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A PROJECT REPORT ON PIPE CRAWLER
A Synopsis
Submitted in Partial fulfillment of Minor Project for the award of
Bachelor of Engineering Degree in Mechanical Engineering
Submitted to
RAJIV GANDHI PROUDYOGIKI VISHWAVIDYALAYA
BHOPAL (M.P.)
MINOR PROJECT SYNOPSIS SUBMITTED BY
1. Shailesh sarodey (0133ME121078)
2. Ramji Patel (0133ME121077)3. Ratnesh Ratnam (0133ME121094)
4. Rohit Sahu (0133ME121082)
5. Sanjay Patel (0133me121089)
Guide Head of the DepartmentMr. N K Sagar Mr. P K Jain
Professor Professor
DEPARTMENT OF MECHANICAL ENGINEERING
SAGAR INSTITUTE OF RESEARCH & TECHNOLOGY
BHOPAL (M.P.)
SESSION-2015-16
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ACKNOWLEDGEMENT
We would like to express our deepest gratitude and sincerely thanks to the faculty members of the
college for giving us an opportunity to undergo minor project.
We are also thankful to Mr. N.K.Sagar (Prof.) for their knowledge and immense guidance.
At last we would like to convey our thanks to all the members of the mechanical department whose
valuable guidance and suggestion helped us in accomplishing this report.
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Table of contents
1.
Introduction……………………………………………….5-6
a. Statement of problem
2.
Modification in Mechanism and its Implementation………7 3. Components of inspection robot…………………………..8-10
4. Inspection interpretation………………………………….11
5. Utility and application……………………………………12-16
a. Implementation
b. Application
6. Conclusion…………………………………………………17
7.
Reference…………………………………………………..17
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ABSTRACT
The project involves the basic concept of designing and fabrication of robot using kinematic
linkage that is modification over old PIPE CRAWLER.
The design consists of a helical compression spring which is responsible for the force that the
robot mechanism exercises on the pipe wall. The helical spring disposed on central axis assures
the repositioning of the structure, in the cause of the pipe diameter’s variation. The central axis
consists of stainless steel pipe of small diameter. Another pipe of larger diameter and smaller
length, attached to the compression spring is mounted in the inner pipe, which is free to slide on
it and thus enables spring to compress freely and accommodate the changes in pipe diameter and
ovality and the advantage of our crawler over the old crawler is, it can be used for different-
different diameters and allows the robot to move within pipes with horizontal, vertical, and
elbow-typed portions.
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INTRODUCTION
The project involves the basic concept of designing and fabrication of robot using kinematic
linkage. The design consists of a helical compression spring which is responsible for the force that
the robot mechanism exercises on the pipe wall. The helical spring disposed on central axis assures
the repositioning of the structure, in the cause of the pipe diameter’s variation. The central axis
consists of stainless steel pipe of small diameter. Another pipe of larger diameter and smaller
length, attached to the compression spring is mounted in the inner pipe, which is free to slide on it
and thus enables spring to compress freely and accommodate the changes in pipe diameter and
ovality .connecting members are welded to the central axis to connect the linkages using bolted
joints. The three wheels at the back are driven by three DC motors (60 r.p.m. 12 V), through
reduction transmission. The rest of the three front wheels are driven by the linkages .Here,
Modified pantograph linkage is used which is a four bar linkage mechanism, where the four
links from a parallelogram. This ensures that the front wheels trace the motion as traced by the
rare wheel, and hence the wheels are properly aligned within the pipe. The motor are connectedand control using a wired remote control (comprising of a DPDT switch and multicolor wires)
powered by 12V to 18V DC supply. Aluminum linkages are used due to its lightness and optimum
required strength to weight ratio. In the present demo model cell phone Bluetooth connectivity is
used to transmit the video on the laptop or PC using mobiola software. Led’s are used as light
source which are mounted near the cell phone for proper camera operation.
