DESIGN OF ROCKER-BOGIE MECHANISM

(Dr. A. P. J. Abdul Kalam U.I.T. Jhabua)

Major Project Report

Submitted by:

Revaram Malee (Roll No. 0887ME171011)

Bachelor of Engineering

IN

MECHANICAL ENGINEERING

Under the Guidance

Of

Prof. Kushal Sharma

(Assistant Professor, ME)

DR. A. P. J. ABDUL KALAM UNIVERSITY INSTITUTE OF TECHNOLOGY

JHABUA, M.P. (INDIA) - 457661
(Constituent College of RGPV BHOPAL)
JUNE 2021
 Design of Rocker-Bogie Mechanism

DECLARATION
We Revaram Malee (Roll No. 0887ME171011) hereby declare that this project
work entitled “Design of Rocker-Bogie Mechanism” was carried out by us under the
supervision of Prof. Kushal Sharma, Asst. Professor, Mechanical Engineering
Department, Dr. A. P. J. Abdul Kalam University Institute of Technology, Jhabua
(M.P.). This project work is submitted to Department of Mechanical Engineering
during the academic year 2020-2021.

Place:

Date:

Name Signature

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 Design of Rocker-Bogie Mechanism

DR. APJ ABDUL KALAM

UNIVERSITY INSTITUTE OF TECHNOLOGY, JHABUA
DEPARTMENT OF MECHANICAL ENGINEERING

SESSION 2020-2021

CERTIFICATE OF APPROVAL

This is to certify that the work embodies in this report entitled “Design of Rocker
Bogie Mechanism” Being submitted by Revaram Malee (0887ME171011), who
carried out the project work under our supervision and guidance of prof. Kushal
Sharma in the “Department of Mechanical Engineering”, Dr. A. P. J. Abdul
Kalam University Institute of Technology, Jhabua (M.P.).

(Internal Examiner) (External Examiner)

Name: Kushal Sharma Name:

Designation:Asst. Professor Designation:
Institute: Dr. APJ Abdul Kalam UIT, Jhabua Institute:
Date: Date:

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 Design of Rocker-Bogie Mechanism

DR. APJ ABDUL KALAM

UNIVERSITY INSTITUTE OF TECHNOLOGY, JHABUA
DEPARTMENT OF MECHANICAL ENGINEERING

SESSION 2020-2021

CERTIFICATE
This is to certify that the work embodies in this report entitled “Design of
Rocker-Bogie Mechanism” being submitted by Revaram Malee
(0887ME171011), who carried out the project work under my supervision and
guidance of prof. Kushal Sharma in the “Department of Mechanical
Engineering”, Dr. A.P.J. Abdul Kalam UIT, Jhabua (M.P.).

Guided & Approved By: Forwarded By:

Prof. (Mr.) Kushal Sharma Dr. Umesh Banodha

Asst. Prof. HOD
Mechanical Engineering Dept. Mechanical engineering Dept.
Dr. A.P.J. Abdul Kalam UIT, Jhabua Dr. A.P.J. Abdul Kalam UIT, Jhabua

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 Design of Rocker-Bogie Mechanism

ACKNOWLEDGEMENT

Knowledge is expression of experience gained in life. It is the choicest possession that should
be happily shared with others.

In this regards we feel great pleasure in submitting this minor project report on “DESIGN OF
ROCKER-BOGIE MECHANISM”. It gives me immense pleasure to express my deepest sense of
gratitude and sincere thanks to my highly respected and esteemed guide “Prof. (Mr.) Kushal Sharma”
(Dept. of ME), Dr. A.P.J. Abdul Kalam UIT, Jhabua for their valuable guidance, encouragement and
help for completing this work. Their useful suggestions for this whole work and co-operative
behaviour are sincerely acknowledged. During this project, we received a lot of help, advice and co-
operation from our esteemed faculty and other distinguished persons. We would also like to thank
“Dr. Umesh Banodha” (H.O.D. Mechanical Engineering Department) for their valuable guidance
through the course of project without whose encouragement the project wouldn’t have been a
success.

We are grateful to our Principal “Dr. K.S. Chandel” and other college authorities for their
support and all those who have directly or indirectly helped us during the project work.

At the end we would like to express my sincere thanks to all my friends and others who
helped me directly or indirectly during this project work.

Submitted by,

Revaram Malee (0887ME171011)

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 Design of Rocker-Bogie Mechanism

ABSTRACT
A major project aims to “Design of Rocker-Bogie Mechanism”. Focus of this project
is to Design the rocker Bogie Mechanism which can be used in many places where human find
difficult to reach like in space mission, bomb disposal, hard to climb places. The work “Design of
Rocker Bogie Mechanism” deals with the important aspect of improving the rover from its previous
design, so in this project we add our research on this project and design to improve model of
Rocker-Bogie Mechanism.

