CHAPTER 18

PRINCIPLES OF
ROBOT LOCOMOTION
As you graduate to building larger mobile robots, you should consider the physical properties of your creations, including their size, weight, and mode of transport. A robot that is too heavy for its frame, or a locomotion mechanism that doesn’t provide sufficient stability, will greatly hinder the usefulness of your mechanical invention.
In this chapter you’ll find a collection of assorted tips, suggestions, and caveats for designing the locomotion systems for your robots. Because the locomotion system is intimately related to the frame of the robot, we’ll cover frames a little bit as well, including their weight and weight distribution. Of course, there’s more to the art and science of robot locomotion than we can possibly cover here, but what follows will serve as a good introduction.
Most hobbyist robots weigh under 20 lbs, and a high percentage of those weigh under 10 lbs. Weight is one of the most important factors affecting the mobility of a robot. A heavy robot requires larger motors and higher capacity batteries—both of which add even more pounds to the machine. At some point, the robot becomes too heavy to even move.
On the other hand, robots designed for heavy-duty work often need some girth and weight. Your own design may call for a robot that needs to weigh a particular amount in order for it to do the work you have envisioned. The parts of a robot that contribute the most to its weight are the following, in (typical) descending order:
  • Batteries
  • Drive motors
  • Frame
A 12-V battery pack can weigh 1 lb; larger-capacity, sealed lead-acid batteries can weigh 5 to 8 lbs. Heavier-duty motors will be needed to move that battery ballast. But bigger and stronger motors weigh more because they must be made of metal and use heavier-duty bushings. And they cost more. Suddenly, your “little robot” is not so little anymore; it has become overweight and expensive.
If you find that your robot is becoming too heavy, consider putting it on a diet, starting with the batteries. Nickel-cadmium and nickel metal hydride batteries weigh less, volt for volt, than their lead-acid counterparts. While nickel-cadmium and nickel metal hydride batteries may not deliver the amp-hour capacity that a large, sealed lead-acid battery will, your robot will weigh less and therefore may not require the same stringent battery ratings as you had originally thought.
When looking at reducing the weight of your robot or modifying it in any way, remember to try to come up with changes that result in additional benefits. For example, if you were to change your batteries to a lighter set, you will discover that you do not need as powerful a motor. Less powerful motors weigh less than the originally specified motors, further decreasing the weight of the motor. This decrease in the weight of the motor could result in the need for smaller and lighter batteries, which allows you to look at using even smaller and lighter batteries, smaller motors, smaller structure, etcetera. This process can repeat multiple times and it isn’t unusual to see a situation where a 10 percent decrease in battery weight results in a 50 percent reduction in overall robot weight. The repeating positive response to a single change is known as a supereffect, and you should remember that the reverse is also true: a 10 percent increase in weight in a robot’s components could result in a 50 percent increase in weight in the final robot.
If your robot must use a lead-acid battery, consider carefully whether you truly need the capacity of the battery or batteries you have chosen. You may be able to install a smaller battery with a lower amp-hour rating. The battery will weigh less, but, understandably, it will need to be recharged more often. An in-use time of 60 to 120 minutes is reasonable (that is, the robot’s batteries must be recharged after an hour or two of continual use).
If you require longer operational times but still need to keep the weight down, consider a replaceable battery system. Mount the battery where it can be easily removed. When the charge on the battery goes down, take it out and replace it with a fully charged one. Place the previously used battery in the charger. The good news is that smaller, lower capacity batteries tend to be significantly less expensive than their larger cousins, so you can probably buy two or three smaller batteries for the price of a single big one.
Drive motors are most often selected because of their availability and cost, not because of their weight or construction. In fact, many robots are designed around the specifications of the selected drive motors. The motors are selected (often they’re purchased surplus), and from these the frame of the robot is designed and appropriate batteries are added. Still, it’s important to give more thought to the selection of the motors for the robot that you have in mind. Avoid motors that are obviously overpowered in relation to the robot in which they are being used. Motors that are grossly oversized will add unnecessary weight, and they will require larger (and therefore heavier and more expensive) batteries to operate.
