Magnetic Crawler Borescope for Electrical Machine Inspection
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Solution Overview
Problem
Existing inspection systems for internal components of machines, particularly electrical machines, face challenges in accessing and visualizing internal features like winding overhangs and air vents without damaging the borescope or the machine components, due to the difficulty in controlling the path of long, flexible borescopes and the non-intuitive relationship between control actions and displayed movements.
Innovation Solution
A magnetic air gap crawler system is used to deliver and position a borescope with an articulating tip, allowing it to extend beyond the crawler's reach and inspect areas that are not line-of-sight observable, by adhering to the machine's magnetic surfaces and using a tether for control and power, enabling precise navigation and imaging of internal components without manual manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a long flexible borescope is used to inspect internal components, then the inspection coverage is improved, but the control precision and ease of operation deteriorate due to non-intuitive relationship between control actions and displayed movements
Solution Approach 1:
The patent replaces manual mechanical control of a flexible borescope with a magnetic crawler system that uses magnetic fields for propulsion and positioning. The crawler is propelled by magnetic attraction between magnets on the crawler and ferromagnetic surfaces, allowing precise control without the non-intuitive flexibility issues of traditional borescopes. The system substitutes mechanical flexibility with magnetic field-based actuation for improved controllability.
Solution Approach 2:
The magnetic crawler acts as an intermediary between the operator and the imaging device. Instead of directly manipulating a flexible borescope, the operator controls the rigid crawler which then positions the borescope or camera at the desired location. This intermediary approach provides intuitive control while maintaining the ability to reach difficult-to-access areas.
2Area of stationary object
If a borescope is manually manipulated to reach hard-to-access areas, then inspection coverage is improved, but the risk of damage to the borescope or machine components increases
Solution Approach 1:
The magnetic crawler propels itself through magnetic attraction to navigation points or markers placed on ferromagnetic surfaces, eliminating the need for manual manipulation. The system uses onboard magnets to adhere to and move along the machine components, allowing autonomous navigation to hard-to-reach areas without human intervention that could cause damage.
Solution Approach 2:
The patent replaces manual mechanical manipulation with magnetic field-based propulsion and positioning. The magnetic crawler uses magnetic attraction to move itself and maintain position, providing precise control that reduces the risk of accidental contact or damage to both the imaging device and machine components.
3Ease of operation
If the rotor is removed to inspect internal components, then the inspection accessibility is improved, but the loss of time and productivity increases
Solution Approach 1:
The magnetic crawler serves as an intermediary that can navigate through the air gap between the rotor and stator without requiring rotor removal. The crawler's ability to adhere to ferromagnetic surfaces allows it to position the imaging device in locations that would otherwise require disassembly, maintaining inspection accessibility while avoiding the time-consuming rotor removal process.
4Measurement precision
If a rigid inspection device is used, then the control precision is improved, but the ability to reach non-line-of-sight areas deteriorates
Solution Approach 1:
The inspection system is segmented into two functional components: a rigid magnetic crawler for precise positioning and control, and a flexible borescope or camera for reaching non-line-of-sight areas. The rigid crawler provides stable, controllable movement to navigation points, while the attached imaging device can be oriented to capture images from difficult-to-reach locations, combining the advantages of both rigid and flexible designs.
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
The system effectively inspects internal components of electrical machines by guiding the borescope tip along desired paths, avoiding damage and allowing visualization of hard-to-reach areas, such as winding overhangs and air vents, with improved control and precision, enhancing inspection coverage without the need to remove the rotor.
Implementation Method 1
A magnetic air gap crawler system is used to deliver and position a borescope with an articulating tip, allowing it to extend beyond the crawler's reach and inspect areas that are not line-of-sight observable, by adhering to the machine's magnetic surfaces
Data Source
AI summary
An inspection system for inspecting an internal component of a machine includes a remote controlled vehicle constructed to fit inside a desired portion of the machine; a controller operative to control an operation of the remote controlled vehicle; a tether coupled to the controller and to the remote controlled vehicle, wherein the tether is operative to transmit control signals from the controller to the remote controlled vehicle; and an imaging device extending from a front portion of the remote controlled vehicle and operative to view the internal component. The imaging device has a flexible articulating tip spaced apart from the front portion of the body.