WO2015095543A1

WO2015095543A1 - Modular confined space crawler for use in machinery

Info

Publication number: WO2015095543A1
Application number: PCT/US2014/071198
Authority: WO
Inventors: George Q. ZHANG; Gregory Rossano; William J. EAKINS; Thomas A. Fuhlbrigge; Sangeun Choi; Hetal V. LAKHANI; Cajetan Pinto; Gregory PENZA; Hermann Herrlich; Robert Kodadek
Original assignee: Abb Technology Ag
Priority date: 2013-12-18
Filing date: 2014-12-18
Publication date: 2015-06-25

Abstract

A modular crawler for inspecting a confined space that can be the air gap of a rotating electrical machinery has a main function module to which drive modules and other function modules that depend on the confined space configuration can be connected. When the confined space the air gap between the rotor and stator of a rotating machine the crawler can be used for operations such as visual inspection, wedge tapping and maintenance. The main module has cameras and on board electronics and can also have a tether to communicate with equipment located outside of the confined space, send video to that equipment and receive commands from an operator of the crawler. The drive modules have tracks that ride on the stator slots. The removable spacers between the modules are adaptive to fit the configuration that the track rides on. The other function modules provide certain other functions.

Description

Modular Confined Space Crawler For Use In Machinery

1. Field of the Invention

The present invention relates to devices for use in the confined space in machinery such as a rotating electrical machine to inspect the air gap in that type of machine and perform other tasks related to such machines.

2. Description of the Prior Art

Devices known as crawlers or robot devices are now used to perform some tasks such as air gap inspection in some designs for motors and generators.

Summary of the Invention

A remotely controlled vehicle for inspecting a confined space in a machine has :

a main module that has first and second longitudinal sides, and one or more devices mounted on the main module for providing predetermined information about the confined space; and

two groups each having one or more modules that are other than the main module connected in parallel to each other, where at least one of the two groups of one or more other modules has at least two modules connected in parallel, and where one of the two groups of one or more other modules connected in parallel to the first longitudinal side of the main module and the other of the two groups of one or more other modules connected in parallel to the second longitudinal side of the main module .

A remotely controlled vehicle for inspecting a confined space in a machine has:

a main module having first and second longitudinal sides, and one or more devices mounted on the main module for providing information about the confined space;

a first group having two or more modules that are other than the main module connected in parallel to each other, the first group connected in parallel to the first longitudinal side of the main module; and a second group having one or more of the other modules connected in parallel to each other, the second group connected in parallel to the second longitudinal side of the main module.

a main function module having first and second longitudinal sides each having one or more locations for receiving a removable spacer, the main function module comprising one or more devices mounted thereon for providing information about the confined space; and

two drive modules each adapted for removable connection by one or more of the removable spacers to an associated one of the one or more locations for receiving one of the removable spacers on the first and second longitudinal sides of the main function module, the two drive modules when energized providing motion to the vehicle .

a main function module having mounted thereon one or more devices for providing information about the confined space, the main function module having first and second longitudinal sides;

two drive modules each adapted for removable connection by one or more removable spacers to an associated one of the first and second longitudinal sides of the main function module, the two drive modules when energized providing motion to the vehicle.

A method for assembling a remotely controlled vehicle for inspecting a confined space in a machine, the vehicle adapted for having one or more function modules each having mounted thereon one or more devices for providing information about the confined space and two longitudinal sides, only one of the one or more function modules being a main function module and two or more drive modules each having two longitudinal sides, the method having the steps of:

selecting the main function module for the vehicle; and

removably connecting one of the two longitudinal sides of each of the two or more drive modules to an associated one of the two longitudinal sides of the main function module.

Description of the Drawing

Fig. 1 shows a cross section of one example of the rotor and stator of a rotating electrical machine in which the crawler can be used.

Fig. 2a illustrates generically with the stator in place in the machine a robot crawler crawling on the teeth of the rotor of the machine .

Fig. 2b shows the crawler crawling on the stator teeth without the rotor in place .

Fig. 3 shows one embodiment for the crawler.

Figs. 4a, 4b and 4c illustrate the highly extendable modular design for the crawler.

