or lateral deflection of the shaft (12) when the magnetically coupled probe (28) encounters the obstacle (26) located inside the channel (20).

Description

[0001] This description relates to inspection tools and methods for inspecting ducts for obstructions located within the duct and for removing these obstructions after they have been detected. Specifically, the description relates to the inspection of vent gas distribution ducts in a battery pack for electric vehicles.

[0002] Electric vehicle battery packs are made up 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).

[0003] DE 10 2010 025 783 A1 describes a device for cleaning glass panes with a tracked vehicle mounted on the outside, which uses magnetic force to move a cleaning magnet on the inside of the pane. The invention relates in particular to a mobile, self-propelled cleaning device for vertical glass surfaces, for removing algae growth from the inner walls of an aquarium, with a docking station for automatic readiness for cleaning. The cleaning device consists of a crawler vehicle equipped with transverse drive elements for changing direction.

[0004] US 2011 / 0214753A1 describes a pipe cleaning device comprising a first element and a second element. The first element comprises a first magnetic or magnetically attracted element and an abrasive cleaning surface. The second element comprises a second magnetic or magnetically attracted element that is magnetically attracted to the first magnetic or magnetically attracted element. When the first element is inserted into a pipe and the second element is positioned next to an outer wall of the pipe, the abrasive surface of the first element contacts an inner wall of the pipe. As the second element is moved along and / or around the outer wall of the pipe, the abrasive surface cleans the inner wall of the pipe.

[0005] This description outlines inspection tools and procedures for inspecting and maintaining the interior of vent gas distribution ducts. A magnetically coupled probe (e.g., an iron-containing steel or magnetic sphere, cylinder, rectangular cube, or disc) is inserted into the vent gas distribution duct. An external, magnetically coupled head is then used to magnetically pull the probe through the vent gas distribution ducts. The inspection tool uses a sensor to monitor the position of the magnetically coupled probe within the duct. When 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 to the obstruction.The magnetically coupled probe can include a steel spoon with sharp upper and lower leading edges that cuts, dislodges, and picks up the obstruction, which can then be removed from the duct by removing the steel spoon. A human operator or a programmed robotic arm can move the magnetically coupled head across the surface of the vent gas distributor in a direction parallel to the duct.

[0006] The invention is defined by the independent claims.

[0007] The inspection tool set according to the invention comprises: a magnetically coupled probe dimensioned to fit into a channel and slide along the channel; an inspection tool comprising a magnetically coupled head located outside the channel; and a sensor attached to or arranged in the magnetically coupled head; wherein the sensor is configured to detect when the magnetically coupled probe has encountered an obstacle located inside 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 inside the channel when the magnetically coupled head is moved outside the channel.The inspection tool set further comprises a shaft attached to the magnetically coupled head and the sensor and positioned 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.

[0008] According to one embodiment, the sensor detects: (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.

[0009] According to another embodiment, the inspection tool is attached to a robot manipulator arm and is manipulated by it; or it is manipulated by a human operator.

[0010] According to another embodiment, the channel is arranged in a battery venting gas distribution system of an electric vehicle.

[0011] According to the invention, a method is also provided. The method for inspecting a channel with an inspection tool comprises: (a) providing an inspection tool comprising: a magnetically coupled probe sized to fit into and slide along the channel; an inspection tool comprising a head located outside the channel; and a sensor attached to or arranged in the head; wherein the sensor is configured to detect when the magnetically coupled probe has encountered an obstruction located inside the channel; and wherein the 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 inside 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 magnet or electromagnet along the channel, thereby applying a moving external magnetic field, which pulls 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 computer or a human operator that the obstruction has been detected. The inspection tool further comprises a shaft attached to the magnetically coupled head, and the method further comprises measuring a lateral force, torque, and / or lateral deflection of the shaft generated when the magnetically coupled probe encounters the obstruction located inside the channel.

