Actuated Sensor Modules for In Situ Generator Gap Inspection
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Solution Overview
Problem
Existing methods for inspecting generators, electric motors, and turbomachines require disassembly and removal of the rotor, which is costly, time-consuming, and risky, and do not provide complete, timely, or safe inspection of the stator and rotor components.
Innovation Solution
A robotic crawler system that can be inserted through the radial air gap between the core iron and retaining ring of generators, electric motors, or turbomachines, allowing for in situ inspection and testing of stator wedges and other components using collapsible and expandable mechanisms, along with sensor modules for visual and mechanical inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complete disassembly and rotor removal is performed for inspection, then inspection completeness is improved, but loss of time and increase of cost worsen
Solution Approach 1:
The inspection system is segmented into a robotic crawler unit that can independently navigate the air gap, separating the inspection function from the need for complete disassembly. The crawler contains its own power source, sensors, and control systems, allowing it to perform inspections while the generator remains assembled.
Solution Approach 2:
The robotic crawler acts as an intermediary device that accesses the inspection area through the air gap without requiring rotor removal. It bridges the gap between the stator and rotor, enabling inspection of both components while maintaining their assembled state.
2Reliability
If complete disassembly and rotor removal is performed for inspection, then inspection completeness is improved, but cost increases
Solution Approach 1:
The robotic crawler is self-contained with integrated power sources (battery), sensors, cameras, and control systems, eliminating the need for external support equipment and personnel during inspection. This self-sufficiency reduces operational costs and simplifies the inspection process.
3Object-affected harmful factors
If rotor removal is performed for inspection, then inspection safety is improved, but loss of time worsens
Solution Approach 1:
The robotic crawler employs dynamic expandable legs that can be deployed and retracted as needed. During inspection, the legs extend to provide stable support against the stator and rotor surfaces. For insertion and retrieval, the legs collapse to a compact configuration, enabling quick movement without requiring generator disassembly.
4Ease of operation
If robotic crawler with expandable legs is used for inspection, then ease of operation is improved, but device complexity worsens
Solution Approach 1:
The robotic crawler utilizes a nested structure where the expandable legs are housed within the main body when retracted. This nesting allows the complex leg mechanism to be compact during insertion and retrieval, while providing full functionality during inspection operations.
Data Source
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AI summary
This disclosure provides systems and methods for an actuated sensor module for in situ gap inspection robots. A mounting interface attaches to the sensor module to the robot system. At least one arm is operatively connected to the mounting interface and has a joint. A sensor head is operatively connected to the arm at the joint and an actuator operatively connected to the arm moves the sensor head around the second joint.