DESIGN AND DEVELOPMENT OF PIPE CLIMBING

ROBOT
A PROJECT REPORT
Submitted by

Rohit Jasoliya : 20ME421

Hunaid Barodawala : 20ME425
Jay Rathod : 20ME020
Rayyan Mansuri : 20ME039

In partial fulfilment for the award of the degree

of
Bachelor of Technology
in
Mechanical Engineering

Prof. Ashish M Thakkar

Birla Vishvakarma Mahavidylaya

Engineering Collage (An Autonomous Institution)
Vallabh Vidyanagar - 388 120
Affiliated to Gujarat Technological University
November 2023
 DESIGN AND DEVLOPMENT OF PIPE CLIMBING ROBOT

CERTIFICATE

Date:

This is to certify that the Project entitled “DESIGN AND DEVELOPMENT

OF PIPE CLIMBING ROBOT” has been carried out by ROHIT JASOLIYA,
HUNAID BARODAWALA, JAY RATHOD, RAYYAN MANSURI in the VII
semester under my guidance in partial fulfilment of the degree of Bachelor of
Technology in Mechanical Engineering, Birla Vishvakarma Mahavidyalaya,
Vallabh Vidyanagar, during the academic year 2023-24.

Guide/s: Prof. Ashish M Thakkar

Dr. V. J. Patel

Head of the Department

Mechanical Engineering

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Originality Report Certificate

It is certified that Project Report titled DESIGN AND DEVELOPMENT OF PIPE

CLIMBING ROBOT by ROHIT JASOLIYA, HUNAID BARODAWALA, JAY RATHOD,
RAYYAN MANSURI has been examined by us. We undertake the following:
(1) Project has significant new work / knowledge as compared already published or are
under consideration to be published elsewhere. No sentence, equation, diagram,
table, paragraph, or section has been copied verbatim from previous work unless it
is placed under quotation marks and duly referenced.
(2) The work presented is original and own work of the author (i.e. there is no
plagiarism). No ideas, processes, results or words of others have been presented as
Author own work.
(3) There is no fabrication of data or results which have been compiled / analyzed.

(4) There is no falsification by manipulating research materials, equipment or

processes, or changing or omitting data or results such that the research is not
accurately represented in the research record.
(5) The report has been checked using <NAME OF ANY REPUTED PLAGIARISM
CHECK SOFTWARE> (copy of originality report attached) and found within
limits, (i.e., permitted similarity index <= 20 %)

Name and Signature of Students:

ROHIT JASOLIYA

HUNAID BARODAWALA

JAY RATHOD

RAYYAN MANSURI

ACKNOWLEDGEMENT
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 DESIGN AND DEVLOPMENT OF PIPE CLIMBING ROBOT

The submission of this project report provides an opportunity to express our heartfelt
gratitude to all those who have supported and guided us throughout this endeavour. Their
invaluable contributions have been instrumental in bringing this project to fruition.

We extend our deepest appreciation to the esteemed staff of the Mechanical Engineering
Department for their unwavering support and encouragement. We are particularly grateful to
Prof. Ashish M Thakkar and Prof. Dr. V. J. Patel, Head of the Mechanical Engineering
Department, Birla Vishvakarma Mahavidyalaya, for their guidance and mentorship.

We are also thankful for the opportunity to work on this inspiring project, which has provided
us with invaluable work experience before entering the corporate world. This experience has
allowed us to interact with experts in our field of study, gaining immensely from their
knowledge and guidance, not only for our project but also for navigating the corporate
environment.

ABSTRACT

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This project introduces an innovative Pipe Climbing Robot designed for diverse industrial
applications. The growing demand for efficient inspection and maintenance of industrial
pipelines has spurred the development of specialized robotic solutions. Our proposed robot
employs a two-phase approach, addressing key challenges in pipeline management.

In the first phase, advanced sensing technologies are utilized for accurate assessment of
pipeline conditions, enabling the detection of defects and gas leak. The integration of state-
of-the-art sensors ensures precise data collection in various industrial environments.

The second phase focuses on the robot's climbing mechanism, incorporating inventive
gripping and traction systems for navigating horizontal, vertical, and inclined pipe surfaces
with stability and precision.

