Systematic design and development of a flexible wheel for low mass lunar rover

Low mass compact rovers provide cost effective means to explore extra-terrestrial terrains. Use of flexible wheels in such applications where the wheel size is restricted, improves traction at reduced slip and sinkage. Design of a flexible wheel for a given mission is a challenging task requiring consideration of stiffness of rim and spokes, stress induced in the wheel, chassis movement during wheel rotation and the operating mode of the wheel. Also, accurate mathematical models are required to save design and development time and reduce the number of prototypes for selection. It is observed that most of the research papers deal with performance testing of flexible wheels and information on analytical formulation is scarce. Therefore, in the present work, a methodology has been formulated to systematically design a flexible wheel for a low mass lunar rover. The prototype performance is tested and compared with analytical estimates and reasons for difference are investigated. Paper contains details of design criteria, mathematical modelling, realisation of wheel prototype, test fixture and analysis test comparison. Authors believe that this work provides a useful aid to the designer to systematically design flexible wheels for low mass lunar rovers.     

Shape effects of wheel grousers on traction performance on sandy terrain

This paper presents the effects of different wheel grouser shapes on the traction performance of a grouser wheel traveling on sandy terrain. Grouser wheels are locomotion gears that allow small and lightweight exploration rovers to traverse on the loose sand on extraterrestrial surfaces. Although various grouser shapes have been analyzed by some research groups, a more synthetic and direct comparison of possible grousers is required for practical applications. In this study, we developed a single wheel testbed and experimentally investigated the effects of four grouser shapes (parallel, slanted, V-shaped, and offset V-shaped) on the traction performance of linear movement on flat sand. The wheel slip, sinkage, traction and side force acting on the wheel axle, the wheel driving torque, and the efficiency of each wheel were examined. Thereafter, the effects on the lateral slope traversability of a small and lightweight four-wheeled rover with different grouser shapes were also examined. The traversability experiment demonstrated the vehicle mobility performance in order to contribute to the design optimization of rover systems. These experimental results and their comparisons suggested that, of the shapes studies herein, the slanted shape was the optimal grouser design for use in wheeled rovers on lunar and planetary soil.     

2D FE–DEM analysis of tractive performance of an elastic wheel for planetary rovers

We have been developing a simulation program for use with soil–wheel interaction problems by coupling Finite Element Method (FEM) and Discrete Element Method (DEM) for which a wheel is modeled by FEM and soil is expressed by DEM. Previous two-dimensional FE–DEM was updated to analyze the tractive performance of a flexible elastic wheel by introducing a new algorithm learned from the PID-controller model. In an elastic wheel model, four structural parts were defined using FEM: the wheel rim, intermediate part, surface layer, and wheel lugs. The wheel rigidity was controlled by varying the Young’s Modulus of the intermediate part. The tractive performance of two elastic wheels with lugs for planetary rovers of the European Space Agency was analyzed. Numerical results were compared with experimentally obtained results collected at DLR Bremen, Germany. The FE–DEM result was confirmed to depict similar behaviors of tractive performance such as gross tractive effort, net traction, running resistance, and wheel sinkage, as in the results of experiments. Moreover, the tractive performance of elastic wheels on Mars was predicted using FE–DEM. Results clarified that no significant difference of net traction exists between the two wheels.     

Design of manned lunar rover wheels and improvement in soil mechanics formulas for elastic wheels in consideration of deformation

Most of the current lunar rover vehicle wheels are inconvenient for changing broken wheels and have poor shock absorbing in driving, so they cannot be used to carry people on the moon. To meet the demands for manned lunar transportation, a new wheel possessing a woven metal wire mesh tire and using hub-rim combination slide mechanism is designed in this article. The characteristics of the new wheel is analyzed by comparing with the same-size conventional rover wheels after demonstrating the validity of FEM simulation. The new wheel possesses lighter structure and superior shock absorbing. It also provides stronger traction because the deformation of the designed wheel increases the contact area between the tire and lunar terrain. In order to establish an on-line soil parameter estimation algorithm for low cohesion soil, the stress distribution along a driven deformable wheel on off-road terrain is simplified. The basic mechanics equations of the interaction between the wheel and the lunar soil can be used for analytical analysis. Simulation results show that the soil estimation algorithm can accurately and efficiently identify key soil parameters for loose sand.     

