110530 CLAWAR generator double-flexible - FINAL - comments removed

This paper describes the design and prototype implementation of a compact climbing robot with magnetic adhesion, which is only 8mm high and allows for moving in any direction on the stators or rotors of power generators. Thanks to a new locomotion system based on flexible magnetic rollers (= magnetic wheels fixed on motorized flexible shafts; patented technology), the robot is able to span over gaps and non-magnetic zones both in axial and circumferential direction while still being flexible enough for adapting to the large curvature of the rotor/stator (~0.5m-2m). With this new design, it is now possible for the first time to access all types of large power generators (>100MW) with only one device – while still keeping the mechanical complexity at a level which allows for realizing the robot in a robust way and at reasonable cost. After a brief description of the industrial environment where it is supposed to be used (inspection of generator stators with the rotor still installed), this paper describes the basic mechanical concept, pointing to the core innovation and the advantages towards previous designs. The paper concludes with a prototype implementation and some test results; and provides an outlook on future extensions in the final industrial version.