Project Report

4/25/2019 Project Report
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Project Report
1. 1. 1 | P a g e DESIGN & FABRICATION OF ROCKER-BOGIE MECHANISM MINOR PROJECT SUBMITTED IN PARTIAL FULFILLMENT OF
REQUIREMENTS FOR THE AWARD OF THE DEGREE OF BACHELOR OF TECHNOLOGY MECHANICAL ENGINEERING BY ANUBHAV
KUMAR DEERGHA GARG (12001004009 ) (12001004015 ) NITIN VERMA RAHUL HANS (12001004037) (12001004044 ) UNDER THE GUIDANCE
OF Dr. AJAY KUMAR DEPARTMENT OF MECHANICAL ENGINEERING FACULTY OF ENGINEERING & TECHNOLOGY D.C.R. UNIVERSITY
OF SCIENCE & TECHNOLOGY MURTHAL, SONEPAT, HARYANA (INDIA) – 131 039 (NOVEMBER 2015)
2. 2. 2 | P a g e DECLARATION BY THE CANDIDATES We hereby certify that the work which is being presented in this Project report entitled ‘DESIGN &
FABRICATION OF ROCKER-BOGIE MECHANISM’ in partial fulfillment of requirements for the award of degree of BACHELOR OF TECHNOLOGY in
MECHANICAL ENGINEERING, submitted to the Dept. of Mechanical Engineering, Faculty of Engg. & Technology, D.C.R. Univ. of Science & Technology,
Murthal, Sonepat (Haryana) is an authentic record of our own work carried out during a period from July 2015 to May 2016 under the supervision of Dr.
AJAY KUMAR The matter presented in this project work has not been submitted to any other University / Institute for the award of B.Tech or any other
Degree / Diploma. Name (Roll. No.) Signature 1. Anubhav Kumar (12001004009) 2. Deergha Garg (12001004015) 3. Nitin Verma(12001004037) 4. Rahul
Hans(12001004044) This is to certify that the above statement made by the candidate is correct to the best of my knowledge & belief. Signature of Supervisor
(s)
3. 3. 3 | P a g e ABSTRACT The rocker-bogie suspension mechanism it’s currently NASA’s favored design for wheeled mobile robots, mainly because it has
robust capabilities to deal with obstacles and because it uniformly distributes the payload over its 6 wheels at all times. Even though it has many advantages
when dealing with obstacles, there is one major shortcoming which is its low average speed of operation, making the rocker- bogie system not suitable for
situations where high-speed traversal over hard-flat surfaces is needed to cover large areas in short periods of time, mainly due to stability problems. Our
propose is to increase the stability of the rocker-bogie system by expanding its support polygon, making it more stable and adaptable while moving at high
speed, but keeping its original robustness against obstacles. The Rocker-Bogie Mobility system was designed to be used at slow speeds. It is capable of
overcoming obstacles that are on the order of the size of a wheel. However, when surmounting a sizable obstacle, the vehicles motion effectively stops while
the front wheel climbs the obstacle. When operating at low speed (greater than 10cm/second), dynamic shocks are minimized when this happens. For many
future planetary missions, rovers will have to operate at human level speeds (~1m/second). Shocks resulting from the impact of the front wheel against an
obstacle could damage the payload or the vehicle.We will develop a method of driving a rocker-bogie vehicle so that it can effectively step over most obstacles
rather than impacting and climbing over them. Most of the benefits of this method can be achieved without any mechanical modification to existing designs –
only a change in control strategy. Some mechanical changes are suggested to gather the maximum benefit and to greatly increase the effective operational
speed of future rovers.
4. 4. 4 | P a g e ACKNOWLEDGEMENT We are highly grateful to the Hon’ble Vice-Chancellor, D.C.R. Univ. of Science & Technology, Murthal, Sonepat for
providing us this opportunity to carry out the present project work. The constant guidance and encouragement received from Dr. Ajay Kumar , Prof. &
Chairperson, Dept. of Mechanical Engineering, D.C.R. Univ. of Science & Technology, Murthal, Sonepat has been of great help in carrying our the present
work and is acknowledged with reverential thanks. We would like to express a deep sense of gratitude and thanks profusely to our Project Supervisor, Dr. Ajay
Kumar , Asstt. Prof./Associate Prof./Professor, Dept. of Mechanical Engineering, D.C.R. Univ. of Science & Technology, Murthal, Sonepat. Without his/her
able guidance, it would have been impossible to complete the project in this manner. The help rendered by Sh. M.S. Narwal B.Tech. Project Coordinator,
Department of Mechanical Engineering, D.C.R. Univ. of Science & Technology, Murthal, Sonepat for his/her wise counsel is greatly acknowledged. We also
express our gratitude to other faculty members of Dept. of Mechanical Engineering, D.C.R. Univ. of Science & Technology, Murthal, Sonepat for their
intellectual support throughout the course of this work. Finally, We are indebted to all whosoever have contributed in this project work. Name Roll. No.
