4992 Final Report 0951

T.C.
BAHÇEŞEHİR UNIVERSITY
FACULTY OF ENGINEERING AND NATURAL SCIENCES
Project 0951
Stair Climbing Robot
Capstone Project Final Report
Sinan Oğuzhan Başkurt

Veysel Bitgül
Mehmet Akif Ekrekli
Kaan Han Elmalı
Advisors:
Assist. Prof. Andrew John Beddall
Assoc. Prof. Armağan Fatih Karamanlı
ISTANBUL, June 2020
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STUDENT DECLARATION
By submitting this report, as partial fulfillment of the requirements of the Capstone course, the
students promise on penalty of failure of the course that
 they have given credit to and declared (by citation), any work that is not their own
(e.g. parts of the report that is copied/pasted from the Internet, design or
construction performed by another person, etc.);
 they have not received unpermitted aid for the project design, construction, report or
presentation;
 they have not falsely assigned credit for work to another student in the group, and not
take credit for work done by another student in the group.
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ABSTRACT
PROJECT 0951
STAIR CLIMBING ROBOT
Sinan Oğuzhan Başkurt

Veysel Bitgül
Mehmet Akif Ekrekli
Kaan Han Elmalı
Faculty of Engineering and Natural Sciences
Advisor:
Assist. Prof. Andrew John Beddall
Assoc. Prof. Armağan Fatih Karamanlı
June 2020
This report is about an autonomous stair climbing robot built by 2 Electrical and
Electronics Engineering students and 2 Mechatronics Engineering students. The designs and
coding are created by this 2 teams mentioned above. Be advised due to Covid-19 pandemic
occurred in Spring Semester of 2020, robot is not finished entirely as planed. However, all
the physical structure, sensor arrays and coding tested and results are collected. The
robot theoretically should climb any stairs autonomously as shown in the report. The
physical structure and electrical systems are not interated physically.
Key Words: Autonomous, Robot, Stair Climbing, All Terrain Robot

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TABLE OF CONTENTS
ABSTRACT ..............................................................................................................................iii
TABLE OF CONTENTS .......................................................................................................... iv
LIST OF TABLES .................................................................................................................... vi
LIST OF FIGURES................................................................................................................... vi
LIST OF ABBREVIATIONS .................................................................................................. vii
1. OVERVIEW........................................................................................................................... 1
1.1. Identification of the need............................................................................................ 1
1.2. Definition of the problem ........................................................................................... 1
1.3. Standards and constraints ........................................................................................... 1
1.4. Conceptual solutions .................................................................................................. 2
1.5. Physical architecture................................................................................................... 4
2. WORK PLAN ........................................................................................................................ 5
2.1. Work Breakdown Structure (WBS) ........................................................................... 5
2.2 Responsibility Matrix (RM) ........................................................................................ 5
2.3. Project Network (PN)................................................................................................. 6
2.4. Gantt Chart ................................................................................................................. 6
3. DESIGN PROCESS ............................................................................................................... 7
3.4. Electrical and Electronics Engineering ...................................................................... 7
3.4.1. Definition of the problem.................................................................................. 7
3.4.2. Review of technologies and methods................................................................ 7
3.4.3. Standards and constraints .................................................................................. 9
3.4.4. Conceptualization.............................................................................................. 9
3.4.5. Physical architecture........................................................................................ 10
3.4.6. Risk assessment............................................................................................... 10
3.4.7. Materialization ............................................................................................. 11
3.4.8. Evaluation........................................................................................................ 12
3.8. Mechatronics Engineering........................................................................................ 13
3.8.1. Definition of the problem ................................................................................ 13
3.8.2. Review of technologies and methods.............................................................. 14
3.8.3. Standards and constraints ................................................................................ 14
3.8.4. Conceptualization............................................................................................ 15
3.8.5. Physical architecture........................................................................................ 16
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3.8.6. Risk assessment............................................................................................... 32
3.8.7. Materialization ................................................................................................ 33
3.8.8. Evaluation........................................................................................................ 33
4. RESULTS............................................................................................................................. 33
5. CONCLUSION .................................................................................................................... 34
ACKNOWLEDGEMENT ....................................................................................................... 35
REFERENCES......................................................................................................................... 36
APPENDIX A .......................................................................................................................... 37
APPENDIX B .......................................................................................................................... 42
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LIST OF TABLES
Table 1 Responsibility Matrix For The Team ................................................................ 5

Table 2 Project Network................................................................................................. 6
Table 3 Gant Chart ......................................................................................................... 6
Table 4 Costs ................................................................................................................ 33
LIST OF FIGURES
Figure 1 Illustration of Robot and Stairs ........................................................................ 1

