Abstract
In this thesis, the development of a novel compliant modular robot is proposed for deploy-
ment in Urban Search And Rescue(USAR) scenarios. In the light of the recent natural disasters
in India and Japan, there is a renewed interest in developing rough terrain robots that can aid
in search and rescue efforts by navigating through the rubble to search for trapped victims and
dispense basic first-aid. Specifically, USAR scenarios are very challenging for robots. Each
disaster is unique and the terrain knowledge gained from one may not be useful in the other.
Additionally, the obstacles are so varied in size, shape and rigidity that a single block mobile
robot is often limited in its ability to traverse due to either its size or its limited internal freedom
to naturally deform along the obstacles.
Keeping this in view, we propose the use of a modular design. Each robot module consists
of a link and a wheel pair, that are capable of traversing on their own. The wheels are powered
to provide propulsion for the robot. The modules are combined to form a snake-like structure
and a joint, called link joint, is created between every module pair to allow free rotation (pitch)
in the sagittal plane. In the literature, these type of robots are called snake-like robots and more
specifically Active Wheel-Passive Joint (AW-PJ) type of robots. These robots typically have
a passive articulation mechanism due to the absence of motors at the link joints to control the
internal configuration of the robot. While these robots have better ability to navigate through
tight pockets, they are also limited in their ability to climb heights greater than one module
length due to the problem of tip-over. The primary contribution of this thesis is to enable these
robots to climb bigger obstacles and develop a methodology to estimate the number of modules
required to climb any given height.
Initial work focused on the development of a semi-active modular robot. The robot had five
modules and it was minimally equipped with two motors, one each at the second and fourth link
joints, respectively. The idea was to use the passive mechanism for climbing steps of smaller
heights and motor only while climbing steps of bigger heights. A model-based controller was
designed for the active link joints to achieve big-step climbing. The robot therefore had the ad-
vantage of height-independent climbing motion as in the case of passive mechanism along with
the extra freedom of active joints for maintaining vehicle stability, when necessary. Efficacy of
the mechanism was exhibited through simulations on steps of various heights. However, it was
realized that this approach was useful to climb heights only upto twice the individual module
length. To climb bigger heights, the robot would need motors at all its link joints, leading to a
more bulkier design. Generally, motors at the link joints are also susceptible to damage due to
impact loads during traversal, making such designs less durable.
In order to overcome this disadvantage, the use of compliant joints is proposed. Motors are
no longer used at the link joints for posture control. Instead, springs are designed such that
they are stiff enough to restrict modules from tipping over while offering sufficient compliance
to maneuver on uneven terrains. Spring stiffness for such joints is estimated by formulating an
optimization problem over the static equilibrium equations of the robot. The optimization ob-
jective is to minimize all link joint moments at every instant of its climbing maneuver. This is
one of the key novelties of the proposed work. A design methodology is also proposed for de-
veloping an n-module compliant robot for climbing given height on a surface with prescribed
coefficient of friction. The performance of the proposed formulation is illustrated for climbing
big obstacles and traversing uneven terrains, using both numerical and experimental validation
on 3- and 5-module robots. The robot is successfully able to climb maximum heights of 17 cm
and 36 cm using 3 and 5 modules, respectively.
As a secondary contribution, an optimal wheel-torque based controller is developed to min-
imize wheel slip. This helps in reducing odometric error and maximizing energy efficiency.
Wheel actuators are the only actively controllable elements of this robot, as the modules are
connected using passive compliant joints. Wheel-slip offers a lot of hindrance while traversing
on uneven terrains. Therefore, minimizing wheel-slip is crucial to augment its performance.
Here, the optimization objective is to minimize the traction-to-normal force ratios at all the
wheels. It is shown both numerically and experimentally that the proposed controller not only
minimizes slip but also reduces the mean torque requirement for traversing on uneven terrains.