Signature 1. Anubhav 12001004009 2. Deergha Garg 12001004015 3. Nitin Verma 12001004037 4. Rahul Hans 12001004044
5. 5. 5 | P a g e LIST OF FIGURES & TABLES Figure 1 MER (Mars Exploration Rover) Figure 2 NASA’s Curiosity Rover Figure 3 Red Rover Figure 4 Lateral
Stability Figure 5 Longitudinal Stability Figure 6 Centre Stage Stairs Figure 7 Calculations at Centre Stage Stairs Figure 8 Library Stairs Figure 9 Calculation
at Library Stairs Table 1 Calculation of Wheel Diameters Table 2 Calculation of Diameter and RPM Table 3 Hardware to be Purchased Table 4 Electrical
Equipments to be Purchased
6. 6. 6 | P a g e Table of Contents Decleration by the Candidates Abstract Acknowledgement List of Figures & Tables CHAPTER 1 INTRODUCTION 1.1
Introduction 1.2 Need & Motivation for the Selection of the Project 1.3 Objective of the Project CHAPTER 2 PAST, PRESENT & FUTURE 2.1 Introduction
2.2 Recent Rovers & their Missions 2.3 Rover Mobility CHAPTER 3 RELATED CONCEPTS & THEORIES 3.1 Design Requirements & Specification 3.2
Related Concepts 3.2.1 Traction & Slip 3.2.2 Lateral Stability 3.2.3 Longitudinal Stability 3.2.4 Static Stability Factor 3.3 Design Analysis CHAPTER 4
CALCULATIONS 1. Diameter of Wheel 2. Calculation of Wheel Base 3. Length of Links 4. Height Calculation 5. Track Width
7. 7. 7 | P a g e CHAPTER 5 CONCLUSIONS 5.1 Conclusion 5.2 Budget & Table of Requirements 5.3 Future Scope References
8. 8. 8 | P a g e CHAPTER 1 INTRODUCTION 1.1 Introduction There is an increasing need for mobile robots which are able to operate in unstructured
environments with highly uneven terrain. These robots are mainly used for tasks which humans cannot do and which are not safe. In order to achieve these
tasks, any mobile robot needs to have a suitable mobile system according to each situation. Among these mobile systems, it’s the rocker-bogie suspension
system that was first used for the Mars Rover Sojourner and it’s currently NASA’s favored design for rover wheel suspension. The rocker-bogie suspension is
a mechanism that enables a six-wheeled vehicle to passively keep all six wheels in contact with a surface even when driving on severely uneven terrain. There
are two key advantages to this feature. The first advantage is that the wheels' pressure on the ground will be equilibrated. This is extremely important in soft
terrain where excessive ground pressure can result in the vehicle sinking into the driving surface. The second advantage is that while climbing over hard,
uneven terrain, all six wheels will nominally remain in contact with the surface and under load, helping to propel the vehicle over the terrain. Exploration
rovers take advantage of this configuration by integrating each wheel with a drive actuator, maximizing the vehicle's motive force capability. One of the major
shortcomings of current rocker- bogie rovers is that they are slow. In order to be able to overcome significantly rough terrain (i.e., obstacles more than a few
percent of wheel radius) without significant risk of flipping the vehicle or damaging the suspension, these robots move slowly and climb over the obstacles by
having wheels lift each piece of the suspension over the obstacle one portion at a time. While performance on rough terrain obstacles is important, it should be
also considered situations where the surface is flat or it has almost imperceptible obstacles, where the rover should increase its speed to arrive faster from point
A to point B.
9. 9. 9 | P a g e 1.2 Need and Motivation for the selection of the project Rocker-bogie suspension system that was first used for the Mars Rover Sojourner and it’s
currently NASA’s favored design for rover wheel suspension. This is a very less explored field of study and could be developed into exploration purpose
instrument. The need to develop specialized high-fidelity systems capable of operating in harsh earth environments typically leads to longer development
timelines and greater expenditures. While specific applications will always require unique designs, there are many commonalities in planetary rovers. Issues
such as mobility, navigation, and vision, may differ slightly between missions but are largely the same in most scenarios. Given these fundamental
characteristics of many planetary rovers we believe that a modular and ruggedized system meeting these basic requirements would aid in the process of
developing space-ready technology. There are currently many mobile research platforms available, yet few are designed to operate in the harsh earth
environments that are often used for planetary surface rover testing. By creating a rover that is suitable for these types of environments, our goal is to facilitate
the development of rovers and their related technologies, in addition to lowering development costs. We also hope that the platform developed can be tested
and improved upon, to potentially serve as a model for a rover that could go to the moon or Mars in the future. Our mission is to design, develop, and test a
rover to serve as a research platform, suitable for testing planetary surface exploration technologies in harsh earth environments. The design will focus on
incorporating features that are believed to be essential for most planetary exploration missions.The Rocker bogie Suspension system can be sent for
reconnaissance purpose,which is exploring the surrounding to give a visualisation to a person or operator sitting somewhere for carrying the operation, by the
help of a video camera. Hence, due to this feature of the rocker bogie suspension system this can be used in military for visualising the scenario at a region
where a bomb is planted. Not only this, the rocker bogie suspension system can be developed into a wheel chair too to take the patients from one place to
another climbing the stairs on its own. It can also be used for material delivery purposes. As explained this is a wide field of study and very less explored. So
this gave the motivation for the development of this suspension system.