Figure 2 Boston Dynamics SPOT [1]............................................................................. 2
Figure 3 Six Wheel Design of The Team ....................................................................... 2
Figure 4 Track Based Design of The Team.................................................................... 3
Figure 5 Final Design of The Robot............................................................................... 4
Figure 6 System Interface Diagram................................................................................ 4
Figure 7 Sensor Array Testing Prototype ....................................................................... 8
Figure 8 Sensor Array Placed on Robot ....................................................................... 10
Figure 9 Front Side of The Sensor Array ..................................................................... 11
Figure 10 Back Side of The Sensor Array.................................................................... 11
Figure 11 Mechanical Design....................................................................................... 13
Figure 12 Boston Dynamics SPOT [1]......................................................................... 14
Figure 13 Robot and the stairs (Scaled) ....................................................................... 15
Figure 14 Side view of the robot .................................................................................. 16
Figure 15 Upper Body Exploded View ........................................................................ 17
Figure 16 Lower Body Exploded View........................................................................ 18
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LIST OF ABBREVIATIONS
M2M Machine-to-Machine
IEEE The Institute of Electrical and Electronics Engineers
EEE Electrical and Electronics Engineering
MCH Mechatronics Engineering
3D Three Dimensional
PVC Polyvinyl Chloride
U-PVC Unplasticised Polyvinyl Chloride
DC Direct Current
TL Turkish Lira
WBS Work Breakdown Structure
CE Conformite Europeenne
IEC International Electrotechnical Commission
ISO International Organization for Standardization
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1. OVERVIEW
This report is about an autonomous stair climbing robot, that built by 4 engineering
students including 2 electrical and electronics students and 2 mechatronics students.
Mehmet Akif Ekrekli and Veysel Bitgül on the mechatronics team and Kaan Han Elmalı
and Sinan Oğuzhan Başkurt on the electrical and electronics team.
1.1. Identification of the need
This product is designed for those who want to reach inaccessible places. The main
objective for this product is to climb any kind of stairs to reach to the top by itself, but it can
be modified easly to be an all terrain robot.
1.2. Definition of the problem
The main task for team to design and costruct a robot that will autonomously climb
the top 19 steps of the Law Faculty staircase (D building). Also it can be able to climb any
kind of stairs autonomously.
Figure 1 Illustration of Robot and Stairs
1.3. Standards and constraints
This robot comply with all the standards to IEEE, CE, IEC and ISO because it’s made
by all original electrical, electronic and electromagnetic devices. Cabling made safely to not to
create a dangerous situation to users. The power supply that provides power to the system and
the motors is 12 Volts DC and it’s below dangerous limit (50 Volts). The two major
constraints are;
 No jumping nor flying allowed.
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 Remote control is not allowed by any means (wifi, radio signals etc.); the vehicle must
be autonomous with all sensors, controls and computation located on the vehicle.
1.4. Conceptual solutions
During design process, we have created multiple conceptual designs. Some of the
significant ones and influential ones for our last desing are;
I. Legged Based Robot;
Figure 2 Boston Dynamics SPOT [1]
This design idea was inspired by Boston Dynamics’ SPOT design. See also Reference
[1]. We didn’t choose this design because of it would be very hard to operate and sustain
within the economical limits we have.
II. 6 Wheel Robot;
Figure 3 Six Wheel Design of The Team
This design idea was inspired by NASA’s Mars Rovers. See also Reference [2]. This
design idea was the most influential one on the final version of design. The reason for that
is Mars Rovers are designed to overcome any terrains that they face, and it’s similar to
this project’s goal, climbing any stairs.
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III. Track Based Robot;
Figure 4 Track Based Design of The Team
This design was also influential on the final design. Tracks are used widespreadly on offroad
vehicles due to it’s high friction levels.
For the electrical systems;
I. Raspberry Pi with image processing

This design wasn’t used on final because it requires higher costs, higher processing power
and higher level of programming languages. It’s simply overengineering for this problem.
II. Arduino MEGA with optic distance sensors
This design wasn’t used on final because optical sensors can be unreliable for this task.
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1.5. Physical architecture
Figure 5 Final Design of The Robot
On final design we blended track based model and 6 wheel model to create the optimum design
for our problem. For the electrical side we choose the Arduino MEGA with ultrasonic sensors
and gyroscopes to navigate the robot through stairs.
Figure 6 System Interface Diagram
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2. WORK PLAN
2.1. Work Breakdown Structure (WBS)
1. Stair Climbing Robot
1.1 Teams
1.1.2. Electrical
1.1.2.1.Order/Manufacture Parts
1.1.2.2.Assemble
1.1.2.3.Test
1.1.3. Mechanical
1.1.3.1.Order/Manufacture Parts
1.1.3.2.Assemble
1.1.3.3.Test
1.2. Autonomous Control and Programming

1.2.2. Autonomous Control
1.2.2.1.Creating a Control Algorithm
1.2.2.2.Motor Control
1.2.2.3.Implementing
1.2.3. Programming
1.2.3.1.Coding
1.2.3.2.Test
1.3. Testing
1.3.1. Testing All The System
2.2 Responsibility Matrix (RM)
Table 1 Responsibility Matrix For The Team
Task Sinan Kaan Akif Veysel

Mechanical R R
Electrical R R
Autono. S S R R
Prog. R R S S
Planning S S S R
Reporting R S S S
Integration S S R S
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2.3. Project Network (PN)
Code Task Responsible

0 Final Documentation Sinan, Veysel, Akif, Kaan
1 Mechanical Analysis and simulations Akif
1.1 Component Research Veysel
1.2 Mechanical Integration Veysel, Akif
1.2.1 Mechanical Design, robot’s frame, carrying Veysel, Akif
elements, connecting parts
1.2.2 Control algorithm Veysel
1.2.3 Design of control systems Akif
1.2.4 Motor integration Veysel, Akif
1.3 Assemble mechanical parts Veysel, Akif
2 Electrical integration, sensors and controller Sinan, Kaan
research
2.1 Deciding on sensors, drivers and other parts Sinan, Kaan
2.1.2 Market research of motors and sensors for needs Kaan
2.2 Integration of algorithm, and control to electrical Sinan, Kaan
system
2.2.1 Sensor array design Sinan, Kaan
2.2.1.1 Circuit design Kaan
2.2.1.2 Power system integration Sinan
2.2.2 Coding for sensor data and movement Sinan
3.1 Testing for mechanical systems Veysel, Akif
3.2 Testing for electrical systems Kaan
3.3 Testing all the system Sinan, Veysel, Akif, Kaan
Table 2 Project Network
2.4. Gantt Chart

