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Table of Contents

Executive Summary 3

Problem Definition 4

Introduction
Technical Review/Background
Design Requirements

Design Description 5

Summary of Design
Design Details
Wiring Diagram

Action Item Report 9

Task Assignment
Gantt Chart

Evaluation 11

Calculations
Test Plan
Results & Discussion

Appendix A: SOLIDWORKS Drawings 15

Appendix B: Bill of Materials 18

Works Cited 19

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Executive Summary
For our project, we set simple objectives that we hoped to accomplish by the end of
week 10. Our main goals were to fulfill the project requirements, complete the
deliverables, and create a fully functional rover that can complete the preliminary
competition track.

We drafted a design via SOLIDWORKS and created a two-level frame that keeps the
battery, gear, and motor on the bottom while leaving the electronics easily accessible
on top. For our structure, we chose birch plywood for fabrication ease and used wood
glue to assemble it. We received $275 for our budget as we chose the 3D printing route.
Under this limit, we used approximately $223 for all required parts and $18 for 4.5
hours of 3D printing, leaving us with about $34 for any additional structure materials.

Problems arose during the fabrication of our steering mechanism. The concept was
complicated, and the main issues came from the 3D-printed parts. 3D printing is only
accurate to specific dimensions, which resulted in us having to sand the parts down to
fit properly. Due to how delicate the printed parts were, there were instances of them
breaking, which meant they had to be reprinted or fixed. Additionally, we made
last-minute changes to the design during our fabrication process. We realized that we
did not create a way for the two front wheels to be secured and allowed them to spin
freely. Redesigning the entire mechanism was not an option, so we created extensions
out of wood to fit bearings for the shafts to spin. These extensions caused a height
increase for the front of the rover, but it turned out to be more optimal for obstacles.
Our servo arm was also revised to be thicker and made out of wood to withstand the
strain from the rover’s turning movements.

After assembly, we attempted to complete the preliminary track. The 85mm front
wheels that we chose for stability caused issues with our steering mechanism. The
front wheels were too big and often got stuck under the bottom plate when we steered.
We planned to push through this issue, but it was not something we could overlook.
We decided to switch the front wheels to 65mm, giving the rover enough clearance to
steer properly. Additionally, some steering parts were not glued together because we
would be unable to troubleshoot if it was glued. This made our steering more
susceptible to turning at any slight movement out of our control. As a solution, we
steered the rover backward over obstacles because the front wheels were more stable.

As a result, we were able to complete the course in approximately 4 minutes and

accomplished all the milestones set for our project. All our project deliverables were
completed by each deadline.

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Problem Definition

Introduction
Our objective was to brainstorm, design, draw, and fabricate a functional
remote-controlled rover capable of going through the preliminary competition track.
This track included five turns, a set of cones, and a ramp. Our goal was to make the
rover stable, aerodynamic, and fast enough to compete against other rovers in a race.
The challenge was to stick to the requirements, utilize all materials available, and
remain within the budget given to us.

Technical Review / Background

Rovers were initially created to aid in planetary exploration as vehicles remotely
controlled from Earth. They trace back to the Soviet Union’s first rover Lunokhod 1,
the first remote-controlled robot to land on the moon in 1970 (David). They later
evolved to pursue further missions; the Sojourner, for example, was the first rover to
reach another planet in 1997 (Uri). These robots come in different sizes and shapes,
but in general terms, they are described to be reliable land vehicles controlled from
the outside that are usually compact. As part of our project, we had to build our rover
to portray these characteristics with the limited materials and budget available, as
well as keeping other design requirements in mind.

Design Requirements
As a team, we agreed to prioritize safety first and functionality second. We kept these
priorities in mind and also followed the requirements listed below during the design
process:
● Size limits: 10-inch width, 16-inch length
● Team design and fabrication (no off-the-shelf chassis or steering
mechanism)
● No internal combustion engines
● Must run for at least 10 minutes without recharging
● Accessible on/off switch
● Removable battery
● Gear guard required
● No sharp objects/corners
● Wires must be placed away from moving parts
● Covered and insulated wires
● Budget: less than $275 with 3D printing

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Design Description

Summary of Design
Initially beginning as a one-level chassis, the KACHOW rover (figure 1) was
eventually revised to become a two-level design to provide more space for all the
electronics and required parts on the rover. Both the top and bottom plates are exact
in size and in shape, 10 inches by 12 inches with the front section being narrower to
accommodate the steering mechanism. The frame itself is 5.70 inches in width
without the wheels and 12 inches in length, with the narrower section at the front
being 4 of the 12 inches. The top and bottom plates are connected using seven
support pieces, which are fabricated by cutting four 0.25-inch squares from a
rectangle with specified dimensions, and assembled with wood glue.

Figures 1 & 2: Rover assembly and the final product

The electrical components are located on the top plate for accessibility and because
they are all lighter in weight. The battery sits at the center of mass on the bottom
plate, as determined on SOLIDWORKS and seen in figure 3, to keep the rover stable
and avoid tipping. Other parts such as the motor and gears are mounted at the back
of the rover, giving more power to the rear wheels.

