Professional Documents
Culture Documents
CHAPTER 01
INTRODUCTION
MGMCET 2013-14
Page 1
MGMCET 2013-14
Page 2
MGMCET 2013-14
Page 3
1.5.6 Mumbai water pipe lines, our robot can locate the exact location where the
crack is present:
This is our main objective of our project. It will be explain in next chapter PROBLEM
DEFINITION
1.6 CONCLUSION
In this chapter we discussed about just of our project topic & its definition and objectives
of our project.
MGMCET 2013-14
Page 4
CHAPTER 02
PROBLEM DEFINITION
2.2NEED
2.2.1 Water pipe lines in MUMBAI:
The pipeline from main source has diameter about 3 to 4 meters after that it has
branches to supply water in different areas.
The big diameters pipelines are easily inspected by manually inspection. But
small diameter pipes which are in branches which has diameter up to 25 inch
which is critical to inspect.
MGMCET 2013-14
Page 5
MGMCET 2013-14
Page 6
2.4 CONCLUSION
In this chapter we highlighted problem definition and try to bold our solution and clarify
the path of our aims related with project.
MGMCET 2013-14
Page 7
CHAPTER 03
LITERATURE SURVEY
3.1 INTRODUCTION
Pipeline video inspection' is a form of telepresence used to visually inspect the
interiors of pipelines. A common application is to determine the condition of small
diameter sewer lines and household connection pipes.
Older sewer lines of small diameter, typically 6-inch (150 mm), are made by the
union of a number of short 3 feet (0.91 m) sections. The pipe segments may be made
of cast iron, with 12 feet (3.7 m) to 20 feet (6.1 m) sections, but are more often made
of vitrified clay pipe (VCP), a ceramic material, in 3 feet (0.91 m), 4 feet (1.2 m) & 6 feet
(1.8 m) sections. Each iron or clay segment will have an enlargement (a "bell") on one
end to receive the end of the adjacent segment. Roots from trees and vegetation may
work into the joins between segments and can be forceful enough to break open a larger
opening in terra cotta or corroded cast iron. Eventually a root ball will form that will
impede the flow and this may cleaned out by a cutter mechanism and subsequently
inhibited by use of a chemical foam - a rooticide.
With modern video equipment the interior of the pipe may be inspected - this is a
form of non-destructive testing. A small diameter collector pipe will typically have a
cleanout access at the far end and will be several hundred feet long, terminating at
a manhole. Additional collector pipes may discharge at this manhole and a pipe (perhaps
of larger diameter) will carry the effluent to the next manhole, and so forth to a pump
station or treatment plant.
MGMCET 2013-14
Page 8
MGMCET 2013-14
Page 9
MGMCET 2013-14
Page 10
MGMCET 2013-14
Page 11
MGMCET 2013-14
Page 12
MGMCET 2013-14
Page 13
3.2.6 Visual:
The visual portion of the inspection consists of observing visible features and
cracks that indicate potential distress.
This inspection requires experienced staff to know which cracks are normal and
which are indicative of a problem. It also requires a thorough understanding of the
width and length of cracks that are normally produced during the production of
pipe as opposed to those that might indicate lack of prestressing, or distress, in the
pipe.
The visual inspection will also include an examination of the joints as well as the
width of joints or the amount of pull the pipeline was subjected to in order to
maintain line and grade. All anomalies will be noted with the distance and
location from known features. In many instances closure pieces, adapters, shorts,
and other specials are inserted in pipelines to make station on outlets and other
tie-in features.
MGMCET 2013-14
Page 14
MGMCET 2013-14
Page 15
MGMCET 2013-14
Page 16
3.4 CONCLUSION
In this chapter we discussed about the different technology used for pipe inspection &
different types of robot used in pipe inspection.
MGMCET 2013-14
Page 17
CHAPTER 04
WORKING PRINCIPLE OF PIPE INSPECTION ROBOT
4.1.1.2Motor:
Motor is used for them to give motion to the wheel and to open and close the robot
position to adjust the self position according to inner diameter of pipe.
There are total 8 motors. Out of which 6 motors are used for to travel the
mechanism and remaining two motors are used for to maintain open and closed position
with the help of screw.
MGMCET 2013-14
Page 18
4.1.1.5 Link no 1
This one part of the mechanism and it welded to the collar as shown in figure and it
moves with collar in horizontal position. It joins with link no 2. The joint is not fixed. It
is movable for the purpose of open and close motion.