Table 3 Gant Chart
Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Akif 1 1.2.3
1.2 1.2.1 1.2.4 1.3 3.1
Veysel 1 .1 1.2 .2
0/3.3
Sinan 2.2.1.2
2/2.1 2.1.2 2.2 2.2.1 2.2.2 3.2
Kaan 2.2.1.1
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3. DESIGN PROCESS
3.4. Electrical and Electronics Engineering
3.4.1. Definition of the problem
This stair climing robot aims to climb any stairs, fully autonomously, without any
remote control or help. By the nature of its design, it can be used as an all terrain
vehicle/robot aswell. This features also provides great flexibility on robot’s usage areas; for
example its can be helpful for disabled people or elders to climb stairs on the other side it
can help law forces to access dangerous areas, buildings, places. This robot can adapt to
new enviroments and conditions very easily.
3.4.2. Review of technologies and methods
This robot is designed very efficient due to economical boundaries. It uses ultrasonic
sensor array that we designed instead of image processing because camera would cost much
more and it would require more powerful processor to do the not same but similar work. On
the front side of the robot, there are 4 ultrasonic sensors measuring real time distance
values to detect the steps of the stairs. It requires upper 2 sensors to be same values, lower 2
sensors to be same values and at the same time lower 2 and upper 2 sensors’ values’
difference should be exact to the steps’ width. Robot also consists of a gyroscopic sensor to
sense the slope. 12 Volts 7Ah DC power supply used in this project. Which is enough for
the robot if we consider, a motor will draw 530mAmps in maximum load conditions. 4 𝑥
530𝑚𝐴 = 2120𝑚𝐴𝑚𝑝𝑠 and
7000𝑚𝐴ℎ ÷ 2120𝑚𝐴 = 3.30 ℎ𝑜𝑢𝑟𝑠 of energy will be supplied in maximum load
conditions of motors. (Sensors’ and microcontroller’s enegy consumption is neglected
because of very low values.)
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Figure 7 Sensor Array Testing Prototype
Flow Chart of Coding Algorithm:
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3.4.3. Standards and constraints
This robot comply with all the standards to IEEE, CE, IEC and ISO because it’s made
by all original electrical, electronic and electromagnetic devices. Cabling made safely to not
to create a dangerous situation to users. The power supply that provides power to the system
and the motors is 12 Volts DC and it’s below dangerous limit (50 Volts).
3.4.4. Conceptualization
Project had 3 concept electronical designs;

I. Raspberry Pi with image processing
II. Arduino MEGA with ultrasonic distance sensors
III. Arduino MEGA with optic distance sensors
Electric and electronic engineering students of this project chose the 2. option due to
economical boundries and being familiar with the sensors. 4 motors has chosen because of the
mechanical design. Motor’s specifications are; 50 RPM 530 mA strain current and 1.21 N/m.
12 Volts 7 Ampere.hour DC power supply has chosen because of the requirements of the
4 motors.
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3.4.5. Physical architecture
Robot contains 7 ultrasonic sensors; 4 on the front, 1 on left, 1 on right and 1 on the
back. A gyroscope placed on top of the robot and Arduino on top aswell. 4, 12 Volts redactor
motors has placed; 2 on tracks and 2 on back wheels. The detection of stairs system works
thanks to 4 ultrasonic sensors placed in front of the robot accompanied by a gyroscope and
the Arduino MEGA.
Figure 8 Sensor Array Placed on Robot
3.4.6. Risk assessment
There are various risks on the system design;

3.4.6.1. Insufficient battery life and ampere rating
In this project this problem is solved by using a 12 Volts 7Ah dry battery. This power
supply offers minimum 3 hours of operation time.
3.4.6.2. Sensor calibration and sensivity
The ultrasonic sensors used in this roject (HC-SR04) can be not sensitive enough for
the purpose but in the coding part it’s eliminated by adding tolerance to the measurement
and calibrating.
3.4.6.3. Unstability of robots’ usage areas