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 Design of Rocker-Bogie Mechanism

TABLE OF CONTENTS

Declaration ………………………………………………………………………………… II
Certificate of approval ……………………………………………………………………... III
Certificate …………………………………………………………………………………... IV
Acknowledgement …………………………………………………………………………. V
Abstract ……………………………………………………………………………………. VI
List of Figures ……………………………………………………………………………. VII

CHAPTER 1.
INTRODUCTION
1.1 Introduction to Space Robot……………………………………………………………... 1
1.2 Types of Space Robotic systems………………………………………………………… 1
1.3 Historical Development …………………………………………………………………. 1
1.4 Types of Exploration Rover Based on Shape ……………………………………………. 2
1.5 The Rocker-Bogie Structure ……………………………………………………………... 3
1.6 Principle …………………………………………………………………………………. 5

CHAPTER 2.
LITERATURE SURVEY
2.1 Existing Literature on Rocker-Bogie Modelling……………………………………… 6
2.2 Summary of Literature Review………………………………………………………. 7
2.3 Gap identification from literature…………………………………………………………. 7

CHAPTER 3
METHODOLOGY
3.1 Geometry of Rocker-bogie…………………………………………………………………. 9
3.2 Principle……………………………………………………………………………………. 10

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 Design of Rocker-Bogie Mechanism

CHAPTER 4
DESIGN PROCEDURE
4.1 Observation…………………………………………………………………………………. 11
4.2 Concept and Theories………………………………………………………………………. 11
4.2.1 Traction and Slip…………………………………………………………………………. 12
4.2.2 Lateral Stability…………………………………………………………………………… 12
4.2.3 Longitudinal Stability……………………………………………………………………... 12
4.2.4 Mobility…………………………………………………………………………………… 12
4.3 Components of Rocker-Bogie Mechanism…………………………………………………. 13
4.3.1 Wheel……………………………………………………………………………………… 13
4.3.2 Gear Motor………………………………………………………………………………… 14
4.3.3 Rocker Frame……………………………………………………………………………… 15
4.3.4 Bogie Frame……………………………………………………………………………… 16
4.3.5 Nut and Bolts……………………………………………………………………………… 16
4.3.6 Toggle switch……………………………………………………………………………… 17
4.4 Design of Rocker-Bogie Mechanism………………………………………………………… 18
4.5 Construction and Working…………………………………………………………………… 19

CHAPTER 5
Result and Discussion…………………………………………………………………………… 21

CHAPTER 6
Conclusion………………………………………………………………………………………. 22

CHAPTER 7
FUTURE SCOPE
7.1 Advantages…………………………………………………………………………………... 23
7.2 Disadvantages…………………………………………………………………………………

REFERENCE

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 Design of Rocker-Bogie Mechanism

LIST OF FIGURES
1.1 Types of Exploration Rovers……………………………………………………………... 3
1.2 Rocker-Bogie Rover ……………………………………………………………………… 4
1.3 Rocker Bogie Mechanism…………………………………………………………………. 5
4.3.1.1 Sketch of Wheel ………………………………………………………………………. 13
4.3.1.2 Drafted Model of Wheel………………………………………………………………. 14
4.3.3.1 Sketch Diagram of Rocker……………………………………………………………. 17
4.3.3.2 3D Model of Rocker…………………………………………………………………… 17
4.3.4.1 Sketch Diagram of Bogie……………………………………………………………… 18
4.3.4.2 3D Model of Bogie……………………………………………………………………. 19
4.4.1 Assembled RBM………………………………………………………………………… 21
4.4.2 Model of RBM…………………………………………………………………………… 21
4.4.3 Top & Side View of RBM………………………………………………………………. 22
4.4.4 Side & Front View of RBM……………………………………………………………… 22

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 Design of Rocker-Bogie Mechanism

CHAPTER – 1

INTRODUCTION

1.1 Introduction to Space Robot

Robot is usually an electro-mechanical machine which is guided by computer or
electronic programming, and is thus able to do tasks on its own.
Space Robots are the robots which are used for various space activities such as
assembly, inspection, maintenance and planetary surface operations like mobility and
exploration as surrogates for human explorers.

1.2 Types of Space Robotic systems

There are mainly two fields in space robotics:

1) Orbital robotic systems

2) Surface robotic systems

The Orbital robotic systems are used in orbital activities such as manipulation,
assembling and servicing in orbit as assistants to astronauts while surface robotic systems
are used in planetary operations like mobility and exploration.

In our study work we are going to deal with surface robotic systems for
planetary exploration and sample collection from the planet has been discussed.

