Design and analysis of differential drive

wheeled mobile robot

A PROJECT REPORT

submitted by

Menati Lokesh (711120114010)

Shaik Jafar (711120114021)

Shaik Masthan Vali (711120114022)

in partial fulfillment for the award of the

degreeof

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

JANSONS INSTITUTE OF TECHNOLOGY, COIMBATORE

ANNA UNIVERSITY: CHENNAI 600 025

MAY 2023

i
 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “Design and analysis

of differential drive wheeled mobile robot for all kinds of
environment ” is the bonafide work
Of “ Menati Lokesh (711120114010) , Shaik Jafar (711120114021) ,
Shaik Masthan Vali (711120114022) ,” who carried out the project work
under my supervision.

.
Submitted for the Project Viva-Voce examination held on .

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENT

It is indeed a great pleasure and proud privilege to acknowledge the

help and support we received from the positive minds around us in making
this endeavor a successful one.
We express our sincere thanks to RTN. MPHF. T. S.
NATARAJAN, Chairman and Mr. T. N. KALAIMANI & Mr. T. N.
THIRUKUMAR, Vice- Chairmen, Jansons Foundation, for providing us
with the necessary facilities.
We would like to express my sincere gratitude and profound thanks
toDr. V. NAGARAJAN, Principal, Jansons Institute of Technology, for
his encouragement and support.
We extended our profound gratitude to Dr. M.
MUTHUKUMARAN M.E., Ph.D., Head of the Department, Department
of Mechanical Engineering, Jansons Institute of Technology, who has
always been a source of inspiration.
We are thankful to our project Coordinator Dr. N. SRINIVASAN
M.E., Ph.D., Associate Professor, Department of Mechanical Engineering
for his kindadvice and valuable guidance in carrying out this project work.
We would like to acknowledge the support and enthusiasm provided
by our Guide Mr. MURALI V M.E., Assistant Professor, Department of
Mechanical Engineering, Jansons Institute of Technology.
We would like to express my thanks to all other teaching and non-
teaching faculties of the Mechanical Engineering Department who helped
us directly and indirectly in all the aspects of the project work enabling me
to get completed the project successfully and perfectly.
Lastly, we thank almighty, my parents, siblings and friends for their
constant encouragement without which this assignment would not be
possible.

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 TABLE OF CONTENTS

CHAPTER TITLE PAGE

NO. NO.
ABSTRACT

1. INTRODUCTION

DIFFERENTIAL DRIVE ROBOTS – TYPES-

PURPOSES

INTRODUCTION TO PROJECT

2. 3D MODELLING AND DESIGN SIMULATION

2.1 RUBBER TRACK BELT DESIGN

2.2 MOUNTING CLAMP AND MOTOR ASSEMBLY

2.3 SCISSOR LIFT MECHANISM

2.4 DESIGN AND ANALYSIS OF SCISSOR LIFTING

MECHANISM
3. ELECTRONICS

3.1 COMPONENTS

3.1.1 INDIVIDUAL CIRCUIT DIAGRAM

3.2 SENSORS

3.2.1 IR SENSOR

3.2.2 IMU SENSOR

4. LITERATURE REVIEW

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5 METHODOLOGY

7. CONCLUSION

8. REFFERENCES

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 ABSTRACT

This project report describes the design, development, and testing of a differential drive
mobile robot designed primarily for all kinds of environment like warehouses, hospitals etc.
The major goal of the project is to develop a mobile robot capable of traversing stairs and
all kinds of surfaces along with loads carrying. Since there is a huge scope of research in
mobile robots, this project gives a start to the path in the search.

The robot system is designed for various applications, including surveillance, inspection,
and transportation. The robot consists of two driving wheels, a caster wheel, a differential
drive mechanism, a frame, and a control system. The design process involved the selection
of appropriate materials, the creation of 3D models, and the simulation of the system's
performance under various loads and conditions.

The differential drive mechanism allows the robot to move in any direction, making it highly
maneuverable and suitable for various applications. The analysis of the system involved the
calculation of various mechanical properties, such as stress, strain, and deflection, under
different loading conditions. The results of the analysis showed that the robot system can
withstand the required loads and operate efficiently in various environments. The project
report concludes with a discussion of the design and analysis process, the results, and
potential future improvements. Overall, the project demonstrates the potential of
SolidWorks software in designing and analyzing complex mechanical systems, such as
differential drive wheeled mobile robots.

The robot's control system was designed using Arduino microcontroller and motor driver.
The control system allows for the robot to be remotely controlled and to follow a pre-defined
path. The robot was tested in various scenarios, including straight-line motion, turning, and
obstacle avoidance. The testing showed that the robot could operate efficiently and
effectively in various environments. In conclusion, the project demonstrates the potential of
SolidWorks software in designing and analyzing complex mechanical systems, such as
differential drive wheeled mobile robots. The robot's design and performance can be
improved by adding sensors for obstacle detection and avoidance, increasing the payload
capacity, and improving the battery life. The robot can be used in various applications,
including surveillance, inspection, and transportation.

Keywords: differential drive mechanism, warehouse management, maneuverability,

automation, logistics, robotics.

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 LIST OF TABLES

TABLE NAME OF THE TABLE PAGE

NO. NO.
1. Characteristics Of Track Belt

2. Electronic components

3. Properties Of Materials

4. Properties Of Sprocket

5. Properties Of Guide Wheels

6. Properties Of Track Belt

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 LIST OF FIGURES

IMAGE NAME PAGE

NO. NO.
1. Existing Wheeled Mobile Robot

2. Differential Drive Robots In industries

3. Track Belt

4. Type Of Wheel Guide

5. Mounting Clamp

6. Clamp and Motor Assembly

7. Nomenclature of Scissor Lift

8. 2D View of Actuators

9. Scissor Lift Equipped with Actuator

10. circuit connections- Motor Driver to Motors and Battery

11. circuit connections- Arduino and RF Ccontrol

12. IR Sensor Unit

13. IR Sensor Connected with Arduino

14. IMU Sensor Unit

15. IMU Sensor Connected With Arduino

16. CAD model Chassis

17. Different Perspective Views Of Chassis

18. Structural Analysis Of The Chassis

19. CAD model of compression spring

20. CAD model of compression spring

21. CAD model of Shock absorber assembly

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22. CAD model of shock absorber bottom

23. CAD model of shock absorber head

24. Stress distribution in suspension system

25. CAD model of sprocket wheel

26. Different views of sprocket

27. Stress analysis at shaft region of sprocket wheel

28. Stress analysis of sprocket wheel

29. Different perspectives of guide view

30. CAD model of Guide wheel

31. Stress analysis of guide wheel

32. Stress distribution at the shaft region

33. Final assembly of robot (Isometric view)

34. CAD Final assembly (close view)

35. Final assembly of robot (Side view)

36. Final assembly of robot (topside view)

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 Chapter 1

Introduction
What is Differential drive.?

The advent of mobile robotics has revolutionized industrial automation, enabling efficient
and flexible solutions for material handling and transportation. Among all kinds of the
mobile robotic systems, the differential drive mobile robot stands out as a versatile and
robust platform, capable of navigating challenging terrains and performing complex tasks.
This research report looks into the design and development of a differential drive mobile
robot built exclusively for medium and small-scale companies, with the primary goal of
ascending stairs while carrying the smallest load possible.
Automation has emerged as a critical driving
factor behind greater efficiency, productivity,
and competitiveness in today's quickly
expanding industrial scene. Mobile robots, in
particular, has transformed material handling
and logistics operations by providing adaptable
solutions that expedite processes and maximize
resource utilization. Among the many mobile
robotic systems available, the differential drive
Figure 1 Existing wheeled mobile robot
mobile robot stands out as a tough and versatile
platform capable of overcoming barriers and
crossing difficult terrain.