This robot will be used in various enviroments and it’s autonomous. These conditions
makes the robots movements, and data needings to understand to enviroment makes harder to
estimate. And also the the operation areas of the robot is rugged. This difficulties overcame by
using heavy duty parts and fastening the electronics to the sturdy places.
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3.4.6.4. Mistakes at testing
Mistakes at testing can be very dangerous because it can cause irreversible damages to
the robot itself. If robot falls down during testing it can broke the system and itself, and we
couldn’t be able to determine the mistake aswell. And on the other hand one mistake that we
overlooked on testing can emerge at the presentation. This difficulties overcame by creating a
safe environment to test and test as much as possible.
3.4.7. Materialization
The physical structure of sensor array has not been changed since 4991 course and it’s
built as planned. The framework that is 3D printed has some aesthetical flaws due to 3D
printer itself but it fulfils the tasks. The results are;
Figure 9 Front Side of The Sensor Array
Figure 10 Back Side of The Sensor Array
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The first thing that electrical and electronics team started to work on the code is to
calibrate the distance sensors, get values from them and to code the microcontroller to
perceive the stairs. Then team worked on program the microcontroller to make it capable
of making decisions. After all of the main structure of coding is finished, team worked on
making it more optimized and efficient.
3.4.8. Evaluation
The final version of the array on work can be seen in this video with details. Please
check the description of the video aswell; https://www.youtube.com/watch?
v=yyYww8ND5vU
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3.8. Mechatronics Engineering
3.8.1. Definition of the problem
There are some challenging stair climbing robots. However almost all of them have risks
on at least one part of working algorithm. For instance, tank track-based robots are having
a great risk of turn over. If the motor calculations are not done perfectly, torque might be
too much for that robots’ weight and it could turn over. For legged based robots, stairs
surface is vital. Depending on the material that is assembled on the robot`s touching point to
the ground, robot can slip and fall over.
Figure 11 Mechanical Design
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3.8.2. Review of technologies and methods
Legged Based Robot;
As shown in Figure 9 in this type of designs carrying

parts are the legs of the robot. Robot climbs the stairs with its
legs, 2 or 4, as a living being (animal, human).
Figure 12 Boston Dynamics

SPOT [1]
Other examples
3.8.3. Standards and constraints
This robot complies with all the standards to IEEE, CE, ASTM, IEC and ISO because
it’s made by all original electrical, electronic and electromagnetic devices. Cabling made
safely to not to create a dangerous situation to users. The power supply that provides power
to the system and the motors is 12 Volts DC and its below dangerous limit (50 Volts).
Constrains:
 No jumping or flying.
 No remote control; the vehicle must be autonomous with all sensors, controls and
computation located on the vehicle.
 The robot must not be assisted in any way by a human once it starts it's climbing task
from the floor below the first step.
 The robot must carry its own energy source.
 The robot must start at the bottom of the stairs, not touching the first step
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A robot will be designed and constructed to autonomously climb the top 19 steps of the
Law Faculty staircase (D building).
Figure 13 Robot and the stairs (Scaled)
3.8.4. Conceptualization
Wheel & Tank-Track Based Robots;
Model of Ours
In these models, robot is carried by wheels or tank tracks. Instead of acting like a living
creature, it moves as a vehicle. In addition, calculations are quite different than legged
based
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robot. Figures 2 and 3 are alternative concept designs.
We designed the robot to prevent those risks. With combining wheel and tank-track
systems the robot will not turn over or slide on the ground and fall.
Figure 14 Side view of the robot
3.8.5. Physical architecture
Physical Structure
There are 3 vital aspects of this part; Weight, Strength, Economy. Our robot
(hereinafter called Necati) must be as light as possible in order to stay in our targeted budget.
Heavier the robot gets, much more expensive motors we will need. Product selection is
another significant point as well. Necati is divided into 2 main subsystems and selected it`s
materials in order to achieve the best weight strength economy ratio.
1. Pipe Framework
PVC pipes are selected to connect entire robot together. The main reason of this choice is that
PVC pipes are light and have the durability we need. Also, it is cheap and could be gathered
easily.
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Figure 15 Upper Body Exploded View
2. Tank Track Body

TTB is the first part that interacts with stairs. Therefore, it is a considerable part. This
subsystem consists of 3 parts, wheels, plate and belt. TTB works as a simple pulley system.
Belt climbs stairs with rotation which is supplied by wheels and plate holds these parts as one.
Selected materials of these parts are given below/
a. Plate: Aluminium
b. Wheel: Rubber, Epoxy
c. Belt: Rubber
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Figure 16 Lower Body Exploded View
3. Supporting Components
Apart from these subsystems there are also supporting equipment such as connections,
rear wheels etc.
A connection is designed for the upper zone connection so that the TTB can move
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easily. This common design was printed with a 3D printer and added to the system.
The joint contains 2 parts and these parts relate to the help of a shaft and a nut. In this
way, the Sub Joint can move comfortably within the upper joint.
Motors (Reference [8])
DC Motors are placed into rear supporting wheels and rear TTB (Tank Truck Base) wheels.
In this placement, rear TTB wheels are main carrier of the system. Rear supporting motors
will help climbing and prevent possible sliding backwards.
To select an optimum DC Motor, a torque calculation is needed. After finding the required
torque, DC Motor could be found on the market. Relevant amps and power values are
discussed with electronics team in order to help them select the battery.
Robot contains 7 ultrasonic sensors; 4 on the front, 1 on left, 1 on right and 1 on the back. A
gyroscope placed on top of the robot and Arduino on top as well. 4 12 Volts redactor motors
have placed; 2 on tracks and 2 on back wheels.
Our Motor's Properties:
Brand: ZHENGK
12V 50 RPM 42mm Geared DC Motor
Working voltage range: 12V
Speed: 50 RPM / Min
Motor diameter: 36mm
Reducer diameter: 42mm
Idle current draw: 55mA
Power: 7.5W
Weight: 230gr
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Basic Theoretical Calculations
-Variables-
Fk = Traction generated by the motor.
Nk = Ground reaction force
fi = friction forces at i-th step
Ni = Supportive force at i-th step
Equations
1-) Energy Equation
1 2𝜋𝑟 1
2 𝑚=𝑚𝑣
𝑚𝑜𝑡𝑜𝑟 () 2
𝑔𝑒𝑎𝑟 𝑔𝑒𝑎𝑟
60 2
𝑔𝑒𝑎𝑟 = 𝑔𝑒𝑎𝑟 𝑔𝑒𝑎𝑟
1 22222 1 1 1 1
[22222
𝑚1 𝑔𝑒𝑎𝑟1 + 12 ]
𝑒𝑎𝑟1 + [ 𝑚2 𝑔𝑒𝑎𝑟2 + 𝑒𝑎𝑟2 ] = [ 𝑚𝑝𝑎𝑙𝑒𝑡 𝑣𝑝𝑎𝑙𝑒𝑡 ]
Touching the Step
𝐹 − 𝑁 sin(46.6) + 𝑓 cos(46.6) = 𝑚𝑥
−𝑚𝑔 + 𝑁 cos(46.6) + 𝑓 sin(46.6) = 𝑚𝑦
−𝑚𝑔𝑝𝑐𝑜(𝜑 + 𝛽) + 𝑁[𝐿𝑐𝑜𝑠(46.6 − 𝛽) + (𝑖ℎ − 𝐿𝑠𝑖𝑛(𝛽)] + 𝑓 sin(46.6 − 𝛽) − 𝑚𝑥𝐺 (𝑦𝐺 + 𝑅)
− 𝑚𝑦𝐺 𝑥𝐺 = 𝐽 𝛽
Robot Stability
1-)𝐸0 = 𝑚𝑔(𝑦 ′ 𝐺 − 𝑦𝐺 ) = 𝑚𝑔(√ℎ2 + 𝑏 2 −
𝜋ℎ
𝑦𝐺 ) 𝛿 = − arctan ( ) − arctan𝐺 ( )
2 𝑏 𝐺 𝑥 −𝑆
2-)𝐸 = 𝑚𝑔(𝑦 ′′ 𝐺 − 𝑦𝐺 ) = (𝑚𝑔√𝑦𝐺2 + (𝑥𝐺 − 𝑆𝑡2 )) (1 − cos(𝛿 ))

