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2. PROJECT DESCRIPTION
The initial configuration of the MRCP is described by a
wheeled 6 x 6 x 4 system with a rocker-bogie-suspension
system, allowing a maximum footprint of 820 x 700 mm.
A realisation of the chassis out of Aluminium profile
frames allows a straight forward adaption of the design Figure 1: MRCP on 20° slope test-track mock-up
for changing configuration parameters (Fig. 1). A counter
rotating differential gear connects the left and right sided Based on derived design requirements of the
rocker bogie suspension, allowing an optimised load development tool, suitable and commercially available
distribution on all wheels. A rectangular central body components for the MRCP prototype model were
structure provides a mechanical interface for additional selected. Driven by a cost-efficient realisation and in
subsystem integration. For application within the test- order to fulfil the budget limitation of maximum 4000 €,
environment at the IRS facilities, this initial design all rover subsystems are realised as commercial of the
includes tethered connection to a mobile power supply shelf (COTS) components if applicable and components
station and control of the rover via an amplified USB data manufactured in the institutes workshops as well as by
connection to an external lab computer. Mobility additive manufacturing. After the successful integration
requirements for the initial MRCP configuration were and first operation of the MRCP, the ongoing verification
of pre-defined design requirements as well as actual Tab. 1. The deviation between the analytical calculation
research topics shall be further described. of the actual specific overall MRCP wheel loads on a flat
surface is 1.01 %, whereas the mean deviation for each
3. ANALYTICAL ASSESSMENT wheel is around 3.65 %. This also includes a potential
Driving design criteria for the analytical assessment are error of the axial force sensor along the measurement.
the implementation of a straight forward adaptability of Axial force sensors and electronics by Burster (Type
the parameters defined by the overall rover configuration 8526) were used for the static force analyses. Calculating
as well as a possibility to further adapt the development the actual system mass at the surface gravity of
tool for future reconfigurations and additional subsystem 9.81 N/m² the MRCP weight is defined as 18.535 kg.
implementations. Characteristic input for the analytical
Table 1: Wheel load distribution vs. analytical output on a flat
tool are kinematic parameters of the suspension system solid surface
defining the overall footprint of the rover. In the design
Left side Right side Total
tool, all subsystems and components are implemented as
Wheel No. #1 #3 #5 #2 #4 #6
point-masses for calculation simplification, whereas the
mass of structural components is calculated along their Mean [N] 29.79 28.66 32.75 29.3 27.57 33.77 181.83
specific weight per length. Major visual output of the tool Analytical [N] 30.71 27.69 31.61 30.71 27.69 31.61 180.02
is a simplified two dimensional characterisation of the Deviation [%] 3.000 3.476 3.606 4.591 0.425 6.823 1.01
suspension system kinematics, including characteristic
parameters for the static stability analyses. Characteristic To also verify the impact of the suspension system
wheel loads depending on the kinematic parameters kinematics while operating the rover in a rough terrain
(Fig. 2) as well as the shifting centre of mass during environment several tests included the wheel load
operation can be derived. classification while driving slopes and overcoming step
sized obstacles, being able to analyse the shift of the
overall centre of mass (CoM) of the system. Tab. 2 gives
the exemplary wheel load characteristics for a 12 cm step
obstacle, whereas the front rocker wheels already
climbed the step and the second pair of wheels rest at its
base (Fig. 3). Further tests included also a nominal
Figure 2: Exemplary kinematic visualisation output for the
“reverse driving”, resulting the bogie wheels climbing
MRCP configuration the obstacles first. The mean divergence between the
development tool and the measured wheel loads
As the mobile capabilities of the overall system are respecting the full test series is 4.23 %.
especially determined by the wheel load characteristics,
major investigations lie in the verification of these Table 2: Wheel loads at 12 cm obstacle overcoming
development parameters. To verify the analytical output Left side Right side Total
of the development tool as well as to characterise the Wheel No. #1 #3 #5 #2 #4 #6
MRCP performance a test campaign was set up at the IRS Mean [N] 27.64 28.98 33.03 28.03 28.09 34.71 180.48
facilities. Analytical [N] 29.26 28.41 32.34 29.26 28.41 32.34 180.02
Deviation [%] 5.540 2.018 2.127 4.211 1.111 7.315 0.255
To verify motor performance characteristics, a drive unit Figure 7: Motor speed testing at +/- 2000 rpm (0.5 Nm load)
test environment was set up. Main goal was to analyse and +/- 8000 rpm (0.25 Nm load) demand
the rover-sided recorded data compared to the data
recorded by the commercially available motor control The electrical power consumption (Pel) of a drive unit
software provided by the manufacturer and haptic (DC motor) follows simplified Eq. 2, which describes the
verification tests. The maximum turning speed of the mechanically applied power (Pmech) due to the load, and
rover wheel drive units is limited by the allowable input characteristic losses (Ploss) such as friction (Pfric),
speed of the ceramic planetary gear of 8000 rpm, which acceleration (Pac) and thermal related losses (Ptherm).