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LITRATURE
Kinematics- It is branch of classical machines that describes the motion of body (object) and
systems (group of object) without consideration of forces that causes the motion. Thus it is the
study from a geometric point of view, to know the displacement and acceleration of a part of
mechanism.
Mechanism-If a no of bodies are connected in such a way that the motion of one causes the
constrained predictable motion of the other, it is known as mechanism.
Machine-It is a mechanism or combination of mechanism which apart from imparting definite
motion to the part, also transmits the available mechanical energy into some kind of desired work.
Kinematic 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.
Kinematic links can be divided into three types:-
1. Rigid link-In this type of links there is no deformation while transmitting the motion. Motion
between the piston and crank can be considered as a rigid link .
2. Flexible link- In this type of link there is partial deformation while transmitting the motion.
Belt drive is an example of this type of link.
3. Fluid link- In this type of link the motion is transmitted with the help of fluid pressure. A
hydraulic brake is the example of fluid link.
Kinetic Pair- When the two kinematic links are joined to have relative motion between them
is known as kinematic pair.
The kinematic pairs are classified as follows:-
According to the nature of contact:-
1. Lower pair-When the two links have surface contact between them,it is known as lower pair.
2. Higher pair- When the two links have line or point contact between them,it is known ashigher pair.
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According to nature of relative motion:-
1. Sliding pair- When one link slides relative to another link,it is known as sliding pair.
2. Turning pair- When one link turns or revolve relative to another link, it is known as turning
pair.
3. Rolling pair- When one link rolls over the other link, it is known as rolling pair.
4. screw pair- If two pair have turning as well as rolling motion between them, it is known as
screw pair.
5. Spherical pair- When a spherical link turns inside a fixed link, it is known as spherical pair.
Degree of freedom:- Degree of freedom are the set of independent displacements and/or
rotation that specify completely the displaced or deformed position and orientation of the body or
system.
Linkages:-A mechanical linkage is a series of rigid links connected with joints to form a closed
chain, or a series of closed chain. Each link has two or more joints, and the joints have various
degrees of freedom to allow motion between the links. A linkage is called a mechanism, if two or
more links are movable with respect to a fixed link. Mechanical linkages are usually designed to
take an input and produce different output, altering the motion, velocity, acceleration, and applying
mechanical advantage.
Types of linkage:-
Four bar linkages are the simplest closed loop kinetic linkage. They perform a wide variety of
motion with a few simple parts. They were also popular in the past due to the ease of calculations, prior to computers, compared to more complicated mechanism.
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Types of four bar linkage:-
Pantograph (four-bar, two DOF)
Crank-slider,(four bar, one DOF)
Grashof, (four bar, one DOF) at least one link can rotate 360°
Four bar linkage often have meshing gears for two of the links, creating a one DOF linkage. They
can provide greater power transmission with more design flexibility then four bar linkage.
Six bars, single DOF offer grater design flexibility then four bar linkage but require more parts
&are more difficult to design:
Watt kinematic chain
Watt I, II
Stephenson kinematic chain
Stephenson I, II, III
Klann linkage which function as a walking mechanism creating nearly straight line output from a
rotary input, six bar, one DOF.
PANTOGRAPH MECHANISM
A pantograph is a mechanical linkage connected in a special manner based on parallelograms so
that the movement of one pen, in tracing an image, produces identical movement in a second
pen. If a line drawing is traced by the first point,
an identical, enlarge or miniaturized copy will be drawn by a pen fixed to other. Because of their
effectiveness translating motion in a controlled fashion, pantographs have come to be used as a
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type of motion guide for object large and small. A common example of the use of a pantograph
assembly as mechanical guide frame is the extension arm of an adjustable wall-mounted mirror.
