Project report - mechanical - internal pipe painting machine

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INTERNAL PIPE PAINTING MACHINE
A PROJECT REPORT
Submitted by
SAJEEV M K MEC17ME028
SALEH P M MEC17ME029
DELTO P ANTONY MEC16ME019
FAHEEM M M MEC17ME014
To
The APJ Abdul Kalam Technological University
In partial fulfillment of the requirements for the award of the Degree
Of
Bachelor of technology
In
Mechanical Engineering
Department of Mechanical Engineering
MALABAR COLLEGE OF ENGINEERING AND TECHNOLOGY
DESHMANGALAM, PALLUR (P.O)
THRISSUR, KERALA-679532
JUNE 2021

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DECLARATION
We undersigned hereby declare that the project report INTERNAL PIPE PAINTING MACHINE
, submitted for partial fulfillment of the requirements for the award of degree of Master of
Technology of the APJ Abdul Kalam Technological University, Kerala is a bonafide work done
by me under supervision of Mr. Sathil.P.T. This submission represents my ideas in my own
words and where ideas or words of others have been included, we have adequately and
accurately cited and referenced the original sources. We also declare that we have adhered to
ethics of academic honesty and integrity and have not misrepresented or fabricated any data or
idea or fact or sourcein my submission. We understand that any violation of the above will be a
cause for disciplinary action by the institute and/or the University and can also evoke penal
action from the sources which have thus not been properly cited or from whom proper
permission has not been obtained. This report has not been previously formed the basis for the
award of any degree, diploma or similar title of any other University.
Place:
Date:

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DEPARTMENT OF MECHANICAL ENGINEERING
MALABAR COLLEGE OF ENGINEERING AND TECHNOLOGY
DESHMANGALAM, PALLUR (P.O)
THRISSUR, KERALA-679532
CERTIFICATE
This is to certify that the report entitled ‘INTERNAL PIPE PAINTING MACHINE’
submitted by SAJEEV M K , SALEH P M , FAHEEM M M , DELTO P ANTONY to the
APJ Abdul Kalam Technological University in partial fulfillment of the requirements for the
award of the Degree Of Bachelor Of technology in Mechanical Engineering in a bonafide record
of the project work carried out by him under my guidance and supervision. This repost has not
been submitted to any other university or institution for any other purpose
Internal Supervisor: External Supervisor:
Mr. Sathil P T
Asst Professor
Department of Mechanical Engineering
U.G Coordinator: Head of the Department:
Mr. Sathil P T Mr. Aneesh A
Asst Professor Asst Professor
Department of Mechanical Engineering Department of Mechanical
Engineering

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ACKNOWLEDGEMENT
First and foremost We thank GOD, the Generous, for having finally made this humble
effort a reality.
We would like to express my deepest gratitude to Dr. P. Babu, Principal, Malabar
College of Engineering and Technology, Pallur for forecasting an excellent academic climate
in the college and for this support and encouragement throughout the course period.
We are very much grateful to Mr. Aneesh A, Assistant Professor and Head of
Department of Mechanical Engineering, Malabar College of Engineering and Technology,
Pallur, for encouragement and inspiration for execution of the seminar.
We wish to thank Mr. Sathil P T, Assistant Professor and our project guide of
Department of Mechanical Engineering, Malabar College of Engineering and Technology,
Pallur whose advice, support, stimulating suggestions and constant encouragement proved
decisive in shaping up of this project.
We would like to take this opportunity to thank my friends who spent their valuable
time and shared their knowledge for helping me to complete the project with the best possible
result
Finally we thank our parents for their inspiration and ever encouraging moral support,
which enabled us to pursue our studies.
FAHEEM M M
SAJEEV M K
DELTO P ANTONY
SALEH P M

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ABSTRACT
Internal corrosion is a great challenge in pipeline transportation. It occurs due
to environmental conditions on the inside of the pipeline. In most cases, the corrosive
materials are contaminants naturally contained within the transported commodity, such
as hydrogen sulphide, carbon dioxide, other chemicals, petroleum products or even
water. In our project we designed an inner pipe line painting machine which is used to
paint the inner pipe line with the help of remote-control drive DC motor. Pressure drop
along the pipeline is the main obstacle to transportation of unprocessed or partly
processed multiphase fluids over long distances. Several parameters contribute to
pressure drop in multiphase flow, e.g., liquid hold-up, precipitations, gas-liquid
surface drag forces, liquid wetting of pipe wall and surface roughness. Application of
coatings inside the pipeline can reduce pressure drop by preventing corrosion,
preventing precipitations on the pipe wall and modify the pipe wall wetting properties.
Meso scale pressure drop tests have shown that pressure drop is significantly affected
by moderate corrosion, even in multiphase flow, demonstrating that application of
internal coatingsis beneficial. However, the coating must have the same lifetime as the
pipeline. In this work we have designed a remote- controlled internal pipe coating
machine of flexible size.

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CONTENTS
Pg. No
1. Introduction 1
1.1. Risk from internal corrosion 2
1.2. Methods to control internal corrosion 2
1.3. Risks of manual processing 3
1.4. Automation 3
1.5. Need for automation 3
2. Literature survey 4
3. Objectives 8
4. Methodology 9
5. Internal pipe coating machine 10
5.1. Types of angle cut machine 10
5.2. Features of angle cut machines 12
6. Design development 13
6.1. Target establishment 13
6.2. Concept modelling 14
6.3. Model designing 34
6.4. Material selection 55
6.5. Final design 57
6.6. Cost and estimation 74
7. Advantages and disadvantages 76
8. Applications 77
9. Conclusion 78
10. References 79

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LIST OF TABLES
Pg. No
6.1 Materials selected 57
6.2 Cost of estimation 74

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Pg. No
LIST OF FIGURES
5.1 Different types of angle cut machines 11
6.1 Schematic representation of DC motor 16
6.2 Schematic representation of DC motor with winding 17
6.3 Schematic representation of working of DC motor 18
6.4 Chemical reaction in battery 21
6.5 Schematic diagram of remote-control transmitting unit 25
6.6 Schematic diagram of remote-control receiving unit 26
6.7 Schematic diagram of transmitter unit 27
6.8 Schematic diagram of transmitter unit 28
6.9 Tone dialling 29
6.10 Schematic diagram of receiver unit 31
6.11 liver mechanism 32
6.12 3D drawing of spray head 35
6.13 Isometric sketch of spray head 35
6.14 2D drawing of spray head 36
6.15 3D drawing of air motor 37
6.16 Isometric sketch of air motor 37
6.17 2D drawing of air motor 38
6.18 3D drawing of Arbor extension 39
6.19 Isometric sketch of Arbor extension 39
6.20 2D drawing of Arbor extension 40
6.21 3D drawing of collar 41
6.22 Isometric sketch of collar 41
6.23 2D drawing of collar 42
6.24 3D drawing of slide material tube 43
6.25 Isometric sketch of material tube 43
6.26 2D drawing of material tube 44
6.27 3D drawing of slide Carrier collar 45
6.28 Isometric sketch of Carrier collar 45
6.29 2D drawing of Carrier collar 46
6.30 3D drawing of slide Carrier collar 47
6.31 Isometric sketch of Carrier collar 47
6.32 2D drawing of Carrier collar 48

