Rotor-Stator Gap Repair Travel for In-Place Electric Machine Maintenance
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Solution Overview
Problem
Conventional systems for inspecting and repairing rotary electric machines, such as power generators or electric motors, require disassembly and are inefficient, prolonging downtime and necessitating multiple workers due to the lack of means to perform repairs within the gap between the stator and rotor.
Innovation Solution
A repair system comprising a traveling device that inserts into the gap between the rotor and stator, equipped with a moving mechanism, imaging device, and repair mechanism, controlled by a control device to apply repair material to defects like loose stator wedges, ensuring efficient repairs without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional inspection methods are used requiring disassembly, then inspection can be performed, but the period during which the rotary electric machine is stopped is prolonged and a large number of workers are required
Solution Approach 1:
The traveling device is inserted into the gap between the stator and rotor, nesting the inspection and repair mechanism within the existing machine structure without requiring disassembly. This allows the device to access the internal components through the available space rather than requiring the machine to be taken apart
Solution Approach 2:
The traveling device autonomously navigates and operates within the gap using its own propulsion and control systems, eliminating the need for external disassembly operations and multiple workers to perform manual inspection tasks
2Measurement precision
If conventional inspection methods are used requiring disassembly, then inspection can be performed, but a large number of workers are required
Solution Approach 1:
The traveling device autonomously performs inspection and repair operations within the gap using integrated sensors, imaging devices, and repair mechanisms, eliminating the need for multiple workers to manually disassemble and inspect components
Solution Approach 2:
The traveling device integrates multiple functions including inspection, imaging, and repair capabilities in a single autonomous platform, replacing the need for multiple specialized workers and separate inspection/repair procedures
3Ease of operation
If conventional traveling systems are used without repair means, then inspection can be performed in the gap, but repairs cannot be carried out efficiently
Solution Approach 1:
The traveling device is equipped with both inspection capabilities (imaging devices, sensors) and repair capabilities (repair material discharge mechanisms) in a single integrated platform, allowing it to perform both functions within the gap without requiring separate systems or disassembly
Solution Approach 2:
The traveling device acts as an intermediary platform that bridges the gap between inspection and repair operations, carrying both diagnostic tools and repair materials to perform complete maintenance cycles within the confined space
Data Source
AI summary
The repair system of an embodiment includes a traveling device that travels while being inserted into a gap interposed between a rotor and stator in the rotary electric machine and a control device that controls operation of the traveling device. The traveling device has a moving mechanism moving the traveling device in the gap and a repair mechanism repairing a repair object part of the rotary electric machine in the gap. The repair mechanism includes a nozzle discharging repair material for repairing the repair object part from a nozzle discharge port. When repairing the repair object part, the control device controls operations of the moving mechanism and the repair mechanism so that the repair material is applied to the repair object part by discharging the repair material from the nozzle discharge port of the nozzle while moving the traveling device.