10. 10. 10 | P a g e 1.3 Objective of the Project We will be focusing on eliminating the shortcomings of the rover. one of the major shortcomings of current rocker-
bogie rovers is that they are slow. In order to be able to overcome significantly rough terrain without significant risk of flipping the vehicle or damaging the
suspension, these robots move slowly and climb over the obstacles by having wheels lift each piece of the suspension over the obstacle one portion at a time.
While performance on rough terrain obstacles is important, it should be also considered situations where the surface is flat or it has almost imperceptible
obstacles, where the rover should increase its speed to arrive faster from point A to point B. The rovers made for the exploration purposes are very costly too.
Due to the high cost of space exploration, most missions to date have been conducted by NASA and other government-supported organizations. However, the
continually decreasing cost of technology and economic potential in natural resources has led some private companies to pursue space transportation and
exploration as a core business. For example, Astrobotic Technology, Odyssey Moon, and Armadillo Aerospace are just a few companies that are developing
rovers and landers for different space missions. While companies like these have made progress in the commercialization of space exploration, the inherently
high costs continue to hinder economic feasibility. We, in India have not conducted any mission for the exploration purposes. Not only mars exploration the
rocker bogie can also be used for military and civil purposes but there also it is needed to be a little cost effective and fast. Thus our concern during the
development of the rover would be to optimise the speed such that the rover do not flip and may travel a litle faster too and make it cost effective with
maximum possible rigidity and ruggedness.
11. 11. 11 | P a g e CHAPTER 2 PAST PRESENT & FUTURE 2.1 Introduction This chapter will begin by reviewing some past space exploration rovers as well
as rovers currently in development. It will discuss specific missions along with the corresponding design features and capabilities, specifically relating to
mobility and navigation, that made these rovers successful in meeting their objectives on the Martian or lunar surface. Next, specific features of these rovers
are discussed in order to learn more about the types of technologies that are often used on exploration rovers. Both hardware and software design choices are
reviewed, as they relate to the mobility challenges of ground compliance and hazard avoidance. Lastly, research into analog testing presents what is currently
being done by NASA and others to validate planetary rovers on Earth. A variety of harsh Earth environments are examined for their suitability in analog
testing based on how well they represent certain aspects of the Martian and Lunar environments. A few NASA sponsored competitions are also reviewed, as
they can often provide unique opportunities for analog testing at NASA facilities. 2.2 Recent Rovers and their Missions Much of space exploration can be
divided into three categories: a quest to better understand our universe, interest, and economic potential in using natural resources outside our planet, and the
future colonization of extra-terrestrial bodies. Furthermore, most interest has been in our moon and Mars, as these planetary bodies are close by, and have
environments that are hospitable enough for rovers, and potentially for future colonization. The moon is also very well suited for scientific equipment such as
radio observatories or IR telescopes, as it has no atmosphere, instruments such as these can measure signals that would otherwise be disturbed or eliminated on
Earth. Interest in Mars mostly relates to expanding our knowledge of the planet, specifically with respect to its
12. 12. 12 | P a g e ability to support a human colony. Learning more about the composition of its atmosphere and soil can tell us whether Mars could potentially
support microbial life. Since 1976, NASA has been exploring the surface of Mars with rovers, starting with the dual landing of Viking 1 and Viking 2 landers.
In 1997, The Mars Pathfinder (MPF) lander delivered the Sojourner Rover to the surface successfully. Most recently, in early 2004, NASA again landed two
more rovers on Mars, Spirit and Opportunity. In November 2011, NASA has launched the Mars Science Laboratory (MSL) with a rover named Curiosity.
Despite the multiple rovers that NASA has sent to Mars, each mission has similar objectives. Making improvements from past Mars rovers, NASA has
continued to develop autonomous navigation to make it easier and quicker to control their rovers, given the relatively large time delays in sending commands.