The differential drive mechanism, which is a

key component of the robot's design, has
various benefits that make it ideal for
industrial applications. The robot can achieve
exact flexibility by separately adjusting the
speed and direction of the two driving wheels,
allowing it to cross tiny corridors, make
abrupt bends, and successfully traverse
complicated settings. This adaptability is
especially important in industrial settings, Figure 2 Differential drive robots in
industries
where space limits and dynamic layouts need
nimble and adaptive robotic systems.

The successful implementation of the differential drive mobile robot has the potential to
revolutionize material handling processes in medium and small-scale industries. By
offering an efficient and cost-effective solution for navigating stairs and carrying loads,
the robot enhances productivity, reduces manual labor, and optimizes operational costs.
Its versatility and adaptability make it suitable for a range of applications, including
manufacturing, warehousing, distribution centers, and other industrial environments.
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 Differential drive robots – types- purposes

Warehousing and Logistics:

Autonomous Mobile Robots (AMRs) with differential drive systems are utilized in
warehouses to select, pack, and transport products effectively. These robots can negotiate
small corridors and carry large goods, optimizing warehouse operations and minimizing
manual labor.

Manufacturing:
Differential drive robots are used in manufacturing facilities for material handling duties
such as transporting components and parts between workstations or assembly lines. They
can transfer big loads precisely, ensuring efficient industrial operations and lowering the
danger of human mistake.

Healthcare:
Differential drive robots are used to transport medical supplies, equipment, and medication
in hospitals and healthcare institutions. These robots can navigate corridors, lifts, and other
limited places, transporting products to various departments or patient rooms while reducing
human labor and boosting throughput.

Agriculture:
Crop harvesting, picking, and transporting are all duties performed by agricultural robots
employing differential drive systems. These robots can navigate fields and orchards while
carrying enormous amounts of gathered product, increasing efficiency and lowering labor
needs in agriculture.

Mining and construction:

Differential drive robots are used for material transport on construction and mining sites,
hauling huge loads of building materials or minerals. These robots can negotiate difficult
terrains and uneven surfaces, increasing safety and productivity in demanding work
environments.

Hospitality and retail:

Differential drive robots are becoming more popular in the retail and hotel industries for
duties such as inventory management, product restocking, and room service. These robots
can traverse stores, hotels, and restaurants on their own, carrying products and delivering
fast customer service.

Security and defense:

Differential drive robots are important in defense and security applications for duties
including bomb disposal, reconnaissance, and payload conveyance in hazardous areas.
These robots can work in difficult terrain, transport big equipment or payloads, and provide
remote monitoring capabilities to guarantee personnel safety.

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 Introduction to project

In today's fast-paced world, efficient and safe load-carrying systems are critical for many
businesses. One major challenge in various settings involves transporting heavy cargo up
and down stairs. This project addresses this challenge by focusing on the design and
development of a differential drive robot capable of climbing stairs with a weight of 30 kg.

The project's primary objective is to design and build a differential drive robot equipped
with a scissor lift that can climb stairs while carrying a payload of 30 kg. This innovative
combination offers several advantages:

Enhanced Functionality: The scissor lift significantly expands the robot's capabilities by
enabling it to:

Lift and Transport Loads: This allows the robot to handle material handling tasks beyond
stair-climbing, significantly increasing its utility.

Reach Elevated Areas: The robot can now access platforms and objects at higher levels,
expanding its potential applications.

Manipulate Objects: The combined movement of the scissor lift and the robot's base allows
for precise manipulation of objects at different heights.

Improved Efficiency and Productivity: The scissor lift can significantly streamline
material handling tasks by:

Reducing the Need for Manual Lifting: The robot can autonomously lift and transport
heavy objects, minimizing the need for manual labor and associated risks.

Enabling Faster Task Completion: The combination of stair-climbing and lifting

capabilities allows the robot to complete tasks more efficiently, leading to increased
productivity.

Optimizing Workflow: The robot can seamlessly integrate into existing workflows,
improving overall operational efficiency.
This project contributes to the field of robotics by providing a cost-effective and reliable
solution for industries requiring efficient stair-climbing and lifting capabilities. The robot's
ability to minimize manual labor, reduce operating costs, and enhance logistical efficiency
makes it a valuable tool for applications in manufacturing, storage, distribution, and beyond.

The robot utilizes a differential drive system for easy traversal and obstacle navigation. The
chassis is constructed from lightweight, yet strong materials like aluminum, providing a
robust structure that can withstand the stresses of stair climbing. Each wheel is powered by

3
a high-torque electric motor, enabling precise control and differential steering. This design
allows the robot to maneuver effectively in tight spaces, making it ideal for stair climbing
activities.
The payload platform is securely mounted on the chassis and can easily carry loads up to 30
kg. Straps and fasteners ensure stability and prevent cargo movement during stair ascent.
The robot's control system utilizes a microprocessor for precise control of motor speed and
direction. Additionally, it features proximity sensors that detect stairs and automatically
initiate the appropriate climbing procedure.

The successful development of this differential drive robot with stair-climbing and lifting
capabilities will significantly contribute to automation and efficiency in load-carrying
activities, especially in environments where stairs are frequently encountered. Its application
potential spans across industries like logistics, warehousing, and construction, where the
ability to climb stairs while carrying large loads is crucial.

By evaluating the robot's performance in terms of stability, maneuverability, payload

capacity, and lifting capabilities, the project aims to provide a solution that enhances
productivity and safety in load-carrying tasks involving stair navigation.

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 2.3D Modelling and Design Simulation

2.1 Rubber Track belt design:

We designed a new structured belt design which is not available in market. We took 2-3
kind of belt designs and formulated and designed our track belt for the robot.

Structure of Rubber track belt

Figure 3 Track belt (a)

Part Characteristics
Rubber Made by mixing natural and synthetic rubbers, this blend
is good for its anti-abrasive properties, as well as its
flexibility and all-weather capabilities. In swampy land,
the soil does not adhere to the track. On harder surfaces,
the mixed rubber blend minimizes noise and vibration.

Metal core (Embedded metal) The Metal core attaches itself to the sprocket and prevents
the Rubber Track from slipping off the wheel. We use a
special adhesive treatment to firmly bond the Metal core to
the rubber.

Steel cord Considering both, the machine weight and the loading
weight, we decide the number and the strength of steel
cords that are inserted and therefore, can determine the
total strength of the rubber track

Table 1 : Characteristics Of Track Belt

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Conventional Wheel guide

Figure 4 Type Of Wheel Guide

The Conventional Type C-2-wheel guide is used in school buses like the Saf-T-Liner C2.
This type of wheel guide is beneficial due to its outstanding visibility, safety features, and
innovative technologies that enhance safety and efficiency. The Conventional Type C-2-
wheel guide is utilized in school buses for its superior safety, visibility, and innovative
features that prioritize passenger safety and comfort.

