Final Design

The frame of the rover is designed to provide a strong, modular foundation that supports and connects all key components. Made from 1.5” square T-slotted aluminum extrusion (24.5” x 14” x 9”), the structure is both durable and flexible, allowing for easy reconfiguration and future modifications. To enhance rigidity and stability, 3/16” thick aluminum brackets are used throughout, ensuring the frame can withstand the stresses of rough terrain. The frame also includes mount bearings for the rocker assembly and flange bearings for the differential bar, facilitating smooth and reliable movement of the rover's critical components. This design prioritizes ease of assembly while maintaining the strength and stability necessary for the rover's demanding operational environment.

The rocker and bogie mechanism is designed to provide exceptional stability and mobility across uneven terrain. Constructed from 3" x 1.5" 6061T aluminum tubing with a 1/8" thickness, the system is both strong and lightweight, capable of handling up to 200 lbs of load with a 2.2 safety factor. The mechanism is designed to climb obstacles up to twice the size of its wheel, ensuring the rover can navigate challenging environments with ease. 3/4" shoulder bolts are used for the rotating bogie and rocker, allowing smooth and controlled articulation. This design enables the rover to maintain stability while adapting to varying surface heights and obstacles, making it ideal for rough, off-road navigation.

The motor and balloon wheel assembly is designed to provide reliable propulsion and mobility for the rover across a variety of terrains. The assembly uses REV Robotics Neo motors paired with 60:1 planetary gearboxes, delivering the necessary torque for efficient movement. Each wheel is equipped with an 11.8" (30 cm) diameter balloon wheel, designed to handle rough and uneven surfaces. A 3D printed hex coupler, along with an aluminum plate and hex hub, is used to connect the wheels to the hex shaft on the gearbox, ensuring a secure and efficient power transfer. The motor mounts are constructed from 3/16" thick 6061 aluminum sheet, providing a strong yet lightweight structure for the motors. Each balloon wheel is rated to carry up to 120 lbs, and with six wheels in total, the assembly can support a substantial load while maintaining stability. This design ensures that the rover can navigate difficult terrains with ease, offering both durability and versatility.

The pod attachment system is designed to securely hold the Lifesaver Pod to the rover's frame while allowing for easy detachment when needed. Linear rails are mounted on each side of the frame to guide and stabilize the pod, ensuring proper alignment during attachment. These rails are currently 3D printed, providing a lightweight yet functional solution. A quick-release fastener is incorporated into the design to securely lock the pod to the frame, enabling swift and efficient pod attachment and removal. This system ensures the pod remains stable and securely in place during rover operation, while also allowing for quick access and reconfiguration as required.