The diverse industrial applications of this Pipe Climbing Robot range from routine
inspections to emergency maintenance tasks. Its ability to access hard-to-reach areas and
operate in hazardous conditions enhances worker safety while minimizing downtime and
operational costs for industrial facilities.

This project offers a comprehensive solution for enhancing the efficiency and reliability of
industrial pipe inspection and maintenance, positioning the robot as an asset in the realm of
industrial automation. The presented Pipe Climbing Robot demonstrates significant potential
to revolutionize the way industrial pipelines are managed, ensuring longevity and optimal
performance.

Table of Contents
1. INTRODUCTION........................................................................................7
1.1 Background..............................................................................................7
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 DESIGN AND DEVLOPMENT OF PIPE CLIMBING ROBOT

1.2 Problem statement....................................................................................8

1.3 Purpose of Project....................................................................................8
1.4 Research Gap...........................................................................................8
1.4 Methodology............................................................................................8
1.5 Features of the project prototype..............................................................9
2. LITERATURE SURVEY..........................................................................10
2.1 Literature Outcome................................................................................10
2.2 Brief History of Work............................................................................11
3. DESIGN OF PIPE CLIMBING ROBOT................................................12
3.1 Design Parameter...................................................................................12
3.2 Calculation.............................................................................................12
3.3 Design Software.....................................................................................13
3.4 CAD Model............................................................................................13
3.5 Equipment Used.....................................................................................15
4. INSPECTION BY PIPE CLIMBING ROBOT.......................................16
4.1 crack and leakage in chemical industries...............................................16
4.2 Causes of Crack......................................................................................16
4.3 Effects of Crack......................................................................................16
4.4 Need for Inspection................................................................................17
4.5 Ultrasonic Sensor...................................................................................17
4.6 Gas Sensor..............................................................................................18
5. MAINTANANCE BY PIPE CLIMBING ROBOT.................................19
5.1 Insulating Attachment...............................................................................19
5.2 Rust Removal Attachment........................................................................19
6. PRPTOTYPE OF PIPE CLIMBING ROBOT........................................21
7. IMPLEMENTATION................................................................................22
7.1 FURTHER SCOPE...................................................................................22
7.2 CONCLUSION.........................................................................................22

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1. INTRODUCTION
1.1 Background
The emergence of pipe climbing robots addresses challenges in industrial pipeline
inspection and maintenance, prompted by safety, efficiency, and cost concerns in traditional
methods. Safety issues associated with human intervention in complex and hazardous
environments drive the exploration of robotic alternatives. The extensive and intricate nature
of industrial pipelines, particularly in sectors like oil and gas, necessitates more efficient and
cost-effective solutions, motivating the development of pipe climbing robots. Integration of
advanced sensing technologies enhances the precision of pipeline assessment, detecting
defects and corrosion. Innovations in robotics, including materials and control systems,
enable climbing robots to navigate various pipe surfaces with stability. The overarching trend
toward industrial automation further propels the development of these robots, aligning with
the industry's pursuit of smart technologies to enhance productivity.

1.2 Problem statement

Design and develop a pipe climbing robot capable of autonomously navigating and
manoeuvring on various types of pipes.

The robot should be able to overcome challenges such as surface textures, and inclinations,
while ensuring stable adhesion and efficient movement.

The project aims to address the need for an innovative solution to inspect, maintain, and

repair pipelines, reducing the risks and costs associated with human intervention

1.3 Purpose of Project

Design and manufacturing of Pipe Climbing Robot that holds inspection and maintenance
facility for various industries.

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1.4 Research Gap

The proposed study aims to demonstrate the adaptability of a pipe climbing robot, stability,
into a smart connected system with real-time, internet-based capabilities for fault detection.
This research project seeks to address analogous questions for a pipe climbing robot:

a. Is it feasible to establish wireless real-time interconnectivity between a pipe

climbing robot and a mobile device connected to the internet?
b. Can the data collected by the pipe climbing robot be manipulated in real-
time?
c. To what extent can the data be interactively visualized in the third dimension
using Augmented Reality, and is it a practical approach for a pipe climbing
robot?

