Rotor Inspection Guide Wire Layout for Precise In-Situ Examination
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Solution Overview
Problem
Conventional rotary electric machine inspection methods require the rotor to be pulled out, leading to high costs and risks of stator or rotor damage, and face challenges in positioning accuracy due to sagging wires supporting the examination unit.
Innovation Solution
A rotary electric machine examination device with a guide wire stretched between base units, a driving rope, and an inspection unit that is restricted by the guide wire, allowing precise movement along the rotor's axial direction and circumferential positioning using a sensor unit and remote device communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the examination unit is supported only by a wire stretched between base units, then the inspection can be performed without pulling out the rotor, but the wire sags due to self-weight causing poor positioning accuracy in radial and circumferential directions
Solution Approach 1:
The guide wire is configured to extend not only in the axial direction but also to have radial extension beyond the rotor outer diameter at base unit positions. This dimensional extension provides additional support points that prevent sagging and improve positioning accuracy in radial and circumferential directions while maintaining the benefit of non-disassembly inspection.
2Reliability
If the rotor is pulled out for inspection, then thorough examination can be performed, but the machine must be stopped for a long period and there is risk of stator or rotor damage
Solution Approach 1:
Base units are attached to both end sides of the rotor before the inspection process begins. These base units serve as predetermined support structures that enable the examination unit to be moved along the axial direction without requiring rotor removal, thus performing thorough inspection while avoiding machine shutdown and physical damage risks.
3Measurement precision
If the guide wire distance to rotor axis is increased at base units compared to inspection unit position, then positioning accuracy is improved, but the guide wire configuration becomes more complex
Solution Approach 1:
The guide wire is configured with asymmetric positioning relative to the rotor axis: at base unit positions, the guide wire extends radially beyond the rotor outer diameter (greater distance from axis), while at the inspection unit position, it is closer to the axis. This asymmetric configuration optimizes positioning accuracy at support points while maintaining operational clearance at the inspection point.
Data Source
AI summary
A rotary electric machine examination device of the present disclosure includes: first and second base units attached to both ends of rotor retaining rings fixed to both axial end sides of a rotor; a guide wire stretched between the first and second base units; an inspection unit which moves on the stator and includes a housing having both side surfaces restricted by the guide wire, and a sensor unit; and a driving rope which drives the inspection unit in the axial direction. The guide wire is stretched such that the distance between the guide wire and the rotation axis at the positions of the first and second base units is greater than the distance between the guide wire and the rotation axis at the position of the inspection unit.