5.Structural Analysis Documentation

5.1. Chassis (monocoque type)

Basic Design data required:

To design any model, we require a basic data like dimensions, limitations, working region
etc, similarly, in this case we have the dimensional limitations because the model has to be
very compact since it has to be operated in all kinds of environment. So, the chassis has to
be given enough ground clearance to travel in terrains and easily move on trams and so on.
Along with that the model has to climb on stairs to take weights to another floor (in some
cases).
Given ground clearance: 100 mm
Length of the robot: 700 mm
Breadth of the robot: 600 mm
Frame thickness: 2mm
Design procedure:
model a chassis for a tracked mobile robot system in SolidWorks, the following procedure
can be followed:

1. Create a new part file: Start by creating a new part file in SolidWorks.
2. Draw a sketch: Draw a sketch on the X-Y plane to define the profile of the chassis.
You can use the rectangle, circle, and spline tools to create the basic shape of the
chassis.
3. Extrude the sketch: Extrude the sketch to create the 3D model of the chassis. You
6
 can specify the height and thickness based on the specifications of the chassis.
4. Add features: Add any additional features to the chassis, such as holes for
mounting components or a cutout for the motor.
5. Check the model: Check the model for any errors or inconsistencies. You can use
the SolidWorks Simulation tool to perform a stress analysis on the chassis to ensure
that it can handle the loads and forces that will be applied to it.

Material selection:
The selection of aluminium A354 alloy for the chassis design of your wheeled mobile robot
is a suitable choice due to its high strength, good fatigue resistance, and excellent castability.
This alloy is commonly used in the automotive industry for chassis, space frames, and other
structural components due to its high strength-to-weight ratio and formability. Additionally,
A354 alloy has a good response to heat treatment, which can further enhance its mechanical
properties.
Moreover, A354 alloy has a high resistance to corrosion, which is an important factor in the
design of chassis and other structural components that are exposed to the environment. The
alloy also has a good response to welding, which is an important consideration in the design
and manufacture of chassis and other structural components. Additionally, its high strength-
to-weight ratio, formability, and corrosion resistance make it an excellent candidate for
chassis and other structural components in the automotive industry.
Properties Metric
Tensile strength 480 MPa
Yield strength 380 MPa
Shear strength 280 MPa
Fatigue strength 85 MPa
Elastic modulus 193 GPa
Poisson's ratio 0.28
Elongation 40%
Table 3: Material properties of Aluminum A354

Design of Chassis:
The design of the chassis is very efficient and have given a good structural rigidity. The
chassis have a good dimension that is readily suitable for every kind of working
environments like warehouses, hospitals etc, the main objective of the project is to develop
a system that can assist in warehouse management. So, the design is done specifically with
the dimension constraints that are suitable for warehouses, which provides the robot a good
manoeuvrability. The chassis design was inspired form a monocoque chassis design which
is mainly used in automobile. The chassis is a single piece chassis capable of holding all the
required components of the vehicle. Likely in our case the chassis is also capable of holding
all the components like motors, electronic system, power source along with additional
machinery which will be useful in performing extra tasks.
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 Figure 5:.CAD model Chassis

Figure 6: chassis at different views

Structural analysis of Chassis:

When performing a structural analysis on a chassis, it's crucial to consider both the payload
and external applied loads. The payload of 12 kg and the external applied load of 50 kg must
be applied correctly to ensure accurate results.
Payload:
The payload is the weight the chassis is designed to carry. In this case, it's 12 kg. This load
should be applied as a force, which can be calculated by multiplying the payload by the
acceleration due to gravity.
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F=m×g
F = 12 kg × 9.81 m/s²
F = 117.72 N (Newtons)
External Applied Load:
The external applied load is the force exerted on the chassis from an external source. In this
case, it's 50 kg. This load should also be applied as a force, which can be calculated by
multiplying the load by the acceleration due to gravity.
F=m×g
F = 50 kg × 9.81 m/s²
F = 490.5 N (Newtons)
During structural analysis in SolidWorks Simulation, the forces are applied as directional
loads (can also be applied as pressure loads, depending on the nature of the load). For
constraints the bolted region is set, as the design includes a M5 bolt at the region as a fixture,
during analysis it was set as bolted constraint. The motor attaching area and the rear wheel
attaching areas were set as fixed geometry to understand the structural behaviour of the
chassis.
When applying loads in SolidWorks Simulation, it's important to consider the units used.
The software supports various units, including kilograms and Newtons. Ensure that the units
used for the loads are
consistent with the units used in the rest of the model and the analysis settings.

Figure 7. Structural analysis of the chassis

In conclusion, the structural analysis of a chassis should consider both the payload and
external applied loads. These loads should be applied as forces, calculated by multiplying
the mass by the acceleration due to gravity. In SolidWorks Simulation, these forces can be
applied as directional loads or pressure loads, depending on the nature of the load.

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5.2 Compression Spring

Basic data required:

The spring's purpose is to support the differential drive robot's weight and allow it to move
smoothly over uneven surfaces. The spring's required force depends on the robot's weight
and the desired deflection.
The required force: F = k x (where F is the force, k is the spring constant, and x is the
deflection.)
k=F/x
we are looking to include around 5 springs on each side totally 10 springs, to maintain belt
from slipping and to maintain belt’s stiffness and also to give required grip between ground
and track.
The total weight of the system is 15 kg + 50 kg, the total weight is 65 kg. when it is converted
to force, we will get 638 N.
Each spring should be carrying 63.8 N. The allowable deflection of the spring is 15mm
k = 63.8/15
k = 4.254 N/mm
The length and diameter of the spring depend on the required force, the maximum
deflection, and the spring constant.
L=nxd
where L is the spring's length, n is the number of coils, and d is the wire diameter.
L = 7 x 2.5
L = 17.5 mm
The spring diameter can be calculated using:
D = (4 F / (π d2 k)) (1/3)
where D is the spring's diameter, F is the force, d is the wire diameter, and k is the spring
constant.
D = (4 x 63.8 / (3.14 x 2.52 x4.254)) (1/3)
D =1.45 mm

Figure 8. CAD model of compression spring

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Material selection:
Firstly, steel alloy is a common material used in metal spring manufacturing, and it is known
for its high strength and durability. This makes it an ideal material for spring applications,
as it can withstand high stress and provide consistent performance over time.
Steel alloy is a versatile material that can be used in various types of springs, including
compression springs, extension springs, and torsion springs. This means that it can be used
in a wide range of applications, making it a practical choice for many engineering projects.
Steel alloy is known for its excellent corrosion resistance, especially when compared to
other materials like music wire. This makes it an ideal material for springs that will be used
in environments with high humidity or moisture, as it will not rust or corrode as easily as
other materials.
Steel alloy is also known for its superior fatigue resistance, which makes it an ideal material
for springs that will be subjected to repeated loading and unloading. This is especially
important for compression springs, as they are often used in applications where they will be
subjected to high stress and repeated loading and unloading.
Mechanical properties of alloy steel:

• Tensile strength: 190 -300 Mpa

• Modulus of Elasticity: 207 Mpa
• Yield strength: 250 – 590 Mpa
• Poisson's ratio: 0.28

5.3 Structural analysis of Spring:

• Created a new configuration for the spring to represent different states of compression
or extension. I defined the dimensions of the spring, including the overall length of
the helical feature, which changed as the spring was compressed or extended.
• Created new configurations for the spring in different states of compression or
extension. For example, I created configurations for the extended, compressed, and
middle states of the spring.
• Defined the loads applied to the compression spring using the Force or Pressure
options in SolidWorks Simulation. I applied a force in the direction opposite to the
spring's action, representing the load applied to the spring.
• Defined the constraints applied to the compression spring using the Fixtures option
in SolidWorks Simulation. I applied a fixed constraint on one end of the spring,
preventing it from moving in any direction.
• Ran the simulation to analyse the structural behaviour of the spring under the applied
loads. I used the simulation to determine the stress, strain, and deformation of the
spring under the applied loads.
• After the simulation was complete, I analysed the results to determine the behaviour
11
 of the spring under the applied loads. I observed the stress, strain, and deformation of
the spring and used this information to optimize the design of the spring.
• The loads and constraints applied to the compression spring were defined as follows:
• Loads: I applied a force of -63.8 N to the compression spring in the direction opposite
to the spring's action. This represented the load applied to the spring.
• Constraints: I applied a fixed constraint to one end of the compression spring,
preventing it from moving in any direction. This allowed the simulation to analyse
the spring's behaviour under the applied load.

