Programmable Quality Inspection for Large

Metallic Surfaces
Submitted in partial fulfilment of the requirements
of the degree of
Bachelor of Mechanical Engineering
by

Bate Naeem Nasar

(Roll No. 802)
Chawan Viraj Mahesh
(Roll No. 806)
Gadhave Rajat Ratnakar
(Roll No. 811)
Pradhan Vibhav Vinayak
(Roll No. 845)

Supervisor :
Prof. Richa Agrawal

Department of Mechanical Engineering

Pillai College of Engineering, New Panvel, Navi Mumbai
University of Mumbai
2017- 18
 CERTIFICATE

This is to certify that the project entitled “Programmable Quality Inspection for Large Metallic
Surfaces” is a bonafide work of

Bate Naeem Nasar

(Roll No. 802)

Chawan Viraj Mahesh

(Roll No. 806)

Gadhave Rajat Ratnakar

(Roll No. 811)

Pradhan Vibhav Vinayak

(Roll No. 845)

submitted to the University of Mumbai in partial fulfillment of the requirement for the award of the
degree of “Undergraduate” in “Mechanical Engineering”.

Prof. Richa Agrawal

Supervisor/Guide

Dr. Dhanraj Tambuskar Dr. Sandeep M. Joshi

Head of Department Principal
 Approval

This project report entitled Programmable Quality Inspection for Large Metallic Surfaces by

Bate Naeem Nasar

(Roll No. 802)

Chawan Viraj Mahesh

(Roll No. 806)

Gadhave Rajat Ratnakar

(Roll No. 811)

Pradhan Vibhav Vinayak

(Roll No. 845)

is approved for the degree of Bachelor of Mechanical Engineering.

Examiners

1.---------------------------------------------

2.---------------------------------------------

Date:

Place:

ii
 Declaration

I declare that this written submission represents my ideas in my own words and where others' ideas
or words have been included, I have adequately cited and referenced the original sources. I also
declare that I have adhered to all principles of academic honesty and integrity and have not
misrepresented or fabricated or falsified any idea/data/fact/source in my submission. I understand
that any violation of the above will be cause for disciplinary action by the Institute and can also
evoke penal action from the sources which have thus not been properly cited or from whom proper
permission has not been taken when needed.

Date: ----------------------------
Bate Naeem Nasar
(Roll No. 802)

-----------------------------
Chawan Viraj Mahesh
(Roll No. 805)

-----------------------------
Gadhave Rajat Ratnakar
(Roll No. 811)

------------------------------
Pradhan Vibhav Vinayak
(Roll No. 845)

iii
 Abstract

There is a shear requirement of the inspection to be carried out in industries in order to

prevent or cure the problem. This project presents a simple, economical yet effective tool for
carrying out inspection task. The purpose of the project is to design and build a wired wall climbing
device. The device will use magnets mounted on wheels which will hold it on the metallic surface
due to magnetic attraction and the drive will be provided by DC Geared motors. The device is to be
used for the purpose of examining cracks, corrosion and other problem areas on the exterior and
interior of large metallic tanks. Our team is responsible for design and fabrication of the device.
Designing of the RC controller will depend on types of sensors mounted and application of the
device.

Currently, there are a couple of methods used for examining problem areas on metallic
tanks. The most primitive method is to erect scaffolding and send up a technician to manually run
tests of the area. This method is both time consuming and dangerous for the technician. Our team
intends to design a device that uses DC power supply to power all aspects of the device including
motors, controller, and sensors. A tether cable will allow communication with the device and
motion control will be achieved by wired RC controller. This will allow the technician to control the
device, troubleshoot, and receive real time data from sensors.

Live streaming of video from camera will be sent to the operator console to guide the
device, analyze and to record the data. The camera is mounted on Pan Tilt mechanism which allows
camera to be swiveled to left-right and up-down allowing it to have a wide area of coverage. The
motion of Pan Tilt will be controlled from operator console. The device is also incorporated with
slider mechanism to have continues inspection and cover more area of inspection. This slider could
be used to mount sensors which will be used for inspection.

The data available from device can be stored and analyzed to predict catastrophic failures
that might lead to capital, human, environmental loss. Thus it will result in cost effective and
reliable inspection device.

iv
 Contents

Title Page No.

Certificate…………………………………………………………………………………...….. i
Approval…………………………………………………………………………………...…… ii
Declaration…………………………………………………………………………………...… iii
Abstract………………………………………………………………………………………… iv
Contents………………………………………………………………………………………… v
List Of Figures……………………………………………………………………………….… viii
List Of Tables………………………………………………………………………………..… x
Chapter 1 Introduction……………………………………………………………………..…... 1
1.2 Outline……………………………………………………………………………… 3
1.3 Application………………………………………………………..……………...… 4
Chapter 2 Literature Review…………………………………………………………………… 7
2.1 Adhesion Mechanism……………………………………………………………..... 8
2.1.1 Vacuum Adhesion……………………………………………………...… 8
2.1.2 Magnetic Adhesion………………………………………………….....… 9
2.1.3 Dry Adhesion………………………………………………………...…... 9
2.1.4 Electrostatic Adhesion…………………………………………………… 9
2.1.5 Other Adhesion Mechanism……………………………………………… 10
2.2 Locomotion Mechanism…………………………………………………………… 11
2.2.1 Legged Locomotion…………………………………………….……...… 11
2.2.2 Tracked Locomotion…………………………………………………...… 11
2.2.3 Wheeled Locomotion………………………………………...………...… 12
2.2.4 Sliding Locomotion………………………………………..…………...… 12
2.3 Problem Statement……………………………………………………………….… 14
2.4 Objectives………………………………………………………………………...… 16
2.5 Scope…………………………………………………………………………......… 16
Chapter 3 Design……………………………………………………………………………...... 17
3.1 Design Of Components…………………………………………………...……...… 17
3.1.1 Frame……………………………………………………………...…....… 17

v
 3.1.2 Base Plate………………………………………………………….…...… 18
3.1.3 Wheel Design…………………………………………………...……...… 18
3.1.4 Motor Selection………………………………………………………...… 20
3.1.5 Magnet Selection…………………………………………..…………..… 21
3.1.6 Slider…………………………………………………………………...… 22
3.2 CAD Model Of Assembly………………………………………...……………...… 23
Chapter 4 Construction…………………………………………………………………….…… 25
4.1 Fabrication…………………………………………………………………..…....… 25
4.1.1 Body……………………………………………………………….…....... 25
4.1.2 Drive Wheel……………………………………………………….…...… 26
4.1.3 Remote Controller…………………………………………………...…… 27
4.1.4 Slider…………………………………………………………………...… 27
4.2 Components……………………………………………………………………..…. 28
4.2.1 Geared DC Motor……………………………………………….……...… 28
4.2.2 Power Supply……………………………………………………...…....… 29
4.2.3 Magnets………………………………………………………………...… 29
4.2.4 Stepper Motor……………………………………………………...…..… 30
4.2.5 Servo Motor………………………………………………………..…...… 31
4.2.6 Arduino………………………………………………………………....… 31
4.2.7 Motor Driver…………………………………………………………...… 32
4.2.8 Light Emitting Diode…………………………………………………..… 32
4.2.9 Camera………………………………………………………………..….. 33
4.3 Bill Of Material………………………………………………………………......… 34
4.4 Constructional Methodology………………………………………...…………..… 36
Chapter 5 Inspection………………………………………………………………………….... 38
5.1 Inspection Mechanism……………………………………………………………... 38
5.1.1 Pan/Tilt Mechanism……………………………………………….…...… 38
5.1.2 Slider Mechanism……………………………………………………...… 40
5.2 Schematic Of Working Setup……………………………………………………… 41
5.3 Working Procedure………………………………………………..……………..… 42
5.4 Actual Working Setup…………………………………….……………………...… 44
Chapter 6 Results……………………………………………………………………...……..… 46
6.1 Overall Dimensions Of Device……………………...…………………………...… 47
vi
 6.2 Key Specification………………………………………………………………...… 48
6.3 Costing………………………………………………………………….………..… 49
6.4 Future Scope……………………………………………………………………..… 51
Chapter 7 Conclusion………………………………………………………………………...… 52
Appendix…………………………………………………………………………………......… 54
Literature Cited………………………………………………………………………….…...… 61
Acknowledgement

