Design Of Fibrication And Pipe Inspection Robot

Design and fabrication of pipe inspection robot 2013

ABSTRACT

A pipe inspection robot is device that is inserted into pipes to check for

obstruction or damage. These robots are traditionally manufactured offshore, are

extremely expensive, and are often not adequately supported in the event or

malfunction. This had resulted in associated environmental services limited. A

Newzealand utilize of this equipment, facing significant periods of down time as they

wait for their robots to be the repaired. Recently, they were informing that several

robots were no longer supported.

This project was conceived to redesign the electronics control systems

one of these PIR, utilizing the existing mechanical platform. Requirements for the

robot were that it must operate reliably in confined, dark and wet environments and

provides a human wears with a digital video feed of the internal status of the pipes.

There robot should as much as possible incorporate off the shaft components, cheap,

and potentially onsite repair. This project details the redesign and constructions of

such robots. It employees there electronic boards integrated with mechanical

components and provides video feedback via custom graphical interface although at

the prototypes state the electronics has been successful with cost of less than a length

of the original robot purchase prize.

Keywords: Robot, Pipes defects, Electronics control systems, Digital video.

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Chapter 1: INTRODUCTION

Pipeline systems deteriorate progressively over time. Corrosion

accelerates progressively and long term deterioration increases the probability of

failure (fatigue cracking). Limiting regular inspecting activities to the "scrap" part of

the pipelines only, results ultimately into a pipeline system with questionable

integrity. The confidence level in integrity will drop below acceptance levels.

Inspection of presently uninspected sections of the pipeline system becomes a must.

This project provides information on the "robotic inspection technology".

Pipelines are proven to be the safest way to transport and distribute

Gases and Liquids. Regular inspection is required to maintain that reputation. The

larger part of the pipelines system is accessible by In-Line Inspection Tools but this

access is limited to the section in between the launching and receiving traps only.

Unfortunately, corrosion does not have this limitation. The industry looks for means

of inspecting these in-accessible pressure holding piping systems, preferably, without

interrupting the operations. It is a fact that sufficiently reliable and accurate

inspection results can only be obtained by direct pipe wall contact/access. If that is not

feasible from the outside, we have to go inside. Since modifying pipeline systems for

In-Line Inspection is mainly not practical, PIPE INSPECTION ROBOT pursues

development of ROBOTIC inspection services for presently in-accessible pipeline

systems.

Robotics is one of the fastest growing engineering fields of today.

Robots are designed to remove the human factor from labor intensive or dangerous

work and also to act in inaccessible environment. The use of robots is more common

today than ever before and it is no longer exclusively used by the heavy production

industries. The inspection of pipes may be relevant for improving security and

efficiency in industrial plants. These specific operations as inspection, maintenance,

cleaning etc. are expensive, thus the application of the robots appears to be one of the

most attractive solutions. Pipelines which are tools for transporting oils, gases and

other fluids such as chemicals, have been employed as major utilities in a number of

countries for long time. Recently, many troubles occur in pipelines, and most of them

are caused by aging, corrosion, cracks, and mechanical damages from the third

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parties. So, continuous activities for inspection, maintenance and repair are strongly

demanded.

The robots with a flexible (adaptable) structure may boast adaptability

to the environment, especially to the pipe diameter, with enhanced dexterity,

maneuverability, capability to operate under hostile conditions. The wheeled robots

are the simplest, most energy efficient, and have the best potential for long range.

Loading the wheels with springs, robots also offer some advantages in

maneuverability with the ability to adapt to in-pipe unevenness, move vertically in

pipes, and stay stable without slipping in pipes. These types of robots also have the

advantage of easier miniaturization. The key problem in their design and

implementation consists in combining the capacity of self-moving with that of self-

sustaining and the property of low weight and dimension. A very important design

objective is represented by the adaptability of the in-pipe robots to the inner diameters

of the pipes. Currently, the applications of robots for the maintenance of the pipeline

utilities are considered as one of the most attractive solutions available Pipe

Inspection Robot is shown in Figure 1.1.

Fig1.1:- Pipe inspection robot

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Chapter 2: PROBLEM STATEMENT

As we are observed that in industry , home , power plant etc. there are

several problems occurs inside the pipe like Corrosion , Cracking , Dent Mark , Metal

Losses etc. so , we are inspecting the pipe with the help of “PIPE INSPECTION

ROBOT”.

Fig 2.1: Flow chart showing scope of pipe inspection

2.1 Geometrical defects

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Buckle: regular buckle and sharp buckle

Ovality

Wrinkle

Knob

Rolling imperfection or angularity

Tube expansion

Joint imperfection: edge displacement & angle error

2.1.1 Ovality

Definition: nearly symmetric deviation of the pipe cross-section from the circular

shape resulting in ellipse cross-section without sharp breakpoints.

Measures: –minimum outside diameter, dk min [mm]; –maximum outside

diameter, dk max [mm].

Possible cause of origin: –pipe manufacturing; –external mechanical impact. ١

٠

2.1.2 Knob

Definition: residual deformation of the pipe wall outside the pipe without sharp edge

extending over an area.

Measures: maximum height, d [mm]; overall dimensions (axial length

×circumferential length), l ×k [mm ×mm].

Possible cause of origin: change in internal pressure interacting with another

defect.

Remark: the knob can be interpreted as the opposite of the regular buckle.

2.1.3 Ruck

Definition: the pipe wall is rippled along its circumference partly or entirely

and the centre line of the pipe remains straight

Measures: – maximum depth of the ripple, db [mm]; –maximum height of the

ripple, dk [mm]; angle subtended by the ruck along the circumference of the

pipe, j [°].

Possible cause of origin: – pipe manufacturing; –soil movement.

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2.1.4 Rolling imperfection or angularity

Definition: during the pipe manufacturing in the vicinity of the plate edge to

be joined by welding (seam) the shape of the pipe deviates from cylindrical

forming a sharp edge.

Measures: – height of the bevel edge, Y [mm]; –chord of the bevel edge, 2A

[mm].

Possible cause of origin: pipe manufacturing.

2.1.5 Tube expansion

Definition: elimination of diameter difference between the two pipe ends to be

joined with welding (girth weld).

Measures: – outside diameter of the pipe to be expanded, D1 [mm]; –wall

thickness of the pipe to be expanded, t1 [mm]; – expansion length, L [mm].

Possible cause of origin: – pipe installation (laying); –repair.

2.1.6 Edge displacement

Definition: radial displacement of parallel centre lines of pipe sections joined with

welding (girth weld).

Measures: eccentricity, e [mm].

Possible cause of origin:–pipe installation (laying); – repair; –pipe

manufacturing.

2.1.7 Angle error

Definition: deviation of centre lines of pipe sections joined with welding (girth

weld).