To do this, on-board stereo vision processing was used to develop an image on the environment, which identified positive and negative obstacles relative to the
ground plane. The other main features of the MERs relate to mobility hardware, which allowed them to traverse the Martian terrain with relative ease. In
continuation of past Mars rover designs, the rocker-bogie suspension was used. It consists of six wheels and multiple axles that allow the rover to overcome
obstacles larger than its wheel diameter. The specialized wheels of the rover are approximately 26 centimeters in diameter and have a unique aluminum flexure
structure to connect the hub to the rim of the wheel. These flexure joints act as shock absorbers which help to reduce the shock loads on other components of
the rover. Each wheel also has small cleats, which have been found to be effective both for soft sandy terrain and in navigating over rocks. Fig. 1 MER Rover
13. 13. 13 | P a g e Curiosity an advantage in terms of its path planning ability. It has a three axis inertial measurement unit (IMU), enabling the rover to make
precise movements while also monitoring the degree of tilt that the rover is experiencing. To tackle the mobility challenge, the 900kg rover has a very similar
6 wheel rocker-bogie suspension as previous Mars exploration rovers have. The larger size combined with the rocker- bogie suspension allows the rover to go
over obstacles 60-75cm higher, which is greater than its wheel diameter of 50cm. It can also safely traverse slopes up to 45°, but is limited to 30° slopes by
software to ensure a factor of safety. Curiosity also has cleated treads that are similar to the MER rovers, which were found to be an optimal solution for
Martian terrain. With a top speed of 4cm/sec, it was the fastest rover sent to Mars. Fig 2. NASA’s Curiosity Rover In reviewing NASA’s rovers for surface
exploration on Mars, there were many similarities in both their mechanical design and software that enable the rovers to perform on-board path planning.
Autonomous planetary navigation combined with hazard avoidance and other self-preservation autonomy makes these rovers excellent platforms to reliably
transport and position their scientific instruments. The biggest changes between missions have been the size of the rover and the types of scientific instruments
it supports.
14. 14. 14 | P a g e Astrobotic Technology Inc. is one such company that has founded itself on making space exploration profitable, by delivering payloads and
performing robotic services on the moon. They are currently in collaboration with Carnegie Mellon University and others, to develop a rover and lander for
their first surface lunar exploration mission, which if successful will satisfy the X-prize criteria as well as other objectives. Their robot, called Red Rover, is
reviewed here because it is one of the most developed lunar exploration rovers. Red Rover is designed to be a scout, exploring places such as polar ice fields
or skylights into lunar lava tubes. Its goal is to determine where the interesting locations are, based on its analysis of chemical composition and high resolution
3D images. To facilitate roving about the lunar surface, Red Rover uses a 4 wheel rocker differencing suspension system. This type of passive suspension is
based on the rocker-bogie design but is simplified by reducing the number of wheels and free-pivoting axles. It drives the two wheels on each side of the rover
together, and thus relies on skid-steering to rotate the rover. For vision, Red Rover has a stereo camera and flash LIDAR which will allow it to make high-
resolution terrain maps. While it will likely have some form of on-board autonomous hazard avoidance or path planning it is unclear exactly to what extent, as
available information only suggests that the rover is teleoperated. Figure 3 is a picture of one of the recent prototypes of Red Rover. Figure 3 Red Rover
15. 15. 15 | P a g e 2.3 Rover Mobility One of the most challenging aspects of rover operation in planetary environments is effective mobility. In order for a rover
to complete any science tasks, it first must be able to move confidently in unforgiving terrain. This may include both challenging surfaces and wider-scale
terrain discontinuities. Surface challenges to rover mobility include fine powders such as lunar regolith, screen fields, and larger rocks. Topographic features
such as craters, hills, gullies, and cliffs present different forms of challenges. To complicate the problem further, many planetary environments are not well
studied, so rover mobility systems must be flexible to accommodate unknown factors. Effective rover mobility systems combine robust mechanical hardware
with sensors and programming to detect impassible terrain. The goal of any rover mobility system is to reduce the impact of variable terrain on the rover’s
ability to traverse a given path. This typically involves a suspension system which allows the rover to travel over certain obstacles in its path as well as absorb
shocks and unevenness. The most basic mobility system is the wheel, and an effective wheel design becomes a major part of any rover drive system. Most
planetary rovers have used all-metal wheels for their high strength-to-weight ratio. NASA/JPL’s 10.5 kilogram Sojourner rover used 13 centimeter one- piece
aluminum wheels with sharp stainless steel cleats to climb obstacles and gain traction in soft soil. Sojourner‟s wheels were rigidly connected to the drive
motors with no suspension elements. It has large billet aluminum with thin straight spokes and a zigzag aluminum pattern machined into the outer surface.