vii
 List of Figures
Fig. 1.1 Weld Deterioration………………………………………………………………....... 2
Fig. 1.2 Evidence Of Interior Shell Corrosion………………………………………..……..... 2
Fig. 1.3 Tank Failure………………………………………………………………………….. 3
Fig. 1.4 Spherical Tank Inspection………………………………..………………………...… 5
Fig. 1.5 Ship Inspection……………………………………………………...……………....... 5
Fig. 1.6 Duct Inspection………………………………………………………..…………...… 6
Fig. 1.7 Windmill Inspection……………………………………………...………………...… 6
Fig. 1.8 Bridge Inspection…………………………………………………………………..… 6
Fig. 1.9 Bridge Inspection………………………………………………………...………....... 6
Fig. 2.1 Conventional Inspection Procedure………………………………………………...... 8
Fig. 2.2 Vacuum adhesion……………………………………………………………….......... 9
Fig. 2.3 Magnetic Adhesion………………………………………………….……………...… 9
Fig. 2.4 Dry Adhesion………………………………………………….…………….……….. 10
Fig. 2.5 Electrostatic Adhesion……………………………………………….……………...… 10
Fig. 2.6 Legged Locomotion………………………………………………….…………….… 11
Fig. 2.7 Tracked Locomotion………………………………………………………………….. 12
Fig. 2.8 Wheeled Locomotion…………………………………………………………..…..… 12
Fig. 2.9 Sliding Locomotion…………………………………………………………….…...... 13
Fig. 2.10 Conventional Inspection Procedure Using Scaffolding…………………………..… 14
Fig. 2.11 Robots for Inspecting Storage Tanks……………………………………………..… 15
Fig. 3.1 Frame…………………………………………………………………………...…..… 17
Fig. 3.2 Base Plate…………………………………………………………………………..… 18
Fig. 3.3 Wheel Design……………………………………………………………...………..... 18
Fig. 3.4 Wheel Rim Design………………………………………………………………..….. 19
Fig. 3.5 Dimensions of Rim…………………………………………………….…………….. 19
Fig. 3.6 Wheel Rim Assembly……………………………………………………….……...… 19
Fig. 3.7 Assembled Wheel………………………………………………………………...…... 20
Fig. 3.8 Free Body Diagram……………………………………………………………......…. 20
Fig. 3.9 Calculation Of Magnetic Force…………………………………………………......… 22
Fig. 3.10 Slider………………………………………………………………………….…...… 22
Fig. 3.11 Exploded View of Assembly………………………………………………………… 23
Fig. 3.12 CAD Assembly……………………………………………………………………… 23

viii
Fig. 3.13 90 degree climb…………………………………………………………………...… 24
Fig. 3.14 Inspection on Curved Surface…………………………………...………………….. 24
Fig. 4.1 Body……………………………………………………………………………….…. 25
Fig. 4.2 Laser Cut Rim…………………………………………………………….……...…… 26
Fig. 4.3 Wheel With Rim……………………………………………………………………… 26
Fig.4.4 Assembled Wheel……………………………………………….……….………….… 26
Fig. 4.5 Remote Controller………………………………………………………….........…… 27
Fig. 4.6 Slider………………………………………………………………………...……..… 27
Fig. 4.7 Geared DC Motors…………………………………………………………..……..… 28
Fig. 4.8 Power Supply……………………………………………………….……...……….… 29
Fig. 4.9 Magnets……………………………………………………………...……………...… 30
Fig. 4.10 Stepper Motor……………………………………………………………………...... 30
Fig. 4.11 Servo Motor…………………………………………………………………...…..… 31
Fig. 4.12 Arduino (UNO & Nano) ………………………………………………..…………… 31
Fig. 4.13 Motor Driver…………………………………………………………………….…... 32
Fig. 4.14 LED………………………………………………………………….……………… 32
Fig. 4.15 Camera…………………………………………………………………….………... 33
Fig. 4.16 Complete Assembly……………………………………………………………….… 37
Fig. 5.1 Pan/Tilt Mechanism…………………………………………………………………... 39
Fig. 5.2 Servo Bracket…………………………………………………………………...…..... 39
Fig. 5.3 Circuit Diagram of Pan/Tilt Mechanism………………………….………………..… 39
Fig. 5.4 Slider……………………………………………………………………………...….. 40
Fig. 5.5 Circuit Diagram of Slider Mechanism……………………………...……………...… 40
Fig. 5.6 Schematic of Working Setup………………………………………………..……...… 41
Fig. 5.7 EziCam Interface and Camera Remote………………………………………..…...… 43
Fig. 5.8 Actual Working Setup……………………………………………………...………… 44
Fig. 5.9 Overhead Testing………………………………………………..…………………… 45
Fig. 5.10 Underneath Inspection of Vehicles…………………...…………………………..… 45
Fig. 6.1 Overall dimensions of crawler…………………………….………………………..… 47
Fig. Appendix I Neodymium Magnets……………………………………………………...… 55
Fig. Appendix II EziCam Application………………………………………………………… 56

ix
 List of Tables

Table 1.1 Application……………………………………………………………………….... 4

Table 4.1 Bill of Material…………………………………………………………….…...….. 34
Table 5.1 Motion Control…………………………………………………………………...... 42
Table 5.2 Pan/Tilt Control……………………………………………………...…………….. 43
Table 6.1 Costing…………………………………………………………………………….. 49
Table Appendix IV Important component of project and its market address………………... 59

x
 Chapter 1

Introduction

Large chemical and petroleum product storage tanks can be found at chemical processing
plants, refineries, and industrial locations [11]. They are huge metal structures 150 feet in diameter
and 50-60 feet tall and can easily hold more than two million gallons of gas or other hazardous
liquids. Most tanks are made of steel plate that is welded together to form the structure. The
material and the weld are inspected for manufacturing defects when constructed but must also be
periodically inspected throughout their service life for signs of damage. The carbon steel is prone to
attack by corrosion and in some circumstances cracks can form over time. NDT personnel use
visual, X-ray, ultrasonic and other inspection methods to search for flaws and service-induced
damage as shown in fig.1.1 & 1.2
 Fig.1.1 Weld Deterioration [12] Fig.1.2 Evidence of Interior Shell Corrosion [12]

Causes of catastrophic tank failure

 Tank shell plates not thick enough for specific gravity of product stored
 Over-filling of tank –over pressure
 Cut-down and re-erected tanks using improper cutting and re-welding procedures
 Improper weld procedures
- Lack of full weld penetrations (lack of weld fusion)
- Improper weld seam spacing
- Lack of radiograph (x-ray) of newly constructed tanks or on repaired tanks
 Lack of weld fusion -Welders not certified and tested to weld procedure
 Weld deterioration/corrosion –especially in lower horizontal and vertical weld seams
 Brittle fracture of steel

Need of tank Inspection

 Prevent leaks into your secondary containment or to groundwater.
 Establish a baseline of tank condition and corrosion rates.
 Identify problems to perform repairs before you have a significant leak or release -Maintain
capital asset.
 Minimize chance of catastrophic tank failure
 Identify areas of degradation before failure
 Provide trend information on deterioration so that life cycle and repair predictions can be
made
 Minimize the out-of-service time to ensure maximum productivity of tanks
2
 Fig.1.3 Tank Failure [12]
Storage tanks require inspection at regular intervals to ensure deterioration is detected at an
early stage. Effective inspection identifies the repairs required before the point where leakage or
other failures occur, avoiding environmental contamination, product loss, or even catastrophic
failure.[35]

Degradation can be caused by environmental conditions such as weather and ground

conditions, or by the contents stored, which may cause internal corrosion. It is often assumed that
leakage will occur before a failure, highlighting thinned areas of shell. This, however, is not always
the case and there are many instances where catastrophic failure occurred without any prior leakage.
Inspection techniques and equipment should therefore be able to identify degradation and potential
total failure, as well as the more likely corrosion that leads to leakage.

1.1 Outline
The report is organized as follows: The introduction is given in Chapter 1. It describes the
fundamental terms used in this project. It motivates to study and understand the different techniques
used in this work. This chapter also represents the outline of the report. The Chapter 2 describes
there view of the relevant various techniques in the literature systems. It describes the pros and
cons of each technique and also states the problem statement along with objectives and scope of
project. Chapter 3 describes the design of various components. It describes the major approaches
used in this work. Chapter 4 describes construction of device. Chapter 5 describes about
the mechanism used for inspection and actual working setup. Chapter 6 describes
testing of design, overall dimensions, key specification costing, appli cations and
future scope. The conclusion of the report is presented in Chapter 7.