Experimental and DEM analyses on wheel-soil interaction

In this paper, the wheel-soil interaction for a future lunar exploration mission is investigated by physical model tests and numerical simulations. Firstly, a series of physical model tests was conducted using the TJ-1 lunar soil simulant with various driving conditions, wheel configurations and ground void ratios. Then the corresponding numerical simulations were performed in a terrestrial environment using the Distinct Element Method (DEM) with a new contact model for lunar soil, where the rolling resistance and van der Waals force were implemented. In addition, DEM simulations in an extraterrestrial (lunar) environment were performed. The results indicate that tractive efficiency does not depend on wheel rotational velocity, but decreases with increasing extra vertical load on the wheel and ground void ratio. Rover performance improves when wheels are equipped with lugs. The DEM simulations in terrestrial environment can qualitatively reproduce the soil deformation pattern as observed in the physical model tests. The variations of traction efficiency against the driving condition, wheel configuration and ground void ratio attained in the DEM simulations match the experimental observations qualitatively. Moreover, the wheel track is found to be less evident and the tractive efficiency is higher in the extraterrestrial environment compared to the performance on Earth.     

Design and development of a new transformable wheel used in amphibious all-terrain vehicles (A-ATV)

Conventional ground-wheeled vehicles usually have poor trafficability, low efficiency, a large amount of energy consumption and possible failure when driving on soft terrain. To solve this problem, this paper presents a new design of transformable wheels for use in an amphibious all-terrain vehicle. The wheel has two extreme working statuses: unfolded walking-wheel and folded rigid wheel. Furthermore, the kinematic characteristics of the transformable wheel were studied using a kinematic method. When the wheel is unfolded at walking-wheel status, the displacement, velocity and acceleration of the wheel with different slip rates were analyzed. The stress condition is studied by using a classic soil mechanics method when the transformable wheel is driven on soft terrain. The relationship among wheel traction, wheel parameters and soil deformation under the stress were obtained. The results show that both the wheel traction and trafficability can be improved by using the proposed transformable wheel. Finally, a finite element model is established based on the vehicle terramechanics, and the interaction result between the transformable wheel and elastic–plastic soil is simulated when the transformable wheel is driven at different unfold angles. The simulation results are consistent with the theoretical analysis, which verifies the applicability and effectiveness of the transformable wheel developed in this paper.     

Mobility performance of a rigid wheel in low gravity environments

To investigate influences of gravity on mobility of wheeled rovers for future lunar/planetary exploration missions, model experiments of a soil-wheel system were performed on an aircraft during variable gravity maneuvers. The experimental set-up consists of a single rigid wheel and a soil bed with two kinds of dry sands: lunar soil simulant and Toyoura sand. The experimental results revealed that a lower gravity environment yields higher wheel slippage in variable gravity conditions. In addition to the partial gravity experiments, the same experiments with variable wheel load levels were also performed on ground (1 g conditions). The on-ground experiments produced opposite results to those obtained in the partial gravity experiments, where a lower wheel load yields lower slippage in a constant gravity environment. In low gravity environments, fluidity (flowability) of soil increases due to the confining stress reduction in the soil, while the effect of the wheel load on sinkage decreases. As a result, both of these effects are canceled out, and gravity seemingly has no effect on the wheel sinkage. In the meantime, in addition to the effect of wheel load reduction, the increase of the soil flowability lessens the shear resistance to the wheel rotation, as a result of which the wheel is unable to hold sufficient traction in low gravity environments. This suggests that the mobility of the wheel is governed concurrently by two mechanisms: the bearing characteristics to the wheel load, and the shearing characteristics to the wheel rotation. It appears that, in low gravity, the wheel mobility deteriorates due to the relative decrease in the driving force while the wheel sinkage remains constant. Thus, it can be concluded that the lunar and/or Mars’ gravity environments will be unfavorable in terms of the mobility performance of wheels as compared to the earth’s gravity condition.     

Measurement and modeling for two-dimensional normal stress distribution of wheel on loose soil

On the Moon or Mars, typical target environments for exploration rovers are covered with fine sand, so their wheels easily slip on such weak ground. When wheel slippage occurs, it is hard for the rover to follow its desired route. In the worst case, the rover gets stuck in loose soil and cannot move anymore. To reduce the risk of the rover getting stuck, analysis of the contact mechanics between the soil and wheel is important. Various normal stress distribution models for under the wheel surface have been proposed so far. However, classical models assume a uniform stress distribution in the wheel’s width direction. In this study, we measured the two-dimensional normal stress distribution of a wheel in experiments. The results clarified that the stress distribution in the wheel’s width direction is a mountain-shape curve with a peak located at the center of the wheel. Based on the results, we constructed a stress distribution model for the wheel’s width direction. In this paper, we report our measurements for the two-dimensional stress distribution of a wheel on loose soil and introduce our stress distribution model for the wheel’s width direction based on our experimental results.     