𝐸𝑡
Final Stability = 𝐷 = 0
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Lowest Torque Calculation
Value of lowest torque could be obtained on the stand still case of robot on the sloppy stairs.
Total torque must be qual to weight`s torque to keep the robot stationary on the stair.
To build a basic torque calculation we took our reference surface as hypotenuse of stairs.
Here is the simplified version of image;
Since there will be only one type of motor for every wheel and gear, we just need to calculate
total weight`s torque and divide it by 4. (Total weight is considered as 10kg.)
𝐺 ∗ 0.124 = 𝑇𝑚𝑜𝑡𝑜𝑟𝑠
12.16 = 𝑇𝑚𝑜𝑡𝑜𝑟𝑠
12.16
𝑇𝑚𝑜𝑡𝑜𝑟 = 4 = 3.04𝑁
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Mechanical Properties
Aluminium 6061 (Profile) (Refence [3])
Chemical Composition:
Fe Si Cr Mn Mg Zn Cu Ti Others Al
0.5 0.6-1.0 0.1 0.2-0.8 0.8-1.2 0.25 0.6-1.1 0.1 0.15 Rest
Physical Properties:
Properties Values
Density 2.7 g/cm3
Melting point 588°C
Mechanical Properties: (for Temper 6)
Properties Values
Tensile strength 115 MPa

Yield strength 48 MPa
Shear strength 83 MPa
Fatigue strength 62 MPa
Elastic modulus 70-80 GPa
Poisson's ratio 0.33
Elongation 25%
Hardness 30
Characteristics:
- High hardness, good curability
- High corrosion resistance
- Good welding can be done.
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PVC Conveyor Belt (Reference [5])
Mechanical Properties:
PVC (plasticised):
Properties Values
Density (g/cc) 1.3 – 1.45
Coefficient of friction 0.4 – 0.5
Yield Strength (MPa) 31 – 60
Young’s Modulus (MPa) 3380
Flexural Strength (MPa) 72
Compression Strength (MPa) 65
Elongation at break 30 - 40%
Hardness 80
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PVC(plactised) which has lower inelasticity than PVC-U is easier at applications of moulding
and extruding. PVC`s is quite low compared to PVC-U in terms of temperature resistance and
resistivity to chemicals.
U-PVC (Frame) (Reference [4])

U-PVC (unplasticised):
Properties Values
Density (g/cm3) 1.41
Tensile Strength N/mm2 52
Yield Strength N/mm2 48
Flexural Strength (N/mm2) 88
Modulus of Elasticity, 3316

(N/mm2)
Hardness (Rockwell R) 115
Poisson’s ratio 0.4
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PVC-U(unplasticised) ,which has great tensile stress of roughly 52 MPa at 293K, is hard and
inelastic and it has resistivity to chemicals. Normally, PVC-U could be used up to 333K, however
the real temperature is conditional on applied stress and environment .
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Carbon/Epoxy Composite Rod (Wheel): (Reference [6])
Property Value
Compressive Strength - Longitudinal 800 - 1300 MPa
Compressive Strength - Transverse 50 - 250 MPa
Density 1.6 g/cm^3

Flexural modulus - Longitudinal 125 GPa
Flexural strength - Longitudinal 1200 MPa
Tensile strength - Longitudinal 1100 - 1900 MPa

