Generator Inspection Robot Navigating Rotor Stator Gaps
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Solution Overview
Problem
Existing inspection methods for generators struggle to effectively and automatically inspect the narrow gap between the rotor and stator without disassembling the components, as they face challenges in navigating and stabilizing the inspection robot within the tight space.
Innovation Solution
A robot device equipped with an inspection robot and a station part featuring an elevating mechanism, which allows the robot to be inserted into the gap between the rotor and stator, travel along the outer peripheral surface, and inspect both components using sensors, while the elevating mechanism enables the robot to traverse the step between the rotor and end ring, ensuring stable adhesion and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the inspection robot is inserted into the narrow gap between rotor and stator, then the inspection capability is improved, but the robot stability and adhesion deteriorate due to the tight space constraints
Solution Approach 1:
The robot employs a compliant body structure that can dynamically adapt its shape and stiffness to maintain stable adhesion on the curved rotor surface while navigating the narrow gap. The body can flex and deform to conform to the rotor's outer peripheral surface, ensuring continuous contact and stability during inspection operations.
Solution Approach 2:
The robot changes its physical parameters including body stiffness, contact pressure, and adhesion force to match the varying conditions within the narrow gap. By adjusting these parameters, the robot maintains optimal stability on the rotor surface while preserving the ability to inspect both the rotor and stator components.
2Adaptability or versatility
If the robot travels along the outer peripheral surface of the rotor, then the inspection coverage is improved, but the difficulty of navigating the step between rotor and end ring increases
Solution Approach 1:
The robot uses its compliant body to dynamically navigate the step transition between the rotor and end ring. The body can deform to bridge the gap and adapt to the changing surface geometry, allowing the robot to traverse the step without disassembly while maintaining inspection coverage.
Solution Approach 2:
The robot utilizes the radial dimension by extending its body outward from the rotor surface to reach and inspect the stator component. This dimensional approach allows the robot to inspect both rotor and stator from its position on the rotor outer peripheral surface, expanding inspection coverage without requiring additional navigation complexity.
3Ease of operation
If the robot is raised from the rotor surface using elevating mechanism, then the robot can be removed from the gap, but the complexity of the station part increases
Solution Approach 1:
The elevating mechanism acts as an intermediary device between the station part and the robot. This mediator component enables easy robot removal and positioning by providing a controlled lifting function, while the overall station part design keeps the added complexity manageable through integration with the existing inspection system.
Data Source
AI summary
According to one embodiment, a robot device includes a robot and a station part. The robot is inserted into a gap between an outer peripheral surface of a first part of a first member and a second member surrounding the outer peripheral surface. The first member includes the first part and a second part. A step is formed between the first part and the second part. The station part includes an elevating mechanism. The elevating mechanism lowers the robot onto the outer peripheral surface of the first member on a lower stage side of the step, and raises the robot from the outer peripheral surface.