1.4 Methodology

Literature survey Prototyping and

Testing

Conceptualization
and requirements Assembly and
Programming
Mechanical
Design and Procurement of
Calculation Components

Electronics and
Sensor Selection

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1.5 Features of the project prototype

a. Issue Identification and Notification
b. Sensors and Inspection Technologies
c. Stable system
d. User friendly

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2. LITERATURE SURVEY
Up until this point in history, the team has come up with defining industrial revolutions. pipe
climbing robots were introduced to address pipeline maintenance challenges, emphasizing
climbing mechanisms and sensor integration. these robots experienced notable advancements
in sensing technologies, incorporating cameras, ultrasonic sensors, and gas detectors for
enhanced pipeline assessment. Subsequently, starting in 2012, there was a progressive
integration of wireless connectivity, artificial intelligence, and augmented reality, culminating
in the present focus on refining autonomy, adaptability, and safety features in the 2020s,
catering to diverse industrial applications. The industrial revolution is the one to which we
are contributing, involving human-machine communication, lesser cognitive load, and
increased level of automation across industries.

2.1 References
 P. Chattopadhyay, “Locomotion Methods of Pipe Climbing robots: A Review,”
Central Mechanical Engineering Research Institute, Durgapur 713209, India, p. 165,
2017.
 H. Y. H. C. S. J. X. Z. Q. W. G Chen, “Design of an embracing-type climbing robot
for variation diameter rod,” Emerald Publishing Limited, p. 140, 2019.
 J. L. &. F. Huang, “Elastic Obstacle-Surmounting Pipeline-Climbing Robot with
Composite Wheels,” Machines 2022, p. 874, 2022.
 S. H. Lee, “Design of the Out-pipe type Pipe Climbing Robot,” International Journal
of Precision Engineering and Manufacturing, p. 14, 2013
 Team BVM, Robofest 2.0 , Pipe Climbing Robot Category

2.2 Literature Outcome

 A comprehensive overview of a robot's design is presented, encompassing intricate
details of its mechanical, electrical, and control system designs. The primary
locomotion mechanism of the robot involves three independently controlled and
length-adjustable driving wheels, each equipped with rubber treads to enhance
traction, while an additional set of four support wheels aids in stabilizing the robot
and preventing slippage.

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 Adjustable frame for accommodating various pipeline sizes, elastic suspension

mechanisms for enhanced stability in the face of obstacles and vibrations, and
composite wheels optimized for superior traction and obstacle traversal.
 The pipe climbing robot is an innovative mechatronic system engineered to facilitate
comprehensive inspection and maintenance tasks within industrial pipelines.
Employing a modular design, the robot incorporates a series of articulated limbs
equipped with adaptive grippers, allowing it to navigate complex pipe geometries
with remarkable agility.
 Powered by a high-torque electric motor and integrated with precision sensors, the
robot ensures seamless traversal along the pipeline, autonomously adapting to
changes in diameter and orientation. Its sensor suite includes high-resolution cameras,
ultrasonic sensors, and thermal imaging devices, providing a comprehensive data set
for thorough inspection.

2.3 Brief History of Work

Our endeavour commenced with an in-depth analysis and assimilation of knowledge drawn
from a comprehensive research paper, serving as the cornerstone of our project. This
foundational research guided our initial design phase, where we meticulously crafted and
presented our conceptual blueprint during the 1st mid-semester examination. The invaluable
insights and constructive feedback from the esteemed panel of judges during this phase
proved instrumental in steering our direction for subsequent stages.

Following the critical feedback received, our team pivoted towards a focused phase of
iterative enhancement. Integrating the judges' comments, we embarked on refining and
optimizing our design, striving for greater efficiency and functionality. This phase marked a
crucial turning point as we transitioned from theoretical concepts to a more refined and
practically viable design.

Building upon our optimized design, our attention shifted towards the meticulous
procurement of materials and components. Aligning with the refined blueprint, this
procurement phase was characterized by a judicious selection process, ensuring the
acquisition of components best suited for the enhanced design. The culmination of this phase
was showcased during the 2nd mid-semester examination, where our evolved design, a
testament to iterative refinement, was presented with pride and confidence.

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 DESIGN AND DEVLOPMENT OF PIPE CLIMBING ROBOT

With the foundation laid by meticulous planning and design optimization, our team then
embarked on the pivotal stage of prototype development. This marked a transformative phase
where theoretical concepts crystallized into a tangible reality. Leveraging our optimized
design as a guide, we diligently constructed and fine-tuned the pipe climbing robot prototype.
This hands-on phase demanded a fusion of technical acumen, collaborative effort, and
problem-solving skills, leading to the creation of a functional and innovative prototype.

