The document describes the development of an inspection robot for steel pipes through a process of continuous improvement using prototypes. The initial prototypes tested different methods of camera implementation and locomotion but faced challenges with range, image quality, and motion control. Subsequent prototypes refined these aspects, with prototype 4 achieving clear images over 50 meters using WiFi. The final prototype had 6 wheels, radio control over 250 meters, and added a cleaning function. This process allowed the company to develop a high-quality inspection robot and save thousands in costs.

1. Continuous
Improvement
Case of Inspection Robot
for Steel Pipes

2. Disclosure
All the following information and their respective intellectual
property belongs to the Chilean companies: Tecpipe S.A. and
Revestec S.A.
The equipment in this case was used by a protected process by
the patent: US 61/854,832.
The current presentation is only for educational purpose.

3. About the case
This real case was developed in 2013 by Tecpipe S.A., a Chilean
company in the HDPE (High Density Polyethylene) industry.
CODELCO, one of the biggest mining companies in Chile, signed a
contract with Tecpipe to lining steel pipes with HDPE. In order to
certify the quality, Tecpipe developed an Inspection Robot.
This presentation will explain the process that allowed to achieve
a highly technological inspection equipment under the logic of
continuous improvements used by Tecpipe and Revestec.

5. Objective
To develop an equipment able to record the actual state inside of
steel pipe.
The reason: when two pipes have joined, sometimes the weld is
irregular and could damage the HDPE tubes. An early detection of
these imperfections could reduce the probability of potential leaks
in pipe welded points.

6. Innovation method
The team developed the follow continuous improvement process:
1 2 3 4 5Understand Define Think Prototype Teste

7. Prototype #1

8. The first used prototype was a
R/C toy car with a very big lamp
over it.
This prototype worked very good
in HDPE pipes. However, the
prototype didn’t work with steel
pipes because the radio
frequency was too weak to
control the vehicle.
It worked for only 2 meters. The
challenge was to use the
inspection robot in 400 meters.
We learned:
• It is not necessary so much
light
• The radio frequency has to be
stronger or find a manual
method to move the device.

9. This was the first result.
The picture was unusable.

10. Prototype #2

11. The second prototype didn´t
use a big lamp, because the
pipe is dark enough to see
inside with a little lamp.
This vehicle used a professional
camera to record a video and
see potential imperfections.
This device didn´t use the radio
frequency, instead we preferred
to add a plastic line to pull it.
We learned:
• The plastic line is not a good
idea for 400 meters of pipe.
• The professional camera is
an over dimensioned device.
• However, it is necessary to
see what is happening inside
the pipe in real time.

12. http://youtu.be/uYLzYlpH_VY

13. This was the second result.
The picture was unusable.

14. Prototype #3

15. The third prototype didn’t use radio
frequency or a manual method to
pull it, it used electric motors to
move. The vehicle was able to
move in one direction and back
using a wire remote control.
We used a GoPRO camera with Wi-
Fi broadcasting in order to receive
the image in real time. This camera
needed more light, so we decided
to install a big photograph lamp in
the front.
We learned:
• GoPRO and the lamp worked
fine.
• The vehicle didn´t move more
than 30 meters. The reason: the
electric tension decreases
gradually through the wire. It´s
necessary to increase the power
of the battery at least 10x.

16. The screen was a little tablet
able to receive Wi-Fi.
We learned:
• Under 50 meters, the Wi-Fi
signal works excellent but is
not useful for 400 meters
because the signal is too
weak.

17. This was the third result.
The picture was absolutely
useful.

18. Prototype #4: Back to the basic

19. Innovation method
Back to the basic….
1 2 3 4 5Understand Define Think Prototype Teste

20. The 3 first prototypes only
demonstrated one thing: the camera
was the correct one.
So, we decided to back to basic and
tried again.
We built a new version without
propulsion, lighter, and absolutely
manual.
We learned:
• The weight is important because
in the pipe the vehicle tent to roll
over.
• It is possible to receive the Wi-Fi
signal if the operator follows close
the vehicle next to the pipe.
• However, the vehicle has to have
propulsion in order to control its
position inside the pipe.

21. Prototype #5: A big jump

22. The 3 first prototypes only
demonstrated one think: the
camera is the correct.
So, we decided to back to basic and
tried again.
We build a new version without
propulsion, lighter, and absolutely
manual.
We learned:
• The weight is important because
in the pipe the vehicle tent to
roll over.
• Is possible to receive the Wi-Fi
signal if the operator follow
close the vehicle next to the
pipe.
• Only is possible to achieve the
point above if the vehicle has a
propulsion in order to control its
position inside the pipe.

23. With all the previous knowledge
using prototypes, the engineers
designed a new vehicle.
Vehicle features:
• Able to drive through 250
meters of pipe. If you need to
inspect 400, you insert the
vehicle in both enters.
• Never roll over because its 6
wheels stabilize the vehicle and
leave the gravity center far
below.
• The radio frequency was
increased in 100x in order to
control the position of the
vehicle in every single place
inside the pipe.

24. Finally, this vehicle was an
inspection robot, able to detect
imperfections in the weld between
pipes.
This continuous improvement
process allowed to save thousand
of dollars in supplies and delivered
a highly quality service to the main
mining company in Chile.

25. http://youtu.be/CixtnW_WV1U

26. Final Version: New features

27. The continuous improvement
process never ends.
After weeks of inspections, we
discovered a new feature for the
inspection robot: a cleaning
function.
After some improvements the final
version was this…

28. The 3 first prototypes only
demonstrated one think: the
camera is the correct.
So, we decided to back to basic and
tried again.
We build a new version without
propulsion, lighter, and absolutely
manual.
We learned:
• The weight is important because
in the pipe the vehicle tent to
roll over.
• Is possible to receive the Wi-Fi
signal if the operator follow
close the vehicle next to the
pipe.
• Only is possible to achieve the
point above if the vehicle has a
propulsion in order to control its
position inside the pipe.

29. Results

30. Increase the inspection scope (mts)
200x

31. Decrease the inspection time (hours)
80%

32. From Asynchronous inspection to
Real time

33. Simple improvements can change everything…

34. innovation
business
Master in Innovation
Adolfo Ibáñez University (2012)
Business Engineer
Alberto Hurtado University (2012)
International Trade Engineer (c)
Metropolitan Technological University (1998)
EduardoReyes
entrepreneurship

35. innovation
business
More Information?
eduardo.reyes.b@me.com
EduardoReyes
entrepreneurship