Measures: angle between the centre action systems

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(a) Cup dent (b) Saucer dent

(c) Welding defects (d) Material loss

Fig 2.2:-Picture showing some defects in pipe

Chapter 3: FIELD OF APPLICATIONS OF PIPE INSPECTION

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3.1 Nuclear power plants:-

Nuclear power plants must place safety concerns on the highest level

of priority before other interests such as their business interests. Regular inspections

of pipe systems need to be carried out and robots from INSPECTOR SYSTEMS are

widely used.

3.2 Conventional power plants:-

By taking advantage of the NDT inspection methods that our robots

offer, defects and faults can be avoided increasing the 'up and running' operational

time of all kinds of pipe systems. Worldwide, many power plants already use our

robots to do just this.

3.3 Refineries:-

The mineral oil industry can benefit from improved supply,

transportation, processing and distribution of mineral oil as well as improved

environmental protection. Our robots are helping to do just this.

3.4 Chemical and petrochemical plant:-

It is of course vital to continually reduce the risks brought about by the

manufacture, transport and storage of chemicals. This means that the possible dangers

need to be examined and the necessary testing and inspections carried out in order to

avoid or at least lessen and contain them. The use of our robots has become obligatory

in many well known companies.

3.5 Offshore:-

The technical demands of offshore rigs as well as safety and

environmental requirements are very high and strongly controlled. This means that

there is an enormous amount of required Non Destructive Testing inspections. Our

robots are used worldwide in offshore applications.

3.6 Long distance city heating pipelines:-

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Leakages in long distance heat conduits, caused through external

corrosion, cause energy and water losses resulting in damage to, among others,

subterranean constructions. Minimizing energy loss during the transport of heat from

source to end user is one of the most important requirements in order to exclude

danger to people and the environment. Our robots help in this important duty.

3.7 Food and drinks industries:-

The hygiene standard in the food and drinks industries is very high.

The condition of the individual pipe networks is therefore decidedly important.

Inspection robots from INSPECTOR SYSTEMS help to maintain and ensure this high

level of hygiene.

3.8 Communal waste water pipe systems:-

Subterranean sewer systems have been responsible for the collection

and transport of waste water since planning and construction began in 1842. With the

Republic of Germany most of these sewage systems are owned by the cities and

community districts. Regular inspection of the roughly 445 km of public sewage

systems is therefore a complex and cost intensive process.

3.9 Gas pipelines:-

Within Germany the total length of the natural gas pipeline network is

something like 335 km. At the moment it is run by 18 national companies and around

730 local ones. Robots from INSPECTOR SYSTEMS are deployed for inspection and

maintenance these flexible robots are well suited for carrying out inspections on pipe

systems, especially those that have a lot of bends, vertical sections and pipe branches.

These robots are mainly used in the nuclear power industry, refineries, chemical

plants, petrochemical plants, the offshore industry, gas pipelines, the beverage

industry and all types of pipe lines up to 500m long. Three drive elements provide a

speed of up to 200 m/h in both horizontal and vertical directions and allow for

effortless bend taking.

Chapter 4: INSPECTION METHODS

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4.1 Video Inspection:

Robots deployed for the video inspection of pipe systems possess a

maneuverable head that can be turned 360° and tilted 90°. This means that even video

pictures can be shot right below the pipe wall. Separate video recording of on-line

video data at the control point allows the operator to monitor, achieve and add

comments to the footage. The camera has been specially designed for use within pipe

systems and has not only great resolution but also a 10x optical zoom function as well

as automatic and manual focusing and adjustable lighting. Using highly specialized,

closed-circuit cameras, we can perform visual inspection of all pipe systems, from as

small as 6 millimeters - or 1/4 inch - in diameter up to any size. Our closed-circuit

cameras are the most reliable and effective way to detect leaks and inspect welds in

pipeline systems. And we are experts at overcoming difficult challenges - if it can be

done, Afonso Group can deliver. We have performed video inspections in sewer lines,

household and commercial sewer cleanouts, hydro facilities, refineries and offshore

installations.

4.2 Visual Inspection:

Due to the cost of advanced inspection techniques, less expensive

forms of Nondestructive evaluation is often desired. Visual inspection is currently one

of the most commonly used nondestructive evaluation techniques because it is

relatively inexpensive as it requires minimal, if any, use of instruments or equipment,

and it can be accomplished without data processing (FHWA, 2001). As mentioned

previously, visual inspection can only detect surface defects. However, a large

number of structural deficiencies have surface indicators (e.g. corrosion, concrete

deterioration). Aside from a limited range of detection, visual inspection does have

further drawbacks. It is extremely subjective as it depends on the inspector’s training,

visual acuity, and state-of-mind. Also external factors such as light intensity, structure

complexity, and structure accessibility play a role in determining the effectiveness of

visual inspection. Recently, the Federal Highway Administration’s Nondestructive

Evaluation Validation Center (NDEVC) conducted a study to investigate the

reliability of visual inspection as it relates to highway bridge inspection (FHWA,

2001). Because visual inspection is so widely practiced, assessing its validity as an

effective means of assessing structural integrity provides insight into the effectiveness

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of bridge inspections in general. The study required bridge inspectors from various

state transportation departments to complete both routine and in-depth inspections of

several decommissioned test bridges. The inspectors were asked to rate the condition

of several different structural elements according to the standards used in actual

bridge inspections. Participants were also subject to observation during the inspection

as well as interviews regarding their personal methods and procedures. Results from

the study indicated that visual inspections are completed with large variability

(FHWA, 2001). Condition ratings for each element varied significantly more than

those predicted by statistical models. Factors affecting variability included a reported

fear of traffic, near visual acuity, color vision, light intensity, structure accessibility

level, and inspector rushed level. Furthermore, in-depth inspections were highly

ineffective for detecting defects that were expected to be identified by such

inspections. In fact, in-depth inspections rarely revealed deficiencies beyond those

founding routine inspections. Again factors affecting the reliability of in-depth

inspections included structure complexity and accessibility, as well as inspector

comfort with access equipment and heights. These results call into question the

reliability of bridge inspection procedures. While the condition rating system is an

attempt to quantify observations, visual inspection remains highly subjective and

dependent upon external factors.

4.3 Ultrasonic inspection

Common non-destructive in-line inspection technologies such as

magnetic flux leakage (MFL), ultrasonic testing (UT) and eddy current systems

cannot detect stress corrosion cracking (SCC), especially in gas pipelines. Based on

an electro-magnetic acoustic transducer (EMAT), a new type of ultrasonic sensor uses

physical effects such as the Lorentz force and magnetostriction. It therefore works

independently of a coupling medium between the sensors and the pipeline to be

inspected, thus providing the ideal crack inspection solution for both liquid and gas

pipelines. First field tests with the 16-in tool have now confirmed the detection

capabilities of this technology under operational conditions. Numerous Rosen EMAT

modules were arranged on an in-line inspection tool to ensure high resolution. The

basic arrangement of the EMAT modules used to inspect a distinct area (pixel) of the

pipeline. The ultrasonic waves only travel a short distance between the EMAT sender

and the receiver. As a result, data evaluation is relatively simple and false alarms can

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be avoided. Fig.3 also illustrates that the sensor arrangement required to inspect one

pixel of the pipeline consists of one EMAT sender and two EMAT receivers. The

EMAT sender generates a tailored shear horizontal wave characterized by distinct

frequencies which make it especially sensitive to near-surface defects.

