CARS: Collapsible Autonomous Robotics Structures

My senior design team designed and built a modular block-based construction robot through a full, iterative engineering process, starting with identifying the problem and defining system requirements for scalability, repeatable motion, and manufacturability. My role included carefully choosing materials, sensors, and actuators, selecting motors based on torque and speed requirements with proper gear ratios and feedback integration. Throughout the project, we continuously prototyped components using 3D printing and small-scale assemblies to verify fit and function. Full-scale manufacturing involved CNC machining, lathe work, laser cutting, water jetting, and secondary finishing, followed by wiring and integration of motors, drivers, and sensors. We implemented control logic in C++ with PID controllers, tuning actuation for smooth and repeatable movement. I was fully responsible for designing, fabricating, and implementing the climbing or Z-movement mechanism, a crucial subsystem for the robot’s functionality. The assembled robot underwent tensile and dynamic performance testing, and design-for-manufacture and assembly considerations were applied to simplify the system and ensure reliability. The final deliverable was a fully functional, manufacturable, and scalable prototype with validated structural integrity and operational performance.