Page 1

This section of calculations determines all torques necessary for

running the robot:
Turning torque appears to be the most critical calcualtion for determining the wheel diameter,
sprocket diameter, and sizing of the motor. It will also be important for adjusting our center of mass
The most torque at any point on the obstacle course will be when the car is loaded with the 2lb fuel
rod and must be able to turn. These next few calculations will set out to confirm these assumptions
by determining the torque required to ascend the 30 degree incline, turning for both loaded and
unloaded conditions, and the required torque to climb over obstacles.
All of the information below belongs to Dr. Lawton and was provided on Moodle
General turning of the robot as a function of the normalized load distribution on the front axle:
W
r
1.9lbf := weight of the robot (unloaded)
r 2 in := radius of the drive wheels
WB 4.56in := wheelbase (length from axle to axle)
w 5.65in := track width (width from centers of wheels (not outer edges))
0.9 := coefficient of friction between wheels and surface to be turned on (estimated for soft
rubber on wood)

incline
30deg := Angle of the incline T
motor
107ozf in 6.688 inlbf = :=

motor
.34722
rev
s
:= angular velocity of motors at max power
Ability to Ascend the incline:
1.) Grip:
grip tan
incline
( )
.5tan
incline
( )
+ 0.866 = := minimum coefficient of friction of the
wheels to climb incline
2.) Torque:
T
incline
r W
r
sin
incline
( )
1.9inlbf = := minimum torque to climb the incline x2 for
max power /2 for 2 servos
3.) Power:
Max power selected motors can drain
P
incline
T
motor
2

motor
0.824W = :=
Mark Yaconetti
Group #6
12/3/2013
Page 2
0 0.05 , 1 .. := T
m
( ) 4 r
WB
w
W
r
1 ( ) [ ] := T
ed
WB
w
W
r
r :=
0 0.2 0.4 0.6 0.8 1
0
1
2
3
Required Motor Torque to Turn
T
m
( )
inlbf
T
ed
inlbf

o is the normalized weight

distribution on the front
axle.
T_ed is the torque required
for even distribution of the
weight of the vehicle and is
the upper bound for the
required torque of the
motors to turn.
Specify the actual alpha (normalized front weight distribution)
in order to determine the torque required to turn.
.56 := This means that alpha of the weight is on the front wheels.
T
m
( ) 2.72inlbf = This is the maximum required motor torque (from all of the motors in the
drivetrain) to turn with the given weight and distribution (unloaded).
Overall vehicle moments to determine turnability
M
frT
2 W
r
WB 1 ( ) := M
drT
1
2
W
r
w := M
drT
4.83 inlbf = M
frT
3.84 inlbf =
THE DRIVE MOMENT MUST BE SIGNIFICANTLY LARGER THAN THE FRICTION MOMENT!
(at least 10%)
M
drT
M
frT
1.26 =
Turning and stability with cargo out front. Use this after you have defined all of the variables
above and below!
Use the calculations below for analyzing turning torque while loaded and stability while loaded.
x
CG
1 ( ) WB := this is the length from front axle to the robot CG (without the cargo);
leave this alone.
x
CG
2.006 in =
Mark Yaconetti
Group #6
12/3/2013
Page 3
W
bl
2 lbf := the weight of the block
L
bl
.5in := the length from the front axle to the center of the cargo
(change this for a given robot!)

RL
W
r
x
CG
W
bl
L
bl

W
r
W
bl
+
( )
WB
:= normalized weight distribution on the rear axle with the crane extended
T
mL
4 r
WB
w
W
r
W
bl
+
( )

RL
1
RL

( )

:= turning torque with the block

RL
0.158 = Danger (instability) for negative or small numbers!

