Bipedal Wheeled Robot

• Mechanical Design: Engineered a custom cycloidal gearbox capable of delivering >139 Nm of torque, integrated with a spring-assisted leg system for improved load-bearing and energy efficiency.

• Software Integration: Developed a dual PID-based control system with sensor fusion, enabling real-time self-balancing and disturbance recovery within 2.5 seconds.

• Latching Mechanism: Designed and tested a hybrid passive-active latching system using an electromagnet and gate latch, achieving over 90% successful coupling in lab conditions.

• Power and Communication Systems: Implemented a 48V high-voltage power distribution and CAN bus communication architecture, optimizing power usage and enabling reliable multi-motor synchronization.

• Validation & Testing: Successfully validated self-balancing performance, communication latency (<10 ms), system runtime (>30 min), and collaborative transport in both simulated and real-world testing environments.

Mechanical Design & Fabrication

• Led the complete mechanical design of the robot, including the chassis, leg system, gearbox, and latching mechanism, using SolidWorks and rapid prototyping techniques.

• Designed and built a custom cycloidal gearbox with a 30:1 reduction ratio, achieving 139.5 Nm of torque—exceeding project requirements.

• Spearheaded the modular chassis design using aluminum extrusions and 3D-printed components, optimizing for strength, adaptability, and ease of maintenance.

• Incorporated spring-assisted legs to reduce motor load and improve power efficiency and vertical mobility.

System Assembly & Integration

• Personally oversaw the entire mechanical assembly of the robot, including gearbox mounting, leg installation, electrical housing, and joint connections.

• Implemented heated inserts, threaded fasteners, and modular subassemblies to ensure robust and serviceable construction.

• Managed alignment and tolerance adjustments across all subsystems to ensure seamless integration between structural and moving parts.

Electronics & Architecture

• Directed the high-level design of the electrical architecture, defining voltage levels, power separation, and subsystem coordination.

• Selected and sourced key components such as:

  • Motors (hub and BLDC)

  • ODrive motor controllers

  • Jetson Orin Nano

Component Sourcing & BOM Management

• Solely responsible for sourcing all mechanical and electrical components, including bearings, aluminum extrusions, fasteners, gear parts, and sensors.

• Managed bill of materials (BOM) logistics, ensuring on-time procurement and compatibility across subsystems.

Simulation & Software Exploration

• Conducted preliminary research into ROS2 simulation environments, including control frameworks and package integration for bipedal robots.

• While implementation was not successful due to time constraints, the investigation helped inform the system’s future scalability and ROS2 integration path.