Generator inspection robot that works without extracting the rotor

• IndustryPower generation
• DisciplineMechatronics and automation
• EquipmentAir-gap robot with track drive, adjustable width and instrumented head
• DeliverableDesign, working prototype and built unit

The challenge

Predictive maintenance on a large generator means pulling the rotor: weeks of outage, lost production and a large crew on site. Inspection and maintenance tasks had to be done inside the air gap with the machine closed.

Scope

• Mechanical design of the robot: adjustable-width chassis, drive tracks and instrumented head
• Electrical and control engineering: power, sensors, PLC and panel
• Acquisition software: logging and comparison of test signals
• Prototyping, bench testing and adjustments on the real stator
• Equipment build and operating documentation

How we worked

Prototype before final drawing. The first prototype was tested on a real stator and its results defined the built version.

One integrating discipline. Mechanical, electronics, control and software were solved by the same team.