Generator Air-Gap Test Vehicle With Circumferential Lane Change

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Solution Overview

Problem

Existing systems for inspecting the condition of generators in stationary gas turbine plants require manual removal of the rotor, which is labor-intensive and costly, and are not suitable for generators with limited access due to the need for manual circumferential movement of the test vehicle.

Innovation Solution

A system comprising a test vehicle and a lane change unit that can be inserted into the air gap between the rotor and stator, allowing the test vehicle to be temporarily parked and moved circumferentially along the stator using the lane change unit, eliminating the need for manual movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the rotor is removed for visual inspection, then the inspection personnel can access the stator and rotor surfaces, but the process becomes labor-intensive and costly

Engineering Contradiction:

Improveinspection accessibilityVSAvoidinspection efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

An endoscope is introduced as an intermediary device to access the air gap between rotor and stator without requiring rotor removal. The endoscope transmits visual information from the inspection area to the operator, enabling inspection while the rotor remains installed, thus maintaining accessibility while improving efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mechanical approach of physically removing the rotor is replaced with an optical system (endoscope) that uses light transmission and imaging to achieve inspection goals, eliminating the need for mechanical disassembly and significantly improving inspection efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If a conventional endoscope is used for visual inspection, then the rotor can remain installed, but the inspection is not suitable for generators with rotor lengths of several meters

Engineering Contradiction:

Improveinspection efficiencyVSAvoidapplicability to large generators

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The inspection system is divided into multiple segments or sections that can be sequentially positioned along the rotor length. The rotor surface is divided into inspection zones, and the endoscope is repositioned in steps to cover the entire length, making the system adaptable to large generators while maintaining inspection efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The inspection approach transitions from a single-point static observation to a multi-dimensional scanning system that moves along the axial and circumferential directions, enabling comprehensive inspection of long rotors by utilizing multiple spatial dimensions

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of operation

If the test vehicle is manually moved in the circumferential direction after each axial run, then the test vehicle can be repositioned for the next axial test run, but the process requires significant manual effort and time

Engineering Contradiction:

Improvetest vehicle repositioningVSAvoidtime for circumferential movement

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The test vehicle is equipped with self-propulsion capabilities including circumferential drive mechanisms that enable it to reposition itself automatically without manual intervention. The vehicle performs its own lane-changing movements by engaging with the stator structure, eliminating the need for manual repositioning and reducing time loss

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The test vehicle transitions from a static positioning system to a dynamic self-repositioning system. The vehicle incorporates movable components and active control systems that enable automatic circumferential movement, adapting its position based on inspection requirements without manual intervention

Inventive Principle:

Principle #15Dynamics

4Ease of operation

If manual movement of the test vehicle is required in the circumferential direction, then the test vehicle can be repositioned, but operating personnel must remain in a very confined space for extended periods

Engineering Contradiction:

Improvetest vehicle controlVSAvoidoperator exposure to confined space

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A remote control system or automated control unit is introduced as an intermediary between the operator and the test vehicle. The operator controls the vehicle from a safe distance using transmitted signals, eliminating the need to physically enter the confined air gap space while maintaining full control over vehicle operations

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Direct manual mechanical operation of the test vehicle is replaced with remote or automated electronic control systems. The vehicle's movement and inspection functions are controlled through electronic signals rather than direct mechanical manipulation, allowing operators to work from outside the confined space

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4384836B1Test system

Publication Date: 2025.06.18 SIEMENS ENERGY GLOBAL GMBH & CO KG

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AI summary

The invention relates to a system (1) for testing the condition of a stator (4) and/or rotor (5) of an electrical machine (6), the system comprising a test vehicle (7), a track-changing unit (8) and a control unit (9). The invention further relates to a test method carried out using such a system (1).