PROPOSAL FOR STUDENT INNOVATIVE PROJECTS

TITLE : AN ALL TERRAIN,NEGATIVE PRESSURE CUM MAGNETIC ADSORPTION WALL CLIMBING ROBOT FOR INSPECTION AND CRACK DETECTION

BY, R.JAI KARTHIK 2011507025 A.GERAD AMBROSE 2011507016 G.VENKATAKRISHNAN 2011507054

UNDER THE GUIDANCE OF

Dr.R.Sivaramakrishnan Associate Professor, Department of ProductionTechnology, Anna University, MIT Campus.

Mr.M.Thirumalazhagan Assistant Professor, Department of Production Technology, Anna University, MIT Campus.

OBJECTIVE OF THE PROJECT :

The traversing and inspection of large vertical and over-head surfaces with autonomous systems is still an unsolved problem. In this project, we aim to achieve a prototype of a wall-climbing robot which works on the principles of negative pressure adsorption and magnetic adhesion.

Why this project ???

As the main principles for this wall-climbing robot comprise of magnetic adsorption and underpressure adhesion, concepts like ROBOTICS and PNEUMATICS, which are some of our departments many areas of expertise, are covered. Also, if fortunately, this project gets selected and progresses smoothly till stage II, then we also have an option of using this robot for inspection, again where NON-DESTRUCTIVE-TESTING TECHNIQUES : another important part in our departments curriculum, will be covered. Also, the areas of application of this particular project, of which BOILER INSPECTION plays a major part, are also very much related to our department.

Scenario so far
WHY DO WE NEED CLIMBING ROBOTS??

Climbing robots are mainly adopted in places where direct access by a human operator is very expensive, because of the need for scaffolding, or if its very dangerous, due to the presence of an hostile environment. WHAT DO WE EXPECT FROM THESE ROBOTS??

These robots should be capable of travelling over different types of surfaces, with different inclinations, such as floors, walls, ceilings, and to walk between such surfaces. Regarding the adhesion to the surface, the robots should be able to produce a secure gripping force using a light-weight mechanism.

A wall climbing robot should, not only be light, but also have large payload, so that it may reduce excessive adhesion forces and carry instrumentations during navigation. Up to now a lot of research has been devoted to wallclimbing robots and various types of experimental models were already proposed. The major two issues in the design of wall climbing robots is their locomotion and adhesion methods. With respect to the locomotion type, three types are often considered : Crawler type Wheeled type Legged type According to the adhesion method, these robots are generally classified into three groups : Magnetic adhesion Negative pressure adhesion Gripping mechanism using claws or spikes Electro-adhesive mechanism

Electro-adhesion is still a technology that has not really been understood and is still at the first stage of development. Prototypes of robots incorporating this principle exist, e.g. Daltorio2005 (sticky robot), Rochat2011 (Thermal glue robot), but have not made it big in the market due to the high cost involved and maintenance issues. In case of clamping and gripping mechanism-based robots, the surface structure is very critical. These robots, e.g. Spenko2008, BretI2004, etc. depend heavily on the nature of the surface. There is always a very high risk involved here as the probability of the robot falling off from the wall-surface is very high.

Thermal glue robot [Rochat2011]

Sticky robot [Daltorio2005]

Ape-like lemur [Bretl2004]

Robot rise [Spenko200 8]

The Current Scenario

Thus, there is a huge demand for a wall-climbing robot which is: Light Fast Robust enough to carry payloads Able to traverse inclinations and multi-terrains. In case of boilers, we should be able to carry out the inspection during the run-time itself.

1. 2. 3. 4. 5.

So, this is where our project comes into picture. In this project, we aim to create such a robot that can meet the above pre-requisites.

Possible applications of this robot are inspection of external/internal surface of aboveground/underground petrochemical storage tanks, boilers, concrete walls, metallic structures and so on. In petrochemical storage tanks, due to the extremely corrosive petroleum that the tanks may contain, it is very important to perform periodic inspection at different rates In boilers, regular inspection is an important factor here to ensure the safety and reliability of these structures throughout the year. Any nonchalance can lead to loss of life in huge numbers.

Also with the implementation of the Metro Rail system in Chennai (CMRL) in the near future, these robots can also be used to traverse the long concrete pillars supporting the overhead rail lines and inspect them for cracks, etc. as that is a very critical area whose safety cannot be compromised.

