Adaptive Screw-Drive In-Pipe Robot with Hall-Effect Force Sensing and Active Gripping Control

Screw-drive in-pipe robots are widely used for inspection and maintenance of pipeline infrastructure because their tilted-wheel locomotion enables continuous traversal of horizontal, vertical, and curved pipes. However, most existing designs rely on passive spring mechanisms to generate wall-contact forces, making traction performance highly sensitive to pipe-diameter variations, friction changes, and manufacturing tolerances. This paper presents an adaptive screw-drive in-pipe robot that integrates adjustable radial geometry, embedded Hall-effect force sensing, and closed-loop gripping-force control. A unified mechanical–geometric model is developed to describe the coupling between actuator displacement, spring compression, wheel-tilt geometry, and pipe-diameter variation. Based on this model, a minimum safe gripping-force condition is derived and used to define a reference force for real-time control. A proportional–derivative controller regulates the gripping force of the front traction module, while a rear stabilizing module ensures axial alignment and suppresses body rotation. Simulation results under realistic diameter transitions and external disturbances demonstrate stable force regulation, preservation of a positive traction margin, and reduced unnecessary actuator effort. The proposed approach enables robust and energy-aware screw-drive locomotion in variable-diameter pipelines. A physical prototype of the robot has been fabricated to support the forthcoming experimental campaign; however, the validation presented in this study is limited to modeling and simulation, with experimental evaluation planned for future work.