IITB Mars Rover Team

System Design And Development Review Report for

International Rover Challenge - 2024

Team Leaders
Gaurav Rathod
rathod.gauravvinod2@gmail.com
+91 86697 23750

Harsh Shah
prodigy.harsh18@gmail.com
+91 94094 75801

Khush Jain
khushchetanjain@gmail.com
+91 93284 41633
Mars Rover Team, IITB Chapter 1. Introduction

1. Introduction
1.1 Motivation
The main objective of the team is to enable students to gain hands-on experience on rovers and
space technology which covers mechanical, electrical, biological, and geological aspects of engineering,
and encourage them to work towards space missions.
To accomplish its mission, the team participates in University Rover Challenge, Mars Society
global, and International Rover Challenge by Mars Society South Asia which provide an opportunity
to work on space challenges under engineering constraints. As the IRC is following the footsteps
of URC, our team wants juniors to participate in the competition and get the overall picture of
the rover development process and logistics in the early years of engineering. Participating in IRC
would also help build relationships with different technical teams of other universities which would
facilitate knowledge and resource sharing between students

1.2 Team Structure

The team consists of 50+ students, ranging from various departments and study programmes offered
at IIT-B, working to gain hands-on knowledge about development of all terrain rovers and space
bio-sciences. The team is majorly divided into Mechanical (subdivided into mobility and robotic
arm), Electronics Hardware, Software, and Bio-Assembly subsystems. We also proactively pursue
research and have RnD subsystems in related domains as well, in order to push the frontiers of
space exploration technologies. (See fig 1.1)

Figure 1.1: Subdivision Distribution (newcomers not included)

Members from all the branches and programs (Btech, Mtech, Phds) are selected through a multi-
stage recruitment process. The process involves recruitment tests, SOP submissions and Interviews.
Every candidate gets equal opportunity for the application.

1.3 Budget and Resource Management

The project has been funded by the institute as a student technical project along with the logistics
and travel expenses. The total sanctioned amount is 15,00,000 INR which has been divided ma-
jorly into fabrication budget and budget required for various electronics & bio-science experimental
apparatus. The budget allocation for various components during the project has been shown in fig
4.1 and fig 4.2. We are also grateful to our sponsors for providing us technical as well as financial
aid to achieve our endeavours.
Our sponsors : SBG Systems, RUCKUS, Solidworks, Ansys

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Mars Rover Team, IITB Chapter 1. Introduction

Figure 1.2: Total Sanctioned Amount

Figure 1.3: Expense Breakdown

1.4 Project Management

The rover development is 6-8 months-long process that can be divided into 3 major phases of
ideation, design & fabrication and testing of various components. The current rover had been
developed for IRC 2022. This year for which the detailed timeline has been shown below.

Figure 1.4: PERT Chart

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Mars Rover Team, IITB Chapter 2. Suspension

2. Suspension
2.1 Design
The rover suspension consists of a conventional 6-wheeled Rocker-Bogie system made of square
carbon fiber pipes along with a four-bar linkage mechanism connecting both rockers. The rover
uses differential (skid) steering for traversal. The rocker-bogie system provides an advantage in
terms of stability on irregular surfaces, obstacle climbing capacity, less wheel pressure, low stress
on links, less power requirements, and ease of operation compared to 4 wheeled systems that we
used in our previous iteration. The purpose of the four-bar linkage mechanism is to implement a
differential between two rockers which minimizes the tilt of the mainframe during obstacle climbing
and prevents free rotation of the chassis about the axis joining two rocker flanges. The complete
suspension weighs 6.67 kg, which includes the rocker part, bogie part, flange assembly, and four-
bar differential mechanism weighing 2.34kg, 2.16kg, 1.58kg, and 0.59kg respectively. This gives us a
weight budget of 53.33kg for the robotic arm, chassis, wheels, bio-assembly, and onboard electronics.