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 Figure 3: Bottom plate components

Slits were cut next to where the motor bracket is positioned in order to make gear
meshing easier as the bracket can be moved anywhere along the slits and secured
using M3 screws. The rear wheel mounts each have two extrusions that are 0.25 by
0.5 inches, which fit within slits made to the bottom plate where the rear wheel
mounts can be attached. To satisfy the gear guard requirement, a rectangular section
was made at the rear end of the rover where the axle and gear are located. A middle
support separates the gear from the battery and the electrical parts, as well as acts as
a safety guard for anybody handling the rover.

Figures 4 & 5: Gear meshing and rear wheel mounts

The steering mechanism incorporates front parallel steering and is 3D printed as its
design is too complicated to be made out of wood. The mechanism sits in a steering
holder at the front, which is attached below the top plate, and goes through the
bottom plate as well. While the rest of the mechanism is 3D printed, the servo arm is
made out of wood because a 3D-printed servo arm would not be able to withstand the
strain placed upon it while in motion. The servo arm is directly attached to the servo
horn, and the servo arm is attached to the steering mechanism using a 20mm screw
and hex nuts.

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 Figures 6 & 7: Steering assembly and final steering mechanism

Design Details
Using SOLIDWORKS, the center of mass is determined to be 7.50 inches in the
x-direction, 11.19 inches in the y-direction, and 16.98 inches in the z-direction. This
center of mass is where the battery is located on the bottom plate.

Figure 8: Final rover chassis drawing

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Electrical Diagram
The diagram below illustrates the electrical circuit of the rover. It includes several
major components: a battery, a brushed electronic speed controller converting the
fixed direct current output to variable direct current output voltage leading towards
the motor and the receiver, and a buck converter changing the 7.2-volt input to 5 volts
for the servo. The receiver is also connected to the servo to send signals directing the
servo to turn the steering mechanism.

The red lines represent electrical inputs into the components, the black lines
represent the outputs leading back to the power source, and the yellow line directs
signals from the receiver to the servo for steering.

Figure 9: Electrical diagram

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Action Item Report

Task Assignment
Our team of six divided up the work for each project task. With An Tran as team
captain, the remaining group members chose their subteams for the project. An was in
charge of the design on SOLIDWORKS, as well as managing the team in the fabrication
and assembly process. Ivana, Andrew, Ansh, Tim, and Rayan helped fabricate the
rover from scratch and assembled it before the deadline.

For project deliverables, we divided up each topic on the final presentation and final
report for each person to complete. Primarily focusing on what everyone
accomplished throughout the project, the topics were assigned by An as follows:
- Timothy Ngo: Project Objectives
- Ivana: Rover Introduction and Project Experience
- An Tran: Rover Design
- Rayan Alabdulmuhsin: Action Item Report
- Andrew: Steering Mechanism and Test Plan
- Ansh Minhas: Evaluation and Results

Deadlines for completing the tasks of each deliverable were set by our team captain,
who based it on the deadlines for each assignment in our class.

Gantt Chart
We utilized a Gantt chart to maintain consistent time management throughout the
project, as well as to keep track of our deadlines and progress as a team. As seen in the
chart (figure 10), our planned dates for completing each task are much earlier than
when we actually completed it because of issues that came up as we progressed. If we
were to complete this project again, we want to allow more time for troubleshooting
and be better prepared at handling any problems that come up.

Figure 10: Gantt chart with main milestones

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 Figure 11: Full design timeline

Figure 12: Full fabrication timeline

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Evaluation

Calculations
Weight of the vehicle: 1.36 kilograms
Gear ratio: 64T/16T
Stall weight: 2.78 kg
Stall torque: 0.43 Nm
Mechanical advantage: 4
Predicted drive time: 21.6 minutes
Battery capacity: 3600 mAh = 3.6 Ah
Total amps used by system: 5A (motor) + 5A (servo) = 10A
Drive time: 3.6Ah / 10A = 0.36hr * 60min = 21.6 minutes
Turning radius: 4.32 inches
Wheelbase: 0.625ft, Turn Radius: 60 degrees
0.625/tan(60) = 0.36ft = 4.32 inches

Our team chose a combination of the 64-teeth driven gear and 16-teeth motor gear
after considering the weight and size of our rover. Knowing that the rover would be
heavy due to the birch plywood and two-level chassis design, we wanted to ensure
that there was enough torque for our rover to move. By choosing this gear ratio, we
have a mechanical advantage of 4. The stall weight of our gear is 2.78kg, which is
more than the weight of our actual rover, 1.36kg. Technically, any gears we used would
have ensured that our rover could move, as all of the stall weights are greater than the
weight of our rover. However, since we wanted as much stall torque as possible, this
gear ratio would allow us to maneuver our rover over the ramp of the preliminary
competition track easily.

Test Plan
The testing process for the rover was to confirm each major part worked
independently from the rest, then assemble them together. The first thing we tested
was the electronic circuits, then the steering mechanism. This was a process that
continued until we drove our rover on the preliminary track successfully. Our third
test was to check the structural integrity of the rover, and the fourth was the motor
and drive function.