RL
W
r
W
bl
+
( )
0.617 lbf = weight on the rear axle
1
RL

( )
W
r
W
bl
+
( )
3.283 lbf = weight on the front axle
This is the maximum required motor torque (from all of the motors in the
drivetrain) to turn with the given weight and distribution (loaded).
T
mL
3.02inlbf =
All of the information above belongs to Dr. Lawton and was provided on Moodle
The following calculations will determine the torque required to climb over obstacles:
L
F
2.56in := distance from the front axle to the center of gravity
L
R
2in := distance from the rear axle to the center of gravity
F
F
L
R
W
r

( )
L
R
L
F
+ r +
:=
force required to lift the front end of the car
F
F
0.579 lbf =
T
F
r F
F
:=
Mark Yaconetti
Group #6
12/3/2013
Page 4
T
F
1.159 lbf in = Torque required to lift the front end of the car
F
R
L
F
W
r

( )
L
R
L
F
+ r
:=
force required to lift the rear end of the car
F
R
1.9lbf =
T
R
r F
R
:=
T
R
3.8lbf in = Torque required to lift the rear end of the car
Safety factor of the motors at max power
FS
motor
T
motor
2
|

\
|
|
.
2
T
R
1.76 = :=
This section of calculations determines the stability of the robot
while ascending the incline:
All of the information below belongs to Dr. Lawton and was provided on moodle
KML 8/16/13 analysis of static tipping on the incline.
Be sure that the parameters of weight and weight distribution model the robot as well as any
addtional payload that the robot is carrying.
Change these variables according to your robot and drivetrain:
W
r
2 lbf := weight of the robot
W
rod
0 lbf := weight of the rod - this is 0 if you do not need to carry the load up the incline
.56 := normalized front weight distribution (from turning torque analysis file).
WB 4.56in := wheelbase - from turning torque analysis file.
D
wh
4 in := r
wh
0.5D
wh
:= diameter and radius of the wheels
Mark Yaconetti
Group #6
12/3/2013
Page 5
h
cg
2.9in := height of the CG above the ground (you may want to get this from Pro/E)
Leave these calculations alone:
L
r
WB := horizontal length from center of rear axle to CG (as the robot sits on the level)
L
f
1 ( ) WB := horizontal length from center of front axle to CG
30deg := angle of incline
N
f
L
r
W
r
cos ( ) h
cg
W
r
sin ( )
L
r
L
f
+
:= normal force (stati c) on the front wheels
N
f
0.33 lbf = If the force on the front wheels is
significantly greater than zero, the
robot is statically stable on the incline.
Let us say that, at minimum, the force
on the front wheels must be at least
20% of the total normal force on all of
the wheels.
N
f_min
0.2W
r
cos ( ) := N
f_min
0.35lbf =
If there is insufficient load on the front wheels going frontwards, the robot must ascend the incline
backwards (heavy-end first). Model this by changing the alpha (to 1-alpha).
All of the information above belongs to Dr. Lawton and was provided on moodle
Mark Yaconetti
Group #6
12/3/2013
Page 6
This section of calculations determines stresses
and deflections on all supporting elements of the
robot:
Stress on the chassis plate:
L
c
6.5in := Length of the chassis plate
W
c
5.25in := Width of the chassis plate
t
c
1
16
in := Thickness of the chassis plate
E 10000ksi := Modulus of elasticity of chassis material
F
m
W
r
W
bl
+ := Force at center of chassis plate
c
p
t
c
2
:= distance to centroid of chassis plate

y
35000psi := yield stress of chassis material
Bendi ng i s the greatest contri butor of stress on the chassi s pl ate, the greatest bendi ng
wi l l occure when the ful l l oad of the robot pl us the fuel rod are appl i ed di rectl y i n the
center of the cassi s (at Lc/2). Al so, we wi l l assume that the moment caused by the
motors at stal l torque wi l l be appl i ed very cl ose to the center of the pl ate. Thi s al l ows
the max moment caused by forces on the pl ate to be added to the motor stal l torque,
whi ch woul d be absol ute worste case scenari o for l oadi ng:
M
maxf
F
m
L
c
2
|

