FABRICATION OF COMPUTERIZED PIPELINE

INSPECTION ROBOT

PROJECT REPORT 2012-2013

Submitted by
(Team name)

Guided by
COLLEGE LOGO

Submitted in partial fulfillment of the requirement for the

Award of Diploma in ----------------------------------------- By

the State Board of Technical Education Government of

Tamilnadu, Chennai.

DEPARTMENT:

COLLEGE NAME:
 PLACE:

COLLEGE NAME

PLACE

DEPARTMENT

PROJECT REPORT-2012-2013

This Report is certified to be the Bonafide work done by

Selvan/Selvi ---------------- Reg.No. ------------ Of VI
Semester class of this college.

Guide Head of the Department

Submitter for the Practical Examinations of the board of

Examinations,State Board of Technical Education,Chennai,
TamilNadu.On -------------- (date) held at the ------------
(college name),Coimbatore

Internal Examiner External Examiner

 ACKNOWLEDGEMENT

At this pleasing movement of having successfully completed our

project, we wish to convey our sincere thanks and gratitude to the
management of our college and our beloved
chairman------------------------.who provided all the facilities to us.

We would like to express our sincere thanks to our principal

------------------for forwarding us to do our project and offering adequate
duration in completing our project.

We are also grateful to the Head of Department prof…………., for

her/him constructive suggestions &encouragement during our project.

With deep sense of gratitude, we extend our earnest &sincere thanks

to our guide --------------------, Department of Mechanical for her/him kind
guidance and encouragement during this project we also express our indebt
thanks to our TEACHING staff of MECHANICAL ENGINEERING
DEPARTMENT, ---------- (college Name).

CONTENTS
CHAPTER NO TITLE

SYNOPSIS
LIST OF FIGURES
1 Introduction
2 Description of equipments
2.1 Motor
2.2 Pipe
2.3 Battery
2.4 Control unit
2.5 Camera
3 Design and drawing
3.1 Drawing for fabrication of computerized pipeline
inspection robot
4 Working principle
5 Advantages and disadvantages
6 Applications
7 List of materials
8 Cost Estimation
9 Conclusion
BIBLIOGRAPHY

PHOTOGRAPHY
 SYNOPSIS

Here we have fabricated new type of robot for pipe lines. The main

aim of this concept is used to automate the pipe line checking. Many oil

industries are using the ladder or crane for checking over the pipe lines. It

may be very risky and manual fault may occur, to avoid this problem we are

going for the automatic checking system with help of robot. The project is

made up of simple arrangements. We can easily fix the robot on the pipe

line. The rotating camera captures the photo of the pipe accordingly and

detects the hole. This equipment has less maintenance. The project consist

the following parts, Motor, Wheels, spring arrangement, Battery and Control

unit.
 CHAPTER-1

INTRODUCTION

While there is no single correct definition of "robot" a typical robot

will have several or possibly all of the following properties.

 It is artificially created.

 It can sense its environment, and manipulate or interact with

things in it.

 It has some ability to make choices based on the environment,

often using automatic control or a preprogrammed sequence.

 It is programmable.

 It moves with one or more axes of rotation or translation.

 It makes dexterous coordinated movements.

 It moves without direct human intervention.

 It appears to have intent or agency.

The last property, the appearance of agency, is important when

people are considering whether to call a machine a robot, or just a

machine.

NEED FOR AUTOMATION

 Automation can be achieved through computers, hydraulics,

pneumatics, robotics, etc., of these sources, pneumatics form an

attractive medium for low cost automation.

The main advantages of all pneumatic systems are economy

and simplicity. Automation plays an important role in mass

production.

Nowadays almost all the manufacturing process is being

atomized in order to deliver the products at a faster rate. The

manufacturing operation is being atomized for the following reasons.

 To achieve mass production

 To reduce man power

 To increase the efficiency of the plant

 To reduce the work load

 To reduce the production cost

 To reduce the production time

 To reduce the material handling

 To reduce the fatigue of workers

 To achieve good product quality

 Less maintenance

CHAPTER-2
 DESCRIPTION OF EQUIPMENTS

2.1. MOTOR

PRINCIPLES OF OPERATION

In any electric motor, operation is based on simple

electromagnetism. A current-carrying conductor generates a

magnetic field; when this is then placed in an external magnetic field,

it will experience a force proportional to the current in the conductor,

and to the strength of the external magnetic field. As you are well

aware of from playing with magnets as a kid, opposite (North and

South) polarities attract, while like polarities (North and North, South

and South) repel. The internal configuration of a DC motor is

designed to harness the magnetic interaction between a current-

carrying conductor and an external magnetic field to generate

rotational motion.