Provided that no cracks are present, the generated wave propagates in

one direction from the EMAT sender to the EMAT receiver which records it as a

transmission signal. If, however, there is a crack-like defect between the EMAT

sender and the EMAT receiver, one part of the signal is reflected back to the EMAT

sender where it is recorded as an echo signal by the second EMAT receiver. This

means that two acoustic data channels exist for each pixel, i.e. one echo and one

transmission channel.Compared with an MFL measurement, the new EMAT module

provides much more information, since not only one value (magnetization level) is

recorded at one particular pipeline position but several vectors (e.g. signal frequencies

and amplitude, travelling time of the acoustic wave etc). Additional data (e.g. lift-off

between the EMAT modules and the pipeline) is stored in separate data channels. This

independent storage ensures that echo and transmission data can be evaluated

unambiguously in relation to the physical measurement.

The overall amplitude of the wave that directly propagates from the

EMAT sender to the transmission receiver depends on the amount of lift-off, the

presence of a defect, and the existence (and type) of external coating. Coating

generally damps the acoustic wave. Therefore, a reduction in the bonding quality of

the coating leads to a significant increase in the signal amplitude. Distinct examples

for several cases are shown below shows that an echo signal is only recorded if a

significant amount of energy is reflected into the EMAT echo receiver. Since this

receiver is active for a short time interval, only signals reflected from specific

positions, but not irrelevant signals emitted from adjacent EMAT senders or late

reflections from other positions, are detected. Owing to the arrangement of the EMAT

modules, the system is especially suitable for the detection of axial features. A

detailed analysis of significant echo signals, eg signal amplitude, arrival time and

frequency content, provides valuable information on the type of defect identified.

One of the findings of the first inspections conducted with the ECD 16-

in tool in both a gas and an oil pipeline was that girth welds can be detected quite

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easily. The reason is that they cause typical signal characteristics in different data

channels (transmission channel, echo channel, lift-off channel). Similarly, long seams

can be observed in echo channels (increase) and transmission channels (decrease).As

illustrated in significant signal increases can be observed, since echo signals clearly

stand out from the background noise (eg girth welds). It shows that time domain

signal analysis allows collection of information about the orientation of the defect in

relation to the pipe axis. This means that the echo channels are sensitive to defects in

both the axial and the circumferential direction.

It follows that a C-scan view of a specific gas pipeline section, and the

explanations in the caption that the transmission channels are not only sensitive to

larger reflectors (signal decrease) but also to different coating qualities (signal

increase if coating is weaker).Rosen has developed an intelligent inspection tool based

on innovative high-resolution EMAT technology. The new technology has been

successfully tested in both an oil and a gas pipeline. The multi-dimensional data sets

provided by the tool allow continuous improvement. The promising results of the first

inspection survey will be further validated by an extensive validation program which

is currently underway.

4.4 Infrared method

The photo depicts the schematics for an infrared sensor which allows you to

detect an object's distance from the robot. The big picture problem is attach this

infrared sensor on both wings of the aerial robot. Attaching these sensors on the wing

tips will help the robot navigate through the halls of any building.. This tutorial shows

you how to construct and test one infrared sensor and takes approximately 3 hours to

complete.

4.4.1 Construction

This section gives step-by-step instructions along with photos to the

construction of IR Proximity Switch. Because this is a very simple circuit, only a

schematic for the sensor is shown here:

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Fig 4.1:-basic design of the infrared proximity sensor

An infrared sensor is an electronic device that emits and/or detects

infrared radiation in order to sense some aspect of its surroundings. Infrared sensors

can measure the heat of an object, as well as detect motion. Many of these types of

sensors only measure infrared radiation, rather than emitting it, and thus are known as

passive infrared (PIR) sensors.

All objects emit some form of thermal radiation, usually in the infrared

spectrum. This radiation is invisible to our eyes, but can be detected by an infrared

sensor that accepts and interprets it. These piezoelectric materials are integrated into a

small circuit board. They are wired in such a way so that when the sensor detects an

increase in the heat of a small part of its field of view, it will trigger the motion

detector's alarm. It is very common for an infrared sensor to be integrated into motion

detectors like those used as part of a residential or commercial security system.

An infrared sensor can be thought of as a camera that briefly

remembers how an area's infrared radiation appears. A sudden change in one area of

the field of view, especially one that moves, will change the way electricity goes from

the pyroelectric materials through the rest of the circuit. This will trigger the motion

detector to activate an alarm. If the whole field of view changes temperature, this will

not trigger the device. This makes it so that sudden flashes of light and natural

changes in temperature do not activate the sensor and cause false alarms.

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4.4.2 WHATE IS IR?

Fig 4.2:- IR sensor

Infrared radiation is the portion of electromagnetic spectrum having

wavelengths longer than visible light wavelengths, but smaller than microwaves, i.e.,

the region roughly from 0.75µm to 1000 µm is the infrared region. Infrared waves are

invisible to human eyes. The wavelength region of 0.75µm to 3 µm is called near

infrared, the region from 3 µm to 6 µm is called mid infrared and the region higher

than 6 µm is called far infrared. (The demarcations are not rigid; regions are defined

differently by many).

Fig 4.3:- spectrum of light

There are different types of IR sensors working in various regions of the IR spectrum

but the physics behind "IR sensors" is governed by three laws:

Planck’s radiation law:

Every object at a temperature T not equal to 0 K emits radiation.

Infrared radiant energy is determined by the temperature and surface condition of an

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object. Human eyes cannot detect differences in infrared energy because they are

primarily sensitive to visible light energy from 400 to 700 nm. Our eyes are not

sensitive to the infrared energy.

Stephan Boltzmann Law

The total energy emitted at all wavelengths by a black body is related

to the absolute temperature as

Wien’s Displacement Law

Wien’s Law tells that objects of different temperature emit spectra that

peak at different wavelengths. It provides the wavelength for maximum spectral

radiant emittance for a given temperature. The relationship between the true

temperature of the black body and its peak spectral existence or dominant wavelength

is described by this law:

The world is not full of black bodies; rather it comprises of selectively

radiating bodies like rocks, water, etc. and the relationship between the two is given

by emissivity (E).

Emissivity depends on object color, surface roughness, moisture

content, degree of compaction, field of view, viewing angle & wavelength

4.4.3 ELEMENTS OF INFRARED DETECTION SYSTEM

Fig 4.4:- Block diagram showing typical system for detecting infrared radiation

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Infrared Source

All objects above 0 K radiate infrared energy and hence are infrared

sources. Infrared sources also include blackbody radiators, tungsten lamps, silicon

carbide, and various others. For active IR sensors, infrared Lasers and LEDs of

specific IR wavelengths are used as IR sources.