It's important to note that this journey, delineated by rigorous research, iterative design
refinement, and hands-on prototyping, forms the backbone of our upcoming final
examination presentation. Our commitment to each phase reflects our team's dedication,
resilience, and collaborative spirit in realizing a sophisticated and functional pipe climbing
robot. As we prepare to present our comprehensive report, our journey symbolizes not just a

project, but a testament to our growth, adaptability, and passion for engineering innovation.

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3. DESIGN OF PIPE CLIMBING ROBOT

3.1 Design Parameter
1. Body weight of robot
2. Frame dimension of robot
3. Features of robot
4. Material selection & availability
5. Method of manufacturing

3.2 Calculation F
Case: 1 Static Force Analysis

N = Normal Force

Mg = Gravitational Force

F = Friction force (µN) N

µN = mg (for robot to be static)

Case: 2 Dynamic Force Analysis

F - Fr – mg = ma mg

F = Force exerted by the Robot to move upward F

Fr = Force due to friction = µN

mg = Gravitational Force

Therefore,

F = ma + mg + µN

x = 1/2 × a×t^2 (When initial velocity is 0)

Now,

Torque τ = F × r

And mg+F
Power P = F × V

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 DESIGN AND DEVLOPMENT OF PIPE CLIMBING ROBOT

∴ P = (ma + mg + µN) × 𝝅𝑫𝑵/𝟔𝟎

Here,

D = Diameter of Wheel

N = rpm of Motor

3.3 Design Software

Design has been made in fusion 360 Student’s Edition. The attempt is to model pipe
climbing robot components, making the next step as accurate as possible.

3.4 CAD Model

Figure 1 CAD Model

Figure 2 Different Views

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3.5 Equipment Used

1. Mechanical components
 Acrylic
 Aluminium Extrusion (6063)
 Friction Wheel
 Spring
 Fasteners
2. Electronics components

 10 RPM 12 W DC motor
 Temperature sensor
 Gas sensor
 Battery (1300 mAh)

3. Software
 Fusion 360
 Arduino IDE

4 Programming language

 Basic python
 Arduino

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 DESIGN AND DEVLOPMENT OF PIPE CLIMBING ROBOT

4. INSPECTION BY PIPE CLIMBING ROBOT

4.1 crack and leakage in chemical industries

Leakage and cracks in chemical industries result from corrosion, mechanical stress, poor
maintenance, and material degradation. Solutions are vital for safety, environmental
protection, regulatory compliance, operational continuity, and asset protection. Implementing
regular inspections, corrosion prevention measures, pressure relief systems, emergency
response plans, training, and technology investment are key strategies for minimizing risks
and ensuring overall industry integrity.

4.2 Causes of Crack

Exposure to corrosive substances or environments leads to the degradation of the pipe
material, weakening it over time and eventually causing cracks

Pipes are susceptible to cracking in areas where there are high levels of stress, such as bends,
joints, or areas with uneven support.

Stress concentrations can result from thermal expansion, pressure changes, or external forces,
leading to the formation of cracks.

Repeated cyclic loading and unloading, common in industrial environments, can lead to
fatigue failure in pipes.

Cracks serve as pathways for leakage, allowing the escape of fluids or gases. This can result
in product loss, environmental damage, and pose safety hazards.

4.3 Effects of Crack

Cracks serve as pathways for leakage, allowing the escape of fluids or gases. This can result
in product loss, environmental damage, and pose safety hazards.

Cracked pipes may experience a reduction in fluid or gas flow efficiency. This can impact the
overall performance of industrial processes, leading to decreased productivity.

Cracks provide points of vulnerability where corrosive agents can penetrate, accelerating the
corrosion process. This further weakens the pipe material and exacerbates the structural
deterioration.

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4.4 Need for Inspection

Crack detection in chemical industries is vital for preventing catastrophic failures, ensuring
personnel safety, and averting environmental contamination from hazardous chemical
releases. Early identification of cracks supports operational efficiency, compliance with
regulations, and protects assets, leading to cost savings and a positive public perception,
emphasizing a commitment to safety and environmental responsibility. Overall, crack
detection prioritizes safety, environmental protection, and the well-being of workers and the
community.

