CHAPTER I

1.INTRODUCTION
1.1 Pipe inspection robot
Robotics is one of the fastest growing engineering fields of today. Robots are
designed to remove the human factor from labor intensive or dangerous work and also to act
in inaccessible environment. The use of robots is more common today than ever before and it
is no longer exclusively used by the heavy production industries. Inspection robots are used
in many fields of industry. One application is monitoring the inside of the pipes and channels,
recognising and solving problems through the interior of pipes or channels. Automated
inspection of the inner surface of a pipe can be achieved by a mobile robot. Because pipelines
are typically buried underground, they are in contact with the soil and subject to corrosion,
where the steel pipe wall, and effectively reducing wall thickness. Although it’s less
common, corrosion also can occur on the inside surface of the pipe and reduces the strength
of the pipe. If crack goes undetected and becomes severe, the pipe can leak and, in rare cases,
fail catastrophically. Extensive efforts are made to mitigate corrosion. Pipe inspection is
necessary to locate defects due to corrosion and wear while the pipe is transporting fluids.
This ability is necessary especially when one should inspect an underground pipe. In this
work, Pipe Inspection Robot (PIR) with ability to move inside horizontal and vertical pipes
has been designed and fabricated. The robot consists of a motor for driving and camera for
monitoring.The inspection of pipes may be relevant for improving security and efficiency in
industrial plants. These specific operations as inspection, maintenance, cleaning etc. are
expensive, thus the application of the robots appears to be one of the most attractive solutions

1.2 PURPOSE OF THE SITUATION

A pipe inspection robot is device that is inserted into pipes to check for obstruction or
damage. Robotics is one of the fastest growing engineering fields of today. Robots are
designed to remove the human factor from labor intensive or dangerous work and also to act
in inaccessible environment. The use of robots is more common today than ever before and it
is no longer exclusively used by the heavy production industries. The inspection of pipes may
be relevant for improving security and efficiency in industrial plants. These specific
operations as inspection, maintenance, cleaning etc. are expensive, thus the application of the
robots appears to be one of the most attractive solutions. Inspection robots are used in many
fields of industry. One application is monitoring the inside of the pipes and channels,
recognizing and solving problems through the interior of pipes or channels. In this work, Pipe
Inspection Robot (PIR) with ability to move inside horizontal and vertical pipes has been
designed and fabricated. The robot consists of a motor for driving and camera for monitoring
station to the contrary. These specific operations as inspection, maintenance, cleaning etc. are
expensive, thus the application of the robots appears to be one of the most attractive
solutions.

1.3 PROBLEM CONTEXT

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”.

1.4 BENEFITS
The inspection of pipes may be relevant for improving security and efficiency in industrial
plants. These specific operations as inspection, maintenance, cleaning etc. are expensive, thus
the application of the robots appears to be one of the most attractive solutions. 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. Save comprehensive investment,
improve work efficiency, more accurate detection. 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 Operating cost related to other method is low. The robot has great application in
accessing the regions of pipe in which human doesn’t have reach. It could be mounted with a
camera which would send us pictures of inside and would help in our inspection.

1.4.1 TANGIBLE BENEFITS

 Save comprehensive investment, improve work efficiency, more accurate detection
 It’s useful for pipe cleaning
 Its flexible makes robot take turns smoothly through various joints in pipe.
 Robot can travel horizontally through pipe.
 Robot can travel vertically through pipe.

1.4.2 INTANGIBLE BENEFITS

 Reduce the risk of being fail and will work more accurately
 This robot will able to provide high accuracy
 Reduces human effort.
 Operating cost related to other method is low.

1.5 TARGET READER

 Nuclear power plants
 Refineries
 Communal waste water pipe systems
 Long distance city heating pipelines
 Gas pipelines

1.5.1 TARGET AUDIENCES OF THE ROBOT ARE FOLLOWING AS:

 APIIT Project manager, Project supervisor, Project advisor

 Any user who will use this robot.

 Any organization that will use this robot.

 Any industrialist person that will use this project.

1.5.2 FIELD OF APPLICATIONS OF PIPE INSPECTION
Nuclear power plants
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 inspectors systems are widely used.

Conventional power plants

By taking advantage of the NDT inspection methods that our robots offer, defects and faults
can be avoided increasing the 'up and running' operational time of all kinds of pipe systems.
Worldwide, many power plants already use our robots to do just this.

Refineries

The mineral oil industry can benefit from improved supply, transportation, processing and
distribution of mineral oil as well as improved environmental protection. Our robots are
helping to do just this.

Chemical and petrochemical plant

It is of course vital to continually reduce the risks brought about by the manufacture,
transport and storage of chemicals. This means that the possible dangers need to be examined
and the necessary testing and inspections carried out in order to avoid or at least lessen and
contain them. The use of our robots has become obligatory in many well-known companies.

Offshore

The technical demands of offshore rigs as well as safety and environmental requirements are
very high and strongly controlled. This means that there is an enormous amount of required
Non Destructive Testing inspections. Our robots are used worldwide in offshore applications.

Long distance city heating pipelines:

Leakages in long distance heat conduits, caused through external corrosion, cause energy and
water losses resulting in damage to, among others, subterranean constructions. Minimizing
energy loss during the transport of heat from source to end user is one of the most important
requirements in order to exclude danger to people and the environment. Our robots help in
this important duty.
Food and drinks industries

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.

Communal waste water pipe systems

Subterranean sewer systems have been responsible for the collection and transport of waste
water since planning and construction began in 1842. With the Republic of Germany most of
these sewage systems are owned by the cities and community districts. Regular inspection of
the roughly 445 km of public sewage systems is therefore a complex and cost intensive
process.

Gas pipelines

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.

1.6 OBJECTIVE OF THE ROBOT

The main objective for developing such is that it can be inserted into pipes to check for
obstruction or damage. One application is monitoring the inside of the pipes and channels,
recognizing and solving problems through the interior of pipes or channels. In this work, Pipe
Inspection Robot (PIR) with ability to move inside horizontal and vertical pipes has been
designed and fabricated. The robot consists of a motor for driving and camera for monitoring
station to the contrary. These specific operations as inspection, maintenance, cleaning etc. are
expensive, thus the application of the robots appears to be one of the most attractive solutions
as it is cheap and at very low maintenance cost.
1.7 ROBOT SCOPE
This robot provide a wide area of scope for the industries, gas pipelines, nuclear power
plants. This type of robot will provide accurate work at minimum cost. The main feature of
this robot is its foldable mechanism which

1.7.1 FUNCTIONALITY OF THE ROBOT

 Its flexible makes robot take turns smoothly through various joints in pipe.
 Robot can travel horizontally through pipe.
 Robot can travel vertically through pipe.

1.7.2 CORE FUNCTIONALITY OF THE ROBOT

The robot has few basic functions with some additional functions. Core functionality of the
robot is mentioned in below

 The foldable mechanism which is very helpful to travel through the various joints in
the pipe
 Fan is attached at the head of the robot to clean the pipe.
 Led is attached to provide sufficient light inside the pipe.