4.1.1.6 Link no 2
This is one part of the mechanism which joints between link no 1 & 3.
4.1.1.7 Link no 3
This is one part of the mechanism which is supported by the link no 2 & 4. This is
important link because motor and wheel are mounted on it as shown in figure.
4.1.1.8 Link no 4
This is fixing link on collar no 2 by welding. During motion transfer it is in fixed
position. It supports to the link no 3.
4.1.1.9 Collar no 2:
This is only used for to support the screw and link no 4
MGMCET 2013-14
Page 19
Page 20
MGMCET 2013-14
Page 21
4.3 CONCLUSION
Here we learned the different parts of robot their construction and working principal.
MGMCET 2013-14
Page 22
CHAPTER 05
DESCRIPTION OF ELECTRICAL COMPONENTS
MGMCET 2013-14
Page 23
MGMCET 2013-14
Page 24
MGMCET 2013-14
Page 25
MGMCET 2013-14
Page 26
5.1.5.1 VCC
Supply voltage.
5.1.5.2GND
Ground.
5.1.5.3 Port 0
Port 0 is an 8-bit open drain bi-directional I/O port. As an output port, each pin can sink
eight TTL
Inputs. When 1s are written to port 0 pins, the pins can be used as high-impedance inputs.
Port 0 can also be configured to be the multiplexed low-order address/data bus during
accesses to external program and data memory. In this mode, P0 has internal pull-ups.
Port 0 also receives the code bytes during Flash programming and outputs the code bytes
during program verification. External pull-ups are required during program verification.
5.1.5.4 Port 1
Port 1 is an 8-bit bi-directional I/O port with internal pull-ups. The Port 1 output buffers
can
Sink/source four TTL inputs. When 1s are written to Port 1 pins, they are pulled high by
the internal pull-ups and can be used as inputs. As inputs, Port 1 pins that are externally
being pulled low will source current (IIL) because of the internal pull-ups. Port 1 also
receives the low-order address bytes during Flash programming and verification.
MGMCET 2013-14
Page 27
5.1.5.5 Port 2
Port 2 is an 8-bit bi-directional I/O port with internal pull-ups. The Port 2 output buffers
can
sink/ source four TTL inputs. When 1s are written to Port 2 pins, they are pulled high by
the internal pull-ups and can be used as inputs. As inputs, Port 2 pins that are externally
being pulled low will source current (IIL) because of the internal pull-ups. Port 2 emits
the high-order address byte during fetches from external program memory and during
accesses to external data memory that use 16-bit addresses (MOVX @ DPTR). In this
application, Port 2 uses strong internal pull-ups when emitting 1s. During accesses to
external data memory that use 8-bit addresses (MOVX @ RI), Port 2 emits the contents
of the P2 Special Function Register. Port 2 also receives the high-order address bits and
some control signals during Flash programming and verification.
5.1.5.6 Port 3
Port 3 is an 8-bit bi-directional I/O port with internal pull-ups. The Port 3 output buffers
can
sink/ source four TTL inputs. When 1s are written to Port 3 pins, they are pulled high by
the interPort Pin Alternate Functions
P1.5 MOSI (used for In-System Programming)
P1.6 MISO (used for In-System Programming)
MGMCET 2013-14
Page 28
5.1.5.7 RST
Reset input. A high on this pin for two machine cycles while the oscillator is running
resets
the device. This pin drives High for 98 oscillator periods after the Watchdog times out.
The DISRTO bit in SFR AUXR (address 8EH) can be used to disable this feature. In the
default state of bit DISRTO, the RESET HIGH out feature is enabled.
5.1.5.8 ALE/PROG
Address Latch Enable (ALE) is an output pulse for latching the low byte of the address
during
MGMCET 2013-14
Page 29
5.1.5.9 PSEN
Program Store Enable (PSEN) is the read strobe to external program memory. When the
AT89S51 is executing code from external program memory, PSEN is activated twice
each machine cycle, except that two PSEN activations are skipped during each access to
external data memory.
5.1.5.10 EA/VPP
External Access Enable. EA must be strapped to GND in order to enable the device to
fetch
code from external program memory locations starting at 0000H up to FFFFH. Note,
however,
that if lock bit 1 is programmed, EA will be internally latched on reset.
EA should be strapped to VCC for internal program executions.
This pin also receives the 12-volt programming enable voltage (VPP) during Flash
programming.
