Dual-View Robot Inspection Module for Generator Air Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for inspecting generators, such as generators, electric motors, or turbomachines, require disassembly and are time-consuming, costly, and unsafe, and existing visual sensors are limited in size and optical focal distance, making efficient imaging of rotor and stator cores challenging.
Innovation Solution
A visual inspection module for a robot with dual view paths, using a robotic crawler that can expand to fit within the annular gap between the core iron and retaining ring, equipped with larger visual sensors and reflectors for improved image resolution and reduced distortion, allowing simultaneous inspection of multiple surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If one or more visual sensors are aimed directly at the rotor and/or stator core, then the inspection can be performed, but the visual sensors are limited in size and optical focal distance, resulting in insufficient image resolution and coverage
Solution Approach 1:
The patent introduces reflectors as intermediary elements to redirect light from the rotor and stator core surfaces to the visual sensors. This allows the use of larger visual sensors with increased optical focal distance for improved image resolution, while the reflectors act as mediators to redirect the light paths, enabling better image quality without requiring the sensors to be positioned directly adjacent to the surfaces being inspected.
2Ease of operation
If a parallelogram-type parallel lift is used to mount the sensor, then the sensor can be positioned in a parallel configuration, but it requires certain axial space in the collapsed state and does not provide necessary resistance for certain tests
Solution Approach 1:
The patent employs a scissor lift mechanism that can dynamically adjust the position of the sensor mount between a collapsed state (requiring minimal axial space for insertion) and an expanded state (providing adequate support and positioning capability). This dynamic transformation allows the system to meet space constraints during insertion while providing the necessary structural support and positioning capability during inspection operations.
3Reliability
If complete disassembly of the stator and removal of the generator rotor is performed, then inspection and testing can be conducted, but the cost, time, and safety risks increase significantly
Solution Approach 1:
The patent segments the inspection function into multiple independent components: visual sensors for imaging, reflectors for light redirection, and a scissor lift mechanism for positioning. This segmentation allows the inspection system to be inserted into the air gap without complete disassembly, maintaining inspection capability while avoiding the time-consuming and risky process of full disassembly and rotor removal.
Solution Approach 2:
The patent replaces the traditional mechanical approach of physical disassembly with an optical-based inspection system. Instead of mechanically removing the rotor and disassembling the stator, the system uses visual sensors and reflectors to optically access and inspect the components in situ, thereby eliminating the need for time-consuming mechanical disassembly while maintaining inspection reliability.
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 efficient, safe, and complete in situ inspection of generator components without disassembly, providing high-resolution images with reduced distortion and improved coverage.
Implementation Method 1
a first reflector reflects an image of the first surface to the first visual sensor, and a second reflector reflects an image of the second surface to the second visual sensor
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A sensor interface module for an inspection robot includes a scissor lift for varied radial positioning of, and a universal sensor mount for mounting, a selected one of a plurality of different sensors. A visual inspection module for the robot includes an inspection unit for simultaneously visually inspecting a first surface facing a first direction and a spaced, second surface facing an opposing, second direction toward the first surface. The inspection unit includes a first visual sensor and a second visual sensor, each visual sensor facing in a direction different than the first and second directions. A first reflector reflects an image of the first surface to the first visual sensor, and a second reflector reflects an image of the second surface to the second visual sensor. A robot system may include the sensor interface module and the inspection unit.