Mechanical Design and Parametric Analysis, Student Project Team
AME 4163 - Principles of Engineering Design (Fall 2025)
THE CHALLENGE:
Developed a shaft-climbing robot concept and supporting design analysis for an autonomous rescue simulation, balancing wheel geometry, payload, traction, and climb speed within a constrained cylindrical shaft.
The device had to climb a 5-inch-diameter, 5-foot-tall shaft while carrying at least 100 g, then activate a mechanism to pop balloons at the exit. The assignment required autonomous operation, a climb time under 90 seconds, a maximum device mass of 3 kg, and a $100 budget. A faster climb and a 400 g payload offered additional performance goals.
THE SOLUTION:
The design process combined mechanical packaging with a parametric study of wheel count, wheel radius, and loaded mass. Excel calculations compared configurations to understand how changes in geometry and payload affected the required drive torque. The study considered two to four wheels and examined the tradeoff between travel per wheel revolution and motor torque demand.
The CAD development addressed the wheel shafts, body, joints, and balloon-popping mechanism as connected subassemblies. Reviewing their interfaces exposed practical assembly issues, including missing mounting provisions and interference between the body and joints. These findings helped turn the initial concept into a more buildable configuration.