Learnings from University Rover Challenge

Designing the future of Mars rovers taught us that the Red Planet's challenges are only stepping stones to engineering greatness

Ever wondered what it takes to build the next generation of Mars rovers?

A Global Stage for Innovation...! URC

This past year, I had the incredible opportunity to participate in the University Rover Challenge (URC), the world's premier robotics competition for college students. Held annually in the desert of southern Utah, URC challenges student teams to design and build Mars rovers capable of working alongside astronauts exploring the Red Planet. My role in this project was to design an in-hub motor mount for the wheels and a four-wheel independent steering mechanism. In this blog, I'll share my experiences, the challenges we faced, and the lessons learned throughout this exciting journey.

And the Journey Begins

The University Rover Challenge is an international competition where students from all over the world come together to test their engineering skills and innovative solutions. Our main motivation for participating was to tackle challenging and highly technical tasks that required multidisciplinary knowledge and strong team coordination. Our initial goal was to create an independent-driving Mars rover equipped with a five-degree-of-freedom robotic arm.

From Concept to Creation: Our Design Process___

We began by identifying the problem statement and breaking it down into subparts to gain a clearer understanding of the requirements. Extensive research was conducted, including reading various research papers, which helped us set achievable goals and deadlines. To keep our resources, research papers, and deadlines organized, we used Notion, a versatile project management tool. Notion allowed us to streamline our workflow, manage tasks efficiently, and maintain clear communication within the team.

Our execution phase started with designing the overall framework and CAD model using Solidworks software. We focused on manufacturability and anticipated the need for multiple iterations. The basic design evolved through several iterations based on available materials and market conditions. After finalizing the design, we performed static analysis using Ansys software to verify its functionality and reliability under expected forces. Motor selection were done according to the forces calculated.

During the project, we faced several challenges, including limited availability of raw materials and machining facilities, manufacturing delays, and assembly issues. These obstacles taught us valuable lessons in resource management and problem-solving. For instance, we had to adjust our design to accommodate available materials and refine our manufacturing processes to reduce errors and improve efficiency.

Key Learnings...!

The project provided numerous learning opportunities, such as:

• Team coordination and interdisciplinary collaboration.
• Dimensioning and drafting 2D drawings for manufacturing.
• 3D model designing and static simulations.
• Understanding tolerances and designing for manufacturability.
• Conducting static analysis and motor selection with appropriate safety factors.

Mistakes made during dimensioning highlighted the importance of accurate tolerancing and precision in manufacturing, leading to a deeper understanding of these crucial aspects.

Tools and Technologies : We utilized several tools throughout the project, including:

• Solidworks: For 3D modeling and designing.
• Ansys: For static simulations and force calculations.
• Notion: For project management and organization.
• Several hand calculations were made for deciding motors

Conclusion: A Transformative Experience

Although we successfully designed the in-hub motor mount and independent steering mechanism, manufacturing errors led us to implement a differential drive system instead. Despite these setbacks, the in-hub motor mount performed excellently, demonstrating the potential of our design.

For future iterations, I would focus on refining the steering mechanism to ensure it functions under the intended conditions. Additionally, I would adopt a more technical approach, with greater emphasis on tolerancing and manufacturability from the outset.

Reflecting on our journey, participating in the University Rover Challenge was a transformative experience. It not only enhanced my technical skills but also underscored the importance of teamwork, planning, and adaptability. As we move forward, I am eager to apply these learnings to future projects and continue pushing the boundaries of innovation.

If you're passionate about robotics and engineering, I encourage you to participate in competitions like the University Rover Challenge. It's an unparalleled opportunity to learn, grow, and contribute to the future of space exploration. Share your experiences, ask questions, and let's inspire each other to reach new heights!