\
|
|
.
13inlbf = :=
M
stallmotors
T
motor
2 13.375inlbf = :=
M
total
M
maxf
M
stallmotors
+ 26.375inlbf = :=
In order to cal cul ate the second moment of area, i t i s fi rst necessary to fi nd the centroi d
of the i rregul ar cross-secti on at the center of the chassi s:
t
sm
1
16
|

\
|
|
.
in := Thickness of bars attached to axle housings
w
sm
.375
2
in := Width of bars attached to axle housings
A
small
t
sm
w
sm
0.012 in
2
= := Cross sectional area of bars attached to axle
housings at the center of the chassis
d
p.sm
1.35in := Distance from bottom of chassis plate to the
bottom of the bars
Mark Yaconetti
Group #6
12/3/2013
Page 7
A
plate
t
c
W
c
0.328 in
2
= := Cross sectional area of chassis plate
A
chassis
A
plate
2 A
small

( )
+ 0.352 in
2
= := Cross sectional area of entire chassis assembly at
the center
Q
1small
A
small
.5w
sm

( )
2 := First moment of area of bars attached to axle
housings
First moment of area of the chassis plate
Q
1plate
A
plate
d
p.sm
t
c
2
+
|

\
|
|
.
:=
Q
1T
Q
1plate
Q
1small
+ := Total first moment of area of entire chassis
assembly
Y
bar
Q
1T
A
chassis
1.295 in = := Location of the centroid in the y direction
(measured from y=0 at the bottom of the bars that
are attached to the axle housings
Usi ng the paral l el axi s theorem to fi nd the second moment of area:
I
plate
1
12
|

\
|
|
.
W
c
t
c
3

(
(

A
plate
d
p.sm
c
p
+ Y
bar

( )
2

+ 2.524 10
3
in
4
= :=
I
small
1
12
|

\
|
|
.
t
sm
w
sm
3

(
(

A
small
Y
bar
w
sm
2

\
|
|
.
2

(
(
(

(
(
(

2 0.034 in
4
= :=
I
chassis
I
plate
I
small
+ 0.036 in
4
= :=

bend
M
total
c
p

( )
I
chassis
22.621psi = :=
FS
chassis

y

bend
1.547 10
3
= :=
Defl ecti on i n the chassi s assembl y:
Solids textbook used for equations in a bending beam for single moment, as well as single force in
the center of the beam. Using superposition, the deflection of the entire assembly can be
calculated:
Mark Yaconetti
Group #6
12/3/2013
Page 8

m
M
total
L
c
2
|
\
|
.

9 3
.5
( )

E I
chassis

1.962 10
4
in = := Deflection caused by moment only
Deflection caused by force acting in the
center only

f
F
m
L
c
3

|
\
|
.
48E I
chassis

6.281 10
5
in = :=

chassis

m

f
+ 2.59 10
4
in = := Max deflection on the chassis
Mark Yaconetti
Group #6
12/3/2013
Page 9
Chain tension:
At stall torque, maximum tension will occur.
r
sprocket
.405in := Radius of sprockets used for the drivetrain
T
chainy
65.lbf := Max tension rating for nylon chain
T
chain
T
motor
r
sprocket
16.512lbf = := Tension on a single line of chain
FS
chain
T
chainy
T
chain
3.936 = := Safety factor of drive chains
Mark Yaconetti
Group #6
12/3/2013
Page 10
Buckling in the rods connecting the axle housings:
The tension in the top chain will be the same as the bottom at stall torque, because the
sprockets will not be rotating.
So, the force on the axles that will be supported by the rod will be double the chain tension at stall
for static equilibrium to be satisfied, the load on the rectangular rods will be roughly half of this
force due to statics (axle housings will take about half of the load)
F
c
T
chain
16.512lbf = := L
rod
5in :=
I
rod
1
12
|

\
|
|
.
w
sm
t
sm
3
3.815 10
6
in
4
= :=
Critical buckling force for fixed end column:
P
cr
( )
2
E I
rod

