Rotating Traction Module for Annular Gap Robot Inspection
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Solution Overview
Problem
Existing methods for inspecting generators, electric motors, and turbomachines require disassembly and removal of the rotor, which is costly, time-consuming, and risky, and do not provide a complete, timely, or safe inspection.
Innovation Solution
A traction module for a robot system with a rotating frame and drive system that allows the robot to extend and orient itself within an annular gap, enabling in situ inspection without disassembly, using a robotic crawler that can collapse and expand to navigate complex machine geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inspection methods are used requiring disassembly and rotor removal, then inspection can be performed, but inspection time increases, costs increase, and safety risks increase
Solution Approach 1:
The inspection system is extracted from the traditional disassembly approach and implemented as a separate robotic inspection module that can operate within the annular gap without removing the rotor. The robotic crawler with sensor modules is inserted through the annular gap to perform inspections while the rotor remains in place, eliminating the need for disassembly while maintaining inspection capability
Solution Approach 2:
A robotic crawler serves as an intermediary device between the inspector and the machine components. The crawler navigates through the annular gap and carries sensor modules that act as intermediaries to detect and measure conditions of the rotor and stator, enabling indirect inspection without physical disassembly or rotor removal
2Reliability
If the robot extends outwardly to greater extent, then traction on uneven surfaces improves, but device complexity increases
Solution Approach 1:
The rotating frame is made dynamically adjustable rather than fixed, allowing it to rotate to different orientations and positions. This dynamic capability enables the drive system to extend outwardly for improved traction on uneven surfaces while maintaining the ability to adapt to different operational conditions, resolving the contradiction between enhanced traction and increased complexity
Solution Approach 2:
The rotating frame serves multiple functions: it positions the drive system for traction, orients the robot for navigation, and adjusts the extension extent for different surface conditions. By consolidating these multiple functions into a single rotating mechanism, the design achieves enhanced traction capability without proportionally increasing overall device complexity
Data Source
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AI summary
A traction module (114, 240, 242, 244, 660, 662 664) for a robot system (108) and a robot system using the traction module, are disclosed. The traction modules comprises an outer frame (666, 668, 670, 810) and a rotating frame (820) rotatably mounted within the outer frame. A drive system (802) is operatively coupled to the rotating frame and configured to drive a traction drive component (678, 680, 682) to propel the robot. An actuator (822) is operatively connected to the rotating frame to controllably rotate the rotating frame. During a first portion of a rotating movement of the rotating frame, the drive system moves between a flat mode position relative to the outer frame and a clearance mode position in which the drive system extends outwardly from the outer frame to a greater extent than in the first position. During a second portion of the rotating movement of the rotating frame, the drive system may be positioned in a desired orientation to propel the robot.