These 50 centimeter wheels support the 900 kilogram rover over obstacles up to 75 centimeters in height. Additionally, MSL’s wheels are needed to support
the rover during its final landing, a large shock load. The Mars Science Laboratory plans to drive about 12 kilometers during its mission, most of it
autonomously. These components are typically articulated to increase the maximum obstacle the rover is capable of traversing, as well as maintain stability on
tilted terrain. These mobility systems can also incorporate passive or active suspension elements which help reduce the shock loading experienced by the rover
chassis. The two most common methods of articulating mobility systems include rocker bogie and rocker differencing. The primary benefit to a rocker-bogie
suspension is that a rover is able to climb an obstacle up to twice the diameter of its wheels while keeping all 6 wheels in contact with the surface. Because the
front and rear wheels can help to push or pull the free-floating bogie link, it is able to go over relatively large obstacles compare to its wheel size. As a
suspension system, the rocker-bogie contains no spring elements, and this helps provide stability while going over large obstacles.
16. 16. 16 | P a g e CHAPTER 3 RELATED CONCEPTS & THEORIES 3.1 Design Reqiurement & Specifications Our main goal is to design, develop, and test a
rover to serve as a mobility platform, suitable for testing planetary surface exploration technologies in harsh earth environments. The design will focus on
incorporating features that are believed to be essential for most planetary exploration missions based on research of past and current rovers. Given what we
have learned about existing rovers and the types of missions they aim to accomplish, our design goals for our rover have been made into these categories: 1.
Mobility and navigation 2. Size and weight restrictions While our rover will not be travelling to space, it is our goal to make a robust and ruggedized platform
that will be suitable for testing in harsh earth environments, on terrain similar to that of our moon and Mars. Given sufficient mobility in planetary
environments, the rover must also be able to accommodate payloads,if possible. Transporting sensitive scientific instruments across rough terrain is the main
goal for nearly all exploration rovers, and thus one of our central requirements. Additionally, to be useful for other users both in academia or industry, the
rover needs to easily integrate new hardware and software as part of its payloads. By providing a robust mobility platform that can accommodate a wide range
of payloads, the rover should prove useful to anyone interested in testing rover related technologies or conducting research in the field of space exploration.
Lastly, the rover will aim to recognize the size and weight constraints that all space bound vehicles face. While there are many resource constraints that
prohibit us from designing a space-ready rover, the design will attempt to accommodate space considerations when possible. In formulating the design
specifications relating to mobility we wanted to ensure that the rover could traverse a wide variety of harsh Earth environments. Such terrain includes deserts,
rock fields, gravel pits, sand dunes, and mountainous areas in many different climates. In examining these terrains we will make design criterias relating to the
size of obstacles, inclines, and speeds that the rover must achieve, in order to ensure that it could maneuver in many different environments. in most scenarios
the ability to go over larger obstacles always increases mobility potential. For our rover we set the goal of being able to traverse obstacles, both positive and
negative to the ground plane.
17. 17. 17 | P a g e 3.2 Related Concepts 3.2.1 Traction and Slip The rover must maintain good wheel traction in challenging rough terrains. If traction is too high,
the vehicle consumes a lot of power in order to overcome the force and move. If traction is too low, the rover is not able to climb over obstacles or inclined
surfaces. Slip occurs when the traction force at a wheel-terrain contact point is larger than the product of the normal force at the same wheel and the friction
coefficient. Hence, no slip occurs if the condition Ti ≤ μNi is satisfied. In reality it is very challenging to determine the precise friction coefficient μ for the
interaction of two surfaces. 3.2.2 Lateral Stability The rover is said to be stable when it is in a quasi-static state in which it does not tilt over. The simplest
approach to find the static stability is using the geometric model, which is commonly referred to as stability margin. As the asymmetric suspension system of
the passively articulated rover has a great influence on the vehicle’s effective stability, a more advanced approach is using a static model. The lateral stability
of the rover ensures that the rover does not tip sideways. As the rover has two symmetric sides, the geometric model is used to find the lateral stability of the
vehicle. Lateral stability is computed by finding the minimum allowed angle on the slope before the rover tips over. Lateral stability is ensured if this angle is
smaller than the maximum angle of incline α on the slope at the wheel-terrain contact points. The angles θl and θr are obtained geometrically. The overall
stability angle θstab can be computed by θstab = min(θr,θl) Lateral stability of the rover is ensured if the overall stability angle θstab ≥ α .:. min(θr,θl) ≥ α
18. 18. 18 | P a g e Fig 4 Lateral Stability Let N1 be the reaction on the right wheel and N2 be the reaction on the left wheel. Let α be the slope of the inclination,
θr & θl be the angle that the point of contact makes with the Centre of Gravity on the left and right wheels respectively.Z be the height of the centre of gravity.