3
1.2 Applications

A climbing robot shall climb; It shall move upwards on metallic surfaces and performs
different jobs. The surfaces could be large metallic surfaces. On principle, all kinds of jobs
which are necessary on the metallic surface of a structures, on a wall and, on a ceiling of
structures like tanks are possible fields for using the device.

Table 1.1 Application

Application
Material testing
Removal of layers
Applying of layers
Examples
Quality inspection, testing
Regular building tests(e.g. Bridges)
Assessment, tests before renovation, redevelopment
Visual surface inspection (video camera)
Layer thickness testing
Moisture testing
Permeability test(porosity)
New non-destructive testing methods
Cleaning layers
De-rusting
Removing of varnish
Decontaminate
Protective coating
Insulating layer
Advertising

This device can be used to:

 Inspect storage tanks and associated containment areas in industrial plants, tank terminals
and other locations
 Measure the shell of tanks and extent of metal loss
 Detect corrosion and delamination
 Remove the need for costly scaffolding or rope access
 Provide quick dada collection in real time analysis.

4
Typical Applications:

 Vertical storage tanks  Pipelines

o Shell  Pressure vessels
o Roof  Spherical tanks
o Internal support stanchions  Tank trucks
 Horizontal storage tanks  Marine vessels
o Shell
o Dome ends

Fig.1.4 Spherical Tank Inspection [25] Fig.1.5 Ship Inspection [26]

5
 This device can be used in Oil and Gas, Chemical, Food, and Marine industries. This could
also be used on large metallic structures such as Windmill, Bridge, AC ducts etc. for inspection
purpose.

Fig.1.6 Duct Inspection [27] Fig.1.7 Windmill Inspection [28]

Fig.1.8 Bridge Inspection [30] Fig.1.9 Bridge Inspection [29]

6
 Chapter 2

Literature Review

This literature review investigates state-of-the-art research work on wall-climbing robots.

The rapid growth of technology has made inspection an essential part of the industrial practice.
Many advanced and traditional techniques are available for inspection today. But still the cost of
inspection practice is considerably high. There is surely a need to reduce the cost of inspection and
make the process economical yet advanced and performance oriented.
Inspections of the tank wall is done manually with the inspector in a man lift or hanging
down from the top as shown in fig.2.1.
 Fig.2.1 Conventional Inspection Procedure

Mobile climbing robots can be used in various applications - not only for non-destructive
testing, but also for cleaning, repairing and other tasks [2]. As the applications are very different,
there exist many types of robots. It mainly involves the advances of various adhesion and
locomotion mechanisms for wall-climbing robots, and also discusses various wall-climbing robots
mobility [1]. The two main criteria to distinguish these types are the adhesion mechanism and the
locomotion principle. According to, the most common adhesion mechanisms are magnetism,
vacuum suction, specific attachment devices such as rails or pegs and grippers/clamps. The
locomotion can be based either on wheels, tracks, legs or arms. For both profiting from the simple
control of wheeled locomotion and the high obstacle passing capabilities of legged locomotion,
some robots use active elements within the structure.

2.1 Adhesion Mechanism

Adhesion mechanisms for wall-climbing robots primarily include vacuum adhesion (or
negative pressure suction), magnetic adhesion, dry adhesion (or Van Der Waals force adhesion) and
electrostatic adhesion [1].

2.1.1 Vacuum adhesion

Vacuum adhesion, or negative pressure suction, is considered the most commonly used
adhesion method for wall-climbing robots. Negative pressure suction cup or chamber is the
common vacuum adhesion mechanisms for wall-climbing robot in practical applicationsas shown in
fig.2.2.

8
 Fig.2.2 Vacuum adhesion [16]

2.1.2 Magnetic Adhesion

Although a magnet adhesion using permanent magnets or electromagnets is not applicable to
concrete or glass surfaces, it offers the best solution to ferromagnetic structure adhesion in terms of
energy efficiency, adhesive force and reliability. It has been adopted by many wall-climbing robots
for clinging to steel structuresas shown in fig.2.3.

Fig.2.3 Magnetic Adhesion [17]

The adhesion force of a magnetic mechanism can be determined by the magnetic property of
the magnet it used, the ferromagnetic characteristics of the surface and the distance between suction
mechanism and the surface.

2.1.3 Dry Adhesion

Dry adhesion, also known as Van Der Waals force, is based on nanofabrication technique
inspired by creatures such as geckos. Dry adhesion mechanism can generate Van Der Waals forces
between the surface and the microscopic fibril tape attached on the robot. Dry adhesion has been
applied in wall-climbing robots to achieve a sticking and releasing mechanism similar to gecko
feetas shown in fig.2.4.

9
 Fig.2.4 Dry Adhesion [18]

2.1.4 Electrostatic Adhesion

Electrostatic adhesion has been developed recently. It has the capability of working on a
wide range of materials, including fibre cloth, wood, glass, metal and some common construction
materials

Fig.2.5 Electrostatic Adhesion [3]

The fundamental principle behind such mechanism is that - when an adhesive pad is placed
near a wall surface, the electrostatic adhesion voltage of the robot can generate electrostatic charges
on the pad whilst induce opposite charges on the wall surface, thus will produce electrostatic
adhesion between the adhesive pad and the wall surfaceas shown in fig.2.5.

2.1.5 Other Adhesion Mechanisms

Besides the four adhesion mechanisms described above, several other adhesion mechanisms
are available for wall-climbing robots, such as
Hot Melt Adhesion: Osswald developed a climbing robot that uses hot melt adhesion mechanism
for attaching. The material used in this adhesion mechanism is temperature-dependent, which
means it can repeatedly transform between fluid and solid states by controlling the temperature.

10
Although hot melt adhesion mechanism can provide robust attach–detach processes, it is relatively
slow, and may leave residue on the path when the robot moves.
Claw: A four-leg climbing robot CLIBO has been developed by Sintov. Specially designed claws
are attached on each leg, which enables the robot to navigate on the rough wall and to move in any
direction.
Gripper: ROMA I is a robot which has two grippers fixed at the end of two arms . The grippers can
perform various actions, such as grasping and releasing.

2.2 Locomotion Mechanism

Another crucial element of wall climbing robot is locomotion mechanism, which determines
the motion capability of the robot. The current locomotion mechanisms of the wall-climbing robot
can mainly be categorized into legged, tracked, wheeled and sliding locomotion mechanisms.

2.2.1 Legged Locomotion

Among all the wall-climbing robots, legged locomotion is predominately used. Depending
on the individual task, different legged wall-climbing robots have been designed. These robots
include biped robot containing several controllable active joints four-legged robot and six-legged
robot as shown in fig.2.6.

Fig.2.6 Legged Locomotion [19]

2.2.2 Tracked Locomotion

Tracked locomotion is relatively faster and less complex. It is also commonly used in
applications such as inspection and maintenance of large tanks. Some tracked robots use magnetic
adhesion mechanism Autonomous wall-climbing robot adopting two tracked belts with segmented

11
magnetsas shown in fig.2.7 have also been developed. The robot is able to make turns by driving
two tracks separately.

Fig.2.7 Tracked Locomotion [20]

2.2.3 Wheeled Locomotion

Similar to tracked robots, wheeled robots do not need multi-degree-of-freedom and gaits
control. Wheeled robots usually have simple mechanical structure and need easy controlas shown in
fig.2.8. Some wheeled wall-climbing robots use magnetic wheels as both adhesion and locomotion
mechanisms.

Fig.2.8 Wheeled Locomotion [21]

2.2.4 Sliding Locomotion

Sliding frame mechanism is another commonly used locomotion mechanism. Sliding
locomotion mechanism often contains two frames which can make linear or rotational relative
movements. Each frame is equipped with independent adhesion unit, such as suction cups or
magnetsas shown in fig.2.9. Consequently, a sliding frame robot can move in the desired direction
by lifting and moving one frame while attaching the other frame on the working surface. Sliding
frame robots usually have simple mechanical structure and reliable adhesion. However, the
12
drawbacks of this mechanism include slow moving speed, discontinuous stick-move-stick
movement, and relative large size.

Fig.2.9 Sliding Locomotion [4]

The simplest structure for a climbing robot is a vehicle on two or more magnetic wheels.
These wheels increase the normal force to the ground and thus allow for being more independent
from the direction of gravity.

