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Manipulator Robot for Crack Detection and Welding in Process Pipes

978-1-4799-5202-1/14/$31.00 ©2014 IEEE

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Design

Base bodyDetection

unitWelder

arm

Block diagram. 1

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TOP VIEW SIDE VIEW

Conceptual Design

Design 1 main features

Differential driveRobotic arm with 3 DOFWelding torchFeed mechanism

Limitations

Caused loading effects Required servo motors

arm

arm

Fig. 1

Fig. 2

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Practical Design – Stage 1Main features

Includes features of design 1linear armCamera Higher loadsProgramming is less complexServo motors replaced by dc gear motors

Limitations

Less control over the arm due to high rpm of dc motorPulse Width Modulation (PWM) technique alone to control speed was in sufficientAs frequency decreases the load bearing capacity decreases

TOP VIEW SIDE VIEW

arm

arm

Fig. 3

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Practical Design – Stage 2

To reduce speed we use PWM

PWM reduces the torque of the shaft

Extra gear attached to solve the problemFig. 4

Fig. 5

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Challenges:

Motor driver

H bridge circuit

Fig. 6

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Flexibility in pipe size

.......Challenges

400 mm

200 mm

650 mm

450 mm

762 mm

Fig. 7 Fig. 8

Fig. 9

Fig. 10

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.......Challenges

Change of centre of rotation

Fig. 11

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STICK ARC WELDING UNIT

GAS WELDING UNIT

MIG WELDING UNIT

.......Challenges

Fig. 12

Fig. 13

Fig. 14

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.......Challenges

Crack detection unit

Dye penetrant inspection

Fig. 15

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Field requirements

Pipes should laid horizontally

Presence of any inflammable gases should be checked

DPI technique is not economically feasible

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Applications

WeldingCrack detectionPaintingDrillingCleaningOperation in hazardous environments Fig. 16

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Existing robots

Crack detecting robotsOuter surface welding robots

Fig. 17

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Re-engineering

PC interfacing Replacing DPI with ultrasonic testing

Fig. 19

Fig. 18

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References

[1] Gupta V., " Working and analysis of the H - bridge motor driver circuit designed for wheeled mobile robots", 2nd International Conference on Advanced Computer Control (ICACC), 2010

[2] http://www.atmel.in/devices/ATMEGA328P.aspx[3] An Arc Welding Robot Control for a Shaped Metal Deposition Plant: Modular Software Interface and Sensors Filippo Bonaccorso, Member, IEEE, Luciano Cantelli, and Giovanni Muscato, Senior Member, IEEE, IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 58, NO. 8, AUGUST 2011.[4] Hemanand, T. and Rajesh, T. " Speed control of brushless DC motor drive employing hard

chopping PWM technique using DSP", India International Conference on Power Electronics, 2006. [5] K.L. Moore, D.S. Naidu, R. Yender, J. Tyler, "Gas metal arc welding control-Part I: Modeling and

analysis," Nonlinear Analysis, Theory, Methods and Applications, vol. 30, pp. 3101-3111, 1997. (Pubitemid 127406978)

[6] Y.M. Zhang and R. Kovacevic, “Real-time sensing of sag geometry for full penetration control in GTA welding,” ASME J. Eng. Znd., to appear, vol. 118, no. 4, 1996.

[7] http://liquidpenetrant.com/penetrant-inspection-process/[8] http://www.st.com/st-web-ui/static/active/en/resource/technical/document/datasheet/

CD00000059.pdf[9] http://www.st.com/web/en/resource/technical/document/datasheet/CD00000240.pdf

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Acknowledgement

Prof. P. R.Madhava Panicker Department of Applied Electronics and Instrumentation Rajagiri School of Engineering and Technology

Asst. Prof. Naveen N Department of Applied Electronics and Instrumentation Rajagiri School of Engineering and Technology

SS casting and metal works Kochupally Nadakkavu PO Udyamperoor Ernakulam