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The Design and Fabrication of an Omni-Directional Vehicle Platform

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The Design and Fabrication of an Omni-Directional Vehicle Platform THE DESIGN AND FABRICATION OF AN OMNI-DIRECTIONAL VEHICLE PLATFORM By CHRISTOPHER ROBERT FULMER A THESIS PRESENTED TO THE GRADUATE SCHOOL OF THE UNIVERSITY OF FLORIDA IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF SCIENCE UNIVERSITY OF FLORIDA 2003 Copyright 2003 by Christopher Robert Fulmer ACKNOWLEDGMENTS The author would like to thank all of those who made his years at the University of Florida a memorable and interesting experience. In particular the author would like to express his deepest gratitude to Dr. Carl Crane for the dedication he has for his students and the engineering program as a whole. The author would also like to thank Dr. John Zigert and Shannon Ridgway for their guidance and many suggestions throughout the development of this project. Thanks go to all the people of the Center for Intelligent Machines and Robotics for their help and friendship. The author would like to thank his parents, Craig and Patty Fulmer, for their support and encouragement throughout the years. To his fiancee, Cindy, he wishes to extend his most heartfelt love and gratitude for inspiring him to make the most out of this opportunity. iii TABLE OF CONTENTS page ACKNOWLEDGMENTS ................................................................................................. iii LIST OF TABLES............................................................................................................. vi LIST OF FIGURES .......................................................................................................... vii ABSTRACT....................................................................................................................... xi CHAPTER 1 INTRODUCTION ........................................................................................................1 Omni-directional Vehicle Platforms............................................................................ 3 Special Wheel Designs......................................................................................... 4 Conventional Wheel Designs ............................................................................... 6 Vehicle Criteria............................................................................................................ 7 Approach...................................................................................................................... 8 Background.................................................................................................................. 8 Permanent-Magnet Motors................................................................................... 8 Performance characteristics..........................................................................11 Cooling.........................................................................................................13 Position sensing............................................................................................14 Gearing ............................................................................................................... 15 Epicyclic gearing..........................................................................................15 Spur gears.....................................................................................................16 2 MOTOR AND GEAR TRAIN DESIGN ...................................................................21 Load ........................................................................................................................... 21 Motor Selection ......................................................................................................... 21 Controller Selection................................................................................................... 24 Gear Train Design...................................................................................................... 25 Gear Backlash..................................................................................................... 27 Bearing Life........................................................................................................ 28 Motor Cooling .................................................................................................... 28 Gearing Features................................................................................................. 29 iv 3 DRIVE WHEEL HOUSING AND JOINT DESIGN.................................................32 Load Considerations .................................................................................................. 32 Joints.......................................................................................................................... 35 4 PERFORMANCE TESTING .....................................................................................39 Dynamometer ............................................................................................................ 39 Cooling ...................................................................................................................... 42 Data Acquisition ........................................................................................................ 43 5 RESULTS...................................................................................................................46 Speed/Torque Curves and Load Testing.................................................................... 46 Maximum Continuous Torque Testing...................................................................... 47 Acceleration............................................................................................................... 51 Energy Balance.......................................................................................................... 54 Thermal Resistance and Capacitance ........................................................................ 56 Motor Parameters and Constants............................................................................... 58 6 SUMMARY AND CONCLUSIONS.........................................................................59 APPENDIX A DIMENSIONAL DRAWINGS..................................................................................61 B GEAR DATA .............................................................................................................96 LIST OF REFERENCES.................................................................................................100 BIOGRAPHICAL SKETCH ...........................................................................................102 v LIST OF TABLES Table page 1-1 Epicyclic gear arrangements...............................................................................16 1-2 Formulas for the dimensioning of spur gears .....................................................18 2-1 Thrust needed to translate a 400lb vehicle..........................................................21 2-2 Estimates for the physical properties of the wheel .............................................22 2-3 Manufacturing data for the 1st stage planetary arrangement...............................26 2-4 Manufacturing data for the 2nd stage planetary arrangement ...........................27 3-1 Maximum forces attainable for the wheel main bearings...................................35 5-1 Steady state averages for continuous torque test. ...............................................50 5-2 Drive wheel parameters ......................................................................................58 A-1 Bill of materials...................................................................................................94 B-1 Manufacturing data for 1st stage planetary arrangement.....................................96 B-2 Manufacturing data for 2nd stage planetary arrangement....................................97 B-3 Backlash considerations for 1st stage of the epicyclic gear train ........................98 B-4 Backlash considerations for 2nd stage of the epicyclic gear train .......................99 vi LIST OF FIGURES Figure page 1-1 Navigation test vehicle ...........................................................................................1 1-2 Vehicle coordinate system......................................................................................2 1-3 Mobility of Ackerman steered vehicle ...................................................................3 1-4 Universal wheel......................................................................................................4 1-5 Universal wheel platform .......................................................................................5 1-6 Mecanum wheel .....................................................................................................5 1-7 Ball wheel...............................................................................................................6 1-8 Active castor wheel ................................................................................................7 1-9 Technology II .........................................................................................................7 1-10 Brushless DC motor types....................................................................................10 1-11 The three types of three phase designs.................................................................10 1-12 Effective torque ripple, three phase bipolar .........................................................11 1-13 Permanent magnet dc motor characteristics.........................................................13
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