Manipulator robot for crack detection and welding
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The document describes the design of a manipulator robot for crack detection and welding in process pipes. It discusses two conceptual designs - the first uses a differential drive base with a 3 DOF robotic arm and welding torch but causes loading effects and requires servo motors. The second design uses a linear arm, camera, higher load capacity, and replaces servo motors with lower RPM DC gear motors to reduce complexity, but has less speed control. It further details challenges in flexibility for different pipe sizes, changing the center of rotation, different welding units, crack detection methods, and field requirements.
![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
163/24/2015 IT EURPIA](https://image.slidesharecdn.com/manipulatorrobotforcrackdetectionandwelding-150324093651-conversion-gate01/85/Manipulator-robot-for-crack-detection-and-welding-16-320.jpg)
Manipulator robot for crack detection and welding
- 1. Manipulator Robot for Crack Detection and Welding in Process Pipes 13/24/2015 IT EURPIA 978-1-4799-5202-1/14/$31.00 ©2014 IEEE
- 2. Design Base body Detection unit Welder arm 23/24/2015 Block diagram. 1 IT EURPIA
- 3. TOP VIEW SIDE VIEW Conceptual Design Design 1 main features Differential drive Robotic arm with 3 DOF Welding torch Feed mechanism Limitations Caused loading effects Required servo motors arm arm 33/24/2015 Fig. 1 Fig. 2 IT EURPIA
- 4. Practical Design – Stage 1 Main features Includes features of design 1 linear arm Camera Higher loads Programming is less complex Servo motors replaced by dc gear motors Limitations Less control over the arm due to high rpm of dc motor Pulse Width Modulation (PWM) technique alone to control speed was in sufficient As frequency decreases the load bearing capacity decreases TOP VIEW SIDE VIEW arm arm 43/24/2015 Fig. 3 IT EURPIA
- 5. Practical Design – Stage 2 53/24/2015 To reduce speed we use PWM PWM reduces the torque of the shaft Extra gear attached to solve the problem Fig. 4 Fig. 5 IT EURPIA
- 6. Challenges: Motor driver H bridge circuit 63/24/2015 Fig. 6 IT EURPIA
- 7. Flexibility in pipe size .......Challenges 400 mm 200 mm 650 mm 450 mm 762 mm 73/24/2015 Fig. 7 Fig. 8 Fig. 9 Fig. 10 IT EURPIA
- 8. .......Challenges Change of centre of rotation 83/24/2015 Fig. 11 IT EURPIA
- 9. STICK ARC WELDING UNIT GAS WELDING UNIT MIG WELDING UNIT .......Challenges 93/24/2015 Fig. 12 Fig. 13 Fig. 14 IT EURPIA
- 10. .......Challenges Crack detection unit Dye penetrant inspection 103/24/2015 Fig. 15 IT EURPIA
- 11. Field requirements 113/24/2015 Pipes should laid horizontally Presence of any inflammable gases should be checked DPI technique is not economically feasible IT EURPIA
- 12. Applications Welding Crack detection Painting Drilling Cleaning Operation in hazardous environments 123/24/2015 Fig. 16 IT EURPIA
- 13. Existing robots Crack detecting robots Outer surface welding robots 133/24/2015 Fig. 17 IT EURPIA
- 14. Re-engineering PC interfacing Replacing DPI with ultrasonic testing 143/24/2015 Fig. 19 Fig. 18 IT EURPIA
- 15. 3/24/2015 IT EURPIA 15
- 16. 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 163/24/2015 IT EURPIA
- 17. 3/24/2015 17 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 IT EURPIA