Fig. 5 shows more details for the crawler shown in Fig. 3.

Fig. 6 shows an exploded perspective for the tethered function module of the crawler.

Fig. 7 shows an exploded perspective for the inner track module of the crawler .

Fig. 8 shows an exploded perspective for the outer track module of the crawler .

Fig. 9 shows the crawler with fixed spacer links between the inner and outer track modules.

Fig. 10 shows examples of the fixed spacer links.

Figs. 11a to 11c shows details for adjustable spacer links and Fig. lid shows a close up of the adjustable spacer links between the inner and outer modules.

Fig. 12a shows an embodiment for the crawler with the adjustable spacer links . Fig. 12b shows a close up of the adjustable spacer links between the inner and outer modules.

Fig. 13 shows the crawler with examples of interchangeable function heads.

Fig. 14 shows and describes the control module with associated equipment for the crawler.

Detailed Description

The crawler or robot device described below is used in operations such as visual inspection, wedge tapping, stator repair and maintenance such as cleaning inside the air gap between the stator and the rotor of rotating electrical machinery. The rotating machinery can be large size motors and generators and other rotating machines such as gearless mill drives that have the same stator, rotator and air gap setup as that in large size motors and generators

Referring now to Fig. 1, there is shown a cross section of one example of the rotor 16 and stator 14 of a rotating electrical machine 10 in which the present crawler or robot device N2, an embodiment for which is shown in Figs. 3 and 5 described below, can be used. The rotating machine 10 is a typical motor/generator with stator 14, rotor 16 and air gap 18. The crawler 12 crawls on the teeth 14a shown in Fig. 2a of stator 14.

As is shown in Figs. 3 and 5, the crawler 12 in this one embodiment has a function module 20 with a tether 20c and inner and outer drive modules 22a and 22b respectively that are attached to each other and in combination are attached to the right and left sides of module 20. Each of the drive modules 22a and 22b has as shown in Fig. 3 a belt drive 22c. The crawler 12 may also have untethered function modules 24 which are not shown in Figs. 3 and 5 and are shown in Figs. 4b and 4c described below.

Referring now to Fig. 2a, there is illustrated generically a robot crawler 12 crawling on the teeth 14a of stator 14 with the rotor 16 in place. The teeth 14a are typically laminated steel or another ferromagnetic material. As is well known, the teeth 14a can be of different configurations of slot dimensions and shapes. Fig. 2b shows the crawler 12 crawling on the stator teeth 14a without the rotor 16 in place. For ease of illustration the copper coils in machine 10 are not shown in Figs. 2a and 2b.

The crawler 12 crawls on the stator teeth 14a by magnetic attachment means, such as the magnets shown in Figs. 7 and 8 described below and identified in those figures by reference numeral 4, that are on each of the drive modules 22a and 22b. The crawler 12 works when the rotor 16 is in place in machine 10 and also when the rotor 16 is not in place.

However, since normally only the stator teeth 14a, which the belt track 22c of each of drive modules 22a and 22b ride on, are made of ferric material, the tracks 22c have to be aligned, or at least substantially aligned, with the stator teeth 14a. The tracks 22c are also shown in Figs . 7 and 8.

Since the teeth dimension and the width ratio between the tooth 14a and wedge 14b shown in cross section in Fig. 2a vary across different motors /generators , the tracks 22c have to be adjustable to match the tooth configuration for a specific machine. As is well known, the wedges 14b keep in place the copper coils that are in machine 10.

Fig. 3 shows a CAD design view of the modular crawler 12. The crawler 12 has one tethered function main module 20 and the combination of inner and outer track- drive modules 22a and 22b on each side of module 20. Module 20 has a visual inspection function provided by on board cameras 20a and 20b. There is a camera on the bottom of module 20 that faces the rotor 16 when the crawler 12 is in the rotating electrical machine 10. This camera is identified by the reference numeral 20f in Fig. 6.