L
rod
2
15.06 lbf = := criticle force for buckling
FS
rod
P
cr
F
c
0.912 = := fairly low, need to add verticle support column
A support needs to be added attaching the chassis to these supports to prevent buckling. Since
the safety factor is less than 1, the rectangular bars will buckle, when this happens, the verticle
support will be the dominating column for buckling.
L
vertsupport
1.25in := length of verticle support column
criticle force for buckling
P
cr2

2
E
I
rod
( )
2

(
(

L
vertsupport
2
120.479 lbf = :=
safety factor of buckling of the verticle support,
this allows for a stable chassis support FS
rod2
P
cr2
F
c
7.296 = :=
verticle supports can be half the size of the rods and can maintain a
safety factor of 7.3
Mark Yaconetti
Group #6
12/3/2013
Page 11
Axle housings:
L
housing
1.25in := d
axle
.25in :=
L
bearing
.75in := w
housing
.5in :=
A
bearing
d
axle
w
housing
0.393 in
2
= := t
housing
.375in :=
Summing forces in the x direction yields a force equal to the tension in the chain for both the top
and bottom of the axle housing due to symmetry. This leaves a force in the bearing equal to
double the chain tension at stall torque.
Summing the forces in the x and y direction:
F
bearingy
W
r
W
bl
+
( )
4
1 lbf = :=
F
bearingx
T
chain
2
( )
33.025lbf = :=
Bearing Stress:

bearingx
F
bearingx
A
bearing
84.097psi = :=

bearingy
F
bearingy
A
bearing
2.546 psi = :=
The chain also causes a bending stress in the axle housing as well as the secondary bearing
housings for the front axles:
I
centerhousing
t
housing
w
housing
3

|
\
|
.
12

(
(
(

w
housing
d
axle
3

|
\
|
.
12

(
(
(

3.255 10
3
in
4
= :=

bendhousing
T
chain
2 L
bearing

w
housing
2

\
|
|
.
I
centerhousing
1.902 10
3
psi = :=

housingtotaly

bendhousing

bearingy
+ 1.905 10
3
psi = := total resulting stress in the
axle housings
Using Mohr's Circle:
Mark Yaconetti
Group #6
12/3/2013
Page 12

housing1

housingtotaly

bearingx
+
( )
2

(
(

bearingx

housingtotaly

( )
2
2

(
(
(

(
(
(

0.5
+ 2.282 10
3
psi = :=

housing2

housingtotaly

bearingx
+
( )
2

bearingx

housingtotaly

( )
2
2

(
(
(

(
(
(

0.5
292.977 psi = :=
using housing1 as the maximum stress caused on the surface:
FS
housing

y

housing1
15.338 = := Safety factor for the bearing hole of the axle housing
Axle Supports (servos for the rear wheels):
The axle supports will bear roughly half of the force from tension in the chains, they also oppose
bending in the axle from that force :
L
axle
1.07in := Distance from outer edge of axle support to outer edge of axle housing
(max possible distance that will cause a bending moment on the shaft)
d
bearingsupport
.3155in := diameter of bearing hole in axle support
B
support
1in := base used for I.support from bending caused
by axle bending
H
support
1in := height used for I.support from bending caused
by axle bending
c
support
.5in :=
max bending stress distance from the
centroid
t
support
t
c
0.063 in = :=
Mark Yaconetti
Group #6
12/3/2013
Page 13
F
bearingsupport
F
bearingx
33.025lbf = :=
Max possible force on the bearing of
the axle supports
M
support
F
bearingsupport
L
axle
35.336inlbf = :=
Max moment possible from bending
in the axle
Second moment of
area of axle support
that resists bending
from the axle
I
support
B
support
H
support
3

