<Mechanical Engineering Graduation Project 2012-1>

PIPE-INSPECTION CRAWLER

AHMAD ZAKI BIN MOHAMED SHUKOR (2009056958) Advisor: Professor. Seung, Jae Moon
Key Words : Pipe-Inspector, Pipe-Inspection Crawler, Pipe-Inspection Robot, Wireless Inspector. SUMMARY The main scope of this pipe-inspection crawler is to locate defects due to corrosion and obstacle in the inner side of the pipe line. Nevertheless, damage still occurs, which reduces the strength of the pipe. If it goes undetected and becomes severe, the pipe can leak and, in rare cases, fail catastrophically. So, extensive efforts are made to mitigate defects.
Notations/Symbol ID : Internal diameter OD: Outer diameter mm: millimeter

2.

DESIGN OF PIPE-INSPECTION CRAWLER

2.1

1.
1.1

INTRODUCTION

Many accidents have happened owing to the crack and the corrosion of pipelines. It 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, this project is hoping a new inspection method from the inside of the pipelines without digging the ground. So a new design in inspecting pipelines is being proposed.

The main components of the crawler consists of five main parts which are helical spring, translational element, 6 sets of small wheels, 3 set with 3 types of metal link, and the central elements as it mains body.

1.2 Objective To inspect pipe inner surface To detect corrosion on the inner surface of a pipe line. To detect obstacles inside a pipeline.
Figure 2.1

2.2 Main components size

Helical spring
Internal Diameter(ID):26 mm. Pitch: 5mm. Length: 65mm, Thickness: 1.75mm

Translational Element
ID:26mm. Outer Diameter (OD): 30mm. Length: 40mm

Wheel
Diameter: 45mm

Link: Distance between the drilled holes

o o o Link 1: 24mm Link 2: 56mm Link 3: 84mm ID : 20mm. OD : 26mm. Length : 220mm.

Central element
Hollow

2.3 Part Drawings The design of this project have been made using latest drawing software such as AutoCAD and ProE software. AutoCAD software is used for drawing the design of the pipe-inspector in 2-dimensional way and ProE in 3-dimensional point of view.

Figure 2.2 (Part drawings using AutoCAD)

Figure 2.4 (Designing using ProE software)

Figure 2.3 (Link components using AutoCAD) 2

3.
3.1

ANALYSIS
3.2 Static analysis of pipe-inspection crawler

The analysis have been done using hand calculations to make sure how much minimum energy is needed to lift the crawler. This analysis also shows that how the concept of using spring to make the crawler have an ability to crawl inside variables type of pipe just adjusting the length of the spring.

3.2 Mechanism of pipe-inspection crawler

Figure 3.2

dW= Fcz dz- Fbx dx= 0 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 = 2.33l sin q , x = 2.33l cos q dW= Fcz d(2.33lsinq)-Fbx d(-2.33lcosq) =Fcz*2.333lcosqdq-Fbx*2.33lsinqdq=0 Rearranging gives, Fbx= Fcz*cosq/sin q

Figure 3.1 D= 2r+2d+2h2cos h1=24mm, h2=56mm, h3=84mm (h1 =OA, h2 = BC = DE, h3 = CF ) 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. For variable pipes, will be 15 to 60 For uniform Diameter, assume = 45

Fbx= Fcz*tan-1 q
Where, Fbx is the Spring force, Fcz is the traction force

D=2*22.5+ 2*26+ 2*56*cos45= 176.2mm

3.3 Kinematics of pipe-inspection crawler

Figure 4.1 Figure 3.3

Central frame : supports and holds batteries Translational element : translates along the
central frame for repositioning Compression Spring : to exert equal forces on the walls and also for repositioning

4.2 Purpose of spring

Figure 3.4 This is a four bar mechanism consisting of three revolute joints and one prismatic as depicted. The total weight W of the robot is the sum of the six traction forces exerted on the rubber belt around the metal rim. Each traction force Fcx is one six of the whole weight of the robot structure. Therell be three actuators to drive the wheels which are at the rear at 120 degrees. Thus, the size of the actuator enclosed in the wheel is calculated by

t= Fcx*R= WR/6

4.2.1 The force that the mini-crawler 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.

4.
4.1

CONSTRUCTION
4.3 Others

The construction of the crawler divided into two parts. First parts are fabricating and constructing the main body of the crawler. using metal as a main material for the body, molding technique was being used to connected between two parts. Except for the links part which been connected using screws. The second part was fixing simple electronic components in right order for the engine, remote controller, LED's functioning properly.

Figure 4.2
4

Table 1 Components and its usage

COMPONENTS

FUNCTIONS
Three set of 4 bar linkages connected at 120 degree to the central frame. Drive the robot (3 set of engines) Friction between the crawler and the pipe Monitoring the pipeline Using a typical remote controller Received the wave transmitted from the transmitter Three 3.7v & 2000mA supply for motor and 9V supply for wireless camera For clear vision inside the pipe

Links

Actuator

Figure 5.1 5.2 The experimental scenes when the robot

Wheels

Wireless camera Transmitter

Receiver

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 160mm to 220mm inner diameter. It have been tested on 200mm pipeline

Batteries

6.

EXPERIMENTAL RESULTS

Light Emitting Diode (LED)

Figure 6.1

6.1

Figure 4.1(Links)

Figure 4.2 (wireless cam)

This picture in figure 6.1 is captured by the wireless camera in the in front of the crawler. This is the result of the project which inspects the inner diameter of the pipe and could be monitored in the laptop. This will tell you where the crack is. If the camera has more pixels, it could find the defects more accurately.

7. 5.
5.1

APPLICATIONS AND FURTHER IDEAS

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.

LOCATING DEFECTS

7.1 7.2 7.3 7.4 7.5

Pipe-Inspection Crawler 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.

8.

CONCLUSION

The design goals of the Pipe Inspection Crawler 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 160mm and 210 mm and it is possible as been showed before.

POSTCRIPS
I would like to thank everyone who has helped me a lot in making this project especially to my mechanical engineering capstone design project advisor and lecturer; Professor Seung, Jae Moon, my senior P. Jagan who helped me in fabricating and constructing the crawler, my fellow mechanical engineering friends, contributing in advising and giving me the spirit to complete the project. Without those honorable people, this project would not have been successful done.

REFERENCE
(1) Eiki Martinson, The Pipe Crawler, http://eikimartinson.com/engineering/pipe/. (2) , 2006, , , pp. 177~200. (3) Elizabeth Svoboda, Pigging the Unpiggable: Robots Keep Gas Lines From Blowing Up, http://www.popsci.com/technology/article/201101/pig-robots-keep-gas-lines-blowing.