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Cal Rover

 

CAL ROVER

Challenge: The University Rover Challenge (URC) is a team based international robotics competition for college students that requires design, testing, and fabrication of a fully functional Mars Rover prototype (mechanical, electrical, and software). supported by the American Institute of Aeronautics and Astronautics, The 2018 Rover Challenge included Terrain Traversal, Autonomous Traversal, object manipulation, Science Analysis, and Astronaut Assistance.

Skills: 3D Printing, CAD Modeling, Design for Machining, FEA Analysis (structural), Gears, Machining, Motors (DC), Motor Control, multi-Disciplinary TEamwork, Pulleys, Water Jetting.

SOLUTION: As a member of the Mechanical Arm sub-system team, I helped design and fabricate a three limbed robotic arm with a customizable claw capable of object manipulation. THe arm was able to rotate a full 360 degrees around the CHASSIS by way of a motorized pulley system and was designed to reach anywhere on the ground within a 3 foot semi-circle in front of the Rover. Each of the three limbs was fabricated from 6061 aluminum and was driven by either a geared down DC motor or a motorized PULLEY/belt system.

The Claw end effector was DESIGNED to have three degrees of freedom: pitch, twist, and the ability to clamp down on, and interact with an object such as a screw driver.

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Cal Rover 2018 URC Submission Video

 
 

The structural arm components were made of 6061 aluminum to minimize weight while maintaining strength, and were designed for water jet fabrication, which was done on campus.

 
 

In addition to water jetting, other custom components were machined by hand from detailed fabrication drawings.

 
 

The shoulder section of the arm was actuated by a geared down DC motor drive, and to allow for arm rotation a large custom made pulley was fixed to the mounting shaft.

 
 

The arm was mounted to the 80/20 extruded aluminum chassis by way of two tapered roller bearings which support the mounting shaft.

 
 

The arm components were assembled and tested for free range of motion and structural integrity, and then the gear and belt drives tested for mesh alignment, backlash and binding.

 
 

The customized claw end effector was designed to have three degrees of freedom: pitch, spin, and the ability to clamp down on an object.

 
 
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The master assembly was modeled and analyzed in SolidWorks, and all fabrication was executed by the Arm Sub-System Team in house at UC Berkeley’s machine shop.

 
 
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All three limbs of the arm mounted to the chassis, equipped with the motors, geardown systems, and pulleys.

 
 
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The arm lifting and supporting a 5 lbs load during testing.