Constraints and parameters:

The materials of the parts are to checked whether they are set correctly, once everything is
set, we have to go to simulation workspace. For the stress analysis, the top part of the shock
absorber is set as fixed region, then the holes are set with bolted joint. The bottom region is
set with roller or slider geometry since the parts has to be show the deformation. The load
is applied on the bottom part of the shock absorber, as it has to counter the force that is
excreted on the model. The load is 63.8 N on each suspension system.

Figure 9: stress analysis in compression spring

5.4 Suspension System Design:

Design of the Compression Spring: Started by designing the compression spring using the
Helical Spring feature in SolidWorks. Specified the wire diameter, mean coil diameter,
number of active coils, and pitch of the spring. And also defined the spring rate and
maximum compression of the spring.

12
 Figure 10: CAD model of shock absorber

Design of the Suspension Head and Bottom Parts: Designed the suspension head and
bottom parts using the Extrude and Revolve features in SolidWorks. Specified the
dimensions and materials of the parts, ensuring they were compatible with the compression
spring.
Assembly of the Suspension System: Assembled the compression spring, suspension head,
and bottom parts using the Assembly feature in SolidWorks. Ensured the parts were properly
aligned and mated, allowing for smooth movement of the suspension system.

Figure 11: CAD model of shock absorber Figure 12: CAD model of shock absorber
bottom head
13
Design procedure:

Draw a sketch: Draw a sketch on the X-Y plane to define the profile of the compression
spring. You can use the circle, line, and spline tools to create the basic shape of the spring.
Extrude the sketch: Extrude the sketch to create the 3D model of the compression spring.
You can specify the height and number of coils based on the specifications of the spring.
Add features: Add any additional features to the spring, such as holes for mounting or a
tapered end.
Create the head and bottom of the shock absorber: Draw a sketch to define the profile
of the head and bottom of the shock absorber. You can use the extrude, revolve, or loft
features to create the 3D model of the head and bottom.
Assemble the components: Assemble the compression spring, head, and bottom of the
shock absorber in SolidWorks. You can use the mate and constraint tools to align the
components and ensure they fit together properly.
Check the model: Check the model for any errors or inconsistencies. You can use the
SolidWorks Simulation tool to perform a stress analysis on the suspension assembly to
ensure that it can handle the loads and forces that will be applied to it.
Structural analysis of suspension assembly:
Structural Analysis of the Suspension System: Performed a structural analysis of the
suspension system using SolidWorks Simulation. Applied loads and constraints to the
system, simulating the forces and movements it would experience in real-world conditions.
Analysed the results of the simulation to ensure the suspension system could withstand the
applied loads and provide a smooth ride.

Optimization of the Design: Based on the results of the structural analysis, optimized the
design of the suspension system. adjusted the dimensions and materials of the parts, ensuring
they were optimized for performance and durability.

Validation of the Design: Validated the design of the suspension system by performing
additional simulations and physical testing. Ensured the system met the required
specifications and performed as expected under various conditions.

The design process for the compression spring and suspension system was iterative, with
multiple rounds of design, analysis, and optimization. The final design was optimized for
performance, durability, and compatibility with the overall vehicle design.

14
The material properties of components in the suspension system play a crucial role in
determining their strength and performance. So, the lower control arm and upper head in a
suspension system is made of aluminium alloy with specific mechanical properties like
tensile ultimate strength, yield strength, Young's modulus, and shear modulus.
Understanding these material properties is essential for accurate stress analysis and design
optimization.

Figure 13: Stress distribution in suspension system

5.5 Design of sprocket wheel:

The torque transmitted by the motor to wheel is 160 kgcm. Which is 15.7 Nm.
Sprocket Wheel Diameter (D): 100 mm
Number of Teeth (N): 21 teeth
Pitch Diameter (P): Calculated based on the number of teeth and pitch of the chain
Material: Aluminium
Load (L): 100 N
Speed (S): 1 m/s
Torque (T): To be calculated based on the load and wheel diameter
RPM (Revolution per Minute): 60
Backlash: 0.1 mm

Pitch Diameter Calculation:

P = (N / π) * Pitch
Sprocket wheel has a pitch of 14 mm:
P = (20 / π) * 14 mm
P ≈ 89.2 mm

15
Speed Calculation:

RPM = (S * 60) / (π * D)
speed of 1 m/s and a wheel diameter of 100 mm:
60 = (S * 60) / (π * 100 mm)
S = 314 mm/s

Figure 14: Different views of sprocket wheel

Figure 15: CAD model of sprocket wheel

16
Design procedure:

Create a new part file: Start by creating a new part file in SolidWorks.
Draw a sketch: Draw a sketch on the X-Y plane to define the profile of the sprocket wheel.
You can use the circle, line, and spline tools to create the basic shape of the sprocket.
Define the tooth profile: Define the tooth profile of the sprocket using the sprocket tooth
formulas. You can use the spline tool to create the tooth profile based on the formulas.
Extrude the sketch: Extrude the sketch to create the 3D model of the sprocket wheel. You
can specify the depth of the extrusion based on the thickness of the sprocket.
Add features: Add any additional features to the sprocket wheel, such as holes for mounting
bolts or a keyway for attaching to a shaft.
Check the model: Check the model for any errors or inconsistencies. You can use the
SolidWorks Simulation tool to perform a stress analysis on the sprocket wheel to ensure that
it can handle the loads and forces that will be applied to it.
Material selection:
A sprocket wheel used with a rubber track belt, the material should be able to withstand the
high tensile strength and reinforce the track for superior strength. According to the search
results, rubber tracks are equipped with a continuous 316 steel belt of high-tensile material
for superior strength, which reinforces the track and enables high performance over extreme
terrains. Therefore, a sprocket wheel made of steel or stainless steel would be suitable for
use with a rubber track belt. These materials are strong, wear-resistant, and capable of
withstanding the load and environmental conditions.
Additionally, steel or 316 stainless-steel sprocket wheels can engage and reinforce the
rubber track's stability and strength, preventing slipping, especially on sharp turns or steep
slopes.

Properties Metric
Tensile strength 580 MPa
Yield strength 290 MPa
Shear strength 344 MPa
Fatigue strength 96.5 MPa
Elastic modulus 193 GPa
Poisson's ratio 0.265
Elongation 40%

Table 4: Material properties of 316 stainless steel

17
Stress analysis of sprocket wheel:

Before the stress analysis, the model is set with the required material specifications. Once it
is set, the simulation workspace is started, the shaft hole is set with a torque that is equal to
the toque the motor produces which is 15.8 N. And the other holes are set with bolted
constrains since they are required to connect the shaft, coupling and the sprocket wheel. And
on the faces of the sprocket teeth, a force of 10 N is applied and the stress analysis is done. The
data is presented below.

Figure 16: stress analysis at shaft region of sprocket wheel

Figure 17: Stress analysis of sprocket wheel

5.6 Design of guide wheel:

The usage of guide wheels in a track belt system serves multiple important purposes that
justify their inclusion in the design:

Stiffness: Guide wheels help maintain the stiffness of the track belt system by providing
18
support and guidance to the belt. This ensures that the belt stays in the correct position and
does not deform excessively, especially when subjected to loads or operating in challenging
environments.

Guiding Purpose: Guide wheels play a crucial role in guiding the track belt along the
intended path. They help prevent the belt from deviating or slipping off its designated track,
ensuring smooth and accurate movement of the belt system.

