Recurring-Structure Component Scanning for Aging Defect Localization
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Solution Overview
Problem
Current methods for detecting signs of aging in components with regularly recurring structures, such as stator winding insulation, are inadequate as they fail to accurately identify and localize aging signs due to complex structures, leading to incomplete detection and potential damage in generators.
Innovation Solution
A method involving scanning in multiple planes to create two-dimensional images, using algorithms to distinguish between inhomogeneities that form recurring patterns and those that do not, allowing for the reliable detection of signs of aging by focusing on non-recurring inhomogeneities, which can be achieved through terahertz, ultrasound, or tomography techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If partial discharge measurement is used to detect signs of aging, then detection capability is improved in regions with high electric field, but detection coverage is reduced to only 30% of the insulation length
Solution Approach 1:
The patent divides the inspection task into two distinct methods: partial discharge measurement for high electric field regions and a new scanning method for remaining regions. This segmentation allows each method to be optimized for its specific application area, achieving both high precision where needed and comprehensive coverage overall.
Solution Approach 2:
The patent develops a universal scanning method that can detect signs of aging in all regions of the insulation, not just those with high electric fields. This multi-functional approach combines the advantages of different detection techniques to provide complete coverage across the entire insulation length.
2Productivity
If partial discharge measurement is used, then detection speed is improved, but localization accuracy deteriorates to approximately 1.2 meters
Solution Approach 1:
The patent introduces a scanning system with multiple sensors as an intermediary between the insulation and the detection process. This intermediary structure enables precise localization by capturing signals from multiple positions simultaneously, achieving both high detection speed and accurate positioning.
3Measurement precision
If high-voltage testing is used to detect significant signs of aging, then detection capability is improved, but reliability deteriorates due to risk of irreparable breakdown
Solution Approach 1:
The patent applies partial action by using low-voltage scanning instead of full high-voltage testing. This partial approach is sufficient to detect signs of aging while avoiding the excessive voltage that would cause breakdown, thus maintaining both detection capability and component reliability.
Solution Approach 2:
The patent employs beforehand cushioning by using gentle scanning methods that prepare for potential weaknesses without triggering breakdown. The low-voltage scanning acts as a cushioning measure that reveals problems before they escalate to catastrophic failure.
4Quantity of substance
If terahertz, ultrasound or tomography techniques are used to scan the component, then detection coverage is improved, but measurement precision deteriorates due to difficulty in distinguishing signs of aging from winding structure
Solution Approach 1:
The patent applies local quality by tailoring the scanning parameters and analysis methods to specific regions and types of defects. Different scanning settings and evaluation criteria are used for different parts of the insulation, enabling precise identification of aging signs while accounting for local structural variations.
Solution Approach 2:
The patent utilizes parameter changes by adjusting scanning frequencies, amplitudes, and analysis thresholds to optimize the distinction between aging signs and normal winding structure. By dynamically changing detection parameters, the system achieves high identification accuracy across diverse inspection scenarios.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable detection and localization of signs of aging in complex structures, facilitating timely repair measures and improving damage assessment without causing irreparable breakdowns.
Implementation Method 1
the very complex winding structure of the insulation can also be seen on the scanning images
Implementation Method 2
ultrasound testing is not plausible because of the many reflections
Implementation Method 3
tomography testing techniques, in which the component to be tested in scanned with the production of scanning images
Implementation Method 4
b) automatically identifying those inhomogeneities that form recurring patterns and those inhomogeneities that do not follow a recurring pattern, using a suitable algorithm
Implementation Method 5
the accuracy of the propagation time measurement of the partial discharge pulses is approximately 1.2 meters
Data Source
AI summary
A method for the non-destructive detecting of ageing symptoms of a component having regularly recurring structures, includes the following steps: a) scanning the component in the region of the recurring structures in a plurality of scanning planes which extend parallel to one another to create at least one scanning image set having a plurality of two-dimensional scanning images, wherein the scanning images show a plurality of inhomogeneities; b) automatically identifying those inhomogeneities that form recurring patterns, and those inhomogeneities that do not follow a recurring pattern, using a suitable algorithm; and c) detecting ageing symptoms exclusively on the basis of those inhomogeneities which are identified in step b) and do not follow a recurring pattern.