1.7.3 ADVANTAGES OF THE ROBOT

 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.

1.7.4 LIMITATION OF PIPE INSPECTION ROBOT

 Pipe inspection robots have such limitations as their ability to turn in a T-shaped
pipe or move in a plug valve.
 This robot does not work in water.
 This robot works only in empty pipe.

1.8 FEASIBILITY
Before developing any project feasibility study plays the major role in the success of the
project. Feasibility study is an analysis of how a project can be completed successfully,
accounting for factors that affect it such as technical, operational, economical, and schedule
factors. The project manager uses this feasibility study to determine the favourable and non-
favourable outcomes of the project before investing a considerable amount of time and
money into the project.

1.8.1 TECHNICAL FEASIBILITY

The different system used in the pipeline inspection robot can be designed. There is
complexity in designing the all system. The components and the hardware for this project are
not easily available. The all systems can be easily implemented in the pipeline inspection
robot.

1.8.2 OPERATIONAL FEASIBILITY

The operational feasibility mainly focusses on the evaluation which will analyse the system
that how well the system is working. And how to deal with the changes occurs in the system
during the development period. The operational feasibility includes the following design-
parameters.

 Reliability: In this, developer checks how much the system is reliable in terms of
hardware that can perform consistently according to its specification.
 Maintainability: In this, developer know how a product can be maintained in order to
correct the defects or their cause, how to replace the faulty components without
replacing the working components.
 Supportability: In this, developer ensures that the project can support multi platforms
without any problem.
 Usability: In this, developer ensures that how the system is learnable to the user. It
must be easy to learn and use for the success of the project.
 Sustainability: In this, developer ensures that the product is sustainable enough, so
that it meets the need of present generation without compromising the need of the
future generation.
 Affordability: In this, developers ensures that the project is affordable to almost all
the target users.
The proposed system will be checked in the terms of the PIECES framework.

 Performance: For calculating the performance of the system, we must know the
Throughput that is the amount of work performed over some period of time and the
response time. We have to check whether our system is properly working on these
 two benchmarks or not. The site is showing the required output in minimum time
period. We have to make our site in such a way that the performance of our project is
maximum in short time.
 Information: System provides the service to the end user with timely, relevant,
accurate and usefully formatted information. Since the user provides the input in the
form to get the generated code. The information handling in the current system is
done manually.
 Economic: Economic feasibility study determines whether the system is cost
effective or not. It will ensure that the cost must be reduced by implementing the new
system.
 Control: It associated with the control and system security for the data control and
the transaction of data. The system that has to be developed has enough control to
resist the system to be hacked, or people who are fraud and it provide enough security
for the information available on the system.
 Efficiency: Efficiency work is to ensure a proper workflow structure to store patient
data; we can ensure the proper utilization of all the resources. It determines whether
the system make maximum use of available resources including time, people, flow of
forms, minimum processing delay. In the current system a lot of time is wasted on
paper work like making new records, updating records.
 Service: This determines whether the reliable services are provided to the users and
whether the system is acceptable or not. This will also check whether there is a scope
of expansion or improvement in the system or not.

1.8.3 ECONOMIC FEASIBILITY

The Economic Feasibility helps the organizations measure the cost and benefits associated
with the project before the financial resources are allocated. This also enhances the project
credibility and helps decision makers to determine the positive economic benefits to the
organization. This typically involves the cost analysis of the project.

1.9 PROJECT MANAGEMENT

Is the science (and art) of organizing the components of a project, whether the project is
development of a new product, the launch of a new service, a marketing campaign, or a
wedding. A project isn’t something that’s part of normal business operations. It’s typically
created once, it’s temporary, and it’s specific. As one expert notes, “It has a beginning and an
end.” A project consumes resources (whether people, cash, materials, or time), and it has
funding limits.

1.10 TIMESCALE

When any job has to be skilled according to a time or date deadline, it is advisable to have at
least some idea of the relationship between the time allowed and the time needed. For time
management as a researcher have to make first of all schedule according to our conversations.

1.11 REQUIREMENTS.

Requirements is the main part of management our pulse of the profession research has shown
that poor supplies organisation is a major cause of project failure. They wants process
generally includes a needs debt, elicitation and analysis of requirement, monitoring and
controlling requirements and evaluation of solutions.

1.12 RESOURCES AND COSTS WITH SUITABLE GRAPHICAL

REPRESENTATION
In this we make a Pie or Bar chart charge compare resources and costs. Resources, the
collective money or its means of producing wealth. Usually, resources. Money, or any
property that can be converted into money; assets.
In project manangnment we have some point like
1. Gantt Chart
2. PERT Chart
3. Earliest Completion Time
4. Latest Completion Time
GANTT CHART
In Gantt chart we discuss our all work and its time schedule. After that we make a graph that
graph has a horizontal bar chart that graphically displays and the time relationships between
the different tasks in a project effective when seeking to communicate schedule.
PERT CHART
Pert chart is a also a function of combination of a process called Program Evaluation Review
Technique (PERT), which was developed by the Navy to manage the construction of nuclear
submarines, and the Critical Path Method (CPM), which was developed by isolated industry
to meet similar needs
1.13 COST ESTIMATION
SR.
NO NAME OF MATERIAL QUANTITY AMOUNT
.
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.

1.14 HEALTH SAFETY AND ETHICAL ASSESSMENT

Basically health safety in nothing that when we are doing some work in that time what we
problem facing regarding health is called health safety and we have to fill some form in
which we have certain condition for working is called Ethical assessment. Now we talk about
what problem we faced regarding making assignment or project. First of all we faced some
problem to forget any component or lost our component. Be careful when we soldering any
component take precaution bear gloves and keep away from eyes. So that your eye is save.
1. Electrical short
2. Soldering burn
3. Data Loss
4. Chemical burn
CHAPTER 2 LITERATURE REVIEW
The purpose of the Literature review is to provide a critical working approach and
Methodologies of the existing system.
A literature review is an important chapter in a thesis where its purpose is to provide the
justification and background for the research undertaken
Introduction
The literature review is simply a summary of ideas and view based on another reference
material.
This section contains the critical analysis of the research done in order to provide the
justification of the research undertaken such the technology used in this project.

2.1 PURPOSE OF LITERATURE REVIEW

The purpose of the literature review is to simply provide the justification used in this project.
Basically developer has divided this section in the parts based in the technology used in this
system.

2.2 TECHNICAL LITERATURE REVIEW

Approximately all the pipeline based systems encounters fault and it is detected primarily by
classical methods like ultrasonic sensing techniques. Pipelines are seems to be very complex
structure researcher across the world are in search of new solutions so that problem detection
in future will easy and trustable.

[1] Discussed the result of a feasibility study of a wheeled multi-joint robot for autonomous
sewer inspection. The robot was cable free and multi-joint which enables high mobility in
sewage systems.

