Designed and implemented state machine based architecture for motion planning, sensor fusion, localization, motion control, and low-level actuator control for an Autonomous Mobile Robot equipped with 5 axis of motion enabling movement in a 3D storage structure. Key features developed in this project were:

• Design of hierarchical state machines that converted high-level goals from the material handling system into commands all the way down to the actuator level (C++).

• Tuning of low-level stepper and servo drives, and performing/supervising their frequency domain stability analysis (Bode Plots etc.).

• Development of MIMO controller for differential drive (C++) for 3 DOF horizontal motion (including line following), 1 DOF horizontal motion (constrained horizontal motion) and 1 DOF vertical motion (this included proprietary algorithms for roll mitigation).

• Development of a novel encoder-only-feedback based wheel slip detection and mitigation algorithm (C++).

• Development of a trajectory generator (C++) for use in both high-level software used for both differential drive control as well as 2 individual motion axes.

• Development of algorithms for coordinating multi-axis motion to eliminate effects of hardware cross-coupling (C++).

• Development of analysis suite (MATLAB, bash) for baseline robot characterization for use in Preventive Maintenance, Root Cause Analysis for HW/SW failures, SQA, and HW qualification.

• Development of full state observer and sensor fusion modules (including Kalman filters) for robot centroid state, incorporating feedback from continuous updates (e.g. lines) as well as discrete structural updates, (C++).

• Signal Processing: Design of solvers, filters (EMA, debounce), hysteresis etc. (C++).

Mechanical Design of AMRs

• Chassis Design: Engineered robust and scalable chassis structures tailored for industrial warehouse environments, capable of handling up to 1,500 kg of load on the AGV.

• Technical Design Requirements: Defined and locked technical specifications, collaborating with JDM partners to ensure seamless integration and manufacturability.

• Conveyor Specification and Selection: Evaluated and selected conveyors to meet operational efficiency, load handling, and compatibility requirements.

• Designed gravity compensation techniques to reduce the physical effort required for rehabilitation tasks, enabling patients to focus on regaining motor functions without overstraining.

• Chutes and Accessory Mountings: Designed sheet metal-based chutes and mounting accessories to enable versatile and secure component integration.