[0012] According to one embodiment, the method further comprises attaching a physical map or projecting a video display onto an outer surface of the battery pack, showing the positions of the 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.

[0013] According to a further embodiment, the method further comprises 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 arranged inside the magnetically coupled head; when the obstacle is detected.

[0014] According to another embodiment, the inspection tool is attached to a robot manipulator arm and the method further comprises moving the inspection tool and the magnetically coupled probe along the channel with the robot manipulator arm.

[0015] According to another embodiment, the method further comprises: (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 completed.

[0016] According to another embodiment, the method further comprises holding the magnetically coupled probe at one end of the channel after completion of the inspection.

[0017] According to another embodiment, the magnetically coupled probe comprises ferrous steel or a magnet; and wherein the magnetically coupled head comprises ferrous steel or a magnet.

[0018] According to a further embodiment, removing the obstruction in step (f) comprises: (1) magnetically moving a magnetically coupled spoon arranged within the channel, having a magnetically coupled head, wherein the magnetically coupled spoon has upper and lower sharp leading edges; (2) cutting and detaching the obstruction from a wall of the channel by pushing the magnetically coupled spoon forward into and past the obstruction, thereby cutting off and producing a detached obstruction; (3) holding the detached obstruction in the magnetically coupled spoon; and then (4) removing the magnetically coupled spoon with the detached obstruction held therein from the channel.

[0019] According to a further embodiment, the method further comprises, after step (2), the suction of the loosened obstruction with a suction tube attached to the rear end of the magnetically coupled spoon, thereby removing the loosened obstruction from the channel.

[0020] According to another embodiment, the method also includes the use of several stationary or rotating blades or a pair of scissor jaws or several rotating gears that cut or grind the obstacle into several small pieces.

[0021] According to another embodiment, the channel is arranged in a battery venting gas distribution system of an electric vehicle.

[0022] According to another embodiment, the method further comprises holding the magnetically coupled probe at one end of the channel after completion of the inspection by rotating a one-way rotating post with a pair of arms that captures and holds the magnetically coupled probe at the end of the channel.

[0023] According to a further embodiment, the method further comprises holding the magnetically coupled probe at one end of the channel after completion of the inspection by using a permanent magnet arranged at the end of the channel to capture and hold the magnetically coupled probe at the end of the channel.

[0024] According to a further embodiment, the method in step (e) comprises alerting a human operator that the obstruction has been located; wherein the inspection tool further comprises a shaft attached to the magnet or 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 obstruction; wherein the inspection tool is mounted on 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. Fig. Figure 1 shows a schematic view of a battery pack with three parallel vent gas distribution channels according to the present description. Fig. Figure 2A shows a schematic view of an example of an inspection tool and probe for inspecting a vent gas distribution duct according to the present description. Fig. Figure 2B shows a schematic view of an example of an inspection tool and probe inspecting a vent gas distribution duct and encountering an obstruction, as described herein. Fig. Figure 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 side wall at one end of a channel, according to the present description. Fig. Figure 3B shows a schematic top view of an example of a vent gas distribution duct with a remote magnetically coupled probe and a blocked endoscope hole according to the present description. Fig. Figure 4 shows a schematic top view of an example of a vent gas distributor with several interconnected parallel channels with a magnetically coupled probe according to the present description. Fig. Figure 5A shows a schematic top view of an example of a vent gas distribution duct with a magnetically coupled probe and a rotatable mechanism acting as a trap, according to the present description. Fig. Figure 5B shows a schematic top view of an example of a vent gas distribution duct with a magnetically coupled probe and a rotatable mechanism which is rotated into a fixed position according to the present description. Fig. Figure 6A shows a schematic top view of an example of a vent gas distribution duct with a magnetically coupled probe and a magnet at one end of the duct according to the present description. Fig. Figure 6B shows a schematic top view of an example of a vent gas distribution duct with a magnetically coupled probe attached to a magnet at one end of the duct, according to the present description. Fig. Figure 7A shows a schematic view of an example of a cylindrical magnet and a spherical probe according to the present description. Fig. Figure 7B shows a schematic view of an example of a cylindrical magnet and a cylindrical probe according to the present description. Fig. Figure 7C shows a schematic view of a horseshoe-shaped magnet and a cylindrical probe according to the present description. Fig. Figure 7D shows a schematic view of an example of a cylindrical magnet and a disc-shaped probe according to the present description. Fig. Figure 7E shows a schematic perspective view of an example of a cylindrical magnet and a spoon-shaped probe according to the present description. Fig. Figure 8A shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution duct with an obstruction inside the duct as described herein. Fig. Figure 8B shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution duct with an obstruction inside the duct as described herein. Fig. Figure 9 shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution duct with an obstruction inside the duct according to the present description. Fig. Figure 10 shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution duct with an obstruction inside the duct according to the present description. Fig. Figure 11 shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution duct with an obstruction inside the duct according to the present description. Fig. Figure 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 description. Fig. Figure 12B shows a cross-sectional view of an example of a magnetically coupled disk with four spherical rollers arranged beneath the disk, according to the present description. Fig. Figure 13 shows an example of a process flow diagram illustrating a procedure for inspecting a vent gas distribution duct. Fig. Figure 14 shows a schematic cross-sectional view of an example for three battery cells and a vent gas distribution duct with an obstruction and a laser located inside the duct, according to the present description. Fig. Figure 15 shows a schematic cross-sectional view of an example of three battery cells and a vent gas distribution duct with an obstruction and an endoscope with snipping jaws arranged inside the duct, according to the present description.