Gap Analysis:
After studying above adhesion mechanisms we found that

 Vacuum adhesion has good adaptability to various types of surfaces (including non-
ferromagnetic surface) but it cannot be used on rough or corroded surface. It also requires a
vacuum pump to produce continuous vacuum pressure hence it is not portable.
 Dry adhesion can be used on any surface but due to complexity in this technique, it cannot
be used in this application.
 Electro static adhesion requires large electrostatic adhesive pads to produce required holding
force. It is also not reliable and requires more power.
 Magnetic adhesion gives higher holding force, higher reliability if permanent magnets used,
also it does not require external power to produce holding force. Compared to other
adhesion mechanisms it gives same holding force in small size. Also it can be easily used on
rough and corroded surface.

Hence considering above factors magnetic adhesion with wheeled locomotion is best suited for
this application.

13
2.3 Problem Statement

It is estimated that 20% of storage tank accidents are caused by cracks or raptures on the
tank structure. The majority of the bulk liquids stored in these tanks includes crude oil and derived
products which are extremely hazardous to the environment, for example, a spill of only one gallon
of oil can contaminate a million gallons of water [10]. On the other hand, such storage tank NDT
inspection process is very costly, long cycle and harmful for both environment and human
inspectors. Currently, there is no inspection solution allowing for low-cost and 100% surface tank
inspection.
The storage of dangerous goods in tanks must be executed in a safe way. In order to reduce
the economic as well as the environmental risks, a thorough knowledge of the tank condition, and in
particular the tank bottom and shells, is of outmost importance [13].
It is necessary to design a device that can carry, control the NDT inspection tool or probes
for the purpose of NDT operation on exterior as well as interior of large metallic tanks. Suitable tool
or probe is needed to be found out which can be used for purpose of inspection of metallic tanks. It
should reduce danger for technician by eliminating direct human interference in testingas shown in
fig.1.1 (a) finally, it should save inspection time and cost without compromising on the quality
levels.

Fig.2.10 Conventional Inspection Procedure Using Scaffolding [14]

The aim is to design cost effective inspection on Ferro-Magnetic structures without the need
for costly scaffolding or rope access. The crawler system can be automatically or manually operated
and transverses the tank shell either at equal distant points or 100% around the tank circumference
as shown in fig.2.10.

14
 Fig.2.11 Robots for Inspecting Storage Tanks [15]

However a much safer way to make an inspection is to use a crawling device. These devices
have magnetic wheels that allow them to cling to the tank walls. Using remote controls, an operator
guides them into positions and makes the necessary inspection. The floor is particularly prone to
thinning due to corrosion attack and tank owners must find the weak spots in the floors before they
breach the tank's integrity. This often involves the costly process of draining the contents, removing
the layer of sludge from the bottom and cleaning the tanks so inspection personnel may enter in.

15
2.4 Objectives
The objective of this work is as follows:

 To study the status of traditional inspection in industry and the technologies involved in it.
 To study scope of automation in inspection.
 To reduce human intervention and improve safety in inspection.
 To design &develop cost effective and reliable inspection system.
 To design & develop versatile inspection tool.

2.5 Scope

This device can be used in Oil and Gas, Chemical, Food, and Marine industries. This could
also be used on large metallic structures such as Windmill, Bridge, AC ducts etc. for inspection
purpose.

16
 Chapter 3

Design
3.1 Design of Components
3.1.1 Frame

Fig.3.1 Frame

Frame is required to have a sturdy structure & should provide maximum space for mounting
of motors and other components. Thus Frame can be made of steel C-sections as shown in fig.3.1.
C-section would provide good strength and is easy to work on.
 The frame is rectangular style design with length: 30 cm, width: 20 cm and height: 4.5 cm.
The Galvanized Steel Sections of 0.20 mm thick, which will be used to form the two longer sides
and the C-section will be fixed using nut-bolts. Galvanized Steel has good corrosion resistance,
good workability, welds easily and also exhibits good strength.

3.1.2 Base plate

Fig.3.2 Base Plate

The frame designed for device needs a base plate for supporting motors, circuits and other
components as shown in fig.3.2. It should also have a slot for slider mechanism. for that 5mm thick
plywood can be used.

3.1.3 Wheel Design

Fig.3.3 Wheel design

18
 The wheels are required to carry magnets on its periphery which would give holding force to
the device. The dimension of wheel should be such that it should provide enough ground clearance
and carry 8 to 10 magnets as shown in fig.3.3 The wheel of 7cm diameter can be used as it a
standard size and easily available. To incorporate magnets easily on periphery of wheel a rim is
designed. The rim will have slots on its periphery for magnets. The rim could be manufactured by
Fused Deposition Modeling (FDM) with PLA material as shown in fig.3.4. This rim can be press
fitted on the wheel.

Fig.3.4 Wheel Rim design

Fused Deposition Modeling (3-D printing) process requires 8 hours of manufacturing time
for each rim and also the cost is very high. So, design was modified and alternative method of
manufacture is to be selected which would be more accurate, high strength, cost effective and also
will require less time to manufacture.
Laser cutting method can be used to manufacture rims, by cutting required shape of rim as
shown in fig.3.5 in sheet of required material and thickness. This will provide optimum design
which will save time and cost and would serve the purpose. Then the rims can fitted on wheels with
suitable means as shown in fig. 3.6.

Fig.3.5 Dimensions of Rim Fig.3.6 Wheel Rim Assembly

19
The magnets can be fitted in slots provided in rim by suitable means as shown in fig.3.7.

Fig.3.7 Assembled Wheel

3.1.4 Motor Selection

The motor is required to provide sufficient torque which would able to lift the load and drive
wheel by overcoming magnetic force with required velocity.

Calculations for Motor Selection

Fig.3.8 Free Body Diagram

20
 Design requires Robot to reach a minimum velocity of 10 meters per minute vertically along
a steel wall. The drive wheel has a diameter of 90 mm and a circumference of 0.2826 m. To achieve
a linear velocity of 10 m/min, the sprocket rotates at 53.19 rpm. Each wheel of the robot has a drive
motor as shown in Figure. The drive motor is a 12V Johnson geared motor. The motor comes with
metal gearbox and off-centered shaft. Shaft has a metal bushing for wear resistance.
The motor’s rotational output speed is 18,000 rpm and the gearbox output speeds is 100
rpm. The diameter of the shaft leaving the gear box is 6 mm steel
Mass of robot (mR) = 2.5 kg
Mass of inspection tool (mI) = 1 kg
Total mass of robot (m) = Mass of robot (mR) + Mass of inspection tool (mI)
m = mR+ mI
m = 2.5 + 1
m = 3.5 kg
Robot is required to travel with velocity (v) of 10 m/min
Force,
F=mxg [g = 9.81]
= 3.5x 9.81
=34.33 N
Power required to climb on metallic wall,
PREQ =Fxv
= 34.33 x 0.2
PREQ = 6.86 Watts
Assuming the motor system to be 70 % efficient, we require to use the motors having power,
PMOTOR = 10 Watts (approx.)
Thus we have selected 12 V DC Johnson Geared Motor which would provide 12Kgf torque.

3.1.5 Magnet Selection

The magnets needs to provide the cohesive force needed to keep the device on a vertical
surface. The magnet will also provide the normal force required to create the friction needed for
mobility. Rectangular magnets are best suited for the application as they would provide proper
contact with metallic surface and will be easy to be fitted on the wheel. Rare earth Neodymium
magnets are best suited for this application. Neodymium magnets are available in varies grades
ranging from N30 to N52 based on magnetic flux density.
21
 Fig.3.9 Calculation of Magnetic Force [22]

As per availability in market, design requirement and magnetic flux N35 grade is selected.
According to wheel size and availability of magnet size35*13*4 mm is selected. This magnet will
provide 50N force.

3.1.6 Slider

Fig.3.10 Slider
Slider is required to have a universal mount to carry various sensors as shown in fig.3.10. It
should also have arrangement to attach belt on it. Slider should be smaller in size and light weight.

22
3.2 CAD Model of Assembly
Fig.3.2.1 Explode View

Fig.3.11 Exploded View of Assembly

Fig.3.12 CAD Assembly

23
 To get the motion as shown in fig. 3.13 the wheels are mounted at extreme ends of the
frame. This would result in first contact of the wheels with the metallic wall and the device would
climb easily.

Fig.3.13 90 degree climb

Fig.3.14 Inspection on Curved Surface

24
 Chapter 4

Construction

4.1 Fabrication

Device includes fabrication of following parts.

