Motor Speed Control

Problem Description

My team designed and built a mobile platform capable of transporting a dynamically unstable load while maintaining controlled motion and stability. The project combined mechanical design, simulation, controls, and physical prototyping to create a system that could move efficiently without causing the load to tip over.

Using CAD modeling, motion analysis, and experimental testing, we developed a motor-controlled vehicle that transported an aluminum extrusion beam across a defined distance while minimizing instability caused by acceleration and deceleration.

Design and Simulation

The initial design process focused on creating a simple and manufacturable platform that could be easily modified throughout testing. Using SolidWorks, I designed the vehicle assembly and conducted motion studies to analyze how acceleration affected the stability of the suspended load.

The simulation allowed us to determine the maximum acceleration and velocity the platform could achieve without causing the beam to fall. By analyzing velocity profiles and motion timing, we developed a control strategy that balanced speed with stability. The design also incorporated wheel and axle configurations optimized for rapid acceleration and straightforward assembly.

Prototype and Control System

After completing the simulations, we built a physical prototype using a 12V gear motor, Arduino UNO, laser-cut structural components, and 3D-printed wheels. The control system regulated motor voltage over time to manage acceleration and deceleration throughout the vehicle's motion.

Through iterative testing and tuning, we adjusted the acceleration profile to maintain stability while minimizing travel time. The final prototype successfully transported the unstable load across the required distance in under 10 seconds without tipping the beam.

Conclusions

This project strengthened my understand of the relationship between mechanical design, dynamic systems, and control strategies. By combining simulation, prototyping, and experimental testing, I gained hands-on experience developing systems that balance performance with stability. The project also reinforced the importance of iterative testing, controls integration, and designing with real-world physical constraints in mind.

Skills

Mechanical Design and Prototyping

  • CAD design (SolidWorks)
  • Motion simulation and analysis
  • Rapid prototyping
  • Mechanical assembly design

Controls and Mechatronics

  • Motor speed control
  • Arduino programming
  • Dynamic system analysis
  • Acceleration and stability control

Engineering Analysis

  • Motion studies and velocity profiling
  • Design iteration and optimization
  • Prototype testing and validation
  • Troubleshooting and debugging

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