. [2] Developed a detection system to identify objects in sewage pipes. A CCD camera was
attached with autonomous sewer robot which provides images that were interpreted by an
attention driven recognition module.

[3] Presented a multi-joint for sewer inspection tasks. It was a multi-joint, cable free robot to
overcome the problems of previous one link cabled vehicles. The mechatronic concept of the
vehicle was also described. The description focused on computer architecture and electronic
components.

[4] Presented a new concept for internal pipe line inspection to detect the failure early and
assess the different sections of the network system. The article also presented the mechanical
design, the electronics and communication system, the fibre-optic bus and the operator
station. Two image-processing algorithms for measuring fissure length and the effective
diameter of the pipe ware also presented.

[5] Presented an algorithm for online distance computation based on images taken in a sewer
by a robot inspection. They used image processing and laser based orientation method to
improve the accuracy of test results.

[6] Proposed the use of laser spot array and TV camera for the vision sensor. The camera
provides the three dimensional position of each spot on the surface of the pipe by means of
triangulation. They also discussed a method to distinguish the pipe shape.

[7] Proposed a custom IR scanner for landmark detection for the autonomous sewer robot
MAKRO. They described how a custom 2D scanner involving infrared distance sensors with
high sampling rates can be employed for robust and fast detection of inlets.

[8] One study has shown that challenges in the field of creating new intelligent machine that
will help in reducing the maintenance cost and they should be adjustable according to the
situation. Although it will be instrumentation focused only yet also it will decrease the human
effort to always keeping an eye over such faulty situations.

According to Martín Enrique Valdivia Mejía [9] (2016)’research paper While the above
development project provides valuable information regarding this thesis that if one has to
design a specific diameter pipeline which is flexible also, caution needs to be exercised
before assembling the components. Proper care should be done and all research should be
completed which are necessary for the development of projects. That is, the differences found
between a well-researched planned development product and an unplanned development
product and result is simply that planned one was found better. It is also sure that software
difference also creates the difference in resultant product.

[10] The current experimental thesis examines and compares the difference between different
types of linkage between the pipes and concludes the best mechanism cluster is mechanical
clutch mechanism. Post event is confirmed by through other evidences. This technique has
been surprisingly neglected until recently, as the majority of the literature on this topic gives
the conformity about it.

Jae Yeon Choi and Hoon Lim(2006) [11] showed that development and up gradation of
technology regarding pipeline inspection has taken place rapidly as from full human based
observation to machine based and then semi-automatic robots.  To appreciate the effects
of this change and shifting of human workforce to machine workforce and then further to
semiautomatic robots is very better than before. Due to this they help in pipeline inspection
inside the house also.

 Traditionally, every machine designed for some specific work need sensors according to the
Ana Carolina Cardoso de Sousa, Dianne Magalh˜aes Viana (2014) [12] However, such a
broad focus may not fully explain how sensors are used in a specific robot and also which
sensor should be used. There is such a typical scene everywhere wherever pipeline is used it
detects the fault and choosing right sensor for specific situation is the first need. If its done
with proper knowledge and experience it will in near future surely help in automate the whole
fault checking system.

[13] Most research involving the Experimentally Induced Information methodology seeks to
identify the influence of different components including sensors, joint bolts and
microcontrollers may therefore be advantageous to also investigate the effects of using
different components and choosing the right one. Ir sensor is considered best in almost all the
situations as per current available technologies. However, few studies have used this
methodology and those that have, have yielded mixed findings. Therefore, future
investigation observing by combining different components to each other to get which will
give the best result.

[14] One way to determine a moving robot is good or bad merely depends on in how many
situation it can move. Pipes can be vertical, horizontal and can be made up of different
materials also. Also there is difference between sizes of pipelines, so robot will be considered
adaptive and good if it is flexible enough to adjust in these parameters. Observation observed
going through different projects and conducting so many experiments, 120 degrees between
legs of robot is found the right one to make it adaptive and flexible.

Although the experiments described in this research paper shows the movement of robot in a
curve trajectory and also the importance of calculating the total displacement of a robot inside
the curved pipelines. It can be done by using Fourier transform technique and total derivative
gives results that help the researcher to find the location of robot inside a curved pipeline so
that in any case (case of some faulty condition in robot) if robot stuck in curved area, it can
be rescued and be repaired.

[15] In this paper, a rotating probe in vinyl chloride pipe was tested, and a new inspection
robot system for drain pipe was developed. In future, we will analyze the image data and the
probe data and research the best method for inspecting the defects and increasing the
detection ability. In addition, we are going to do research on a smaller robot system and
wireless radio communication system for small size’s long drain pipe.

[16] As it is well known that working and movement speed of any machine or robots really
matters. It thoroughly depends on power of motors, no of wheels, and at what rate it is
receiving the input signal and resulting in output which is basically the processing speed. It
can be increased by image processing technique by inspecting the robot at every location.
This paper has presented the development and implementation of an imaging system that can
be used for high speed inspection of pipes.

[17] Proposed a robotic system for in-pipe inspection of underground urban gas pipelines. It
was based on visual and non-destructive testing (NDT). The robot was configured as an
articulated structure like a snake with a tether cable. It had several characteristic feature
superior to the others especially the steering mechanism called Double Active Universal Joint
(DAUJ).

[18] Further extended their work in this paper. They described the strategies developed for
the automation of defect classification in pipes and explored new methods to fuse intensity
and positional information and showed how they can be used to improve multi variable defect
classification.

[19] Created an intelligent sensing approach for improved and automated pipe condition
assessment. A novel method for extracting and analysing intensity variations in the acquired
images was introduced.

[20] Further extended their work. In this paper, the morphology-based pipe defect
segmentation is proposed and discussed to be an improved approach for automated diagnosis
of pipe defects on CCTV images using Otsu’s technique for segmentation and radial basis
network (RBN) based diagnostic system.

A very important design goal of the robotic systems is the adaptability to the inner diameters
of the pipes. So, we had proposed a new design in inspecting pipelines. The major advantage
is that it could be used in case of pipe diameter variation with the simple mechanism. We
developed a pipe inspection robot that can be applied to 140- 180mm pipeline. The
kinematics of mechanism and actuator sizing of this robot have been investigated. A real
prototype was developed to test the feasibility of this robot for inspection of in-house
pipelines. We used a PCB board that can operate DC motor. Good conceptive and element
design could manage all the problems. The types of inspection tasks are very different. A
modular design was considered for PIC that can be easily adapted to new environments with
small changes. Presence of 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 propulsion of the robot has been successfully conducted using only three
motors, a radical simplification over existing efforts. The robot is designed to be able to
traverse horizontal and vertical pipes. We had experimented our project and we got the test
results. Several types of modules for pipe inspection minirobot have been presented. Many of
the design goals of the Pipe inspection robot have been completely fulfilled.

