Modular Uni-Member Robot Chassis for Field Repair and Lower Cost

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Solution Overview

Problem

Existing outdoor autonomous land care robots are large, cumbersome, expensive, and have limited capability, requiring massive power and being complex in design and operation, which makes them costly to manufacture, maintain, and operate.

Innovation Solution

A cost-effective, modular, and field-repairable chassis and mechanical components for autonomous multi-purpose electric outdoor ground utility robots, featuring a single panel, uni-member U-shaped bended frame, reduced part count, high strength, and easy assembly and modification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional chassis designs are used for autonomous robots, then structural strength is maintained, but manufacturing cost increases and assembly complexity increases

Engineering Contradiction:

Improvechassis strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The chassis is divided into modular sections (front end, rear end, mid-section) that can be independently manufactured and assembled. This segmentation allows each module to be optimized for its specific function while reducing overall manufacturing complexity and cost.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple functional components are merged into integrated assemblies. For example, the wheel assembly combines the wheel, axle, and mounting structure into a single modular unit, reducing part count and simplifying both manufacturing and field repair operations.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If traditional chassis designs are used for autonomous robots, then structural strength is maintained, but device complexity increases

Engineering Contradiction:

Improvechassis strengthVSAvoidpart count

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If traditional chassis designs are used for autonomous robots, then structural integrity is maintained, but ease of repair in field conditions deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidfield repairability

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The chassis is divided into modular sections (front end, rear end, mid-section) connected by standardized interfaces. This allows damaged sections to be quickly removed and replaced in the field without requiring complex repairs, maintaining structural integrity while enabling rapid field replacement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design enables quick replacement of damaged modular sections in the field. Rather than attempting complex repairs, damaged modules can be discarded and replaced with pre-manufactured replacement modules, significantly improving field repairability while maintaining structural integrity through standardized connection interfaces.

Inventive Principle:

Principle #34Discarding and recovering

4Ease of manufacture

If modular components are used to reduce part count, then ease of assembly improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improveassembly easeVSAvoidinterface precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Standardized universal interfaces are designed for all modular connections throughout the chassis. These standardized interfaces (such as standardized mounting holes, connection geometries, and fastening mechanisms) ensure that while manufacturing precision at each interface is maintained, the overall assembly process is simplified and can be performed with standard tools and procedures.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12269530B2Modular, cost-effective, field repairable chassis and mechanical components for heavy duty autonomous robot

Publication Date: 2025.04.08 DCENTIZED SYST LLC

AI summary

A method of creating a configurable, uni-member, bended frame chassis comprising the steps of having a single sheet of material; forming holes at predetermined locations in said single sheet of material; using the single sheet of material and forming a base, a first side, a second side, a first top plate and a second top plate by; bending the material lengthwise and upwardly and forming the first side; bending the material lengthwise and upwardly and forming the second side; and having the base formed between the first side and the second side; bending the material lengthwise at a top of the first side and forming the first top plate; and bending the material lengthwise at a top of the second side and forming the second top plate.