Uses:-
Perhaps the pantograph that is most familiar to the general public is the extension arm of an
adjustable wall-mounted mirror. In another application similar to drafting, the pantograph isincorporated into a pantograph engraving machine with a revolving cutter instead of a pen and a
tray at the pointer into fix precut lettered plates (referred to as ‘copy’), which the pointer follows
and thus the cutter, via the pantograph, reproduces the copy at a ratio which the pantograph armshave been set. The typical range of ratio is maximum 1:1 minimum 50:1 (reduction) In this way
machinists can neatly and accurately engrave numbers and latter on to the part.
The device which maintains electrical contact with the contact wire and transfers power from the
wire to the traction unit, used in electric locomotive and trains, is also called a ‘’Pantograph’’.
Certain types of trains on the New York city subway use end pantograph gates (which, to avoidinterference, compress under spring pressure around curves while the train is en-route) to prevent
passenger on station platforms from falling into the gaps between the cars.
Herman Hollerith’s “keyboard punch” used for the 1890 US Census was a pantograph design and
sometimes referred as ”The pantograph punch”.
An early 19th century device employing this mechanism is the polygraph, which produces a
duplicate of a letter as the original is written.
Longarm quilting machine operators may trace a pantograph, paper pattern with a laser pointer to
stitch a custom pattern on to the quilt.
Linn Boyd Benton invented a pantographic engraving machine for type design, which was capablenot only of scaling a single font design pattern to a variety of sizes , but could also condense,
extend and slant the design.
Pantograph are also used as guide frames in heavy duty application including scissor lifts material
handling equipment stage lift and specialty hinges (such as for panel doors on boats and airplane)
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STATEMENT OF THE PROBLEM
Plumbing networks, like any other structure, are vulnerable to damage from various sources:
thermal cycling (especially when ground freezes around the pipe), mechanical impacts or
vibrations, corrosion, etc. Pipes can fill or clog with debris, sediments, and living organisms.
Smaller fluid systems, such as those serving residences, may be repaired with easy, low-costmethods; in many cases it may be best to simply replace the pipes. Operators of larger, complex
systems, however, frequently need some better way of dealing with plumbing failures. Forinstance, it is not cheap to replace large diameter pipes; it is even worse if hundreds of meters of
pipeline must be unearthed to determine which section is responsible for a drop in pressure.
Preventative inspection can be another difficult requirement of industrial users: critical systems orthose serving sensitive machinery may have to be inspected periodically, to ensure the safety of
human users or to prevent damage to expensive systems.
It is possible to detect cracks or corrosion thinning in plumbing with various methods of
non-destructive testing, such as eddy-current or ultrasonic sensors, but these require access to theoutside of the pipes; difficult and costly in many situations, such as long, buried lengths.
Furthermore, this does not address the problem of clogging or fouling. In many such applications,an internal inspection solution may be preferable.
If a robot were designed to travel the length of the pipe and conduct such inspections,
it might have other uses as well. For instance, it could carry a cleaning mechanism or manipulators
to remove foreign objects. It could pull electrical or communications cables through conduits. Such
a machine has potential as a life-saving tool also: when buildings collapse, due to earthquakes or
other disasters, the internal pipe network may still be navigable for a pipe-crawling robot, which
could carry video cameras or microphones to locate signs of humans trapped below.
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Modification in Mechanism and its Implementation
The mechanism used in for the robot is the Modi f ied pantograph mechani sm. The reason for the
same are listed below:
1. Simplicity of this mechanism compared to other straight line mechanisms.
2. The front wheels are driven with the help of links of pantograph mechanisms.
3. It ensures that the front wheels trace the same motion as traced by the rear wheels, and hence
the wheels are properly aligned within the pipe.
4. This mechanisms allows the movement of the wheels along the radial direction. This aspect is
very important, because distortion forces no longer appear, as the robot passes over the obstacles.
5. It can assure the adaptability of robots to different pipe diameters.
This is the old model of pipe crawler which can be used in horizontal pipes and for a certaindiameter of pipe but our modification can work on different-different diameters and allows the
robot to move within pipes with horizontal, vertical, and elbow-typed portions.
