Design and fabrication of rocker bogie suspension system

DESIGN AND FABRICATION OF ROCKER
BOGIE MECHANISM
Anubhav Kumar
12001004009
Nitin Verma
12001004037
Deergha Garg
12001004015
Rahul Hans
12001004044
Under the Guidance of
Dr. Ajay Kumar
Mechanical Engineering Department

Deenbandhu Chhotu Ram University of Sc. &Tech. Murthal
1

BOGIETO
MECHANISM
CONTENTS
BE COVERED
Introduction
Need and Motivation for the Project
Objective of the Project work
Past Present & Future of the Project
Related Concepts & Theories
Wheel Design
Requirements
Calculations
Budget & Table of Requirements

BOGIE
MECHANISM
INTRODUCTION
The rocker-bogie suspension system was rst used for the Mars Rover and is
currently NASAs favoured design for rover wheel suspension. The intelligently
designed wheel suspension allows the vehicle to traverse over very uneven or
rough terrain and even climb over obstacles.
The rocker-bogie suspension is a mechanism that enables a six-wheeled
vehicle to passively keep all six wheels in contact with a surface even when
driving on severely uneven terrain.
One of the major shortcomings of current rocker-bogie rovers is that they are
slow. In order to be able to overcome significantly rough terrain without
significant risk of flipping the vehicle or damaging the suspension, these robots
move slowly and climb over the obstacles by having wheels lift each piece of the
suspension over the obstacle one portion at a time.
These robots are mainly used for tasks which humans cannot do and which
are not safe.
3

BOGIE MECHANISM
Need and Motivation for the selection of Project
Rocker-bogie suspension system that was first used for the Mars Rover Sojourner
and its currently NASAs favored design for rover wheel suspension.
The need to develop specialized high-fidelity systems capable of operating in
harsh earth environments typically leads to longer development timelines and
greater expenditures.
Not only this, the rocker bogie suspension system can be developed into a wheel
chair too to take the patients from one place to another climbing the stairs on its
own.
It can also be used for material delivery purposes. This is a wide field of study and
is very less explored. So this gave us the motivation for the development of this
rocker bogie suspension system in a cost effective manner.
4

BOGIE MECHANISM
Objective of Project Work
We will be focusing on eliminating the shortcomings of the rover that is the
current rocker-bogie rovers is that they are slow.
The rovers made for the exploration purposes are very costly too. Due to the
high cost of space exploration, most missions to date have been conducted by
NASA and other government-supported organizations.
We, in India have not conducted any mission for the exploration purposes. Not
only mars exploration the rocker bogie can also be used for military and civil
purposes but there also it is needed to be a little cost effective and fast.
Our concern during the development of the rover will be to optimise the speed
such that the rover do not flip and may travel a litle faster too and make it cost
effective with maximum possible rigidity and ruggedness.

BOGIE MECHANISM
Past, Present and Future
Since 1976, NASA has been exploring the surface of Mars with rovers,
starting with the dual landing of Viking 1 and Viking 2 landers.
In 1997, The Mars Pathfinder (MPF) lander delivered the Sojourner Rover to
the surface successfully.
In early 2004, NASA again landed two more rovers on Mars, Spirit and
Opportunity.
Most Recently in 2011, NASA has launched the Mars Science Laboratory
(MSL) with a rover named Curiosity.

BOGIE MECHANISM
Curiosity Rover
Curiosity is a car-sized robotic
rover exploring Mars as part of
NASA's Mars Science
Laboratory(MSL) mission.
Launch date: November 26, 2011
Rocket: Atlas V
Manufacturer: NASA
Operator: NASA
Mission Type :- Mars Exploration
Rover
Launch Mass:- 900 Kg
Max Speed:- 50mm/s
Average Speed :- 10mm/s
7

Related Concepts and TheoriesBOGIE MECHANISM
Traction and Slip
The rover must maintain good wheel traction in challenging rough terrains.
If traction is too high, the vehicle consumes a lot of power in order to overcome
the force and move.
If traction is too low, the rover is not able to climb over obstacles or inclined
surfaces.
Slip occurs when the traction force at a wheel-terrain contact point is larger
than the product of the normal force at the same wheel and the friction
coefcient. Hence, no slip occurs if the condition
Ti Ni
is satised.
In reality it is very challenging to determine the precise friction coefcient for
8
the interaction of two surfaces

