© RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006 Task 3.1: Design and development of the mobile system – RESCUER – with integration of commercially available components. + WP8 Design and development of the mobile platform

INDEX Design and development of the mobile platform 1. Selected Track Characteristics 2. Discarded options 3. Suspension system design 4. Sprocket Design 5. Pulley Design 6. Test platform 7. Validation Tools 8. Design process and planning © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006

1.SELECTED TRACK CHARACTERISTICS Final track selection: -Special belting: Two models have been selected: -70 tooth stair climbing track -Technical data: Width: 80 mm Height: 8-10 mm Teeth height: 32 mm Material: Composite polymer + 2 levels of internal textile type cloth Designed for : Max 300 Kg Pitch 38.2 mm Overall Length = 70 x 38.2 = 2674 mm Weight = 6 Kg Max. tension force: never had a track break. © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006

1.SELECTED TRACK CHARACTERISTICS The designed undercarriage compatible with the Centipede type (same width, pitch): Advantages: Built in suspension Goes up stairs and over obstacles very well Height of the lugs can be varied depending on vehicle weight Disadvantages: Needs careful retention or it twists in use © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006

1.SELECTED TRACK CHARACTERISTICS Some additional notes: -Best run with as low an installation tension as possible, as this keeps the power absorbed by the track to a minimum. -Problem is that during turning, the forces twisting the track out of engagement with the guides, need to be countered by keeping the track tighter than would otherwise be required. -Possibility: to vary tension depending on the operation conditions: -straight line vehicle operation with little turning -stair climbing or 0 turning © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006

2. DISCARDED OPTIONS © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006 Miniexcavator tracks Qinetiq Special Track Design Agreement with the Cardiff University Offered the RESCUER consortium a free license for manufacture of QinetiQ's design in return for for low cost injection- moulding tooling.

3. SUSPENSION SYSTEM DESIGN Design of the principal block has been modified -New design is specific for the given track -Two axes reduce forces -All parts are symetric -Designed for underwater operation © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006

3. SUSPENSION SYSTEM DESIGN Selected shock absorber © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006 Weight (N)Ry (N)lm (mm)lr (mm)  Fspring (N)Fspring (total) (N) , , , , ,38654, ,148786

3. SUSPENSION SYSTEM DESIGN © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006 Sealing is used for: -Avoid contaminants and humidity to enter into the bearing -Retain the bearing lubricant. RUBBING SEALINGS: -Efficiency depends on the pressure between lip and contact surface. -Very reliable sealing Designed for underwater operation: -External side with protection cover -Internal side by means of a rubbing sealing -Space between axis and bearings filled with oil

4. SPROCKET DESIGN © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March teeth -Diameter 150 mm -Fabricated on steel, weight = 2 Kg. -Directly attached to gearbox -Need two lateral disks (flanges, not drawn) to help the track entering into the sprocket

5. PULLEY TENSIONER DESIGN © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March Excavator tensioner system -Tension force adjustment -Allows fast changing/installing the track -Alternatively a pneumatic dumper can be mounted -Displacement on a dust protected linear guide

6. TEST PLATFORM © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006

7. VALIDATION TOOLS © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006 Allow to compare alternative designs easily Cosmos / Abaqus -Strain -Stress -Displacement -Frequencies -Temperature, effects of heat transfer -Effects of cyclic loading and fatigue operating conditions in parts and assemblies …

8. DESIGN PROCESS AND PLANNING © RESCUER Consortium Meeting Genoa March 2006 © RESCUER Consortium Meeting Genoa March 2006 Complete Design and Test Components March - Wheels and Hubs machined - Drive Train design completion - Prototype chassis design April – Assemble and test drive train May – Definite Undercarriage design June – Undercarriage mounted June – Prototype chassis operational Design FEA Validation Prototype Validation Build