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COMPONENTS OF INSPECTION ROBOT
1 1
8
2
7 3
4.1
6 5 4.2
1. Compression Helical spring
With the use of the spring, force is generated on the pipe wall and hence it assures the
repositioning of the structure in the case of the pipe diameter variation occur. Since the spring is
connected to the link using a sliding member it readjust the positions of the link to accommodate
the diameter changes. We have used spring of patented cold drawn, steel wire, grade 1.
2. Sliding pipe
This is bigger diameter and smaller length pipe which is in contact with the spring and slidesfreely on the central pipe thus enabling the spring to compress freely and accommodate diameter
changes.
3. Actuator support
Actuator actuate the wheels and we need to fix it on a proper position so it can transmit
motion to the wheels.
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4. Connecting members (4.1worm wheel and 4.2worm gear)
Worm wheel provide motion from worm gear to wheels and worm gear provide motion from
motor to worm wheel. After all the motion is transferred from motor to wheels.
5. Actuator
To actuate the wheels. Tree rear wheels are actuated by DC geared motors (60r.p.m) and the
other three forward wheels are driven through linkages. The motor contents the gear assembly totransmit the vertical motion of input shaft to the horizontal motion. The operating voltages limited
to 12V only.
6. Central Pipe:
It is the men component on which the complete structure of the robot is mounted. It acts
as the chassis of the robot. Different members such as helical spring, sliding member, linkconnecting member all the links are attached on to this pipe. Here we have used HSS(high speed
steel) pipe which is suitable according to the requirement market availability and cost.
7. Links
The links are used to form a four bar linkage mechanism, the modified pantograph
mechanisms which drive the front wheels with the help of rear wheels. These linkages areconstructed using aluminum ribs of 25mm and are connected to each other and the connecting
members using bolted joints.
8. Wheels
Formability of robot inside circular pipe, a 120° arrangement of linkages is formed in which
wheels are attached at end point of the upper links hence providing contact with the inner surface.Wheels are having rubber lining to improve contact friction between the walls and the wheels and
to increase grip of the wheels hence improving the stability of the robot.
9. Light source
For inspection of low light conditions it is necessary to provide an extra light source near the
camera so as to visualize properly in darker condition. for this purpose, LEDs are being mounted
near the camera lens. It is important to have correct light intensity so as to gate clear view hence
arrangement is made in such a manner that light properly falls on the surface of the pipe also.
10. Video Camera
For visual assessment there are many kinds of wireless or wired webcam available in the market
which have there specified range of operation. They also have a specified resolution capacity and
frame capturing capacity under motion or capturing of moving object so selection is based uponthe RPM at which the robot is working and the single sending power of the wireless webcam since
proper transmission is also a factor which effects the visual inspection while operation .
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11. Battery
The supply of power to the robot can be done through AC supply connected to a 12V
transformer and a capacitor circuit for converting it in to12V DC supply or using a 12V DC
,rechargeable or non-rechargeable available in the market to actuate the DC motor attached in the
rear wheels for the movement of the robot in the pipe.
11. Remote control
To control the robot the remote control can be wired or wireless. For wireless arrangement a
transmitter receiver (RF/IR) is required for the wire control, DPDT switches and wires can be used.
Here we have used DPDT switches and multi-cored wires for the operation of the robot. Themotors are connected in series and a single switch is used to operate the three motors
simultaneously.
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DESIGN AND FABRICATION
After performing various design calculation of the linkages, spring, etc. the next step was to
prepare a prototype for analysis. wooden ribs of xmm and ymm thickness were taken and linksof length h1,h3 and two links of length h2 were cut from it and hence the modified pantograph
mechanisms is constructed. The motion and hence the diameter variation that the robot can provide was studied. By using wooden link mechanisms, we iterated the various link length of
the final mechanisms.
We also modeled it using the software pro engineering in which the exact dimension of the robot
were taken to view the final form of the robot. The images are given below
After making a single unit of a modified pantograph mechanisms unit symmetrically arranged at
120º phase angle, and six wheels mounted on the links and the spring, we initiated the fabrication
of the robot.