Wheels' performance of Mars exploration rovers: Experimental study from the perspective of terramechanics and structural mechanics

The soft ground and stones on the surface of Mars may cause sinkage of and damage to the wheels of a Mars rover. Therefore, we analyzed the performance of a wheel-step Mars rover from the perspective of terramechanics and structural mechanics. Using China’s Mars rover wheel prototype and wheel-soil interaction testbed, we obtained the driving performance of the wheels of a Mars rover under various conditions, including full skidding conditions. The vertical load set in the tests was determined using the gravity of Mars and the mass of the wheel-step Mars rover. The results indicate that the driving torque, sinkage, and resistance coefficient have a linear relationship with the wheel vertical load. An analysis of the structural mechanical characteristics of the wheel of the Mars rover was conducted by testing the radial, axial, torsional, and deflection stiffness. We found that the wheel ribs can improve the stiffness of the wheel but may reduce its driving performance. The analysis methods and evaluation indices can be used to analyze the performance of the wheels of other Mars rovers. Furthermore, the findings of this study can be used to optimize wheel design and motion control of wheel-step Mars exploration rovers.     

The ExoMars rover locomotion subsystem

ExoMars is the European Space Agency (ESA) mission to Mars planned for launch in 2018, focusing on exobiology with the primary objective of searching for any traces of extant or extinct carbon-based micro-organisms. The on-surface mission is performed by a near-autonomous mobile robotic vehicle (also referred to as the rover) with a mission design life of 180 sols. The rover has a 6 × 6 × 6 with 6 wheel-walking drive configuration (all 6 wheels are driven, steered and have a ‘walking’ capability) and has flexible wheels providing enhanced traction compared to rigid wheels of the same diameter. The suspension is a passive ‘3-bogie’ system which offers the same 6 wheel contact on uneven ground and mobility performance as the NASA-JPL ‘rocker-bogie’ suspension used on previous Mars rovers, but permits elimination of the differential linkage present in that design. Mars presents several challenges to the rover locomotion subsystem with its rock-strewn surface, sand dunes, rocky outcrops, craters and slopes. The unknown nature of the terrain to be traversed imposes several constraints on the locomotion subsystem design that need to be evaluated and incorporated within the flight model for its successful operation on Mars. In addition, accommodation within the confines of the lander and successful egress from it over deflated airbags places stringent constraints on locomotion subsystem mass, stowage envelope, deployment and wheel design. This paper documents the evolution of the ExoMars rover vehicle locomotion configuration from an early design concept to the current mission baseline design. The discussion involves various tradeoffs supported by mechanical and terramechanical analyses, simulations and testing performed on full-scale locomotion breadboard models at single wheel level and system level.     

Predicting the performances of rigid rover wheels on extraterrestrial surfaces based on test results obtained on earth

With a growing number of nations interested in planetary exploration, research and development of extraterrestrial rovers have been intensified. The usual practice is to test the performances of rovers on soil simulants on earth, prior to their deployment to extraterrestrial bodies. It is noted that in the tests the soil simulant is subject to the earth gravity, while the terrain on the extraterrestrial surface is subject to a different gravity. Therefore, it is uncertain whether the rover/rover wheel would exhibit the same performance on the extraterrestrial surface as that obtained from tests conducted on earth. This paper describes a practical methodology that can be employed to predict the performances of rover wheels on extraterrestrial surfaces, based on test results obtained on earth. As rigid wheels are used in many extraterrestrial rovers, this study focuses on examining the effects of gravity on the sinkage and compaction resistance of rigid rover wheels. Predictions obtained using the methodology are shown to correlate reasonably well with test data.     

Multi-objective traction optimization of vehicles in loose dry sand using the generalized reduced gradient method

A work optimization strategy is combined with algorithms within the vehicle-terrain interface (VTI) model to maximize the traction of a four-wheel vehicle operating on loose dry sand. The optimization model distributes traction among the steered and non-steered wheels with the work optimum coefficient (WOC) of each wheel treated as an independent design objective. Drawbar pull (DBP), motion resistance (MR), longitudinal traction coefficient (LTC), lateral force coefficient (LFC), tire deflection, and wheel slip are key parameters that appear in the VTI model for traction performance analysis. The analysis includes wheels of different diameters, widths, heights, and inflation pressures, under variable wheel slips. A multi-objective optimization problem is formulated over a thirteen-dimensional search space bounded by eight design constraints. The generalized reduced gradient method is used to predict optimal values of the design variables as well as ground and traction parameters such as DBP, MR, LTC, and LFC for maximum slope climbing efficiency. The WOCs are maximized for lateral slip angles between 0° and 24° to find a set of Pareto optimal solutions over a wide range of weight factors. A method to apply the optimization results for predicting vehicle performance and traction control on dry sand is presented and discussed.     