[0025] This description outlines inspection tools and procedures for inspecting and maintaining the interior of vent gas distribution ducts. An iron or magnetic probe (e.g., a steel ball, cylinder, rectangular cube, or disc) is inserted into the vent gas distribution duct. An external magnetic field from a magnetically coupled head is then used to magnetically pull the probe through the vent gas distribution ducts. The inspection tool uses a sensor to monitor the position of the magnetically coupled probe within the duct. When 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 to the obstruction.The magnetically coupled probe can be a steel spoon with sharp leading edges on the top and bottom, which cuts, detaches, and collects the obstruction. Removing the magnetically coupled spoon from the duct allows for its removal. A human operator or a programmed robotic arm can move the magnetically coupled head across the surface of the vent gas distributor in a direction parallel to the duct.

[0026] The term "magnet", as used here, can include permanent magnets, electromagnets or combinations thereof.

[0027] Fig. Figure 1 shows a schematic view of an example of a battery pack with three parallel vent gas distribution channels as described herein. Passages 8, 8', and 8" each connect the vent gases of battery cells 60, 60', and 60" to the vent gas distribution channels 20, 20', and 20", respectively. The potting 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 shell 64 is arranged above and transversely to the battery cells 20, 20', and 20". The lower wall 24 extends horizontally across the bottom of the vent gas distribution channels 20, 20', and 20". The TP shell 22 is arranged horizontally above the upper part of the vent gas distribution channels 20, 20' and 20". The upper shear plate 68 is arranged horizontally above the TP shell 22, with the potting layer 66 positioned between the TP shell 22 and the horizontal upper shear plate 68.

[0028] Fig. Figure 2A shows a schematic view of an inspection tool 15 and a magnetically coupled probe 28 for inspecting a vent gas distribution duct 20 according to the present description. The inspection tool 15 comprises 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 robot arm 18 via a rotatable joint 16. Alternatively, the sensor 14 can be handheld and guided by a human operator (not shown) who follows a template attached to the battery pack, which visually indicates the location of the parallel vent gas distribution ducts within the structure that houses the battery pack (see Figure 2A). Fig. 1) The inspection tool 15 may include electronic and visual and / or acoustic warning means (not shown) to wirelessly alert a human operator or a monitoring computer that an obstacle has been detected. The sensor 14 may be located inside the magnetically coupled head 10.