Let's start by looking at a simple 2-pole DC electric motor (here

red represents a magnet or winding with a "North" polarization, while

green represents a magnet or winding with a "South" polarization).

 Every DC motor has six basic parts -- axle, rotor (armature),

stator, commutator, field magnet(s), and brushes. In most common

DC motors, the external magnetic field is produced by high-strength

permanent magnets. The stator is the stationary part of the motor --

this includes the motor casing, as well as two or more permanent

magnet pole pieces. The rotor (together with the axle and attached

commutator) rotate with respect to the stator. The rotor consists of

windings (generally on a core), the windings being electrically

connected to the commutator. The above diagram shows a common

motor layout -- with the rotor inside the stator (field) magnets.

The geometry of the brushes, commutator contacts, and rotor

windings are such that when power is applied, the polarities of the

energized winding and the stator magnet(s) are misaligned, and the
rotor will rotate until it is almost aligned with the stator's field

magnets. As the rotor reaches alignment, the brushes move to the

next commutator contacts, and energize the next winding. Given our

example two-pole motor, the rotation reverses the direction of current

through the rotor winding, leading to a "flip" of the rotor's magnetic

field, driving it to continue rotating.

In real life, though, DC motors will always have more than two

poles (three is a very common number). In particular, this avoids

"dead spots" in the commutator. You can imagine how with our

example two-pole motor, if the rotor is exactly at the middle of its

rotation (perfectly aligned with the field magnets), it will get "stuck"

there. Meanwhile, with a two-pole motor, there is a moment where

the commutator shorts out the power supply. This would be bad for

the power supply, waste energy, and damage motor components as

well. Yet another disadvantage of such a simple motor is that it would

exhibit a high amount of torque "ripple" (the amount of torque it could

produce is cyclic with the position of the rotor).

 So since most small DC motors are of a three-pole design, let's

tinker with the workings of one via an interactive animation

(JavaScript required):

A few things from this -- namely, one pole is fully energized at a

time (but two others are "partially" energized). As each brush

transitions from one commutator contact to the next, one coil's field

will rapidly collapse, as the next coil's field will rapidly charge up (this
occurs within a few microsecond). We'll see more about the effects of

this later, but in the meantime you can see that this is a direct result

of the coil windings' series wiring:

There's probably no better way to see how an average DC

motor is put together, than by just opening one up. Unfortunately this

is tedious work, as well as requiring the destruction of a perfectly

good motor.

The guts of a disassembled Mabuchi FF-030-PN motor (the

same model that Solarbotics sells) are available for (on 10 lines / cm
graph paper). This is a basic 3-pole DC motor, with 2 brushes and

three commutator contacts.

The use of an iron core armature (as in the Mabuchi, above) is

quite common, and has a number of advantages. First off, the iron

core provides a strong, rigid support for the windings -- a particularly

important consideration for high-torque motors. The core also

conducts heat away from the rotor windings, allowing the motor to be

driven harder than might otherwise be the case. Iron core

construction is also relatively inexpensive compared with other

construction types.

But iron core construction also has several disadvantages. The

iron armature has a relatively high inertia which limits motor

acceleration. This construction also results in high winding

inductances which limit brush and commutator life.

In small motors, an alternative design is often used which

features a 'coreless' armature winding. This design depends upon the

coil wire itself for structural integrity. As a result, the armature is

hollow, and the permanent magnet can be mounted inside the rotor

coil. Coreless DC motors have much lower armature inductance than

iron-core motors of comparable size, extending brush and

commutator life.

The coreless design also allows manufacturers to build smaller

motors; meanwhile, due to the lack of iron in their rotors, coreless

motors are somewhat prone to overheating. As a result, this design is

generally used just in small, low-power motors. Beamers will most

often see coreless DC motors in the form of pager motors.

Again, disassembling a coreless motor can be instructive -- in

this case, my hapless victim was a cheap pager vibrator motor. The

guts of this disassembled motor are available (on 10 lines / cm graph

paper). This is (or more accurately, was) a 3-pole coreless DC motor.