4.1.1 Body

Fig.4.1 Body
 Design has a main frame/housing of steel C-section. The frame is a simple, box style design;
length: 30 cm, width: 20 cm, height: 4.5 cm. The design utilizes Galvanized Steel Sections which is
0.20 mm thick, which is used to form the two longer sides and the ends will be fixed using nut-bolts
as shown in fig. 4.1. Galvanized Steel has good corrosion resistance, good workability, welds easily
and also exhibits good strength. A 5mm thick plywood is fitted to main frame with the help of nut-
bolts as a base plate for mounting of motors and other elements.

4.1.2 Drive Wheel

Design is modified and laser cutting method of manufacturing is chosen. New design has the
rim in two halves. Each wheel will have 4 halves. The rim is manufactured by cutting required
shape in acrylic sheet of 8mm thickness as shown in fig. 4.2. This rim is fitted on the wheel by
using a strong epoxy adhesive (bond tight) as shown in fig. 4.3.

Fig.4.2 Laser Cut Rim Fig.4.3 Wheel with Rims

Each wheel will carry 10 magnets in slots provided in rims. Magnets are fitted with the help
of same epoxy adhesive as shown in fig. 4.4.

Fig.4.4 Assembled Wheel

26
4.1.3 Remote controller

SPMS is used to power drive motor and stepper motor. It requires wired connection. The
drive motors are control by DPDT switches.

Fig. 4.5 Remote Controller

The remote-controller used is a Switch Box made up of Polypropylene plastic. Two DPDT
switches for drive control and two potentiometer for Pan/Tilt control of camera are fitted in switch
box as shown in fig. 4.5. It also consists of a slider switch to turn ON/OFF the DC power supply to
the device.

4.1.4 Slider
Slider is made of an aluminum channel as shown in fig. 4.6. It slides on a steel rod fitted in
frame. It carries a mount for sensors which protrudes out from base plate. Slider gets motion from
belt which is attached to it with the help of a metal strap.

Fig. 4.6 Slider

27
4.2 Components
The assembly consists of following components:

4.2.1Geared DC Motors

Fig. 4.7 Geared DC Motors

Johnson Geared Motor as shown in fig. 4.7 is used to provide drive to the device.
Specifications:
 100RPM 12V DC motors with Metal Gearbox
 18000 RPM base motor
 6mm shaft diameter
 Gearbox diameter 37 mm.
 Motor Diameter 28.5 mm
 Length 63 mm without shaft
 Shaft length 15mm
 300gm weight
 12kgf torque
 No-load current = 800 mA (Max), Load current = upto 9.5 A (Max)

28
4.2.2Power Supply

Fig.4.8 Power Supply

Each drive motors requires approx. 1.5A current to provide required torque to climb on
vertical wall. There are 4 such motors used and thus it requires total 6A current. The stepper motor
used for the slider mechanism requires 1.4A current to operate. So, total current requirement of the
device is approx. 7.4A and to provide this current through battery is not feasible. More number of
batteries will be required and it also increases the weight and cost. This system will be less reliable.
Thus, wired power supply is used. To have continues 12 V DC supply which would provide min. of
8A current input to the device, SMPS is used.

A Switched-Mode Power Supply (SMPS or Switcher) as shown in fig. 4.8 is an

electronic power supply that incorporates a switching regulator to convert electrical
power efficiently. SMPS main function is to convert the AC current to DC.SMPS regulate
and provide reliable output irrespective of variation in input voltage for proper functioning of
device. The power supply provides the drive motor with 12V.
Power supply ratings are as follows: i) Input: 230/110 Volts AC
ii)Output: 12Volts 10 Amp. DC.
4.2.3 Magnets
To provide the cohesive force needed to keep the crawler on a vertical surface, permanent
rare earth magnets called Neodymium magnets of N35 grade as shown in fig. 4.9 are used. These
magnets will also provide the normal force required to create the friction needed for mobility. The
Neodymium magnets are rated according to the magnetic force they provide. The magnets used on
this design are having the dimensions: {35 mm (length) x 13 mm (width) x 4mm (thickness)}.

29
 Fig.4.9 Magnets

There are 10 magnets per wheel, situated 1.5 cm from end to end, along the entire outer
circumference of the wheel. A special adhesive called bond tight is used to secure the magnets on
the outer circumference of the wheel. The pull off force associated with each magnet is50N. It also
varies directly with grading, size, and shape of the magnet.

4.2.4 Stepper Motor

Fig.4.10 Stepper Motor

The device consist a slider mechanism in which reciprocating motion is obtained by using
timing belt and pulley mechanism. To get required stroke of slider, motor is required be rotated by
certain rotations. For that stepper motor as shown in fig. 4.10 is selected.
Stepper motors are DC motors that move in discrete steps. They have multiple coils that are
organized in groups called "phases". By energizing each phase in sequence, the motor will rotate,
one step at a time. With a computer controlled stepping we can achieve very precise positioning
and/or speed control. So, stepper motors is the motor of choice for many precision motion control
applications. Specification:

 Phase current: 1.4 Amp

 Step Angle : 1.8 Degree
 Length (L): 40mm
 Configuration: 4 wire bipolar stepper motor
 Weight: 280 grams
 Holding Torque: 4.2kgcm bipolar mode
 Width:42.3
 Resistance/phase: 1.65ohm

30
4.2.5 Servo Motor

Fig.4.11 Servo Motor

Pan/tilt mechanism requires motor with high torque and limited rotation for that servo
motors are best suited. A servo motor as shown in fig. 4.11 is an electrical device which can
push or rotate an object with great precision. It is used to rotate an object at some specific angles
or distance. The position of a servo motor is decided by electrical pulse and its circuitry is
placed beside the motor.

 Temperature range: 0- 55deg

 Weight: 55g
 servo wire length: 32cm
 Dimension: 40.7×19.7×42.9mm
 Current draw at idle 10MA
 Stall torque: 9.4kg/cm (4.8v)
 No load operating current
 Operating speed: 0.20sec/60degree (4.8v)
draw 170MA
 Operating voltage: 4.8~ 6.6v
 Stall current draw 1200MA
 Gear Type: Metal gear

4.2.6 Arduino (UNO & Nano)

Fig.4.12 Arduino (UNO & Nano)

31
 In device, it is required to control servo and stepper motors by a microprocessor for required
application .for that Arduino boardsas shown in fig. 4.12 are used. Arduino board designs use a
variety of microprocessors and controllers. The boards are equipped with sets of digital and
analog input/output (I/O) pins that may be interfaced to various expansion boards
or Breadboards (shields) and other circuits. The boards feature serial communications interfaces,
including Universal Serial Bus (USB) on some models, which are also used for loading programs
from personal computers. The microcontrollers are typically programmed using a dialect of features
from the programming languages C and C++. In addition to using traditional compiler toolchains,
the Arduino project provides an integrated development environment (IDE) based on
the Processing language project.

4.2.7 Motor Driver

Fig.4.13 Motor Driver

To control stepper motor as mentioned above a motor driver is required along with Arduino.
The A4988 stepper motor driver carrier as shown in fig. 4.13 is a breakout board for Allegro’s
A4988 micro-stepping bipolar stepper motor driver. The driver features adjustable current limiting,
overcurrent and over temperature protection, and five different micro-step resolutions (down to
1/16-step). It operates from 8 – 35 V and can deliver up to approximately 1 A per phase without a
heat sink or forced air flow (it is rated for 2 A per coil with sufficient additional cooling)

4.2.8 Light-Emitting Diode (LED)

Fig. 4.14 LED

32
 For visual inspection of internal surfaces of tanks, pressure vessels, pipes, etc light source is
required. Thus two LED’s as shown in fig. 4.14 are fitted at front side of crawler which can be
turned NO/OFF by push button. These LED’s are powered by 9V Zinc Carbon battery.

4.2.9 Camera

Fig. 4.15 Camera

For visual inspection and to guide the device in closed areas of large metallic surfaces
camera is needed. This camera should provide live streaming to operator console through cable or
Wi-Fi network. Camera is required to record good quality photo/video and should be compact,
lightweight, longer battery life and should have wireless control.
Considering above parameters, EKEN H9R camera as shown in fig. 4.15 is used to serve the
purpose.
Features:

 170 degree wide angle.

 Built-in Wi-Fi 802.11 b/g/n.
 4K ultra HD video shooting.
 2-inch TFT LCD.Live preview
 Provide stunning video quality with 1080p at 60 fps.
 Uses Sunplus 6350 chipset and OV4689 image sensor.
 2.4G 3m water resistance remote controller (built-in 3V CR2032 button cell battery)
 Remote Control Distance: 20m

33
4.3 Bill of Material

Table 4.1 Bill of Material

Sr. Component Material Qty.