We first took an aluminum rib and cut various links according to the design links length using a
cutter. Then we drilled holes of amm and bmm on those links using amm and bmm drill bits bymounting it on the drill machine of the work shop.
Then the link connecting member work cut from the cast iron ribs of the dimension p*qmm 2 of
the thickness lmm and bmm holes were drilled and the members were welded on the central pipe
of diameter smm and length tmm using electric arc welding.
Now the sliding member was prepared using pipe of diameter kmm and a washer of inner
diameter of k+1mm, was welded on the end of kmm pipe. Now, this was assembled with the pipe of diameter jmm with a some filing or grinding of the inner surface for free sliding of the
outer pipe on the inner pipe. Next, a spring was connected whose one end is fixed on the plate
attached with the jmm diameter pipe and hence the grinding helps in free compression of the
spring for accommodating pipe diameter variation and ovality.
Now the links are connected to reach other by bolted joints forming modified pantographmechanisms and three motors were connected in series and wheels were mounted on the
assembly then the wiring was done with the remote control having a single deck switch.
The complete model will be demonstrated in major project.
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Inspection interpretation or discussion
As aim of the project is expected to perform the visual inspection of the internal pipe surface
of different pipe of different-different material and diameters using pipe inspection robot, the
expected interpretation which are drown by the operating robot inside the pipe are listed below.
1.
The pipe may very rugged throughout its length having many irregularities on the surface.2. The pipe may have severe cracks and improper surface texture at various sections of the
pipe.
3. The images will show the surface conditioning of the internal pipe surface.4. The cracks can be seen with the help of the robot camera and we can cure it before any
serious problem may occur. because the enlargement can cause linkage problems in the pipe
and can even cause failure of the pipe from those points due to high stress concentration
Water hammer and pressure transient are common problem in the pipe lines of any hydraulic
machine installation, due to this irregularities and improper surface finis , it will and in hence the
problem and might cause busting of pipe.
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UTILITY AND APPLICATIONS OF PROJECT
IMPLEMENTATION OF PROJECT IN INDUSTRIES:
Plumbing networks , like any other structure ,are vulnerable to damage from various sources :
thermal cycling (especially when ground freezes around the pipe), mechanical impacts orvibration, corrosion etc. pipe can fill or clog with debris ,sediments, or as with the zebra mussel
infestation in the northeast US ,living organisms .smaller fluid system, such as those serving
residences ,may be repaired with easy, low cost method: in many cases it may be best to simplyreplace the pipe .operators of larger ,complex system ,however frequently need some better way
of dealing with plumbing failures. For instance, it is not cheap to replace large diameter pipe; it is
even worse if 100m of pipe line must be un earthed to determine which section is responsible for
a drop in pressure. Preventative inspection can be another difficult requirement of industrial users:critical system or those surveying sensitive machinery may have to be inspected periodically, to
ensure the safety of human users are to prevent damage to expensive system.
It is possible to detect cracks or corrosion thinning in plumbing with various methods of non
destructive testing , such as eddy-current or ultra sonic sensor, but these required access to the out-side of the pipes ;difficult and costly in many situation ,such as long, buried lengths. Further- morethis does not address the problem of clogging of fouling. in many such application ,an internal
inspection solution may be preferable .
ROVVER operation
Robotics is one of the fastest growing engineering field of today .robots are design to or move the
human factor form labor intensive or dangerous work and also to act in inaccessible environment.the use of robot is more common today then- ever before and it is no longer exclusively used by
the heavy production industries. The inspection of the pipe may be relevant for improving security
and efficiency in industrial plant. These specific operation as inspection, maintenance cleaning etc are 3 expensive, thus the application of the robots appears to be one of the most attractive solution.
