Manufacturing and Simulation of a Tracked Mobile Robot for Harsh Terrain and High-Impact Conditions

The design and manufacturing of mobile track robots require careful consideration of both mechanical performance and operational adaptability, especially in challenging terrains such as stairs, obstacles, and inclined surfaces. This paper presents a comprehensive analysis of the development, simulation, and validation of a tracked robot designed for high-performance in rough environments. The manufacturing process involved selecting key components such as motors, oil seals, ball bearings, shock absorbers, and tracks through a rigorous evaluation of alternatives. Materials such as Aluminum 6061-T6 and polyamide were chosen based on their mechanical properties, machinability, and environmental resistance. The robot's structure was fabricated using CNC machining and laser cutting, ensuring high precision and durability. To assess the robot's maneuverability, simulations were performed in MSC ADAMS to evaluate its performance during stair climbing, obstacle traversal, and navigation of 45-degree inclined surfaces. The results from the simulations were validated through real-world testing, confirming the accuracy of the simulated models. The shock absorption system, based on the Christy model, effectively reduced dynamic forces during impacts, while the torque limiter in the power transmission system ensured the protection of critical components under heavy loads. The validated simulations demonstrate the robot's ability to maintain stability and maneuverability in complex environments, making it a robust solution for applications requiring high adaptability, such as industrial inspection, search and rescue, and military operations.