Tensile strength - Transverse 50 MPa
Volume fraction of fibres 55 - 60%
Young's Modulus - Longitudinal 120 - 140 GPa
Young's Modulus - Transverse 10 GPa
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PLA (Polylactic Acid) (For 3d printed connecting parts) (Reference [7])
Mechanical Nominal Value Unit Test Method

Tensile Modulus
73°F 129000 to 529000 psi ASTM D638
73°F 416000 to 519000 psi ISO 527-2
Tensile Strength
Yield, 73°F 8990 to 9040 psi ASTM D638
Yield, 73°F 2250 to 10400 psi ISO 527-2
Break, 73°F 5550 to 8420 psi ASTM D638
Break, 73°F 2000 to 10200 psi ISO 527-2
73°F 2560 to 9310 psi ASTM D638
73°F 6530 to 9430 psi ISO 527-2
Tensile Elongation
Yield, 73°F 9.8 to 10 % ASTM D638
Break, 73°F 0.50 to 19 % ASTM D638
Break, 73°F 1.0 to 12 % ISO 527-2
Flexural Modulus
73°F 330000 to 652000 psi ASTM D790
73°F 44200 to 1.38E+6 psi ISO 178
Flexural Strength
73°F 8360 to 15800 psi ASTM D790
73°F 1310 to 16000 psi ISO 178
Density / Specific
Gravity
-- 1.22 to 1.30 ASTM D792
73°F 1.24 to 1.25 g/cm³ ISO 1183
Note:
1 PSI = 0,00689475728 MPa
28
29
Material Budget
30
Control Algorithm:
Our distance sensors are fully connected to microcontroller. They are taking power and
sending signals to microcontroller directly. Our battery is supplying power to microprocessors and
motors via motor drivers. Also, microcontroller sends signals to drivers to control the motors.
Interface Design:
31
3.8.6. Risk assessment
Task Associated Risk Severity Probability Risk Management of Risk

Score
Local The components to be Critical Low Medium Components can be
component purchased in Turkey (6) imported or used
purchase might not be in stocks. components can be
found.
Assembly of Broken parts and Critical Low Medium Spare parts can be
the robot components (6) bought-built.
Transporting The robot might fall Critical Low Medium Transportation of the
the Robot while it is carried and (6) robot can be done with
break some rules.
Soldering Short circuits/body Critical Medium High After soldering every

burns (8) solder pad must be
checked for overflowed
solder and soldering must
be done with adequate
equipment.
Building of Lack of manufacturing Critical Medium High Different materials which
the prototype processes in university (8) can be manufactured by
site using 3D printer can be
used.
32
3.8.7. Materialization
The robot could not be physically built due to the pandemic.a
3.8.8. Evaluation
The robot, where we have made theoretical research, calculation and technical
drawings, has not come to a conclusion due to test requirements and not being built.
4. RESULTS
Due to Covid-19 pandemic the project didn’t finished as planned. The teams are worked
separately and created their own products. For the electrical and electronics engineering team
the final results can be seen at this video;
https://www.youtube.com/watch?v=yyYww8ND5vU
For the mechatronics engineering side, technical drawing can be found at Appendix B.
Table 4 Costs
Component Quantitiy Cost

Zonder Tube 3 Meters 30 TL
45° Elbow Tube 4 Pieces 15 TL
90° Elbow Tube 2 Pieces 10 TL
Tank Pallets 2 Pieces 30 TL
Wheel 2 Pieces 85 TL
Filament for 3D Printer 1 Kilogram 80 TL
Sheet Metal 2 m^2 100 TL
Arduino MEGA 2560 1 Piece 60 TL
Motor Driver (L298N) 2 Pieces 24 TL
12V 50 RPM DC Motor
4 Pieces 300 TL
with Reducer
Ttec 12V 7Ah Battery 1 Piece 65 TL
Ultrasonic Distance
6 Pieces 36 TL
Sensor (HC-SR04)
Six Axis Gyrsocope
Accelometer Module 1 Piece 10 TL
(MPU6050)
Breadboard 1 Piece 24 TL
Jumper Cable 40x3 Pieces 12 TL
TOTAL 881 TL
33
5. CONCLUSION
Due to Covid-19 pandemic, the teams couldn’t finish this project as planned before at
Capstone Project 4991 course. But for this reason, this project can’t be specified directly as a
failure.
Teams tried to adapt the project into to the situation and created systems for required
objectives that discussed and determined with their advisors before. The electrical
and electronics team has built and tested the designed sensor array and developed the coding
for the robot. For the mechatronics side, the team has developed 3D modelling.
In the future, if the suitable environment and time occurs, teams would like to integrate
the systems into final product and test the project as a whole, and develop it if any faults
occur.
Meanwhile working on this project, the major things that the teams are learnt from this
project are how to work remote and far away from each other, and how to deal with
extraordinary situations, as the world is going through in 2020. Other than that teams learnt
how to work as a team. The team members didn't stay as a team for so long before. Also the
team gained experience on programing language C, SolidWorks CAD, and on project
management.
34
ACKNOWLEDGEMENT
We wish to thank our advisers Assist. Prof. Andrew John Beddall and Assoc. Prof.
Armağan Fatih Karamanlı. Also thanks to the Kılavuz Konveyör for the tank track belts
fabricated for us.
35
REFERENCES
[1] Boston Dynamics SPOT, [Online]. Available from BostonDynamics:

