Motor Core Slot Tap Inspection Using Non-Contact Optical Sensing
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Solution Overview
Problem
Existing methods for inspecting motor core slot taps are complicated, require sensor installation, and are inaccurate due to eddy current losses from heat generation, especially in structures with multiple slots and taps.
Innovation Solution
A non-contact method using an optical sensor to project light onto the motor core slots, convert reflected light into electrical signals, amplify, digitize, and analyze the signals to detect tap presence, omission, and calculate distances, with visual display of results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct eddy current detection is used to inspect slot taps, then tap presence can be detected, but the inspection becomes complicated and requires sensor mounting
Solution Approach 1:
The patent replaces the direct eddy current detection method with an optical detection system. Instead of using electrical sensors that require mounting on the motor core, the invention uses optical sensors to detect reflected light from the slot taps, thereby substituting a mechanical/electrical system with an optical system that is less intrusive and more accurate
Solution Approach 2:
The patent introduces light as an intermediary medium between the inspection system and the slot taps. By projecting light onto the taps and detecting the reflected light, the system creates an indirect detection path that avoids the need for direct electrical contact and complex sensor mounting
2Measurement precision
If sensor mounting is performed for direct eddy current detection, then current can be detected, but inspection time increases and process becomes complicated
Solution Approach 1:
The patent replaces the time-consuming sensor mounting and electrical detection process with a rapid optical detection system. The optical sensor can quickly scan the slot taps without requiring physical mounting, significantly reducing inspection time while maintaining or improving measurement precision
Solution Approach 2:
The patent performs preliminary setup of the optical detection system before inspection begins. Once configured, the system can rapidly inspect multiple slot taps without repeated mounting operations, thereby reducing overall inspection time through preliminary system preparation
3Reliability
If eddy current method is used for tap inspection, then tap presence can be detected, but accuracy is reduced due to eddy current losses from heat generation
Solution Approach 1:
The patent substitutes the eddy current-based electrical detection method with an optical detection method. This replacement eliminates the harmful eddy current losses and heat generation associated with electrical detection, while improving inspection reliability through non-contact optical measurement
Solution Approach 2:
The patent converts the potential harm of eddy current losses into a benefit by using optical detection. Instead of dealing with the harmful thermal effects of eddy currents, the system uses light reflection properties to detect tap presence, turning the inspection process into a non-intrusive, loss-free measurement
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
Accurately inspects motor core slot taps without sensors, quickly and conveniently, detecting tap presence, omission positions, and distances, improving efficiency over direct current detection methods.
Implementation Method 1
an optical sensor for projecting light onto a slot of the motor core and converting reflected light into an electrical signal
Data Source
AI summary
Disclosed are a device and a method for inspecting a slot tap of a motor core to accurately inspect a slot tap of a non-molding type motor core in a non-contact manner, and the method for inspecting the slot tap of the motor core is implemented through the process that initializes the device for inspecting the slot tap of the motor core, moves the optical sensor to an inspection position using a servo motor, projects light onto a slot of the motor core using the optical sensor, converts reflected light into an electrical signal to obtain tap detection data, analyzes the obtained tap detection data, generates an analysis result as a tap inspection result to store the analysis result in a memory, and visually displays the tap inspection result.