The frame of the robot can add a surprising amount of weight. An 18-in2, 2-ft high robot constructed from extruded aluminum and plastic panels might weigh in excess of 20 or 30 lbs, without motors and batteries. The same robot in wood (of sufficient strength and quality) could weigh even more.
Consider ways to lighten your heavy robots, but without sacrificing strength. This can be done by selecting a different construction material and/or by using different construction techniques. For example, instead of building the base of your robot using solid -in (or thicker) aluminum sheet, consider an aluminum frame with crossbar members for added stability. If you need a surface on which to mount components (the batteries and motors will be mounted to the aluminum frame pieces), add a -in acrylic plastic sheet as a "skin" over the frame. The plastic is strong enough to mount circuit boards, sensors, and other lightweight components on it.
Aluminum and acrylic plastic aren’t your only choices for frame materials. Other metals are available as well, but they have a higher weight-to-size ratio. Both steel and brass weigh several times more per square inch than aluminum. Brass sheets, rods, and tubes (both round and square) are commonly available at hobby stores. Unless your robot requires the added strength that brass provides, you may wish to avoid it because of its heavier weight.
Ordinary acrylic plastic is rather dense and therefore fairly heavy, considering its size. Lighter-weight plastics are available but not always easy to find. For example, ABS and PVC plastic—popular for plumbing pipes—can be purchased from larger plastics distributors in rod, tube, and sheet form. There are many special-purpose plastics available that boast both structural strength and light weight. Look for Sintra plastic, for example, which has an expanded core and smooth sides and is therefore lighter than most other plastics.
For robots that have additional “decks,” like the robot shown in Fig. 18-1, select construction materials that will provide rigidity but the lowest possible weight. One technique, shown in the figure, is to use -in thin-wall (Schedule 125) PVC pipe for uprights and attach the "decks" using or all-thread rod. The PVC pipe encloses the all-thread; both act as a strong support column. You need three such columns for a circular robot, and four columns for a square robot. For small robots, consider electronic circuit board standoffs, which are six-sided rods with the ends drilled and tapped for 4-40 screws.
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Unless your robot is heavy, be sure to use the thinner-walled Schedule 125 PVC pipe. Schedule 80 pipe, commonly used for irrigation systems, has a heavier wall and may not be needed. Note that PVC pipe is always the same diameter outside, no matter how thick its plastic walls. The thicker the wall, the smaller the inside diameter of the pipe. You can readily cut PVC pipe to length using a PVC pipe cutter or a hacksaw, and you can paint it if you don’t like the white color. Use Testor model paints for best results, and be sure to spray lightly. For a bright white look, you can remove the blue marking ink on the outside of the PVC pipe with acetone, which is available in the paint department of your local home improvement store.
A critical issue in robot frame design is excessive weight that causes the frame to sag in the middle. In a typical robot, a special problem arises when the frame sags: the wheels on either side pivot on the frame and are no longer perpendicular to the ground. Instead, they bow out at the bottom and in at the top (this is called negative camber). Depending on which robot tires you use, traction errors can occur because the contact area of the wheel is no longer consistent. As even more weight is added, the robot may have a tendency to veer off to one side or the other.
There are three general fixes for this problem: reduce the weight, strengthen the frame, or add cross-braces to prevent the wheels from cambering. Strengthening the frame usually involves adding even more weight. So if you can, strive for the first solution instead—reduce the weight.
If you can’t reduce weight, look for ways to add support beams or braces to prevent sagging. An extra cross-brace along the wheelbase (perhaps stretched between the two motors) may be all that’s required to prevent the problem. The cross-brace can be made of lightweight aluminum tubing or even from a wooden dowel. The tubing or dowel does not need to support any weight; it simply needs to act as a brace to prevent compression when the frame sags and the wheels camber.