https://www.bostondynamics.com/spot [Accessed: May 20, 2020]
[2] NASA Mars Rovers, [Online]. Available from NASA:
https://mars.nasa.gov/mer/ [Accesed: May 19, 2020]
[3] 6061 Aluminum Alloy, [Online]. Available from Seykoç Alüminyum:
http://seykoc.com.tr/icerik/6061?dil=tr [Accesed: May 20, 2020]
[4] U-PVC Pipe, [Online]. Available from Kalde Boru:
http://kalde.com/cdn/archive/document/65/k -pvc-tk-tr-01_04_2015_web.pdf
[Accesed: May 19, 2020]
[5] PVC Properties, [Online]. Available from Vinidex:
https://www.vinidex.com.au/technical -resources/material-properties/pvc-properties/
[Accesed May 18, 2020]
[6] Carbon / Epoxy Composite Materials – Properties, [Online]. Available from Azo
Materials: https://www.azom.com/article.aspx?ArticleID=1995 [Accesed: April 29,
2020]
[7] Polylactic Acid (PLA) Typical Properties, [Online]. Available from Prospector:
https://plastics.ulprospector.com/generics/34/c/t/polylactic -acid-pla-properties-
processing [Accesed: April 30, 2020]
[8] Motor and Reducer Properties (Model No: ZGB42REE(A6249) ), [Online]. Available
from Zhengke Motor:
https://www.zhengkemotor.com/upload/file/201809/1536071578332463.pdf
[Accesed: April 30, 2020]
[9] Adafruit Library for Accelorometer (MPU6050), [Online]. Available from GitHub:
https://github.com/adafruit/Adafruit_MPU6050 [Accesed: May 29, 2020]
36
APPENDIX A
The sensor array on action can be seen on this video;
Click Here (YouTube Link)
The Coding of The Sensor Array:
//Assistance was obtained from the Adafruit library samples

//Libraries
#include <Adafruit_MPU6050.h>
#include <Adafruit_Sensor.h>
#include <Wire.h>
Adafruit_MPU6050 mpu;
//Variables
//Variables for smoothing

float oldacc;
float avgacc;
float newacc;
//Ultrasonic sensor pins and variables

int trigPin1 = 4;
int echoPin1 = 3;
int trigPin2 = 7;
int echoPin2 = 6;
int trigPin3 = 9;
int echoPin3 = 8;
int trigPin4 = 10;
int echoPin4 = 11;
long duration1, duration2, duration3, duration4, cm1, cm2, cm3, cm4, inches1,
inches2, inches3, inches4;
//Motor driver pins

int enA = 22; //Enable pin for first motor
int in1 = 27; //control pin for first motor
int in2 = 26; //control pin for first motor
int in3 = 25; //control pin for second
motor int in4 = 24; //control pin for
second motor int enB = 23;//Enable pin for second
motor
//Motor speed value pins

int motor_speed;
int motor_speed1;
void setup(void) {
Serial.begin(115200); // To start serial consol at 115200 bit rate
while (!Serial)
delay(10); // Will pause until serial console opens
//Initializng the Motor Pins
pinMode(enA, OUTPUT);
pinMode(in1, OUTPUT);
37
pinMode(enB, OUTPUT);
//Initializing the HCSR04 Sensor Pins

pinMode(trigPin1, OUTPUT);
pinMode(echoPin1, INPUT);
Serial.println("MPU6050 test!");
// Try to initialize!
if (!mpu.begin()) {
Serial.println("Failed to find MPU6050 chip");
while (1) {
delay(10);
}
}
Serial.println("MPU6050 Found!");
//Calibration
mpu.setAccelerometerRange(MPU6050_RANGE_8_G);
Serial.print("Accelerometer range set to: ");
switch (mpu.getAccelerometerRange()) {
case MPU6050_RANGE_2_G:
Serial.println("+-2G");
break;
break;
break;
break;
}
mpu.setFilterBandwidth(MPU6050_BAND_21_HZ);
Serial.print("Filter bandwidth set to: ");
switch (mpu.getFilterBandwidth()) {
case MPU6050_BAND_260_HZ:
Serial.println("260 Hz");
break;
break;
break;
break;
break;
38
break;
break;
}
Serial.println("");
delay(100);
}
void loop() {
/* Get new sensor events with the readings */

sensors_event_t a, g, temp;
mpu.getEvent(&a, &g, &temp);
/* Print out the values */

/* Serial.print("Acceleration X: ");
Serial.print(a.acceleration.x);
Serial.print(", Y: ");
Serial.print(a.acceleration.y);
Serial.print(", Z: ");
Serial.print(a.acceleration.z);
Serial.println(" m/s^2"); */
//SMOOTHING PART (cycles 25 times, adds them to each other to take average)
for (int cycle = 0; cycle < 25; cycle++) {
sensors_event_t a, g, temp;
mpu.getEvent(&a, &g, &temp);
//Calculating the angle of acceleration
float accxy = (a.acceleration.z * a.acceleration.z) + (a.acceleration.y *
a.acceleration.y);
float denominator = sqrt (accxy);
float angle = atan2(a.acceleration.x, denominator); //angle is in terms of
radian
float degree = angle * 180 / 3.14159265; //converting radian to degree
//Serial.println(degree);
oldacc = newacc + degree;

newacc = oldacc;
}
avgacc = oldacc / 25;
newacc = 0;
//Decision making part

if (avgacc > 95) {
climbing();
}
else if (avgacc < 80) {
climbing();
}
else {
detection();
}
Serial.println("");
delay(10);
39
}
// Detecion function
void detection() {
// Set motors to 55
// For PWM maximum possible values are 0 to 255
//Robot will turn right constantly to detect the stairs

analogWrite(enA, 55);
analogWrite(enB, 55);
digitalWrite(in1, HIGH);
digitalWrite(in2, LOW);
//Ultrasonics sensors’ measuring part (each one for one sensor)