And yl and yr be the perpendicular between the point of contact and the Centre of Gravity. In this condition to ensure the stability the rover should not tip off
the inclined. And hence the normal reaction on any of the wheel should not be 0. Taking moment at the left wheel. Mg z sin α + Mg yl cos α = N1 (yl+yr)
Dividing the equation by z Mg sin α + Mg yl/z cos α = N1 (yl+yr)/z From the figure above the yl/z = tan θl and yr/z =tan θr Mg sin α + Mg tan θl cos α = N1
(tan θl + tan θr) Let θl θr and α be very small then Mg α + Mg θl = N1 (θl + θr) Mg( α + θl ) = N1 (θl +θr) Mg > N1 ( α + θl ) < (θl +θr) α < θr Hence to ensure
stability this condition should be fulfilled.
19. 19. 19 | P a g e 3.2.3 Longitudinal Stability The computation of the longitudinal stability of the rover makes use of a statical model as it is not symmetric in
longitudinal direction. Using a statical model, the mechanical properties of the suspension system are taken into account. According to , longitudinal stability
of the vehicle is given when all wheels have ground contact and the condition Ni > 0 is satisfied, where Ni is the normal force at wheel i. It should be noted
that even though this condition is compulsory for the statical model to work, a physical rover does not necessarily tip if a wheel looses contact to the ground.
However, it is less steerable. Figure 5 Longitudinal Stability 3.2.4 Static Stability Factor The Static Stability Factor (SSF) of a vehicle is one half the track
width, TW, divided by h, the height of the center of gravity above the road. The inertial force which causes a vehicle to sway on its suspension (and roll over
in extreme cases) in response to cornering, rapid steering reversals or striking a tripping mechanism, when sliding laterally may be thought of as a force acting
at the CoG to pull the vehicle body laterally. A reduction in CoG height increases the lateral inertial force necessary to cause rollover by reducing its leverage,
and the advantage is represented by an increase in the computed value of SSF. A wider track width also increases the lateral force necessary to cause rollover
by increasing the leverage of the vehicle's weight in resisting rollover, and that advantage also increases the computed value of SSF. The factor of two in the
computation "TW over 2h" makes SSF equal to the lateral acceleration in g's (g-force) at which rollover begins in the most simplified rollover analysis of a
vehicle represented by a rigid body without suspension movement or tire deflections
20. 20. 20 | P a g e 3.3 Design & Analysis Under this section we will discuss our complete rover design and discuss how our key design decisions were made in
order to meet the requirements and goals presented in the previous sections. Each one of these is related to meeting fundamental requirements. Mobility
Mobility relates to the rover’s capacity to traverse varying terrains, slopes, and obstacles. In beginning the process of formulating the drive architecture we
reviewed current and past rovers in consideration of chassis design, suspension methods, wheel design, and power requirements. Since nearly all rover
hardware is related to mobility, this section will review most of the mechanical design including the chassis, suspension, and wheel components. These rovers
move slowly and climb over the obstacles by having wheels lift each piece of the suspension over the obstacle one portion at a time. NASA’s currently favored
design, the rocker-bogie, uses a two wheeled rocker arm on a passive pivot attached to a main bogie that is connected differentially to the main bogie on the
other side. The ride is further smoothed by the rocker which only passes on a portion of a wheel’s displacement to the main bogie. Each wheel is
independently driven. The maximum speed of the robots operated in this way is limited to eliminate as many dynamic effects as possible, and so that the
motors can be geared down so that the wheels can individually lift a large portion of the entire vehicle’s mass. In order to go over an obstacle, the front wheels
are forced against the obstacle by the rear wheels. The rotation of the front wheel then lifts the front of the vehicle up and over the obstacle. The middle wheel
is the pressed against the obstacle by the rear wheel and pulled against the obstacle by the front, until it is lifted up and over. Finally, the rear wheel is pulled
over the obstacle by the front two wheels. During each wheel’s traversal of the obstacle, forward progress of the vehicle is slowed or completely halted. We
will be using the same mechanism the six wheel independent drive to cross the obstacles but without any differential. To further simplify the design we choose
to use one motor to directly drive each wheel. Since it is a skid steering rover an alternative solution could be to have one motor drive two wheels on either
side, resulting in fewer motors and less mass. However, having one motor for each wheel reduces the need for a complex power transfer system, which is often
done with belts, gears, or drive shafts. The material used for the links should be cheap as well as light in weight thats why we will use the Acrylic material
which has the required properties of light weight and rigidity.