Prediction of wheel performance by analysis of normal and tengential stress distributions under the wheel-soil interface

Prediction of wheel performance by analysis of normal stress distribution under the wheel-soil interface was reported by one of our research members. In this study analysis of both normal and tangential stress distributions are included for the prediction of wheel performance. A visco-elastic soil model based on a three-element Maxwell model is used to evaluate normal stress distribution under a wheel running on soft ground. The values of the parameters characterizing the visco-elastic behavior of the soil can be derived from plate penetration tests. A rigid wheel-soil interface model is used to evaluate the tangential stress distribution under the wheel-soil interface. Shear deformation modulus, cohesion and angle of internal shearing resistance of the soil are derived from shear-displacement tests. Test results indicate that both maximum normal and shear stress occur in front of the wheel axle, and the location of peak normal stress shifts backwards towards the wheel axle while that of tangential stress shifts forwards when slippage is increased from a low value. Increasing slippage also causes a decrease in normal stress and an increase in tangential stress. Coefficients of traction and tractive efficiency are low at low slippage, increase with an increase in slippage, and level off at higher slippage.     

Performance evaluation of a wire mesh wheel on deformable terrains

Because of the unique lunar environment, a suitable wheel for lunar rover decides the rover’s trafficability on deformable terrains. The wire mesh wheel (hereinafter referred to as WMW) has the advantages of light weight and superior stability, been widely adopted for lunar rovers. But a comprehensive research on performance of WMW on deformable terrains has not been conduct. This paper would provide particular study on a type WMW, including quasi-static pressure-sinkage test and driving performance. A novel pressure-sinkage model for the WMW on deformable soils was presented. In order to investigate the sinkage characteristics of the WMW, tests were performed using a single-wheel testbed for the WMW with different loads and velocities. The effects of load and velocity on sinkage were analyzed, and the relationship between real and apparent sinkage was presented. The research on traction performance of WMW under different slip ratios (0.1–0.6) was also conducted, contrast tests were proceed by using a normal cylindrical wheel (hereinafter referred to as CW). The traction performance of WMW is analyzed using performance indices including wheel sinkage, drawbar pull, driving torque, and tractive efficiency. The experimental results and conclusions are useful for optimal WMW design and improvement/verification of wheel–soil interaction mechanics model.     

Traction performance of a pushed/pulled drive wheel

A comprehensive method for prediction of off-road driven wheel performance is presented, assuming a parabolic wheel–soil contact surface. The traction performance of a driven wheel is predicted for both driving and braking modes. Simulations show significant non-symmetry of the traction performance of the driving and braking wheels. The braking force is significantly greater than the traction force reached in the driving mode. In order to apply the suggested model for prediction of the traction performance of a 4WD vehicle, the load transfer effect was considered. Simulated traction performances of front and rear driven wheels differ significantly, due to the load transfer. In the driving mode, the rear driven wheel develops a net traction force greater than that of the front wheel. On the other hand, in the braking mode the front driven wheel develops a braking force significantly greater than that of the rear driven wheel due to a pushed/pulled force affected by the load transfer. The suggested model was successfully verified by the data reported in literature and by full-scale field experiments with a special wheel-testing device. The developed approach may improve the prediction of off-road multi-drive vehicle traction performance.     

Traveling performance analysis of planetary rovers using a repeatable test system in vacuum

In this study, the effect of a vacuum environment on the traveling characteristics of planetary rovers is experimentally investigated. For this study, a wheel traveling test system that enables a wheel to travel at various speeds and traction loads in a vacuum chamber was developed. In this system, the ground can be prepared before each run, and the wheel can travel in similar ground conditions repeatedly. Subsequently, using this system, traveling tests of the wheel were conducted in the atmosphere and medium vacuum. The wheel was tested at different speeds and various traction loads (i.e., drawbar pulls) on a sandbox filled with three types of material. Wheel slip and sinkage were quantitatively compared in the atmosphere and vacuum. From the experiment, it was confirmed that the medium vacuum environment does not significantly affect the traveling performance of the wheel.     

