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 for monitoring a component in a turbomachine can include a strain sensor comprising at least two reference points disposed on a surface of the component, and a data acquisition device connected to the turbomachine comprising a field of view, wherein the field of view is positioned to at least periodically capture the strain sensor on the component.

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 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 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 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 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 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: 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: Various aspects include methods of inspecting a substantially round hole in a material. One method can include: feeding a probe axially into the substantially round hole until the probe completely passes through the substantially round hole while the probe is activated; rotating the probe at least ninety degrees around a primary axis of the substantially round hole after feeding the probe completely through the substantially round hole; removing the probe axially from the substantially round hole after rotating the probe at least ninety degrees while the probe is activated; and compiling at least one of eddy current data or ultrasound data about the hole from the feeding of the probe axially into the substantially round hole and the removing of the probe axially from the substantially round hole.

Abstract: A method for inspecting a component is presented. The method includes inducing, by an inductive coil, an electrical current flow into the component. Further, the method includes capturing, by an infrared (IR) camera, at least a first set of frames and a second set of frames corresponding to the component, wherein the first set of frames is captured at a first time interval and a second set of frames is captured at a second time interval. Also, the method includes constructing, by a processing unit, a thermal image based on at least the first set of frames and the second set of frames corresponding to the component. Furthermore, the method includes determining presence of a thermal signature in the thermal image, wherein the thermal signature is representative of a defect in the component.

Abstract: A valve body in a passage of a housing connected to a through hole in a sealed machine casing can allow an inspection apparatus into an interior of the casing when open, and prevents fluid flow through the passage when closed. Seals can engage the inspection apparatus to prevent fluid flow through the passage during inspection or inspection apparatus movement. A guide conduit in the casing can include branches and can guide the inspection apparatus to multiple inspection sites. Guide marks can identify the branches to assist with navigation within the casing.

Abstract: A system for monitoring a component is provided. The system may include a strain sensor configured on the component, an electrical field scanner for analyzing the strain sensor, and a processor in operable communication with the electrical field scanner. The processor may be operable for measuring an electrical field value across the strain sensor along a mutually-orthogonal X-axis and Y-axis to obtain a data point set. The processor may further be operable for assembling a field profile of the strain sensor based on the data point set. Methods of using the system are also provided.

Abstract: Various aspects include methods of inspecting a substantially round hole in a material. One method can include: feeding a probe axially into the substantially round hole until the probe completely passes through the substantially round hole while the probe is activated; rotating the probe at least ninety degrees around a primary axis of the substantially round hole after feeding the probe completely through the substantially round hole; removing the probe axially from the substantially round hole after rotating the probe at least ninety degrees while the probe is activated; and compiling at least one of eddy current data or ultrasound data about the hole from the feeding of the probe axially into the substantially round hole and the removing of the probe axially from the substantially round hole.

Abstract: A system and related methods for evaluating a component using a reference feature and a replicate of the reference feature. The component has an exterior surface with a reference feature thereon. The method includes determining an initial condition of the reference feature, subjecting the component to at least one duty cycle after determining the initial condition, determining a subsequent condition of the reference feature after the at least one duty cycle while the component is in a service position, and forming a replicate of the reference feature while the reference feature is in one of the initial condition or the subsequent condition. One of the initial condition or the subsequent condition may be determined based on the replicate of the reference feature.

Abstract: A method for inspecting a component is presented. The method includes inducing, by an inductive coil, an electrical current flow into the component. Further, the method includes capturing, by an infrared (IR) camera, at least a first set of frames and a second set of frames corresponding to the component, wherein the first set of frames is captured at a first time interval and a second set of frames is captured at a second time interval. Also, the method includes constructing, by a processing unit, a thermal image based on at least the first set of frames and the second set of frames corresponding to the component. Furthermore, the method includes determining presence of a thermal signature in the thermal image, wherein the thermal signature is representative of a defect in the component.

Abstract: Systems for monitoring a component in a turbomachine can include a strain sensor comprising at least two reference points disposed on a surface of the component, and a data acquisition device connected to the turbomachine comprising a field of view, wherein the field of view is positioned to at least periodically capture the strain sensor on the component.

Abstract: Components can comprise a substrate, an embedded strain sensor comprising at least two reference points disposed on the substrate, and an outer coating disposed over at least a portion of the embedded strain sensor.