The multiple function task and drive module design of crawler 12 and its modules allows crawler 12 to have more modules than the tethered module 20 and the drive modules 22a and 22b shown in Fig. 3. The other modules, such as drive modules in addition to modules 22a and 22b and non-tethered function modules 24, are added as is shown in block diagram form in Figs. 4b and 4c described below on one or both sides of the crawler 12 shown in Fig. 3.

Figs. 4a, 4b and 4c illustrate the highly extendable modular design for crawler 12.

As shown in Fig. 4a, crawler 12 can have one tethered function module 20 and one drive module 22 that can either be 22a or 22b or the combination thereof on each side of module 20. Thus Fig. 4a shows in block diagram form the embodiment for the crawler 12 shown in Fig. 3.

As shown in Fig. 4b, crawler 12 can have a tethered function module 20 having a drive module 22 connected to each side of module 20, a function module 24 connected to the left side of the drive module 22 connected to the left side of tethered function module 20 and an additional drive module connected to the left side of module 24. As shown in Fig. 4c, the modular crawler 12 can have multiple functional modules 24 and multiple drive modules 22. There can be no limit to the number of modules 22 and 24. However, a predetermined number of modules 22 and 24 are used to achieve the desired functions for the given application.

As shown in Figs. 4a and 4b, the tether 20c of function module 20 does not have to be in the center of the crawler 12 as shown in Figs. 3 and 4c. The black squares on the tethered function module 20 in Figs. 4a and 4b and on the function module 24 in Fig. 4b each represent a camera. The function module shown 24 in Fig. 4b is a wedge tapper.

Linking between the functional and drive modules 22a and 22b and 24 is accomplished by the use of the hinge type linkages 15 shown in Figs. 3 and 5 and in more detail in Figs. 6-8. The hinge pins are identified in Fig. 7 by the reference numeral 6. Each hinge linkage 15 mates with an associated receptacle 17 examples of which are shown in Figs. 5 and 6.

In order to accurately fit the stator slot, linkages

15 can also be applied between the two tracks of the drive modules 22aa and 22b. The linkage 15 can be in different lengths to adjust the distances among the tracks and modules 22 and 24 to make sure that the magnets 4 shown in Fig. 7 in the tracks 22c are on or near the teeth 14a of the stator 14 when the crawler 12 is installed in the air gap 18 of machine 12.

The number of drive modules 22a and/or 22b connected directly to each other or by linkages 15 is not limited. With the additional drive modules 22a and/or 22b, the crawler 12 has the higher magnetic attraction forces required by operations such as wedge tapping and stator repair, and can carry out multiple operations in a single crawler deployment .

Electrical connection between the tracks and modules can be by physical quick connectors. As shown in Fig. 6, the printed circuit board identified by reference numeral 2i in that figure on tethered function module 20 has a connector identified by reference numeral 13 on its left and right sides respectively. The connectors 13 are connected to an associated connector identified by reference numeral 13 in Fig. 7 on each of the inner track modules 22a by a suitable connector such as a ribbon cable or other wiring (not shown in Fig. 7) whose length depends on the width of the spacer between module 20 and module 22a. Connectors identified by reference numeral 19 in Fig. 6 on the front and back respectively of the PCB 21 connect with other electronics on the function module 20 (e.g. cameras 20a and 20b and related components such as LEDs 20d) . Contactless communication could be used in this embodiment. Controls can be by one main module 20 or distributed to different functional modules 24 depending on the number and type of the functional modules 24.

As shown in Fig. 6, crawler 12 has a dust cover 21a for PCB 21. Fig. 6 also shows a single camera 20b directly facing forward as it is on the edge of crawler 20 opposite to the edge to which tether 20c is connected and two other cameras also identified by 20a as they each face forward and to the side and a single rear facing camera 20b. Module 20 also has a downward facing camera 20f mounted on module 20 between the front and side facing cameras 20a and PCB 21. Dust cover 21a also covers the rear of downward facing camera 20f . Also shown in Fig. 6 are brackets 20e for the side facing cameras 20a.

Crawler 12 may have fixed spacer links 26 between the inner and outer track modules 22a and 22b as shown in Fig. 9. Examples of types of the fixed spacer links 26 are shown in Fig. 10. As shown in Figs. 9 and 10, the fixed spacer links have set screw holes 26a that hold hinge pins identified by the reference numeral 6 in Figs . 6 and 7 that run parallel to the tracks identified by reference numeral 1 in Fig. 7.