Preventing Belt Slippage: Guide wheels help prevent belt slippage by ensuring that the belt
stays aligned and engaged with the drive system. This is essential for maintaining the
efficiency and reliability of the track belt system, especially during high-speed or heavy-
load operations.

Enhancing Stability: By providing a stable and controlled path for the track belt, guide
wheels contribute to the overall stability of the system. This stability is essential for ensuring
precise movement, reducing vibrations, and enhancing the overall performance of the track
belt system.

In conclusion, the usage of guide wheels in a track belt system is essential for maintaining
stiffness, guiding the belt along the intended path, preventing belt slippage, and enhancing
the stability of the system. These factors collectively justify the importance and
effectiveness of guide wheels in ensuring the optimal operation of a track belt system.

Design procedure:

Procedure for Modelling a Guide Wheel in SolidWorks Software:

1. Create a new part file in SolidWorks and create the basic shape of the guide
wheel. This can be done using the Extrude Boss/Base feature, which allows you to
create a 3D solid from a 2D sketch.
2. Add the necessary features to the guide wheel to make it functional. This may
include adding a hub for mounting, adding spokes for strength and rigidity, or
adding a tire for traction.
3. Create the necessary mating features to allow the guide wheel to interface with
other components in the system. This may include adding splines, gears, or
pulleys to the guide wheel to allow it to interface with motors or other drive
mechanisms.

Material selection:

6061 Aluminum Alloy is a suitable material for guide wheels due to its good strength and
hardness properties, which minimize wear and ensure long-lasting performance. The 1045
carbon steel and 420 stainless steels are commonly used track materials, but aluminum can
also be used with polymer guide wheels. Aluminum alloy is lightweight, which is beneficial
for reducing the overall weight of the system and improving its performance. Additionally,
aluminum alloy is corrosion-resistant, which is important for applications in humid, liquid,
19
or corrosive environments. The material is also relatively affordable and widely available,
making it a cost-effective solution for guide wheel applications. Overall, aluminum alloy is
a versatile and practical material for guide wheels, offering a balance of strength, durability,
and affordability.

Properties Metric
Tensile strength 310 MPa
Yield strength 276 MPa
Shear strength 207 MPa
Fatigue strength 96.5 MPa
Elastic modulus 68.9 GPa
Poisson's ratio 0.33
Elongation 12-17%
Hardness, Brinell 95

Table 5: Material properties of 6061 Aluminium alloy

Figure 18: Different perspectives of guide view

20
 Figure 19: Guide wheel isometric view

Design calculations:
calculations for designing guide wheels for a track belt system:
Track Belt Material: Rubber with a tensile strength of 20 MPa
Guide Wheel Material: Steel with a yield strength of 250 MPa
Belt Width: 50 mm
Belt Thickness: 5 mm
Guide Wheel Diameter: 10 mm
Operating Load: 500
Friction Coefficient: 0.3

Belt Tension (T):

T = Load / (2 * sin(θ))
θ = sin^-1 (μ), where μ is the friction coefficient
T = 500/2*sin^-1(sin (0.3))
T = 833 N

Belt Stress (σ):

σ = T / (Belt Width * Belt Thickness)
σ = 500 / (50 * 5)
σ = 5 N/mm2
21
Guide Wheel Load (P):
P = T / (2 * Guide Wheel Radius)
P = 500/(2*10)
P = 10 N

Guide Wheel Stress (σ_guide):

σ_guide = P / (π * Guide Wheel Radius2)
σ_guide = 500/(3.14 * 102)
σ_guide = 1.59 N/mm2

Structural analysis of Guide wheel:

• Created a model in SolidWorks and defined the geometry of the guide wheel,
including the shaft region and the roller fixture.
• Defined the material properties of the guide wheel, such as its density, elastic
modulus, and Poisson's ratio.
• Defined the constraints for the simulation, such as the roller fixture and the torque
applied to the guide wheel. In this case, the torque applied is 1.59 Nm.
• Defined the load conditions for the simulation. This includes the radial and axial
loads on each bearing element in the guide wheel system design.
• Ran the simulation and analyse the results. This includes the life of the guide wheel
system, which is limited to the life of the most heavily loaded bearing in the design.
• Use the results of the simulation to evaluate the performance of the guide wheel and
make any necessary changes to the design.

Figure 20: stress analysis of guide wheel (i)

22
 Figure 21: Structural analysis of guide wheel (ii)

5.7 Design of track belt:

calculations for designing a track belt for your tracked mobile robots:

1. Track Width Calculation:

o Given: Robot weight = (100 +20) kg
o Track width = Robot weight / (Track pressure * Ground bearing capacity)
o Assuming a track pressure of 0.005 kg/mm² and a ground bearing capacity of
0.04 kg/mm²:
o Track width = 120 kg / (0.005 kg/mm² * 0.04 kg/mm²) = 60 mm
2. Track Length Calculation:
o Track length from the design is 2073.4 =2074 mm
3. Track Tension Calculation:
o Given: Robot weight = 120 kg, Coefficient of friction = 0.8
o Formula: Track tension = Robot weight * Coefficient of friction
o Track tension = 120 kg * 0.8 = 96 kg

Figure 32 stress distribution at the shaft region

4. Track Durability Calculation:
o Given: Expected lifespan = 1000 hours, Expected wear rate = 0.1 mm/hour
o Formula: Total wear = Expected lifespan * Expected wear rate
o Total wear = 1000 hours * 0.1 mm/hour = 100 mm

23
Design procedure:

Procedure for Modelling a Track Belt in SolidWorks Design Software:

1. Start a new part file in SolidWorks and create the basic shape of the track belt.
This can be done using the Extrude Boss/Base feature, which allows you to create a
3D solid from a 2D sketch.
2. Add the necessary features to the track belt to make it functional. This may
include adding teeth or cleats for traction, adding holes for mounting hardware, or
adding reinforcing ribs for strength.
3. Create the necessary mating features to allow the track belt to interface with
other components in the system. This may include adding splines, gears, or
pulleys to the track belt to allow it to interface with motors or other drive
mechanisms.
4. Use SolidWorks Simulation to analyze the stress and strain on the track belt
under various loads and conditions. This can help you to optimize the design for
strength, durability, and performance.
5. Create detailed drawings and models of the track belt for use in manufacturing
and assembly. This may include creating 2D drawings for machining or fabrication,
or creating 3D models for use in assembly jigs and fixtures.
6. Test the track belt under real-world conditions to ensure that it meets the
necessary performance and durability requirements. This may include testing on
various surfaces, under various loads, and in various environmental conditions.

Material selection:
Natural rubber (NR) is a suitable material for the belt design due to its excellent properties,
such as high tensile strength, elasticity, and resistance to wear and tear. NR is a versatile
material that can withstand a wide range of temperatures and environmental conditions,
making it an ideal choice for heavy-duty applications. Furthermore, NR has excellent
frictional properties, which are essential for the track belt to maintain its grip on the ground
and prevent slippage. Additionally, NR has a high resistance to abrasion, which is crucial
for the belt to withstand the constant friction and wear caused by the movement of the
tracked mobile robot. Moreover, NR is a biodegradable and eco-friendly material, which is
an added advantage in today's environmentally conscious world. Therefore, the selection of
natural rubber material for the belt design is justified due to its excellent properties and eco-
friendly nature.