MGMCET 2013-14
Page 30
5.1.5.12 XTAL2
Output from the inverting oscillator amplifier
Oscillator Characteristics
XTAL1 and XTAL2 are the input and output, respectively, of an inverting amplifier that
can be
Configured for use as an on-chip oscillator, as shown in Figure 11-1. Either a quartz
crystal or
Ceramic resonator may be used. To drive the device from an external clock source,
XTAL2
Should be left unconnected while XTAL1 is driven, as shown in Figure 11-2. There are
no
Requirements on the duty cycle of the external clock signal, since the input to the internal
clocking
Circuitry is through a divide-by-two flip-flop, but minimum and maximum voltage high
and low
Time specifications must be observed.
Figure shows Oscillator Connections
C2
MGMCET 2013-14
Page 31
Program Memory
If the EA pin is connected to GND, all program fetches are directed to external memory.
On the AT89S51, if EA is connected to VCC, program fetches to addresses 0000H
through FFFH are directed to internal memory and fetches to addresses 1000H through
FFFFH are directed to external memory.
Data Memory
The AT89S51 implements 128 bytes of on-chip RAM. The 128 bytes are accessible via
direct
and indirect addressing modes. Stack operations are examples of indirect addressing, so
the 128 bytes of data RAM are available as stack space.
MGMCET 2013-14
Page 32
5.2 RELAY
5.2.1 Introduction:
A relay is an electrically operated switch. Many relays use an electromagnet to
operate a switching mechanism, but other operating principles are also used. Relays find
applications where it is necessary to control a circuit by a low-power signal, or where
several circuits must be controlled by one signal. The first relays were used in long
distance telegraph circuits, repeating the signal coming in from one circuit and retransmitting it to another. Relays found extensive use in telephone exchanges and early
computers to perform logical operations. A type of relay that can handle the high power
required to directly drive an electric motor is called a contactor. Solid-state relays control
power circuits with no moving parts, instead using a semiconductor device to perform
switching. Relays with calibrated operating characteristics and sometimes multiple
operating coils are used to protect electrical circuits from overload or faults; in modern
electric power systems these functions are performed by digital instruments still called
"protection relays
Page 33
MGMCET 2013-14
Page 34
MGMCET 2013-14
Page 35
MGMCET 2013-14
Page 36
MGMCET 2013-14
Page 37
5.2.4 Applications:
Relays are used to and for:
Control a high-voltage circuit with a low-voltage signal, as in some types of
modems or audio amplifiers,
Control a high-current circuit with a low-current signal, as in the starter solenoid
of an automobile,
Detect and isolate faults on transmission and distribution lines by opening and
closing circuit breakers (protection relays),
MGMCET 2013-14
Page 38
Contact sequence "Make before Break" or "Break before Make". For example,
the old style telephone exchanges required Make-before-break so that the
connection didn't get dropped while dialing the number.
Rating of contacts small relays switch a few amperes, large contactors are rated
for up to 3000 amperes, alternating or direct current
Voltage rating of contacts typical control relays rated 300 VAC or 600 VAC,
automotive types to 50 VDC, special high-voltage relays to about 15 000 V
Coil voltage machine-tool relays usually 24 VAC, 120 or 250 VAC, relays for
switchgear may have 125 V or 250 VDC coils, "sensitive" relays operate on a few
mill amperes
Coil current
Assembly Some relays feature a sticker that keeps the enclosure sealed to allow
PCB post soldering cleaning, which is removed once assembly is complete.
Mounting sockets, plug board, rail mount, panel mount, through-panel mount,
enclosure for mounting on walls or equipment
"Dry" contacts when switching very low level signals, special contact materials
may be needed such as gold-plated contacts
Coil protection suppress the surge voltage produced when switching the coil
current
MGMCET 2013-14
Page 39
Regulatory approvals
Stray magnetic linkage between coils of adjacent relays on a printed circuit board.
5.3 DC MOTOR
5.3.1 Introduction & working principle:
A DC motor relies on the fact that like magnet poles repels and unlike magnetic
poles attracts each other. A coil of wire with a current running through it generates
a electromagnetic field aligned with the center of the coil. By switching the current on or
off in a coil its magnet field can be switched on or off or by switching the direction of the
current in the coil the direction of the generated magnetic field can be switched 180. A
simple DC motor typically has a stationary set of magnets in the stator and an
armature with a series of two or more windings of wire wrapped in insulated stack slots
around iron pole pieces (called stack teeth) with the ends of the wires terminating on
a commutator. The armature includes the mounting bearings that keep it in the center of
the motor and the power shaft of the motor and the commutator connections. The
winding in the armature continues to loop all the way around the armature and uses either
single or parallel conductors (wires), and can circle several times around the stack teeth.