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6.33 3D drawing of slide holder strap 49
6.34 Isometric sketch of holder strap 49
6.35 2D drawing of holder strap 50
6.36 3D drawing of slide carriage 51
6.37 Isometric sketch of carriage 51
6.38 2D drawing of carriage 52
6.39 3D drawing of slide Wheel assembly 53
6.40 Isometric sketch of Wheel assembly 53
6.41 2D drawing of Wheel assembly 54
6.42 Final 3D design back view 58
6.43 Final 3D design front view 58
6.44 Final 2D drawing back part 59
6.45 Final 2D drawing front part 60
6.46 Manufacturing process 61
6.47 Metal cutting 62
6.48 Lathe machine 63
6.49 Sawing machine 64
6.50 Welding 65
6.51 Welding 66
6.52 Welding process 67
6.53 Drilling process 68
6.54 Drilling bit 69
6.55 Drilling machine 70
6.56 Inspection process 71
6.57 Schematic diagram of Inner pipe painting robot 72

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CHAPTER 1
INTRODUCTION
Corrosion is the deterioration of metal that results from an electrochemical reaction
with its immediate surroundings. This reaction causes the iron in the steel pipe or
other pipeline appurtenances to oxidize (rust). Corrosion results in metal loss in the
pipe. Over time and if left unmitigated, corrosion can cause the steel to lose its
strength and possibly render it unable to contain the fluid in the pipeline at its
operating pressure.
Internal corrosion occurs due to environmental conditions on the inside of the
pipeline. In most cases, the corrosive materials are contaminants naturally contained
within the transported commodity, such as hydrogen sulphide, carbon dioxide, other
chemicals, petroleum products or even water. Because pipelines are extremely long-
serving and critical infrastructure, it is paramount for pipeline operators to maintain
the physical integrity of pipelines. Fortunately, there are effective methods for
preventing and mitigating internal corrosion damage to pipelines, including many that
are very technologically advanced.
1.1. RISKS FROM INTERNAL CORROSION
Internal corrosion can result in gradual and usually localized metal loss on the interior
surface of pipeline systems resulting in reduction of the wall thickness of the pipe or
other equipment. This metal loss can occur relatively evenly over an area of the pipe’s
interior surface or in isolated spots on the interior surface. The loss of material from
corrosion can eventually result in “pinhole” leakage, or a crack, split, or rupture of
the pipeline unless the corrosion is repaired, the affected pipe section is replaced, or
the operating pressure of the pipeline is reduced.
Left untreated, some internal corrosion can weaken the pipe where the corrosion
occurs, and make the pipe more susceptible to overpressure events, earth movement,

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and other external stresses. Thus, internal corrosion can sometimes also increase the
risk of other types of pipeline failures.
1.2. Methods to control internal corrosion
• Modern manufacturing processes for steel pipe and protective internal
coatings are subject to rigorous fabrication, installation, inspection, and
quality control standards to reduce the occurrence of pipe and coating defects
that can lead to internal corrosion.
• Pipeline operators control the moisture and chemical content of the products
transported through their pipelines (usually, but not always possible) to
prevent internal corrosion.
• Pipeline operators routinely run devices called “cleaning pigs” through their
lines toremove accumulations ofmaterials that can lead to internal corrosion.
• Pipeline operators also sometimes introduce corrosion inhibitors into the
pipeline to prevent internal corrosion.
• These preventive measures are routinely monitored and tested to maintain
their effectiveness.
From these methods most easy and secure method is coating inner part of pipe which
is widely done. This is currently done by internal pipe coating machine, where the
paints are sprayed by a spin kote passing through the pipe manually.
1.3. RISK OF MANUAL PROCESSING
The defects by corrosion as explained is great. Thus, proper coating to be done. Some
of the risks in manual processing are:
• Time consuming
• Uniform coating (constant pulling)
• Selective coating
The solution for these risks is atomizing and the project does it.

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1.4. AUTOMATION
This is an era of automation where it is broadly defined as replacement of manual effort
by mechanical power in all degrees of automation. The operation remains an essential
part of the system although with changing demands on physical input as thedegree of
mechanization is increased.
Degrees of automation are of two types:
o Full automation.
o Semi automation.
In semi automation a combination of manual effort and mechanical power is required
whereas in full automation human participation is very negligible.
1.5. NEED FOR AUTOMATION
Automation can be achieved through computers, electronics, hydraulics, pneumatics,
robotics, etc., of these sources; electronics form an attractive medium for low-cost
automation. The main advantages ofall electronic systems are economy and simplicity.

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CHAPTER 2
LITERATURE SURVEY
Seth Berrier his paper describes a computer graphics program that hasbeen developed
to overcome some of the limitations of the orthodox colour fan deck. A computer
graphic program for organizing and displaying the colours in a paint collection is
presented. A virtual representation for the traditional colour card fan deckis described.
This interactive program provides a lightness, chroma and hue interface for selecting a
colour from the collection. Software for visualizing a paint colour on a three-
dimensional surface is also discussed. This tool allows the user to evaluate the sheen of
a solid paint colour and the travel of a metallic or pearlescent paint colour. Inthis paper
a novel interface was presented that allows to navigate through the colour cards of a
traditional fan deck.
Nordson Corporation Most paint application systems are unique and designed for a
particular manufacturing process and/or finish requirement. Selecting the best finishing
method to meet both the technical and economic requirements for a specific system
requires a careful evaluation of many factors. When compared to conventional air spray,
airless spray applications can provide a higher transfer efficiency in a finishing
operation. In many applications airless can provide maximum material utilization and
reduced operating costs. For finishers, this translates into superior finishing quality and
optimum cost effectiveness, making it the efficient choice for many of today’s liquid
painting applications.
As coating particles are blown at high speed toward the part, many are dispersed into
the air. As due tohigh velocity air combined withcoating particles creates cloud as they
bounce off part resulting of wastage of paint with lower painting efficiency.
Application Guide by Createx Distribution paper gives basic information and
environmental condition about paint like recommended painting conditions: 70º F or

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higher in a dry, dust-free environment. When painting in humid or colder conditions,
allow for extended drying time. Use of air decreases drying time and is recommended
as the primary means to cure paint. Heat may also assist curing. Air source should be
free of contaminates, especially oil and water.
David Hradil have studied clay minerals and iron oxides are intimately related in the
process of their natural formation. Their mineralogical composition and physical
properties correspond to the physical–chemical conditions of weathering, sedimentation
and alteration processes by means of which these minerals are associatedgiving different
types of laterites, ferrolites, ochres, and coloured clays and soils. Very early in human
history, these and other clay materials were adopted as mineral pigments. Their
structural and mineralogical features are directly related with their natural genesis and
provenance and help us in the study of historical painting techniquesand materials. This
paper gives general information about geological sources and theircharacteristics, the
literary evidence of use of different forms of earthy pigments on historical paintings,
about analytical methods suitable in their identification within the ground and colour
layers of the painting, and handling with the samples of works of art.The examples
focused preferentially on the period of European mediaeval and baroque painting.
Clayey painting materials, particularly extenders, priming coats and many earthy
pigments are important components of the ground and colour layers of historical
paintings. Their characterization, however, is underestimated in the examination of the
colour layer. The present systematic knowledge on mineral deposits and weathering
crusts and the state of art of mineralogy of clays and other microparticulate minerals
offer a new challenge to focus on the detailed evaluation of the clayey pigments in
materials research of art works.
Allan Rodrigues He summarizes current trends in instrumental colour styling, colour
matching and production shading of paint and factors essential to success, with
particular emphasis on automotive finishes and research within ASTM and Detroit
Colour Council committees. Use of identical flake in standard and batch may not
provide the same flop, sparkle or texture if rheology or solids content of two paints
differ. These factors affect the orientation of the flake as the paint dries, resulting in a

