Our Complex Integrations team has iterated on a previous custom integration using our Warthog unmanned ground vehicle and OutdoorNAV autonomy software. While we retained many of the key features from the earlier design, the customer requested the robot to be water resistant and easier to service.
Let’s walk through the improvements our team made on this custom integration and explore how these can shape future AMR designs.
Reflecting on the Previous Version
Before diving into the upgrades, the previous iteration of this integration that was already equipped with an impressive array of payloads and sensors, including:
- Two heavy-duty UR16e robotic manipulators
- Two UR teach pendants with custom holding brackets
- Two RealSense depth cameras for arm positioning mapping
- Three Azure Kinect cameras for enhanced perception
- Ultra-wideband positioning system for accurate localization
- 12 ultrasonic sensors for obstacle detection
- Industrial-grade computer with GPU for heavy-duty processing
While this setup was functional and powerful, there was room for improvement in areas like weather resistance, hardware accessibility, and overall performance optimization.
Key Upgrades in the New Version
In this iteration, we focused on increasing operational efficiency, durability, and ease of maintenance, all while ensuring that the robot meets the customer’s specific needs.
Optimized Payload and Sensor Configuration
To support payload manipulation and retrieval, we mounted both robotic arms on the left side of the vehicle, alongside key sensors such as Azure Kinect cameras and a RealSense camera.
Each Azure Kinect camera is paired with its own dedicated Intel NUC computer, which is networked to the main industrial computer, now equipped with a Quadro RTX-A4000 graphics card and 11th Gen Intel i7 processor for superior computational power. We also installed two 20,000 lumen light bars to provide ample illumination for both the cameras and the robotic arms during operation.
Enhanced Obstacle Avoidance
The previous version relied on a single 3D LiDAR sensor with a 360-degree field of view. In the new version, two 2D LiDAR sensors were added on opposing corners of the vehicle, eliminating the blind spots and extending obstacle avoidance capabilities along the edge of the vehicle.
Improved Mobility and Stability
While the previous Warthog design used all-terrain tires, turf tires were chosen this time for smoother, more efficient turning on hard ground where this AMR will primarily operate. Turf tires also offer a wider inflation pressure range which helps with suspension fine tuning. We added custom counterweights to balance the robotic arms, preventing side-to-side shifts when the arms are fully extended. The previous design utilized standard gym-style weights, our team designed a sleeker, more compact counterweight system, which offers both style and stability.
Water Resistant and Serviceable Bulkhead
The most exciting upgrade is the serviceable and water resistant bulkhead. This new bulkhead was designed with rugged environments in mind, ensuring the Warthog can operate in all weather conditions without exposing its internal components to the elements. The bulkhead features dual side hatches with custom sliding drawers, providing easy access to the computer and power electronics for maintenance or upgrades.
Additionally, at the customer’s request, the mass and volume of the support structure was reduced for the arms and counterweights, which not only cuts down on material costs but also improves the overall efficiency of the robot.
We also leveraged 3D printing in this build, producing over 20 custom parts. This approach allows for rapid prototyping, cost-effective customization, and easy upgrades—further reducing the lead time for future iterations.
Looking Ahead
This custom Warthog integration exemplifies our commitment to continuous improvement. By listening to customer feedback and challenging the norm of design, we developed a more robust, capable, and user-friendly robot.
To learn more about our platforms, custom integrations, or to discuss how we can tailor a solution for your specific needs, don’t hesitate to contact our team. Check out the sensors and payloads integrated on this project at the Components Store.