(a) Complete Rover Assembly (b) Suspension CAD

Figure 2.1: Suspension Design

2.2 Performance Metrics

With a total span of 1050mm (end to end) and a Ground Clearance of 350mm, the rocker-bogie
assembly consists of hollow square tubes for efficient stress distribution and a triangular four-bar
differential mechanism. Assuming bogie in the forward direction of motion, the new chassis and
electrical box designs are compliant with the suspension to set the center of mass approximately at
the center of the rover, with sufficient clearance of CoM from the ground of 300mm. The rocker
center or rotation, axle of middle wheel motor and center of mass of rover being approximately in
the same vertical plane helps climb a maximum of 54.30◦ slope upwards and descend a maximum
of 53.95◦ slope downwards without any tilt or toppling. The maximum rotation of the bogie with
respect to the rocker is restricted using stoppers to eliminate a wheelie by limiting the swing for
rockers. In addition to it, the rover can successfully traverse sideways on a maximum slope of
38.10◦ . With the diameter of wheels being 200mm, the obstacle climbing capacity of the rover
is 300mm which is equal to the bogie link length. Compared to our previous iterations where
we encountered a problem of vibration of the chassis due to the backlash errors in the gearbox
assembly, this iteration consists of a four-bar differential mechanism consisting of a total of 8 joints.
As the rockers are rotating about a hinge, and the four-bar is rotating in the plane perpendicular
to it, the rocker links are coupled to the differential by simple ball-socket joints. This enables
the rover to eliminate large moments that may generate and topple the suspension, thus allowing
smooth traversal over uneven and sloping terrains.

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Mars Rover Team, IITB Chapter 3. Wheels and Chassis

(a) Line Diagram (b) Obstacle Climbing

Figure 2.2: Suspension Design Diagrams

2.3 Simulations
Ranging from validating and simulating individual components to integrating them all and per-
forming rigorous testing of full assembly on the rover structure, suspension design is in complete
working condition and has passed all the field trials like rugged terrain traversal, obstacle climbing,
slope climbing, as well as sideways traversal. The kinematics and compliance of the simulation are
compared with the field trials to verify the suspension model. Careful attention has been paid
to the input loads and the boundary conditions to ensure that the dynamic stress distribution is
accurately reproduced. Critical locations that lead to failure are correctly identified using ANSYS
and MATLAB simulations, and design modifications are done to the area of weakness. Real-time
hybrid simulations have been carried out to study strain gauging and fatigue analysis. The stress
analysis was carried out for individual members to optimize their weight. The rocker-bogie assem-
bly assembly has a dynamic load factor of 2 and a safety factor of 1.5 under extreme boundary
conditions.

(a) Rocker Bogie Simulations (b) Differential - Triangular Link Simulations

Figure 2.3: Suspension Simulations

3. Wheels and Chassis

3.1 Wheels
3.1.1 Design Constraints
• The slope climbing capacity of the rover, acceleration time, and number of drive wheels are the
basis of the selection of motors.
• Grouser shape and tread patterns are designed to maximize the traction for terrain traversal on
slopes and rocky surfaces
• Wheel spokes are vertically compliant to absorb shocks and impulsive loads

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Mars Rover Team, IITB Chapter 3. Wheels and Chassis

(a) Front View (b) Back View

Figure 3.1: Wheel CAD

3.1.2 Design
The spoke hub and rim are laser cut from
stainless steel material sheets. The rim is rolled
using a sheet metal bending process and welded
with the hub to form the core load-bearing
structure of the wheel. The rim design en-
sures proper traction and prevents the accumu-
lation of foreign substances within the wheel.
The spokes ensure maximum shock absorption
without compromising the wheel’s integrity. D-
bore-shaped hubs are used for the wheel hub
assembly. It ensures that the wheel stays cou-
pled to the suspension throughout the mission.
A 70/90mm ID/OD radial contact bearings are
used to distribute loads of the rover on the sus-
pension. Figure 3.2: Wheel Envelope
A new grouser envelope has been designed to enhance traction on varied terrains. The incor-
poration of a wavy grouser pattern enhances its ability to withstand both radial and transverse
forces. This pattern is slotted into the wheel rim, thereby improving grip along the rim. The
grouser height, width, and frequency were optimized to increase tractive efficiency. The envelopes
are 3D printed using Thermoplastic Polyurethane (TPU) as it offers impressive elasticity and tensile
strength while ensuring durability and resilience in wear and tear. Moreover, its low-temperature
performance makes it suitable for diverse environmental conditions, while its abrasion resistance
guarantees longevity. The selection of TPU also takes into account its shock-resistant nature, pro-
viding an additional layer of protection and damping capability.

3.1.3 Simulations
Multiple simulations were performed to ensure that the wheel design would meet the specifications
of the competition. They were performed under two main categories.
• To test the structural integrity of the wheel profile, a force equivalent to half the weight of the
rover, i.e., 300N, was loaded on the rim, and the results were obtained.
• To ensure that the motor shaft stays clenched inside the D-bore hub, a moment of 40 N-m
was loaded on the motor shaft, and a downward force of 300N on the D-bore hub during the
simulations.