Properties Metric
Tensile strength 25 MPa
Yield strength 0 MPa
Shear strength 207 MPa
Fatigue strength 96.5 MPa
24
Elastic modulus 3 MPa
Poisson's ratio 0.5

Table 6 Properties of Track Belt

Structural analysis:
For a rubber track belt, it is important to consider the material nonlinearity due to the belt
rubber material, as this can significantly affect the stress and strain on the belt. You can use
nonlinear finite element analysis to calculate the stresses, as described in. This will help to
ensure that the belt can handle the loads and stresses that it will be subjected to during
operation. In addition, you may want to consider using a model-free control of tension and
speed for the conveyor system, as described in. This can help to ensure that the belt operates
at a constant speed and tension, which can improve its performance and longevity. By
following these steps and using the SolidWorks Simulation tools, you can perform a stress
analysis on a rubber track belt and ensure that it is designed to handle the loads and stresses
that it will be subjected to during operation.

2.3 Scissor lift mechanism:

Scissor Lift with Actuators:

A scissor lift with actuators is a platform lifting mechanism that utilizes two or more linear
actuators to raise and lower a platform vertically. This combination offers several
advantages.

Powerful and Compact: Actuators provide efficient and powerful linear motion, enabling
the scissor lift to handle significant loads. Additionally, the compact size of actuators
allows for a more space-saving design compared to hydraulic or pneumatic systems.

Precise Control: Actuators offer precise control over the platform's movement, allowing
for smooth and controlled lifting and lowering. This is crucial for applications requiring
accurate positioning and stability.

Clean and Efficient: Unlike hydraulic and pneumatic systems, actuators operate
electrically, eliminating the need for oil, hoses, and compressors. This results in a cleaner
and more environmentally friendly system.

Low Maintenance: Actuators require minimal maintenance compared to other lifting

mechanisms. They have fewer moving parts, leading to less wear and tear and lower
maintenance costs.

25
Components of a Scissor Lift with Actuators:

Scissor arms: These are the primary structure of the lift, forming the crisscross pattern
that allows for vertical movement.
Linear actuators: These convert electrical energy into linear motion, responsible for
extending and retracting the scissor arms. Common types include ball screw actuators and
lead screw actuators.
Platform: This is the surface where the load is placed and lifted.

Control system: This provides an interface for controlling the lift's movement, typically
through a motor controller or PLC.
Sensors: These monitor various parameters such as platform height, load weight, and
actuator position, providing feedback to the control system.

Need of a Scissor Lift with Actuators in Our Main Project

Enhanced Functionality and Versatility:

The scissor lift significantly expands the robot's capabilities by enabling it to:

Lift and Transport Loads: This adds a crucial dimension to its functionality, allowing it to
handle material handling tasks beyond stair-climbing.

Reach Elevated Areas: The robot can now access platforms and objects at higher levels,
expanding its potential applications.

Manipulate Objects: The combined movement of the scissor lift and the robot's base
allows for precise manipulation of objects at different heights.
This increased versatility makes the robot a valuable tool for various industrial scenarios.

Improved Efficiency and Productivity:

The scissor lift can significantly streamline material handling tasks by:

Reducing the Need for Manual Lifting: The robot can autonomously lift and transport
heavy objects, minimizing the need for manual labor and associated risks.

Enabling Faster Task Completion: The combination of stair-climbing and lifting

capabilities allows the robot to complete tasks more efficiently, leading to increased
productivity.

Optimizing Workflow: The robot can seamlessly integrate into existing workflows,
improving overall operational efficiency.

26
2.4 DESIGN AND ANALYSIS OF SCISSOR LIFTING MECHANISM:

The mobile elevating work platform (MEWP) is a mechanical device for temporary access
to inaccessible areas, typically at height. It encompasses various types such as scissor lifts,
also known as "aerial work platforms" or "cherry pickers". These lifts can be hydraulic,
pneumatic, or mechanical, each with its own advantages and drawbacks depending on the
industry and application. Scissor lift design is favored for its ergonomic benefits and sturdy
frame, offering increased structural strength compared to other options in the market.

Working

Scissor lifts are commonly powered by three main systems: gasoline, electricity, or
hydraulics. Electrically powered lifts are preferred in environments where flammable
materials are present, while gasoline-powered ones are suitable for outdoor use but not
recommended in areas with excessive vapors. Hydraulic lifts utilize pressurized fluid in
tubing to operate, although temperature fluctuations can cause issues. Another type,
pneumatic lifts, operate using compressed air and are environmentally friendly and efficient.
Each system has its advantages and limitations, catering to different needs and
environments.

Major Components in Scissor Lift

The five major parts of a motor scissor lift table typically include:

1. Platform: This is the flat surface where the load or personnel stands or rests during
operation.

2. Scissor Mechanism: Comprising multiple interconnected metal arms, the scissor

mechanism extends and retracts to raise and lower the platform.

3. Motor: The motor provides the power necessary to operate the scissor lift, driving the
hydraulic or electric system that raises and lowers the platform.

4. Hydraulic System (if applicable): In hydraulic scissor lifts, a hydraulic system

consisting of a pump, fluid reservoir, cylinders, and control valves powers the lifting
mechanism.

5. Control Panel: This interface allows the operator to control the lift's movement,
including raising, lowering, and stopping. It may include buttons, switches, or a joystick
for precise control.

27
 Figure 22: Nomenclature Of Scissor Lift

The Actuator

Figure 23: Linear actuator diagram

28
Usually, the translating end will be attached to some point on the lift, and the static end
will be attached to some fixed support. Hence, when the actuator extends, it will cause the
lift to extend.

It should be noted that this does not imply loss of generality, as the derivation holds true
even if the force is applied by any means other than a linear actuator.

Figure 24 : Scissor Lift Equipped with Actuator

29
3. ELECTRONICS

3.1 COMPONENTS

S.NO Name of the component Quantity(units)

1. Arduino Uno – microcontroller 1

2. MDD20A – motor driver 1

3. PS2X – RF controller 1

4. Jumper wires 50 units

Table 2 : Electronic components

3.1.1 INDIVIDUAL CIRCUIT DIAGRAM

Figure 25: circuit connections- Motor driver to motors and battery

Figure 26: circuit connections- Arduino and rf control

30
3.2 SENSORS

3.2.1 IR SENSOR: IR sensors can be used to detect obstacles in the path of the robot.
This can be achieved by emitting IR radiation and measuring the amount of reflected light.
When the sensor detects an obstacle, it can send a signal to the control unit to stop or change
direction, preventing collisions and damage to the robot.

Figure 27: IR sensor

Figure 28: IR sensor and Arduino uno connections

31
 3.2.2 INERTIAL MEASUREMENT UNIT ( IMU ) : An IMU combines
accelerometers, gyroscopes, and sometimes magnetometers to provide information about
the robot's orientation, velocity, and acceleration. This data is crucial for maintaining
stability and controlling the movement of the robot.

Figure 29: IMU sensor

Figure 30: IMU sensor and Arduino uno connections

32
4. LITERATURE REVIEW

The goal of this study of the literature is to thoroughly delve into the research and
advancements around differential drive wheeled mobile robots that are particularly created
for stair climbing.

4.1.1 Review 1

Title: Development of a Differential Drive Robot Platform with External Force Sensing
Capabilities for Logistical Tasks in Hospital Environments
Authors: Tim Andersson, August Kihlberg
Abstract: The kinematics of differential drive robots are crucial for understanding their
motion and control. These robots consist of two drive wheels on a common axis, allowing
independent speed control for each wheel. The robot's motion is determined by the
Instantaneous Center of Curvature (ICC), which is the point about which the robot rotates.
The ICC can be calculated using the wheel velocities and the distance between the wheel
centers. Differential drive robots are sensitive to changes in wheel velocities and ground
conditions, requiring careful control and potential support from additional castor wheels.
For constrained indoor environments, differential drive robots with two caster wheels at
the rear and two drive wheels at the front enable climbing inclined planes and maintaining
constant ground contact for drive wheels, while offset placement of drive wheels from the
center of mass increases moment of inertia and turning power requirements.

