Industrial endoscopy technology, as a mature non-destructive testing method, plays a crucial role in the operation and maintenance of wind power, especially in the regular inspection and fault early warning of the core component of wind turbine gearboxes, where it has become an indispensable tool. By delving into the interior of the gearbox, it enables operation and maintenance personnel to have an intuitive understanding of the operating status and identify early potential hazards, thereby providing a solid guarantee for the safe and stable operation of wind turbine units.

The Necessity and Application Scenarios of Industrial endoscopes in the inspection of wind turbine gearboxes

The gearbox of a wind turbine is the core component of the transmission chain in a wind turbine unit. Its purchase cost accounts for a relatively high proportion of the entire machine, and it is also a link that is prone to failure. Wind turbine units are typically designed to have a service life of 20 years, but if regular maintenance and inspection are not carried out, it is difficult to ensure their expected operating cycle. Due to the complex internal structure and confined space of the gearbox, traditional detection methods often require extensive disassembly, which is time-consuming, labor-intensive and prone to introducing secondary faults. Industrial endoscopes, with their slender and flexible insertion tubes and high-definition cameras, can penetrate deep into gearboxes without disassembling them to conduct direct visual inspections of key components such as gears, bearings, and shafts. The main inspection targets include whether there are pitting, spalling, cracks or broken teeth on the tooth surface of gears, whether there are scratches, wear or plastic deformation on the roller and raceway surfaces of bearings, and whether there are foreign objects inside, etc. For instance, after the gearbox has been in operation for one year, it is recommended to use an endoscope for inspection to monitor its degradation.

Technical features of the dedicated endoscope for the inspection of fan gearboxes

To meet the special working environment and inspection requirements of the fan gearbox, the dedicated industrial endoscope features a series of characteristics. First of all, in terms of portability and robustness, considering that wind farms are usually located in remote areas and the nacelle space of wind turbines is narrow, operation and maintenance personnel need to carry equipment to climb high towers. Therefore, portable video endoscopes such as IPLEX G Lite weigh only about 1.15 kilograms, have a compact structure and are dust-proof and water-proof, and can withstand certain drops and vibrations. It is very suitable for on-site use. Secondly, in terms of probe diameter and interchangeability, to cope with the different spatial structures inside the gearbox, the inspection kit is usually equipped with lenses of various diameters. For instance, inspecting relatively large gear teeth may require a 6mm or 8mm lens to obtain a brighter field of view and panoramic observation, while to explore the narrow gap between roller bearings and raceways, a thinner 4mm diameter lens is needed for close observation. Thirdly, oil-proof design and clear imaging are of vital importance. The gearbox is filled with lubricating oil inside. If oil stains get on the lens, it will seriously affect the observation. The oil cleaning lens end adapter specially designed for gearbox inspection can use capillary action to suck away the oil stains on the lens surface, thereby obtaining a clear image. In addition, high-resolution images combined with intelligent lighting technology are crucial for the early detection of tiny pitting, cracking and other defects. Finally, flexible guiding capabilities and auxiliary accessories can enhance the detection efficiency. The sensitive end bending control function helps inspectors precisely locate the target during remote operation. Flexible indwelling catheters, magnetic fixation devices and other accessories can also assist the inserted tubes to reach the inspection areas such as planetary gear carriers and various grades of bearings more smoothly.

Implementation and data analysis of industrial endoscopy inspection

Effective endoscopic inspection is not merely about obtaining images; it also involves a scientific inspection process and data management. During the implementation of the inspection, it is recommended to conduct baseline inspection on newly put into operation gearboxes and record their initial status for subsequent comparison. In actual operation, prefabricated catheters or Flex-and-Stay catheters can be used to guide the inserted tubes to specific detection points. In terms of data analysis and management, the value of industrial endoscopes lies more in the long-term tracking and early warning of equipment status. By comparing internal images taken in different periods, operation and maintenance personnel can identify the development trend of defects, thereby providing a key basis for predictive maintenance. The accompanying detection management software (such as the InHelp software of Evident) can help operation and maintenance personnel manage a large number of detection images and videos in an orderly manner. For instance, before the inspection, independent image folders are established for each gear and bearing position in the gearbox. During the inspection, the images will be automatically saved in the corresponding folders and meaningful file names will be generated. This greatly facilitates subsequent image search, defect assessment and report generation. The file marking function enables inspectors to add evaluation annotations and preset comments to images, further simplifying the report production process.

In conclusion, industrial endoscopes offer an intuitive, efficient and non-disassemblable inspection solution for the maintenance of fan gearboxes. It can help operation and maintenance personnel promptly identify early fault hazards, achieving a shift from passive maintenance to proactive prevention. This is crucial for reducing unplanned downtime of wind turbines, optimizing operation and maintenance costs, and ensuring power generation. It is an important technical support for the safe production and economic benefit improvement of wind farms.