BOGIE MECHANISM

Lateral Stability
The rover is said to be stable when it is in a quasi-static state in which it does

not tilt over.
The lateral stability of the rover ensures that the rover does not tip sideways.
As the rover has two symmetric sides, the geometric model is used to nd the
lateral stability of the vehicle.
Lateral stability is computed by nding the minimum allowed angle on the
slope before the rover tips over.
Lateral stability of the rover is ensured if the overall stability angle
stab
.:. min(r,l)
9
10

BOGIE MECHANISM
Mg z sin + Mg yl cos = N1 (yl+yr)

Dividing the equation by z
Mg sin + Mg yl/z cos = N1 (yl+yr)/z

From the figure above the yl/z = tan l and yr/z =tan r
Mg sin + Mg tan l cos = N1 (tan l + tan r)
Let l r and be very small then
Mg + Mg l = N1 (l + r)
Mg( + l ) = N1 (l +r)
Mg > N1
( + l ) < (l +r)
< r
11

BOGIE
MECHANISM
Longitudinal Stability
According to, longitudinal stability of the vehicle is given when all wheels have
ground contact and the condition Ni > 0 is satised, where Ni is the normal
force at wheel i.
It should be noted that even though this condition is compulsory for the statical
model to work, a physical rover does not necessarily tip if a wheel looses
contact to the ground. However, it is less steerable.
12

BOGIE
MECHANISM
Static Stability Factor
The Static Stability Factor (SSF) of a vehicle is one half the track width, TW,
divided by h, the height of the center of gravity above the road.
A reduction in CoG height increases the lateral inertial force necessary to cause
rollover by reducing its leverage, and the advantage is represented by an
increase in the computed value of SSF.
A wider track width also increases the lateral force necessary to cause rollover
by increasing the leverage of the vehicle's weight in resisting rollover, and that
advantage also increases the computed value of SSF.
The inertial force which causes a vehicle to sway on its suspension (and roll
over in extreme cases) in response to cornering, rapid steering reversals or
striking a tripping mechanism, when sliding laterally may be thought of as a force
acting at the CoG to pull the vehicle body laterally.
SSF= TW/(2*h)
13

BOGIE MECHANISM
Mobility
In order to go over an obstacle, the front wheels are forced against the obstacle
by the rear wheels. The rotation of the front wheel then lifts the front of the vehicle
up and over the obstacle.
The middle wheel is the pressed against the obstacle by the rear wheel and
pulled against the obstacle by the front, until it is lifted up and over.
Finally, the rear wheel is pulled over the obstacle by the front two wheels. During
each wheels traversal of the obstacle, forward progress of the vehicle is slowed
or completely halted.
These rovers move slowly and climb over the obstacles by having wheels lift
each piece of the suspension over the obstacle one portion at a time.
14

BOGIE MECHANISM
Wheel Design
Velocity
8cm/s
Velocity
Diamete
r
M
cm
10
0.153
20
10cm/s
Velocity
Diamete
r
m
cm
15.277
10
0.191
0.076
7.638
20
30
0.051
5.092
40
0.038
50
12cm/s
Diamete
r
m
cm
19.096
10
0.229
22.915
0.095
9.548
20
0.115
11.458
30
0.064
6.365
30
0.076
7.638
3.819
40
0.048
4.774
40
0.057
5.729
0.031
3.055
50
0.038
3.819
50
0.046
4.583
60
0.025
2.546
60
0.032
3.183
60
0.038
3.819
70
0.022
2.182
70
0.027
2.728
70
0.033
3.274
80
0.019
1.910
80
0.024
2.387
80
0.029
2.864
90
0.017
1.697
90
0.021
2.122
90
0.025
2.546
100
0.015
1.528
100
0.019
1.910
100
0.023
2.292
110
0.014
1.389
110
0.017
1.736
110
0.021
2.083
120
0.013
1.273
120
0.016
1.591
120
0.019
1.910
130
0.012
1.175
130
0.015
1.469
130
0.018
1.763
140
0.011
1.091
140
0.014
1.364
140
0.016
1.637
RPM
RPM
RPM
15