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Mars Rover Team, IITB Chapter 3. Wheels and Chassis

Figure 3.3: Labelled Wheel Diagram

3.2 Chassis
The chassis framework employs a novel and layered design with sectioned regions for the various
subsystems. The primary structural members involved are square aluminum alloy pipes. The chassis
has been designed to optimally accommodate the electrical and mechanical sub-units, keeping in
mind their inter-dependencies and external accessibility for easier tuning and modifications. In
addition, it also factors in the mass distribution of interior components, resulting in a robust
design that can sustain rough terrain traversal without unfavorably loading the suspension.

3.2.1 Design
The base structure of the chassis consists of the main frame with provisions for anterior coupling
to the bio frame and the arm frame. The main frame has a layered design to reduce the length
of the chassis and thus increase clearance during traversal of steep slopes and scarps. The central
part of the main frame houses the electrical box. The electrical box is a detachable unit with con-
cealed drawer slides which aid in hassle-free removal and re-attachment. The bio frame houses the
habitation and life detection assembly and the arm frame provides a structural base for the robotic
arm assembly. Both chassis sub-units have been designed to minimize footprint and weight without
compromising on functionality. All exposed surfaces of the chassis are shielded using aluminum
sheets and polycarbonate panels. The top rear end of the mainframe uses translucent polycarbon-
ate panels in combination with laser-cut aluminum for the visibility of positioned LED strips that
indicate the rover’s traversal mode.
We have made a complete overhaul of our rover’s elecrical box- optimizing spatial efficiency, de-
signing features coherent with our chassis, and introducing a flat top to hoist our future plans to
integrate our rover with a UAV. The components inside are easy to access because of a magnetic

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Mars Rover Team, IITB Chapter 3. Wheels and Chassis

Figure 3.4: Chassis Assembly

latch, and a detachable plate secured by toggle clamps. We used Ansys to predict the performance
under loads, with a safety factor of 2 and chose aluminum sheets with appropriate thickness for
the sheet metal bending process accordingly.

(a) Chassis Structural Framework (b) Arm Frame

Figure 3.5: Chassis CAD

3.2.2 Material Selection

Aluminum alloys provide a number of advantages [13] when fabricating structural components:
• High elastic modulus and relatively high tensile strength
• No cold welding due to the oxide layer formation
• Corrosion resistant due to thin and stable oxide layer formation
• Low out-gassing, high ductility, good strength and stiffness to mass ratio
• Aluminum alloys don’t have ductile to brittle transition temperature
Our alloy selection hinged on availability in market and machinability. The structural members
are 19mm ∗ 19mm ∗ 3mm square Aluminum 6061-T6 pipes. The selected alloy has good corrosion
resistance and excellent joining characteristics [15], which is particularly useful due to the numerous
welded connections.
The aluminum plates are made of Aluminum 5052-H32. It has good workability and is easier to

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Mars Rover Team, IITB Chapter 4. Robotic Arm

laser cut into required shapes due to its comparatively low reflectivity among aluminum alloys [14].
The fabricated chassis weighs 9kg with these choice of materials.

3.2.3 Simulations
The chassis is a critical subsystem of the rover, and its durability and structural soundness are vital
considerations. Stringent and repeated ANSYS simulations were performed on the chassis frame to
optimize the dimensions before final fabrication.
Maximum deformation and von-Mises stress was analyzed to have safe values of 10µ m and 5MPa
respectively. The site of both maxima was the frontal region of the chassis main frame, near the
electrical box housing.

(a) Total Deformation

(b) Equivalent von-Mises Stress

Figure 3.6: ANSYS Simulations

4. Robotic Arm
4.1 Features
The robotic arm is a technological marvel, which is responsible for the most significant functions of
the Rover, including various tasks such as picking up objects, screwing screwdrivers, opening/closing
drawers, pushing buttons, operating joysticks, and plugging plugs to sockets. The robotic arm
exhibits an array of advanced features that contribute to its exceptional functionality:
• It has 7 degrees of freedom, including gripper jaw motion and conventional geometric movements,
which makes the arm achieve unparalleled flexibility in navigating its environment.
• It is capable of lifting objects weighing more than 5kg, the arm’s design efficiently transfers loads
directly to arm linkages for enhanced structural integrity.
• It can reach ground as well as a height of 1.5 meters above the ground, this allows the arm to
manipulate objects with precision in a wide operational space.
• The addition of elbow rotation introduces an extra degree of freedom, enhancing adaptability in
complex environments.