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ROVVER inspector crawler
The robots with a flexible structure may boast adaptability to the environment, especially to the pipe diameter; with enhance dexterity, maneuverability capability to operate under hostile
condition. The wheeled robots are the simplest, most energy efficient, and have the best potential
for long range. Loading the wheels with spring, robots also offer some advantages inmaneuverability with ability to adapt to in pipe unevenness , move vertical in pipe and stay stable
without slipping in pipes .This types of robots also have the advantages of easier miniaturization
several pipe inspection robots have been constructed experimentally, some are even commercially
available products.
The simplest of these (and consequently the most numerous in the market) are a platform restingon wheels or tractors treads underneath. Such robots suffer from an inability to negotiate vertical
section of pipe . In addition many have limited steering ability and may be too long to pass througheven horizontal elbows. Envirosight LLC offers a series of such robots in there line of ROVVERinspection crawlers these are tethered four or six wheeled vehicle which carry a range of video
cameras and are available in size as small as 4 inches.
More advanced pipe inspectors are capable of travelling through vertical pipes. One of these,
developed by Rob Probe Technologies Inc., is capable of traveling through complex pipe networks
from 8 to 12 in internal diameter. Three rubber track unit pressed against the walls in equilateralconfiguration propel this device. It is not articulated, but is short enough to negotiate most turns.
Numerous other robots, mostly research projects, have been constructed of this type, using either
tracks or wheels.
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Yet more complex are vehicles that use serpentine motions or “inch-worm” mechanisms for
propulsion. These have shown promise but remain experimental. A project by North Carolina StateUniversity uses pneumatic mechanisms at either end of the robot to grip the walls of the pipe,
while an expanding center section produces motion in stages. A “robot snake” by the Institute for
Autonomous Intelligent Systems uses a sinusoidal motion and a large number of wheels along its
length to propel itself in an extremely flexible way.
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APPLICATION
Accessing unpiggable pipelines
Pipeline cleaningo Brush
o
Jettingo Chemical
ILI inspectiono MFL
o UT
o Eddy current
o EMAT
o EMIT
Stuck pig removal
Flange testing
Plug setting
Hydro testing Visual inspection
o Camera
Pipeline gauging, mapping and data collection
o Laser
o Sonar
o Inertial navigation
o Temperature profiling
o Pressure profiling
o Dynamic motion
Pipeline repair system
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CONCLUSION
The goals of design of the pipe inspection robots are to inspect internal conditioning of pipes of
different diameter and different material. This project will be a basic model which can be tested ina pipe and the internal defects can be captured and it will be helpful to conclude the design. We
can conclude about success benefits of pipe to implement on a large scale in industries forinspection and other purposes. Conclusion are listed below-
1. Wireless operation- the wired robot can converted into a wireless robot by using a wireless
remote control using RF/IR module type controller and PCB circuited with the transmitterand receiver to actuate the motors wirelessly.
2. Webcam- This can be done by using various wireless video cameras. The cameras of
various sizes and resolution are available in market which can be used.
3. Sensors- The robot can be equipped with various types of sensors which can measuredistances and hence locate the regions where defects are present. It can also act as life
savers, in case of fires, earth quakes and other disasters by mounting sensors that can detect
voice and hence locate the trapped people so that they can be rescued.4.
Ultrasonic, eddy current, or other sensors could be mounted on the robot for non-
destructive testing of pipes integrity.
5. Another useful feature would be two-axis control over the video camera, allowing theoperator to examine the sides of the pipe closely, even better would be the inclusion of
such a camera in the rear section as well, fascinating backwards travel and providing a
view, possibly of the robot itself so that mechanical difficulties or other issues can be
diagnosed.6. Finally it might be possible to enhance the mobility of the pipe crawler so that tees and
other fitting can be successfully negotiated – such improvements might consist of servo-
motors that can direct the head tail sections in order to initiate turns actively.
REFERENCE
1. from Wikipedia 2. http://www.iaarc.org/publications
3. http://ieeexplore.ieee.org/
4.
http://cdn.intechweb.org/
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