The Robots in these days is very common in use. These robots can take the place of human in
dangerous area. Inspection and performing the maintenance work in pipeline is very
dangerous for human because, the pipeline is very long, narrow and maybe it is because
choking. So, the robot will replace the human in doing inspection. The designed and
fabricated Pipeline inspection robot can move forward straight, right direction and left
direction and has a wireless camera to monitor the pipeline from any crack, leakage, deposit
or any abnormality things. The camera will take the picture of any crack in the pipe and
transfer the data to the computer. This data is very useful to monitor the pipe line. The
microcontroller (PIC16f628A) which is used is controlled by program to give the robot
command. This will reduce the time consuming for work, to reduce the cost of man power
and minimize potential risks. Further improvement can be done in the pipeline inspection
robot by adding sensors to avoid collision the walls. Also we can add timer and to measure
distance travelled in the pipeline to know the location of crack.

2.3 PRESENT WORK

From above survey, the maximum work has been done in the developed countries where the
sewer blockage occurs rarely. Hence all the available equipment’s are generally for
inspection of pipeline especially the crack detection of pipes. No work is found for the
blockage detection inside a sewer line. The main objective of the present work is detecting
the blockage and calculating its location parameters of the blockage. To solve the above
problem, the present work designs and develops a robotic system. This robotic sewer
inspection equipment with the embedded system has two main units’ i.e. robotic vehicle and
sensor unit. The robotic vehicle carries the sensors and moves in the sewer pipeline as
required. Both units have their own embedded control systems. The complete equipment size
is small and capable of being introduced into the sewer pipeline through any manhole or
inspection chamber available in the sewer system. The vehicle is designed and a prototype is
made and tested. The robotic vehicle is designed with three wheels, two of them driven by
motors. The motor is controlled automatically and calculation of travelled distance with
directions for desired movement inside sewer line is done by an embedded processor through
embedded software and supporting hardware, sensors etc.
The sensor unit uses ir sensors. The sensors have mounting with the provisions for changing
the direction of the sensor. These sensors are responsible for giving data of transmission and
reflection of ultrasound waves by the variations in the medium of its transmission inside the
line due to blockage or deformities in the line. The signals are analysed to measure the
distance of blockages or other defects of the pipeline. The data provided by the sensors are
stored in the available memory, processed by embedded processor or supporting computer,
analysed and conclusions derived for obtaining the blockage and its location parameter.

2.4 CONCLUSION
From the research it can be seen that pipeline inspection robot is very much useful in modern
society. Robots play an important role in inside pipe-network maintenance and their
repairing. Some of them were designed to realize specific tasks for pipes with constant
diameters, and other may adapt the structure function of the variation of the inspected pipe.
This types of robot can be implemented by using recent available technology. Many of the
design goals of the Pipe inspection robot have been completely fulfilled. Foldable mechanism
has been described which is very much useful and with great advantage it can overcome
without any difficulties. A modular design was considered for easily adapted to new
environments with small changes. Presence of 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.
CHAPTER III
3. Componets used in Project
A microcontroller is a self-contained system with peripherals, memory and a processor that
can be used as an embedded system. Most programmable microcontrollers that are used today
are embedded in other consumer products or machinery including phones, peripherals,
automobiles and household appliances for computer systems. Due to that, another name for a
microcontroller is "embedded controller." Some embedded systems are more sophisticated,
while others have minimal requirements for memory and programming length and a low
software complexity. Input and output devices include solenoids, LCD displays, relays,
switches and sensors for data like humidity, temperature or light level, amongst others.

3.1 TYPES OF MICROCONTROLLERS

There are several different kinds of programmable microcontrollers at Future Electronics. We

stock many of the most common types categorized by several parameters including Bits,
Flash size, RAM size, number of input/output lines, packaging type, supply voltage and
speed. Our parametric filters will allow you to refine your search results according to the
required specifications.

Programmable microcontrollers contain general purpose input/output pins. The number of

these pins varies depending on the microcontroller. They can be configured to an input or an
output state by software. When configured to an input state, these pins can be used to read
external signals or sensors. When they are configured to the output state, they can drive
external devices like LED displays and motors.

Future Electronics has a wide range of programmable microcontrollers, including pic, low
power, and LCD, USB and wireless microcontrollers from several manufacturers. Once you
decide if you need 8 bit, 16 bit general purpose, 16 bit digital signal controllers or 32 bit
microcontrollers, you will be able to choose from their technical attributes and your search
results will be narrowed to match your specific microcontroller application needs.

We deal with several manufacturers such as Cypress, Microchip, NXP, Renesas Electronics,
STMicroelectronics or Zilog. You can easily refine your programmable microcontroller
product search results by clicking your preferred microcontroller brand from the list of
manufacturers below.
Programmable microcontrollers are designed to be used for embedded applications, unlike
microprocessors that can be found in PCs. Microcontrollers are used in automatically
controlled devices including power tools, toys, implantable medical devices, office machines,
engine control systems, appliances, remote controls and other types of embedded systems.

3.2 Choosing the Right Microcontroller

With the FutureElectronics.com parametric search, when looking for the right
microcontrollers, you can filter the results by the number of Bits required. We carry the
following size microcontrollers:

32 bit Microcontrollers in Production Ready Packaging or R&D Quantities: If the quantity of

32 bit microcontrollers is less than a full reel, we also offer many of our 32 bit
microcontroller products in tray, tube or individual quantities that will avoid unneeded
surplus.

 8 bit Microcontrollers
 16 bit Digital Signal Controllers (DSC)
 16 bit General Purpose Microcontrollers
 32 bit Microcontrollers

Once you choose the microcontroller size, you can narrow them down by various attributes:
by RAM size, Flash size, number of input lines, speed and supply voltage to name a few. You
will be able to find the right LCD, low power, USB, wireless or pic microcontrollers using
these filters.

3.3 ARDUINO
Arduino is an open-source prototyping platform based on easy-to-use hardware and
software. Arduino board are able to read inputs - light on a sensor, a finger on a button, or a
Twitter message - and turn it into an output - activating a motor, turning on an LED,
publishing something online. You can tell your board what to do by sending a set of
instructions to the microcontroller on the board. To do so you use the Arduino programming
language (based on Wiring), and the Arduino Software (IDE), based on Processing.
 Figure 1Arduino Board

Over the years Arduino has been the brain of thousands of projects, from everyday objects to
complex scientific instruments. A worldwide community of makers - students, hobbyists,
artists, programmers, and professionals - has gathered around this open-source platform, their
contributions have added up to an incredible amount of accessible knowledge that can be of
great help to novices and experts alike.

Arduino

A microcontroller board, contains on-board power supply, USB port to communicate with
PC, and an Atmel microcontroller chip. It simplify the process of creating any control system
by providing the standard board that can be programmed and connected to the system without
the need to any sophisticated PCB design and implementation. It is an open source hardware,
anyone can get the details of its design and modify it or make his own one himself.