result in a maximum MRCP velocity for straight driving
𝑃𝑒𝑙 = 𝑃𝑚𝑒𝑐ℎ + 𝑃𝑙𝑜𝑠𝑠 = 𝑈 ∗ 𝐼𝑚𝑜𝑡 (2)
of vmax = 21.07 cm/s. Nevertheless, a nominal input speed
(straight forward driving) for all drive units of 1000 rpm
Eq. 3 and 4 describe simplified relations of the motor
result in the nominal rover velocity vnom = 2.63 cm/s.
voltage related to the speed constant kn and motor torque
First tests for the verification of commanded, recorded constant km, which are provided by the manufacturer.
and actual speed control of the drive units were
𝑛
conducted in a test environment prior to the final 𝑈 = 𝐼𝑚𝑜𝑡 ∗ 𝑅 + (3)
integration of the rover. The tests included all expected 𝑘𝑛
demanded turning speeds during rover operation (up to
𝑀𝐿𝑜𝑎𝑑
8000 rpm clock- and counter clockwise) in either a no 𝐼𝑖𝑑 = (4)
𝑘𝑚
load mode, or with several simulated torque loads (up to
1.50 Nm) at the gear output shaft. Test results for a single
The recorded drive unit power consumption results from
wheel test in Fig. 7 show, that a test series of commanded,
the recorded motor current Imot and the corresponding
recorded and actual turning speeds can be verified with a
voltage U, determined by Eq. 3. For DC motors, Eq. 2
low average speed variation of below 0.7 %. The speed
can be further derived as formulated in Eq. 5,
ramps result from the limited temporal resolution of the
implementing the motor resistance R, as well as resistive
acquired data, as well as by a specific acceleration and
torques MRes due to friction, acceleration etc. The no load
deceleration of the motors. The mean recorded motor
current I0 describes losses such as inertia of the rotor,
speed deviation for a large scale test series is 3.66 %.
friction of the bearings, core losses etc.
Additionally, correlations between applied load, motor
𝜋
speed and current were determined in order to analyse the 𝑃𝑒𝑙 = ∗ 𝑛 ∗ (𝑀𝐿𝑜𝑎𝑑 + 𝑀𝑅𝑒𝑠 ) + 𝑅 ∗ (𝐼𝑖𝑑 + 𝐼0 )² (5)
drive unit characteristics. In a set up test environment 30
according loads up to 1.5 Nm were applied to a single For the analytical approach, the ideal current Iid (Eq. 4)
drive unit at different motor speeds up to 8000 rpm. In
resulting for a specific load Mload is calculated. Iid
therefore implies the losses due to the planetary reduction printed circuit board (PCB) to the drive unit motor
gear, which are considered to be constant for this controller (ESC). All ESC can be individually
simplification. Fig 8 shows an exemplary plotted drive reconfigured by accessing an integrated micro USB
unit power consumption at 2000 rpm for varying loads, connector. This interface is also used to simultaneously
comparing the consumption calculated by recorded data transmit the drive unit data to the lab computer and
provided from the MRCP and the analytical expected analyse the data provided by the manufacturer within the
power consumption. Also, the power consumption development tests. The servo controller (U2D2) is
calculated by data recorded from manufacturer software directly connected via the BBB`s USB adapter and
(ESC) is shown. The overall mean deviation of the provides a RS485 communication to the steering unit
analytical values and the data recorded by the MRCP on- servos. The servo hub also allows daisy chain
board computer (OBC) is 5.6 %. transmission between the main controller and the steering
units. The PCB includes a power supply unit, distributing
required bus voltage to all consumers. MRCP main
power supply is provided by a 5 m long twisted and
grounded cable connected to an external mobile power
supply station. Internal converters provide redundant
24 V bus voltage for the drive unit motor controller and
12 V bus voltage for the drive unit interfaces, as well as
a 5 V bus for devices inside the avionics box and the
OBC. The power supply unit also routes a separated
Figure 8: Recorded and analytical drive unit power
redundant 24 V and 12 V power supply to a D-SUB
consumption for characteristic load tests at 2000 rpm
interface at the front of the avionics box for the supply of
Due to losses, which might not be respected in this additional payloads or rover subsystems. All internal
assessment, deviations may vary for other loads and consumers are connected to a redundant fuse board on the
motor speeds. Respective tests showed deviations of up PCB for overvoltage protection.
to 8 %.
Figure 12: Exemplary harness design for the drive and steering
unit
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