4.1.2 Review 2

Title: Exploring Mobile Robots: Concepts, Methods, Theory, and Applications.

Authors: Francisco Rubio, Francisco Valero, and Carlos Llopis-Albert
Abstract: The locomotion of mobile robots is a crucial element in their design, enabling
movement across various environments, from controlled factory floors to challenging
terrains like Mars. Robots such as Sojourner, Spirit, Opportunity, and Curiosity have
showcased their mobility in extreme conditions. Additionally, mobile robots operate
underwater for ocean observations in areas like slits and gullies. Examples include Ling
Shuai's underwater robots and Khatib et al.'s study on various underwater tasks.
Furthermore, robots extend their mobility to the skies through unmanned aerial vehicles
(UAVs). The rise of driverless autonomous vehicles underscores the growing significance
of locomotion systems, which must exhibit manoeuvrability, controllability, efficiency,
and stability across land, water, and air mediums. Autonomous mobile robots heavily rely
on sensors for environmental perception and internal status monitoring, enabling tasks like
positioning, localization, mapping, and object recognition. Recent advancements in sensor
technology and artificial intelligence are enhancing capabilities such as speech
recognition, bringing robots closer to mimicking human abilities. The control system of a
mobile robot encompasses perception, processing, cognition, and action, facilitating tasks
and goal achievement. Cognitive models and AI algorithms play a vital role in decision-
making, path planning, and environmental interaction. Nonlinear control techniques are
employed to manage the robot's nonlinear dynamics and effectively track its position.
33
4.1.3 Review 3
Title: Mobile Robots in Manufacturing
Authors: Michael Shneier, Roger Bostelman
Abstract: Effective communication and mutual awareness are crucial as humans and
robots increasingly share workspaces. Robots can learn tasks through demonstration or
gestures, and advanced personal care robots like Care-O-bot showcase interactive
capabilities applicable to industrial mobile robots. In large facilities, mobile robots use
various localization and navigation methods, including SLAM algorithms and sensor data,
to balance a priori planning with dynamic path generation. Effective coordination of
industrial vehicles in manufacturing settings involves planning paths to prevent collisions,
managing traffic flow, optimizing material delivery, and scheduling vehicle recharge
times. Situation awareness is a key factor in human-robot collaboration, with models and
metrics being developed to measure and improve it. Communication channels, such as
Human-Machine Interfaces (HMIs), play a crucial role in conveying information between
humans and robots.

4.1.4 Review 4
Title: Design and Control for Differential Drive Mobile Robot
Authors: Boru Diriba Hirpo, Prof. Wang Zhongmin.
Abstract: Differential drive wheeled mobile robots are common in mobile robotics,
consisting of two separately driven wheels on a common axis and one or more passive
castor wheels for stability. They change direction by varying the relative rate of rotation of
their wheels. The kinematics of differential drive robots are fundamental for design and
control software development. The robot's position is described using two coordinate
systems: the inertial coordinate system (global frame) and the robot coordinate system
(local frame attached to the robot). The robot's motion is controlled using a kinematic-
based PID control system, which adjusts the speeds of the DC motors or the entire robot
platform based on kinematic modeling. These robots are widely used in various
applications, including industrial, service, and research, due to their ease of programming
and control

4.1.5 Review 5
Title: Quantitative Design Analysis of an Electric Scissor Lift
Authors: Omar Y. Ismael, Mohammed Almaged, Ali Mahmood.
Abstract: Lifting systems are vital in industrial applications for tasks like load lifting,
cleaning, and maintenance. Common types include scissor lifts, articulated lifts, and
telescopic lifts. Scissor lifts, popular for cleaning and maintenance, feature interconnected
platforms that elevate through a scissor’s mechanism. Electric scissor lifts use DC motors
for propulsion and levitation, designed for efficiency. Components like brushless DC
geared motors and motor-ball screw arrangements are chosen for performance and
durability. Material selection enhances durability and reliability, extending the lift's
lifespan. Design considerations like actuator selection, gearbox design, stress analysis, and
power requirements ensure optimal performance and safety. Force analysis, considering
lift capacity, platform mass, safety factor, and scissor arm mass, determines forces on each
joint for stress analysis and component selection. Ball-screw selection involves
34
establishing bearing ratings using SKF tools, with critical considerations on position and
fixing to minimize force requirements. A ball-screw capable of bearing over 78.5 kN is
selected after calculating the total force needed

4.1.6 Review 6
Title: Kinematics, Localization and Control of Differential Drive Mobile Robot
Authors: Sandeep Kumar Malu & Jharna Majumdar.
Abstract: Autonomous mobile robots (AMRs) are used in various fields, including
industry, military, and security environments. The two-wheel drive with differential
steering and a free balancing wheel is a common drive mechanism due to its good
manoeuvrability, especially in indoor environments. Differential drive robots are non-
holonomic systems, and their kinematics are fundamental for understanding their
mechanical behaviour. Control designs using feedback linearization offer better
performance compared to conventional linearized controllers. Methods to reduce odometry
error and efficient localization using RFID technology have also been explored. The
model is utilized as a motion controller in a closed-loop control scheme, with basic motion
tasks involving moving between two robot postures and following a given trajectory. The
control algorithm is designed to drive the robot from its current configuration to the goal
position. The proposed control law is state-dependent, ensuring asymptotic convergence to
the goal position without attaining the exact position. In industrial applications, lifting
systems like scissor lifts are crucial for tasks such as load lifting, cleaning, and
maintenance. These systems use DC motors for propulsion and levitation, with
components carefully selected for performance and durability. Design considerations,
including actuator selection, gearbox design, stress analysis, and power requirements, are
evaluated to ensure optimal performance and safety.

4.1.7 Review 7
Title: Analysis and Design of Sprocket Driven Transmission System
Authors: Pushkar Badawane, Riddhesh Bandre, Laukik Kharche.
Abstract: Roller chain drives are widely used for power transmission due to their constant
ratio and reliability, but challenges like noise and vibration persist, especially with the
demand for higher speeds and lighter weight in automotive applications. Research has
focused on improving the dynamic behaviour of roller chain drives through dynamic
models and computer-aided analyses. Tensioners, polygonal action, impact, and span
length changes are considered in these analyses. New sprocket tooth profiles have been
explored to reduce vibration and noise by minimizing polygonal action and meshing
impact. Some studies have investigated tooth profiles combining involute and beeline
features to address meshing impact and velocity fluctuations. The non-conjugate action
during the meshing process between the chain and sprocket leads to polygonal action and
meshing impact, causing uneven chain velocity, vibration, noise, and transmission
irregularities. These issues restrict roller chain drive applications to lower speeds. Efforts
have been made to develop tooth profiles with approximate conjugate action to enhance
performance at high speeds.

35
4.2 METHODOLOGY

• Stair Climbing Challenges: Researchers have noted a number of difficulties in

creating wheeled mobile robots that can climb stairs. The unevenness of the stair
surfaces, the different stair heights, and the requirement for stability and balance
during climb and descent are some of these difficulties. Existing research sheds light
on these difficulties and how they affect the performance and design of robots.

• Different wheel designs and configurations have been proposed and researched to
improve the ability of wheeled robots to climb stairs. According to the literature,
using wheels that are specifically made to give better grip and adaptation to
different stair geometries, such flippers or tracks, is a good idea. The positioning
and direction of the wheels are also very important for stability and successful stair
climbing.

