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Overview

Work Package 2 transforms your MATLAB simulation into physical reality through mechanical and electrical design. You’ll create:
  • 3D CAD model of the robot chassis and components
  • PCB/wiring diagram for all electrical connections
  • Bill of Materials with exact part specifications
  • Assembly documentation for building the robot
Duration: 4 weeks (runs in parallel with WP1 and WP3) Can be split: Different team members work on CAD vs PCB simultaneously

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Deliverables

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D2.1: CAD Design

Suggested Time: 4 weeks What to deliver:
  • Complete 3D model of robot in CAD software (Fusion 360, SolidWorks, or FreeCAD)
  • Assembly with all components (chassis, motors, wheels, electronics mounting)
  • Bill of Materials (BOM) including all fasteners
  • Key dimensions and technical drawing
  • STL files ready for 3D printing
Success Criteria:
  • Model is mechanically sound (proper clearances, mounting holes)
  • All parts fit together in assembly
  • Realistic and buildable design
  • Professional-quality renderings for documentation

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D2.2: PCB Design

Suggested Time: 4 weeks What to deliver:
  • Complete wiring diagram or PCB schematic (EasyEDA, Cadence, or KiCad)
  • Clear connection diagram showing all components
  • Power distribution design
  • Cable routing plan
  • Safety considerations documented
Success Criteria:
  • All electrical connections clearly shown
  • No short circuit risks
  • Proper gauge wires for current levels
  • Organized and maintainable layout
  • Can be replicated by another team
3D Printing Limit: Each group has maximum 2 prints. Design carefully and learn from other groups before printing!

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Why Prototyping Matters

CAD lets you verify mechanical fit before ordering parts. Check clearances, mounting holes, and assembly sequence virtually.
Understand what needs to be fabricated (3D printed, laser cut, purchased). Generate accurate BOM with quantities.
PCB/wiring design prevents shorts, fires, and component damage. Plan for proper fusing, wire gauge, and connections.
CAD and schematics are universal language. Mechanical and electrical team members coordinate through drawings.

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Design Requirements

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Mechanical Requirements

Your robot must accommodate: Motors & Wheels:
  • 4× DC motors (12V, 333RPM) with encoders
  • 4× Mecanum wheels (typically 100mm diameter)
  • Motor mounting brackets with proper alignment
Electronics:
  • ESP32 microcontroller board
  • 4× IBT-2 motor drivers (BTS7960)
  • ICM-20948 IMU sensor
  • Raspberry Pi 4/5 (onboard computer)
  • LiDAR A1M8 sensor
  • Camera module (optional)
Power:
  • Battery pack (LiPo/Li-Ion, 12V, 5000mAh+)
  • Power distribution (12V for motors, 5V for logic)
  • Emergency stop switch (recommended)
Dimensions:
  • Wheelbase (L): ~300mm (suggested)
  • Track width (W): ~250mm (suggested)
  • Overall footprint: flexible, but consider maneuverability
  • Height: accommodate all electronics and sensors

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Electrical Requirements

Power Distribution:
  • 12V main bus for motors
  • 5V regulated for ESP32, Raspberry Pi, sensors
  • Proper current handling for each motor driver (~3A peak per motor)
Signal Connections:
  • ESP32 GPIO to motor drivers (PWM, EN)
  • ESP32 GPIO to encoders (quadrature A/B)
  • ESP32 I2C to IMU
  • USB between Raspberry Pi and ESP32 (optional, can use serial)
  • LiDAR to Raspberry Pi (USB)
Safety:
  • Fuses on power lines
  • Emergency stop capability
  • Proper wire gauge (see AWG charts)
  • Heat dissipation for motor drivers

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Work Package Timeline

1

Week 1: Research & Concept

  • Study existing Mecanum robot designs
  • Define key dimensions from MATLAB simulation
  • Sketch concept layouts
  • Begin component research for BOM
2

Week 2-3: CAD Modeling

  • Model individual parts (chassis, motor mounts)
  • Import or model purchased components
  • Create assembly
  • Check clearances and fit
  • Start PCB/wiring diagram in parallel
3

Week 3-4: Refinement

  • Iterate design based on feedback
  • Finalize dimensions
  • Complete BOM with sources and prices
  • Generate technical drawings
  • Prepare files for 3D printing
4

Week 4: Documentation

  • Render high-quality images
  • Export STL files
  • Finalize wiring diagram
  • Write assembly instructions
  • Order components!
Parallel Work: CAD designer and PCB designer can work simultaneously. Coordinate on mounting holes and component placement.

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Next Steps

Choose your path based on your role:

CAD Design

Learn CAD modeling for robot chassis

PCB Design

Create electrical wiring diagrams

Mechanical Assembly

Assembly guidelines and 3D printing

Hardware Reference

Component specifications and datasheets

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References

[1] KUKA OmniMove Platform: https://www.kuka.com/ [2] Mecanum Wheel Suppliers: VEX Robotics, AndyMark, RobotShop