Minicamera Monitoring for Electric Machine Stator Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric generator inspection methods are complex and require partial disassembly and gas flushing, especially for hydrogen-cooled generators, making them time-consuming and risky.
Innovation Solution
A minicamera system is integrated within the generator housing, connected to an evaluation system via wireless or wired transmission, allowing for remote monitoring of stator end windings without opening the machine, with movable nonmagnetic guide elements ensuring safe and clear views during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection is performed by opening the generator through manhole covers, then the stator end windings can be inspected, but the procedure requires partial disassembly and considerable complexity
Solution Approach 1:
A minicamera is installed in advance within the generator housing at a position where it can observe the stator end winding. This preliminary installation eliminates the need for partial disassembly during inspection, as the camera is already positioned to capture images of the critical components without requiring opening of manhole covers or removal of end plate upper parts.
Solution Approach 2:
Instead of directly observing the stator end winding through physical access, a visual copy (image) is captured by the minicamera and transmitted to an evaluation system. This allows inspectors to view high-resolution images of the windings remotely, replacing the need for physical access and simplifying the inspection process.
2Temperature
If hydrogen cooling is used, then cooling efficiency is improved, but gas flushing and safety measurements are required before inspection
Solution Approach 1:
The minicamera captures visual copies of the stator end winding condition and transmits them for evaluation. This allows inspection to be performed remotely without requiring the hydrogen to be flushed out or safety measurements to be taken, as no human access to the hydrogen-filled environment is needed.
Solution Approach 2:
The inspection process replaces mechanical access (opening covers, flushing gas) with an optical system (minicamera). The camera system can operate within the hydrogen-cooled environment without requiring the hydrogen to be removed, substituting physical intervention with remote optical observation.
3Productivity
If the generator operates continuously at high speed, then productivity is improved, but vibrations and centrifugal forces increase mechanical loading on stator end windings
Solution Approach 1:
The minicamera system enables continuous monitoring of the stator end winding condition during generator operation. By capturing images at regular intervals or continuously, the system allows assessment of the windings' mechanical condition without interrupting the generator's continuous high-speed operation, thus maintaining productivity while monitoring strength-related issues.
Solution Approach 2:
The evaluation system analyzes images captured by the minicamera and provides feedback on the condition of the stator end windings. This feedback mechanism allows operators to assess the impact of continuous high-speed operation on the windings and take preventive measures before mechanical failures occur, addressing the strength concern while maintaining continuous operation.
Data Source
AI summary
A monitoring system for monitoring an electric machine is provided. A mini-camera for observing the electric machine is arranged inside the electric machine. Moreover, the mini-camera is arranged movably on guide elements, wherein the guide element is designed in such a way that the mini-camera is held in an uncritical parked position during the operation of the electric machine.