Programmable Quality Inspection For

Large Metallic Surfaces

UNDER THE GUIDANCE OF

PROF. RICHA AGRAWAL

PRESENTED BY:

NAEEM N BATE 802

V IRAJ M CHAWAN 806
RAJAT R GADHAWE 811
VIBHAV V PRADHAN 845
 Outline
• Problem Statement
• Objectives
• Applications
• Literature Survey
• Methodology
• Design And Construction
• Inspection
• Device Specification
• Design Testing
• Future Scope
• References
• Acknowledgement
 Why inspect Metallic Surfaces?

Weld Deterioration Tank Failure

Interior Shell Corrosion

 Problem Statement
Inspections of the tank walls is done manually with the inspector in a man lift, on
scaffolding or hanging down from the top .

Conventional Method of Inspection

 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.

 Applications
This device can be used in
• Oil and Gas industry
• Chemical industry
• Food industry
• Marine industry
Other Applications

• Windmill

• Bridge

• Basement

• AC Duct, etc
 Literature Survey
Adhesion Mechanism Locomotion Mechanism
• Vacuum adhesion • Legged Locomotion
• Magnetic Adhesion • Tracked Locomotion
• Dry Adhesion • Wheeled Locomotion
• Electrostatic Adhesion • Sliding Locomotion
Methodology
 Design and Construction
Frame and Base Plate

Frame Base Plate Assembled Body

Magnet Selection

Neodymium Magnets
Calculation of Magnetic Force (Grade N35)
 Drive Wheel Design
• 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
• To incorporate magnets easily on periphery of wheel a rim is designed.

Assembled Wheel design Wheel Rim design

 Wheel Design

Dimensions of Rim Wheel Rim Assembly Assembled Wheel Design

Laser Cut Rim Wheel with Rims Assembled Wheel

Motor Selection
Geared DC Motors

FBD of System 12V Johnson Geared Motor

Remote Controller
• A remote-controller is used to control the motion of the robot.
• It contains:
– 2 DPDT switches
– 2 potentiometers
– 1 ON/OFF switch

Remote Controller
 Camera
EKEN H9R

• 170 degree wide angle

• Built-in Wi-Fi
• 4K ultra HD video shooting.
• video quality with 1080p at 60 fps
• Remote Control Distance: 20m
Cad Assembly

Exploded View of Assembly CAD Model Assembly

 Device

Complete Assembly
 Inspection
• Tanks are 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.

• Inspections include detection of wall thickness, corrosion, wear and tear, cracks,
..blow holes, weld deterioration, leakages, etc.

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

mechanisms.
• Pan/Tilt (Visual Inspection)
•Slider
Pan/Tilt Mechanism (Visual Inspection)

Servo Bracket
Camera

Arduino Nano Servo Motor

Pan/Tilt Mechanism (Visual Inspection)

Circuit Diagram of Pan/Tilt Mechanism

EziCam Interface
 Slider Mechanism

Stepper Motor Slider Motor Driver Arduino UNO

Slider Mechanism
Step Calculation:

Step Angle = 1.8 Degree

No. of steps required per rotation = 360/1.8 = 200
Diameter of belt pulley = 12mm
Distance travelled by belt in each rotation of motor = 37.7mm
No. of rotations required to get desired belt travel =
(Stroke of slider)
No. of steps required to get desired belt travel (stroke of slider)
No. of rotations x No. of steps required per rotation
Example:
Stroke = 160mm

No. of rotations required to get desired belt travel = = 4.24

No. of steps required to get desired belt travel (stroke of slider) = 4.24 x 200 = 848
Schematic Of Working Setup
Actual Working Setup
Overall Dimensions
 Key Specification
Dimensions: 0.3x0.32m
Weight: 3.5kg
Adhesion: Neodymium Magnet wheels
Drive: DC geared motor
Drive wheels: Outer diameter 0.09m
Speed: 0.3 m/sec
Power supply: 12 Volt DC
Interface: Wired
Pay load: 4.5 kg
Camera: 4k action camera
Max. tether length: 2m
Wi-Fi range: 20m
Ground Clearance: 0.02m
Pan/tilt: 180 degree
 Future Scope
• Automation
• Interplaner transition
• Robotic arm
• Pipe inspection
• Locating device
• 3D Mapping
 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 specific obstacles”,

2008.

3. C. Rui, "A Gecko-Inspired Electro adhesive 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. Weimin Shen and Jason GuYanjunShen,”Permanent Magnetic System Design for the Wall-Climbing Robot”, Conference Paper in

Applied Bionics and Biomechanics, January 2006. 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.

6. B.Vishanth, S.Kathiravan, S.Giri Prasad, R.Raju, D.James Deepak “Analysis Of Wall Climbing Robot”, 2014.

7. Ayyagari D P Prudvi Raj ,DeviduttaNayak “Design And Development Of Wall Climbing Robot”, National Institute of technology,

Rourkela, 2014.
 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.