// The sensor is triggered by a HIGH pulse of 10 or more microseconds.
// Give a short LOW pulse beforehand to ensure a clean HIGH pulse:
digitalWrite(trigPin1, LOW);
delayMicroseconds(5);
digitalWrite(trigPin1, HIGH);
duration1 = pulseIn(echoPin1, HIGH);
cm1 = (duration1 / 2) / 29.1; // Divide by 29.1 or multiply by 0.0343
inches1 = (duration1 / 2) / 74; // Divide by 74 or multiply by 0.0135
40
//Printing inches and centimeters (optional)
/*Serial.print(inches1);
Serial.print("in1, ");
Serial.print(inches2);
Serial.print(cm1);
Serial.print("cm1 ");
Serial.print(cm2);
Serial.print(cm3);
Serial.print(cm4);
Serial.println();*/
//Decision making part for if stairs found or not

Serial.print("SEARCHING");
if (cm1 == cm4 && cm3 == cm2)
{ Serial.print("Stairs found");
Serial.println("");
//Just to be sure that gyro is not zero and robot started to climbing the
stairs
delay(300);
}
}
void climbing() {
Serial.print("CLIMBING");
}
41
APPENDIX B
For the technical drawings please check the next pages.
42
300
45
40
20
105
45 R5
0
O.
60
6
.
8 7 6 5 4 3 2 1
1 3 5 4 6 7
2
F F
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 Part 1 PVC Pipe - 270mm 2
2 Part 2 Pipe Elbow 4

E E
3 5 Part 5 PLA PAD 1
6 Part 6 Joint F 2
2
D 7 Part 7 Joint M 2
D
8 Part 8 T-Pipe Joint 1
C C
B B
UNLESS OTHERWISE SPECIFIED: DEBURR AND
BREAK DO NOT SCALE DRAWING REVISION
FINISH: DIMENSIONS ARE IN MILLIMETERS SHARP
SURFACE EDGES
FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME DATE TITLE:
SIGNATURE
DRAWN
CHK'D
APPV'D
DWG NO.
A
A MATERIA
Upper Body Exploded

MFG
Q.A
L: A3
WEIGHT: SCALE:1:10 SHEET 1 OF 1

8 7 6 5 4 3 2 1
183,44
NO.
45
60
170
180
240
270
5
R2
R9
5
10
R2
190
5
0
24
RESİM
NO.
52,50
14
R1
10
2
R3
R9
220
R4
2
R10
0
R26 R32
R40
0
20
6
20
4
R3
R2
0°
12
5
R3,1
30
30
R42,50
30
3,4
0
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T.C.

FACULTY OF ENGINEERING AND NATURAL SCIENCES

Capstone Project Final Report

Sinan Oğuzhan Başkurt

ISTANBUL, June 2020

Sinan Oğuzhan Başkurt

Faculty of Engineering and Natural Sciences

Key Words: Autonomous, Robot, Stair Climbing, All Terrain Robot

Table 1 Responsibility Matrix For The Team ................................................................ 5

Figure 1 Illustration of Robot and Stairs ........................................................................ 1

IEEE The Institute of Electrical and Electronics Engineers

EEE Electrical and Electronics Engineering

MCH Mechatronics Engineering

PVC Polyvinyl Chloride

U-PVC Unplasticised Polyvinyl Chloride

WBS Work Breakdown Structure

IEC International Electrotechnical Commission

ISO International Organization for Standardization

1.1. Identification of the need

1.2. Definition of the problem

Figure 1 Illustration of Robot and Stairs

1.3. Standards and constraints

 No jumping nor flying allowed.

1.4. Conceptual solutions

Figure 2 Boston Dynamics SPOT [1]

II. 6 Wheel Robot;

Figure 3 Six Wheel Design of The Team

Figure 4 Track Based Design of The Team

For the electrical systems;

I. Raspberry Pi with image processing

Figure 5 Final Design of The Robot

Figure 6 System Interface Diagram

2.1. Work Breakdown Structure (WBS)

1. Stair Climbing Robot

1.2. Autonomous Control and Programming

2.2 Responsibility Matrix (RM)

Table 1 Responsibility Matrix For The Team

Task Sinan Kaan Akif Veysel

Code Task Responsible

Table 2 Project Network

2.4. Gantt Chart

3.4. Electrical and Electronics Engineering

3.4.1. Definition of the problem

3.4.2. Review of technologies and methods

Flow Chart of Coding Algorithm:

Project had 3 concept electronical designs;

Figure 8 Sensor Array Placed on Robot

3.4.6. Risk assessment

There are various risks on the system design;

3.4.6.3. Unstability of robots’ usage areas

Figure 9 Front Side of The Sensor Array

Figure 10 Back Side of The Sensor Array

3.8.1. Definition of the problem

Figure 11 Mechanical Design

Legged Based Robot;

As shown in Figure 9 in this type of designs carrying

Figure 12 Boston Dynamics

3.8.3. Standards and constraints