““DEFECT IDENTIFICATION IN PIPE DEFECT IDENTIFICATION IN PIPE

LINES USING PIPE INSPECTION LINES USING PIPE INSPECTION

ROBOT”ROBOT”ARJUNKUMAR.M.BETAGERI ARJUNKUMAR.M.BETAGERI 11stst sem sem

COMPUTER INTERGATED MANUFACTURING COMPUTER INTERGATED MANUFACTURING EngineeringEngineering

DAYANANDA SAGAR COLLEGE OF ENGINEERINGDAYANANDA SAGAR COLLEGE OF ENGINEERING

Department of studies in Mechanical Engineering

INTRODUCTIONINTRODUCTIONMany accidents have happened owing to the crack and the corrosion of pipelines. We will have severe damages if fluid leaks from the pipeline and explodes. It is very difficult to inspect the pipelines because they are buried under the ground. Therefore, we are hoping a method of inspection method with a simple four bar mechanism from the inside of the pipelines without digging the ground. So we proposed a new design in inspecting pipelines.

OBJECTIVESOBJECTIVESThe main objectives are as follows• To fabricate a pipe inspection robot.• To design CAD models using Pro ENGINEER.•To simulate the assembled CAD models using Pro animation• To determine the amount of voltage and current required for the motor.

METHODOLOGYMETHODOLOGYDesign and development of pipe

inspection robot using CAD software.Fabrication of CAD models by means of

manufacturing equipments.Assembling all the fabricated parts.Fixing a camera, motors, LEDs and

mounting the circuit board onto the crawler.

Making it to crawl inside a pipe by means of a remote to capture the video image in a monitor.

EXPERIMENTSEXPERIMENTSTo design a robot with constrained

motion in CAD modeling.

To determine the torque required for the motor to make the crawler move.

To determine the actual weight of the robot with the available actuator.

To determine the supply voltage for the motor.

To design a robot with constrained To design a robot with constrained motion in CAD modeling.motion in CAD modeling.This experiment plays a vital role to make

the translational element sliding along the central frame without stoppage in between. When the translational element slides, the robot diameter should be varied in order to attain the purpose of fabricating it. Certain considerations should be made if the crawler tends to get locked because of the linkages. These considerations could be given as an input in CAD modeling. In this way, I found the reason to use a compression spring for the return motion and also for the proper traction between the wheels and the pipe.

To determine the torque required To determine the torque required for the motor to make the crawler for the motor to make the crawler move.move.The total weight of the crawler should be defined. It

might help us in determining the torque required by the motors.

The total weight W of the robot is the sum of the six traction forces exerted on the wheel. Thus, each traction force Frx is one six of the whole weight of the robot structure. Thus, the size of the actuator enclosed in the wheel is calculated by

t= Fs*R/6

Where Fs is the spring force in N

R is the radius of the wheel, t is the torque required /wheelSince only three motors could be used at the rear end, we can double the value of the torque per wheel.

To determine the actual weight of To determine the actual weight of the robot with the available the robot with the available actuator.actuator.The supply required for the 3 individual motors

will be 12V. This 280:1 gear motor spins at 60RPM at 12V, drawing 70mA at stall generating 43 in.oz(0.3036 Nm) torque (free running at 57.6mA).Torque= Force * RadiusForce= Torque/Radius= 0.3036/0.0225= 13.49N= 1.375kg

From the calculation, it is clearly known that an individual motor will drive the robot having 1.375 kg. Perhaps 3 motors could be used for the crawling, so that total weight of the robot should be restricted to 4.13 kg or below.

To determine the supply To determine the supply voltage for the motor.voltage for the motor. The supply required for an actuator is 12V, 70mA.

Three actuators will be used for the robot to creep inside a pipe. Since the voltage required is 12V, we need to ensure that the connection should be in parallel where the voltage remains the same and the current will be sum of all the current values in each individual.

Required voltage will be 12V (Parallel connection)

Required current I= I1+I2+I3

= 70+70+70 = 210mA

The motors draw 210mA from the battery. If we use 2100mAh battery, it will last for 10 hours for a single charge. 18650 Lithium batteries are available in the market with 3.7V, 2100mAh.

Hence it is concluded that three 18650 Lithium batteries with 3.7V, 2100mAh should be used for the actuators to rotate in order to make the crawler to move inside the pipe.

This mechanism has got 3 revolute pairs and a prismatic pair, so the mechanism involved here is a four bar mechanism.

Number of links, n- 4

Number of joints, j- 4

Number of higher pair, h- 0

F = 3 (n – 1) – 2 j - h.

Therefore, F= 3 (4- 1) – 2* 4 – 0

F= 3*3 – 2*4= 9 – 8

F= 1 If F = 1, the mechanism has fully constrained motion

and this represents a working mechanism which has practical utility. All the working mechanisms have single degree of freedom.

DEGREES OF FREEDOMDEGREES OF FREEDOM

TOTAL DEGREE OF TOTAL DEGREE OF FREEDOMFREEDOM This machine has got 3 four bar mechanisms held at

120 degrees each. These mechanisms in turn have 3 revolute pairs and a prismatic pair, and the degree of freedom for these mechanisms will be one, which explains that the mechanism is fully constrained.