Transmission Medium:

Three main types of transmission medium used for Infrared

transmission are vacuum, the atmosphere, and optical fibers.The transmission of IR –

radiation is affected by presence of CO2, water vapour and other elements in the

atmosphere. Due to absorption by molecules of water carbon dioxide, ozone, etc. the

atmosphere highly attenuates most IR wavelengths leaving some important IR

windows in the electromagnetic spectrum; these are primarily utilized by thermal

imaging/ remote sensing applications.

Medium wave IR (MWIR:3-5 µm)

Long wave IR (LWIR:8-14 µm)

Choice of IR band or a specific wavelength is dictated by the technical

requirements of a specific application.

Optical Components:

Often optical components are required to converge or focus infrared

radiations, to limit spectral response, etc. To converge/focus radiations, optical lenses

made of quartz, CaF2, Ge and Si, polyethylene Fresnel lenses, and mirrors made of

Al, Au or a similar material are used. For limiting spectral responses, band pass filters

are used. Choppers are used to pass/ interrupt the IR beams.

Infrared detectors:

Various types of detectors are used in IR sensors. Important

specifications of detectors are

Photosensitivity or Responsivity is the Output Voltage/Current per watt of

incident energy. Higher the better.

Noise Equivalent Power (NEP)

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NEP represents detection ability of a detector and is the amount of

incident light equal to intrinsic noise level of a detector.

Detectivity (D*: D-star)

D* is the photosensitivity per unit area of a detector. It is a measure of

S/N ratio of a detector. D* is inversely proportional to NEP. Larger D* indicates

better sensing element. In addition, wavelength region or temperature to be measured,

response time, cooling mechanism, active area, no of elements, package, linearity,

stability, temperature characteristics, etc. are important parameters which need

attention while selecting IR detectors.

Signal Processing:

Since detector outputs are typically very small, preamplifiers with

associated circuitry are used

Reflectance Sensors:

This type of sensors house both an IR source and an IR detector in a

single housing in such a way that light from emitter LED bounces off an external

object and is reflected into a detector. Amount of light reflected into the detector

depends upon the reflectivity of the surface.

This principle is used in intrusion detection, object detection (measure

the presence of an object in the sensor’s FOV), barcode decoding, and surface feature

detection (detecting features painted, taped, or otherwise marked onto the floor), wall

tracking (detecting distance from the wall), etc.

It can also be used to scan a defined area; the transmitter emits a beam

of light into the scan zone, the reflected light is used to detect a change in the reflected

light thereby scanning the desired zone.

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4.4.4 Cathode-Ray Oscilloscope:

Fig 4.5:- Picture showing the cathode-ray oscilloscope

The cathode-ray oscilloscope (CRO) is a common laboratory

instrument that provides accurate time and aplitude measurements of voltage signals

over a wide range of frequencies. Its reliability, stability, and ease of operation make

it suitable as a general purpose laboratory instrument. The heart of the CRO is a

cathode-ray tube shown schematically in Fig. 4.6

Fig 4.6:- Cathode ray tube (a) schematic, (b) detail of the deflection plates.

The cathode ray is a beam of electrons which are emitted by the

heated cathode (negative electrode) and accelerated toward the fluorescent screen.

The assembly of the cathode, intensity grid, focus grid, and accelerating anode

(positive electrode) is called an electron gun. Its purpose is to generate the electron

beam and control its intensity and focus. Between the electron gun and the fluorescent

screen is two pair of metal plates - one oriented to provide horizontal deflection of the

beam and one pair oriented to give vertical deflection to the beam. These plates are

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thus referred to as the horizontal and vertical deflection plates. The combination of

these two deflections allows the beam to reach any portion of the fluorescent screen.

Wherever the electron beam hits the screen, the phosphor is excited and light is

emitted from that point. This conversion of electron energy into light allows us to

write with points or lines of light on an otherwise darkened screen.

In the most common use of the oscilloscope the signal to be studied is

first amplified and then applied to the vertical (deflection) plates to deflect the beam

vertically and at the same time a voltage that increases linearly with time is applied to

the horizontal (deflection) plates thus causing the beam to be deflected horizontally at

a uniform (constant> rate. The signal applied to the verical plates is thus displayed on

the screen as a function of time. The horizontal axis serves as a uniform time scale.

The linear deflection or sweep of the beam horizontally is

accomplished by use of a sweep generator that is incorporated in the oscilloscope

circuitry. The voltage output of such a generator is that of a saw tooth wave as shown

in Fig. 2. Application of one cycle of this voltage difference, which increases linearly

with time, to the horizontal plates causes the beam to be deflected linearly with time

across the tube face. When the voltage suddenly falls to zero, as at points (a) (b) (c),

etc...., the end of each sweep - the beam flies back to its initial position. The

horizontal deflection of the beam is repeated periodically, the frequency of this

periodicity is adjustable by external controls.

To obtain steady traces on the tube face, an internal number of cycles

of the unknown signal that is applied to the vertical plates must be associated with

each cycle of the sweep generator. Thus, with such a matching of synchronization of

the two deflections, the pattern on the tube face repeats itself and hence appears to

remain stationary. The persistence of vision in the human eye and of the glow of the

fluorescent screen aids in producing a stationary pattern. In addition, the electron

beam is cut off (blanked) during fly back so that the retrace sweep is not observed.

CRO Operation:

A simplified block diagram of a typical oscilloscope is shown in Fig. 3.

In general, the instrument is operated in the following manner. The signal to be

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displayed is amplified by the vertical amplifier and applied to the verical deflection

plates of the CRT. A portion of the signal in the vertical amplifier is applied to the

sweep trigger as a triggering signal. The sweep trigger then generates a pulse

coincident with a selected point in the cycle of the triggering signal. This pulse turns

on the sweep generator, initiating the sawtooth wave form. The sawtooth wave is

amplified by the horizontal amplifier and applied to the horizontal deflection plates.

Usually, additional provisions signal are made for appliying an external triggering

signal or utilizing the 60 Hz line for triggering. Also the sweep generator may be

bypassed and an external signal applied directly to the horizontal amplifier.

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Chapter 5: Design of Pipe Inspection Robot

5.1 Selection of materials:

The materials used for this machine are light and rigid. Different materials

can be used for different parts of the robot. For optimum use of power the materials

used should be light and strong. Wood is light but it is subjected to wear if used for

this machine. Metals are the ideal materials for the robot as most if the plastics cannot

be as strong as metals. Material should be ductile, less brittleness, malleable, and high

magnetic susceptibility. Among the metals, aluminum is the material chosen for the

linkages and the common rod, which is made as hollow for reduction in weight.

However, other materials are chosen for the motor.

The materials chosen for the motor should have high magnetic susceptibility

and should be good conductor of electricity. The materials are copper and so on. But

aluminum is chosen as the materials for the linkages and central body because of its

much-desired Properties. Aluminum has lightweight and strength; it can be used in a

variety of applications. Aluminum alloys with a wide range of properties are used in

engineering structures .The strength and durability of aluminum alloys vary widely,

not only because of the Components of the specific alloy, but also because of heat

treatments and manufacturing Processes. Another important property of aluminum

alloys is their sensitivity to heat.