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Mars Rover Team, IITB Chapter 4. Robotic Arm

• The base allows for complete 360◦ rotation about the vertical axis, providing seamless adaptabil-
ity to various orientations.
• The materials of the arm are able to survive in extreme temperatures ranging from -150◦ C to
+80◦ C and operate between -110◦ C to +50◦ C.

Figure 4.1: Robotic Arm

4.2 Materials
The robotic arm’s structural integrity is enhanced through strategic material selection, ensuring op-
timal performance and durability. The shoulder features parallel aluminum plates, intricately folded
at the edges to augment stiffness and bolster the arm’s robustness. Complementing this, the elbow
is crafted from a high-strength carbon fiber tube, providing the necessary structural support for
lifting heavy objects without compromising on agility. Additionally, precision engineering is evident
in the base, where turntable crossed roller bearings coupled with a worm gear drive contribute
to both the smoothness and precision of rotational movements. These material choices collectively
contribute to the arm’s strength, flexibility, and reliability, meeting the demanding requirements of
its diverse operational capabilities.

4.3 Simulations
Simulation played a pivotal role in refining and optimizing the design of the robotic arm, ensuring
its performance meets the desired specifications. ANSYS Static Structural was instrumental in the
material selection process, allowing for a meticulous evaluation of different materials to achieve the
ideal combination of strength and stiffness for each component. This informed decision-making in
crafting the shoulder from parallel aluminum plates and the elbow from a carbon fiber tube. Fur-
thermore, a comprehensive transient analysis was conducted to scrutinize the gripper’s performance
during dynamic motions, accounting for factors like drag and inertia. These simulations provided
valuable insights into the arm’s behavior under various operational conditions, guiding the design
process to enhance overall efficiency, durability, and precision. The iterative nature of these simu-
lations allowed for continuous refinement, ensuring the robotic arm not only meets but exceeds the
performance expectations in its diverse range of applications.

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Mars Rover Team, IITB Chapter 5. Habitability and Life Detection

Figure 4.2: Static Simulation of Shoulder Link Figure 4.3: Elbow Stress Distribution

5. Habitability and Life Detection

5.1 Experiments Performed
We revamped our entire testing assembly, including the tests involved for enhancing the simplicity,
accuracy, and robustness of tests. We have specifically chosen colorimetric tests for ease of detection
of any extinct or extant life forms and compounds hinting toward the future possibility of life.

5.1.1 Diphenylamine DNA estimation

Testing for DNA and RNA is a conclusive way to determine the presence of life which can be
done by the diphenylamine test. The test is based on the fact that DNA contains nitrogenous
bases. The deoxyribose in DNA in the presence of acid forms �-hydroxy levulinic aldehyde which
reacts with diphenylamine to give a blue color. Results can be observed after mixing the sample
and reagent, heating for a few minutes, and cooling to room temperature. If DNA is present in
the sample, the mixture will turn blue. In the case of RNA, the test results in a green colored
solution due to the formation of the non-deoxy pentose species of the compound above.

5.1.2 Bradford method for protein estimation

Proteins, considered the basic building blocks of life, are a good starting point in the search for
life and can be estimated by Bradford’s method. The assay is based on a dye, Coomassie Brilliant
Blue G-250 (Bradford’s Reagent), to bind to proteins’ hydrophobic regions and cause a shift in its
absorbance spectrum, resulting in the conversion of the light brown unbound dye to a blue-colored
bound dye-protein complex. Results can be seen within a few minutes of mixing the sample and
reagent.

5.1.3 XTT assay

The XTT assay is a type of colorimetric assay that can be used to detect metabolic activity
in living cells; where XTT is a yellow tetrazolium salt. The tetrazolium salt XTT (2,3-bis-(2-
methoxy-4-nitro-5-sulfophenyl)-5- [(phenylamino)carbonyl]-2H-tetrazolium hydroxide) gets reduced to
an orange colored formazan product in the presence of active electron transport chain in living cells,
which can be estimated visually. The assay can be performed by incubating a sample from the
extraterrestrial environment with XTT and inspecting the color change of the resulting formazan
product. The reaction shows results within a few minutes.