As shown in Fig. 9, the fixed spacer link 26 has a hinge pin on each side of the link 26. There are two set screws 26b holding each hinge pin in place. Thus each fixed spacer link has four set screws 26b.

Crawler 12 may also have adjustable spacer links 28 one embodiment is shown in more detail in Figs. 11a, lib and 11c. As shown in Fig. 11a, each adjustable spacer link 28 has an associated spacer receptacle 28a and a spacer head post 28c attached to a spacer head 28d. As shown in Fig. 11, the spacer head is received in an associated receptacle on module 22a.

Also as shown in these figures, there is a set screw 28b in spacer receptacle 28a that when loosened allows the spacer post 28c to slide left and right, that is perpendicular to the track on modules 22a and 22b. The set screw 28b is tightened to lock the mated spacer head 28d in place. Fig. lib shows the spacer link 28 in a retracted position and Fig. 11c shows the spacer link 28 in an extended position. Fig. lid shows two track modules 22a and 22b connected to each other by the adjustable spacer links 28. Fig. lid also shows a wire 29 that is used to connect a connector on module 22a to an associated connector on module 22b. Fig. lid further shows the set screw 28b and the four screws for each of the two hinge pins that are in spacer 28.

Fig. 12a shows a close up of an actual crawler 12 with a tethered function module 20 connected to a function module 22a that is in turn connected to a function module 22b. This crawler 12 has the adjustable spacer links 28. Fig. 12b is identical to Fig. lid.

Fig. 13 a crawler 12 with a changeable function head 30. The function head 30 can have different embodiments three of which are shown in Fig. 13. Head 32 has three cameras, head 34 has one camera and head 36 has a proximity sensor.

Each of the heads has dowel pins 30a that mate with an associated hole on module 20 and a connector 30b that mates with an associated connector 30c on module 20. As is well known, set screws not shown Fig. 13 can be used to hold an interchangeable head in place after the head is mated to module 20.

Referring now to Fig. 14 there is shown and described the control module 38 with associated equipment for crawler 12. The associated equipment includes a control cabinet 38a that includes several monitors 38b (the embodiment in Fig. 14 shows two large and three small monitors), a tether 38c between the crawler 12 and the control cabinet 38a, a DVR 38d in cabinet 38a, a drawer 38e in cabinet 38a with a keyboard and a mouse in the drawer and a control unit 38f that has a joystick, lighting and speed control for the crawler 12.

It is to be understood that the description of the foregoing exemplary embodiment ( s ) is (are) intended to be only illustrative, rather than exhaustive, of the present invention. Those of ordinary skill will be able to make certain additions, deletions, and/or modifications to the embodiment ( s ) of the disclosed subject matter without departing from the spirit of the invention or its scope, as defined by the appended claims .

Claims

What is claimed is:

1. A remotely controlled vehicle for inspecting a confined space in a machine comprising:

a main module comprising first and second longitudinal sides, and one or more devices mounted on said main module for providing predetermined information about said confined space; and

two groups each comprising one or more modules that are other than said main module connected in parallel to each other, where at least one of said two groups of one or more other modules has at least two modules connected in parallel, and where one of said two groups of one or more other modules connected in parallel to said first longitudinal side of said main module and the other of said two groups of one or more other modules connected in parallel to said second longitudinal side of said main module .

2. The vehicle of claim 1 wherein one of said one or more other modules in each of said two groups is a drive module which when energized provides motion to said vehicle.

3. The vehicle of claim 2 wherein said drive module in each of said two groups is the furthest module from said associated one of said first and second main module longitudinal sides to which each of said two groups is connected.

4. A remotely controlled vehicle for inspecting a confined space in a machine comprising:

a main module comprising first and second longitudinal sides, and one or more devices mounted on said main module for providing information about said confined space;

a first group comprising two or more modules that are other than said main module connected in parallel to each other, said first group connected in parallel to said first longitudinal side of said main module; and

a second group comprising one or more of said other modules connected in parallel to each other, said second group connected in parallel to said second longitudinal side of said main module.

