Mechanical design and development of a differential drive mobile robot

Lee, Kim Long (2024) Mechanical design and development of a differential drive mobile robot. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This study addresses the mechanical design challenges of differential drive mobile robots in light and medium industrial environments, where traditional systems face significant limitations in compactness and component integration. The primary objectives are to design and develop a differential drive mobile robot with an integrated belt drive system, simulate and analyse its performance using MSC Adams software, and evaluate its efficiency, focusing on torque characteristics. Utilising Fusion 360 for 3D modelling, the design prioritises ease of fabrication and assembly through 3D printing technology. Simulations and experimental validations on various terrains, including flat platforms and slopes of 5%, 10%, and 15%, revealed that the robot operates smoothly on flat surfaces with minimal torque variations. However, increased slope gradients significantly raise the torque required by both wheels, reflecting the effort needed to overcome gravitational resistance. On 10% and 15% slopes, the control system struggled to maintain stable motion, evidenced by frequent and irregular torque oscillations and trajectory deviations, primarily due to loss of traction experienced by the drive wheels during transitions from flat ground to slopes, a consequence of the robot's design. The loss of traction during transitions onto slopes pointed to the limitations of the current wheel and caster design. This research presents a reliable approach to developing compact and efficient differential drive mobile robots, offering valuable insights for enhancing productivity and flexibility in industrial automation within spatially limited and dynamically challenging environments. Integrating advanced simulation tools and practical validation techniques ensures that the developed robotic systems are well-suited to meet the evolving needs of modern industrial applications.

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