1.3 Historical Development

The research on surface exploration rovers began in the mid-1960s, with an

initiative (that never flew) for unmanned rover for the surveyor lunar landers and a man
rover (Moon Buggy) for the human landers in the united states. In the same period, research
and development began for a teleoperated rover named Lunokhod in the Soviet Union. Both
the Apollo manned rover and Lunokhod unmanned were successfully demonstrated in the
early 1970s on the Moon. In the 1990s the exploration target had expanded to Mars and in
1997, the Mars pathfinder mission successfully deployed a micro rover name Sojourner that

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 Design of Rocker-Bogie Mechanism

safely traversed the rocky field adjacent to the landing site by autonomously avoiding
obstacles. Following on from this success, today autonomous robotic vehicle is considered
indispensable technology for planetary exploration. The twin Mars exploration rover, Sprit
and Opportunity, were launched in 2003 and have had remarkable success in terms of
remaining operational in the harsh environment of Mars for over four years. In the future the
Mars Science Laboratory (MSL) known as Curiosity is a NASA rover scheduled to be
launched between October and December 2011 and perform the first-ever precision landing
on Mars, and India’s Chandrayaan-2 mission to land a motorized over on the Moon likely in
2012, as a part of its second Chandrayaan mission. The wheeled rover will move on the lunar
surface, to pick up soil or rock samples for onsite chemical analysis.

Types of Exploration Rover Based on Shape

1. Mechanisms which utilize limitless rotational movement; (Wheeled Rover fig. 1.1
a)

2. Mechanisms which utilize leg motion; (Legged Robot 1.1b)

3. Mechanisms which utilize rotation and leg motion; (Wheeled Leg Robot fig. 1.1c)

4. Mechanisms which utilize articulated body motion; (Snake Type Creeping

Propulsion motion fig. 1.1d)

Fig. 1.1a Sojourner Fig. 1.1b Dante-11

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 Design of Rocker-Bogie Mechanism

Fig. 1.1c Athlete Fig. 1.1d ACM-III

Fig. 1.1 Types of Exploration Rovers

Many planetary exploration rovers have been developed since 1960s. According to the
features of the mobile mechanism of robot’s planetary exploration rovers have some types
wheeled, legged and tracked etc. Wheeled mobile mechanisms have some excellent features, such
as high speed on a relatively flat terrain and easily control, so many researchers trended to design
their exploration rovers with wheeled structure. Currently, wheeled structure planetary rovers have
4-wheeled, 6-wheeled and 8-wheeled etc. Among them, the 6-wheel mobiles system with rocker
bogie mechanism has superior adaptability and obstacle climbing capability, which had been
applied in rocky series and Sojourner mars rover.

1.5 The Rocker-Bogie structure:

The Rocker bogie system is the suspension arrangement used in the Mars rovers for both the
Mars Pathfinder and mars Exploration Missions. Its currently NASA’s favored design.

A 6-wheeled rover with rocker bogie structure is studied in this work. This has six
independently driven wheels mounted on an articulate passive suspension system. The four comer
wheels are steerable. With this design, while traversing rugged terrain, each wheel trends to contact
with the ground. The principle of the 6-wheel mobile mechanism of planetary rover with rocker-
bogie structure is shown in fig. 1.2.

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 Design of Rocker-Bogie Mechanism

Six wheels independently driven by the motors are mounted on an articulate frame. The
frame has two rocker arms connected to the rover body. Each rocker has a rear wheel connected to
one end and a bogie connected to the other end. The bogie is connected to the rocker with a free
pivoting joint and at each end of the bogie there is drive wheel, the rockers are connected to the rover
body is it the differential joint.

Fig. 1.2 Rocker Bogie-Rover

The term “Rocker” originates from shaking thing of the bigger, frontward leg to each aspect
of suspension mechanism. These “Rockers” are identified with each extraordinary and the rover case
utilizing a differential. Comparative with suspension, after one “rocker” is going up, option is
coming down. The frame proceeds with the regular pitch demeanour of the two rockers. One finish
of a “Rocker” is outfitted with a constrained wheel, and the opposite end is rotated to the bogie. The
“Bogie” some portion of the time frame alludes to the litter, rearward leg that turns to the rocker
inside the middle and which has a force wheel at each quit. Intruders had normally used as burden
wheels in the paths of military tanks as idlers circulating the weight over the territory and had been

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 Design of Rocker-Bogie Mechanism

furthermore ordinarily used in “trailers or semi-trailer trucks”. The two tanks and semi-trailers
presently pick trailing arm suspensions.

1.6 PRINCIPLE
 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 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.
 These rovers move slowly and climb over the obstacles by having heels lift each piece
of the suspension over the obstacle one portion at a time.