The total amount of current sent to the coil, the coil's size and what it's wrapped around
dictate the strength of the electromagnetic field created.
The sequence of turning a particular coil on or off dictates what direction the
effective electromagnetic fields are pointed. By turning on and off coils in sequence a
rotating magnetic field can be created. These rotating magnetic fields interact with the
magnetic fields of the magnets (permanent or electromagnets) in the stationary part of the
motor (stator) to create a force on the armature which causes it to rotate. In some DC
motor designs the stator fields use electromagnets to create their magnetic fields which
MGMCET 2013-14
Page 40
motor can be controlled by changing the voltage applied to the armature. The
introduction of variable resistance in the armature circuit or field circuit allowed speed
control. Modern DC motors are often controlled by power electronics systems which
adjust the voltage by "chopping" the DC current into on and off cycles which have an
effective lower voltage.
Since the series-wound DC motor develops its highest torque at low speed, it is
often used in traction applications such as electric. The DC motor was the mainstay of
electric traction drives on both electric and diesel-electric locomotives, street-cars/trams
and diesel electric drilling rigs for many years. The introduction of DC motors and
an electrical grid system to run machinery starting in the 1870s started a new second
Industrial Revolution. DC motors can operate directly from rechargeable batteries,
providing the motive power for the first electric vehicles and today's hybrid
cars and electric cars as well as driving a host of cordless tools. Today DC motors are still
found in applications as small as toys and disk drives, or in large sizes to operate steel
rolling mills and paper machines.
If external power is applied to a DC motor it acts as a DC generator, a dynamo.
This feature is used to slow down and recharge batteries on hybrid car and electric cars or
to return electricity back to the electric grid used on a street car or electric powered train
line when they slow down. This process is called regenerative braking on hybrid and
electric cars. In diesel electric locomotives they also use their DC motors as generators to
MGMCET 2013-14
Page 41
Page 42
5.4 BATTERY
5.4.1 Introduction
The leadacid battery was invented in 1859 by French physicist Gaston
Plant and is the oldest type of rechargeable. Despite having a very low energy-to-weight
ratio and a low energy-to-volume ratio, its ability to supply high surge currents means
that the cells have a relatively large power-to-weight ratio. These features, along with
their low cost, make it attractive for use in motor vehicles to provide the high current
required by automobile starter motors.
As they are inexpensive compared to newer technologies, lead-acid batteries are
widely used even when surge current is not important and other designs could provide
higher energy densities. Large-format lead-acid designs are widely used for storage in
backup power supplies in cell phone towers, high-availability settings like hospitals,
and stand-alone power systems. For these roles, modified versions of the standard cell
may be used to improve storage times and reduce maintenance requirements.
This battery provides 6V in our project. We want 12 volt requirement. So, we
connected two batteries in series.
MGMCET 2013-14
Page 43
5.5 TRANSISTOR
A transistor is a semiconductor device used
to amplify and switch electronic signals and electrical power. It is composed of
semiconductor material with at least three terminals for connection to an external circuit.
A voltage or current applied to one pair of the transistor's terminals changes the current
through another pair of terminals. Because the controlled (output) power can be higher
than the controlling (input) power, a transistor can amplify a signal. Today, some
transistors are packaged individually, but many more are found embedded in integrated
circuits.
The transistor is the fundamental building block of modern electronic devices, and
is ubiquitous in modern electronic systems. Following its development in 1947 by John
Bardeen, Walter Brattain, and William Shockley, the transistor revolutionized the field of
electronics, and paved the way for smaller and cheaper radios, calculators,
and computers, among other things. The transistor is on the list of IEEE milestones in
electronics, and the inventors were jointly awarded the 1956 Nobel Prize in Physics for
their achievement.
5.6 CRYSTAL
5.6.1 Description:
Crystals are commonly used to provide a stable clock source for microcontrollers. This has a freq. tolerance of +-50ppm, temperature stability of +-50ppm, and
load capacitance of 18pF. It's slightly more than 1/8" tall.