Work shop procedures involving heating are complicated by the fact that

aluminum, unlike steel, will melt without first glowing red. Aluminum alloys, like all

structural alloys, are also subject to internal stresses following heating operations such

as welding and casting. The problem with aluminum alloys in this regard is their low

melting point, which make them more susceptible to distortions from thermally

induced stress relief.

The toughness, as measured by crack propagation energy, decreases as yield

stress increases.

At the same yield stress, the under aged structure has greater toughness than

the over aged structure.

. Page 22


5.2 Effect of Temperature:

Another important property of aluminum alloys is their sensitivity to

heat. Work shop procedures involving heating are complicated by the fact that

aluminum, unlike steel, will melt without first glowing red. Aluminum alloys, like all

structural alloys, are also subject to internal stresses following heating operations such

as welding and casting. The problem with aluminum alloys in this regard is their low

melting point, which make them more susceptible to distortions from thermally

induced stress relief.

The toughness, as measured by crack propagation energy, decreases as yield

stress increases.

At the same yield stress, the under aged structure has greater toughness than

the over aged structure.

5.3 Mechanism:

The mechanism involved here is a four bar mechanism consisting of

three revolute joints and one prismatic joint as depicted

Fig 5.1: Mechanism of PIR

H = 2r + 2d + 2h2×cosθ,

Where,

h1 = 30 mm, h2 = 85 mm, h3 = 105 mm (h1 =OA, h2 = BC = D, h3 = CF)

. Page 23


H=2×36+2×28+2×85×cos 45

H=248.20mm

Where D - Diameter of the pipe in mm, d - Distance between EE’ in mm.h1, h2, h3

are the length of the links in mm. r-Radius of the wheel, H=Height of robot outside

the pipe.

For uniform Diameter,

Assume D = 2r+2d+2h2cosθ

D=2×36+2×28+2×85×cos50

D=237.27mm

5.2.1 Kinematics of Mechanism:

The linkage structure can be represented as in figure depicted. This is a

four-bar mechanism Consisting of three revolute joins and one prismatic as depicted.

Thus, the motion of all revolute joints can be described in terms of the displacement

db .

5.2.2 Static Analysis:

In order to decide the actuator size, it is necessary to perform the static

analysis. Assume that in (Figure 4), Fcx and Fcz denote the reaction force and the

traction force exerted on the four-bar by the driving wheel, respectively. Now

applying the virtual work principle to the free-body diagram gives:

Figure 5.2: Linkages of PIR

. Page 24


Figure 5.3: Static Analysis

δW = Fcz δz – Fbx δx = 0

Where, Fbx is spring force. This is because only Fcz and Fbx conduct

work. The corresponding coordinates of these forces relative to the coordinate located

at the A hinge are expressed as: z = 2.33/ sin θ, x = 2.33/ cos θ

δW = Fczδ (2.33l sinθ) – Fbxδ (–2.33l cosθ)

= Fcz*2.333/ cosθ– Fbx*2.33/ sin θ δθ.= 0

Rearranging gives:

Fbx = Fcz*cosθ/sinθ

Thus, the spring force at the prismatic joint B is related to the normal force

Fcz by Fbx = Fcz*tanθ

And the total weight W of the robot is the sum of the six traction forces exerted on the

belt. Thus, each traction force Fcx is one six of the whole weight of the robot

structure. Thus, the size of the actuator enclosed in the wheel is calculated by: τ =

Fcx*R = WR/6

. Page 25


Where, R is the radius of the wheel. From the above static analysis, it

is also known that the large weight of the robot does not influence the foldable motion

of the linkage. The spring stiffness is found to be 0.9 N/ mm and the spring force is

found to be 4.5. Thus we came to the conclusion that the actuator should have at least

3 kg torque. So, we used 3 actuators with 1.5 kg torque (total 4.5 kg torque). It is safe

to use an actuator with more torque than the required torque.

5.3 Design of various elements of PIR

5.3.1 Helical spring

Inner diameter – 18 mm

Outer dia – 20 mm

Pitch – 5 mm

Length of the spring – 60 mm

Material – Stainless steel

Figure 5.4: Helical Spring

5.3.2 Translational Element

Inner diameter – 18 mm

Outer diameter – 23 mm

Length of the element – 25 mm

Material – Mild steel

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Figure 5.6: Translational Element

5.3.3Wheel

Diameter – 72 mm

5.3.4 Distance between the Extreme links

Drilled Holes (Figure 7)

Link 1 – 30 mm

Link2 – 85 mm

Link3 – 105 mm

Thickness – 3 mm

Drilled holes – 12 and 6 mm

Material – Acrylic

Figure 5.7: Extreme links

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5.3.5 Central Element

Hollow

Inner dia – 15 mm

Outer dia – 20 mm

Length – 220 mm

Material – Mild steel

Figure 5.8: Central Element

5.4 COMPONENTS OF PIPE INSPECTION ROBOT

Central Frame

Central body is the frame of the robot. It supports all other

components and holds batteries at the centre of the body. The joints are brazed on the

central frame at 120 degrees. The central body is drilled and its ends are threaded

internally for the insertion of pencil batteries and closing with externally threaded

caps. Wireless camera is fixed at one end of the frame.

Fig 5.9:- Central Frame

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5.4.1 Translational Element

Translational Element is the movable part in the robot which slides

along the central body for repositioning in case of pipe diameter variation. This

element is drilled at the centre for the translating along the central body. This will

restrict the links to some extreme angles beyond which it could not be translated. The

extreme angles are found to be 15 degrees and 60 degrees. The joints are brazed on

the translational element at 120 degrees for the links to be fixed onto it.

5.4.2 Compression Spring

A spring is an elastic object used to store mechanical Energy. Spring

used here is made out of hardened steel. Compression spring is mainly used to exert

tension. The purpose of spring is as follows:

The force that the mini robot mechanism exercises on the pipe walls is

generated with the help of an extensible spring.

The helical spring disposed on the central axis assures the repositioning of the

structure, in the case of the pipe diameters variation.

Fig 5.10:- Compression Spring

5.4.3 Links

Each resistant body in a machine which moves relative to another

resistant body is called Kinematic link or element. A resistant body is which do not go

under deformation while transmitting the force. Links are the major part of the robot

which translates motion. Links are connected to form a linkage. The mechanism

involved here is a 4 bar mechanism which has 3 revolute pairs and1 single prismatic

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pairs as depicted. Links holds the receiver, switch, and 9v battery for the camera. Also

it supports the actuator.

Fig 5.11:- Links

5.4.4 Actuators

Actuators are the drive for the robot. Since we have chosen aluminum

material for fabrication, the weight is comparatively less. So the motor should have 2

kg torque to travel inside the pipe. We used 3 motors which has 1 kg torque to make

the robot in motion. The supply for the motor is 6v which is from the central body.