2.2 PIPE

A pipe is a tube or hollow cylinder used to convey materials or

as a structural component. The terms pipe and tube are almost

interchangeable. A pipe is generally specified by the internal diameter

(ID) whereas a tube is usually defined by the outside diameter (OD)

but may be specified by any combination of dimensions (OD, ID, wall

thickness). A tube is often made to custom sizes and may often have

more specific sizes and tolerances than pipe. Also, the term tubing

can be applied to non-cylindrical shapes (i.e. square tubing). The

term tube is more widely used in the United States, whereas pipe is

more common elsewhere in the world.

Both pipe and tube imply a level of rigidity and permanence,

whereas a hose is usually portable and flexible. Pipe may be

specified by standard pipe size designations, such as nominal pipe

size (in the United States), or by nominal, outside, or inside diameter

and wall thickness. Many industrial and government standards exist

for the production of pipe and tubing.

2.3. BATTERY

In our project we are using secondary type battery. It is

rechargeable type. A battery is one or more electrochemical cells,

which store chemical energy and make it available as electric current.

There are two types of batteries, primary (disposable) and secondary

(rechargeable), both of which convert chemical energy to electrical

energy. Primary batteries can only be used once because they use

up their chemicals in an irreversible reaction. Secondary batteries can

be recharged because the chemical reactions they use are reversible;

they are recharged by running a charging current through the battery,

but in the opposite direction of the discharge current. Secondary, also

called rechargeable batteries can be charged and discharged many

times before wearing out. After wearing out some batteries can be

recycled.

Batteries have gained popularity as they became portable and

useful for many purposes. The use of batteries has created many

environmental concerns, such as toxic metal pollution. A battery is a

device that converts chemical energy directly to electrical energy it

consists of one or more voltaic cells. Each voltaic cell consists of two

half cells connected in series by a conductive electrolyte.

 One half-cell is the positive electrode, and the other is the

negative electrode. The electrodes do not touch each other but are

electrically connected by the electrolyte, which can be either solid or

liquid. A battery can be simply modeled as a perfect voltage source

which has its own resistance, the resulting voltage across the load

depends on the ratio of the battery's internal resistance to the

resistance of the load.

When the battery is fresh, its internal resistance is low, so the

voltage across the load is almost equal to that of the battery's internal

voltage source. As the battery runs down and its internal resistance

increases, the voltage drop across its internal resistance increases,

so the voltage at its terminals decreases, and the battery's ability to

deliver power to the load decreases.

2.4. CONTROL UNIT

In our project the main device is a micro controller. It is used to

control the whole unit of this project. The micro controller is

connected to the control unit.

Microcontrollers are destined to play an increasingly important

role in revolutionizing various industries and influencing our day to

day life more strongly than one can imagine. Since its emergence in

the early 1980's the microcontroller has been recognized as a

general purpose building block for intelligent digital systems. It is

finding using diverse area, starting from simple children's toys to

highly complex spacecraft. Because of its versatility and many

advantages, the application domain has spread in all conceivable

directions, making it ubiquitous. As a consequence, it has generate a

great deal of interest and enthusiasm among students, teachers and

practicing engineers, creating an acute education need for imparting

the knowledge of microcontroller based system design and

development. It identifies the vital features responsible for their

tremendous impact; the acute educational need created by them and

provides a glimpse of the major application area.

ADVANTAGES OF MICROCONTROLLERS

If a system is developed with a microprocessor, the designer

has to go for external memory such as RAM, ROM or EPROM and

peripherals and hence the size of the PCB will be large enough to

hold all the required peripherals. But, the micro controller has got all

these peripheral facilities on a single chip so development of a similar

system with a micro controller reduces PCB size and cost of the

design.

One of the major differences between a micro controller and a

microprocessor is that a controller often deals with bits , not bytes as

in the real world application, for example switch contacts can only be

open or close, indicators should be lit or dark and motors can be

either turned on or off and so forth.

2.5 CAMERA

A camera is a device used to capture images, either as still

photographs or as sequences of moving images (movies or videos).

The term comes from the Latin camera obscura for "dark chamber"

for an early mechanism of projecting images where an entire room

functioned as a real-time imaging system; the modern camera

evolved from the camera obscura.

Cameras may work with the light of the visible spectrum or with other

portions of the electromagnetic spectrum. A camera generally

consists of an enclosed hollow with an opening (aperture) at one end

for light to enter, and a recording or viewing surface for capturing the

light at the other end. Most cameras have a lens positioned in front of

the camera's opening to gather the incoming light and focus all or

part of the image on the recording surface. The diameter of the

aperture is often controlled by a diaphragm mechanism, but some

cameras have a fixed-size aperture.