BOGIE MECHANISM
Requirements
Power Supply :- 12-0-12 Step Down transformer

Drive Motor
:- Depends upon Availability & Calculation

We have chosen 30 rpm motor
Controls
:- Joysticks will be used for each halves
Other
Requirements :-
Full Wave Rectifier for the conversion of

A.C. To D.C.
16

BOGIE MECHANISM
Application & Future Scope
With the development in technology the rover can be used for reconnaissance
purposes with the cameras installed on the rover and minimizing the size of
rover.
With some developments like attaching arms to the rover it can be made
useful for the Bomb Diffusing Squad such that it can be able to cut the wires
for diffusing the bomb.
By the development of a bigger model it can be used for transporting man and
material through a rough terrain or obstacles containing regions like stairs.
We could develop it into a Wheel Chair too. It can be send in valleys, jungles
or such places where humans may face some danger.
It can also be developed into Suspension System for the automobile
vehicles through proper research.
17

BOGIE MECHANISM
Calculation-1
1. Diameter of Wheel
100 = DN/60
DN=1909.86
D
10
20
Selected DN combination:
190.99
D = 70 mm
95.49
N = 27.28 rpm
N
30
63.66
40
47.75
50
38.2
60
31.83
70
27.28
80
23.87
90
21.22
100
19.1
18

BOGIE MECHANISM
2. Calculation of Wheel base
= 21.80
Now, width of the stairs is 400 mm.
So the maximum length of the rover
can be 400mm.
To deduce the wheel base,
Total length (radius of front wheel + radius of rear wheel)
=400-(35+35)
=330 mm
19

BOGIE MECHANISM
3. Length of Links
20

BOGIE MECHANISM
3. Length of Links
Total Wheel base = 330 mm
Let us assume,
=45
In Triangle BNC,
angle BNC = 90
Angle NBC = Angle NCB = 45

Therefore,
NC = NB
NC2 + NB2 = BC2
BC2 = 2(NC)2
=2(165)2
=54450
Therefore,
BC = 233.33mm
(1)
Rounding off to 230mm.

BC = 230mm
21

BOGIE MECHANISM
3. Length of Links (Contd)
Substituting to eqn (1) we get,
2302 = 2(NC) 2
NC = 162.63
Also,
AN = NC = 162.63
In triangle AMN,
angle AMN = 90
AM2 + MN2 = AN
2AM2 = AN2
2AM2 = 162.63 2
AM = 114.99
=115 mm
Now, due to symmetry,
AM = MN = 115 mm
BM = AB AM
=230 115
=115 mm
Therefore,
BM = 115
22

BOGIE MECHANISM
4. Height Calculation:
Height2 = BC2 NC2
(2302 162.632)1/2 = 162.639 mm
Net Height = height + radius
= 162.639 + 35
= 197.639 mm
5. Track Width
Tw = 513.86
23

BOGIE MECHANISM
Calculation - 2
= 25.016
Wheelbase = 300 2(35)
= 230mm
24

BOGIE MECHANISM
Calculation -2
Using same method used earlier dimension of the links is calculated

for the stair shown in previous slide.

BOGIE MECHANISM
Budget and Table of Requirements
S. No
Item
Qty
Link
Material
Acrylic/Woo
d
Shaft
SS
100
Nut Bolts /Washers
4/8
SS
50
Wheel
Plastic
35
Motor
Alloy
5
Electrical
purchase
Budget
500/100
150
S. No
Item
Qty
Transformer
150
Rectifier
20
Joystick
80
PCB
50
Wires and Cables
150
Budget
26

BOGIE MECHANISM
27

BOGIE MECHANISM
Structure Without the assembly of motors and wheels

28

BOGIE MECHANISM
Structure with assembly of all required equipments

29

BOGIE MECHANISM
Initial Working of the Mechanism

30

BOGIE MECHANISM
Working on a Complex Trackl

31

Design and fabrication of rocker bogie suspension system

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Design and fabrication of rocker bogie suspension system

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DESIGN AND FABRICATION OF ROCKER

Mechanical Engineering Department