Systems and apparatus for inspection of electric generator rotor slot wedges in-situ and methods of using the same

Patent metadata

Field	Value
Publication number	US-10197538-B2
Application number	US-201615013416-A
Country	US
Kind code	B2
Filing date	Feb 2, 2016
Priority date	Feb 2, 2016
Publication date	Feb 5, 2019
Grant date	Feb 5, 2019

Abstract

System, methods, and devices for inspecting generator rotor slot wedges in-situ are provided. The system includes a controller operably connected to a remote-control carriage for transmitting control signals and receiving data. The carriage includes a drive module for moving the carriage into an inspection area, e.g., through an air gap between the rotor and stator, and an inspection module operable to inspect a rotor wedge surface. The inspection module includes a jack assembly and a transducer assembly. The jack assembly is operably connected to the transducer assembly, and configured to elevate the transducer assembly to the rotor wedge surface for inspection.

First claim

We claim:

1. A generator inspection vehicle sized and configured to fit within an air gap between a stator and a rotor of the generator, the vehicle comprising:
a frame;
a drive module attached to the frame for maneuvering the inspection vehicle on an interior surface of the generator; and
an inspection module operatively attached to the frame and operable to extend and retract in response to one or more signals from a remote device, and to inspect a rotor wedge surface in-situ when extended,
wherein the inspection module comprises:
a jack assembly configured to extend and retract in response to the one or more signals;
a transducer assembly configured to inspect the wedge surface in response to one or more signals, and to transmit image data corresponding to the inspected wedge surface,
wherein the transducer assembly is attached to the jack assembly,
wherein the jack assembly is configured to elevate the transducer assembly towards the wedge surface for inspection,
wherein the jack assembly comprises a lower portion attached to the frame,
wherein the jack assembly comprises an upper portion attached to the transducer assembly,
wherein the upper portion comprises a platform on which the transducer assembly is located, and
wherein the platform is fully supported on all four corners to vertically raise the transducer assembly perpendicular the inspected wedge surface.

2. The vehicle of claim 1 , wherein the drive module comprises:
a drive train that utilizes magnetic adhesion to traverse the interior surface of the generator; and
a motor operatively connected to the drive module and configured to provide a motive force to the drive train in response to one or more signals from a remote device.

3. The vehicle of claim 1 , wherein the jack assembly includes a pneumatic system operably to elevate the upper portion of the jack assembly towards the wedge surface.

4. The vehicle of claim 1 , wherein the transducer assembly comprises:
an ultrasonic transducer and an applicator,
wherein the ultrasonic transducer is configured to inspect the wedge surface and transmit the image data; and
wherein the applicator is configured to apply a couplant to one of the wedge surface and the ultrasonic transducer during inspection of the wedge surface.

5. The vehicle of claim 4 , wherein the couplant is applied to both the wedge surface and the ultrasonic transducer.

6. The vehicle of claim 1 further comprising:
a visual aid operatively coupled to one of the jack assembly, transducer assembly and frame, and operable to observe and transmit information corresponding to the vehicle position relative to the wedge surface to be inspected.

7. The vehicle of claim 6 , wherein the visual aid is a camera or video camera.

8. The vehicle of claim 1 further comprising:
a camera operatively connected to the inspection module and configured to transmit information corresponding to the position of the inspection module related to the wedge surface to be inspected.

9. A system for inspecting generator rotor slot wedges in-situ comprising:
a controller operatively connected to an inspection vehicle;
wherein the controller is configured to maneuver the inspection vehicle within the generator and to receive image data from the inspection vehicle during the in-situ inspection; and
wherein the inspection vehicle is sized and configured to fit through an air gap between a stator and a rotor of the generator and within a passage, and is operably configured to elevate a transducer assembly carried by the inspection vehicle to a rotor wedge surface for inspection and in response to one or more signals from the controller,
wherein the inspection vehicle comprises an inspection module comprising a jack assembly and a transducer assembly attached to the jack assembly,
wherein the jack assembly is configured to elevate the transducer assembly towards the wedge surface for inspection,
wherein the jack assembly comprises a lower portion attached to the frame,
wherein the jack assembly comprises an upper portion attached to the transducer assembly,
wherein the upper portion comprises a platform on which the transducer assembly is located, and
wherein the platform is fully supported on all four corners to vertically raise the transducer assembly perpendicular the inspected wedge surface.

10. The system of claim 9 , wherein the connection between the controller and the inspection vehicle is via one or more electrical cables, and the one or more signals travel via the electrical cables.

11. The system of claim 9 , wherein the connection between the controller and the inspection vehicle is wireless.

12. The system of claim 9 , wherein the inspection vehicle comprises:
a drive module attached to a frame; and
wherein the drive module maneuvers the inspection vehicle within the generator in response to the one or more signals, and
wherein the inspection module elevates and inspects the wedge surface in response to the one or more signals.

13. The system of claim 12 further comprising:
a second drive module attached to the frame and disposed on an opposite side of the inspection module from the first drive module.

14. The system of claim 9 ,
wherein the transducer assembly is configured to inspect the wedge surface and transmit image data corresponding to the inspected wedge surface to the controller.

15. The system of claim 9 wherein the inspection module further comprises:
a hydraulic or pneumatic cylinder and piston connected to the jack assembly for elevating the transducer assembly to the wedge surface.

16. The system of claim 9 further comprising:
a camera assembly operatively connected to the inspection vehicle, and configured to transmit views corresponding to the position of the inspection vehicle within the generator to a display of the controller.

17. A method for inspecting generator rotor slot wedges in-situ, comprising the steps of:
maneuvering an inspection vehicle, via a remote controller, through an air gap of the generator and into alignment with a rotor slot wedge for inspection;
elevating at least a portion of the inspection vehicle to a surface of the wedge such that the portion of the inspection vehicle is proximate or adjacent to the surface; and
inspecting the surface, via a transducer of the inspection vehicle, by capturing image data corresponding to the surface and transmitting the image data to the remote controller,
wherein the inspection vehicle comprises a jack assembly for attaching the transducer,
wherein the jack assembly is configured to elevate the transducer towards the wedge surface for inspection,
wherein the jack assembly comprises a lower portion attached to the frame,
wherein the jack assembly comprises an upper portion attached to the transducer assembly,
wherein the upper portion comprises a platform on which the transducer assembly is located, and
wherein the platform is fully supported on all four corners to vertically raise the transducer assembly perpendicular the inspected wedge surface.

18. The method of claim 17 further comprising the step of:
upon completion of the first wedge surface inspection in-situ, maneuvering the inspection vehicle into alignment with a second wedge for inspection.

19. The method of claim 17 , further comprising the step of:
retracting the elevated portion of the inspection vehicle upon completion of the surface inspection in-situ, such that the inspection vehicle is sized to clear the air gap.

Assignees

• Siemens Energy Inc

Inventors

• Alford James
• Moore Charles C
• Rasselkorde El Mahjoub
• Bauer James A
• Beuten Joseph T

Classifications

• G01N29/225

  Supports, positioning or alignment in moving situation · CPC title

• G01N29/262

  by electronic orientation or focusing, e.g. with phased arrays (phased arrays per se G10K11/34) · CPC title

• G01N27/90

  using eddy currents · CPC title

• G01N2291/106

  one or more transducer arrays · CPC title

• G01N29/28

  providing acoustic coupling {, e.g. water (impedance matching G10K11/02)} · CPC title