 CHAPTER-3

DESIGN OF EQUIPMENT AND DRAWING

DC MOTOR

DIMENSION OF 10 RPM MOTOR

Motor specification
Rpm =10
Volt= 12
Watt = 6
Motor calculation
To find the rpm of the motor
Rpm = 120 x Frequency / No. of Poles
120 = standard
Frequency = .25
No. of Poles = 3
There fore
Rpm = 120 x Frequency / No. of Poles
= 120x .25 /3
= 10 rpm

To find the torque of the motor

P = 2x3.14xnxt/60
T = px60/2x3.14xnxt
T =6x60/2x3.14x10
T= 5.72 N-m
The shaft is made of MS and its allowable shear stress =2 MPa
Torque = 3.14 x fs x d ³ / 16

5.732x103= 3.14 x fs x 5 ³ / 16

Torque =X 10³ mm

Fs=3.14*1.7/16*5.732x103

Fs =1.912x103
BLOCK
DRAWING FOR FABRICATION OF COMPUTERIZED PIPELINE

INSPECTION ROBOT
 CHAPTER – 4

WORKING PRINCIPLE

Here we are using robot with six wheels, and the arrangement of the

wheels are; three wheels are in the rear end with attachment of motor. And

other three wheels are in front of the robo. The movement of the robot is

done with the help of motors coupled with the rear wheels. The forward and

reverse directions of the motor are controlled by the control unit. Using this

equipment we can easily inspect the pipe line with attachment of camera.

The camera is mounted at the front of the robot so that the damages in the

pipe lines can be detected easily. The camera is connected to the PC by

which the detections and holes can be identified for rectification. This

project is very helpful for oil industries. The spring arrangement in the robot

is used to expand and shrink the wheel set up according to the diameter of

the pipe lines.

 CHAPTER-5

ADVANTAGES AND DISADVANTAGES

ADVANTAGES

 Implementation is easy

 Maintenance is easy

 Easy to operate

 Less cost

 Less manual work

DISADVANATGES

It can be used only for the particular sizes of pipes only.

 CHAPTER-6

APPLICATIONS

Applicable in oil industries etc..,

 CHAPTER-7

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are

discussed below.
1. Properties:

The material selected must posses the necessary properties for

the proposed application. The various requirements to be satisfied

Can be weight, surface finish, rigidity, ability to withstand

environmental attack from chemicals, service life, reliability etc.

The following four types of principle properties of materials

decisively affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific

gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue

resistance, impact resistance, eleastic limit, endurance limit, and

modulus of elasticity, hardness, wear resistance and sliding

properties.

The various properties concerned from the manufacturing point

of view are,

 Cast ability

 Weld ability

 Forge ability

 Surface properties

 Shrinkage

 Deep drawing etc.

2. Manufacturing case

Sometimes the demand for lowest possible manufacturing cost or

surface qualities obtainable by the application of suitable coating

substances may demand the use of special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately

the material. For example, it would never be desirable to go casting of

a less number of components which can be fabricated much more

economically by welding or hand forging the steel.

4. Availability of Material:

Some materials may be scarce or in short supply.it then

becomes obligatory for the designer to use some other material which

though may not be a perfect substitute for the material designed.the

delivery of materials and the delivery date of product should also be

kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the

forces involved are high and space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of

material plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-

maintenance of the designed part are involved in the selection of

proper materials.
 CHAPTER-8

COST ESTIMATION

1. MATERIAL COST

SR.
NAME OF MATERIAL QUANTITY AMOUNT
NO.
1. M. S. round bar 2 120
2. Acrylic sheet 2 230
2. Screw 40 250
4. Nut 40 200
5. M.S. plate 1 90
6 Sheet metal (pipe) 1 1500
7. D.C. Motor 12 2220
11. Remote 3 switch 1 350
12. RF module 2 950
12. Robot wheel 6 950
14. Spring 2 350
15. Adapter ( 12V) 1 450
16. Supply wire 10 feet 1 120
TOTAL 8120 Rs.
 CHAPTER-9

CONCLUSION

The project carried out by us will make an impressing mark in

the field of robotics. Hence we proved that our model reduces the

human effort and cost for remedies for such problems in industries.
 BIBLIOGRAPHY

1. Design data book -P.S.G.Tech.

2. Machine tool design handbook –Central machine tool Institute,

Bangalore.

3. Strength of Materials -R.S.Kurmi

4. Manufacturing Technology -M.Haslehurst.

5. Design of machine elements- R.s.Kurumi

PHOTOGRAPHY