Project
| # | Title | Team Members | TA | Documents | Sponsor |
|---|---|---|---|---|---|
| 20 | Magnetic-Wheeled Pipe Climbing Robot for PowerTool Rust Removal |
Huanyu Feng Junxiang Qin Xiaocheng Zhang Xuhao Yang |
design_document1.pdf final_paper1.pdf proposal1.pdf |
Jiahuan Cui | |
| # Problem Corrosion of steel infrastructure causes trillions of dollars in economic losses globally each year. For external steel pipework, rust removal is a necessary prerequisite for reliable coating adhesion. However, traditional manual grinding and wire brushing are labor-intensive and expose workers to hazards such as working at heights, confined spaces, dust, and vibration. Furthermore, manual cleaning often results in inconsistent surface quality, which negatively impacts long-term corrosion resistance. # Solution Overview The proposed solution is a magnetic-wheeled pipe-climbing robot capable of automated power-tool rust removal on external steel pipes. By automating the grinding and brushing process, the robot reduces human exposure to extreme and hazardous maintenance conditions. To ensure consistent surface quality, the robot features a flexible end effector with force-position adjustment to stabilize tool-to-surface contact over pipe curvatures and irregularities. # Solution Components ## Mobility and Adhesion Subsystem • Compact 4-wheel chassis compatible with the curvature of steel pipes. • Drive motor assembly for locomotion. • Magnetic adhesion wheels designed to provide passive, continuous attraction and sufficient traction margin to prevent slippage during grinding. ## Rust Removal End Effector Subsystem • Modular, interchangeable abrasive tool head to mount attachments like wire brushes, fiber discs, or nonwoven conditioning discs. • Tool head motor with controllable rotational speed. • A flexible normal mechanism, such as springs or a leadscrew motor, to provide mechanical buffering and absorb vibration. ## Control and Sensing Subsystem • Force sensor or load cell to measure normal contact force. • Closed-loop control system that uses force sensor data and the leadscrew motor to implement a normal position compensation loop. • Protection logic system to handle abnormal events like tool jamming, sudden loss of adhesion, or emergency stops. # Criteria of Success • The robot must maintain reliable magnetic adhesion and traction on curved steel surfaces without slipping while under tangential tool loads. • The rust removal end effector must successfully maintain stable normal contact force when encountering surface irregularities like welds, pits, and thickness variations. • The system must achieve specific target cleanliness grades (e.g., ISO 8501-1 St 2/St 3 or SSPC-SP 11) and surface roughness/profile metrics required for industrial coating preparation. |
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