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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.
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Design and fabrication of pipe inspection robot
Chapter 1: INTRODUCTION
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Design and fabrication of pipe inspection robot
parties. So, continuous activities for inspection, maintenance and repair are strongly
demanded.
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Design and fabrication of pipe inspection robot
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.
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Design and fabrication of pipe inspection robot
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.
2.1.2 Knob
Definition: residual deformation of the pipe wall outside the pipe without sharp edge
extending over an area.
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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Design and fabrication of pipe inspection robot
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.
Definition: radial displacement of parallel centre lines of pipe sections joined with
welding (girth weld).
Definition: deviation of centre lines of pipe sections joined with welding (girth
weld).
Measures: angle between the centre action systems
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Design and fabrication of pipe inspection robot
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Design and fabrication of pipe inspection robot
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.
3.3 Refineries:-
3.5 Offshore:-
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Design and fabrication of pipe inspection robot
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.
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.
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Design and fabrication of pipe inspection robot
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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
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.
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
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Design and fabrication of pipe inspection robot
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
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.
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
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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.
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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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Wiens 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:
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Fig 4.4:- Block diagram showing typical system for detecting infrared radiation
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:
Optical Components:
Infrared detectors:
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Design and fabrication of pipe inspection robot
Signal Processing:
Reflectance Sensors:
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Design and fabrication of pipe inspection robot
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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Fig 4.6:- Cathode ray tube (a) schematic, (b) detail of the deflection plates.
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Design and fabrication of pipe inspection robot
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:
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Design and fabrication of pipe inspection robot
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
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Design and fabrication of pipe inspection robot
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.
5.3 Mechanism:
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Design and fabrication of pipe inspection robot
H = 2r + 2d + 2h2cos,
Where,
H=236+228+285 cos 45
H=248.20mm
D=236+228+285 cos 50
D=237.27mm
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Design and fabrication of pipe inspection robot
Thus, the motion of all revolute joints can be described in terms of the displacement
db .
W = Fcz z Fbx x = 0
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Design and fabrication of pipe inspection robot
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 , x = 2.33/ cos
Rearranging gives:
Fbx = Fcz*cos/sin
Thus, the spring force at the prismatic joint B is related to the normal force
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: =
Fcx*R = WR/6
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.
Inner diameter 18 mm
Outer dia 20 mm
Pitch 5 mm
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Design and fabrication of pipe inspection robot
Inner diameter 18 mm
Outer diameter 23 mm
5.3.3Wheel
Diameter 72 mm
Link 1 30 mm
Link2 85 mm
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Design and fabrication of pipe inspection robot
Link3 105 mm
Thickness 3 mm
Material Acrylic
Hollow
Inner dia 15 mm
Outer dia 20 mm
Length 220 mm
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Design and fabrication of pipe inspection robot
Central Frame
The force that the mini robot mechanism exercises on the pipe walls is
generated with the help of an extensible spring.
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Design and fabrication of pipe inspection robot
The helical spring disposed on the central axis assures the repositioning of the
structure, in the case of the pipe diameters variation.
5.4.3 Links
5.4.4 Actuators
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Design and fabrication of pipe inspection robot
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
5.4.5 Batteries
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 LEDs.
5.4.6 Transmitter
The extension cable which attached the camera with output device
transmits the video and picture.
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Design and fabrication of pipe inspection robot
Chapter 6: CONSTRUCTION
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
1200 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 1200 in lateral spacing & the
another end is attach to the links B4,B5,B6 at point with pin joint as shown in fig.
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Design and fabrication of pipe inspection robot
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.
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
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.
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Design and fabrication of pipe inspection robot
Chapter 7: WORKING
Fig 7.1:- Block diagram showing working principal of pipe inspection robot
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Design and fabrication of pipe inspection robot
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.
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Design and fabrication of pipe inspection robot
. 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.
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Design and fabrication of pipe inspection robot
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 ,
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
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Design and fabrication of pipe inspection robot
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.
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2. Preprocessing
3. Segmentation
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
chances for success of other processes. In this application, the preprocessing
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Design and fabrication of pipe inspection robot
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 segmentationa 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.
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.
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Design and fabrication of pipe inspection robot
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
8.1 Dc motor
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Design and fabrication of pipe inspection robot
8.1.1 Description:
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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Design and fabrication of pipe inspection robot
8.3 CAMERA
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;
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Design and fabrication of pipe inspection robot
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
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Design and fabrication of pipe inspection robot
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
SR.
NAME OF MATERIAL QUANTITY AMOUNT
NO.
1. M. S. round bar 12.7mm dia. 3mm 2 60
thick
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 feet9 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
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Design and fabrication of pipe inspection robot
9.1 Advantages
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.
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Design and fabrication of pipe inspection robot
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:
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Design and fabrication of pipe inspection robot
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
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+pipe
+inspection&printsec=abstract#v=onepage&q=of%20pipe
%20inspection&f=false
http://ieeexplore.ieee.org/xpl/mostRecentIssue.jsp?punumber=3951
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Design and fabrication of pipe inspection robot
http://www.faadooengineers.com/tube/2012/06/11/mechanical-engineering-
project-pipe-inspection-robot/
En.wikipedia.org/wiki/Pipeline_vedio_inspection
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