The electrical components needed to be tested first because the other three functions
relied heavily on electrical functionality. The steering system and drive function are
strictly dependent on it, while the structural aspect was influenced by the placing of

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electronics onto the two-plate chassis. We first soldered each component together as
indicated by the wiring diagram, then tested for continuity between each component,
and finally confirmed the remote control functionality of the servo and motor. After
getting our soldering checked by a teaching assistant, we were asked to redo it as there
were exposed wires and one soldering point came apart. As a result, it delayed our
assembly process because we had to remove the solder from the buck converter and
motor, then re-solder all the wires again.

We began testing the steering system as soon as the servo was functional because we
anticipated that the steering would require the most troubleshooting and be a long
process. Issues arose with the steering mechanism because the 3D printer could not
print to the exact dimensions specified by our CAD files, which meant we had to sand
the parts for a better fit. We then tested the mechanism alone with no power or
wheels. Once we determined that it was functional, we tested it with wheels attached,
then with the servo arm attached. It was evident during these tests that our wooden
servo arm was weak and was unable to steer the rover at times, so we included more
hex nuts to secure it in place. In order to complete the track, we steered our rover
backward through the ramp and cones, as the front wheels were more stable and
secure than our steering mechanism.

Testing the structural integrity of the rover was a simple process of putting all of the
pieces together, gluing and taping where necessary to hold certain components more
rigidly in place, and driving it at our desired speed.

During the drive function test, we ensured that firstly, the motor and pinion gear can
spin alone, and secondly, the motor can function with the drive gear attached to the
rear wheel shaft. The motor was fully functional from the beginning and required little
testing. After determining that the rover could drive, we performed ground tests of the
entire rover assembly working together—both on and off the course.

Results & Discussion

The first thing to consider when evaluating our rover is to see if it met all the product
specifications assigned to us. Made out of birch plywood, our rover is under the size
limit by being approximately 10 inches wide and 12 inches long, while staying within
the budget of $275 that includes 3D printing costs. Additionally, our rover met our
main objectives of being fully functional and able to complete the obstacle course.

Our rover excelled in areas of rigidity, stability, and durability. This is mainly due to
our two-plate design and support pieces. All of the electronic components were

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tightly secured using screws and strong double-sided tape. During the drive, there
were times when the rover fell off the ramp or went off course. However, it remained
intact without any damage.

Figure 13 & 14: Final completed rover

Despite its successes, the chassis design also had its downsides. The rover’s agility
was affected by the weight of our complicated chassis design. Due to its weight, we
changed from a 52-teeth gear to a 64-teeth gear which made our rover slower.
Additionally, the two-plate design was hard to fabricate as any cuts made to the
bottom plate (ie. supports and steering mechanism) had to be aligned perfectly to
match the top plate. The bottom plate also interfered with the front wheels as there
was not enough space for the wheels to turn properly, which caused them to get
stuck. This greatly hindered our rover’s agility, as we were forced to make long and
slow turns to ensure that our front wheels would not get stuck. Our preliminary track
completion time was 4 minutes and 23 seconds, approximately fourteen times slower
than the winning rover at 19.24 seconds.

Throughout the project, we learned that it is best to keep the design simple, whether
it is the chassis or the steering mechanism. If we designed these components to be
simpler, we would save time on fabrication and allow more time for troubleshooting.

As a group, we learned that dividing the work more efficiently among ourselves
would allow us to complete the project better. If everybody contributed equal
amounts of work, it would remove the pressure of completing the project alone on
any individual. Additionally, we learned that time management is important. There
were several instances where we worked last minute until the deadline, which is not
ideal as it prevented us from creating quality work. Finally, communication was a
vital factor in the success of our team. Throughout the quarter, we kept close contact
with each other by texting updates after any changes were made to the rover or any

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deadlines were approaching. However, as we reflected on this project, our team
agreed that we all should have placed more importance on our weekly team
meetings, as communicating face-to-face was the most effective method to
collaborate and update each other. These are all things we will consider and
implement as we head into next quarter’s ENGR 7B class with different teammates.

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Appendix A: SOLIDWORKS Drawings
All figures in this report can be found in full size here.

Chassis drawing showcasing all parts, including a two-level frame concept and steering mechanism.

Bottom plate drawing showing accurate dimensions, cuts, and the battery.

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Top plate drawing showing cuts for electrical components, such as the servo, and wire management.

Steering mechanism drawing showing accurate dimensions sent for 3D printing.

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Rear wheel mount drawing showing dimensions used for fabricating parts out of wood.

Side supports drawing showing dimensions for side supports made out of wood.

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Appendix B: Bill of Materials

KACHOW remained under the budget of $275 while including 3D printing costs of $18 for 4.5 hours.

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 Works Cited

David, Leonard. “Lunar Lost & Found: The Search for Old Spacecraft.” Space.com,
Space, 27 Mar. 2006,
https://www.space.com/2199-lunar-lost-search-spacecraft.html.

Mars, Kelli. “25 Years of Continuous Robotic Mars Exploration.” NASA, NASA, 13 Sept.
2022,
https://www.nasa.gov/feature/25-years-of-continuous-robotic-mars-explora
tion-from-pathfinder-to-perseverance.

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