[0029] With further reference to Fig. 1. The magnetically coupled probe 28 is inserted into the vent gas distribution duct 20, where it is drawn against the upper duct wall 22 by magnetic attraction. The duct wall 22 can be made of a non-magnetic material (e.g., a polymer or aluminum). The magnetically coupled probe 28 can be made of an iron-containing material, steel, low-carbon steel, or a magnet. The magnetically coupled head 10 can be a magnet; in this case, the magnetically coupled probe 28 can be an iron-containing steel part or a magnet. Alternatively, the magnetically coupled head 10 can also be made of an iron-containing steel part; in this case, the magnetically coupled probe 28 is a magnet. In all these options, the magnetically coupled head 10 and the magnetically coupled probe 28 are magnetically coupled to each other 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 entered the channel 20 through a small opening or hole (not shown) in the upper channel wall 22. Fig. 2A, the magnetically coupled probe 28 has not yet encountered the obstacle 26. The magnetically coupled probe 28 can be in the shape of a sphere, a cylinder, a rectangular cube, a disk, or a U-shaped spoon / ladle.

[0030] 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 this description. In this figure, the magnetically coupled probe 28 has come into contact with the obstruction 26, which displaces the probe 28 downwards from the ceiling of the duct 20 by a distance = d. This displaces the probe 28 horizontally relative to the head 10 by a distance = X, 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 displacements (d, X) of the probe 28 from its normal (undisplaced) position can be detected by the sensor 14 in various physical or electrical ways.In one example, a strain gauge 17 can be vertically attached to one side of the shaft 12. This strain gauge 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), can be calculated from sensor 14 and strain gauge 17. A sudden increase in this force F indicates that the magnetically coupled probe 28 has touched the obstacle 26.

[0031] In another example, the magnetically coupled head 10 can include a capacitance sensor that monitors the capacitance of the separation between the magnetically coupled probe 28 and the magnetically coupled head 10. The gradual increase in the distances d and X, which increase upon contact of the magnetically coupled probe 28 with the obstacle 26, increases the capacitance of the inspection tool 15. In another example, the electrical inductance of an electromagnetically coupled head 10 can be monitored for sudden changes in inductance when an obstacle 26 is detected. In yet another example, a magnetic field sensor (e.g., a Hall sensor) can 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 can 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 can include an eddy current sensor that monitors changes in 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.

[0032] 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 side wall 30 at one end of the channel 20, as described herein. 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.

[0033] Fig. Figure 3B shows a schematic top view of an example of a vent gas distribution duct 20 with a removed magnetically coupled probe 28 and an endoscope hole 32 closed with a plug 40, as described herein. The hole 32 is closed with the plug 40 after the magnetically coupled probe 28 has been removed from the duct 20.

[0034] Fig. Figure 4 shows a schematic top view of an example of a vent gas distributor 42 with several interconnected parallel channels 20, 20', 20" and so on, and a magnetically coupled probe 28 as described herein. The magnetically coupled probe 28 enters at a corner of the vent gas distributor 42 and is pulled by the moving inspection tool 15 (not shown) along the length of the interconnected vent gas distributor channels 20, 20', 20" and so on, thereby searching for one or more obstructions (not shown) that might be located within the channels 20, 20', 20" and so on. Several vent gas distributor channels 20, 20', 20" and so on form a serpentine pattern of interconnected paths 44 separated by several parallel inner walls 34, 34' and so on.When the magnetically coupled probe 28 reaches the end of the interconnected channels 20, 20', 20" and so on, it can either (1) be removed through a temporary hole or opening in a side wall of the vent gas distributor 42 (the hole will be closed later), or (2) be trapped / captured / held / retained inside the distributor 42 by the trap 46. The trap 46 may, for example, include a rotary mechanism (see ). Fig. 5A and Fig. 5B). Alternatively, trap 46 can include a permanent magnet (see Fig. 6A and Fig. 6B). Alternatively, trap 46 can also include a sticky, self-adhesive pad (not shown).