Structure design and traction trafficability analysis of multi-posture wheel-legs bionic walking wheels for sand terrain

Nowadays, the existing walking wheels still have problems with the wheel-legs structure and the traction trafficability on the loose sand. It is commonly believed that African ostrich (Struthio camelus) is a kind of bipedal species with superior running performance on the sandy environment. Being enlightened by this, four bionic walking wheels (herringbone wheel, in-line wheel, V-shaped wheel and combination wheel) were designed and tested by imitating the structure and posture of ostrich’s feet travelling on sand. The results showed that when the wheel load was 20, 30 and 50N respectively and the slip ratio was less than 35%, the herringbone wheel had better traction trafficability than that of other wheels. When the wheel load was 30, 50 and 70N and the slip ratio was more than 35%, the in-line wheel had better performance than that of other wheels. It was shown in this thesis that the bionic walking wheels designed with the multi-posture wheel-legs and the simple structure could reduce the soil resistance and the disturbance to sand, thereby achieving a superior performance of traveling on sand. In addition, a new idea and research method for designing of walking mechanism on soft terrain has been provided in this thesis.     

A simulation model for the prediction of the ground pressure distribution under tracked vehicles

A computer based simulation model for the prediction of the ground pressure distribution beneath tracked vehicles under static conditions has been developed. The model can differentiate between various track designs and is based on an analytical method developed and described by Garber and Wong. Simulating the model with the parameters of a rubber tracked forestry vehicle (FARMI TRAC 5000) led to several conclusions. The road wheel arrangement has a considerable effect on the ground pressure distribution: increasing the number of road wheels reduces the maximum ground pressure and improces the uniformity of the pressure distribution. The radius of the road wheel, the stiffness of the suspension and the stiffness of the track tensioning device have an insignificant effect on the ground pressure distribution. In contrast, the initial track tension and the width of the track have a significant effect on the ground pressure distribution: increasing the initial track tension reduces the maximum ground pressyre and improves the uniformity of the pressure distribution. The same conclusions are valid for an increase of the track width. This model can be used as a tool to assist in the design of off-road vehicles, and is currently being used in the design of forestry vehicles in Ireland.     

Experimental study and analysis on driving wheels’ performance for planetary exploration rovers moving in deformable soil

Planetary rovers are different from conventional terrestrial vehicles in many respects, making it necessary to investigate the terramechanics with a particular focus on them, which is a hot research topic at the budding stage. Predicting the wheel-soil interaction performance from the knowledge of terramechanics is of great importance to the mechanical design/evaluation/optimization, dynamics simulation, soil parameter identification, and control of planetary rovers. In this study, experiments were performed using a single-wheel testbed for wheels with different radii (135 and 157.35 mm), widths (110 and 165 mm), lug heights (0, 5, 10, and 15 mm), numbers of lugs (30, 24, 15, and 8), and lug inclination angles (0°, 5°, 10°, and 20°) under different slip ratios (0, 0.1, 0.2, 0.3, 0.4, 0.6, etc.). The influences of the vertical load (30 N, 80 N, and 150 N), moving velocity (10, 25, 40, and 55 mm/s), and repetitive passing (four times) were also studied. Experimental results shown with figures and tables and are analyzed to evaluate the wheels’ driving performance in deformable soil and to draw conclusions. The driving performance of wheels is analyzed using absolute performance indices such as drawbar pull, driving torque, and wheel sinkage and also using relative indices such as the drawbar pull coefficient, tractive efficiency, and entrance angle. The experimental results and conclusions are useful for optimal wheel design and improvement/verification of wheel-soil interaction mechanics model. The analysis methods used in this paper, such as those considering the relationships among the relative indices, can be referred to for analyzing the performance of wheels of other vehicles.     

Grousers improve drawbar pull by reducing resistance and generating thrust at the front of a wheel

Grousers are commonly used to increase wheel traction, though how grousers exactly influence wheel thrust and resistance, and thus drawbar pull, has continued to remain an open topic of research. This work explores rigid wheels with grousers traveling on homogeneous granular soil. Unique experiments that provide insights into what grousers are doing at various points on a wheel are presented. To perform these experiments, a novel wheel that enables grousers to extend and retract in various regions around the wheel is developed; specifically grousers can always be extended at the front of the wheel but retracted below the wheel, even as the wheel rotates. These experiments show that grousers are much more effective at increasing drawbar pull when they are interacting with soil ahead of the wheel, rather than below it. A wheel with grousers engaging soil only ahead of the wheel, and not below it, nonetheless achieves over 80% of the relative improvement in drawbar pull that a “full grouser” wheel achieves over a grouserless wheel. This reveals how thrust is generated primarily by the front-most grouser, and further suggests that the reduction of resistive forward soil flow also plays a key role in increasing drawbar pull.