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different apparent texture and sparkle. For automotive colour matching required diffuse
colour matching requires only absorption and scattering coefficients to predict
reflectance. Ambient temperature is required fordrying and in controlled conditions.
BerardoNaticchia have shared that construction projects are getting bigger and more
complex, hence also the productivity of the construction industry must be improved,
while preserving its labour from hazardous job sites. Such requirements can be
accomplished by the adoption of robotized products, which, however, need to be
quickly developed and marketed. In this paper, first the issue of a new miniature
laboratory for developing lightweight and well-coordinated robotized systems is
pursued, then a novel robot device for high quality multi-colour interior wall painting
carried by a robot arm is developed and successfully tested. Thanks to the new 1:6
scaled down laboratory and its six degree of freedom robot arm on a hexapod for
horizontal moves, we tested the opportunity to introduce also in the building sector
miniature robots that can change the ergonomics standardly adopted by construction
workers. It is analysed how and why switching from full size to miniature robots is
convenient in construction. In addition, a new system adding further features to
robotized painting has been conceived. Our new multi-colour spraying end-tool was
developed and fixed on the robot arm, in order to be able to reproduce coloured
artworks. Finally, a methodology to reproduce colours from digital format of artworks
is presented.
Dr. Sapna Johnson had studied lead is a highly toxic metal found in small amounts in
the earth’s crust. Because of its abundance, low cost, and physical properties, lead and
lead compounds have been used in a wide variety of products including paint, ceramics,
pipes, gasoline, batteries, and cosmetics. In India, as in most developing countries the
battery industry is the principle consumer of lead using an estimated 76% of the total
primary and secondary lead produced annually. Lead is takenup by humans by ingestion
and inhalation. Eating lead bearing paints by children and drinking of lead contaminated
water are important sources of non-industrial poisoning.Lead absorbed in course of
occupational exposure is superimposed on lead absorbed from other means which leads
to increased bodyburden of lead.Lead-based paints have

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disappeared from consumer sales for residential use in developed countries because of
toxicity concerns. However, paint containing lead is still being used for certain
industrial painting requirements. Lead is added to paint to speed drying, increase
durability, retain a fresh appearance, and resist moisture that causes corrosion.

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CHAPTER 3
OBJECTIVES
The main objective of this work is to to design and fabricate an inner pipe painting
robot. The main objective is divided into two specific objectives in order to achieve
overall goal of the project.
1. Study existing models.
2. Design the product.
3. Fabricate

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CHAPTER 4
METHODOLOGY
Method followed forthe project include
(i) Studying existing model.
(ii) Model designing (3D & 2D) using CAD software

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CHAPTER 5
INTERNAL PIPE COATING MACHINE
Internal Pipe Painting Equipment designed to apply internal coatings to the pipe.
These attachments have a pneumatic driven spray head that will spray most all
coatings from the thinnest to the most viscous. The coating to be applied is fed to the
spray head through a fluid manifold for maximum material disbursement. All tools
include pipe centering carriages. These tools are suitable to spray the internal diameter
of pipe from 2” to 96”.
These Coating Tools are generally fed paint by airless spray pump. To get perfect
results use the appropriate delivery system for your specific coating to assure an even
and consistent dry film thickness throughout the pipe. There are Internal Pipe Coating
Attachment which provides an innovative and efficient solution to the difficult job of
applying paint to the inside of the pipe, conduit, tubing or other cylindrical structures.
With the Internal Pipe Coating Attachment atomization, we can apply a uniform layer
of paint at remarkable speed.
5.1. TYPES OF ANGLE-CUT MACHINES
There are many types of internal pipe coating equipment. Two main
components differ its types and uses. The spin-kote and carriage. They are used
considering the applications, productions and cost. Commonly known types are listed
below with figures:
• Spin kote 25 with 3” to 5”

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Fig. 5.1 Different types of angle cut machines. (1) Spin kote 25 with 3” to 5”, (2)
Spin kote 512 with 5” to 12” ,(3) Spin kote 817 with 8” to 17”, (4) Spin kote 1236
with 12” to 36”, (5) Spin kote 4869 with 48” to 96”

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5.2. FEATURES OF ANGLE CUT MACHINES
• Easy Set-Up and Operation
Internal Pipe Coating Attachment set up is quick and easy (the pump size will
depend upon paint viscosity, hose length, and tip size). It is powered by
compressed air, which operates the rotating head and the carriage legs.
• A Simple, Fast, and Cost-Effective Job
Internal Pipe Coating Attachment offers an effective and precise method of
coating pipe. The investment will reward you with the highest rate of speed and
most accurately applied the coating, saving you time and money.

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CHAPTER 6
DESIGN DEVELOPEMENT
For developing the design and better understanding we have divided overall
process as given below:
1. Target establishment
2. Concept modelling
3. Defining Components and descriptions
4. Model designing (3D & 2D)
5. Material selection
6. Assembling
7. Cost estimation
8. Manufacturing
6.1. TARGET ESTABLISHEMENT
Our overall objective is to develop a remote-controlled internal pipe coating
machine:
• Flexible to different pipe dimensions
• Low weight
• Portable

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• Easy to assemble and disassemble
• Low cost
• Safe
• Easy to use
• Battery used as power
• Automated
6.2. CONCEPT MODELING
After gaining a strong sense of the problem statement and objectives, we developed
a list of functions our product must do. Once we knew how our product would function, we
started formulating ideas. Some techniques used were brainstorming and brainwriting.
Brainstorming is a method design teams use to generate ideas to solve clearly defined design
problems, whereas brainwriting is writing down ideas and passing them to another group
member to expand on them. Finally, combined them to come up with new ideas. Through the
design ideation techniques, we developed various ideas that satisfy specifications. The
preliminary ideas we came up with develop a remote-controlled actuating part which can be
equipped on the currently available machine with certain modifications in carriage unit.
For this design main components needed are:
1. A DC motor
2. A gear mechanism
3. A remote-control unit
4. Liver mechanism,
5. Painting Mechanism,

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COMPONENTS AND DESCRIPTION
The components that are used in the project INNER PIPE PAINTING
ROBOTare as follows,
• DC motor,
• Battery,
• Remote control unit,
• Wheel arrangement,
• Spring,
• Liver mechanism,
• Painting Mechanism,
• Spur gear mechanism
1. D.C. MOTOR (PERMANENT MAGNET):
An electric motor is a machine which converts electrical energy to mechanical
energy. Its action is based on the principle that when a current-carrying conductor is
placed in a magnetic field, it experiences a magnetic force whose direction is given by
Fleming’s left hand rule.
When a motor is in operation, it develops torque. This torque can produce mechanical
rotation. DC motors are also like generators classified into shunt wound orseries wound
or compound wound motors.
FLEMING’S LEFT HAND RULE:
Keep the fore finger, middle finger and thumb of the left hand mutually perpendicular
to one another. If the fore finger indicates the direction of magnetic field and middle
finger indicates direction of current in the conductor, then the thumbindicates the
direction of the motion of conductor.

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PRINCIPLE OF OPERATION OF DC MOTOR:
In figure 6.1 the current carrying conductor is placed in the magnetic field.
Fig. 6.1 schematic representation of DC motor
The result is to increase the flux density in to the region directly above the conductor
and to reduce the flux density in the region directly below the conductor. It is found that
a force acts on the conductor, trying to push the conductor downwards as shown by the
arrow. If the current in the conductor is reversed, the strengthening of flux linesoccurs
below the conductor, and the conductor will be pushed upwards.
Now consider a single turn coil carrying a current as shown in the above figure. in view
of the reasons given above, the coil side A will be forced to move downwards, whereas
the coil side B will be forced to move upwards. The forces acting on the coilsides A
and B will be of same magnitude. But their direction is opposite to one another.
As the coil is wound on the armature core which is supported by the bearings, the
armature will now rotate. The commutator periodically reverses the direction of current
flow through the armature. Therefore, the armature will have a continuousrotation.