No.

1 C-Section Galvanized Steel 1 metre

2 Angle Joints Steel 4

3 Screw & Nut Stainless Steel 30

4 Motor Screw And Washer Steel 16

5 Motor Mount Steel 4

6 12 V Johnson Geared Motor - 4

7 Wheel 7 x 4 cm Virgin Plastic 4

8 Neodymium Magnets Ndfebr 40

9 5mm Wooden Ply wood 0.09 m2

10 SMPS 12 V - 1

11 Circuit Wire Copper 4 metre

12 RC Controller Box With Switch - 1

13 Arduino Uno - 1

14 Arduino Nano - 1

15 Stepper Motor Nema 17 - 1

34
16 Motor Driver A4988 - 1

17 Servo Motor MG995 - 2

18 Coupler Aluminum 2

19 Pan/ Tilt Clamp Aluminum 2

20 9v Battery Zinc Carbon 3

21 Battery Connector - 3

22 Potentiometer - 2

23 Camera EKEN H9R - 1

24 Timing Belt Rubber 1

25 Belt Pulley Aluminum 2

26 Nut Bolt Steel 40

27 HDMI Cable - 1

28 On/Off Push Buttons Plastic 3

30 Handle Stainless Steel 1

32 LED - 2

33 Rim (laser cut) Acrylic 16

35
4.4 Constructional Methodology

Construction process consists of different manufacturing techniques and use of various materials.
Steps involved in fabrication of the device are as follows:

1. Frame is constructed by joining two300mm and two 200mm C section made of galvanized
steel by using steel angels and nut and bolt.
2. Ply of required size is cut for base plate. Slot for slider and various holes for mountings are
made on the base plate. Base plate is then fitted with the help of nut and bolts.
3. DC geared Motors are fitted to base plate with help of motor mounts.
4. Pan/Tilt mechanism consisting two servo motors is assembled using screws and couplers.
This assembly is fitted to the base plate and frame with the help of nut and bolts at the front
face of the device.
5. Camera mounting is fitted to the oblique U shaped clamp and camera is mounted on this
mounting with screw.
6. Slider mechanism is assembled on the device by fitting the stepper motor, rod, pulley and
belt. Stepper motor is fitted on the base belt with the help of mountings. Pulleys are fitted on
the shaft by tightening Allen screw.
7. The slider is inserted on rod and connected to belt with help of clamp and screws.
8. Arduino UNO and Nano are fitted to the base plate. Then wiring required for Dc geared
motor, Stepper motor and Servo motor is done by soldering the wires to respective terminals
of components.
9. LEDs are fitted on the front face of the device on the frame.
10. Push button for ON/OFF of LEDs and Arduino are fitted to the frame.
11. 9V Battery is connected to LEDs and Arduino for power supply.
12. All wires from the device are bunched and brought to the Remote controller.
13. The remote control is constructed by fitting 2 DPDT switches and two potentiometer to
switch box made of plastic. A slider switch is also fitted to the remote control.
14. Power supply wires from the remote are connected to SMPS and it is powered using AC
supply.
15. Wheels for the device are assembled using standard wheel of 65mm diameter, rim and
magnets. Acrylic rims are manufactured using laser cutting process. Each wheel consists of

36
 4 semi-circular rim. Semi-circular rims are fixed to the standard wheel using adhesive, bond
tight.
16. Ten magnets on each wheel are fitted on the rim in the slots provided by using adhesive,
bond tight
17. This assemble wheels are mounted on the shaft of DC geared motor with the help of screw.
18. Cover for the device is manufactured by cutting required size and shape of transparent
acrylic sheet. This cover is fitted by screws on the top of the frame.

Fig. 4.16 Complete Assembly

37
 Chapter 5

Inspection
The tank material and the welds are inspected for manufacturing defects when constructed
but must also be periodically inspected throughout their service life for signs of damage. The carbon
steel is prone to attack by corrosion and in some circumstances cracks can form over time. Thus
Tanks requires various inspections for detection of wall thickness, corrosion, wear and tear, cracks,
blow holes, weld deterioration, leakages, etc.

5.1 Inspection Mechanisms

To serve the purpose of inspection the device is provided with following mechanisms.

5.1.1 Pan/Tilt Mechanism

Pan/Tilt mechanism with a camera is used for Visual inspection of welds, plates, and
appurtenances. Pan/Tilt mechanism is shown in fig.5.1. This mechanism allows operator to pan and
tilt the camera through RC controller. This will increase the viewing angle of camera and serve its
purpose for surveillance.

It consist of two servo motors one for pan and later for tilt. These motors are mounted using
clamps and couplers.
 Fig. 5.1. Pan/Tilt Mechanism Fig. 5.2 Servo Bracket

These motors are mounted using clamps and couplers. The camera is mounted on oblique U shape
aluminum servo bracket shown in fig.5.2. The Pan and tilt motion is controlled by potentiometers
fitted in RC controller. To get required motion control following circuit is used.

Circuit Diagram

Fig. 5.3 Circuit Diagram of Pan/Tilt Mechanism [23]

The program code for above circuit is given in Appendix III (1).

39
5.1.2 Slider Mechanism
For inspection purpose the sensor is required to move along the direction perpendicular to
the motion of device with certain velocity and length of stroke. This will scan area of metallic
surface while moving. The area scanned will have width equal to stroke of slider and length equal to
distance travelled by device.

Fig. 5.4 Slider

To get required reciprocating motion timing belt and pulley mechanism as shown in fig. 5.4
is used. The pulley is driven by stepper motor. The slider mechanism consists of a aluminum slider
which has provision to mount various sensors, which is guided by a steel rod fitted to frame. The
slider is attached to belt and moves along with it. The belt gets controlled motion by stepper motor
through pulley. The motor is rotated to certain rotations to required stroke of slider. For this
Arduino is programmed to control stepper motor through motor driver (A4988).
The mechanism used in device gives maximum stroke of 16cm.
Circuit Diagram:

Fig. 5.5 Circuit Diagram of Slider Mechanism [24]

The circuit used to control stepper motor for specific rotations includes Arduino Uno, motor
driver A4988 and SMPS. The program code for above circuit is given in Appendix III (2).

40
5.2 Schematic of Working Setup

Fig. 5.6 Schematic of Working Setup

41
5.3 Working Procedure

In order to perform inspection using this device, following steps should be followed:

1. Place the device on the metallic surface to inspect.

2. Connect SMPS to 230V AC power supply.
3. Start power supply to motors by turning ON slider switch on the remote.
4. Turn on camera by long pressing the power button.
5. Connect camera with monitoring device either by Wi-Fi or HDMI cable.
6. Turn on LED by pressing push button
7. Start slider by supplying power to control circuit by pressing the push button.
8. If required turn on battery supply to pan tilt mechanism.
9. To control motion of the device use DPDT switches on remote controller.

Table 5.1 Motion Control

Movement Left Switch Right Switch

Forward Top Top

Reverse Bottom Bottom

Right Top Off

Left Off Top

360 Right Top Bottom

360 Left Bottom Top

42
10. To control Pan/Tilt of camera use potentiometer on remote.

Table 5.2 Pan/Tilt Control

Movement Top Potentiometer Bottom Potentiometer

Tilt Up Rotate Clockwise --------

Tilt Down Rotate Anticlockwise --------

Pan Right -------- Rotate Clockwise

Pan Left -------- Rotate Anticlockwise

11. To capture photos or record videos use remote as shown in fig. provided or use mobile
application named EziCam as shown in fig.5.3.

Fig. 5.7 EziCam Interface and Camera Remote

12. To inspect the metallic surface drive the device and record the data.
13. The recorded data is analyzed to make further decisions by the management.

43
5.4 Actual Working Setup

Fig. 5.8 Actual Working Setup

44
 Fig. 5.9 Overhead Testing

Fig. 5.10 Underneath Inspection of Vehicles

45
 Chapter 6

Result

The development of adhesion and locomotion mechanisms, which include magnetic adhesion
and wheeled locomotion are comprehensively investigated in this report. The advantages of this
adhesion/locomotion mechanism are discussed in terms of its reliability, flexibility, and complexity.
This is successfully equipped in the device and tested on metallic plate as shown in Fig. 5.8.