5.6.2 More information and instructions:
Spec sheet: here (ABL type)
MGMCET 2013-14
Page 44
MGMCET 2013-14
Page 45
5.7 TRANSFORMER
5.7.1 Working principal:
A transformer is an electrical device that transfers energy between two circuits
through electromagnetic induction. A transformer may be used as a safe and
efficient voltage converter to change the AC voltage at its input to a higher or lower
voltage at its output. Other uses include current conversion, isolation with or witho ut
changing voltage and impedance conversion.
A transformer most commonly consists of two windings of wire that are wound
around a common core to provide tight electromagnetic coupling between the windings.
The core material is often a laminated iron core. The coil that receives the electrical input
energy is referred to as the primary winding, while the output coil is called the secondary
winding.
An alternating electric current flowing through the primary winding (coil) of a
transformer generates a varying electromagnetic field in its surroundings which causes a
varying magnetic flux in the core of the transformer. The varying electromagnetic field in
the vicinity of the secondary winding induces an electromotive force in the secondary
winding, which appears a voltage across the output terminals. If a load impedance is
connected across the secondary winding, a current flows through the secondary winding
drawing power from the primary winding and its power source.
A transformer cannot operate with direct current; although, when it is connected
to a DC source, a transformer typically produces a short output pulse as the current rises.
5.7.2 Applications:
Transformers perform voltage conversion; isolation protection; and impedance
matching. In terms of voltage conversion, transformers can step-up voltage/step-down
current from generators to high-voltage transmission lines, and step-down voltage/step-up
current to local distribution circuits or industrial customers. The step-up transformer is
used to increase the secondary voltage relative to the primary voltage, whereas the stepdown transformer is used to decrease the secondary voltage relative to the primary
MGMCET 2013-14
Page 46
5.9 CONCLUSION
In this chapter we discussed about different type of electrical components which we used
in our academic project.
MGMCET 2013-14
Page 47
CHAPTER 06
SENSOR
6.1 INTRODUCTION
In our project we used two sensors for general purpose use of our robot. First one
is gas sensor and another is temperature sensor.
A sensor is a physical device or biological organ that detects, or senses, a signal or
physical condition and chemical compounds.
6.2 OVERVIEW
Most sensors are electrical or electronic, although other types exist. A sensor is a
type of transducer. Sensors are either direct indicating (e.g. a mercury thermometer or
electrical meter) or are paired with an indicator (perhaps indirectly through an analog to
digital converter, a computer and a display) so that the value sensed becomes human
readable. In addition to other applications, sensors are heavily used in medicine, industry
and robotics. Technical progress allows more and more sensors to be manufactured with
MEMS technology. In most cases this offers the potential to reach a much higher
sensitivity. See also MEMS sensor generations.
MGMCET 2013-14
Page 48
metal detectors
gas and liquid flow sensors: flow sensor, anemometer, flow meter, gas meter,
water meter, mass flow sensor
Page 49
MGMCET 2013-14
Page 50
6.4.3 Advantage:
From the point of view of temperature measurement applications, NTC types are used far
more than PTC ones. Due to its characteristics, PTC types are more frequently used as
thermostats to sense and regulate temperatures (inside ovens, for instance).
Main advantages of (NTC) thermistors are:
Small size
Inexpensive
High stability
6.4.4 Disadvantage:
Main disadvantages of thermistors are:
Non-linear
MGMCET 2013-14
Page 51
MGMCET 2013-14
Page 52
(2.3)
where:
1. RT is the zero-power R at T(K),
2. R0 is the zero-power R at a known temperature T0,
3. is the material constant for the thermistor.
Note: zero-power resistance is the resistance of a thermistor at a temperature measured
when there is negligible self-heating (due to Joules effect).
Alternatively, the following Steinhart-Hart equation can be used for computation of
temperature, giving relatively accurate thermistor curves:
(2.4)
where:
1. T is the temperature in K;
MGMCET 2013-14
Page 53
MGMCET 2013-14
Page 54
6.6 CONCLUSION
In this chapter we discussed about different type of sensors and deeply learned
temperature and gas sensor.
MGMCET 2013-14
Page 55
CHAPTER 07
DESIGN
7.1 DEFINITION
Machine Design or Mechanical Design can be defined as the process by which
resources or energy is converted into useful mechanical forms, or the mechanisms so
as to obtain useful output from the machines in the desired form as per the needs of
the human beings.
Machine Design is the application of: mathematics, kinematics, statics, dynamics,
mechanics of materials, engineering materials, mechanical technology of metals and
engineering drawing.
