Prototype Process
The prototyping process consisted of 2 parts. The physical small scale model, and the simulated design testing. Due to the nature of the design it was apparent early on that a true small scale model could not be accurately made. The scaling of the components could not be done to exact specifications without designing every part from scratch. This was fixed by using the physical prototype to show the control system and the intended function of the cart. The simulated model would be used to accurately show how loads would affect the cart frame and suspension system.
Physical Prototype
The physical prototype was built using simple materials and premade electronic systems. The motors, battery and control systems were purchased from preexisting inventory but were selected as they would be accurate representations of a full scale model
The frame was constructed from wood for durability and strength. The track system was custom designed and built using 3d printed parts for ease of manufacturing
Simulated Design
To accommodate for the difference in materials used for the prototype and ideal design solid works simulations were used
Stress/strain analysis were conducted on the frame and cart as a whole to show how much weight could realistically be supported by the design
The suspension system for the tracks was also a vital testing part as they had to be able to dampen any movement and support the maximum payload