5.2 Bio-sensors
SHT10 temperature and humidity sensor module and MQ-4 methane sensor attached to the robotic
arm are used for analysis. The temperature and humidity of the soil could be linked to the presence
of specific microbes. Using proteins’ temperature, we can deduce the presence of Psychrophile (10°-
15°), Psychrotroph (15°-30°), Mesophile (30°- 45°) or Thermophile (50°-85°and above). If methane
is found on Mars, two possibilities could be considered. Firstly, the frozen methane left by ex-
tinct microbes was released into the atmosphere due to climatic changes. Alternatively, there is a

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Mars Rover Team, IITB Chapter 6. Power, Electronics and Communication

possibility that microbes are still alive. The geological (abiotic) origin can be traced back to the
fact that, in the presence of certain inorganic catalysts, hydrogen combines with carbon to form
methane, which links the presence of methane to the subsurface hydro-thermal activity.

5.3 Results
Together, data from the mineral analysis and visual feed from the bio-analysis allow us to estimate
the viability and presence of life. Also an uncontaminated soil sample is brought back from the
site for further testing.

6. Power, Electronics and Communication

In the current year, the Electronics & Controls subsystem has directed its attention towards three
pivotal elements: enhancing user-friendliness, minimizing system setup time, and ensuring reliability
in diverse operating conditions. Drawing insights from past-year performances, receiving feedback,
and encountering challenges, there is a pressing need to transition to a more streamlined and
polished interface connecting the system’s various components.

Figure 6.1: Hardware Overview

6.1 Controls and Locomotion

6.1.1 Hardware involved
For mobility, the rover utilizes a combination of DC motors, servos, & linear actuators. We use
the Intel NUC [1], a mini PC that is used to control all the onboard electronic components via
ROS2. To interface DC motors & linear actuators, RoboClaw [9] motor drivers with high current
ratings (45 A), built-in encoder & potentiometer support are employed while an ESP-32 is used to
control the servos via a USB-UART communication system interfaced to the NUC.

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Mars Rover Team, IITB Chapter 6. Power, Electronics and Communication

The upgraded electronic enclosure signifies a substantial leap

forward in spatial efficiency, greatly enhancing accessibility
for improved maneuverability and user convenience. No-
tably, a partially acrylic flat top has been incorporated to
address the potential Faraday cage effect, a precaution taken
due to the enclosure being sealed to prevent dust infiltra-
tion. From an electrical perspective, the wiring has been
meticulously designed for efficiency and easy access, featur-
ing space-grade GX16 connectors to ensure optimal perfor-
mance and reliability. Figure 6.2: Electronic enclosure

6.1.2 Rover Mobility

The Rover is powered by six Brushed DC motors, each featuring encoders for closed-loop velocity
control. These encoders serve the dual purpose of providing odometry feedback to the basestation,
thereby enhancing operational efficiency and maneuverability. The motors are controlled through
the Roboclaw motor driver, simplifying the integration of encoder data.

6.1.3 Arm Mobility

The robotic arm is actuated via a combination of three lin-
ear actuators, two servos, & two DC motors. Combination
of different actuators enables non-linear control. By placing
a linear limit on the movement of these joints, actuators cir-
cumvent this issue. The arm is driven through an Inverse
Kinematics (IK) based scheme implemented on the MoveIt
framework to provide an intuitive control for the base sta-
tion controller. By utilizing the potentiometer feedback from
the actuators in an URDF model of the rover, and the 3D
point cloud data from the mounted depth camera, the com-
plete state of arm and the 3D view of gripper’s vicinity is
visualized in RViz, which in turn improves the intuitiveness
of the arm control at the base station. This also opens ex- Figure 6.3: IK visualization in RViz
citing prospects of seamless arm control via VR and Deep
Learning [2], and is a step towards achieving autonomy even
in the arm operations.

6.1.4 Base-station Control

A ROS2-interfaced dual-shock analog joystick [5] and a mono-analog joystick [6] are used to control
the rover. For the integration of video streams and access bio-assembly functions & bio-sensor data,
a Django-based online GUI has been developed.

