Automated Eddy Current Probe Positioner for Steam Generator Tube Sheets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual and time-consuming process of inspecting and testing steam generator tube sheets requires an efficient and automated solution for positioning test and repair equipment, which existing technologies have not adequately addressed.
Innovation Solution
A robotic tool positioner with a sliding body, rotating gripper pod, and machine vision, capable of moving across the tube sheet, supporting eddy current test probes and repair tools, and utilizing a simplified serial network for control and data acquisition, with pneumatic actuators and Hall effect sensors for precise tube gripping and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated positioning apparatus is implemented, then inspection speed and accuracy are improved, but device complexity increases
Solution Approach 1:
The automated positioning apparatus is divided into distinct functional modules: a robotic arm for positioning, a test probe for inspection, a control system for coordination, and a data acquisition system for recording results. This segmentation allows each component to be optimized independently while maintaining overall system productivity and reducing complexity through modular design.
2Extent of automation
If automated positioning apparatus is implemented, then labor requirements are reduced, but device complexity increases
Solution Approach 1:
The robotic arm is designed with universal gripping capabilities that can accommodate various test probe types and configurations. The positioning system can adapt to different tube sheet geometries and inspection requirements through programmable motion control, reducing the need for multiple specialized devices and thereby managing complexity while maintaining high automation.
3Measurement precision
If precise positioning is achieved, then measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The positioning system incorporates feedback mechanisms through sensors that detect the actual position of the test probe relative to the tube sheet. This feedback is fed to the control system, which adjusts the robotic arm positioning in real-time to achieve and maintain precise measurement accuracy, managing complexity through intelligent control rather than mechanical complexity.
4Ease of operation
If integrated cable system is implemented, then ease of operation is improved, but cable management complexity increases
Solution Approach 1:
Multiple cable functions including power supply, data transmission, and signal routing are merged into a single integrated cable harness that connects the robotic arm to the base station. This consolidation simplifies operation by reducing the number of separate connections required while managing internal cable complexity through structured design and routing.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An apparatus for automated inspection and repair of a tube sheet. The apparatus has a rotating gripper pod, comprising at least one tube gripper, a sliding body portion containing the gripper pod; a housing portion comprising at least one tube gripper and a tool head coupling. The tool head coupling swapably attaches to a eddy current test probe and at least one kind of tube repair tool. Novel, auto-locking tube grippers are also disclosed. A serial bus connects electronic modules within the apparatus and also connects the apparatus to an external controller.