Fig. 1.3 Rocker Bogie Mechanism

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 Design of Rocker-Bogie Mechanism

CHAPTER – 2
LITERATURE SURVEY

2.1 Existing Literature on Rocker-Bogie Modelling

 Shigeo Hirose et al., (1995) "The author outlined the fundamental considerations for the
planetary rover. They compared the wheeled, legged and articulated body shapes, and it
was found that the wheel type is currently the optimum for a planetary rover. Next, they
studied specific method for configuring a planetary rover with one, two, three and four
wheel".
 Miller and Lee et al., (2002) at "NASA described a method of driving a rocker bogie
vehicle than can effectively step over most obstacles rather than impacting and climbing
over them. They suggested some mechanical changes to gather the maximum benefit and
to greatly increase the effective operational speed of future rovers. Most of the benefits
of this method can be achieved without any mechanical modification to existing designs
but a change in the control strategy".
 Lamonet Al., (2004) "The author described quasi-static modelling considering the
system constraints: maximal and minimal torques, positive normal forces of a six-
wheeled robot with a passive suspension mechanism together with a method for
selecting the optimal torques. The method is used to limit wheel slip and to improve
climbing capabilities”.
 Lindemann et al., (2005) "The author described the Mars exploration rovers named
spirit and opportunity which were landed on the Mars surface in January 2004”. To
assess the mobility characteristics of the rover in the Mars environment, engineering
slopes, rock obstacles, and soft soil. Also, to gain better insight into the rovers'
capabilities, a dynamic model of the rovers was created in the software package
ASAMS. The rover model was then used to simulate many of the test cases, which
provided a means for model correction and correlation".
 Mongkol Thianwiboon and Viboon Sangveraphunsiri et al. (2006) "The author proposed
a method for kinematics modelling of a six-wheel Rocker Bogie mobile robot. The
forward kinematics is derived by using wheel Jacobina matrices in conjunction with
wheel-ground contact angle estimation. The inverse kinematics is to obtain the wheel

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 Design of Rocker-Bogie Mechanism

velocities and steering angles from the desired forward velocity and turning rate of the
robot. By comparing information onboard sensors and wheel velocities traction to
minimize wheel slip. Simulation is done with a rover that has rocker-bogie in two
coordinates of surface including climbing slope and travel over a ditch".
 Bai-chao et al. [6] (2007), ''The author analysed the structure of the new suspension and
the kinematics of the levers, and to know, the distortion capability of the suspension,
relational equations of the suspension levers are established. To test the capability of
suspension, they design a prototype rover with the new suspension and take a test of
climbing obstacles, and the prototype rover with a new type of suspension had an
excellent capability to climb up obstacles with keeping cab smooth in the result”.
 Hacot et.al [7] (1998) "The author at MIT presented the models of Mechanics and
method for solving the inverse kinematics of the rocker bogie rover. The quasi-statics
force analysis was described for the rover. The simulation of the rover was done and
compared with the experimental results".

2.2 Summary of Literature Review

The commencement of the "Rocker-bogie suspension Mechanism" is followed by

the advancement to earthbound rover 's which are cell Robot's, interestingly expected to
proceed onward an earthly surface. Beginning rover had been teleoperated like the "Lunokhod
I" while progressing ones are absolutely self-overseeing, alongside Discovery, FIDO, these
days propelled "Curiosity Mars examination rover". The rover should have been tough and
strong since it must face up to clean, enthusiastic breezes, utilization, and enormous
temperature changes underneath bewildering conditions. Most noteworthy rover stay controlled
utilizing batteries that are empowered by sun situated blocks throughout the day set over their
surface. The development machine of rover remains fundamental to allow it to show up at
target districts, lead studies, and accumulate estimations and to put itself according to the
intrigue. "There are 3 boss sorts of rover development progressed so far for instance Wheeled,
legged, and caterpillar movement. The vital differentiation among the irregular structures of
planetary robots exists in such a movement system. Extensively in the wake of turning out to be
many-legged and crossbreed robots, most experts still care about wheeled progress for rover as
a result of its train straightforwardness and benefits, and among wheeled speed position, the

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 Design of Rocker-Bogie Mechanism

rocker-bogie suspension machine-based arrangement remains commonly liked. The outdated