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A simplified model of such a motor is shown in figure 6.2. The conductors are
wound over a soft iron core. DC supply is given to the field poles for producing flux.
The conductors are connected to the DC supply through brushes
Fig. 6.2 schematic representation of DC motor with winding
Let'sstart by looking at the overall plan of a simple 2-pole DC electric motor. Asimple
motor has 6 parts, as shown in the diagram below.
• An armature or rotor
• A commutator
• Brushes
• An axle
• A field magnet
• A DC power supply of some sort
When you put all of these parts together, what you have is a complete electric
motor:

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Fig. 6.3 schematic representation of working of DC motor
In this figure, the armature winding has been left out so that it is easier to see the
commutator in action. The key thing to notice is that as the armature passes through
the horizontal position, the poles of the electromagnet flip. Because of the flip, the
North pole of the electromagnet is always above the axle so it can repel the field
magnet's North pole and attract the field magnet's South pole. If you ever take apart an
electric motor you will find that it contains the same pieces described above: two small
permanent magnets, a commutator, two brushes and an electromagnet made bywinding
wire around a piece of metal. Almost always, however, the rotor will have three poles
rather than the two poles as shown in this article. There are two good reasons for a
motor to have three poles:
It causes the motor to have better dynamics. In a two-pole motor, if the electromagnet
is at the balance point, perfectly horizontal between the two poles of the field magnet
when the motor starts; you can imagine the armature getting "stuck" there. That never
happens in a three-pole motor.
Each time the commutator hits the point where it flips the field in a two-pole motor,
the commutator shorts out the battery (directly connects the positive and negative
terminals) for a moment. These shorting wastes energy and drains the battery
needlessly. A three-pole motor solves this problem as well. It is possible to have any

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number of poles, depending on the size of the motor and the specific application it is
being used in.
2. BATTERIES
In isolated systems away from the grid, batteries are used for storage of excess solar
energy converted into electrical energy. The only exceptions are isolated sunshine load
such as irrigation pumps or drinking water supplies for storage. In fact, for smallunits
with output less than one kilowatt. Batteries seem to be the only technically and
economically available storage means. Since both the photo-voltaic system and
batteries are high in capital costs.
It is necessary that the overall system be optimized with respect to available energy
and local demand pattern. To be economically attractive the storage of solar electricity
requires a battery with a particular combination of properties:
(1) Low cost
(2) Long life
(3) High reliability
(4) High overall efficiency
(5) Low discharge
(6) Minimum maintenance
(A) Ampere hour efficiency
(B) Watt hour efficiency
We use lead acid battery for storing the electrical energy from the solar panel forlighting
thestreet and so about the lead acid cells are explained below.

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LEAD-ACID WET CELL:
Where high values of load current are necessary, the lead-acid cell is the type most
commonly used. The electrolyte is a dilute solution of sulfuric acid (H₂SO₄). In the
application of battery power to start the engine in an auto mobile, for example, the
load current to the starter motor is typically 200 to 400A.
One cell has a nominal output of 2.1V, but lead-acid cells are often used in a series
combination of three for a 6-V battery and six for a 12-V battery. The lead acid cell
type is a secondary cell or storage cell, which can be recharged. The charge and
discharge cycle can be repeated many times to restore the output voltage, as long asthe
cell is in good physical condition. However, heat with excessive charge and discharge
currents shortens the useful life to about 3 to 5 years for an automobile battery. Of the
different types of secondary cells, the lead-acid type has the highest output voltage,
which allows fewer cells fora specified battery voltage.
CHEMICAL ACTION:
Sulfuric acid is a combination of hydrogen and sulphate ions. When the cell
discharges, lead peroxide from the positive electrode combines with hydrogen ions to
form water and with sulphate ions to form lead sulphate. Combining lead on the
negative plate with sulphate ions also produces he sulphate. Therefore, the net result of
discharge is to produce more water, which dilutes the electrolyte, and to form lead
sulphate on the plates. As the discharge continues, the sulphate fills the pores of the
grids, retarding circulation of acid in the active material. Lead sulphate is the powder
often seen on the outside terminals of old batteries.
When the combination of weak electrolyte and sulphating on the plate lowers the
output of the battery, charging is necessary. On charge, the external D.C. source
reverses the current in the battery. The reversed direction of ions flows in the
electrolyte result in a reversal of the chemical reactions. Now the lead sulphates on the
positive plate reactive with the water and sulphate ions to produce lead peroxide

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and sulfuric acid. This action re-forms the positive plates and makes the electrolyte
stronger by adding sulfuric acid.
At the same time, charging enables the lead sulphate on the negative plate to react with
hydrogen ions; this also forms sulfuric acid while reforming lead on the negativeplate
to react with hydrogen ions; this also forms currents can restore the cell to full output,
with lead peroxide on the positive plates, spongy lead on the negative plat e, and the
required concentration of sulfuric acid in the electrolyte.
The chemical equation forthe lead-acid cell is
Pb + PbO₂ + 2H₂SO₄ 2pbSO₄ + 2H₂O
On discharge, the pb and PbO₂ combine with the SO₄ ions at the left side of the
equation to form lead sulphate (PbSO₄) and water (H₂O) at the right side of the
equation.
Fig. 6.4 Chemical reaction in battery

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One battery consists of 6 cells, each have an output voltage of 2.1V, which are
connected in series to get a voltage of 12V and the same 12V battery is connected in
series, to get a 24 V battery. They are placed in the water proof iron casing box.
CARING FOR LEAD-ACID BATTERIES:
Always use extreme caution when handling batteries and electrolyte. Wear gloves,
goggles and old clothes. “Battery acid” will burn skin and eyes and destroy cotton and
wool clothing.
The quickest way of ruin lead-acid batteries is to discharge them deeply and leave
them stand “dead” for an extended period of time. When they discharge, there is a
chemical change in the positive plates of the battery. They change from lead oxide
when charge out lead sulphate when discharged. If they remain in the lead Sulphate
State for a few days, some part of the plate dose not returns to lead oxide when the
battery is recharged. If the battery remains discharge longer, a greater amount of the
positive plate will remain lead sulphate. The parts of the plates that become “sulphate”
no longer store energy. Batteries that are deeply discharged, and then charged
partially on a regular basis can fail in less than one year.
Check your batteries on a regular basis to be sure they are getting charged. Use a
hydrometer to check the specific gravity of your lead acid batteries. If batteries arecycled
very deeply and then recharged quickly, the specific gravity reading will belower than
it should because the electrolyte at the top of the battery may not have mixed with the
“charged” electrolyte.
Check theelectrolyte level in thewet-cell batteries at the least four times a year andtop
each cell of with distilled water. Do not add water to discharged batteries.
Electrolyte is absorbed when batteries are much discharged. If you add water at this
time, and then recharge the battery, electrolyte will overflow and make a mess.
Keep the top of your batteries clean and check that cables are tight. Do not tighten or
remove cables while charging or discharging. Any spark around batteries can cause a
hydrogen explosion inside, and ruin one of the cells, and you.

