06:15 PM to 03:00 AM. These were the best hours of my college life, spent with MRM (Mars Rover Manipal) at the Manipal Workshop. After months of daily evening meetings and building prototypes to create a strong foundation in developing mechanical elements, our team was finally ready for the real challenge.

As the elected drive train lead, I realized that our previous Rover iterations struggled with traversing extreme terrains like steep ditches or rocky gardens. Additionally, the traditional rocker-bogie suspension caused middle-wheel traction loss during zero-radius turns, resulting in wheel bouncing. This became my problem statement.

1. Problem Identification - The suspension needed to:
 1.1 Traverse extreme terrain such as rocks, deep craters, and loose soil.
 1.2 Climb an incline & decline grade of 60` while maintaining chassis stability
 1.3 Overcome traction loss in the middle wheel of a rocker-bogie suspension

As the drive-train lead, my main task was developing the Rover’s suspension while collaborating with teammates on the 6-DOF robotic manipulator (a swivel base with timing belt transmission, an articulated arm, and an end effector with a bevel gear differential), a carbon fiber space frame chassis, and fully floating metal-casted wheels.

Developing the suspension system was an exciting challenge -
1. Research and Analysis - Extensive research was conducted into:
1.1 Existing suspension systems used used by various teams and organizations.
1.2 Material properties to balance strength to weight ratio.

1. Conceptualization and Ideation - Explored multiple concepts:
 1.1 By iterating the line diagram of different geometries and mechanism
1.2 By Performing kinematic analysis on the mechanisms that allowed traversal of large craters with the smallest wheelbase and offered the best load distribution on the wheels.

2. Design and Simulation - The suspension design was iteratively developed to:
 2.1 Pass the dynamic simulation analysis to ensure the effective link lengths and spring stiffness
 2.2 Pass the static structural analysis through Ansys FEA
 2.3 Ensure ease of manufacturability and assembly with other components like wheels and chassis

3. Testing: The manufactured concept of the novel 6 wheeled suspension was subject to:
 3.1 Field trials on rugged terrain to assess real-world performance and identify areas for improvement.
 3.2 Iterative modifications, ensuring the rover met all mission requirements.

A patent has been filed for this custom 6-wheeled multi-link dependent suspension system based on a 5-bar mechanism that has a dynamic axis of rotation, and I envision it playing a crucial role in disaster relief. Designed for rugged terrain, it could be invaluable after earthquakes, allowing rescue vehicles to traverse rubble and debris where conventional vehicles fail. This system ensures critical aid can reach even the most inaccessible areas, making it a vital tool in emergency response.

Finally, in the spirit of teamwork, mentoring became one of the most rewarding parts. Leading “task phase” sessions for newer members, I helped them dive into their topics, prepare reports, and brainstorm solutions. This ensured a smooth knowledge transfer and continuous improvement for future iterations of the rover.