Number of links, n- 15

Number of joints, j- 20

Number of higher pair, h- 0

F= 3(n-1)-2j-h

F= 3(15-1)- 2*20-0

F= 42-40

F=2.

Hence it is concluded that it can crawl inside a pipe and also it could be adjusted based on the pipe diameter.

STATIC ANALYSISSTATIC ANALYSIS  Applying the virtual work

principle to the free-body diagram gives

dW= Frz dz- Fqx dx= 0

where Fqx is a spring force.

This is because only Frz and Fqx conduct work. The corresponding coordinates of these forces relative to the coordinate located at the A hinge are expressed as

z = 1.2l sin , x = 1.2l cos

STATIC ANALYSISSTATIC ANALYSISdW= Frz d(1.2lsin)-Fqx d(-1.2lcos)

=Frz*1.2lcosd-Fqx *1.2lsind=0

Rearranging gives

Fqx= Frz*cos/sin

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

Fqx= Frz*tan-1

And the spring compressive force Fs of the robot is the sum of the six traction forces exerted on the wheel. Thus, each traction force Frx is one six of the compressive spring force of the robot structure.

Fqx = Fs/6

Where Fs is the spring force in N

Thus, the size of the actuator enclosed in the wheel is calculated by

= Frx*R= FsR/6 at = 45 degrees

where R is the radius of the wheel.

MACHININGMACHINING PROCESSPROCESS

Radial arm drill machine

Boring operation

Brazing

Gas welding

DESIGN SPECIFICATIONDESIGN SPECIFICATION 1. Helical spring: Inner Diameter:

26.5 mm, coil diameter: 2.5mm, Pitch- 5mm. Length- 85mm

2. Translational Element: Inner dia-26mm. Outer diameter- 30mm. Length- 40mm

3. Wheel: Diameter- 50mm 4. Link:

Distance between the drilled holes

Link 1- 30mm Link2- 66mm Link3- 84mm 5. Central element: Hollow- Inner

diameter- 20mm. Outer diameter- 26mm. Length- 220mm.

DESIGN OF PIPE INSPECTION DESIGN OF PIPE INSPECTION ROBOTROBOT

CENTRAL ELEMENT:

Hollow:Inner diameter- 20mm.Outer diameter- 26mm.Length- 220mm.Material: Stainless steelCENTRAL ELEMENT

TRANSLATIONAL ELEMENT: Inner diameter- 26mm. Outer diameter- 30mm. Length of the element -40mmMaterial- Stainless steel

TRANSLATIONAL ELEMENT

HELICAL SPRINGInner diameter- 26.5mmOuter diameter- 31.5mmWire diameter- 2.5mmPitch- 5mmLength of the spring- 70mm Material- Spring Material HELICAL SPRING

WHEEL:

Wheel diameter: 50mmWidth of the wheel: 6mmCentre hole: 5mmMaterial: Metal rim with rubber

WHEEL

THREADED CAP:

Step diameter: 36, 20mm (threaded)Centre hole: 6mm

THREADED CAP

LINKS I & IILINKS I & II

LINKS III & IVLINKS III & IV

Wireless communicationWireless communication

Radio frequency AntennaTransmitterReceiver

PIC robot tested successfully for movement in horizontal and vertical pipes.

Stages shows that the robot moving in horizontal, inclined and vertical pipe.

The robot has a good mobility and ability to pass over small obstacles.

the experimental scenes when the robot moved in the horizontal and

vertical direction. For ease of observation pipelines were made of PVC

plastics pipes. Testing could be done on pipelines having 140mm to 190mm

inner diameter. We tested on 160mm pipeline

Locating DefectsLocating Defects

Allow inspection of inaccessible and/or hazardous

equipment or work areas.

provide on-line inspection/maintenance without loss

of equipment/plant availability.

remove humans from potentially hazardous work

situations

reduce equipment/plant downtime.

improve maintenance and inspection procedure

thorough better coverage and documentation.

ApplicationsApplications

To design the robot with track and wheel. (Under

process)

To determine type of flow and fluid using sensors.

To rectify defects by mounting robotic arm.

To inspect and rectify flaws in a nuclear reactors

pipeline.

Further ideas & Further ideas & implementationimplementation

EXPECTEDEXPECTED RESULTRESULTThe expected result will be the crawling of

the robot inside a pipe at any inclination and the capturing image will be viewed simultaneously through the monitor. The purpose of the spring is to make the crawler re-positioning and to exert proper traction between wheels and the pipe. This is a robot with simple crawling mechanism to crawl inside the pipelines given that the torque of the motor will be able to make the robot creep inside a pipe and to inspect it with the help of camera. The wireless communication will ensure the robot crawling inside a pipe upon transmitting the signals. The captured image will be monitored and the clear view of the pipes which are buried under ground will be viewed.

CONCLUSIONCONCLUSIONThe design goals of the Pipe Inspection

Robot is the adaptability to the inner diameters of the pipes and it have been completely fulfilled, the propulsion of the robot has been successfully conducted using three motors, and the inspection is done using a wireless camera.

The prototype is designed in order to inspect pipes with variable diameters within 140 and 190 mm and we got the experimental Results.

THANK YOUTHANK YOU