[0035] Fig. Figure 5A shows a schematic top view of an example of a vent gas distribution duct with a magnetically coupled probe and a rotatable mechanism acting as a trap, according to the present description. The rotatable mechanism 48 comprises a first and a second short arm (i.e., wings) 50 and 52, arranged at right angles to each other and attached to a rotatable vertical post 48. The magnetically coupled probe 28 is magnetically coupled to and rests on the second arm 52. Fig. 5A on.

[0036] 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, which is rotated into a fixed position according to the present description. Here, the rotatable post 48 has rotated 90 degrees counterclockwise, causing the first arm 50 to enclose and hold the magnetically coupled probe 28 between the first arm 50 and the second arm 52, as well as against the partition 34 and the lower wall segment 37 (forming a box-shaped trap).

[0037] Fig. Figure 6A shows a schematic top view of an example of a vent gas distribution duct 20I with a magnetically coupled probe 28 and a magnet 54 at one end of the duct according to the present description. The magnetically coupled probe 28 is attracted to the magnet 54 at the end of the duct 20.

[0038] Fig. Figure 6B shows a schematic top view of an example of a vent gas distribution duct 20 with a magnetically coupled probe 28 attached to a magnet 54 at one end of the duct 20, as described herein. The magnet 54 holds the magnetically coupled probe 28 at the end of the duct 20.

[0039] 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 description. The magnetically coupled head 10 can be made of a rare-earth magnetic material, ferrite, or another 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.

[0040] 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 description. The magnetically coupled head 10 can be made of a rare-earth magnetic material, ferrite, or another 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.

[0041] 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 description. The magnetically coupled head 10 can be made of a rare-earth magnetic material, ferrite, or another magnetic material (e.g., NdFe). 35The 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.

[0042] 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 description. The magnetically coupled head 10 can be made of a rare-earth magnetic material, ferrite, or another magnetic material (e.g., NdFe). 35The magnetically coupled probe 28 can be made of steel, low-carbon steel, steel 1010, 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.

[0043] Fig. Figure 7E shows a schematic perspective view of an example of a U-shaped magnetically coupled probe 28 with upper and lower sharp leading edges 66 and 63, respectively, as described herein. The magnetically coupled probe 28 can also be referred to as a "spoon probe 62". The U-shaped magnetically coupled probe 28 can be dimensioned to fit inside a vent gas distribution duct, being small enough to easily traverse and move through a 180-degree turn at the ends of a pair of parallel, adjacent vent gas distribution ducts (see Figure 7E). 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 potting compound (e.g., obstruction 26); in this case, a separate magnetically coupled probe 28 would be used during the inspection steps.

[0044] Fig. Figure 8A shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60" and a vent gas distribution duct 20 with an obstruction 26 within the duct, as described herein. The obstruction 26 may be a lump of potting compound that has penetrated the duct 20. The steel bucket 62 is a U-shaped "shovel" that can be magnetically drawn into the duct 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 robot arm (not shown) to hold and manipulate. The steel bucket 62 may include a pair of lower and upper sharpened tips / blades 63 and 65, respectively, which can cut the protruding obstruction 26 from the lower 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 lower wall 24). The severed obstacle 26' is then held inside the steel bucket 62 (see figure). Fig. 8B), whereby the steel bucket 62 can later be removed from the channel 20. The lower sharpened tip / blade 63 extends horizontally further 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 if the obstruction 26 has penetrated from the upper TP shell 22. It should be noted that the external 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 rotation at the reversal point 45 of the parallel channels 20' and 20" in the vent gas distributor 42 without becoming stuck at the reversal point 45 (see Fig. 4).