3.4 RF Module

Introduction

The TX is an ASK transmitter module .The result is excellent performance in a simple - to -

use .The TX is designed specifically for remote - control , wireless mouse and car alarm
system operating at 315/433.92 MHz . The RX is a miniature receiver module that receives
On - off keyed modulation signal and demodulated to digital signal for the next decoder
stage. The result is excellent performance in a simple - to - use, with a low external
component count. The RX is designed specifically for remote-control and wireless security
receiver operating at 315/434 MHz

Figure 2 RF Module (Receiver)

FEATURES
 Easy to use.
 TX:
 Power supply and/or modulation input voltage: 2.2 to 5.5v.
 Operating temperature: -40 to +80C.
 RX:
 Power supply and/or modulation input voltage: .5v.
 Operating temperature: -20 to +80c.
APPLICATIONS

 Vehicle monitoring.
 Radio tags reading.
 Wireless fire protection systems.
 Digital home automation.
Pin Details
 Figure 3 RF Module (Transmitter)

Pin Name Details

1 GND Ground
2 data data
3 NC NC
4 Vcc Power supply
5 Vcc Power supply
6 GND ground
7 ANT antenna
8 GND ground
9 data data
10 Vcc Power supply
11 ANT antenna
WORKING
The RF module, as the name suggests, operates at radio frequency. The corresponding
frequency range varies between 30 kHz & 300 GHz. In this RF system, the digital data is
represented as variations in the amplitude of carrier wave. This kind of modulation is known
as Amplitude Shift Keying (ASK). Transmission through RF is better than IR (infrared)
because of many reasons. Firstly, signals through RF can travel through larger distances
making it suitable for long range applications. Also, while IR mostly operates in line-of-sight
mode, RF signals can travel even when there is an obstruction between transmitter &
receiver. Next, RF transmission is more strong and reliable than IR transmission. RF
communication uses a specific frequency unlike IR signals which are affected by other IR
emitting sources. This RF module comprises of an RF transmitter and an RF receiver. The
transmitter/receiver (Tx/Rx) pair operates at a frequency. An RF transmitter receives serial
data and transmits it wirelessly through RF through its antenna connected at pin4. The
transmission occurs at the rate of 1Kbps - 10Kbps.The transmitted data is received by an RF
receiver operating at the same frequency as that of the transmitter.

The RF module is often used along with a pair of encoder/decoder. The encoder is used for
encoding parallel data for transmission feed while reception is decoded by a decoder.
3.5 IR SENSOR
Infrared sensor is a sensor that used to detect present and absent of a particular object. It use a
specific light in the Infrared spectrum. An LED released an infrared light and the light
emitted will be detect by the sensor. Fig shows there is no object present in front of the sensor
whereas Figure shows there is an object present in front of the sensor.

Figure 4 IR Sensor

Figure 5 IR sensor Working

TYPES OF IR SENSORS

Infrared sensors can be passive or active. Passive infrared sensors are basically Infrared
detectors. Passive infrared sensors do not use any infrared source and detects energy emitted
by obstacles in the field of view. They are of two types: quantum and thermal. Thermal
infrared sensors use infrared energy as the source of heat and are independent of wavelength.
Thermocouples, pyro electric detectors and bolometers are the common types of thermal
infrared detectors.

Quantum type infrared detectors offer higher detection performance and are faster than
thermal type infrared detectors. The photosensitivity of quantum type detectors is wavelength
dependent. Quantum type detectors are further classified into two types: intrinsic and
extrinsic types. Intrinsic type quantum detectors are photoconductive cells and photovoltaic
cells.

Active infrared sensors consist of two elements: infrared source and infrared detector.
Infrared sources include an LED or infrared laser diode. Infrared detectors include
photodiodes or phototransistors. The energy emitted by the infrared source is reflected by an
object and falls on the infrared detector.

Figure 6 IR sensor Working

IR TRANSMITTER

Infrared Transmitter is a light emitting diode (LED) which emits infrared radiations. Hence,
they are called IR LED’s. Even though an IR LED looks like a normal LED, the radiation
emitted by it is invisible to the human eye.

The picture of a typical Infrared LED is shown below.

 Figure 7 LED

There are different types of infrared transmitters depending on their wavelengths, output
power and response time. A simple infrared transmitter can be constructed using an infrared
LED, a current limiting resistor and a power supply. The schematic of a typical IR transmitter
is shown below.

Figure 8 Circuit of IR sensor

When operated at a supply of 5V, the IR transmitter consumes about 3 to 5 mA of current.

Infrared transmitters can be modulated to produce a particular frequency of infrared light.
The most commonly used modulation is OOK (ON – OFF – KEYING) modulation.

IR transmitters can be found in several applications. Some applications require infrared heat
and the best infrared source is infrared transmitter. When infrared emitters are used with
Quartz, solar cells can be made.

IR RECEIVER
Infrared receivers are also called as infrared sensors as they detect the radiation from an IR
transmitter. IR receivers come in the form of photodiodes and phototransistors. Infrared
Photodiodes are different from normal photo diodes as they detect only infrared radiation.
The picture of a typical IR receiver or a photodiode is shown below.

Figure 9 IR receiver

Different types of IR receivers exist based on the wavelength, voltage, package, etc. When
used in an infrared transmitter – receiver combination, the wavelength of the receiver should
match with that of the transmitter.

A typical infrared receiver circuit using a phototransistor is shown below.

 Figure 10 IR Receiver Circuit

It consists of an IR phototransistor, a diode, a MOSFET, a potentiometer and an LED. When

the phototransistor receives any infrared radiation, current flows through it and MOSFET
turns on. This in turn lights up the LED which acts as a load. The potentiometer is used to
control the sensitivity of the phototransistor.

SERVO MOTOR

A servomotor is a rotary actuator or linear actuator that allows for precise control of angular
or linear position, velocity and acceleration. It consists of a suitable motor coupled to a sensor
for position feedback. It also requires a relatively sophisticated controller, often a dedicated
module designed specifically for use with servomotors.

Servomotors are not a specific class of motor although the term servomotor is often used to
refer to a motor suitable for use in a closed-loop control system.

Servomotors are used in applications such as robotics, CNC machinery or automated

manufacturing.

To fully understand how the servo works, you need to take a look under the hood. Inside
there is a pretty simple set-up: a small DC motor, potentiometer, and a control circuit. The
motor is attached by gears to the control wheel. As the motor rotates, the potentiometer's
resistance changes, so the control circuit can precisely regulate how much movement there is
and in which direction.

When the shaft of the motor is at the desired position, power supplied to the motor is stopped.
If not, the motor is turned in the appropriate direction. The desired position is sent via
electrical pulses through the signal wire. The motor's speed is proportional to the difference
between its actual position and desired position. So if the motor is near the desired position, it
will turn slowly, otherwise it will turn fast. This is called proportional control. This means
the motor will only run as hard as necessary to accomplish the task at hand, a very efficient.