5. The vehicle of claim 4 wherein said two or more other modules in said first group are a first other module having a longitudinal side connected to said first longitudinal side of said main module and an opposed longitudinal side connected to a longitudinal side of a second other module.

6. The vehicle of claim 5 wherein said first group has a third other module and said longitudinal side of said second other module opposed to said first other module longitudinal side connected to said main module is connected to a longitudinal side of said third other module .

7. A remotely controlled vehicle for inspecting a confined space in a machine comprising:

a main function module having first and second longitudinal sides each having one or more locations for receiving a removable spacer, said main function module comprising one or more devices mounted thereon for providing information about said confined space; and

two drive modules each adapted for removable connection by one or more of said removable spacers to an associated one of said one or more locations for receiving one of said removable spacers on said first and second longitudinal sides of said main function module, said two drive modules when energized providing motion to said vehicle.

8. The remotely controlled vehicle of claim 7 further comprising a module that is other than said main function module and said drive modules having one or more devices mounted thereon for providing information about said confined space that is in addition to said information provided by said main function module and first and second longitudinal sides each having one or more locations for receiving another spacer to removably connect said module that is other than said main function module and said drive modules to the longitudinal side of one of said drive modules not connected to said main function module, said drive module longitudinal to which said module that is other than said main function module and said drive modules is removably connected by said another spacer having an associated location for receiving said another spacer .

9. The remotely controlled vehicle of claim 8 further comprising another drive module in addition to said first and second drive modules, said another drive module having first and second longitudinal sides one of which has one or more locations for removable connection by an associated one of yet another spacers to that one of said first and second longitudinal sides of said module that is other than said main function module and said drive modules not connected by one or more of said another spacers to said drive module removably connected to said main function module.

10. The remotely controlled vehicle of claim 7 wherein said main function module further comprises a tether connected to one end of said main function module.

11. A remotely controlled vehicle for inspecting a confined space in a machine comprising:

a main function module having mounted thereon one or more devices for providing information about said confined space, said main function module having first and second longitudinal sides;

two drive modules each adapted for removable connection by one or more removable spacers to an associated one of said first and second longitudinal sides of said main function module, said two drive modules when energized providing motion to said vehicle.

12. The vehicle of claim 11 wherein said main function module has a tether for connection to a device external to said machine to provide signals to remotely control said vehicle when said vehicle is in said confined space .

13. The vehicle of claim 11 further comprising one or more function modules that are other than said main function module each also having mounted thereon one or more devices for providing information about said confined space and adapted for removable connection by said one or more spacers to a longitudinal side of an associated one of said two drive modules so as to be in parallel with said two drive modules and said main function module; and

said one or more spacers for removably connecting said first and second drive modules to an associated one of said first and second longitudinal sides selected from a group of spacers comprising spacers have a fixed length and spacers having an adjustable length.

14. A method for assembling a remotely controlled vehicle for inspecting a confined space in a machine, said vehicle adapted for having one or more function modules each having mounted thereon one or more devices for providing information about said confined space and two longitudinal sides, only one of said one or more function modules being a main function module and two or more drive modules each having two longitudinal sides comprising :

selecting said main function module for said vehicle; and

removably connecting one of said two longitudinal sides of each of said two or more drive modules to an associated one of said two longitudinal sides of said main function module.

15. The method of claim 14 further comprising selecting another of said one or more function modules other than said main function module and removably connecting said selected another function module to a side of one of said one or more drive modules removably connected to said main function module that is opposite the side of said drive module removably connected to said main function module.

16. The method of claim 14 wherein said main function module has a tether attached thereto at other than said longitudinal sides.

17. The method of claim 14 wherein one of said two longitudinal sides of each of said two or more drive modules is removably connected to an associated one of said two longitudinal sides of said main function module by one or more spacers .

18. The method of claim 15 wherein said selected another function module is removably connected by one or more spacers to a side of one of said one or more drive modules removably connected to said main function module that is opposite the side of said drive module removably connected to said main function module.