STM Journals Peer-reviewed research from Consortium e-Learning Network

Journal of Polymer & Composites Review Article Special issue

Design and Performance Evaluation of PLA-based Umbrella Wheels for Stair-Climbing Robotic Applications

  1. Penta Srinivas Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, GreenFileds, Vaddeswaram
  2. G.Yedukondalu Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, GreenFileds, Vaddeswaram
  3. Bondili Harshith Singh Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fileds, Vaddeswaram

Abstract

Staircase climbing robots require a complex design capable of navigating various stair configurations. A crucial component of such robots is the wheel mechanism. This paper focuses on the umbrella wheel mechanism and its application in staircase climbing robots. In this study, a PLA–based umbrella wheel structure is developed and fabricated using fused deposition modeling (FDM) for application in stair-climbing robots. The umbrella wheel geometry enables transformation from a circular rolling configuration on flat surfaces to an expanded segmented profile for step climbing. A mathematical model describing the kinematics of the four-segment umbrella wheel mechanism is formulated to predict segment positions, velocities, and accelerations during operation. The kinematic model was compared with ADAMS multibody simulation results and qualitatively examined using a 3D-printed prototype during stair-climbing tests. Structural performance of the 3D printed PLA-based wheel is evaluated using finite element analysis in ANSYS to determine stress distribution under stair-climbing and flat-surface loading conditions. Simulation results reveal that peak von Mises stresses occur near the junctions of long and short arms, while remaining within safe limits for the selected PLA-based material. The combined results show that the 3D printed PLA-based umbrella wheel can achieve sufficient mechanical strength, stable deformation behavior, and good step engagement, which can be used for the purpose of stair climbing. The proposed approach identifies the potential of additively manufactured structures in lightweight, customizable and functionally adaptive robotic mobility systems.

Keywords

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