Figure 11 Servo Motor

Servos are controlled by sending an electrical pulse of variable width, or pulse width
modulation (PWM), through the control wire. There is a minimum pulse, a maximum pulse,
and a repetition rate. A servo motor can usually only turn 90 degrees in either direction for a
total of 180 degree movement. The motor's neutral position is defined as the position where
the servo has the same amount of potential rotation in the both the clockwise or counter-
clockwise direction. The PWM sent to the motor determines position of the shaft, and based
on the duration of the pulse sent via the control wire; the rotor will turn to the desired
position. The servo motor expects to see a pulse every 20 milliseconds (ms) and the length of
the pulse will determine how far the motor turns. For example, a 1.5ms pulse will make the
motor turn to the 90-degree position. Shorter than 1.5ms moves it to 0 degrees, and any
longer than 1.5ms will turn the servo to 180 degrees.

When these servos are commanded to move, they will move to the position and hold that
position. If an external force pushes against the servo while the servo is holding a position,
the servo will resist from moving out of that position. The maximum amount of force the
servo can exert is called the torque rating of the servo. Servos will not hold their position
forever though; the position pulse must be repeated to instruct the servo to stay in position.

TYPES OF SERVO MOTORS

There are two types of servo motors - AC and DC. AC servo can handle higher current surges
and tend to be used in industrial machinery. DC servos are not designed for high current
surges and are usually better suited for smaller applications. Generally speaking, DC motors
are less expensive than their AC counterparts. These are also servo motors that have been
built specifically for continuous rotation, making it an easy way to get your robot moving.
They feature two ball bearings on the output shaft for reduced friction and easy access to the
rest-point adjustment potentiometer.

SERVO MOTORS APPLICATIONS:

Servos are used in radio-controlled airplanes to position control surfaces like elevators,
rudders, walking a robot, or operating grippers. Servo motors are small, have built-in control
circuitry and have good power for their size.
In food services and pharmaceuticals, the tools are designed to be used in harsher
environments, where the potential for corrosion is high due to being washed at high pressures
and temperatures repeatedly to maintain strict hygiene standards. Servos are also used in in-
line manufacturing, where high repetition yet precise work is necessary.

3.6 MOTOR DRIVER L293D

• L293D is a dual H-bridge motor driver integrated circuit (IC).
• Motor drivers act as current amplifiers since they take a low-current control signal
and provide a higher-current signal.
• This higher current signal is used to drive the motors.

Figure 12 L293D Motor Driver Circuit

 L293D contains two inbuilt H-bridge driver circuits. In its common mode of
operation, two DC motors can be driven simultaneously, both in forward and reverse
direction.

Operation of motor driver

 L293D has 2 set of arrangements where one set has input 1, input 2, output 1 and
output 2 and other set has input 3, input 4, output 3 and output 4, according to block
diagram if pin no 2 & 7 are high then pin no 3 & 6 are also high.

 If enable 1 and pin number 2 are high leaving pin number 7 as low then the motor
rotates in forward direction.
3.7 5V POWER SUPPLY USING 7805 VOLTAGE REGULATOR

In most of our electronic products or projects we need a power supply for converting mains
AC voltage to a regulated DC voltage. For making a power supply designing of each and
every component is essential. Here I’m going to discuss the designing of regulated 5V Power
Supply.

Let’s start with very basic things the choosing of components

COMPONENT LIST

 Voltage regulator
 Capacitors
 1k Resistor
 Led diode

VOLTAGE REGULATOR

As we require a 5V we need LM7805 Voltage Regulator IC.

7805 IC RATING

 Input voltage range 7V- 35V

 Current rating Ic = 1A
 Output voltage range   VMax=5.2V ,VMin=4.8V 

Figure 13 7805 IC

CAPACITORS
What we are going to do, is build this power supply, with a couple of simple changes. This
regulator needs a 1000 uF capacitor on the input side, and a 100 uF capacitor on the output
side. The capacitors help filter the input and output from noise created by the power supply,
and/or the load. We will add larger capacitors on both sides, to help keep our power supply
clean, and noise free. Secondly, there is no way of knowing if our power supply is working,
so we will add a little LED as our power indicator.

Figure 14 Capacitor

1K OHM RESISTOR WITH LEWith the quick calculation above, you can see that for
maximum brightness of our red LED, we need a resistor of 100 ohm. Since I don't really care
about maximum brightness, I'd rather have a dimmer LED and save my battery; so I decided
to use a 1k ohm resistor instead, which will still give me plenty of brightness and increase
my battery life.

 If enable 2 and pin number 10 are high leaving pin number 15 as low then the motor
rotates in forward direction.
 Figure 151K ohm resistor circuit

3.7 ATEMAGA- 328

The Atmega328 is a very popular microcontroller chip produced by Atmel. It is an 8-bit
microcontroller that has 32K of flash memory, 1K of EEPROM, and 2K of internal SRAM.
The Atmega328 is one of the microcontroller chips that are used with the popular Arduino
boards. The Atmega328 is a very popular microcontroller chip produced by Atmel. It is an 8-
bit microcontroller that has 32K of flash memory, 1K of EEPROM, and 2K of internal
SRAM. The Atmega328 is one of the microcontroller chips that are used with the popular
Arduino boards.

The ATmega328 is a single-chip microcontroller created by Atmel in the megaAVR family.

The Atmel 8-bit AVR RISC-based microcontroller combines 32 kB ISP flash memory with
read-while-write capabilities, 1 kB EEPROM, 2 kB SRAM, 23 general purpose I/O lines, 32
general purpose working registers, three flexible timer/counters with compare modes, internal
and external interrupts, serial programmable USART, a byte-oriented 2-wire serial interface,
SPI serial port, 6-channel 10-bit A/D converter (8-channels in TQFP and QFN/MLF
packages), programmable watchdog timer with internal oscillator, and five software
selectable power saving modes. The device operates between 1.8-5.5 volts. The device
achieves throughput approaching 1 MIPS per MHz..
 Figure 16 Atmega 328

The Atmel AVR core combines a rich instruction set with 32 general purpose working
registers. All the 32 registers are directly connected to the Arithmetic Logic Unit (ALU),
allowing two independent registers to be accessed in a single instruction executed in one
clock cycle. The resulting architecture is more code efficient while achieving throughputs up
to ten times faster than conventional CISC microcontrollers.

3.8 POWER SUPPLY

There is an additional power supply source present in Arduino microcontroller. Power
supply port is present at the corner of the arduino microcontroller. Either we can use this
power supply port by connecting with external power supply. (i.e., ac power supply), or by
connecting an dc power supply through input pins. These power supplies produce an active
form to the arduino microcontroller. These arduino microcontrollers can accept a range of
power supply. When the power supply voltage range Exceeds, the microcontroller gets
damaged. Hence, only the particular range of power supply should be given to the arduino
microcontroller.

