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Customizing the crawler undercarriage is a comprehensive project. The core lies in ensuring that the undercarriage performance precisely matches your equipment and the application scenarios of the machine. For specific cooperation, we can systematically communicate through six aspects: application requirement analysis, core parameter calculation, structural selection, electronic control design, testing and verification, and modular design.
✅ Step 1: Clearly define the application requirements of the machine
This is the foundation of all design work. You need to be clear about:
· Application scenarios and environments: Are they in an extremely cold (-40°C) or hot open-pit mine, in a deep mine shaft, or on a muddy farmland? Different environments directly affect the selection of materials, lubricants and seals. At the same time, it is necessary to clarify whether the main task is transportation, material distribution, debris removal or the carrying of other operation modules.
· Performance indicators: The maximum load capacity, driving speed, climbing angle, obstacle clearance height and continuous working duration that need to be determined.
· Budget and maintenance: Consider the initial cost and the convenience of maintenance after long-term use.
✅ Step 2: Calculation of Core Parameters and Selection of Structure
Based on the requirements of the first step, proceed to the specific design.
1. Power system calculation: Through calculations of driving force, driving resistance, climbing resistance, etc., the required motor power and torque are determined, and accordingly, the appropriate drive motor and walking reducer models are selected. For small electric chassis, the battery capacity needs to be calculated based on the power.
2. "Four rollers and one track" selection: "Four rollers and one track" (sprocket, track rollers, top rollers, front idler, and track assembly) are the core walking components, and their cost can account for 10% of the entire machine.
- Tracks: Rubber tracks have good shock absorption and cause little damage to the ground, but their lifespan is usually about 2,000 hours; steel tracks are more durable and suitable for harsh terrains.
- Gear train: It needs to be selected based on the load-bearing capacity and working conditions. For example, the fully automatic load-bearing wheel assembly line can ensure stable quality.
✅ Step 3: Electrical and Control System Design
· Hardware: Includes the main controller, motor drive module, various communication modules (such as CAN, RS485), etc.
· Software: Develops the chassis motion control program and may integrate positioning and navigation functions (such as UWB). For multi-functional chassis, the modular design (quickly switching operation modules through aviation connectors) can enhance convenience.
✅ Step 4: Simulation and Test Validation
Before manufacturing, perform kinematic and dynamic simulations using software, and conduct finite element stress analysis on key components. After the prototype is completed, conduct on-site field tests to evaluate its actual performance.
✅ Step 5: Modularization and Customization Trends
To enhance adaptability, modular design can be considered. For instance, installing a rotating device enables the mechanical operation to rotate 360 degrees; adding a telescopic cylinder device enables the mechanical device to pass through limited spaces; installing rubber pads reduces the damage to the ground caused by the steel tracks; adjusting the number of pulley modules and drive modules to regulate the vehicle length and power; designing various platforms to facilitate the secure connection of the upper equipment.
If you could tell me the specific purpose of your custom-made crawler undercarriage (such as for agricultural transportation, special engineering, or robot platform), I can offer you more targeted selection suggestions.