23
On charge, with reverse current through the electrolyte, the chemical action is reversed.
Then the pb ions from the lead sulfate on the right side of the equation re-form the lead
and lead peroxide electrodes. Also the SO₄ ions combine with H₂ ionsfrom the water to
produce more sulfuric acid at the left side of the equation.
CURRENT RATINGS:
Lead-acid batteries are generally rated in terms of how much discharge currents they
can supply for a specified period of time; the output voltage must be maintained above
a minimum level, which is 1.5 to 1.8V per cell. A common rating is ampere- hours
(A.h.) based on a specific discharge time, which is often 8h. Typical values for
automobile batteries are 100 to 300 A.h.
As an example, a 200 A.h battery can supply a load current of 200/8 or 25A, used on
8h discharge. The battery can supply less current for a longer time or more current for
a shorter time. Automobile batteries may be rated for “cold cranking power”, which is
related to the job of starting the engine. A typical rating is 450A for 30s at a temperature
of 0-degree F.
Low temperatures reduce the current capacity and voltage output. The ampere-hour
capacity is reduced approximately 0.75% for each decrease of 1º F below normal
temperature rating. At 0ºF the available output is only 60 % of the ampere-hour battery
rating.
In cold weather, therefore, it is very important to have an automobile battery unto full
charge.In addition, the electrolyte freezes more easily when diluted by water in the
discharged condition.
SPECIFIC GRAVITY:

24
Measuring the specific gravity of the electrolyte generally checks the state of discharge
for a lead-acid cell. Specific gravity is a ratio comparing the weight of a substance
with the weight of a substance with the weight of water. For instance, concentrated
sulfuric acid is 1.835 times as heavy as water for the same volume. Therefore, its
specific gravity equals 1.835. The specific gravity of wateris 1, since itis thereference.
Specific-gravity readings are taken with a battery hydrometer, such as one in figure
(7). Note that the calibrated float with the specific gravity marks will rest higher in an
electrolyte of higher specific gravity.
The importance of the specific gravity can be seen from the fact that the open-circuit
voltage of the lead-acid cell is approximately equal to
V = Specific gravity + 0.84
For the specific gravity of 1.280, the voltage is 1.280 = 0.84 = 2.12V, as an example.
These values are for a fully charged battery.
CHARGING THE LEAD-ACID BATERY:
The requirements are illustrated in figure. An external D.C. voltage source is
necessary to produce current in one direction. Also, the charging voltage must be more
than the battery e.m.f. Approximately 2.5 per cell are enough to over the cell
emf. so that the charging voltage can produce current opposite to the direction of
discharge current.
It may be of interest to note that an automobile battery is in a floating-charge circuit.
The battery charger is an AC generator or alternator with rectifier diodes, driver by a
belt from the engine. When you start the car, the battery supplies the cranking power.
Once the engine is running, the alternator charges the battery. It is not necessary for the
car to be moving. A voltage regulator is used in this system to maintain the outputat
approximately 13 to 15 V.

25
It is a good idea to do an equalizing charge when some cells show a variation of 0.05
specific gravity from each other. This is a long steady overcharge, bringing the battery
to a gassing or bubbling state. Do not equalize sealed or gel type batteries.
With proper care, lead-acid batteries will have a long service life and work very well
in almost any power system. Unfortunately, with poor treatment lead-acid battery life
will be very short.
3. REMOTE CONTROL UNIT: -
The message to be communicated has to be first converted into an electrical signal
by the help of a suitable transducer. The electrical signal so obtained has to besuitable
processed and amplified before being fed to the channel. The information signal called
the modulating signal is used to modulate a high frequency sine wave signal. The type
of modulation depends on the requirements.
Fig. 6.5 Schematic diagram of remote-control transmitting unit
The carrier signal generated by the oscillator goes to the RF output power
amplifiers through the buffer and RF amplifiers. The RF amplifier sends the signal
containing all bands of frequencies.

26
RECEIVER
Fig. 6.6 Schematic diagram of remote-control receiving unit
Practically all receivers today are super heterodyne. The RF amplifier is tuned to the
required incoming frequency. The output of the RFA is combined with the local
oscillator voltage and normally converted into a signal of lower fixed frequency. This
IF signal contains the same modulation as the original carrier. It is then amplified and
detected to obtain information.
A fixed frequency difference is maintained between the local oscillator and RF
frequency with the help of capacitance tuning. IF stage consists of a number of
transformers which provides a large gain. The characteristics of the IFA are kept
independent of the frequency to which the receiver is tuned, so that the sensitivity of
the super heterodyne remains fairly uniform throughout its tuning range. The various
blocks of super heterodyne receiver is explained as follows.
TRANSMITTER (CODE GENERATION)
OPERATION:
When a button on the keyboard is pressed two tones corresponding to that key
is generated. The tones corresponding to that key is generated.

27
Fig. 6.7 Schematic diagram of transmitter unit
The tones generated are fed to IC UM9121 5B which is an encoder, it converts the
messages into electrical signals and feeds them to the FM transmitter. The FM
transmitter thereafter transmits the signal with atmosphere as the medium (or) channel,
via a telescopic antenna which provides point to point links. The range ofoperation of
the circuit depends on the range of operation of the FM transmitter employed in the
circuit.
Thus, the signal is transmitted from the keyboard corresponding to the relay to be
triggered. Therefore, transmission can be done in an efficient manner using this circuit.
FM TRANSMITTER
FM transmission can be done by two methods:
1. Where frequency modulated waves can be directly produced by varying the
master oscillator frequency, in this case L-C oscillator is used (drift in
frequency).
2. Where a crystal oscillator is used which phase is modulated by the audio
signals (drift free frequency).

28
In this project, FM transmission is done such that the signal transmitted falls between
the desired bandwidth limits. In this case the frequency deviation is produced in
proportion to the amplitude of the signal received. The resulting FM wave is then
passed through a number of frequency multiplier stages. These sages not only raise the
center frequency of the signal but the frequency deviation is multiplied by the same
factor as well. The modulated wave is then amplified by the class C power amplifier
and then transmitted.
A part of frequency multiplier stage is fed to the AFC circuit in order to make correction
in case of any drift in the center frequency due to changes in the circuit parameters. Thus
change in center frequency can be correct and transmission by theFM transmitter can
be made accurate.
Fig. 6.8 Schematic diagram of transmitter unit

29
TONE DIALING (DTMF)
Dual Tone Multi – Frequency is the method employed in the transmitter part
of the circuit. The user by means of this method will be able to control the operations
of different relays. The keypad normally consists of 12 keys representing numbers 0
to 9 and the symbols * and # employed forspecial purposes.
When a key is pressed the electronic circuit generates two tones corresponding to that
key. It key 5 is pressed, tones of 770 and 1336 Hz will be generated.
Fig. 6.9 Tone dialing

30
Being the most common method replacing rotary dials has the following advantages.
ADVANTAGES:
1) Dialing is very fast as compared to pulse dialing.
2) It uses solid state circuits for tone generation and detection.
3) After the call has been connected, it can be used for low-speed data
transmission.
4) It is more compatible with electronically controlled exchanges.
RECEIVER (DECODER)
The transmitted signals are received by an FM receiver which receives all incoming
signals within a particular bandwidth. The reception is also done with the help of
telescopic antennas. The signal obtained is fed to IC 8870P which is a decoder. This
IC converts the signal to its original form. It gives binary output corresponding to the
signal received from the transmitter. This 4 bit binary number is fed to IC4067, which
is a 4 to 16 line decoder IC.
Depending on the binary input, one of the outputs of IC4067 will go high and the
corresponding relay will be activated. This mode has to be held until another
deactivating signal is passed, in order to hold this mode a flip flop IC – CD4013 is
connected to IC 4067. IC – CD4013 holds this mode until another deactivating signal
is fed to the system.
Therefore ON & OFF operation of all relays can be controlled by using this logic. The
whole system can be reset by pressing the (*) buttonin the transmitter part of thecircuit.