Machine design can lead to the formation of the entirely new machine or it can lead
to up-gradation or improvement of the existing machine.
It also involves application of other subjects like thermodynamics, electrical
theory, hydraulics, engines, turbines, pumps etc. Machine drawing is the integral
part of the machine design, since all the components or the machines that have
been designed should be drawn to manufacture them as per the specifications.
Without machine drawing the subject of machine design is incomplete.
MGMCET 2013-14
Page 56
8 inch
12 inch
2. After that we make a rough simulation model on paper and take idea about perfect
dimension and material available in market.
3. We did a market survey and check availability.
4. We make another simulation model which is more perfect than previous one and
check it for our inspection range.
5. After confirms the inspection range we did force and motion analysis.
6. Check out whole assembly for different type of stresses.
7. Change the model where require as per assembly and durability point of view.
8. Decide the clearance where require.
MGMCET 2013-14
Page 57
70mm
Thickness of plate
3mm
Height of plate
18mm
MGMCET 2013-14
Page 58
PARTS
MASS
WEIGHT
Gram
Link 1
110
1.1
Link 2
150
1.5
Link 3
280
2.8
Link 4
210
2.1
Motor
150
1.5
Wheel
70
0.7
25
0.25
Collar 1
150
1.5
Screw
250
2.5
10
150
1.5
wheel
= 1.5 + 0.25 + 0.7
MGMCET 2013-14
Page 59
MGMCET 2013-14
Page 60
Indication
+ve
-ve
Clockwise +ve
Anticlockwise
-ve
MGMCET 2013-14
Page 61
ANS (N)
RASIN66
-36.905
RBSIN66
27.57
RA
-40.39
RB
30.1
6mm
5.82mm
MGMCET 2013-14
Page 62
P/A
0.75 N/mm2
= 36.905 30
= 1107.15 N-mm
= 6.125 77
= 471.625 N-mm
Y = 18/2 = 9mm
I = bd3 /12
(b= 3mm,
d=18mm)
= 1485 mm4
MGMCET 2013-14
Page 63
12mm
5. No of starts
6. Coefficient of friction
tan = 0.1
Diameter
30mm
Bore diameter
M12
Length
18mm
1 N/mm2
Total weight lift by screw = ( (Weight of motor + weight of nut, bolt & other
accessories + weight of wheel + weight of link 1 + weight of link 2 + weight of link 3
+ weight of link 4 ) 3) + weight of round nut and collar
= ((1.5 + 0.25 + 0.7 + 1.1 + 1.5 +2.8 +2.1) 3) + 1.5
= 31.35 N
MGMCET 2013-14
Page 64
= 11 mm
= Lead / ( / d)
= 0.1157
= Ft (d / 2)
= 37.62 N-mm = 37.62 10 -3 N-m
=do pitch
= 10 mm
MGMCET 2013-14
Page 65
=W/A
= 31.35 / 78.53
= 0.39 N/mm2
= (16 T) / ( dc3)
= 0.91 N/mm2
= 0.5 ( c2 + 4 s2)
= 0.93 N/mm2
= Pitch / 2
= 1 mm
Pb
= w / (dtn)
= 0.1 N/mm2
MGMCET 2013-14
Page 66
Design of welding at the junction where 20 mm diameter sliding contact bearing is weld
to 45 mm diameter circular plate.
Basic assumption
1. The weld portion is subjected to bending moment when the total load act at the
end point of section.