FIDO rover and the Sojoumar contain 6 self-governing quick and pushed wheels suspended
from a "Rocker-bogie Mechanism" for perfect suspension and ground opportunity. Harsh Seven
Rover has a comparative suspension system that moves in front wheels. The Nano vagabond
and Nomad Rovers have four controlled wheels suspended from gatecrashers and CRAB
Rover uses two equivalent bogie segments on each side to vanquish limitations and colossal
openings."[5] Most, the item program smoothing out searches for a perfect inside the obliged
game plan space offered a principal reaction, and "Dr. Li et al. Decide a logical structure to
summarize rover suspension limits that describe the geometry of the rocker-bogie system. The
goal at the back of the progression of the rocker-bogie suspension contraption is to develop a
gadget that confines the quality usage, the vertical expulsion of the drifter's point of
convergence of mass, and its pitch edge. In this examination, we endeavor to move these critical
blessings embedded with the Rocker-Bogie structure into conventional motors to take out pain
and complexities present in the standard suspension system is outstanding and suspension
game plan of generous vehicles”. [2]

2.3 Gap identification from literature:

The existing literature shows that researchers have attempted kinematic

analysis of rocker bogie rover and studied the behaviour of the rover. This has been done with
the assumption that rover moves with a very slow speed.
This work presents a 6-wheel Rocker-Bogie mechanism. In this project
we design and fabricate 6-wheel Rocker-Bogie mechanism.

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 Design of Rocker-Bogie Mechanism

CHAPTER – 3
METHODOLOGY

According to the examination, its miles find that the rocker-bogie instrument decreases its
developments to a large portion of the speed when contrasted with other suspension
frameworks in light the fact that every one of the bogie’s six wheels has a fair-minded
component for development and wherein the two front and two back wheels have character
directing structures which permits the vehicle to show in area as 0 degree turning proportion.
Each wheel likewise has thick spikes that offer grasp for hiking in delicate sand and scrambling
over rocks effortlessly. To vanquish vertical obstruction faces, the front wheels are compelled
contrary to the hindrance utilizing the inside and back wheels which produce most extreme
required force. The pivot of the front wheel at that point lifts the front of the vehicle up and
over the obstruction and impedin1ent overwhelmed. Those wheels which stay inside the
centre are then squeezed contrary to the hindrance by means of the back haggles towards
the obstacle by the front till the time it's far lifted up and over. Finally, the back wheel is
pulled over the hindrance with the guide of the front wheels because of utilizing the draw
power. During each wheel's traversal of the hindrance, forward improvement of the vehicle
is eased back or totally ended which at long last jam vehicle's centre of gravity. The
methodology for this project is similar to the fabrication analysis process. The
methodology is explained in four parts. System parts are given with their specification and
dimension. Modelling will have a simple layout type diagram in thesis. In this diagram the
parts are explained by their major dimensions only. Working has just functional details in
paragraphs. The delayed or incomplete portion of fabrication is not explained. These
portions are explained by topic “improvements and modification”. The methodologies of
these attachments are explained in few sub- headings.

3.1 Geometry of rocker bogie

As per the research it is find that the rocker bogie system reduces the motion by half
compared to other suspension systems because each of the bogie's six wheels has an

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 Design of Rocker-Bogie Mechanism

independent mechanism for motion and in which the two front and two rear wheels have
individual steering systems which allow the vehicle to turn in place as 0 degree turning
ratio. Every wheel also has thick cleats which provides grip for climbing in soft sand and
scrambling over rocks with ease.

In order to overcome vertical obstacle faces, the front wheels are forced against the
obstacle by the centre and rear wheels which generate maximum required torque. The
rotation of the front wheel then lifts the front of the vehicle up and over the obstacle and
obstacle overtaken. Those wheels which remain in the middle, is then pressed against the
obstacle by the rear wheels and pulled against the obstacle by the front till the time it is
lifted up and over. At last, the rear wheel is pulled over the obstacle by the front two wheels
due to applying pull force. During each wheel's traversal of the obstacle, forward progress
of the vehicle is slowed or completely halted which finally maintain vehicles centre of
gravity. The above said methodology is being practically proved by implementing it on
five-wheel drive ATV system in order to gain maximum advantage by rocker bogie system.

3.2 Principle

The rocker-bogie design consisting of no springs and stub axles in each wheel which
allows the chassis to climb over any obstacles, such as rocks, ditches, sand, etc. that are up
to double the wheel's diameter in size while keeping all wheels on the ground maximum
time. As compared to any suspension system, the tilt stability is limited by the height of the
centre of gravity and the proposed system has the same. Systems employing springs tend to
tip more easily as the loaded side yields during obstacle course. Dependent upon the centre
of overall weight, any vehicle developed on the basis of Rocker bogie suspension can
withstand a tilt of at least 50 degrees in any direction without overturning which is the
biggest advantage for any heavy loading vehicle. The system is designed to be implemented
in low speed working vehicles such as heavy trucks, Bulldozers which works at slow speed
of around 10 centimetres per second (3.9 in/s) so as to minimize dynamic shocks and
consequential damage to the vehicle when surmounting sizable obstacles.

