Extendable Carrier Inspection Device for Narrow Ferromagnetic Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inspection devices for narrow air gaps between ferromagnetic surfaces, such as in generators, require access from both sides and are not suitable for gaps smaller than 40 mm, limiting their applicability and efficiency in maintaining machinery without dismantling.
Innovation Solution
A device with an elongated, extendable carrier equipped with magnets for contact with ferromagnetic surfaces, allowing controlled insertion and movement within the gap, and a curvature for rigidity, enabling inspection without enlarging the gap, along with a sensor platform and rolling elements for smooth navigation and signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional inspection device with wheels and motors is used, then the device can move along surfaces, but it requires access from both sides of the machine and cannot inspect gaps smaller than 40 mm
Solution Approach 1:
The inspection device is divided into multiple segments that can extend and collapse. The carrier consists of an elongated element with sensors distributed along its length, allowing the device to adapt to different gap sizes by extending to reach across the gap or collapsing for storage and transport through narrow openings.
Solution Approach 2:
The device transitions from a static structure to a dynamic one that can change its configuration. The carrier can extend and retract, and the sensor platform can adjust its position, enabling the device to inspect gaps of varying sizes and navigate through limited access points without requiring disassembly of machine components.
2Ease of operation
If the air gap is enlarged by removing components to allow inspection device access, then inspection can be performed, but machine dismantling is required which increases time and effort
Solution Approach 1:
The inspection device uses a flexible, elongated carrier that can bend and conform to narrow spaces. This flexible structure allows the device to pass through narrow air gaps without requiring the gap to be enlarged or machine components to be removed, enabling inspection through existing access points.
Solution Approach 2:
The device approaches the inspection problem from a different dimensional perspective by using an elongated carrier that extends perpendicular to the rotor axis, allowing sensors to reach across the air gap from one side without requiring access from both sides or enlargement of the gap.
3Measurement precision
If a rigid mast structure is used for sensor positioning, then the sensor can be positioned accurately, but the device cannot be stored compactly or placed in limited spaces
Solution Approach 1:
The rigid mast is segmented into collapsible sections that can be folded or retracted. The elongated carrier can be divided into segments that telescope or fold together, maintaining sensor positioning accuracy when extended for inspection while reducing to a compact form for storage and transport in limited spaces.
Solution Approach 2:
The carrier and sensor platform use a nested configuration where smaller components are housed within larger ones when not in use. The sensor platform can be retracted into the carrier, and the carrier itself can be folded or collapsed into a compact package, enabling compact storage while maintaining full inspection capability when deployed.
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 and precise inspection of narrow air gaps as small as 4 mm without the need to enlarge them, facilitating easy storage, transport, and versatile placement in limited spaces, while maintaining consistent contact with the ferromagnetic surfaces.
Implementation Method 1
The carrier has a plurality of magnets which are distributed over the length of the carrier and which bring and hold the carrier in contact with a ferromagnetic surface
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A device for inspecting a gap between two surfaces, at least one of which is ferromagnetic, such as in a generator, comprises a sensor platform (26) for one or more sensors (26a) and an elongated, extendable carrier (23) for the sensor platform (26). The carrier (23) can be inserted into and removed from the gap through an access opening and can be extended along the length of the gap by means of a drive (24) and retracted outside the gap. According to the invention, the carrier (23) has a curvature in its extended state in a cross-section perpendicular to its longitudinal extent. Additionally, the carrier (23) has a plurality of magnets (27), which bring the carrier (23) into contact with a ferromagnetic surface.The magnets (27) are attached to the side of the carrier (23) facing away from the ferromagnetic surface, ensuring that the carrier (23) slides along a ferromagnetic surface. The device enables the inspection of gaps from a height of 4 mm and is characterized by its simple and compact design.