2. S = 5mm
So throat thickness (t)
t
= 0.707 S
MGMCET 2013-14
Page 67
=P/A
= P e (e = 88mm)
= 2978.8 N-mm
= (tD2) / 4
= 1110.553 mm3
=M/Z
= 2.68 N/mm2
MGMCET 2013-14
Page 68
MGMCET 2013-14
Page 69
Ixx
= MI of ABCD MI of EFGH
= ((65 523) / 12) ((62 463 ) / 12)
= 258724 mm4
= IG1 2 + a1h12
= ((3 65 3) /12) + (195 8.112)
= 81481.8095 mm4
Iyy2
= IG2 2 + a2h2 2
= ((46 3 3) /12) + (138 22.89 2)
= 72408.8898 mm4
Iyy
MGMCET 2013-14
Page 70
=P/A
= ( / 4) d2. (d = 6 mm)
=28.27 mm2
remaining accessories) 2
Weight of other remaining accessories = 5N assume
= (31.35 + 2.5 + 1.5 + 5) 2
= 80.7 N
MGMCET 2013-14
Page 71
=P/A
= P / (d 6)
= 2.77 N/mm2
18 mm
12 mm
L/D = 1.5
So consider infinity range from PSG design data book
Load = P = (weight of link 4 3) + weight of motor
Note: the weight of motor is added for additional factor of safety
P
= (2.1 3) + 1.5
= 7.8 N
MGMCET 2013-14
Page 72
Maximum clearance
Minimum clearance
MGMCET 2013-14
Page 73
Clearance ratio
= Cavg / D
= 0.1275
MGMCET 2013-14
Page 74
Let
Calculation of collar no 1 in X direction
X = Angle of link no 3 with respect to its original position
Y = Distance in X direction (from point A as shown in simulation model
Y1 = 38 mm
X0 = 110
Y0 = 9.5 mm
MGMCET 2013-14
Page 75
7.15 CONCLUSION
In this chapter we totally derive the forces on the linkages and try to make perfect design
for manufacturing purpose. We design here different parts of robot with specific standard
assumption and in next chapter we evaluate the material selection for robot.
MGMCET 2013-14
Page 76
CHAPTER 08
MATERIAL SELECTION
8.1 INTRODUCTION
The proper selection of material for the different part of a machine is the main
objective in the fabrication of machine. For a design engineer it is must that he be
familiar with the effect, which the manufacturing process and heat treatment have on the
properties of materials. The Choice of material for engineering purposes depends upon
the following factors
1. Availability of the materials.
2. Suitability of materials for the working condition in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.
MGMCET 2013-14
Page 77
MGMCET 2013-14
Page 78
MGMCET 2013-14
Page 79
8.6 CONCLUSION
In this chapter we learned different type of material properties and with the help of this
properties how to select the material as per availability. Finally we select the MILD
STEEL with the help of design chapter.
MGMCET 2013-14
Page 80
CHAPTER 09
MANUFACTURING
9.1 INTRODUCTION
Manufacturing involved in conversion of race material into the finished product
used for some useful purpose
To understand the manufacturing system in better way, it is divided into three
parts.
1. input
2. process
3. output
Mean
Process
Material
machined
Product
Service
MGMCET 2013-14
Page 81
PART NAME
Link 1
3 18 mm plate
Link 2
3 18 mm plate
Link 3
3 18 mm plate
Link 4
3 18 mm plate
Collar 1
32 mm diameter rod
Collar 2
20 mm diameter rod
C channel
3 18 mm plate
Circular plate
48 mm diameter rod
Screw
14 mm diameter rod
NO
MGMCET 2013-14
Page 82
Description
Machine
of Operation
used
Cutting
Bench vice
Hacksaw
Filing
Bench vice
File
Marking
Sr no
Drilling
Grinding
MGMCET 2013-14
Tool used
Measuring
Time
instrument
(minute)
Steel rule
30
24
Punch,
Vernier
hammer
caliper
Vertical
Drill of
Vernier
drilling
6mm
caliper
machine
diameter
Grinding
Grinding
machine
wheel
18
12
12
Page 83
Description
Machine
of Operation
used
Cutting
Bench vice
Hacksaw
Filing
Bench vice
File
Marking
Sr no
Drilling
Grinding
MGMCET 2013-14
Tool used
Measuring
Time
instrument
(minute)
Steel rule
30
24
Punch,
Vernier
hammer
caliper
Vertical
Drill of
Vernier
drilling
6mm
caliper
machine
diameter
Grinding
Grinding
machine
wheel
18
24
24
Page 84
Description
Machine
of Operation
used
Cutting
Bench vice
Hacksaw
Filing
Bench vice
File
Marking
Sr no
Drilling
Grinding
MGMCET 2013-14
Tool used
Measuring
Time
instrument
(minute)
Steel rule
30
24
Punch,
Vernier
hammer
caliper
Vertical
Drill of
Vernier
drilling
6mm
caliper
machine
diameter
Grinding
Grinding
machine
wheel
18
24
24
Page 85
Description