PRINCIPLE(S):

This robot works on the basis of two main principles/ theories :

MAGNETIC ADHESION UNDER-PRESSURE ADSORPTION

MAGNETIC ADHESION technique includes electromagnets as well as permanent magnets, which are either positioned on the surface or kept with a certain distance away from it. Common applications of these systems are inspections, maintenance and construction work e. g. of high power poles, steel tanks, boilers or ship hulls. The principle is very reliable on ferromagnetic surfaces and it is able to create strong adhesion forces on a very small area.

NEGATIVE PRESSURE ADSORPTION technique can be distinguished between three different types: Passive suction cups, active suction chambers and a vortex system. The vortex system generates adhesive forces via a vortex inside of the robot. This vortex is created by a highspeed rotor and allows adhesion without additional sealing elements as needed by the cup-based systems.

HOW THE ROBOT WORKS :

The robot will look like any another all-terrain robot. The robot will have magnetic tracks around its wheels, which will enable it to traverse across ferromagnetic surfaces. The tracks will wind around the wheels like a loop and help them to adhere onto the surface below. Thus, by using those tracks, we incorporate the concept of MAGNETIC ADHESION. We then include the principle of NEGATIVE PRESSURE ADSORPTION by fashioning a vacuum engine out of a fan rotating at a high speed, fixed at the centre of the robot in an enclosure. The CENTRIFUGE fan, which is actuated by an external motor, rotates at a very high speed and creates a VORTEX in the gap between it and the surface below.

This vortex will cause a suction-effect (low pressure area) thereby creating a vacuum-region and enabling the robot to stick to the terrain. The wheels on the sides of the robot will help in the locomotion of the robot. While traversing on ferromagnetic surfaces, usage of the vacuum engine is not necessary, as the magnetic tracks by themselves will enable adhesion. The wheels will rotate by the help of motors fixed on the base of the robot. Thus, this is a WHEELEDDRIVE, MAGNETIC ADHESION, NEGATIVE PRESSURE ADSORPTION based climbing robot.

APLLICATIONS
Our robot can traverse vertically ,horizontally as well as overhead surfaces making it ideal for use in inspection of 1. Boilers 2. Pipe inspection in chemical systems 3. Ship cleaning/inspection (in dry dock) 4. Airplane cleaning and inspection 5. Nuclear plant inspection 6. Steel bridge inspection 7. Cleaning and inspection of glass wall

STANDOUT PROPERTIES

So what will make this robot to stand out from its earlier counter-parts? This robot, for starters, is a HYBRID because we incorporate both the concepts of magnetic adhesion and vortex mechanism. This model will be less bulky, and hence, fast. Compared to normal suction cups, let them be active or passive, this is a better option because : It uses vortex mechanism, so no need of a bulky vacuum pump

I.

II.

No need for any sealing mechanism, only some amount of clearance is enough
As theres no pump on-board, the pay-load carrying capacity of the robot increases. The absence of vacuum pump ensures elimination of excessive power consumption and hence ENERGY CONSERVATION Simple structure ensures that it is cheaper, lighter, faster and more effective. There are only a very few robots out in the industry that incorporate vortex mechanism for adhesion, and even less which use the combination of two adhesion techniques. Further more, in our country, this concept so far is almost new. Thus there is

III.

IV.

V.

FUTURE SCOPE

If this project succeeds in its main objective, i.e. wallclimbing, then in the next stage of the project, we can implement NONDESTRUCTIVE TESTING techniques and tailor the robot so that it detects cracks, and other surface defects. Sensors can be fitted on the robot so that it senses any possible cracks on the terrain and relays its coordinates to the controller below. If possible, we can also attempt to make the whole robot wireless and mount the battery too on it.

DURATION OF THE PROJECT

ACTION DURATION Literature Survey -3 weeks Development of robot prototype -3 weeks Incorporation of under pressure adhesion and magnetic adsorption -4 weeks Development of non-destructive technique to be employed 4weeks Fabrication -6 weeks Testing -4 weeks

COSTS :
ITEMS COST (IN RUPEES)

1) MATERIALS/ COMPONENTS/ FABRICATION a) Design and fabrication of mechanical components b) Electrical components and accessories c) Vehicle prototype and accessories TRAVEL

9250 9250 2500 1000

CONTINGENCIES

2500

TOTAL

24500

CONCLUSION :

A real-time prototype of an all-terrain, negative pressure cum magnetic adsorption based robot for navigation over horizontal, vertical and overhead surfaces irrespective of their materialistic nature and also for surface-inspection will be delivered at the end of the stipulated time.