21. 21. 21 | P a g e Wheel Design The wheels are needed to be wider for increasing the traction to traverse upon the obstacles. And their diameter depend upon the
availability and amount of speed required. The actual rover uses billet wheels, and machine the wheel and tread from one piece of round aluminum stock.The
main problem during the selection of the wheels is light weight consideration and the distribution of load on the wheels. Velocity 8cm/s Velocity 10cm/s
Velocity 12cm/s RPM Diameter RPM Diameter RPM Diameter M cm m cm M cm 10 0.153 15.277 10 0.191 19.096 10 0.229 22.915 20 0.076 7.638 20 0.095
9.548 20 0.115 11.458 30 0.051 5.092 30 0.064 6.365 30 0.076 7.638 40 0.038 3.819 40 0.048 4.774 40 0.057 5.729 50 0.031 3.055 50 0.038 3.819 50 0.046
4.583 60 0.025 2.546 60 0.032 3.183 60 0.038 3.819 70 0.022 2.182 70 0.027 2.728 70 0.033 3.274 80 0.019 1.910 80 0.024 2.387 80 0.029 2.864 90 0.017
1.697 90 0.021 2.122 90 0.025 2.546 100 0.015 1.528 100 0.019 1.910 100 0.023 2.292 110 0.014 1.389 110 0.017 1.736 110 0.021 2.083 120 0.013 1.273 120
0.016 1.591 120 0.019 1.910 130 0.012 1.175 130 0.015 1.469 130 0.018 1.763 140 0.011 1.091 140 0.014 1.364 140 0.016 1.637 Table 1 Calculation of
Wheel Diameters Hence for the light weight and cost effectiveness of the rover we will choose plastic wheels with rubber treads available in the market
depending upon the calculations. While our wheel design may not be optimized in terms of strength and weight reduction, it will result in a cost effective
solution with minimal manufacturing time, and a wheel that should meet all design goals.
22. 22. 22 | P a g e Drive motor Selection Since the rover consists of six indepently drive wheels hence the drive motor is needed for every wheel. The Selection of
drive motor depends upon the speed of the rover that is desired. We will try to design the rover for a speed of 10 cm/s and will choose the parameters based
upon it. The rover is designed to cross the obstacle and hence need more traction thus the motor choosed should be of low rpm but the rpm cannot be very low
because to maintain the speed the diameter of the wheel will have to be increased thus an optimum rpm motor is needed to be selected. We will be using a 30
rpm motor with 12V DC because it is well suited depending upon the requirements and calculations. Power Supply The MER has to travel the surface of mars
where there is no availability of power source thus it used solar cell to charge the battery and derive the power from the battery for the motors and other
equipments. But since we are using the rover on the earth surface and our main focus is the development of mechanism rather than the power source so we
will be using the cheapest possible alternative that is the 12 0 12 Step down Transformer and a Full wave Rectifier for converting the AC into DC to supply
the adequate power to all motors in connection. Control The Control of the rover will be manual with the help of a joysticks for driving each side of the rover
separately. It will be helpful while taking a turn. All the connections will be wired and no wireless means will be used because we need to simulate the
mechanism and not the actual rover and to make it cost effective in all possible manners.
23. 23. 23 | P a g e CHAPTER 4 CALCULATIONS Calculation 1 1. Diameter of Wheel 𝑉 = πDN 60 Assumed speed be 10 cm/s i.e. 100mm/s Therefore, 100 =
πDN 60 DN=1909.86 D N 10 190.99 20 95.49 30 63.66 40 47.75 50 38.2 60 31.83 70 27.28 80 23.87 90 21.22 100 19.1 Table 2 Calculation of Diameter and
RPM So the selected D-N combination is- D = 70 mm N = 27.28 rpm
24. 24. 24 | P a g e 2. Calculation of Wheel Base Figure 6 Centre Stage Stairs θ = tan−1 y x θ = tan−1 160 400 Therefore, θ = 21.80˚ Now, width of the stairs is
400 mm. So the maximum length of the rover can be 400mm. To deduce the wheel base, Total length – (radius of front wheel + radius of rear wheel) =400-
(35+35) =330 mm
25. 25. 25 | P a g e 3. Length of Links Figure 7 Calculations at Centre Stage Stairs Total Wheel base = 330 mm Let us assume, Θ=45˚ In Triangle BNC, angle
BNC = 90˚ Angle NBC = Angle NCB = 45˚ Therefore, NC = NB NC2 + NB2 = BC2 … (Pythagporas Theorem) BC2 = 2(NC)2 … (1) =2(165)2 =54450
Therefore, BC = 233.33mm Rounding off to 230mm. BC = 230mm Substituting to eqn (1) we get,