Device is tested for inter-plane transition as shown in Fig.3.13 and inspection of overhead
surfaces as shown in Fig.5.9. The device can also be used for underneath inspection of vehicles as
shown in Fig. 5.10. The inspection tools used on device, Pan Tilt and Slider Mechanism
successfully tested during inspection on metallic plate.

The overall dimensions, key specifications, costing and applications are highlighted further.
6.1 Overall Dimensions of Device

Fig.6.1 Overall dimensions of crawler

47
6.2 Key Specifications

1. Dimensions 0.3x0.32m

2. Weight 3.5kg

3. Adhesion Neodymium Magnet wheels

4. Drive DC geared motor

5. Drive wheels Outer diameter 0.09m

6. Speed 0.3 m/sec

7. Power supply 12 Volt DC

8. Interface Wired

9. Pay load 4.5 kg

10. Camera 4k action camera

11. Max. tether length 2m

12. Wi-Fi range 20m

13. Ground Clearance 0.02m

14. Pan/tilt 180 degree

48
6.3 Costing
Following table shows cost of each component and total cost of device.

Table 6.1 Costing

Sr. Component Qty. Rate Cost

No.
(In Rs.) (In Rs.)

1 C-Section 3.5 Ft. 20/Ft. 100

2 Angle Joints 4 4 16

3 Screw & Nut-Bolt 45 2 90

4 Motor Screw And 16 2 32

Washer

5 Motor Mount 4 15 60

6 12 V Johnson Geared 4 550 2200

Motor

7 Wheel 7 x 4 cm 4 40 160

8 Neodymium Magnets 40 75 3000

9 5mm Wooden Ply 1Sq.Ft 30/Sq.Ft 30

10 SMPS 12 V 1 550 550

12 RC Controller Box 1 80 80
With Switch

13 Arduino Uno 1 380 380

14 Arduino Nano 1 390 250

15 Stepper Motor Nema 1 750 750

17

49
16 Motor Driver A4988 1 150 150

17 Servo Motor Mg995 2 500 1000

18 Coupler 2 50 100

19 Pan/ Tilt Clamp 2 120 240

20 9v Battery & Battery 3 20 60

Connector

22 Potentiometer 2 20 40

23 Camera Eken H9r 1 3100 3100

24 Timing Belt 1 100 100

25 Belt Pulley 2 200 400

27 HDMI Cable 1 300 300

28 On/Off Push Buttons 3 15 45

29 Spray Paint 1 250 250

30 Handle 1 20 20

31 Wires 200 200

32 Led 2 10 20

33 Laser Cutting Of Rim 16 25 400

34 Consumables 200 200

Total 14323

50
6.4 Future Scope:
Further analysis can be focused on how to detect obstacles and generate path while moving
upward. This requires artificial intelligence. Wireless RC system can be used for better operation
and mobility. Device can be fully automated by programming its action to perform repetitive task.
NDT probes viz. Ultrasonic, Eddy current, Gas Detector, can be mounted on the wall climber.
Carrying capacity can be increased by use of track/belt system or by using stronger magnets on
wheels. Aluminum or other synthetic materials can be used to reduce weight of device. A joystick
controller can be designed to control the robot. The device can be equipped with a locating device
like encoder to record the location (co-ordinate with respect to fixed reference point) of defective
area.
The adhesion and locomotion methods of wall-climbing device could be designed in
accordance with the specific applications. Some tasks and application environments involve
complex structures such as steps, obstacles and different inclined planes. Inter-plane transitions can
be improved by manipulating the mechanism to adhere to the new plane and detach the device from
previous plane alternatively. It can also be used for inspection of pipe by modification in wheel
design. Device can also be equipped with universal robotic arm with several degrees of freedom to
perform several tasks.

51
 Chapter 7

Conclusion

This project investigated the design and development of a wall-climbing inspection device to
inspect large metallic surfaces. The device is applicable for various inspection tasks, such as
detection of cracks, corrosion, thickness measurement on large metallic surfaces like tanks, ducts,
pressure vessels, bridges, and so on.

This simpler, compact and lightweight device provides a safe and effective means to deal with
hazardous inspection operations. The device is built to climb on relatively smooth as well as rough
surfaces (corroded surface). Various inspections instruments or tools can be mounted on it to carry
up on wall.
 Due to optimizations in structure and components, its mass is 3.5 kg, the size is
300x320x200mm³ – small enough to fit well in the almost all environments. This magnetic wheeled
climbing device has the capability to work in all inclination. The device can climb on 900 surfaces
and is also capable of inspecting overhead surfaces as shown in Fig. 5.9. It is capable of carrying
payload of weight around 4.5kg.

This device provides safety by reducing direct human intervention in the process of inspection.
Economy is provided along with ease of operation, reducing demand of highly skilled labour. Thus
it is an alternative for most primitive method to erect scaffolding and perform inspection task.

53
 Appendix

Appendix I: Rare Earth (Neodymium) Magnets

The magnets used on the robot are rare earth magnet.

 Neodymium magnets, invented in the 1980s, are the strongest and most affordable type of rare-
earth magnet. They are made of an alloy of neodymium, iron and boron (Nd2Fe14B), sometimes
abbreviated as NIB.
 They have the highest magnetic field strength and have a higher coercivity (which makes them
magnetically stable), but they have a lower Curie temperature and are more vulnerable to
oxidation than samarium-cobalt magnets. Corrosion can cause unprotected magnets to spall off
a surface layer, or to crumble into a powder.
 Use of protective surface treatments such as gold, nickel, zinc and tin plating and epoxy resin
coating can provide corrosion protection.
 Originally, the high cost of these magnets limited their use to applications requiring
compactness together with high field strength. Both the raw materials and the patent licenses
were expensive.
 Beginning in the 1990s, NIB magnets have become steadily less expensive, and the low cost has
inspired new uses such as magnetic construction toys.
 Fig. Appendix I Neodymium Magnets [31]

Appendix II: EziCam

EziCam is application available on Google playstore and apple store, used to interface camera
with mobile phone or tablet via Wi-Fi network. EziCam allows seeing what camera sees on
smartphone or tableting in real time as shown in fig.. Operator will also be able to take pictures and
record videos by using smartphone as a Wi-Fi remote control. In addition, use it to download files
from camera for further analysis.

 Key Features of application:

 See what camera sees with live preview
 Play back videos and view photos
 Video resolution settings
 Image size settings
 White balance settings
 Browse and delete files on the camera’s micro SD card
 Format a MicroSD card.
 Battery Status
 Wi-Fi signal strength

55
 Fig. Appendix II EziCam Application [32]

Appendix III: Arduino Programs

1.Pan / Tilt Mechanism

Following program code is used in Arduino Nano to control servo motors used in pan/tilt
mechanism [33].

#include <Servo.h> // add servo library

//define our servos

Servo servo1;

Servo servo2;

//defive our potentiometer

int pot1 = A1;

int pot2 = A3;

//variable to read the values from the analog pin (potentiometers)

int valpot1;
56
 int valpot2;

void setup()

//attaches our servos on pins 3-5 to the servos

servo1.attach(3);

servo2.attach(4);

void loop()

//reads the value of potentiometers (value between 0 and 1023)

valpot1 = analogRead(pot1);

valpot1 = map (valpot1, 0, 1023, 0, 180);//scale it to use it with the servo(value betweeen 0
and 180)

servo1.write(valpot1); //set the servo position according to the scaled value

delay(15);

valpot2 = analogRead(pot2);

valpot2 = map (valpot2, 0, 1023, 0, 180);

servo2.write(valpot2);

delay(15);

2. Slider Mechanism
Following program code is used in Arduino Uno to control stepper motor used in slider
mechanism [34].

int Index;
void setup()
{
57
pinMode(6, OUTPUT); //Enable
pinMode(5, OUTPUT); //Step
pinMode(4, OUTPUT); //Direction
digitalWrite(6,LOW);
}
void loop()
{
digitalWrite(4,HIGH);
for(Index = 0; Index < 1550; Index++)
{
digitalWrite(5,HIGH);
delayMicroseconds(500);
digitalWrite(5,LOW);
delayMicroseconds(500);
}
delay(100);
digitalWrite(4,LOW);
for(Index = 0; Index < 1550; Index++)
{
digitalWrite(5,HIGH);
delayMicroseconds(500);
digitalWrite(5,LOW);
delayMicroseconds(500);
}
delay(100);
}

58
Appendix IV: Important component of project and its market address
Table Appendix IV

SR.NO. PART NAME ADDRESS

1. i.12 V Johnson Mac-Net Technology,

…Geared Motor With
18, Shreee Ganesh Bhuvan, (Kalpana Bldg), 1st
…Mounts
Floor, 357-Lamington Road, Opp. Police Station,
ii. Wheel Grant (East), Mumbai- 400 007 (INDIA).

iii. SMPS 12 V

iv.RC Controller Box

…..With Switches

v. Screws

2. Neodymium Magnets JRC Industries,

69, Kazi Sayed Street, Opp. Canara Bank, Masjid

Bunder (w), Mumbai- 400 003. India.