3.9 LCD
LCD (Liquid Crystal Display) screen is an electronic display module and find a wide range of
applications. A 16x2 LCD display is very basic module and is very commonly used in
various devices and circuits. These modules are preferred over seven segments and other
multi segment LEDs. The reasons being: LCDs are economical; easily programmable; have
no limitation of displaying special & even custom characters (unlike in seven segments),
animations and so on.
A 16x2 LCD means it can display 16 characters per line and there are 2 such lines. In this
LCD each character is displayed in 5x7 pixel matrix. This LCD has two registers, namely,
Command and Data.
The command register stores the command instructions given to the LCD. A command is an
instruction given to LCD to do a predefined task like initializing it, clearing its screen, setting
the cursor position, controlling display etc. The data register stores the data to be displayed
on the LCD. The data is the ASCII value of the character to be displayed on the LCD. Click
to learn more about internal structure of a LCD.

Figure 17 LCD 16*2

DC motors:
DC (direct current) motor works on the principle, when a current carrying conductor is placed
in a magnetic field; it experiences a torque and has a tendency to move. If the direction of
current in the wire is reversed, the direction of rotation also reverses. When magnetic field
and electric field interact they produce a mechanical force, and based on that the working
principle of dc motor established. DC motors are used to achieve the drive on wheels and
rotation of rods. Two types of DC motors used in the project are shown in Fig
 CHAPTER IV

4. CONSTRUCTION OF ROBOT
The major concepts/components used in this project are RF technology, motor driver,
Chassis- designing, power circuit and power transmission etc. We designed an RF based
control system to control. Robot. The signal get generated and transmitted with the help of
antenna, provided on it. Now the receiving section which we already installed on the robot
will receive the signals and send the received signals to the motor drive, on the basis of which
motor driver will drive the robot and robot climb on the pole.
Radio Frequency is a flexible technology that is convenient, easy to use, and well suited for
automatic operation. It combines advantages not available with other technologies. It can be
supplied as read-only or read/write, does not require contact or line-of-sight to operate, can
function under a variety of environmental conditions, and provides a high level of data
integrity. In addition, because the technology is difficult to counterfeit, RFID provides a high
level of security. Radio waves transfer data between an item to which an RFID device is
attached and an RFID reader. The device can contain commands for robot. RF technology
uses frequencies within the range of 50 kHz to 2.5 GHz. An RFID system typically includes
the following components:
 An RF devices (transponder or tag) that contains data about an item/location
 An antenna used to transmit the RF signals between the reader and the RFID device
 An RF transceiver that generates the RF signals
 A reader that receives RF transmissions and passes the data to a host system for
processing. To control robot a remote is designed which has a number of switches on
its control board. As soon as you press any button it transmits signals that are received
by receiving section then it decodes it and on the basis of signals, motion takes place
 in the robot like forward, backward. Robot receives this signal with the help of
antenna present on the head of the robot

4.1 BLOCK DIAGRAM

Figure 18Block Diagram of working Robot

4.2 SOFTWARE DESIGN

This is the proteus design of pipeline inspection in which the three motors are connected to a
single L293D. As we require a 5V we need LM7805 Voltage Regulator IC which is
connected to L293D to give power to motor
 Figure 19 Proteus design of pipeline robot

The RF module, as the name suggests, operates at radio frequency. LCD is connected to a
arduino Nano of pin no. A0 and A1. The TX is an ASK transmitter module .The result is
excellent performance in a simple - to - use .The TX is designed specifically for remote -
control , wireless mouse and car alarm system operating at 315/433.92 MHz . The TX
connection , Gnd pin is connected to a gnd pin of Nano and Vcc is connected to the 5v of
nano pin. The RX is a miniature receiver module that receives On - off keyed modulation
signal and demodulated to digital signal for the next decoder stage. The result is excellent
performance in a simple - to - use, with a low external component count. The RX is designed
specifically for remote-control and wireless security receiver operating at 315/434 MHz.

Figure 20 Proteus Design of Rf controller

CHAPTER V

5. IMPLEMENTATION
5.1 SELECTION OF MATERIALS
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 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.

 The toughness, as measured by crack propagation energy, decreases as yield stress

increases.
 At the same yield stress, the under aged structure has greater toughness than the over
aged structure.

5.2 EFFECT OF TEMPERATURE

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 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.

 The toughness, as measured by crack propagation energy, decreases as yield stress

increases.
 At the same yield stress, the under aged structure has greater toughness than the over
aged structure.

5.3 Mechanism
The mechanism involved here is a four bar mechanism consisting of three revolute joints and
one prismatic joint as depicted
 Figure 21 Mechanism OF pipeline Inspection Robot

H = 2r + 2d + 2h2×cosθ,

Where,

h1 = 30 mm, h2 = 85 mm, h3 = 105 mm (h1 =OA, h2 = BC = D, h3 = CF)

H=2×36+2×28+2×85×cos 45

H=248.20mm

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, H=Height of robot outside the pipe.

For uniform Diameter,

Assume D = 2r+2d+2h2cos θ

D=2×36+2×28+2×85×cos 50

D=237.27mm

5.3.1 KINEMATICS OF MECHANISM

The linkage structure can be represented as in figure depicted. This is a four-bar mechanism
Consisting of three revolute joins and one prismatic as depicted. Thus, the motion of all
revolute joints can be described in terms of the displacement db .

5.3.2 STATIC ANALYSIS

In order to decide the actuator size, it is necessary to perform the static analysis. Assume that
in (Figure 4), Fcx and Fcz denote the reaction force and the traction force exerted on the four-
bar by the driving wheel, respectively. Now applying the virtual work principle to the free-
body diagram gives:
 Figure 22 Linkages of PIPE INSPECTION ROBOT

Figure 23 Static Analysis

δW = Fcz δz – Fbx δx = 0

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 θ, x = 2.33/ cos θ

δW = Fczδ (2.33l sinθ) – Fbxδ (–2.33l cosθ)

= Fcz*2.333/ cosθ– Fbx*2.33/ sin θ δθ.= 0

Rearranging gives:

Fbx = Fcz*cosθ/sinθ

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

Fcz by Fbx = Fcz*tanθ

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: τ = 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 4.2. 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.

5.4 DESIGN OF VARIOUS ELEMENTS OF PIPE INSPECTION ROBOT

HELICAL SPRING
Inner diameter – 18 mm
Outer dia – 20 mm
Pitch – 5 mm
Length of the spring – 60 mm
Material – Stainless steel

TRANSLATIONAL ELEMENT
Inner diameter – 18 mm
Outer diameter – 23 mm
Length of the element – 25 mm
Material – Mild steel
WHEEL

Diameter – 72 mm

DISTANCE BETWEEN THE EXTREME LINKS

Drilled Holes (Figure 7)
Link 1 – 30 mm
Link2 – 85 mm
Link3 – 105 mm
Thickness – 3 mm
Drilled holes – 12 and 6 mm
Material – Acrylic
CENTRAL ELEMENT
Hollow
Inner dia – 15 mm
Outer dia – 20 mm
Length – 220 mm
Material – Mild steel
CHAPTER VI

6. TESTING AND RESULTS

6.1 TESTING PLAN DIAGRAM
This methodology gives way about how work is to be carried out in systematic way. It is
standard process of describing process, how it is done in simplest manner.