• Sensor Integration: When constructing a differential drive wheeled robot for stair
climbing, sensor integration is a key component. The use of numerous sensors,
including proximity sensors, depth cameras, and IMUs, to sense the surroundings
and produce pertinent input for navigation and control is suggested in the literature.
The review will examine the various sensor modalities used and how well they work
to overcome the difficulties of stair climbing.

• Navigation and Control Algorithms: Reliable and safe stair climbing depends on
effective navigation and control algorithms. A variety of strategies, including
kinematic and dynamic models, are presented in the literature now in circulation to
obtain exact control during stair climb and descent. The review will assess how well
various algorithms support stability, obstacle avoidance, and precise motion
planning.

• Research investigations have built prototypes of differential drive wheeled robots

for stair climbing. Prototype Development and Experimental Evaluation. These
prototypes have been tested in experimental settings to see how well they operate
and what they are capable of. These prototypes, their design elements, and the
outcomes of experimental assessments will all be covered in the review.

• Comparison of Current Approaches: A thorough review will compare and analyse

the advantages and disadvantages of various approaches used in differential drive
wheeled robots for stair climbing. This examination will provide light on
contemporary methods and identify areas that require more study and development.

36
Final assembly

Figure 31: Final assembly of robot (Isometric view)

Figure 32: CAD Final assembly (close view)

37
Figure 33: Final assembly of robot (top side view)

Figure 34: Final assembly of robot (Side view)

38
6. CONCLUSION

The goal of this project was to develop and create a differential drive robot that could
climb stairs and carry a weight of around 50 kg. The goal was to create a flexible and
useful system that would help small and medium-sized businesses move big cargo
throughout their facilities. To attain the required result, a variety of design considerations,
production techniques, and testing methods were used throughout the project.

The design process includes a careful examination of the needs and limitations particular
to the intended application. The robot's sturdy chassis, strong motors, and differential drive
system were all included into its design to ensure effective mobility and weight bearing
capabilities.

Traditional and contemporary production methods were used in conjunction during the
manufacturing process. High-strength materials were used in the fabrication of the chassis
and structural elements to ensure their longevity and load-bearing capabilities. To obtain
the best performance and dependability, the mechanical parts, including the differential
drive system, were painstakingly c
constructed and put together.
In-depth testing and validation processes were carried out to assess the robot's
functionality and conformity to the design specifications. The robot's capacity to carry
loads of up to 50 kg was tested under a variety of load circumstances. It repeatedly proved
to be capable of doing so. In simulated industrial conditions, the robot's maneuverability
and stair-climbing skills were assessed. The robot was effective in negotiating obstacles
and ascending stairs without jeopardizing stability or safety.

This project's successful conclusion will have a big impact on small and medium-sized
businesses. The created differential drive robot provides an effective, affordable, and
scalable alternative for moving big loads inside industrial buildings. Due to its adaptability
and agility, it can go across a variety of terrains and barriers, making it suited for a variety
of industrial applications.

The project's results also present opportunities for additional improvements and
alterations. Future revisions may concentrate on adding sophisticated navigational tools,
autonomous abilities, or remote-control features. These improvements would make the
robot even more safe, productive, and adaptable to the changing demands of small- and
medium-sized businesses.

In conclusion, the design and production of a differential drive robot that can climb stairs
and carry a weight of around 50 kg have been successfully completed. The project's goals
were achieved, and the created robot had the qualities needed for industrial load transfer.
The robot's durability, flexibility, and agility make it a great asset for small and medium-
sized businesses, with the potential to simplify internal logistics processes and boost
overall productivity. In order to meet the changing demands of the industrial sector, the
project sets the groundwork for continued research and innovation in this area.
39
7.REFFERENCES
1. AUTHER NAMES: K. Narendra Kumar, A. Gopichand, M. Gopala Anjaneyulu, B. Gopi Krishna
TITLE: DESIGN AND DEVELOPMENT OF ADJUSTABLE STAIR CLIMBING ROBOT
YEAR PUBLISHED: Volume: 02 Issue: 04 | Apr-2013.
ZONE: IJRET: International Journal of Research in Engineering and Technology
ISSN: 2319-1163

2. AUTHER NAMES: Muhammad Umar Masood, Muhammad Ahsan Sami, Haris Sohail, Muhammad
Mujtaba, Muhammad Abubakar Siddique, Hashir Akram , Nasir Rashid , Mohsin I. Tiwana , Javaid
Iqbal.
TITLE: Design and Development of a Semi-Autonomous Stair Climbing Robotic Platform For Rough
Terrains.
YEAR PUBLISHED: Oct. 18-21, 2017, Ramada Plaza, Jeju, Korea.
ZONE :2017 17th International Conference on Control, Automation and Systems (ICCAS 2017)

3. AUTHER NAMES: Sandeep H.Deshmukh; Devesh Yadav & Binni Chowalloor

TITLE: DEVELOPMENT OF STAIR CLIMBING TRANSPORTER
YEAR PUBLISHED: Bangalore, India, December 12-13, 2007
ZONE: 13th National Conference on Mechanisms and Machines (NaCoMM07), IISc

4. AUTHER NAMES: Sayali H. Kakade, Ankit I. Kohare, Somen P. Rakhunde, Kiran N. Borkar, Poonam
G. Bhoyar, Akash O. Pandey, Jayant Y. Hande
TITLE: A Review on Automatic Staircase Climbing Platform.
YEAR PUBLISHED: Volume: 05 Issue: 03 | Mar-2018
ZONE: International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

5. AUTHER NAMES: Basil Hamed,

TITLE: Design and Implementation of Stairclimbing Robot for Rescue Applications
ZONE: International Journal of Computer and Electrical Engineering,
YEAR PUBLISHED: 3June, 2011

6. AUTHER NAMES: Weijun Tao1, Yi Ou and Hutian Feng

TITLE: Research on Dynamics an Stability in the Stairs-climbing of a Tracked Mobile Robot
ZONE: International Journal of Advanced Robotic Systems, YEAR PUBLISHED:2 May, 2012

7. AUTHER NAMES: G. Elena and A. J. Maria

TITLE: “The evolution of robotics research,” Robotics and Automation
YEAR PUBLISHED: vol. 3, no. 10, pp. 90-102, 2007.

8. AUTHER NAMES: Rupesh Gupta, Chanpreet Singh, Rajeev Kumar Dang

TITLE: “Stair Climbing Robot”
ZONE: International Journal of scientific research,
Dalhousie University, Halifax, Canada (2015) ISSN NO 2277-8179.

9. AUTHER NAMES: Love P. Kalra and Jason Gu

TITLE: An autonomous self-contained wall climbing robot for non-destructive inspection of above-
ground storage tanks
ZONE: Dalhousie University, Halifax, Canada
YEAR PUBLISHED: Volume 34 · Number 2 · 2007 · 122–127

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10. AUTHER NAMES: Zhu, J., Sun, D. and Tso, S-K.
YEAR PUBLISHED: 2002
TITLE: “Development of a tracked climbing robot”,
ZONE: Journal of Intelligent and Robotic Systems,

11. AUTHER NAMES: Anastasios. Mourikis, Nikolas Trawny, Stergios. Roumeliotis, Daniel M.
Helmick Larry Matthies
TITLE: Autonomous Stair Climbing for Tracked Vehicles
YEAR PUBLISHED :2007

12. AUTHER NAMES: J. Liu, Y. Wang, S. Ma, and B. Li,

TITLE: “Analysis of stairs-climbing ability for a tracked reconfigurable modular robot,”
ZONE: Proc. IEEE International Workshop on Safety, Security and Rescue Robotics, Kobe, Japan,
YEAR PUBLISHED :2005, pp. 53–38.

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