26. 26. 26 | P a g e 2302 = 2(NC) 2 NC = 162.63 Also, AN = NC = 162.63 In triangle AMN, angle AMN = 90 AM2 + MN2 = AN2 … (Pythagoras Theorem)
2AM2 = AN2 2AM2 = 162.63 2 AM = 114.99 =115 mm Now, due to symmetry, AM = MN = 115 mm BM = AB – AM =230 – 115 =115 mm Therefore, BM
= 115 4. Height Calculation: Height2 = BC2 – NC2 (2302 – 162.632 )1/2 = 162.639 mm Net Height = 162.639 + 35 … (net ht = ht + radius) = 197.639 mm
27. 27. 27 | P a g e 5. Track Width 𝑆𝑆𝐹 = 𝑇𝑤 2ℎ 1.3 = 𝑇𝑤 2 × 197.639 Tw = 513.86 Calculation-2 6. Calculation of Wheel Base Figure 8 Library Stairs θ = tan−1
y x θ = tan−1 140 300 Therefore, θ = 25.016˚ Now, width of the stairs is 300 mm. So the maximum length of the rover can be 300mm. To deduce the wheel
base, Total length – (radius of front wheel + radius of rear wheel)
28. 28. 28 | P a g e =300-(35+35) =230 mm 7. Length of Links Figure 9 Calculation at Library Stairs Total Wheel base = 230 mm Let us assume, Θ=45˚ In
Triangle BNC, angle BNC = 90˚ Angle NBC = Angle NCB = 45˚ Therefore, NC = NB NC2 + NB2 = BC2 … (Pythagporas Theorem) BC2 = 2(NC)2 … (1)
=2(115)2
29. 29. 29 | P a g e =26450 Therefore, BC = 162.63 mm Rounding off to 162 mm. BC = 162mm Substituting to eqn (1) we get, 1622 = 2(NC) 2 NC = 114.55
Also, AN = NC = 114.55 In triangle AMN, angle AMN = 90 AM2 + MN2 = AN2 … (Pythagoras Theorem) 2AM2 = AN2 2AM2 = 114.55 2 AM = 80.999
=81 mm Now, due to symmetry, AM = MN = 81 mm BM = AB – AM =162 – 81 =81 mm Therefore, BM = 8 8. Height Calculation: Height2 = BC2 – NC2
(1622 –1152 )1/2 = 114.101 mm Net height = Height + Radius of wheel
30. 30. 30 | P a g e = 114.101 + 35 = 149.101 mm 9. Track Width 𝑆𝑆𝐹 = 𝑇𝑤 2ℎ 1.3 = 𝑇𝑤 2 × 149.101 Tw = 387.66 mm
31. 31. 31 | P a g e CHAPTER 5 CONCLUSIONS 5.1 Conclusion This project will try reaching nearly all of our design requirements, and in many respects
exceeding original design goals. Furthermore all components, mechanical and electrical, will be thoroughly tested as a completed system in real-world field
testing conditions to validate their success. Overall, preliminary estimates for the general scope, budget, and timeline, for the project will be closely followed;
with the exception if the project goes moderately over budget. 5.2 Budget and Table of Requirements S. No Item Qty Material Budget Net 1 Link 4 Acrylic 50
200 2 Shaft 1 SS 50 50 3 Bearing 4 SS 20 80 4 Wheel 6 Plastic 15 90 5 Motor 6 Alloy 150 900 Total 1320 Table 3 Hardware to be Purchased Electrical
purchase S. No Item Qty Budget Net 1 Transformer 1 500 500 2 Rectifier 1 30 30 3 Joystick 2 30 60 4 PCB 2 25 50 5 Wires and Cables 150 150 Total 790
Table 4 Electrical Equipments to be Purchased
32. 32. 32 | P a g e With the total of Electrical and Hardware Purchases the rover will cost around Rs. 2110 or a little more. 5.3 Future Scope As modular research
platform the rover developed by this project is designed specifically to facilitate future work. With the development in technology the rover can be used for
reconnaissance purposes with the cameras installed on the rover and minimising the size of rover. With some developments like attaching arms to the rover it
can be made useful for the Bomb Diffusing Squad such that it can be able to cut the wires for diffusing the bomb. By the development of a bigger model it can
be used for transporting man and material through a rough terrain or obstacle containg regions like stairs.We could develop it into a wheel chair too. It can be
send in valleys, jungles or such places where humans may face some danger. It can also be developed into low cost exploration rover that could be send for
collecting information about the environment of some celestial bodies.
33. 33. 33 | P a g e REFERENCES mars.nasa.gov/mer/home robots.mit.edu/publications/papers/1998_07_Hac_Dub_Bid https://www.youtube.com/watch?
v=bP7p5Bd2d50 https://en.wikipedia.org/wiki/Longitudinal_static_stability www.nhtsa.gov/cars/rules/regrev/evaluate/809868/pages/IntroBack
www.esmats.eu/amspapers/pastpapers/pdfs/2004/harrington
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Rahul Hans, Executive - VRF and Chiller Service

Published on Oct 6, 2016

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Shubham kumar , Student at Hindu College of Engineering

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