Yet another method is to apply extreme camber to the wheels, as shown in Fig. 18-2. This minimizes the negative effects of any sagging, and if the tires have a high frictional surface traction is not diminished. However, don’t do this with smooth, hard plastic wheels as they don’t provide sufficient traction. You can camber the wheels outward or inward. Inward (negative) camber was used in the old Topo and Bob robots made by Nolan Bushnell’s failed Androbot company of the mid-1980s. The heavy-duty robot in Fig. 18-2 uses outward (positive) camber. The robot can easily support over 20 lbs in addition to its own weight, which is about 10 lbs, with battery, which is slung under the frame using industrial-strength hook-and-loop (Velcro or similar) fasteners.
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Your robot’s horizontal center of balance (think of it as a balance scale) indicates how well the weight of the robot is distributed on its base. If all the weight of a robot is to one side, for example, then the base will have a lopsided horizontal center of balance. The result is an unstable robot: the robot may not travel in a straight line and it might even tip over.
Ideally, the horizontal center of balance of a robot should be the center of its base (see Fig. 18-3a). Some variation of this theme is allowable, depending on the construction of the robot. For a robot with a single balancing caster, as shown in Fig. 18-3b, it is usually acceptable to place more weight over the drive wheels and less on the caster. This increases traction, and as long as the horizontal center of balance isn’t extreme there is no risk that the robot will tip over.
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Unequal weight distribution is the most troublesome result if the horizontal center of balance favors one wheel or track over the other—the right side versus the left side, for example. This can cause the robot to continually “crab” toward the heavier side. Since the heavier side has more weight, traction is improved, but motor speed may be impaired because of the extra load.
City skyscrapers must be rooted firmly in the ground or else there is a risk they will topple over in the slightest wind. The taller an object is, the higher its center of gravity. Of critical importance to vertical center of gravity is the “footprint” or base area of the object—that is, the amount of area in contact with the ground. The ratio between the vertical center of gravity and the area of the base determines how likely it is that the object will fall over. A robot with a small base but high vertical center of gravity risks toppling over. You can correct such a design in either of two ways:
  • Reduce the height of the robot to better match the area of the base, or
  • Increase the area of the base to compensate for the height of the robot.
(There is also a third method called dynamic balance. Here, mechanical weight is dynamically repositioned to keep the robot on even kilter. These systems are difficult to engineer and, in any event, are beyond the scope of this book.)
Which method you choose will largely depend on what you plan to use your robot for. For example, a robot that must interact with people should be at least toddler height. For a pet-size robot, you’ll probably not want to reduce the height, but rather increase the base area to prevent the robot from tipping over.
The way your robot gets from point A to point B is called locomotion. Robot locomotion takes many forms, but wheels and tracks are the most common. Legged robots are also popular, especially among hobbyists, as designing them represents a challenge both in construction and weight-balance dynamics.
Wheels, and to a lesser extent tracks, are the most common means chosen to move robots around. However, some wheels are better for mobile robots than others. Some of the design considerations you may want to keep in mind include the following:
  • The wider the wheels, the more the robot will tend to stay on course. With very narrow wheels, the robot may have a tendency to favor one side or the other and will trace a slow curve instead of a straight line. Conversely, if the wheels are too wide, the friction created by the excess wheel area contacting the ground may hinder the robot’s ability to make smooth turns.
  • Two driven wheels positioned on either side of the robot (and balanced by one or two casters on either end) can provide full mobility. This is the most common drive wheel arrangement and is called a differential drive.
  • Tracks turn by skidding or slipping, and they are best used on surfaces such as dirt that readily allow low-friction steering.
  • Four or more driven wheels, mounted in sets on each side, will function much like tracks. In tight turns, the wheels will experience significant skidding, and they will therefore create friction over any running surface. If you choose this design, position the wheel sets close together.
  • You should select wheel and track material to reflect the surface the robot will be used on. Rubber and foam are common choices; both provide adequate grip for most kinds of surfaces. Foam tires are lighter in weight, but they don’t skid well on hard surfaces (such as hardwood or tile floors).
