Robot Pipe Navigation

Designing a Robot That Fits Where Humans Can't

Skills Used:

Robotics

System Design

Mechanical Design

Prototyping

Project Scoping

0-1 Development

Computer-Aided-Design (CAD)

Budgeting

For my senior capstone, I helped design and build the "Robotic Pipe Navigator," an autonomous robot delivering cold spray repairs inside natural gas pipelines. Using a scissor lift frame, custom rack-and-pinion gearing, and a servo-driven arm, the system centers itself in pipes from 1 – 2.5 ft in diameter and achieves full 360-degree repair coverage. I designed custom components in SolidWorks, fabricated parts via resin 3D printing and laser-cut Delrin, and managed project scope, budget, and team responsibilities across two semesters. As a result, we ended up delivering a functional prototype that validated a scalable approach to robotic pipeline servicing.

Overview

For my senior capstone, I collaborated on the design and development of an autonomous robotic frame capable of delivering a cold spray repair system inside natural gas pipelines. The project aimed to modernize inspection and maintenance workflows across industrial environments like petrochemical facilities and utility infrastructure. Spanning two academic semesters, I combined hands-on engineering development with structured project management to take the system from concept to functional prototype.

Project Objective

My primary objective was to design a robotic system capable of autonomously navigating inside pipelines of varying diameters while supporting precise positioning of a cold spray repair mechanism. The system needed to maintain stable operation, adapt to different pipe sizes, and enable full 360-degree repair coverage to improve inspection and maintenance efficiency. In parallel, I had to carefully plan scope, budget, and responsibilities to ensure feasibility within time and cost constraints.

What Was Done

Developed the "Robotic Pipe Navigator," an autonomous platform for in-pipe inspection and repair, incorporating a scissor lift frame to maintain centering within pipes ranging from 1 ft to 2.5 ft in diameter.
Implemented a rack-and-pinion mechanism for structural stability and resistance to external forces, designing a fully custom tooth profile in SolidWorks.
Built a servo-driven rotating arm using a 270-degree servo paired with custom gearing to achieve full 360-degree spray coverage, with key structural components fabricated via resin 3D printing.
Designed a drivetrain of DC motors capable of pivoting and adjusting to accommodate varying pipe diameters based on standardized natural gas pipeline specifications.
Integrated limit switches into the arm's rack-and-pinion system to automatically detect and map pipe diameter changes, enabling adaptive positioning during traversal.
Selected laser-cut Delrin sheets for the structural frame to balance durability, precision, and cost.
Authored a detailed scope document defining requirements, constraints, and success criteria, and mapped out material costs early to source components for affordability and manufacturability.
Divided responsibilities across mechanical design, CAD development, fabrication, and systems integration, coordinating regularly to keep subsystems aligned, and iteratively adjusted features based on testing feedback, budget limitations, and manufacturing constraints.

End Result

I delivered a functional autonomous robot capable of navigating pipeline environments, adjusting to varying diameters, and performing real-time positional control for inspection and repair tasks. It demonstrated reliable maneuverability, structural durability, and effective adaptation across diverse pipe configurations, while reducing anticipated inspection and maintenance costs. The project validated a scalable approach for robotic pipeline servicing applications, delivered within defined budget and scope constraints.