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Designed and fabricated a remote-controlled manipulation device using SolidWorks to transport objects of varying geometries with high precision. I optimized the mechanical linkages and gripping claw for structural integrity and component clearance, integrating microcontrollers to ensure reliable movement. This project showcases my ability to build tactile, interactive hardware that accurately and safely engages with its physical environment.
Developed as part of a semester-long Design-Build-Test (DBT) curriculum at the University of Houston, this project required engineering a remote-controlled device to transport objects of varying geometries (markers, wooden cones, and ping pong balls) into tiered scoring zones. The core engineering challenge was navigating strict volume and base-area constraints while actively optimizing the design to minimize overall assembly weight and maximize task-completion speed.
During the initial brainstorming phase, we evaluated several distinct approaches, including an aerial drone with a suspended claw and a stationary telescoping crane. After a feasibility review, the team selected my hand-drawn linkage concept (pictured below). To validate the mechanism before physical fabrication, I rapidly translated this sketch into a preliminary SolidWorks assembly to simulate the kinematics and verify component clearances.
Rough Sketch of Possible Forces and Dimensions to Reach the Furthest Zone
A CAD of the Armcar Fully Extended with the Claws Closed
Raised and Claws Open
To ensure reliable manipulation of all target objects, I imported their exact geometries into SolidWorks to virtually test and refine the gripper mechanism as seen below. The claw was redesigned to securely interface with the highly variable shapes. During physical fabrication, I integrated elastic elements at the contact points to maximize gripping friction. Additionally, I engineered a passive tensioning system within the claw assembly to maintain clamping force and secure the object, acting as a fail-safe when the servos were unpowered.
Redesigned Claw with Ping Pong Ball
Redesigned Claw with Wooden Cone
Verifying Claw Dimensions and Servo Horn Connection
Initial Assembly of the Armcar MK1
Initial Assembly Cont.
MK2 Prototype Completed
This device was executed by a multi-disciplinary team. While my teammates managed the drivetrain, telemetry, and microcontroller integration, I led the mechanical design and fabrication of the servo-actuated manipulator arm and claw. To the left is our initial physical prototype, and the videos below provide functional demonstrations validating the kinematics of the claw and locomotion systems in real-time.
To reduce overall mechanical complexity, I refined the initial dual-servo linkage into a single-pivot arm. A kinematic review revealed that the secondary arm servo was redundant; the operational requirements could be fully satisfied using only two active degrees of freedom: one actuator to control the arm's elevation angle and a second to drive the claw.
Armcar Movement Control Test.mp4Locomotion Testing
Armcar Claw Test Vid.mp4Claw Testing
To maximize the payload-to-weight ratio, I selected balsa wood for the primary arm linkage, as it offered a lower density than the alternative 5%-infill PLA. The actuators were secured to the arm using custom 3D-printed PLA housings. To optimize the end-effector, I reinforced the claw geometry with structural ribbing to maintain rigidity under the load of the elastics. Locomotion is driven by DC motors via H-bridge controllers, utilizing 3D-printed wheels fitted with high-friction elastic treading. The system is teleoperated using an RF transceiver communicating with an onboard Arduino Uno R3. Finally, a rear steel caster was integrated to enable zero-radius pivoting while providing essential counterweight ballast, and a foam plow was mounted to the front chassis to manipulate ground-level objects.
Armcar MK2 Testing
Armcar MK3 Final Full Assembly within Constraining Transport Box
Pictured below is the finalized SolidWorks assembly alongside the fully integrated physical prototype presented at the final design review. The accompanying media demonstrates the device's operational deployment during the wooden cone testing trial. Validating our mechanical design, the system successfully executed a multi-object retrieval—securing a dual-cone payload—and navigated the course to deposit them in the maximum-distance tier, achieving a top-tier performance score.
Labeled SolidWorks CAD Render of the Armcar MK3
Sideview of the Armcar MK3 Full Assembly
Armcar MK4 Device during final testing video.mp4While the manipulator successfully met all spatial and performance constraints, active testing revealed areas for future optimization. In a second iteration, I would transition the primary linkage material from balsa wood to a carbon fiber composite to further maximize the strength-to-weight ratio without sacrificing rigidity. Additionally, upgrading the control system from an Arduino to a more robust, industrial-grade microcontroller would reduce telemetry latency. Ultimately, this project served as a comprehensive, hands-on application of kinematic design, mechanical fabrication, and mechatronic integration.
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