The 3 motors are placed at120 degrees and are supported on the links by a tag

Fig 5.12:- Actuator (Bo Motor)

5.4.5 Batteries

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Shaft


Batteries give supply for a motor and wireless camera. Motor and radio

frequency gets 6v supply from the central body and wireless camera gets supply from

a 9vbattery. And 3v batteries for transmitter which has two toggle switch. One is for

motor forward and reverse control and the other one is for glowing LED’s.

5.4.6 Transmitter

The extension cable which attached the camera with output device

transmits the video and picture.

5.4.7 Features of pipe inspection robot

Flexible, self propelled

Can take bends up to 1.5 D (partly 1.0)

Vertical pipe sections can be traveled

Pipe lengths of up to 500m can be traveled

Can operate in pipes larger than 3 inches

High quality camera with 10x optical zoom

Pipe branches and diameter deviations present no problem

Chapter 6: CONSTRUCTION

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A pipe inspection robot consist of central element having 12.7 mm dia,

, 3 mm thickness and 176 mm in length , one translational element having 15mm dia.

3mm thick & 20mm in length. There are 12 links out of which 3 links are 105mm

(A1, A2, A3),6 links of 85mm(B1,B2,B3,B4,B5,B6) & another 3 links of

30mm(C1,C2,C3).The spring is 90mm in length.

The central element are joined to the 6 links the length of 28mm.On

the central element links are attached to fulcrum with pin joint on the periphery with

120Y lateral spacing at the points 1,2,3 resp. as shown in fig.

Also 3 links are B4,B5,B6 are attach to another point 4,5,6 which are

50mm from point 1,2,3 as shown in fig. in the same way as in previous point. The one

end of the three links which are 30mm in dia.(C1,C2,C3) are attach to the translation

element in outer side to fulcrum with pin joint which are 120Y in lateral spacing & the

another end is attach to the links B4,B5,B6 at point with pin joint as shown in fig.

The another link with length (A1,A2,A3) is attach to the end of the

links (B1,B2,B3,B4,B5,B6) at the distance as shown in fig. The motor & wheels are

mounted on the links (A1, A2, A3) as shown in fig..The front end of the structure is

attached with the swiveling & turning head consist of camera & fitted with BO motor.

Fig 6.1: Construction of links

The camera & lights are mounted in a swiveling head are attached to

the cylindrical body. The swiveling head are integrated to the lighting device a

typically used in LED. The LED is used to illuminate inside the pipe line. The

camera is pan & tilt by remotely. The motor wiring as shown in fig. are supply with

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12v dc power supply through adaptor. The 3v dc power is supplied to the BO motor

of camera. Operate the motor wheel the robot remote is connected.

Fig 6.2: Construction of camera head

The camera is connected to the display equipment(output) via long

cable wound upon a winch There are 6 wheels the dia. Of wheel 72mm.There are 6

D.C motor having 10rpm & 12v.There are 2 BO motor having 60rpm & 3-9v.The BO

motor is used for actuate the camera & light and it is fixed to the front side of the

robot. The spring is attached to the end of the robot and it provide expand &

compression motion to the links with the help of translational element.

Chapter 7: WORKING

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Fig 7.1:- Block diagram showing working principal of pipe inspection robot

7.1 Working of the Pipe Inspection Robot:

As Pipe Inspection Robot is designed mainly for circular bore pipes, it

have ability to move inside any bore diameter pipes ranging from 8 inch to 10 inch

( 203mm to 254mm ). Suitable mechanisms are provided so that it gains ability to

move inside the bends and tapered pipes. The PIR have ability to see inside the dark

pipes where no human eyes can see. This made possible by mounting the surveillance

camera and LEDs on head of the PIACR. The output is send to outside screen where

the digital hi-quality image can be received.

The perfect fitness between the pipe and robot is first conformed after

inserting the robot in the pipe. Then the supply of DC 12V dc current from is on for

working of robot and the camera is also started. With the help robot control having

three buttons, working of robot can be easily control the motions which is forward

and reverse by one button and by other two buttons the motion which is swiveling and

tilting of the camera head fitted in front of the robot can be control so that we can see

the pictures and videos inside the pipe.

Working of PIR is starts from its insertion in pipe. The front three arms is

compressed by hand and then inserted in the pipe and then back three arms is inserted

by pushing the PIR. The motors driven are the first six arms mentioned here, they pull

whole setup. PIR is about 175 cm in length and to move it freely inside the bend pipes,

a 2 degree of freedom joining is provided at the middle so that it can turn easily. As

switch is on and current is flowing through wires, wheels starts moving and forces PIR

. Page 34


to propel forward. Using the friction between wheels and pipe, the motion of wheels

become possible

Fig7.2: PIR moving inside the pipe

. PIR could have more than three arms for better judgment and

perfection but it would increase the weight and cost of manufacturing and hence we

need to do tradeoff between money involvement and perfection. PIR wheel motion is

provided with 10 rpm, 12 V DC motors hence its speed can be maintained between -

10 to 10 rpm. The power provided to motors is from single 12V dc adapter hence load

on each motor will be minimum that expected.

As we mentioned earlier that PIR will be able to move inside any

diameter ranging between 203mm to 254mm, we had to provide auto adjusting

mechanism that can expand and contact as PIR moves inside the pipe. Spring of

suitable stiffness is mounted on base rod, as seen in figure, so that as arms gets

contracted due to load of compression against pipe, spring get compressed and tend to

expand outward trying to push arms back to their normal position but as pipe restrict

them, they cannot move. We took good care of stiffness of spring such that it can

move against the pipe and do not put too high pressure of tires which can jam it and

restrict the motion. Even if the pipe interior is smooth, using pressure between

compressed tire and pipe, PIR can move easily. This is another application of spring.

The main idea behind providing small shock-ups is not meant to

absorb shocks but to make good individual expansion of arms in case of bends and

turns. When a vehicle turns, two vehicles cannot have same angular velocity. Hence

the outer arm must expand and shorter arm must compress. But as if we have used

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http://udayhiwarale.asia/piacr/images/demo/joint.jpg


simple links then this wouldn't be possible. The mini suspension arms (previously

mentioned shock-ups) provide individual expansion provision to arms and hence all

arms are sticked to the pipe while turning. If we were not used the mini suspension

arms then one of the which might not be able to make constant contact with pipe

interior and whole setup would be unstable, might collapse under gravity.

Fig 7.3: Picture showing working of PIR inside the pipe

The robot is run inside pipe by forward and reverse motion of the

wheel which has the speed of 10 rpm. This constant slow speed is to insure better

inspection because of the high speed there may be possibility to miss the any defect.

The camera is tilted by another button provided camera head motion on the remote

control. The swiveling of camera can be achieved for 180 degree in addition two 180

degrees for tilting and thus in combination the envelope of 180 degree can be easily

seen through the camera. The output image from camera is send to Computer screen

which may be laptop, monitor, TV or any such device which gives the visual picture.