Machine
of Operation
used
Cutting
Bench vice
Hacksaw
Filing
Bench vice
File
Marking
Sr no
Drilling
Grinding
MGMCET 2013-14
Tool used
Measuring
Time
instrument
(minute)
Steel rule
30
24
Punch,
Vernier
hammer
caliper
Vertical
Drill of
Vernier
drilling
6mm
caliper
machine
diameter
Grinding
Grinding
machine
wheel
18
12
12
Page 86
Description
Machine
of Operation
used
Facing
Lathe
Turning
Drilling
Sr no
Measuring
Time
instrument
(minute)
Carbide tool
Lathe
Carbide tool
Lathe
Center drill
Tool used
of 12mm
diameter
4
Parting
MGMCET 2013-14
Lathe
Parting
Page 87
Description
Machine
of Operation
used
Facing
Lathe
Turning
Drilling
Sr no
Measuring
Time
instrument
(minute)
Carbide tool
Lathe
Carbide tool
Lathe
Center drill
Tool used
of 12mm
diameter
4
Parting
MGMCET 2013-14
Lathe
Parting
Page 88
Description
Machine
of Operation
used
Cutting
Bench vice
Bending
Bench vice
Sr no
MGMCET 2013-14
Measuring
Time
instrument
(minute)
Hacksaw
Steel rule
Hammer
Steel rule
Tool used
Page 89
Description
Machine
of Operation
used
Facing
Lathe
Turning
Drilling
Sr no
Measuring
Time
instrument
(minute)
Carbide tool
Lathe
Carbide tool
Lathe
Center drill
Tool used
of 12mm
diameter
4
Parting
MGMCET 2013-14
Lathe
Parting
Page 90
Machine
of Operation
used
Facing
Lathe
Turning
Threading
Sr no
Measuring
Time
instrument
(minute)
Carbide tool
Lathe
Carbide tool
10
Lathe
Outer
16
Tool used
threading
tool
(square
thread)
2mm pitch
4
Parting
Lathe
Parting
9.5 CONCLUSION
In this chapter we studied different parts of robot, their manufacturing process with
proper sequence.
MGMCET 2013-14
Page 91
CHAPTER 10
BUDGET ESTIMATION
10.1 INTRODUCTION
Cost estimation may be defined as the process of forecasting the expenses that
must be incurred to manufacture a product. These expenses take into a consideration all
expenditure involved in a design and manufacturing with all related services facilities
such as pattern making, tool, making as well as a portion of the general administrative
and selling costs.
MGMCET 2013-14
Page 92
Page 93
MGMCET 2013-14
Page 94
MGMCET 2013-14
Page 95
COMPONENT
QTY.
COST/UNIT
TOTAL
Motor
250
2000
Battery
500
1000
Camera
2000
2000
Crystal
20
20
Pipe
2000
2000
LCD
200
200
89s51
100
100
350
350
Relay
18
72
Wheel
80
480
Material
10m
IC base
10
10
Ic-adc0808
100
100
Thermistor
20
20
Switch
15
15
TOTAL
MGMCET 2013-14
500
9497
Page 96
MACHINE
TIME IN
RATE
HOURS
IN RS.
OPERATION
RUPEES
Welding machine
120
240
Drilling machine
80
Making holes
80
Grinding machine
80
Cutting machine
80
Finishing the
components
Parting off objects
TOTAL
80
80
480
AMOUNT
OPERATION
HOURS
RATE/HOUR
Welding
75
150
Drilling
50
50
Grinding
50
50
Cutting
50
50
100
300
NO.
TOTAL
MGMCET 2013-14
PAID
600
Page 97
TYPE OF COST
COST (RS)
Different parts
9497
Machine cost
480
Labor cost
600
1500
12077
10.9 CONCLUSION
In this chapter we discussed about different type of costing and evaluate the final cost of
product.
MGMCET 2013-14
Page 98
CHAPTER 11
ADVANTAGE & LIMITATION OF PROJECT AND ITS
FUTURE SCOPE
11.1 ADVANTAGES
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.
11.2 LIMITATION
Pipe inspection robots have such limitations as their ability to turn in a T-shaped
pipe or move in a plug valve.
Another drawback of earlier robots is that the friction between the pipe and the
cables for communication and power supply makes it difficult to move a long
distance. A fiber optic communication system can reduce the friction.
This robot does not work in water.
This robot works only in empty pipe.
MGMCET 2013-14
Page 99
11.3.3 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.
MGMCET 2013-14
Page 100
MGMCET 2013-14
Page 101
11.4 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 inpipe 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-304mm 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.
MGMCET 2013-14
Page 102
CHAPTER 12
BIBLIOGRAPHY
Following different references we have taken to make our project success one:
MACHINE DESIGN-------------------------------------------------------R S KHURMI
MGMCET 2013-14
Page 103