6.1.5 Bio-Assembly
A Raspberry Pi [7] is utilized to control the host of devices - stepper motors, servo motors, linear
actuators, temperature sensors, heating modules, and lasers. A unique PCB is necessary for ade-
quate power distribution as well as the effective signal coupling between the various drivers and the
RPi due to the significant variability of the bio-assembly subsystem electronic support. A 40-pin flat
ribbon cable transfers signals from the PCB, while GX16 connectors are used to transmit power.
Reverse and short protection diodes along with filtering capacitors line the interface protecting all
on-board electronics from any potential bio-malfunctions

6.2 Communications and Video feed

Learning from our previous IRC 2023 competition experience, we have shifted to a dual-band com-
munication system, operating simultaneously on the 2.4 GHz & 5 GHz bands to guard against

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Mars Rover Team, IITB Chapter 6. Power, Electronics and Communication

interferors whilst providing a long-range, wide-band, and reliable communication setup. The Ubiq-
uiti RocketM2 wireless bridges [10] use the 2.4 GHz band (IEEE 802.11n) to provide long-range
communication and minimum interference. We use RUCKUS T350 APs [4] in the 5.6 GHz band
(IEEE 802.11ac) that provide a large bandwidth and high data speeds, suitable for video feeds.
One AP operates using a sector antenna placed on a rotating mount at the base station, and
another AP on the rover uses an omnidirectional antenna. Using the GPS locations of the base
station antenna and the rover, the sector antenna rotates such that the rover stays inside the sec-
tor always to enable communication throughout the missions. The communication system has been
tested to provide a 1 km non-line-of-sight range & is in compliance with FCC UNII-1 regulations.
However, we are in the process of optimizing the antenna profile of the RocketM2 to improve
long-range reliability. Using a link metric based on RSSI and throughput values, the optimal band
is determined. With the help of time-series forecasting algorithms, the previously observed Signal
Strength (RSSI) values are used to anticipate future RSSI values, hence reducing the chances of
communication blackouts.
We have used FPV drone camera and transmitters, routed through a novel switching circuit. A high
speed CMOS Multiplexer is connected via Rpi, and appropriately scripted such that the switching
between various video streams using the joystick at the basestation. A Dual-Lens Panoramic Camera
, a Fosscam IP Camera [3] & Intel Realsense D435 [8]) are used to create various other views.
Fosscam supports pan & tilt movements and the Dual-Lens Camera offers a 1:3 panoramic view.
The overall network is bifurcated with an onboard L-LAN and a point-to-point network for long-
range communication (Fig 6.1). A Netgear Router [11] provides easy scalibility in on-board cameras
enabling multiple views for ease of operation. Being the main drive camera, the Panoramic camera
would use the 2.4GHz band, with all the others on 5GHz. Under critical communication duress
camera feeds are automatically optimized.

6.3 System Integration - PCB

Figure 6.4: Bio-science PCB Figure 6.5: Roboclaw PCB

This year, we have developed a novel electrical system for our rover, which consists of custom-made
Printed Circuit Boards (PCBs) that interface with the Roboclaw motor drivers. Each PCB can host
three motor drivers, which regulate the speed and direction of the rover’s drive and arm motors.
The PCBs enable communication with the Roboclaw motor drivers using only two wires: RX and
TX instead of the previous USB to USB communication. This method uses Packet Bus Serial Mode,
which allows multiple devices to share the same serial bus, differentiating via addresses of various
Roboclaws . We also use the same PCBs for connecting to the encoders of the motors, along with
voltage regulation for them, which provides us with feedback to implement closed loop control.RC
filters have also been implemented, which help with noise attenuation received from the feedback.
Figure 6.5 provides a snapshot of one of the boards. Due to the high variability of the bio-assembly
subsystem electronic support, a custom PCB is essential for proper power distribution as well as
efficient signal linkage between the various components and the bio-RPi. The PCB will sit in the
bio-house, collecting all bio-components into one interface. These then travel to the elec box via
one connector to be interface with the RPi and main rover power line. All the signal and power
flow for the bio-subsystem would be via the board to provide a reliable path, reducing risk of
human error.

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Mars Rover Team, IITB Chapter 7. Autonomous Traversal and Path Planning

6.4 Power Distribution and BMS

Four 11.1 Volt Li-Ion battery packs (Max. Current - 105A, Energy - 35Ah each) with built-in
BMS can sustain the rover for more than three hours on a single charge. Regulated DC-DC USB
NUC Converter [1] & DC-DC buck/boost converters setup the backbone of our power system. Hi-
Grade Silicone wires [16] of 12, 14, & 18 AWG standards along with aviation-grade GX16s, T-Tap
terminals are used to accomplish the efficient wiring.

