Distributed sensor network for nondestructively monitoring and inspecting insulated electrical machine components

A method of non-destructive testing, the method comprising:

• collecting at least one radiographic image of an insulated electrical component of a predetermined service age, the insulated electrical component comprising a conducting element, an insulating material covering the conducting element, a first radiographically-visible conductor sensor node coupled to the conducting element, at least one second radiographically-visible conductor sensor node coupled to the conducting element spaced a first distance in a predetermined direction from the first radiographically-visible conductor sensor node at the predetermined service age, a first radiographically-visible insulator sensor node coupled to the insulating material and not coupled to the conducting element, and at least one second radiographically-visible insulator sensor node coupled to the insulating material and not coupled to the conducting element and located a second distance in the predetermined direction from the first radiographically-visible insulator sensor node at the predetermined service age;
• and
• comparing the first distance to the second distance from the first radiographic image to determine an occurrence of debonding in the insulated electrical component;
• wherein the first distance differing from the second distance indicates the occurrence of debonding in the insulated electrical component.

A method of manufacturing an insulated electrical component comprising:

• coupling a first radiographically-visible conductor sensor node to a conducting element;
• coupling at least one second radiographically-visible conductor sensor node to the conducting element a first distance in a predetermined direction from the first radiographically-visible conductor sensor node;
• and
• bonding an insulating material to the conducting element and the radiographically-visible conductor sensor nodes;
• wherein the radiographically-visible conductor sensor nodes are distinguishable from the conducting element and the insulating material in a radiographic image.

An insulated electrical component comprising:

• a conducting element;
• a first radiographically-visible conductor sensor node coupled to the conducting element;
• at least one second radiographically-visible conductor sensor node coupled to the conducting element a first distance in a predetermined direction from the first radiographically-visible conductor sensor node;
• and
• an insulating material bonded to the conducting element;
• wherein the first radiographically-visible conductor sensor node and the second radiographically-visible conductor sensor node are distinguishable from the conducting element and the insulating material in a radiographic image.