Thanks to the ready availability of smart microcontrollers, along with the low cost of R/C (radio-controlled) servos, legged automatons are becoming a popular alternative for robot builders. Robots with legs require more precise construction than the average wheeled robot. They also tend to be more expensive. Even a basic six-legged walking robot requires a minimum of two or three servos, with some six- and eight-leg designs requiring 12 or more motors. At about $12 per servo (more for higher-quality ones), the cost can add up quickly!
Obviously, the first design decision is the number of legs. Robots with one leg (hoppers) or two legs are the most difficult to build because of balance issues, and will not be addressed here. Robots with four and six legs are more common. Six legs offer a static balance that ensures the robot won’t easily fall over. At any one time, a minimum of three legs touch the ground, forming a stable tripod.
In a four-legged robot, either the robot must move one leg at a time—keeping the other three on the ground for stability—or else employ some kind of dynamic balance when only two of its legs are on the ground at any given time. Dynamic balance is often accomplished by repositioning the robot’s center of gravity, typically by moving a weight (such as the robot’s head or tail, if it has one). This momentarily redistributes the center of balance to prevent the robot from falling over. The algorithms and mechanisms for achieving dynamic balance are not trivial. Four-legged robots are difficult to steer, unless you add additional degrees of freedom for each leg or articulate the body of the beast like those weird segmented city buses you occasionally see.
The movement of the legs with respect to the robot’s body is often neglected in the design of legged robots. The typical six-legged (hexapod) robot uses six identical legs. Yet the crawling insect a hexapod robot attempts to mimic is designed with legs of different lengths and proportions—the legs are made to do different things. The back legs of an insect, for example, are often longer and are positioned near the back for pushing (this is particularly true of insects that burrow through dirt). The front legs may be similarly constructed for digging, carrying food, fighting, and walking. You may wish to replicate this design, or something similar, for your own robots. Watch some documentaries on insects and study how they walk and how their legs are articulated. Remember that the cockroach has been around for over a million years and represents a very advanced form of biological engineering!
Next to the batteries, the drive motors are probably the heaviest component in your robot. You’ll want to carefully consider where the drive motor(s) are located and how the weight is distributed throughout the base.
One of the most popular mobile robot designs uses two identical motors to spin two wheels on opposite sides of the base (the differentially driven robot). These wheels provide forward and backward locomotion, as shown in Fig. 18-4, as well as left and right steering. If you stop the left motor, the robot turns to the left. By reversing the motors relative to one another, the robot turns by spinning on its wheel axis (turns in place). You use this forward-reverse movement to make hard or sharp right and left turns.
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You can place the wheels—and hence the motors—just about anywhere along the length of the platform. If they are placed in the middle, as shown in Fig. 18-5, you should add two casters to either end of the platform to provide stability. Since the motors are in the center of the platform, the weight is more evenly distributed across it. You can place the battery or batteries above the centerline of the wheel axis, which will maintain the even distribution.
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A benefit of centerline mounting is that the robot has no “front” or “back,” at least as far as the drive system is concerned. Therefore, you can create a kind of multidirectional robot that can move forward and backward with the same ease. Of course, this approach also complicates the sensor arrangement of your robot. Instead of having bump switches only in the front of your robot, you’ll need to add additional ones in the back in case the robot is reversing direction when it strikes an object.
You can also position the wheels on one end of the platform. In this case, you add one caster on the other end to provide stability and a pivot for turning, as shown in Fig. 18-6. Obviously, the weight is now concentrated more on the motor side of the platform. You should place more weight over the drive wheels, but avoid putting all the weight there since maneuverability and stability may be diminished.
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One advantage of front-drive mounting is that it simplifies the construction of the robot. Its steering circle, the diameter of the circle in which the robot can be steered, is still the same diameter as the centerline drive robot. However, it extends beyond the front/back dimension of the robot (see Fig. 18-7). This may or may not be a problem, depending on the overall size of your robot and how you plan to use it. Any given front-drive robot may be smaller than its centerline drive cousin. Because of the difference in their physical size, the diameter of the steering circle for both may be about the same.