31
Fig. 6.10 Schematic diagram of receiver unit
6. LIVER MECHANISM: -
A. Degrees of Freedom
F = 3(n-1) - 2f1 - f2
n = no. of links of mechanism with fixed links.
f1 = no. of pin joints or revolute pairs or pairs that permits one degree of freedom.
f2 = no. of roll-slide pairs.
F = 3*(8-1) - 2(9)-0 = 21 -18
F = 3

32
Fig. 6.11 liver mechanism
We are using a universal coupling so our robot has 6-degrees of freedom.
7. PAINTING MECHANISM: -
Painting mechanism is spraying mechanism by rotation. Shaft is rotated by pressurized
air motor. When the pressurized air is passed to the motor the axle rotatesin speed. The
material is dropped on the highly rotating head which splits the material. i.e., it applies
kinetic energy on the material and the material splashes on the inner wall.
8. SPUR GEAR MECHANISM: -
Spur gears are used to transmit motion from dc motor to the wheels.
The spur gears, which are designed to transmit motion and power between parallelshafts,
are the most economical gears in the power transmission industry.

33
APPLICATION:
• Material handling
• Feed drives
• Machine tools
• Conveyors
• Marine hoists
INTERNAL SPUR GEAR:
The internal gears are spur gears turned "inside out." In other words, the teeth are cut
into the inside diameter while the outside diameter is kept smooth. This design allows
for the driving pinion to rotate internal to the gear, which, in turn, allows for clean
operation. Intended for light duty applications, these gears are available only in brass.
When choosing a mating spur gear, always remember that the difference in the number
of teeth between the internal gear and pinion should not be less than 15 or 12.
APPLICATIONS:
• Light duty applications
• Timing
• Positioning
• Rollers
• Indexing

34
EXTERNAL SPUR GEAR:
Perhaps the most often used and simplest gear system, external spur gears are
cylindrical gears with straight teeth parallel to the axis. They are used to transmitrotary
motion between parallel shafts and the shafts rotate in opposite directions.
They tend to be noisy at high speed as the two gear surfaces come into contact at once.
Internal spur gears: The internal spur gear works similarly to the external spurgears
except that the pinion is inside the spur gear. They are used to transmit rotary motion
between parallel shafts but the shafts rotate in the same direction with this
arrangement.
6.3. MODEL DESIGNING
With the above defined description components were designed in 3D and 2D designing
software. Some modifications were done in dimensions using optimization features in
software. 3d and 2d designs of each component and its specifications are explained in
following sessions.
6.4.1. Design of Spray Head
Spray head is the basic part which distributes the input material radially. 3D drawing
and its sketches with isometric view is shown in the fig. 6.12 and 6.13:

35
Fig. 6.12 3D drawing of spray head
Fig. 6.13 Isometric sketch of spray head
Specifications of the design are:
• The spray head can be easily assembled or disassembled
• It includes:
• Pores through which the material from the material tube is forced out with
pressure
• Considerable width is given so that material loss can be controlled

36
2D drawing is shown in fig. 6.14
Fig. 6.14 2D drawing of spray head
6.4.2. Design Of Motor
Motor converts the pressure of air into mechanical energy and rotates thespray head.3D
drawing and its sketches at isometric view is shown in the fig. 6.15 and fig. 6.16:

37
Fig. 6.15 3D drawing of air motor
Fig. 6.16 Isometric sketch of air motor

38
• The threaded part projecting out is connected to head
• Air pipe is tightly fitted in internal thread hole back of it
• The projected threaded part is the rotating part.
• The body is hold by collars during work
2D drawings is shown in fig. 6.17
Fig. 6.17 2D drawing of air motor

39
6.4.3. Design of Arbor Extension
It extends the drive shaft of air motor to fit the spray head. 3D drawing and its
sketches at isometric view is shown in the fig. 6.18 and fig. 6.19:
Fig. 6.18 3D drawing of Arbor extension
Fig. 6.19 Isometric sketch of Arbor extension

40
• It is fitted on the threaded shaft of motor
• It gives flexibility to change head designs of different height
2D drawings is shown in fig 6.20
Fig. 6.20 2D drawing of Arbor extension

41
6.4.4. Design of Collar
Collar is the part which holds the motor tightly. 3D drawing and its sketches with
isometric view is shown in the fig.6.21 and 6.22:
Fig. 6.21 3D drawing of collar
Fig. 6.22 Isometric sketch of collar

42
• Dimensions are selective to the motor
• Screw holes are provided to fit between the upper and lower collars and
carriage and collar
Fig. 6.23 2D drawing of collar

43
6.4.5. Design of Material Tube
Material tube transfer the coating material from tank to the head.3D drawing isshown
in the fig.6.24:
Fig. 6.24 3D drawing of slide material tube
Fig. 6.25 Isometric sketch of material tube

44
• Thin tube
• Back movement not allowed
• Increases pressure
2D drawings is shown in fig. 6. 26
Fig. 6.26 2D drawing of material tube

45
6.4.6. Design of Carrier Collar
Carrier collar fits the head part collar to carriage. 3D drawing is shown in the fig.6.27:
Fig. 6.27 3D drawing of slide Carrier collar
Fig. 6.28 Isometric sketch of Carrier collar

46
• It contains thread holes to tight collars
• It contains pin holes to be attached on strap hold.
Fig. 6.29 2D drawing of Carrier collar

47
6.4.7. Design of Centre Carrier Collar
Carrier collar holds the centre part collar to carriage. 3D drawing is shown in the
fig.6.30
Fig. 6.30 3D drawing of slide Carrier collar
Fig. 6.31 Isometric sketch of Carrier collar

48
• It contains thread holes to tight collars
• It contains threads on which carriages are pinned.
Fig. 6.32 2D drawing of Carrier collar

49
6.4.8. Design of Holder Strap
Holderstraps connect collars to carriage. 3D drawing is shown in the fig.6.33:
Fig. 6.33 3D drawing of slide holder strap
Fig. 6.34 Isometric sketch of holder strap

50
• It is pinned on both sides an allow rotational movements at the ends
• It is perfectly fitted to the carriage and collar
Fig. 6.35 2D drawing of holder strap

51
6.4.9. Design of Carriage
Carriage is the main part which makes the machine flexible for different diameter
tubes. 3D drawing is shown in the fig.6.36:
Fig. 6.36 3D drawing of slide carriage
Fig. 6.37 Isometric sketch of carriage

52
• It includes three pin holes
• One connected to the carrier collar
• Other two connected to the wheel shafts
•
Fig. 6.38 2D drawing of carriage

53
6.4.10.Design of Wheel
Wheel makes the motion through the pipe simple. 3D drawing is shown in the
fig.6.39:
Fig. 6.39 3D drawing of slide Wheel assembly
Fig. 6.40 Isometric sketch of Wheel assembly

54
• It consists of Rubber tyres for avoiding slip
• Stopper to avoid axle slip It is connected to the carriage through
a bush bearing so that themovement become smooth
Fig. 6.41 2D drawing of Wheel assembly
•

55
6.4. MATERIAL SELECTION
Considering the dimensions and forces applied, materials are selected. Each
component functions differ and differ in its material specifications. Material selection
and its specifications are briefly described.
Carbon Steel
Majority of components should be strong moderately. The material should be easy to
machine, cost effective and considerable weight. We found carbon steel as the best
material with specific properties.it has the following properties:
• Low hardenability
• Medium strength, ductility and toughness
• Density = 7.85E-06 kg / mm3
• Young's Modulus = 200000 MPa
• Poisson's Ratio = 0.29
• Yield Strength = 350 MPa
• Ultimate Tensile Strength = 420 MPa
• Thermal Conductivity = 0.0476 W / (mm C)
• Thermal Expansion Coefficient = 1.2E-05 / C
• Specific Heat 480 J / (kg C)
Steel
Some of the part should be strong enough like header parts. We found steel as the
material commonly used for such needs. It has the following properties
• High tensile strength.
• High impact strength.
• Good ductility and weldability.
• A magnetic metal due to its ferrite content.

