Crawler Inspection Mapping Haptic Feedback Confined Space
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Solution Overview
Problem
Existing inspection systems for rotating electrical machines face challenges in efficiently inspecting and maintaining air gaps without disassembling the machinery, particularly due to the complexity and cost associated with removing the rotor, and the difficulty in accurately mapping and navigating the small, confined air gap region.
Innovation Solution
A crawler system with haptic feedback and mapping capabilities that allows for inspection and repair of rotating electrical machines, equipped with modular designs, sensors, and feedback mechanisms to navigate and identify defects within the air gap without removing the rotor, utilizing cameras, accelerometers, gyroscopes, and haptic feedback to assist operators in orientation and defect detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If rotor disassembly is performed for inspection, then inspection accessibility is improved, but system complexity and cost increase
Solution Approach 1:
A crawler device is introduced as an intermediary inspection tool that can navigate the air gap between stator and rotor without requiring rotor disassembly. The crawler carries sensors and cameras to inspect the air gap region, providing accessibility to the inspection target while avoiding the complexity of complete disassembly.
2Reliability
If rotor disassembly is performed for inspection, then inspection completeness is improved, but loss of time increases
Solution Approach 1:
The crawler device is prepared in advance with all necessary inspection equipment (sensors, cameras, navigation systems) before being deployed into the air gap. This preliminary preparation allows the inspection to be conducted immediately upon insertion, eliminating the time-consuming disassembly process while ensuring comprehensive inspection coverage.
3Device complexity
If traditional inspection methods are used, then device simplicity is maintained, but measurement precision deteriorates
Solution Approach 1:
Traditional mechanical measurement tools are replaced with electronic sensors and optical cameras mounted on the crawler. These electronic measurement systems provide higher precision for air gap mapping and defect detection while maintaining relative simplicity through integrated electronics rather than complex mechanical measurement mechanisms.
4Device complexity
If manual navigation is used in air gap, then device simplicity is maintained, but ease of operation deteriorates
Solution Approach 1:
The crawler is equipped with sensors that provide real-time feedback on its position, orientation, and surrounding environment. This feedback is transmitted to the operator, enabling precise manual navigation through the confined air gap. The feedback mechanism improves ease of operation without requiring overly complex autonomous navigation systems.
Data Source
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AI summary
A modular crawler device is used to inspect a confined space in a machine. The inspection coverage area and corresponding status can be mapped so that the inspection location and associated data are graphically visualized. One or more sensors are coupled with the crawler so as to provide positional data and information regarding defects within the confined space. The sensed information is used to generate an inspection map that provides inspection history, logged data and a reference that are useful in scheduling the next inspection. The output of the sensors can also be used to provide haptic feedback to an operator.