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 Design of Rocker-Bogie Mechanism

CHAPTER – 4
DESIGN PROCEDURE

4.1 Observation

The fundamental issue identified with contemporary suspension frameworks snared in

overwhelming stacking vehicles rover (" Including the ones with lively and semi lively suspension
systems") is their moderate pace of development which crash the beat to absorb the shocks created
by utilizing wheels which remain the aftereffect of two elements. In the first place, to disregard
impediments, the vehicle should be outfitted down apparently to take into account adequate force to
raise the mass of the vehicle. Thusly, this diminishes normal pace which can't go on without serious
consequences on account of overwhelming stacking vehicles. Second, if the rover is venturing at an
exorbitant speed and experiences a snag ("Height greater than 10 percent of wheel range"), there
could be a monstrous amazement spread by means of the body which could harm the suspension or
overturn down the whole rover. That is the reason present-day overwhelming stacking rover venture
at a speed of 10cm/s by means of lopsided landscape. The product based leaving the " rocker-bogie
suspension mechanism" portrays the energy and proficiency related utilities in an aggregate way.

4.2Concept and Theories

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 Design of Rocker-Bogie Mechanism

4.2.1 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 obstacle or inclined surfaces and slip will
occur.
 ln reality it is very challenging to determine the precise friction coefficient µ for the
interaction of two surfaces
4.2.2 Lateral Stability

 The rover is said to be stable when it is in an unbalanced in which it does not tilt over.
 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
tips over.
 Lateral stability of the rover is ensured if the overall stability angle.

4.2.3 Longitudinal Stability

 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 statically model to
work, physical rover does not necessarily tip if a wheel loose contact to the ground.
However, it is less steerable.

4.2.4 Mobility

 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.

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 Design of Rocker-Bogie Mechanism

 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.
 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.

4.3 Components of Rocker-Bogie

 Wheel
 Gear motor
 Rocker frame
 Bogie frame
 Nut and Bolts
 Toggle Switch
 Battery

4.3.1 Wheel
Wheel is simple and from plastic and hard fiber only.
Wheel diameter – 70mm, Wheel width – 40mm
Shaft diameter – 8mm

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 Design of Rocker-Bogie Mechanism

Fig 4.3.1.1 Sketch of Wheel

Fig 4.3.1.2 Drafted Model of Wheel

4.3.2 Gear Motor

A "gear motor" is a specific type of motor that is planned to deliver inordinate force while
keeping a gradual torque, low velocity, motor yield. the gear motor can be situated in loads of
various applications and are likely applied in bunches of gadgets in home appliance. “Gear motors
are normally utilized in contraptions like can openers, stockpiling entryway openers, washing gadget
time control handles, or even electric morning timers. Regular business utilizations of a Gear motor
include health facilities bed, modern jacks, cranes, and a lot of different projects which can be

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 Design of Rocker-Bogie Mechanism

beyond any reasonable amount to list."

Basic Principles of operation

A gear motor can be either an AC (alternating current) or a DC (direct cu rrent) electric motor.
Most gear motors have an output of between about 1,200 to 3.G80 revolutions per minute (RPMS).
These types of motors also have two different speed specifications: normal speed and the stall-
speed torque specifications.

Gear motors are primarily used to reduce speed in a series of gears, which in turn create s
more torque. This is accomplished by an integrated series of gears or a gear box being attached to
the main motor rotor and shaft via a second reduction shaft. The second shaft is then connected
to the series of Scars or gearbox to create what is known as a series of reduction gears.
Generally speaking, the longer train of reduction gears, the lower output of the end, or final,
gear will be.

An excellent example of this principle would be an electric time clock (the type that u see
hour, minute anti second hands). The synchronous AC motor that is used to power the time clock
will usually spin the rotor at around 1500 revolutions per minute. However, a series of
reduction gears is used to slow the movement of the hands on the clock.

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 Design of Rocker-Bogie Mechanism

For example, while the rotor spins at about 1500 revolution per minutes, the reduction gears allow the final
second-hand gear to spin at only one revolution per minutes. This is what allows to make one complete
revolution per minute on the face of the clock.

4.3.3 Rocker Frame

The Rocker-Bogie design has no springs or stub axles for each wheel, allowing the rover in
climb over obstacles, such as rocks, that are up to twice the wheel's diameter in size while keeping all
six wheels on the ground. As with any suspension system, the tilt stability is limited by the height
of the centre of gravity. Systems using springs tend to tip more easily as the loaded side yields.
Based on the centre of mass, the Curiosity rover of the Mars Science Laboratory mission can
withstand a tilt of at least 45 degrees in any direction without overturing, but automatic sensors
limit the rover from exceeding 30-degree tilts. The system is designed to be used at slow speed of
around 10 centimetres per second (3.9 in/s) so as to minimize dynamic shocks and consequential
damage to the vehicle when surmounting sizable obstacles.

