Abstract: A sensor interface module for an inspection robot includes a scissor lift for varied radial positioning of, and a universal sensor mount for mounting, a selected one of a plurality of different sensors. A visual inspection module for the robot includes an inspection unit for simultaneously visually inspecting a first surface facing a first direction and a spaced, second surface facing an opposing, second direction toward the first surface. The inspection unit includes a first visual sensor and a second visual sensor, each visual sensor facing in a direction different than the first and second directions. A first reflector reflects an image of the first surface to the first visual sensor, and a second reflector reflects an image of the second surface to the second visual sensor. A robot system may include the sensor interface module and the inspection unit.

Abstract: A traction module for a robot system and a robot system using the traction module having, an outer frame and a rotating frame rotatably mounted within the outer frame. A drive system is operatively coupled to the rotating frame and configured to drive a traction drive component to propel the robot. An actuator is operatively connected to the rotating frame to controllably rotate the rotating frame. During a first portion of a rotating movement of the rotating frame, the drive system moves between a flat mode position relative to the outer frame and a clearance mode position in which the drive system extends outwardly from the outer frame to a greater extent than in the first position. During a second portion of the rotating movement of the rotating frame, the drive system may be positioned in a desired orientation to propel the robot.

Abstract: This disclosure provides systems and methods for in situ gap inspection in a machine, such as a generator, an electric motor, or a turbomachine, with an end region. A robotic crawler is configured to navigate an annular gap of the machine. A visual inspection module is connected to the robotic crawler and includes an extension member for extending a camera into the end region to collect visual inspection data.

Abstract: This disclosure provides systems and methods for an actuated sensor module for in situ gap inspection robots. A mounting interface attaches to the sensor module to the robot system. A least one arm is operatively connected to the mounting interface and has a joint. A sensor head is operatively connected to the arm at the joint and an actuator operatively connected to the arm moves the sensor head around the second joint.

Abstract: Systems and methods for in situ gap inspection in a machine, such as a generator, an electric motor, or a turbomachine are described. A robotic crawler has multidirectional traction modules, an expandable body, and sensor modules. A control system communicates with the robotic crawler to provide a control signal to navigate an inspection path within an annular gap of the machine. The inspection path includes axial and radial movements to inspect the annular gap using the sensor modules.

Abstract: This disclosure provides systems and methods for in situ gap inspection in a machine, such as a generator, an electric motor, or a turbomachine. A robotic crawler includes an expandable body, multidirectional traction modules, and sensor modules. The expandable body is movable between a collapsed state and an expanded state. The multidirectional traction modules are removably connected to and positioned by the expandable body and configured to engage opposed surfaces within an annular gap of the machine. The sensor modules are removably connected to and supported by the expandable body and include a plurality of sensor types to inspect the annular gap of the machine.

Abstract: This disclosure provides systems and components for an omnidirectional traction module for use in a robot, such as a crawler robot used in in situ gap inspection in a machine, such as a generator, an electric motor, or a turbomachine. The traction module may include an outer frame and a rotating frame rotatably mounted within the outer frame. At least one drive system may be mounted within the rotating frame. The at least one dive system may have a fixed orientation within the rotating frame. An actuator may be operatively connected to the rotating frame to controllably rotate the rotating frame to a desired orientation for robot travel.

Abstract: This disclosure provides systems and methods for in situ gap inspection in a machine, such as a generator, an electric motor, or a turbomachine. A robotic crawler has multidirectional traction modules, an expandable body, and sensor modules. A control system communicates with the robotic crawler to provide a control signal to navigate an inspection path within an annular gap of the machine. The inspection path includes axial and radial movements to inspect the annular gap using the sensor modules.

Abstract: This disclosure provides systems and components for an omnidirectional traction module for use in a robot, such as a crawler robot used in in situ gap inspection in a machine, such as a generator, an electric motor, or a turbomachine. The traction module may include an outer frame and a rotating frame rotatably mounted within the outer frame. At least one drive system may be mounted within the rotating frame. The at least one dive system may have a fixed orientation within the rotating frame. An actuator may be operatively connected to the rotating frame to controllably rotate the rotating frame to a desired orientation for robot travel.

Abstract: This disclosure provides systems and methods for in situ gap inspection in a machine, such as a generator, an electric motor, or a turbomachine, with an end region. A robotic crawler is configured to navigate an annular gap of the machine. A visual inspection module is connected to the robotic crawler and includes an extension member for extending a camera into the end region to collect visual inspection data.

Abstract: This disclosure provides systems and methods for in situ gap inspection in a machine, such as a generator, an electric motor, or a turbomachine. A robotic crawler includes an expandable body, multidirectional traction modules, and sensor modules. The expandable body is movable between a collapsed state and an expanded state. The multidirectional traction modules are removably connected to and positioned by the expandable body and configured to engage opposed surfaces within an annular gap of the machine. The sensor modules are removably connected to and supported by the expandable body and include a plurality of sensor types to inspect the annular gap of the machine.

Abstract: This disclosure provides systems and methods for an actuated sensor module for in situ gap inspection robots. A mounting interface attaches to the sensor module to the robot system. A least one arm is operatively connected to the mounting interface and has a joint. A sensor head is operatively connected to the arm at the joint and an actuator operatively connected to the arm moves the sensor head around the second joint.

Abstract: Locating systems and methods for components are provided. A component has an exterior surface. A method includes locating a surface feature configured on the exterior surface along an X-axis and a Y-axis by analyzing an image of the component to obtain X-axis data points and Y-axis data points for the surface feature. The method further includes directly measuring the surface feature along a Z-axis to obtain Z-axis data points for the surface feature, wherein the X-axis, the Y-axis and the Z-axis are mutually orthogonal. The method further includes calculating at least two of a pitch value, a roll value or a yaw value for the surface feature.

Abstract: Certain embodiments of the disclosure may include systems, methods, and apparatus for locating and drilling closed holes of a gas turbine component. According to an example embodiment, the method can include receiving position data associated with one or more holes in a gas turbine component; receiving predefined hole position data from manufacturing data associated with the gas turbine component; determining at least one missing hole, based at least in part on comparing the received position data to the predefined hole position data; and drilling at least one hole in the gas turbine component corresponding to the determined at least one missing hole.

Abstract: Locating systems and methods for components are provided. A component has an exterior surface. A method includes locating a surface feature configured on the exterior surface along an X-axis and a Y-axis by analyzing an image of the component to obtain X-axis data points and Y-axis data points for the surface feature. The method further includes directly measuring the surface feature along a Z-axis to obtain Z-axis data points for the surface feature, wherein the X-axis, the Y-axis and the Z-axis are mutually orthogonal. The method further includes calculating at least two of a pitch value, a roll value or a yaw value for the surface feature.

Abstract: Certain embodiments of the disclosure may include systems, methods, and apparatus for locating and drilling closed holes of a gas turbine component. According to an example embodiment, the method can include receiving position data associated with one or more holes in a gas turbine component; receiving predefined hole position data from manufacturing data associated with the gas turbine component; determining at least one missing hole, based at least in part on comparing the received position data to the predefined hole position data; and drilling at least one hole in the gas turbine component corresponding to the determined at least one missing hole.