Figure 24 Plan Diagram of Pipeline Robot

 Figure 25 Working of Robot

The block diagram shows how the pipeline inspection robot will work and how it will carried.
Pipeline Inspection robot will be controlled by RF module device and it will inspect inside
the pipeline by crawling inside the pipeline. It will crawl both horizontally as well as
vertically. It will check for if there is any obstacle in the pipe or not and it will check for the
if any crack is there or not.

6.2 DIFFERENT TESTING MODULE

An RF transceiver module incorporates both a transmitter and receiver. 
6.2.1 TRANSMITTER SECTION TESTING MODULE

Figure 26 RF transmitter

The TX is an ASK transmitter module .The result is excellent performance in a simple - to -

use .The TX is designed specifically for remote - control , wireless mouse and car alarm
system operating at 315/433.92 MHz . The RF module, as the name suggests, operates at
radio frequency. The corresponding frequency range varies between 30 kHz & 300 GHz. In
this RF system, the digital data is represented as variations in the amplitude of carrier wave.
This kind of modulation is known as Amplitude Shift Keying (ASK). Transmission through
RF is better than IR (infrared) because of many reasons. Firstly, signals through RF can travel
through larger distances making it suitable for long range applications. Also, while IR mostly
operates in line-of-sight mode, RF signals can travel even when there is an obstruction
between transmitter & receiver. Next, RF transmission is more strong and reliable than IR
transmission. RF communication uses a specific frequency unlike IR signals which are
affected by other IR emitting sources. This RF module comprises of an RF transmitter and
an RF receiver. The transmitter/receiver (Tx/Rx) pair operates at a frequency. An RF
transmitter receives serial data and transmits it wirelessly through RF through its antenna
connected at pin4. The transmission occurs at the rate of 1Kbps - 10Kbps.The transmitted
data is received by an RF receiver operating at the same frequency as that of the transmitter.

The RF module is often used along with a pair of encoder/decoder. The encoder is used for
encoding parallel data for transmission feed while reception is decoded by a decoder.
Command has to be send from TX to move robot forward or backward and to stop the robot.
Signal is been send from TX to RX. Three buttons have been added to TX to move pipe
inspection robot to horizontally and vertically in other case to move backward and forward.
The third button is added to stop the robot. LCD have been attached to the Transmitter
module to display if there is any obstacle or if any crack is detected or not.

6.2.2 RECEIVER MODULE TESTING

Figure 27 RF Receiver

An RF receiver module receives the modulated RF signal, and demodulates it. There are two
types of RF receiver modules: super heterodyne receivers and super-regenerative receivers.
Super-regenerative modules are usually low cost and low power designs using a series of
amplifiers to extract modulated data from a carrier wave. Super-regenerative modules are
generally imprecise as their frequency of operation varies considerably with temperature and
power supply voltage. Super heterodyne receivers have a performance advantage over super-
regenerative; they offer increased accuracy and stability over a large voltage and temperature
range. This stability comes from a fixed crystal design which in the past tended to mean a
comparatively more expensive product. However, advances in receiver chip design now
mean that currently there is little price difference between super heterodyne and super-
regenerative receiver modules. The RF module is often used along with a pair of
encoder/decoder. The encoder is used for encoding parallel data for transmission feed while
reception is decoded by a decoder. The RX encode the signal provided by TX and helps robot
to move backward and to move forward.

6.3 RESULT
As we can see in the image below when we give command through Rf module (TX) to make
the robot crawl inside the pipeline as we can see that the pipeline robot have crawl down
inside the pipe Now from the below image we can see that the pipeline robot have been move
in upward direction when the Rf module gives command to move upwards the robot crawl
upwards inside the pipeline.

CHAPTER VII

7. DISCUSSION
As Pipe Inspection Robot is designed mainly for circular bore pipes, it have ability to move
inside any bore diameter pipes ranging from 8 inch to 10 inch ( 203mm to 254mm ). Suitable
mechanisms are provided so that it gains ability to move inside pipes.

The perfect fitness between the pipe and robot is first conformed after inserting the robot in
the pipe. 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.

Working of PIPE INSPECTION ROBOT is starts from its insertion in pipe. The front three
arms is compressed by hand and then inserted in the pipe and then back three arms is inserted
by pushing the PIPE INSPECTION ROBOT. The motors driven are the first six arms
mentioned here, they pull whole setup. PIPE INSPECTION ROBOT is about 175 cm in
length and to move it freely inside the bend pipes, a 2 degree of freedom joining is provided
at the middle so that it can turn easily. As switch is on and current is flowing through wires,
wheels starts moving and forces PIPE INSPECTION ROBOT to propel forward. Using the
friction between wheels and pipe, the motion of wheels become possible

As we mentioned earlier that PIPE INSPECTION ROBOT will be able to move inside any
diameter ranging between 203mm to 254mm, we had to provide auto adjusting mechanism
that can expand and contact as PIPE INSPECTION ROBOT moves inside the pipe. Spring of
suitable stiffness is mounted on base rod, as seen in figure, so that as arms gets contracted
due to load of compression against pipe, spring get compressed and tend to expand outward
trying to push arms back to their normal position but as pipe restrict them, they cannot move.
We took good care of stiffness of spring such that it can move against the pipe and do not put
too high pressure of tires which can jam it and restrict the motion. Even if the pipe interior is
smooth, using pressure between compressed tire and pipe, PIPE INSPECTION ROBOT can
move easily.

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.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 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.

7.2 FUTURE IMPLEMENTATION

 Rotating Probe - A rotating probe using piezo element for inspecting the inside of
pipes with a touch sensor system. When the rotating probe touched the defected area,
the piezo film could detect the curve and change of the stress
  Radiography Methods- X-rays, gamma radiation or neutron rays can penetrate
structural materials and therefore can be used on inspection purposes. The amount of
radiation absorbed by the material is dependent upon the density and thickness. This
radiation can be detected and recorded on either film or sensitized paper, viewed on a
fluorescent screen, such as a television screen, or detected and monitored by
electronic sensing equipment. Using this method, limitations are imposed by
accessibility to both sides of the object, long exposure times, and safety precautions
required to protect both the operators and public.

Chapter VIII

8.CONCLUSION
Robots play an important role in inside pipe-network maintenance and their repairing. Some
of them were designed to realize specific tasks for pipes with constant diameters, and other
may adapt the structure function of the variation of the inspected pipe.
In this project inside pipe modular robotic system are proposed. An important design goal of
these robotic systems is the adaptability to the inner diameters of the pipes. The given
prototype permits the usage of a mini-cam for visualization of the in-pipe inspection or other
devices needed for failure detection that appear in the inner part of pipes (measuring systems
with laser, sensors etc.)
The major advantage is that it could be used in case of pipe diameter variation with the
simple mechanism. We developed a pipe inspection robot that can be applied to 203mm-
254mm pipeline. A real prototype was developed to test the feasibility of this robot for
inspection of in-house pipelines.
The types of inspection tasks are very different. A modular design was considered for easily
adapted to new environments with small changes. Presence of 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.

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