7. Autonomous Traversal and Path Planning

7.1 Simulation Environment
The simulation environment is designed to mimic
the actual conditions of the Martian environment.
It is based on the official 3D models issued pub-
lished by NASA-JPL, including the Mars terrain
map, which is based in real martian holography.
In addition to the base world, arrows and other
obstacles have been added manually at multiple
places to simulate the real conditions for the au-
tonomous traversal of the rover. The arrows spec-
ify a path that the rover follows to navigate from
the start to the end goal.
Figure 7.1: Simulated Gazebo Environment

7.2 Path Planning

The rover uses a mapping algorithm, for Simultane-
ous Localization and Mapping (SLAM). It creates a
2D occupancy grid map from the LiDAR scan data
and 3D pointcloud from depth-camera and the mo-
bile robot pose as well as the cost map which uses
the gradient approach to give larger costs to posi-
tions closer to the obstacles. A photo-realistic 3D
model of the environment is also created by Real-
Time Appearance-Based Mapping (RTAB Map) based
on an incremental appearance-based loop closure de-
tector. The set of trajectories shown by the white
region are those with positive scores which is calcu-
lated based on factors like closeness to the goal and
proximity to obstacles. The path with the highest
Figure 7.2: Optimal paths found
score out of those is highlighted in black. The local
planner selects the optimal path to take using the obstacle cost map. The green trajectory in the
image refers to the inputs from the global planner and the blue one for the inputs from the global
planner of the Dynamic Window Approach (DWA).

7.3 Arrow Detection Algorithm

To detect the direction of the arrow from the captured feed(I) of the rover, we required a scale
and orientation invariant algorithm, since plane of the arrow may not be perpendicular to optical
axis of the camera and the distance may vary depending on the position of the rover. To achieve
this we detected the arrow using contour detection(after carrying out processing on the image)
and identified the correct contour using convexity properties of the arrow. We carried out the
implementation using OpenCV library for image processing. The algorithm is described as follows:

1. Pre-processing of the image to get edges in the image(using canny edge detection algorithm)
with reduced noise(using repeated erosion and dilation).

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Mars Rover Team, IITB Chapter 7. Autonomous Traversal and Path Planning

2. Detection of contours and filtering them based on contour area

3. Approximating the filtered contours as polygons
4. Detection of convexity defects(which should be 2 if an arrow is detected)

5. Identifying the tip of the arrow from the information of convexity defective points and the
other points of the approximated polygon
6. Determining the direction of arrow by comparing the arrow tip with position of back edge of
the arrow

(a) Edge detection and noise reduction on input image (b) Arrow detection by finding contours

Figure 7.3: Arrow Detection algorithm steps

Figure 7.4: Arrow Detection Pipeline

7.3.1 Orientation prediction

In order to determine whether the arrow is pointing right or left, the above described algorithm
is sufficient, since the tip of the arrow is obtained using the above algorithm. However, in order
to get the orientation of the arrow in 3-D, the point cloud data, having the depth information of

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Mars Rover Team, IITB Chapter 7. Autonomous Traversal and Path Planning

the plane of the arrow is used. Best fit plane is evaluated from the cartesian coordinates of points
on the plane, hence accounting for the noise in data. The equation obtained is then used to find
the normal of the plane, and hence, the orientation of the arrow. The implementation of this is
carried out using Open3d library(open-sourced) [12].

7.3.2 Simulation results

Figure 7.5 shows some instances of arrow detection carried out in simulation. Figure 7.6 shows
arrow detection(represented by bounding box over the arrow) on point cloud data of the scene.

(a) Detection on far off arrow sign (b) Detection on different orientation
of arrow

Figure 7.5: Arrow Detection examples in simulation

Figure 7.6: Bounding box over arrow(on point cloud of the scene)

7.4 Arrow Follow Algorithm

The rover starts with the initialisation of the previous goal coordinates to the current location in
the map frame. Next, the arrow detection algorithm is run. If the arrow has not been detected the
rover moves in the direction suggested by the previous goal. If an arrow is detected, Depth Camera
data is used to locate the arrow. Post detection, the rover checks if it has been already visited and
exists in the completed goals, if so it ignores the arrow else it adds the arrows to list of goals and
moves in the direction of the arrow. The algorithm also accounts for errors by utilising recovery
methods under which the rover changes its orientation to detect arrows and if unsuccessful, the
rover moves to its last good location. The rover is able to function well in case of depth camera
failure by utilising other camera feeds. In this case, orientation calculation is based on homography
estimation (SolvePnP function by OpenCV library). In order to facilitate a larger field of view, the
stereo camera is placed on a rotating assembly that would help to gain full 180°field of view. The
rotating camera has also been integrated in simulation testing for validation of the algorithm.