3. Camera Alphatronics

EKEN H9R Shop No-9, Lenyadri CHS, Opposite Madhavi

Society,, Sector 19A, Nerul East,, Navi Mumbai,
Maharashtra 400706

4. Wheel Rim Design World

(Laser Cutting) Shop no 1 B Vinayak apt Sect 23 Opp. Seawoods

Rly Stn. ( E ), Navi Mumbai, Maharashtra 400706

59
5. i. Stepper Motor New Silikon Electronics

ii. Servo Motor 351, Kalpana Mansion, Lamington Road, Shop

Number. 4, Topiwala Ln, Grant Road East, Grant Rd,
iii. Motor Driver
Mumbai, Maharashtra 400007

iv. Timing Belt and

…..Pulley

v. Servo Clamps and

….Coupler

6. i. Arduino UNO Signative Solution

ii. Arduino NANO Shop no-06, plot no-E69 sector - 3, Belpada,

Kharghar, Ganesh Nagar, Belpada, CBD Belapur,
iii. Potentiometer
Navi Mumbai, Maharashtra 410210

iv. Batteries and

….Connector

v. LED

7. i. Plywood Panvel Tools And Hardware Store

ii.Galvanized Steel Plot No. 278, Salman Building, Shop No. 3, Opposite
…C- sections Pancharatna Hotel, Below S.B.I., M.G. Road, Old
Panvel, Navi Mumbai, Maharashtra 410206
iii. Spray Paint

60
 Literature Cited
[1] Shanghai, China, Yuan Chang, Xiao-Qi Chen,Chang Y., Chen “Design of A Scalable Wall
Climbing Robot for Inter-Plane Traversing”, The 4th International Conference on Robotic
Welding, Intelligence and Automation (RWIA‟2014), , Oct. 25-27, 2014.
[2] Fischer, Wolfgang; Tâche, Fabien; Siegwart, Roland,”Magnetic Wall Climbing Robot for
Thin Surfaces with specificobstacles”, 2008.
[3] C. Rui, "A Gecko-Inspired Electroadhesive Wall-Climbing Robot," Potentials, IEEE, vol.
34, pp. 15-19,2015.
[4] A. Faina, et al., "Development of a climbing robot for grit blasting operations in shipyards,"
in Robotics and Automation, 2009. ICRA '09. IEEE International Conference on, 2009, pp.
200-205.
[5] WeiminShen and Jason GuYanjunShen,”Permanent Magnetic System Design for the Wall-
Climbing Robot”, Conference Paper in Applied Bionics and Biomechanics, January 2006.
[6] Hwang Kim, Dongmok Kim, Hojoon Yang, Kyouhee Lee, KunchanSeo, Doyoung Chang
and Jongwon Kim,”Development Of A Wall-Climbing Robot Using A Tracked Wheel
Mechanism”, School of Mechanical and Aerospace Engineering, Seoul National University,
Seoul, Korea, April 16, 2008,
[7] B.Vishanth, S.Kathiravan, S.Giri Prasad, R.Raju, D.James Deepak “Analysis Of Wall
ClimbingRobot”, 2014.
[8] Ayyagari D P Prudvi Raj ,DeviduttaNayak “Design And Development Of Wall Climbing
Robot”, National Institute of technology, Rourkela, 2014.
[9] Shunsuke Nansai and Rajesh Elara Mohan “A Survey of Wall Climbing Robots: Recent
Advances and Challenges”, 1 July 2016.
[10] Problem statement.Available online: http://www.tankrob.eu/introduction/
[11] Introduction. Available online: https://www.nde-ed.org/AboutNDT/SelectedApplications/
TankInspection/ TankInspection.htm
[12] Chris Brooks, “API 653 Tank Inspection, Tank Maintenance, And Causes Of Tank
Failure”, Storage-Tanks-Inspection-Maintenance and Failure
[13] Problem Statement. Available online: https://www.sgs.com//media/global/documents/
brochures/ sgs-ind-storage-tank-a4-en-14.pdf
[14] Conventional Inspection Procedure Using Scaffolding Available online: http://www.
coatingspromag.com/articles/steel-coatings/2014/12/some-like-it-geothermal-power-plant-
recoat
[15] Robots for Inspecting Storage Tanks. Available online: http:// mechatronics.mit .edu/ low
temperature/
[16] Vacuum adhesion. Available online: https://www.slideshare.net/Jawad_Ahmad/design-of-
a-wall-climbing-robot-with-passive-suction-cups-62230472
[17] Magnetic Adhesion. Available online: https://www.researchgate.net/figure/Robot-system-
to-apply-a-rubber-magnet-adhesive-vertical-direction-adhesion-peeling_fig10_267984265
[18] Dry Adhesion. Available online:
https://spectrum.ieee.org/ns/images/public_html/automaton/stanford_STICKYBOT-
thumb.jpg
[19] Legged Locomotion. Available online: https://www.researchgate.net/figure/The-
illustration-of-legged-locomotion_fig1_273588216
[20] Tracked Locomotion. Available online: https://www.robotshop.com/ca/en/dfrobotshop-
rover-arduino-robot-construction-kits.html
[21] Wheeled Locomotion. Available online: http://rover.space.tu-berlin.de/?page_id=339
[22] Calculation Of Magnetic Force. Available online: https://www.duramag.com/neodymium-
magnets-ndfeb/neodymium-magnetic-pull-force-calculator/
[23] Circuit Diagram of Pan/Tilt Mechanism. Available online: https://www.youtube.com/
watch?v=uIdEdCDBU-E

62
[24] Circuit Diagram of Slider Mechanism. Available online: https://www.youtube.com/
watch?v=-q9tl-hhHgY&feature=youtu.be
[25] Spherical Tank Inspection. Available online: http://www.integrityndt.com.tr/rafineri-
muayene-yonetimi/
[26] Ship Inspection. Available online: http://www.greenshiptech .com/Marine_
and_Industrial_ Inspection.htm
[27] Duct Inspection. Available online:http://www.sdairquality.com/commercial-air-duct-
cleaning-san-diego/
[28] Windmill Inspection. Available online: http://aerialvistaproductions.com/715-2/715/
[29] Bridge Inspection. Available online: https://www.stantec.com/en/services/bridge-
inspection-assessment/about-bridge-inspection-assessment
[30] Bridge Inspection. Available online: http://www.srsrailuk.co.uk/access-vehicles/bridge-
inspection
[31] Neodymium Magnets. Available online: https://area-info.net/global-neodymium-magnet-
market/
[32] EziCam application. Available online: https://play.google.com/store/apps/ details?id=com
.eken.icam.sportdv.app&hl=en
[33] Pan/ Tilt Code. Available online: http://mertarduinotutorial.blogspot.in/2016/12/arduino-
tutorial-04-servo-motor-control.html
[34] Slider Mechanism Code. Available online: https://github.com/TasmanianDevilYouTube/
Arduino/tree/master/RepRap_a4988_controller_with_stepper_motor
[35] Available online: http://mechanical.final-year-projects.in/a/77-wall-climbing-robot.html
[36] https://www.silverwingndt.com/applications/storage-tanks-integrity/
[37] Available online http://www.vegarobokit.com

63
 Acknowledgement
We would like to express our deepest gratitude to all those who were instrumental in
completion of this project. Special thanks to Dr. Sandeep M. Joshi, Principal PCE, New Panvel
for providing us the opportunity and the facility to carry out our project. We are thankful to our
respected Dr. Dhanraj Tambuskar, HOD of Mechanical Dept. PCE, New Panvel for his
necessary help and encouragement. It gives us immense pleasure to thank our project guide
Prof. Richa Agrawal Dept. of Mechanical Engineering for her pedagogy and unswerving
guidance in completion of this project. We would also like to thank Prof. Shridhar Deshmukh ,
Prof. Ameya Nijasure & Prof. Salim Jafri for their wholehearted support and for providing
invaluable inputs and information.