End Region Inspection Module Using an Air-Gap Crawler
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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 or safe inspections.
Innovation Solution
A robotic crawler system that can be inserted through the radial air gap between the core iron and retaining ring of a machine, allowing for in situ inspection of the rotor and stator core, equipped with a visual inspection module and extension member for inspecting hard-to-reach end regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complete disassembly and rotor removal is performed for inspection, then inspection completeness is improved, but time consumption and cost increase
Solution Approach 1:
The inspection system is divided into modular components: a robotic crawler for navigation, an extendible mast for reaching different depths, and interchangeable inspection tools. This segmentation allows the system to perform complete inspections without full disassembly by accessing different regions through the air gap.
Solution Approach 2:
The robotic crawler acts as an intermediary device that passes through the air gap between rotor and stator to reach inspection areas. This mediator enables inspection of internal components without requiring removal of the rotor, thus reducing time while maintaining completeness.
2Measurement precision
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 equipped with its own power source, navigation capabilities, and inspection tools, enabling it to autonomously perform inspection tasks within the air gap. This self-service capability eliminates the need for expensive disassembly operations while achieving complete inspection coverage.
3Measurement precision
If rotor removal is performed for inspection, then inspection completeness is improved, but safety risks increase
Solution Approach 1:
The robotic crawler serves as a safe intermediary that can be inserted through the air gap to inspect rotor and stator components without physical removal. This eliminates safety hazards associated with rotor handling while maintaining inspection completeness through extended mast and various inspection tools.
4Device complexity
If traditional inspection methods are used, then equipment complexity is reduced, but inspection completeness deteriorates
Solution Approach 1:
The robotic crawler is designed as a universal inspection platform that can perform multiple functions: navigation through the air gap, extension to reach different depths, and accommodation of various inspection tools (visual, electrical, mechanical). This multi-functionality achieves complete inspection without proportionally increasing equipment complexity.
5Measurement precision
If robotic crawler with extension member is used for end region inspection, then inspection completeness is improved, but device complexity increases
Solution Approach 1:
The inspection system uses a nested structure where the mast can be extended from the crawler body, and inspection tools are nested within the mast. This nested doll approach enables end region inspection capability while minimizing device complexity by collapsing the structure when not in use.
Data Source
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AI summary
This disclosure provides systems and methods for in situ gap inspection in a machine, such as a generator, an electric motor, or a turbomachine, with an end region. A robotic crawler is configured to navigate an annular gap of the machine. A visual inspection module is connected to the robotic crawler and includes an extension member for extending a camera into the end region to collect visual inspection data.