JPL states that this Rocker Bogie system reduces the motion of the main MER vehicle body by
half compared to other suspension systems. Each of the rover independent motor. The two front
and two rear wheels have individual steering motors which allow the vehicle to turn in place. Each
wheel also has cleats, providing grip for climbing in soft sand and scrambling over locks. The
maximum speed of the robots operated in this way is limited to eliminate as many dynamic effects as
possible in that the motors can be geared down, thus enabling each wheel to individually lift a large
portion of the entire vehicle’s mass.

In order to go over a vertical obstacle face, the front wheels are forced against the obstacle by
the centre and rear wheels. The rotation of the front wheel then lifts the front of the vehicle up and
over the obstacle. The middle wheel is then pressed against the obstacle by the tear wheels 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. This is not an issue for the operational speeds
at which these vehicles have been operated to date.

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 Design of Rocker-Bogie Mechanism

Fig 4.3.3.1 Sketch Diagram of Rocker

Fig 4.3.3.2 3D View of Rocker

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 Design of Rocker-Bogie Mechanism

4.3.4 Bogie Frame

The term ‘Bogie’ refers to the links that have a drive wheel at each end. Bogie were
commonly used as load wheels in the tracks of army tanks as idlers distributing the load over
the terrain. Bogie were also quite commonly used on the trailers of semitrailer trucks. Both
now prefer trailing arm suspensions.

The "bogie" some portion of the timeframe alludes to the littler, rearward leg that
turns to the rocker inside the middle and which has a force wheel at each quit. Intruders
had been normally used as burden wheels in the paths of military tanks as idlers
circulating the weight over the territory and had been furthermore ordinarily used in
"trailers of semi-trailer trucks". The two tanks and semi-trailers presently pick trailing
arm suspensions.

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 Design of Rocker-Bogie Mechanism

Fig 4.3.4.1 Sketch Diagram of Bogie

Fig 4.3.4.2 3D View of Bogie

4.3.5 Nut and Bolts
A nut is a type of fastener with a threaded hole. Nuts are almost always used in
conjunction with a mating bolt to fasten two or more parts together. The two partners are kept
together by a combination of their threads' friction. a slight stretching of the bolt, and compression
of the parts to be held together. This use flexibility connecting with rocker and link.

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 Design of Rocker-Bogie Mechanism

4.3.6 Toggle Switch

In electrical engineering, a switch is an electrical component that can break an
electrical circuit, interrupting the current or diverting it from one conductor to another. The
mechanism of switch may be operated directly by a human operator to control a circuit (for
example, a light switch or keyboard button), may be operator by a moving object such as a
door-operated switch, or may be operated by some sensing element for pressure, temperature
or flow. A relay is a switch that is operated by electricity. Switches are made to handle a
range of voltages and currents; very large switches may be used to isolate high-voltage
circuits in electrical substations.

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 Design of Rocker-Bogie Mechanism

4.4 Design of Rocker-Bogie Mechanism

We design Rocker-Bogie mechanism in a 3D model in solid work and 2D model in
AutoCAD. we design a wheel, rocker-bogie frame in solidwork and AutoCAD.

 Rocker is connected to bogie with the help of free pivot joint, this joint is a hinged joint not
fixed.
 Both rockers are connected with a differential so that RBM can move on uneven path
smoothly.
 All six wheels are connected to bogie & rocker with the help of free pivot joint.

Fig 4.4.1 Assembled RBM

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 Design of Rocker-Bogie Mechanism

Fig 4.4.2 Model of RBM

Fig 4.4.3 Top & Side Veiw of RBM

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 Design of Rocker-Bogie Mechanism

Fig 4.4.4 Side & Front View of RBM

4.5 Construction and Working Principle

The rocker bogie suspension system, which was specifically designed for space
exploration vehicles have deep history embedded its development. The term “rocker”
describes the rocking aspect of the larger links present each side of the suspension system
and balance the bogie as these rockers are connected to each other and the vehicle chassis
through a selectively modified differential. Fig encounter area of rocker bogie suspension
system. As accordance with the motion to maintain center of gravity of entire vehicle, when one
rocker moves up-word, the other goes down. The chassis plays vital role to maintain the average
pitch angle of both rockers by allowing both rockers to move as per the situation. As per the acute
design, one end of a rocker is fitted with a drive wheel and the other end is pivoted to a box which
provides required motion and degree of freedom. Fig 2D(AutoCAD) Line diagram of Rocker-
bogie suspension system and its motile joints. In the system, “bogie” refers to the conjoining

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 Design of Rocker-Bogie Mechanism

links that have a drive wheel attached at each end. Bogies were commonly used to bare loading as
tracks of army tanks as idlers distributing the load over the terrain. Bogies were also quite
commonly used on the callers of semi-trailer trucks as that very time the trucks will have to carry
much heavier load.