The camera sends this picture to the output screen with help of extension cable as

shown in figure.

Operator can control the robot and see the picture of the inside pipe on

the output screen and thus if there is any defect such as such as internal material loss ,

. Page 36


big crack, weld defects dents corrosion erosion or blockage in the pipe . The exact

location of the defect is judge by the distance meter provided on the robot it gives

distance in centimeters from the starting point from which the robot was inserted

inside the pipe. the distance the robot can travel i.e. the length which it can capable to

inspect is depends upon the length of the extension cable provided to robot. To insure

the tractive force required pulling the long extension cable and other accessories,

robot train can be used which can be made by joining the two or more robots through

the universal joints at the end. The inspection can be done on the basis of video and

pictures inside the pipe provided by camera. The result can be obtained directly on the

basis of these pictures or with the help image processing. The image processing can

be explained as follows.

7.1.1 IMAGE PROCESSING

Fig 7.4 :- Fundamental steps in digital image processing system

In imaging science, image processing is any form of signal processing

for which the input is an image, such as a photograph or video frame; the output of

image processing may be either an image or a set of characteristics or parameters

related to the image. Most image-processing techniques involve treating the image as

a two-dimensional signal and applying standard signal-processing techniques to

it.Image processing is referred to processing of a 2D picture by a computer.

. Page 37


Basic definitions: An image defined in the “real world” is considered to be a function

of two real variables, for example, a(x,y) with a as the amplitude (e.g. brightness) of

the image at the real coordinate position (x,y).

Modern digital technology has made it possible to manipulate multi-

dimensional signals with systems that range from simple digital circuits to advanced

parallel computers. The goal of this manipulation can be divided into three categories:

Image Processing (image in -> image out)

Image Analysis (image in -> measurements out)

Image Understanding (image in -> high-level description out)

An image may be considered to contain sub-images sometimes

referred to as regions-of-interest, ROIs, or simply regions. This concept reflects the

fact that images frequently contain collections of objects each of which can be the

basis for a region. In a sophisticated image processing system it should be possible to

apply specific image processing operations to selected regions. Thus one part of an

image (region) might be processed to suppress motion blur while another part might

be processed to improve color rendition. Sequence of image processing:

The most requirements for image processing of images is that the

images be available in digitized form, that is, arrays of finite length binary words. For

digitization, the given Image is sampled on a discrete grid and each sample or pixel is

quantized using a finite number of bits. The digitized image is processed by a

computer. To display a digital image, it is first converted into analog signal, which is

scanned onto a display. Closely related to image processing are computer graphics

and computer vision. In computer graphics, images are manually made from physical

models of objects, environments, and lighting, instead of being acquired (via imaging

devices such as cameras) from natural scenes, as in most animated movies. Computer

vision, on the other hand, is often considered high-level image processing out of

which a machine/computer/software intends to decipher the physical contents of an

image or a sequence of images (e.g., videos or 3D full-body magnetic resonance

scans).

. Page 38


In modern sciences and technologies, images also gain much broader

scopes due to the ever growing importance of scientific visualization (of often large-

scale complex scientific/experimental data). Examples include microarray data in

genetic research, or real-time multi-asset portfolio trading in finance.

Before going to processing an image, it is converted into a digital form.

Digitization includes s sampling of image and quantization of sampled values. After

converting the image into bit information, processing is performed.

7.1.2 STEPS IN IMAGE PROCESSING

The various steps required for any digital image processing applications are listed

below:

1. Image grabbing or acquisition

2. Preprocessing

3. Segmentation

4. Representation and feature extraction

5. Recognition and interpretation.

Preprocessing: A process to condition/enhance the image in order to make it suitable

for further processing. It is more appropriate to explain the various steps in digital

image processing with an application like mechanical components classification

system. Let us consider an industrial application where the production department is

involved in the manufacturing of certain mechanical components like bolts, nuts, and

washers. Periodically, each one of these components must be sent to the stores via a

conveyor belt and these components are dropped in the respective bins in the store

room.

In the image acquisition step using the suitable camera, the image of

the component is acquired and then subjected to digitization. The camera used to

acquire the image can be a monochrome or color TV camera which is capable of

producing images at the rate of 25 images per sec.

The second step deals with the preprocessing of the acquired image.

The key function of preprocessing is to improve the image such that it increases the

. Page 39


chances for success of other processes. In this application, the preprocessing

techniques are used for enhancing the contrast of the image, removal of noise and

isolating the objects of interest in the image.

The next step deals with segmentation—a process in which the given

input image is partitioned into its constituent parts or objects. The key role of

segmentation in the mechanical component classification is to extract the boundary of

the object from the background. The output of the segmentation stage usually consists

of either boundary of the region or all the parts in the region itself. The boundary

representation is appropriate when the focus is on the external shape and regional

representation is appropriate when the focus is on the internal property such as

texture. The application considered here needs the boundary representation to

distinguish the various components such as nuts, bolts, and washers.

In the representation step the data obtained from the segmentation step

must be properly transformed into a suitable form for further computer processing.

The feature selection deals with extracting salient features from the object

representation in order to distinguish one class of objects from another. In terms of

component recognition the features such as the inner and the outer diameter of the

washer, the length of the bolt, and the length of the sides of the nut are extracted to

differentiate one component from another.

Feature Extraction: A process to select important characteristics of an image or object.

The last step is the recognition process that assigns a label to an object

based on the information provided by the features selection. Interpretation is nothing

but assigning meaning to the recognized object. The various steps discussed so far are

depicted in the schematic diagram as shown in Figure. We have not yet discussed

about the prior knowledge or the interaction between the knowledge base and the

processing modules.

Knowledge about the problem domain is coded into the image

processing system in the form of knowledge database. This knowledge is as simple as

describing the regions of the image where the information of interest is located. Each

module will interact with the knowledge base to decide about the appropriate

. Page 40


technique for the right application. For example, if the acquired image contains spike-

like noise the preprocessing module interacts with the knowledge base to select an

appropriate smoothing filter-like median filter to remove the noise.

Chapter 8: SPECIFICATION

. Page 41


8.1 Dc motor

Fig 8.1:- Dc motor

8.1.1 Description:

The 12V DC Geared Motor can be used in variety of robotics

applications and is available with wide range of RPM and Torque.

Length: 80mm

Torque: 1.5 kg.cm

Shaft Diameter: 6mm

Weight: 130.00g m

Speed : 10 RPM

8.2 Bo Motor

8.2.1 Description

60 rpm Single/Dual Shaft Plastic Gear Motor - Bo Motor gives good torque

and rpm at lower operating voltages, which is the biggest advantage of these motors.

Small shaft with matching wheels give optimized design for your application or

robot. Mounting holes on the body & light weight makes it suitable for in-circuit

placement.