56
• Good malleability with cold-forming possibilities.
• Density 7.85E-06 kg / mm^3
• Young's Modulus 220000 MPa
• Poisson's Ratio 0.275
• Yield Strength207 MPa
• Ultimate Tensile Strength 345 MPa
• Thermal Conductivity0.045 W / (mm C)
• Thermal Expansion Coefficient 1.2E-05 / C
.

57
MATERIALS SELECTED :
Table 6.2 materials selected
COMPONENT MATERIAL
1 SPRAY HEAD STEEL
2 ARBOR EXTENSION CARBON STEEL
3 HOLDER STRAP CARBON STEEL
4 COLLARS CARBON STEEL
5 CARRIAGE CARBON STEEL
6 WHEELS RUBBER
6.5. FINAL DESIGN
Now the design can be assembled virtually using 3D software to test its fits. The
fig. 6.37 and fig. 6.38 shows the 3D and 2D drawings of inner pipe painting robot

61
MANUFACTURING PROCESS
Manufacturing processes are the steps through which raw materials are transformed
into a final product. The manufacturing process begins with the creation of the
materials from which the design is made. These materials are then modified through
manufacturing processes to become the required part. Manufacturing processes can
include treating (such as heat treating or coating), machining, or reshaping the
material. The manufacturing process also includes tests and checks for quality
assurance during or after the manufacturing, and planning the production process prior
to manufacturing.
Fig. 6.46 Manufacturing process
METAL CUTTING:
Metal cutting or machining is the process of by removing unwanted material from a
block of metal in the form of chips.

62
Cutting processes work by causing fracture of the material that is processed. Usually,
the portion that is fractured away is in small sized pieces, called chips. Common cutting
processes include sawing, shaping (or planning), broaching, drilling, grinding,turning
and milling. Although the actual machines, tools and processes for cutting look very
different from each other, the basic mechanism for causing the fracture can be
understood by just a simple model called for orthogonal cutting.
Fig. 6.47 Metal cutting
In all machining processes, the work piece is a shape that can entirely cover the final
part shape. The objective is to cut away the excess material and obtain the final part.
This cutting usually requires to be completed in several steps – in each step, the part is
held in a fixture, and the exposed portion can be accessed by the tool to machine in that
portion. Common fixtures include vise, clamps, 3-jaw or 4-jaw chucks, etc. Each
position of holding the part is called a setup. One or more cutting operation may be
performed, using one or more cutting tools, in each setup. To switch from one setup to

63
the next, we must release the part from the previous fixture, change the fixture on the
machine, clamp the part in the new position on the new fixture, set the coordinates of
the machine tool with respect to the new location of the part, and finally start the
machining operations for this setup.
Therefore, setup changes are time-consuming and expensive, and so we should try to
do the entire cutting process in a minimum number of setups; the task of determining
the sequence of the individual operations, grouping them into (a minimum number of)
setups, and determination of the fixture used for each setup, is called process planning.
These notes will be organized in three sections:
(i) Introduction to the processes,
(ii) The orthogonal cutting model and tool life optimization and
(iii) Process planning and machining planning formilling.

64
Fig. 6.48 Lathe machine
SAWING:
Cold saws are saws that make use of a circular saw blade to cut through various typesof
metal, including sheet metal. The name of the saw has to do with the action that takes
place during the cutting process, which manages to keep both the metal and the blade
from becoming too hot. A cold saw is powered with electricity and is usually a stationary
type of saw machine rather than a portable type of saw.
Fig. 6.49 Sawing Machine
The circular saw blades used with a cold saw are often constructed of high-speed steel.
Steel blades of this type are resistant to wear even under daily usage. The endresult is
that it is possible to complete a number of cutting projects before there is a

65
need to replace the blade. High speed steel blades are especially useful when the saws
are used for cutting through thicker sections of metal.
Along with the high-speed steel blades, a cold saw may also be equipped with a blade
that is tipped with tungsten carbide. This type of blade construction also helps to resist
wear and tear. One major difference is that tungsten tipped blades can be re-sharpened
from time to time, extending the life of the blade. This type of blade is a good fit for
use with sheet metal and other metallic components that are relatively thin in design.
WELDING:
Welding is a process for joining similar metals. Welding joins metals by melting and
fusing 1, the base metals being joined and 2, the filler metal applied. Welding employs
pinpointed, localized heat input. Most welding involves ferrous-based metalssuch as
steel and stainless steel. Weld joints are usually stronger than or as strong as the base
metals being joined.
. Fig. 6.50Welding

66
Welding is used for making permanent joints. It is used in the manufacture of
automobile bodies, aircraft frames, railway wagons, machine frames, structural works,
tanks, furniture, boilers, general repair work and ship building.
Several welding processes are based on heating with an electric arc, only a few are
considered here, starting with the oldest, simple arc welding, also known as shielded
metal arc welding (SMAW) or stick welding. In this process an electrical machine
(which may be DC or AC, but nowadays is usually AC) supplies current to an electrode
holder which carries an electrode which is normally coated with a mixture of chemicals
or flux. An earth cable connects the work piece to the welding machine to provide a
return path for the current. The weld is initiated by tapping ('striking') thetip of the
electrode against the work piece which initiates an electric arc. The high temperature
generated (about 6000oC) almost instantly produces a molten pool and the end of the
electrode continuously melts into this pool and forms the joint.
Fig. 6.51 Welding
The operator needs to control the gap between the electrode tip and the work piecewhile
moving the electrode along the joint.

67
Fig. 6.52 Welding
In the shielded metal arc welding process (SMAW) the 'stick' electrode is covered with
an extruded coating of flux. The heat of the arc melts the flux which generates agaseous
shield to keep air away from the molten pool and also flux ingredients react with
unwanted impurities such as surface oxides, creating a slag which floats to the surface
of the weld pool. This forms a crust which protects the weld while it is cooling. When
the weld is cold the slag is chipped off.
The SMAW process cannot be used on steel thinner than about 3mm and being a
discontinuous process, it is only suitable for manual operation. It is very widely used
in jobbing shops and for onsite steel construction work. A wide range of electrode
materials and coatings are available enabling the process to be applied to most steels,
heat resisting alloys and many types of cast iron.
DRILLNG:

68
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular
cross-section in solid materials. The drill bit is a rotary cutting tool, often multipoint.
The bit is pressed against the workpiece and rotated at rates from hundreds to
thousands of revolutions per minute. This forces the cutting edge against the
workpiece, cutting off chips (swarf) from the hole as it is drilled.
Fig. 6.53 Drilling process
The geometry of the common twist drill tool (called drill bit) is complex; it has straight
cutting teeth at the bottom – these teeth do most of the metal cutting, and it has curved
cutting teeth along its cylindrical surface. The grooves created by the helical teeth are
called flutes, and are useful in pushing the chips out from the hole asit is being
machined. Clearly, the velocity of the tip of the drill is zero, and so this region of the
tool cannot do much cutting. Therefore, it is common to machine a smallhole in the
material, called a center-hole, before utilizing the drill. Center-holes are made by
special drills called center-drills; they also provide a good way for the drill bit to get
aligned with the location of the center of the hole. There are hundreds of

69
different types of drill shapes and sizes; here, we will only restrict ourselves to some
general facts about drills.
Fig. 6.54 Drilling Bit
Common drill bit materials include hardened steel (High Speed Steel, Titanium Nitride
coated steel); for cutting harder materials, drills with hard inserts, e.g., carbideor CBN
inserts, are used;
Ingeneral, drills for cuttingsofter materials have smaller point angle, while those forcutting
hard and brittle materials have larger point angle;
If the Length/Diameter ratio of the hole to be machined is large, then we need a special
guiding support for the drill, which itself has to be very long; such operationsare called
gun-drilling. This process is used for holes with diameter of few mm or more, and L/D
ratio up to 300. These are used formaking barrels of guns;

70
Fig. 6.55 Drilling Machine
Drilling is not useful for very small diameter holes (e.g., < 0.5 mm), since the tool may
break and get stuck in the work piece; - Usually, the size of the hole made by a drill is
slightly larger than the measured diameter of the drill – this is mainly because of
vibration of the tool spindle as it rotates, possible misalignment of the drill with the
spindle axis, and some other factors;
For tight dimension control on hole diameter, we first drill a hole that is slightly smaller
than required size (e.g., 0.25 mm smaller), and then use a special type of drillcalled a
reamer. Reaming has very low material removal rate, low depth of cut, but gives good
dimension accuracy.