4.6

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 Design of Rocker-Bogie Mechanism

CHAPTER – 5

RESULT AND DISCUSSION

In this project we have design a Rocker-Bogie mechanism by using Solidwork. In this
project our aim to modify the design of Rocker-Bogie Mechanism and improve its performance.
Presented situation was faced presenting two modes of operation within same working principle
which is a rocker-bogie system with a robust obstacles traverse features and another is an
expanded support hexagon achieved by rotating the bogies of each side of the vehicle. The
proposed modification increases in the stability margin with the 3D model done in Solidwork. In
future, if the system installed in heavy vehicles and conventional off-road vehicles, it will
definitely decrease the complexity as well as power requirements to retain bumping within it.

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 Design of Rocker-Bogie Mechanism

CHAPTER – 6
CONCLUSION
The steering mechanism was successfully installed and operated using mechanical gears in the
existing rocker bogie rover design. The drawback of this system is that the rover designed with this
steering mechanism is limited to traverse in less rough or only plain surface. Attempts can be made to
modify and solve this problem to design a more stable rover so that the vehicle can travel in both
smooth and rough surface.

In this project we have design a Rocker-Bogie mechanism by using Solidwork. In this project
our aim to modify the design of Rocker-Bogie Mechanism and improve its performance. Presented
situation was faced presenting two modes of operation within same working principle which is a
rocker-bogie system with a robust obstacles traverse features and another is an expanded support
hexagon achieved by rotating the bogies of each side of the vehicle. The proposed modification
increases in the stability margin with the 3D model done in Solidwork. In future, if the system
installed in heavy vehicles and conventional off-road vehicles, it will definitely decrease the
complexity as well as power requirements to retain bumping within it.

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 Design of Rocker-Bogie Mechanism

CHAPTER – 7

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 minimizing the size of the
rover. By the development of a bigger model, it can be used for transporting man and material
through a rough terrain or obstacle containing regions like stairs. We could develop it into a
wheel chair too. It can be sent 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.

7.1 ADVANTAGES

 The design is simple and reliable.

 Load on each wheel is nearly similar.
 The mechanism allows climbing obstacles twice the size of wheel diameter
 It has no axles and springs which helps to maintain equal traction force on all the
wheels.

7.2 DISADVANTAGES

 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.

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 Design of Rocker-Bogie Mechanism

REFERENCE

[1] S. Hirose, A. Kawakami, K. Kato, and H. Kuwahara, et al. (1999) "Supe r-Mechano -
Colony and SMC Rover with Detachable Wheel Units", Proc. COE workshop '99, pp.67-72.

[2] Miller, David P.; Lee, Tze- Liang et al. (March 17- 21, 2002). "High-speed traversal of
rough terrain using a rocker -bogie mobility system"

[3] Lamon, P, Krebs, A, Lauria, M, et al. (ICRA 2004), "Wheel torque control for a rough
terrain rover. In: IEEE international conference on robotics and automation

2004." IEEE: ETH-Zurich.

[4] Lindemann, RA, Voorhees, 0. et.al (2005) "Mars exploration rover mobility assembly
design, test and performance. In: IEEE international conference on systems, man and
cybernetics", Vol. 1, Waikoloa, Hl, pp. 450- 455. IEEE.

[5] SJ Mo ngkol Thianwiboon and Viboon Sangveraphunsir et.al (2006), "Traction Control for
a Rocker -Bogie Robot with Wheel-Ground Contact Angle Estimation"

[6] Chen Bai-chao et .al (2007),"Design and Simulation Research on a New Type of Suspension
for Lunar"

[7] Hacot, H., et al. (1998)" The Kinematic Analysis and Motion Control of a Planetary
Rover", Master's Thesis, Department of Mechanical Engineering, Massachusetts
Institute of Technology, Cambridge, MA,

[8] A. Mukherjee, R. Karmakar and A. K. Samantaray, “Bond graph in hIo‹1eling, Simulation and
Fault Identification”. CRC Press, FL, USA, 2006.

[9] K. lagnemma and S. Dubowsky, “Mobile Robot Rough-Terrain Control (RTC) for “Planetary
Exploration”, Proceedings of the 26th ASME Biennial Mechanisms and Robotics Conference,
Baltimore, MD, 2000.

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[10] Brooks Thomas; Graham Gold; Nick Sertic; DARK ROVER ROCKER-BOGIE
OPTIMIZATION DESIGN, The University of British Columbia, Project Number 1076 January 18,
2011

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