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As mentioned earlier, most robots employing the two-motor drive system use at least one unpowered caster, which provides support and balance. Two casters are common in robots that use centerline drive-wheel mounting. Each caster is positioned at opposite ends of the robot. When selecting casters it is important to consider the following factors:
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A variety of methods are available to steer your robot. The following sections describe several of the more common approaches.
For wheeled and tracked robots, differential steering is the most common method for getting the machine to go in a different direction. The technique is exactly the same as steering a military tank: one side of wheels or treads stops or reverses direction while the other side keeps going. The result is that the robot turns in the direction of the stopped or reversed wheel or tread. Because of friction effects, differential steering is most practical with two-wheel-drive systems. Additional sets of wheels, as well as rubber treads, can increase friction during steering.
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Pivoting the wheels in the front is yet another method for steering a robot (see Fig. 18-11). Robots with car-type steering are not as maneuverable as differentially steered robots, but they are better suited for outdoor uses, especially over rough terrain. You can obtain somewhat better traction and steering accuracy if the wheel on the inside of the turn pivots more than the wheel on the outside. This technique is called Ackerman steering and is found on most cars but not on as many robots.
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One of the biggest drawbacks of the differentially steered robot is that the robot will veer off course if one motor is even a wee bit slow. You can compensate for this by monitoring the speed of both motors and ensuring that they operate at the same r/min. This typically requires a control computer, as well as added electronics and mechanical parts for sensing the speed of the wheels.
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To have the highest tech of all robots, you may want omnidirectional drive. It uses steerable drive wheels, usually at least three, as shown in Fig. 18-13. The wheels are operated by two motors: one for locomotion and one for steering. In the usual arrangement, the drive/steering wheels are ganged together using gears, rollers, chains, or pulleys. Omnidirectional robots exhibit excellent maneuverability and steering accuracy, but they are technically more difficult to construct.
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The speed of the drive motors is one of two elements that determines the travel speed of your robot. The other is the diameter of the wheels. For most applications, the speed of the drive motors should be under 130 r/min (under load). With wheels of average size, the resultant travel speed will be approximately 4 ft/s. That’s actually pretty fast. A better travel speed is 1 to 2 f/s (approximately 65 r/min), which requires smaller diameter wheels, a slower motor, or both.
How do you calculate the travel speed of your robot? Follow these steps:
1. Divide the r/min speed of the motor by 60. The result is the revolutions of the motor per second (r/s). A 100-r/min motor runs at 1.66 r/s.
2. Multiply the diameter of the drive wheel by pi, or approximately 3.14. This yields the circumference of the wheel. A 7-in wheel has a circumference of about 21.98 in.
3. Multiply the speed of the motor (in r/s) by the circumference of the wheel. The result is the number of linear inches covered by the wheel in 1 s.
With a 100-r/min motor and 7-in wheel, the robot will travel at a top speed of 35.168 in/s, or just under 3 ft. That’s about 2 mi/h! You can readily see that you can slow down a robot by decreasing the size of the wheel. By reducing the wheel to 5 in instead of 8, the same 100-r/min motor will propel the robot at about 25 in/s. By reducing the motor speed to, say, 75 r/min, the travel speed falls even more, to 19.625 in/s. Now that’s more reasonable.
Bear in mind that the actual travel speed once the robot is all put together may be lower than this. The heavier the robot, the larger the load on the motors, so the slower it will turn.
Robots can’t locomote where they can’t fit. Obviously, a robot that’s too large to fit through doorways and halls will have a hard time of it. In addition, the overall shape of a robot will also dictate how maneuverable it is, especially indoors. If you want to navigate your robot in tight areas, you should consider its basic shape: round or square.
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While you’re deciding whether to build a round- or square-shaped robot, consider that a circle of a given diameter has less surface area than a square of the same width. For example, a 10-in circle has a surface area of about 78 in2. Moreover, because the surface of the base is circular, less of it will be useful for your robot (unless your printed circuit boards are also circular). Conversely, a 10-by-10-in square robot has a surface area of 100 in. Such a robot could be reduced to about 8.5 in2, and it would have about the same surface area as a 10-in round robot, and its surface area would be generally more usable.