71
INSPECTION:
Critical appraisal involving examination, measurement, testing, gauging, and
comparison of materials or items. An inspection determines if the material or item isin
proper quantity and condition, and if it conforms to the applicable or specified
requirements. Inspection is generally divided into three categories: (1) Receiving
inspection, (2) In-process inspection, and (3) Final inspection. In quality control
(which is guided by the principle that "Quality cannot be inspected into a product")
the role of inspection is to verify and validate the variance data; it does not involve
separating the good from the bad.
Fig. 6.56 Inspection process
ASSEMBLY:
An assembly line is a manufacturing process (most of the time called a
progressive assembly) in which parts (usually interchangeable parts) are added as the
semi-finished assembly moves from work station to work station where the parts are

72
added in sequence until the final assembly is produced. By mechanically moving the
parts to the assembly work and moving the semi-finished assembly from work station
to work station, a finished product can be assembled much faster and with much less
labor than by having workers carry parts to a stationary piece for assembly.
WORKING PRINCIPLE
The major concepts/components used in this project are RF (Radio Frequency)
technology, D.C motor, Chassis designing, power circuit and power transmission etc.
We designed an RF based control system to control Robot. The signal gets generated
and transmitted with the help of antenna, provided on it. Now the receiving section
which we already installed on the robot will receive the signals and send the received
signals to the motor drive, on the basis of which motor driver will drive the robot and
robot climb on the inner side of the pipe.
Fig. 6.57 Working principle

73
Radio Frequency is a flexible technology that is convenient, easy to use, and
well suited for automatic operation. It combines advantages not available with other
technologies. It can be supplied as read-only or read/write, does not require contact or
line-of-sight to operate, can function under a variety of environmental conditions, and
provides a high level of data integrity.
The device can contain commands for robot. RF technology uses frequencies
within the range of 50 kHz to 2.5 GHz. An RF transceiver that generates the RF signals.
A reader that is receives RF transmissions and passes the data to a host system for
processing. To control robot a remote is designed which has a number of switcheson
its control board. As soon as you press any button it transmits signals that are received
by receiving section then it decodes it and on the basis of signals, motion takes place in
the robot-like forward, backward. Robot receives this signal with the help of antenna
present on the head of the robot.
Painting mechanism is spraying mechanism by rotation. Shaft is rotated by
pressurised air motor. When the pressurised air is passed to the motor the axle rotates
in speed. The material is dropped on the highly rotating head which splits the material.
i.e., it apply kinetic energy on the material and the material splashes on the inner wall.

74
6.6. COST ESTIMATION
For fabrication cost should be estimated and it consist of material laborand other costs
which areestimated below
MATERIAL COST:
MATERIAL UNIT RAT
E (Rs)
COST(Rs
)
DC motor 1 3000 3000
Air motor 1 2000 2000
shafts 4 80 320
Bush bearing 8 500 4000
Spur gear 3 500 1500
wheel 8 120 960
RF remote
control
1 700 700
Battery 1 5000 5000
Bolt and Nuts 12 20 240
Steel carbon 3Kg 60 180
Total 17900
From the above table we estimated the total material cost = Rs 17,900

75
2. LABOUR COST
Lathe, drilling, welding, grinding, power hacksaw, gas cutting is doneand a totalcost
can beestimated:
Labour Cost = 6000
3. OVERHEAD CHARGES
The overhead charges are arrived by “Manufacturing cost”
Manufacturing Cost = Material Cost + Labour cost
= 17,900 + 6000
= 23,900
Overhead Charges = 20% of the manufacturing cost
= 4780
TOTAL COST
Total cost = Material Cost + Labour cost + Overhead Charges
=
=
23,900 + 4780
28,980 ~ 29,000
Total cost for this project= Rs. 29,000

76
CHAPTER 7
ADVANTAGES & DISADVANTAGES
Advantages:
1. The painting robot saves on time required for painting.
2. The painting robot saves on the labour cost
3. As robot is automatic, it reduces human effort.
4. Easy to maintain.
5. Cost effective
Disadvantages:
1.Additional cost is high.
2. High maintenance is required.

77
CHAPTER 8
APPLICATIONS
1. Painting boiler feed pipes.
2. Painting water supply pipes.
3. Painting process industry pipes
4. Painting oil refinery pipes etc.
5. Painting screen type water filters.

78
CHAPTER 9
CONCLUSION
A strong multidiscipline team with a good engineering base is necessary for
the Development and refinement of advanced computer programming, editing
techniques, diagnostic Software, algorithms for the dynamic exchange of
informational different levels of hierarchy.
This project work has provided us an excellent opportunity and experience, to
use our limited knowledge. We gained a lot of practical knowledge regarding,
planning, purchasing, assembling and machining while doing this project work.
We are proud that we have completed the work with the limited time
successfully. The “FABRICATION OF INNER PIPE PAINTING ROBOT “is
working with satisfactory conditions. We are able to understand the difficulties in
maintaining the tolerances and also quality.
We have done to our ability and skill making maximum use of available
facilities. In conclusion remarks of our project work. Thus, we have developed a
“INNER PIPE PAINTING ROBOT”. By using more techniques, they can be
modified and developed according to the applications.

79
CHAPTER 10
REFERENCES
[1] Manfred E. Nicklas, “Internal Coating and Sand Blasting Bug for Pipe” United States
Patent - 4,036,173. Harvey, La. July 21, 1975.
[2] Paul M Cook & Richard F Otte, Raychem Corporation, Californea, “Apparatus for Internal
Pipe Protection” Jul_ 31, 1980.
[3]. Michael Baker Jr., Inc & Raymond R. Fessler, “Final report Pipeline Corrosion” U.S.
Department of Transportation Pipeline and Hazardous Materials Safety, November 2008.
[4] Neil G. Thompson, Dublin, Ohio. “Gas And Liquid Transmission Pipelines”, CC
Technologies Laboratories, Inc.2003.
[5] 09337, Washington, “Orbiter Pipe Painting Unit” June2004. [6] Dr. Anees U. Malik, “An
Investigation Report On The Failure Of Makkah-Taif Water Transmission System”,
March1989.
[7]. PSG “design data book”; PSG college of technology.
[8] “Machine Design”; R S Khurmi; S Chand & co ltd; 14th edition; 1996.
[9] INDUSTRIAL ELECTRONICS AND ROBOT Scbuler.H. A, W.L. McNamee.
[10] ELECTRICAL DEVICES AND CIRCUITS - ALLEN MATHOR
[11] Google, Wikipedia ……

Project report - mechanical - internal pipe painting machine

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