[0045] Fig. Figure 8A shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60" and a vent gas distribution duct 20 with an obstruction 26 inside the duct, as described herein. In this view, the steel bucket 62 holds the detached obstruction 26'. The steel bucket 62, holding the detached obstruction 26', can later be removed from the duct 20, thus clearing the duct 20 of obstructions. Note: Multiple obstructions (not shown) can be cut off individually and collected by the steel bucket 62 before the steel bucket 62 is removed from the duct 20.

[0046] 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 inside the channel 20 according to the present description. 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 severed obstruction 26 to be vacuumed out of the interior of the steel bucket 62 and permanently removed, particularly if the obstruction 26 is liquid or semi-liquid. The flexible vacuum tube 70 can have a sufficiently large diameter to guide a solidified, severed obstruction 26' through the tube 70.

[0047] Fig. Figure 10 shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60" and a vent gas distribution duct 20 with an obstruction 26 inside the duct 20 according to the present description. This figure is identical to Fig. 9, with the exception of the addition of a sharp array 72 consisting of several sharp blades at the front end of the steel spoon 62. The sharp array 72 crushes the obstruction 26 into several smaller pieces that can be more easily suctioned through the flexible vacuum tube 70.

[0048] Fig. Figure 11 shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60" and a vent gas distribution duct 20 with an obstruction 26 inside the duct 20 according to the present description. This figure is identical to Fig. 9, except that a horizontal shaft 73 (attached to the steel spoon 62) with one or two rotating sharp blades 74 has been added, which are rotatably attached to 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 suctioned through the flexible vacuum tube 70. The rotating blades 74 can be driven by a battery-powered motor (not shown) or by vacuum.

[0049] Fig. Figure 12A shows a schematic top view of an example of a magnetically coupled disk 28 with four spherical rollers 76, 76' and so on, arranged below the disk 28, according to the present description.

[0050] Fig. Figure 12B shows a cross-sectional view of an example of a magnetically coupled disk 28 with four spherical rollers 76, 76', and so on, arranged beneath the disk 28, as described above. 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 as they slide along the channel 20.

[0051] Fig. Figure 13 shows an example of a process flow diagram illustrating a procedure 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: Placing a magnetically coupled head in the immediate vicinity of the channel; Step 106: Pushing the magnetically coupled head and pulling the magnetically coupled probe into the channel; 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: Alerting a computer or a human operator that the obstacle has been detected.

[0052] Fig. Figure 14 shows a schematic cross-sectional view of an example for three battery cells 60, 60', 60" and a vent gas distribution duct 20 with an obstruction 26 and a magnetically coupled laser 80 located inside the duct 20, according to the present description. The magnetically coupled laser 80 can be inserted into the duct 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 to it, can be made with a steel housing and be brought (i.e., pulled) into a suitable position by the magnetically coupled head 10. Alternatively, the magnetically coupled laser 80 can also act as a magnetically coupled probe 28 and be pulled by the magnetically coupled head 10 along the duct 20 until it encounters the obstruction 26 and a computer or a Operator alerted.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.

[0053] Fig.Figure 15 shows a schematic cross-sectional view of an example of three battery cells 60, 60', 60" and a vent gas distribution duct 20 with an obstruction 26 and an endoscope 90 with a pair of scissor jaws 92, 92' arranged within the duct 20, as described herein. Once the position of an obstruction 26 in the duct 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 duct 20 near 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 suctioned out with a suction hose (not shown).

[0054] In some embodiments, the magnetically coupled probe 28 can be configured to grind the obstacle 26 with one or more rotating rollers or gear elements (not shown) which can be driven by a battery-powered motor (not shown).

[0055] In some embodiments, a computer-aided algorithm can be used to control a robot arm that guides the magnetically coupled probe 28 through the interconnected series of parallel vent gas distributor channels 20, 20', 20" and so on within the vent gas distributor 42.

[0056] In some embodiments, the vent gas distribution channels 20, 20', 20" and so forth and the distributor 42 itself may be made of a non-magnetic material (e.g. aluminium, a polymer or fiber-reinforced polymer composite material).