Figure 3 Different Cracks in Pipes

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4.5 Ultrasonic Sensor

Figure 4 Ultrasonic Sensor

The ultrasonic sensor integrated into our inspection robot is a cutting-edge device designed
for precise and non-destructive evaluation of industrial pipelines. This sensor utilizes
ultrasonic waves to detect and analyse the internal condition of pipes, providing crucial data
for inspection and maintenance purposes.

Incorporates distance measurement capabilities, allowing accurate mapping of the pipe's

geometry. Enables the identification of irregularities, bends, or deformities that may impact
structural integrity.

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4.6 Gas Sensor

Figure 5 Gas Sensor

Gas sensor is an integral component of the inspection robot, designed to detect and analyse
the presence of gases within industrial pipelines. This sensor plays a crucial role in
identifying leaks, monitoring air quality, and ensuring the safety of the inspected
environment.

Incorporates selective sensing capabilities, allowing it to distinguish between different gases

based on their unique chemical signatures. Enhances the specificity and accuracy of gas
identification

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5. MAINTANANCE BY PIPE CLIMBING ROBOT

Our pipe climbing robot stands as an innovative solution for enhancing the efficiency and
safety of pipeline inspection and maintenance. Its advanced features and precise control
mechanisms make it a valuable asset in ensuring the reliability of industrial pipelines while
minimizing downtime and operational risks.

5.1 Insulating Attachment

Here, a rail guide is provided for 360 rotating motions for inspecting and maintanence on the
pipe surface and a 3 wheeled drive for cpimbing. here, the insulation attachment is described
with purpose of insulating the detected crack by using specific sensor.

Figure 6 Robot with Insulating Arrangement

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5.2 Rust Removal Attachment

A rust removal attachment is described, the rust on the pipe can be removed by using twisted
wire cup primarily and the pipe surface is cleaned by blower and rust removal solution is
applied by using specific brush on the surface and further by using the twisted wire cup the
solution is cleared from the surface. And the same is procced for the cleaning of whole pipe.

Figure 7 Model with Rust Removal Arrangement

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6. PRPTOTYPE OF PIPE CLIMBING ROBOT

The development of a prototype stands as a pivotal phase in our project, reflecting our
commitment to cost-effectiveness and efficient time utilization. Recognizing the significance
of delivering results within constrained resources, the prototype serves as a tangible
demonstration of our solution's core functionalities, design principles, and intended user
experience.

By focusing on this iterative and foundational model, we aim to streamline the project's
development trajectory. The prototype embodies our innovative approach to test and validate
key concepts, swiftly incorporating feedback and making necessary refinements. This agile
methodology empowers us to identify potential challenges early on, enabling timely
adjustments while maintaining the project's momentum.

Driven by our dedication to achieving project goals within set parameters, the prototype not
only showcases our progress but also serves as a tangible representation of our commitment
to efficiency and quality.

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Birla Vishvakarma Mahavidyalaya Size: A4

Title: Robot Assembly

Team:
Pipe Climbing All dimensions are in
Robot mm

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 DESIGN AND DEVLOPMENT OF PIPE CLIMBING ROBOT

Top View Bottom View

Front View

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7. IMPLEMENTATION

7.1 FURTHER SCOPE

Robot is currently equipped with gas sensor and thermal sensor, in future we can modify the
robot by attaching various attachment such as insulating attachment, rust removal attachment
and various other attachments which are beneficial for industrial needs.

We can implement Machine learning algorithms so that robot can automatically align itself to
pipe and continues its motion to desired position , making robot completely autonomous .

Also, a rail guide is provided for 360 rotation motion for inspecting and maintenance on the
pipe surface.

7.2 CONCLUSION
The development and implementation of the pipe climbing robot equipped with advanced
sensors represent a significant milestone in the field of industrial inspection and maintenance.
This innovative project offers a holistic solution to address the challenges associated with
pipeline integrity, safety and operational efficiency.

The integration of the ultrasonic sensor allows for precise and non-destructive evaluation of
the pipe's internal condition

The gas sensor provides real-time monitoring of gas concentrations, enabling the prompt
identification of leaks and potential safety hazards

The pipe climbing robot's versatile design, including the climbing mechanism and
manipulator arm, allows for adaptability to various pipe surfaces and effective execution of
maintenance tasks.

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