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http://www.robosoftsystems.co.in/roboshop/media/catalog/product/cache/1/image/500x500/9df78eab33525d08d6e5fb8d27136e95/d/c/dc-motor.jpg


Fig 8.2 :- Bo Motor

Series: Bo Motor DC Geared

Operating voltage : 3V to 9V

Motor Speed: 60 rpm at 9V

Motor torque: 1.5 Kgf.cm

8.3 CAMERA

Fig 8.3: Camera head.

1/4 SONY CCD ; 520TVL resolution; 0.01LUX; color / black and white aut

omatic switching

Zoom: 10 times (1X optical, 1X electronic), focus automatically

With high brightness LED light source.

Pan:360°; Tilt: 180°

Pressure:8-18PSI

Shell material: aviation alu minum, stainless steel, the surface oxidation proc

ess

Size: diameter:40mm, length: 70 mm;

. Page 43

http://shop.technogravity.com/image/cache/data/Motors/BO%20Motors/BO%20Motor%20150%20rpm%20-%2003-500x500.jpg


8.4 CIRCUIT DIAGRAM

Fig 8.4. Circuit for wheel motor

8.5 DISTANCE METER

Fig: 8.5 Distance meter

Advanced digit counter, which have five digit counters. These are

especially made for low cost hand winding machines. Our Digital Counters are

equipped with left/right lever reset & both side drive shaft extension. Along with this,

these are equipped with top going or top coming drive direction. Further

specifications are as the following:

Overall size (mm) : L-166, W-66, H-70

Mounting holes: 4 hole, 5mm X-98.5 mm, Y-16.5 mm.

8.6 BILL OF MATERIAL

SR.

NO.

NAME OF MATERIAL QUANTITY

1. M. S. round bar 02

. Page 44


2. Acrylic sheet 1*2 feet 02

3. Screw 40

4. Nut 40

5. M.S. plate 01

6 Sheet metal (pipe) 8 feet 01

7. D.C. Motor 12

8. Bo Motor 02

9. CCD Camera 01

10. Extension cable of camera 01

11. Remote 01

12. Robot wheel 12

13. 10 core wire 15 feet 01

14. Spring 02

15. Adapter ( 12V) 01

16. Supply wire 10 feet 01

17. Washer 40

8.7 COST OF ESTIMATION

SR.

NO

NAME OF MATERIAL QUANTITY AMOUNT

. Page 45


.

1. M. S. round bar 12.7mm dia. ×3mm

thick

2 60

2. Acrylic sheet 3mm thick 2 160

3. Screw 12.7mm 40 20

4. Nut 40 20

5. M.S. plate 1 20

6 Sheet metal (pipe) 8 feet×9” 1 1500

7. D.C. Motor 12v/10 rpm 12 2220

8. Bo Motor 3v/60 rpm 2 325

9. CCD Camera 12 mega pixel 1 650

10. Extension cable of camera 10m 1 150

11. Remote 3 switch 1 90

12. Robot wheel 12 480

13. 10 core wire 15 feet 1 150

14. Spring 2 60

15. Adapter ( 12V) 1 450

16. Supply wire 10 feet 1 30

17. Washer 40 20

TOTAL 6435 Rs.

Chapter 9: Advantages of pipe inspection robot

9.1 Advantages

. Page 46


The pipe inspection robot inspects situation inside the pipe which will be

recorded and displayed on the monitor screen, it also facilitates working

personnel for effective observation, detection, quick analysis and diagnosis.

Save comprehensive investment, improve work efficiency, more accurate

detection.

Reduce the frequency of entering into the testing environment.

Operating cost related to other method is low.

Cost of manufacturing of this robot is relatively low.

9.2 Limitation of pipe inspection robot

Pipe inspection robots have such limitations as their ability to turn in a T-

shaped pipe or move in a plug valve.

Another drawback of earlier robots is that the friction between the pipe and the

cables for communication and power supply makes it difficult to move a long

distance. A fiber optic communication system can reduce the friction.

This robot does not work in water.

This robot works only in empty pipe.

CONCLUSION:

Robots play an important role in inside pipe-network maintenance and

their repairing. Some of them were designed to realize specific tasks for pipes with

. Page 47


constant diameters, and other may adapt the structure function of the variation of the

inspected pipe.

In this project inside pipe modular robotic system are proposed. An

important design goal of these robotic systems is the adaptability to the inner

diameters of the pipes. The given prototype permits the usage of a mini-cam for

visualization of the in-pipe inspection or other devices needed for failure detection

that appear in the inner part of pipes (measuring systems with laser, sensors etc).

The major advantage is that it could be used in case of pipe diameter

variation with the simple mechanism. We developed a pipe inspection robot that can

be applied to 203mm- 254mm pipeline. A real prototype was developed to test the

feasibility of this robot for inspection of in-house pipelines.

The types of inspection tasks are very different. A modular design was

considered for easily adapted to new environments with small changes. Presence of

obstacles within the pipelines is a difficult issue. In the proposed mechanism the

problem is solved by a spring actuation and increasing the flexibility of the

mechanism. The robot is designed to be able to traverse horizontal and vertical pipes.

Several types of modules for pipe inspection mini robot have been presented. Many of

the design goals of the Pipe inspection robot have been completely fulfilled.

REFRENCES:

Books

. Page 48


Theory of Machine -Prof. R. S. Khurmi & Prof. J. K. Gupta.

Automation production systems, and Computer-Integrated Manufacturing -

Prof. M. P. Groover

Links:

http://www.ulcrobotics.com/products

http://www.piacr.tk/Introduction to Pipe Inspection and Cleaning Robot

http://www.sciencedirect.com/science/article/pii/S0094114X06002254

http://capitalpipeliners.com/cctv-pipe-inspection-method-applicability

http://www.google.co.in/patents?

hl=en&lr=&vid=USPAT5084764&id=tislAAAAEBAJ&oi=fnd&dq=+of+pip

e+inspection&printsec=abstract#v=onepage&q=of%20pipe

%20inspection&f=false

http://ieeexplore.ieee.org/xpl/mostRecentIssue.jsp?punumber=3951

http://www.faadooengineers.com/tube/2012/06/11/mechanical-engineering-

project-pipe-inspection-robot/

En.wikipedia.org/wiki/Pipeline_vedio_inspection

. Page 49

http://www.faadooengineers.com/tube/2012/06/11/mechanical-engineering-project-pipe-inspection-robot/

http://www.faadooengineers.com/tube/2012/06/11/mechanical-engineering-project-pipe-inspection-robot/

http://ieeexplore.ieee.org/xpl/mostRecentIssue.jsp?punumber=3951

http://www.google.co.in/patents?hl=en&lr=&vid=USPAT5084764&id=tislAAAAEBAJ&oi=fnd&dq=+of+pipe+inspection&printsec=abstract#v=onepage&q=of%20pipe%20inspection&f=false



http://capitalpipeliners.com/cctv-pipe-inspection-method-applicability

http://www.ulcrobotics.com/products

Technology

Design Of Fibrication And Pipe Inspection Robot