[0057] In some embodiments, the magnetically coupled probe 28 can be a spoon-shaped scoop 62 with an upper and a lower sharp leading edge 65 and 63 respectively, which is made of steel or a magnetic material.

[0058] In some embodiments, the vent gas distribution channel 20 can be a rectangular, tubular channel.

[0059] In some embodiments, the vent gas distribution channel 20 can be an integral part of a battery pack in an electric vehicle, an electric aircraft, an electric boat or submarine, or an electric drone.

[0060] In some embodiments, the obstruction 26 may comprise a lump of potting compound that has penetrated the channel 20.

[0061] In some embodiments, the inspection tool 25 may also include a shaft 12 which is attached to the magnetically coupled head 10.

[0062] In some embodiments, the method may further include measuring a lateral force, torque and / or lateral deflection of the shaft 12 that is generated when the magnetically coupled probe 28 encounters an obstacle 26 inside the channel 20.

[0063] 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 with the sensor 14 when the obstacle 26 is detected.

[0064] In some embodiments, the inspection tool can be attached to a robot manipulator arm 18; and the method can further comprise moving the inspection tool 15 and the magnetically coupled probe 28 along the channel with the robot manipulator arm 18.

[0065] 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 detached and / or ground down the obstruction 26.

[0066] In some embodiments, the method may further include removing the magnetically coupled probe 28 from the channel after the inspection is completed.

[0067] 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.

[0068] In some embodiments, the removal of the obstruction 26 may comprise: (1) magnetically driving the magnetically coupled head 10 and a magnetically coupled spoon 62 arranged inside the channel, the magnetically coupled spoon 62 comprising a lower and an upper sharp leading edge 63 and 65, respectively; (2) cutting and detaching the obstruction 26 from a wall of the channel 20 by advancing the magnetically coupled spoon 62 into and past the obstruction, thereby cutting off and producing a detached obstruction 26'; (3) holding the detached obstruction 26' in the magnetically coupled spoon 62; and then (4) removing the magnetically coupled spoon 62 with the detached obstruction held therein from the channel 20.

[0069] In some embodiments, the method may further include suctioning up 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.

[0070] In some embodiments, the magnetically coupled spoon 62 can comprise several stationary or rotating blades 74 that cut the obstruction into a multitude of small, individual fragments that are easier to remove (e.g. by suction).

[0071] In some embodiments, the channel 20 can be arranged within a battery venting gas distribution system 42 of an electric vehicle.

[0072] In some embodiments, holding the magnetically coupled probe 28 at one end of the channel 20 after completion of the inspection may include rotating a unidirectional rotatable post 48 with a pair of arms 50, 52 which captures and holds the magnetically coupled probe 28 at the end of the channel 20.

[0073] In some embodiments, retaining the magnetically coupled probe 28 at one end of the channel 20 after completion of the inspection may involve the use of a permanent magnet 54 arranged at the end of the channel 20 to capture and retain the magnetically coupled probe 28 at the end of the channel 20.

[0074] In some embodiments, the inspection tool 15 can be attached to a robot manipulator arm 18; and the method can further comprise moving the inspection tool 15 and the magnetically coupled probe 28 along a length of the channel with the robot manipulator arm 18.

[0075] In some embodiments, a paper or plastic “map” showing the interconnected channels 20, 20’, 20” and so forth can be attached or affixed to the outer surface of the battery pack to indicate the location of the internal channels. This can assist a human operator in manually moving the inspection probe 15 along the windings of the interconnected channels 20, 20’, 20” and so forth. Alternatively, a video projector can project the “map” of the channels 20, 20’, 20” and so forth onto the outer surface of the battery pack.

[0076] In some embodiments, a magnetically coupled laser 80 with a steel housing can be inserted into the channel 20, magnetically drawn to a point on the obstacle 26 by the magnetically coupled head 10, and then irradiate the obstacle 26, causing it to heat up and vaporize.