|
\
|
.
12

(
(
(

0.083 in
4
= :=

bearingsupport
M
support
c
support

( )
I
support
212.019 psi = :=
Bending stress caused by
bending in the axle
Bending due to bearing force on the axle support:
Max possible moment caused
by the bearing force on the axle
supports (used distance from
end to end) [same moment will
be applied to the servos on the
rear axles]
M
support2
F
bearingsupport
H
support
33.025inlbf = :=
Second moment of area of axle
support that resists bending
caused by bearing force (max
distances possible used)
I
support2
t
support
H
support
3

|
\
|
.
12

(
(
(

5.208 10
3
in
4
= :=

bearingsupport2
M
support2
c
support

( )
I
support2
3.17 10
3
psi = :=
max bending stress caused by
bearing force
Maximum stress that the axle
supports will need to handle
FS
support

y

bearingsupport2
11.04 = :=
Mark Yaconetti
Group #6
12/3/2013
Page 14
Axle Stresses:
largest force stress will occur in the plane that the chain force is applied at the axle housing, use
Mohr's cirlcle to find max stress on the shaft from both torsion and shear from the chain force as
well as bending from the chain force at the center of the axle (max possible bending stress)
M
axle
T
chain
L
axle
2
8.834 inlbf = :=
Max possible bending moment
arrangement on the axle
I
axle
d
axle
4

|
\
|
.
64
1.917 10
4
in
4
= :=
Second moment of area of axle

bendaxle
M
axle
d
axle
2

\
|
|
.
I
axle
5.759 10
3
psi = :=
Max bending stress at surface
of axle

maxaxle
T
chain

d
axle
2
4

336.387 psi = :=
Max shear

torsion
T
motor
d
axle
2

\
|
|
.
I
axle
2
2.18 10
3
psi = :=
Max torsion at surface of axle
Assume that shear and shear due to torsion are both in the same direction to model a worst case
scenario:

axle

maxaxle

torsion
+ 2.516 10
3
psi = :=
Using Mohr's Circle:

axle1

bendaxle
2
|

\
|
|
.

bendaxle
2
|

\
|
|
.
2

axle
( )
2
+

(
(
(

0.5
+ 6.703 10
3
psi = :=
Mark Yaconetti
Group #6
12/3/2013
Page 15

axle2

bendaxle
2

bendaxle
2
|

\
|
|
.
2

axle
( )
2
+

(
(
(

0.5
944.464 psi = :=

drillrod
1030MPa :=
FS
axle

drillrod

axle1
22.286 = :=
Mark Yaconetti
Group #6
12/3/2013
Page 16
Time to traverse course (rough estimate):

motor
0.347
rev
s
=
V
linear

motor
r 2 2.285
ft
s
= := Linear velocity at max power output
Time to traverse each individual section of the obstacle course:
d
blocks
5ft := rough distance of obstacles that need to be climbed over
V
linearblocks
V
linear
.75 1.713
ft
s
= := estimate about 3/4 speed while climbing over small
obstacles
time
blocks
d
blocks
V
linearblocks
2.918s = := time to traverse small block obstacles
d
walls
3ft := rough distance of travel to weave through tall obstacles
V
linearwalls
V
linear
.5 1.142
ft
s
= :=
estimate about 1/2 speed while weaving through
walls
time
walls
d
walls
V
linearwalls
2.626s = :=
time to traverse through walls
d
incline
4ft := rough distance needed to travel up ramp
V
linearincline
.85V
linear
1.942
ft
s
= := operating near max power while ascending incline
Mark Yaconetti
Group #6
12/3/2013
Page 17
time
incline
d
incline
V
linearincline
2.06s = := time to traverse incline
time
inclinedown
.5time
incline
1.03s = := assume half time to go back down the incline
time
lift
45s := assume 15 seconds to complete tasks at the top of
the ramp (will vary greatly from run to run, difficult to
estimate due to lack of knowledge of robot
controlability)
Time
total
2time
blocks
2time
walls
+ time
incline
+ time
inclinedown
+ time
lift
+ 59.178s = :=
It is reasonable to assume that this number will have an error of +/- 15 seconds to leave room for
unkown controllability
Mark Yaconetti
Group #6
12/3/2013