  

16
Mars Rover Team, IITB Chapter 7. Autonomous Traversal and Path Planning

Appendix
Pseudo Codes for Autonomous algorithms

Algorithm 1: Arrow Detection algorithm Algorithm 2: Arrow Follower algorithm

using Contour Detection 1 my_client ← client
Data: Image feed: I 2 while rospy is not shutdown do
Result: direction 3 found, theta, orient ←
1 direction ← none my_client.arrow_detect()
2 #pre-processing 4 if found then
3 Iedge ← cannyEdgeDetection(I) 5 #q (quaternion) is updated
4 Ireduced ← noiseReduction(Iedge ) 6 if already
5 #contour detection and getting correct my_client.is_complete(posx, posy,
contour q) then
6 contours ← detectContours(Ireduced ) 7 #the goal has already been
7 for cnt in contours do visited
8 #finding the convex hull of the 8 continue
polygon approximation of contours 9 end
9 approx ← approxPolyDP(cnt) 10 posx, posy,q ←
10 hull ← convexHull(approx) my_client.bot_to_map(posx,posy,q)
11 sides ← len(hull) 11 my_client.move_to_off_goal(posx,posy,
12 #if the sides of convex hull is 4 or 5 q, frame = ”map”, off_dist = 1)
and is 2 less than sides of polygon... 12 prev_x, prev_y, prev_q
13 if 6 >sides> 3 and sides + 2 == ←posx,posy, q
len(approx) then 13 my_client.add_to_com-
14 #get the indices of points present pleted(posx,posy,q)
in polygon but not in convex hull 14 # In case of errors
15 indices ← diffPoints(approx,hull) my_client.recovery() is called
16 #get the arrow tip 15 else
17 for i in [0,1] do
16 end
18 j ← (indices[i] + 2) %
17 # When arrow has not been found
len(approx)
move the rover in the direction of
19 if approx[j] == approx[indices[i
previous arrow detected
- 1] - 2] then
18 nearby_goal ← just_ahead(prev_x,
20 #storing the arrow tip and a
prev_y, prev_q)
point in back edge
19 my_client.send_goal(*nearby_goal)
21 arrowTip ← approx[j]
20 end
22 back ←
approx[(j-1)%len(approx)]
23 end
24 end
25 #if arrowTip exists get the
direction of the arrow
26 if arrowTip then
27 if arrowTip.x<back.x then
28 direction ← left
29 end
30 if arrowTip.x>back.x then
31 direction ← right
32 end
33 end
34 end
35 end
36 return direction

17
Mars Rover Team, IITB References

References
[1] Converter. https://www.mini-box.com/DCDC-NUC.

[2] Deep reinforcement learning. https://blog.floydhub.com/robotic-arm-control-deep-reinforcement-learning/.

[3] Fosscam. http://foscam.us/poe-ip-cameras/foscam-fi8910e-black-poe-ip-camera.html.

[4] RUCKUS P300 data sheet.

[5] Joystick. https://www.amazon.in/Logitech-F310-Gamepad-Cable-Connection/dp/

B003VAHYQY.

[6] Mono-joystick. https://www.google.com/url?sa=i&url=https%3A%2F%2Fwww.

amazon.in%2FLogitech-Extreme-Gaming-Joystick-White%2Fdp%2FB00A76N8RO&psig=
AOvVaw1fWfhUH5nV4EB-MQQpcLuD&ust=1701020179965000&source=images&cd=vfe&
opi=89978449&ved=0CBQQjhxqFwoTCNiLjY_Y34IDFQAAAAAdAAAAABAD.

[7] Raspberry pi. https://www.raspberrypi.com/.

[8] Realsense. https://realsense.intel.com/depth-camera/.

[9] Roboclaw motor controllers. https://www.pololu.com/category/124/roboclaw-motor-controllers.

[10] Rocketm2. https://www.amazon.in/Ubiquiti-Networks-ROCKETM2-Rocket-M2-Outdoor/dp/

B00HXT8P0I.

[11] Router. https://www.netgear.com/in/home/wifi/routers/.

[12] Open3D.

[13] alcotec. About Aluminum Alloys.

[14] matweb. Al 5052-H32 Datasheet.

[15] matweb. Al 6061-T6 Datasheet.

[16] Rhino. Link to Wire Specification.

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