[0077] In another example, the laser 80 can act 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.

[0078] 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.

Claims

[1] Inspection tool set, comprising: a magnetically coupled probe (28) dimensioned to fit into a channel (20) and slide along it; an inspection tool (15) with a magnetically coupled head (10) arranged outside the channel (20); and a sensor (14) which is attached to or arranged in the magnetically coupled head (10); wherein the sensor (14) is configured to detect when the magnetically coupled probe (28) has encountered an obstacle (26) located within the channel (20); and wherein the magnetically coupled head (10) and the magnetically coupled probe (28) are magnetically coupled to form a magnetically coupled probe / head pair having a magnetic strength sufficient to pull the magnetically coupled probe (28) inside the channel (20) when the magnetically coupled head (10) is moved outside the channel (20); a shaft (12) attached to the head (10) and the sensor (14), which is arranged between the head (10) and the sensor (14); and wherein the sensor (14) is configured to detect an increase in a lateral force, torque and / or lateral deflection of the shaft (12) when the magnetically coupled probe (28) encounters the obstacle (26) located inside the channel (20). [2] Inspection tool set according to claim 1, wherein the sensor (14) 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 arranged inside the magnetically coupled head (10); when the magnetically coupled probe (28) encounters the obstacle (26). [3] Inspection tool set according to claim 1, wherein the inspection tool (15) is attached to and manipulated by a robot manipulator arm (18); or is manipulated by a human operator. [4] Inspection tool set according to claim 1, wherein the channel (20) is arranged in a battery venting gas distribution system (42) of an electric vehicle. [5] Method for inspecting a channel (20) using an inspection tool set, the method comprising: (a) Providing (100) an inspection tool set comprising: a magnetically coupled probe (28) which is dimensioned to fit into the channel (20) and slide along it; an inspection tool (15) with a magnetically coupled head (10) arranged outside the channel (20); and a sensor (14) which is attached to or arranged in the magnetically coupled head (10); wherein the sensor (14) is configured to detect when the magnetically coupled probe (28) has encountered an obstacle (26) located within the channel (20); and wherein the magnetically coupled head (10) and the magnetically coupled probe (28) are magnetically coupled to form a magnetically coupled probe / head pair having a magnetic strength sufficient to pull the magnetically coupled probe (28) inside the channel (20) when the magnetically coupled head (10) is moved outside the channel (20); (b) Inserting (102) the magnetically coupled probe (28) into the channel (20); (c) Placing (104) the magnetically coupled head (10) in the immediate vicinity of the channel (20) and sliding the magnetically coupled head (10) along the channel (20), thereby pulling the magnetically coupled probe (28) along the channel (20); (d) Detecting (108) one or more changes in a physical, electrical and / or magnetic property of the inspection tool (15) with the sensor (14) when the magnetically coupled probe (28) encounters the obstacle (26); and (e) Alerting (110) a computer or a human operator that the obstacle (26) has been detected; wherein the inspection tool (15) further comprises a shaft (12) which is attached to the magnetically coupled head (10); and wherein the method further comprises measuring a lateral force, torque and / or lateral deflection of the shaft (12) generated when the magnetically coupled probe (28) encounters the obstacle (26) located within the channel (20). [6] The method of claim 5, further comprising attaching a physical map or projecting a video display onto an outer surface of a battery pack showing the positions of the internal channels (20, 20', 20") within the battery pack, and using the map or video display to guide a human operator to move the magnetically coupled probe (28) along the channel (20). [7] Method according to claim 5, further comprising measurement with the sensor (14): (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 (10); when the obstacle (26) is discovered. [8] Method according to claim 5, wherein the inspection tool (15) is attached to a robot manipulator arm (18); and the method further comprises moving the inspection tool (15) and the magnetically coupled probe (28) along the channel (20) with the robot manipulator arm (18).

Images