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Surveyor Bot Design and Development (Nov 2021 - May 2024)

Skills: System Engineering, Mechanical Design, End-to-end R&D, System integration, Lab Testing, Field testing

          Solidworks, Teamcenter PLM/PDM, FEA, Fast-Prototyping, Fabrication, Machining, 3D Printing.

Role: Main contributor of mechanical design and integration, patent holder, technical program manager (TPM)

Product Site: https://www.offworld.ai/products/surveyor

In a groundbreaking project at OffWorld, our team of over 20 engineers developed a versatile surveying robot for mining applications.

 

This robot has a universal interface hollow payload bay in the center of the chassis, where multiple mining, exploration and surveying tools such as GPRs, magnetometers, LiDAR, spectrometers, etc. can be integrated in a protected manner to conduct surveys over muck piles and extreme terrain conditions both in open pit and underground environments. I was instrumental in the development of a new patented inverted tension/suspension mobility system consisting of an inverted roller secondary system and a symmetrical chassis, the robot can maintain nominal functionality even after rolling over, so it is particularly effective in diverse mining scenarios, such as navigating post-blast muck piles. Our approach involved agile, iterative design enhancements, and the prototype was validated through rigorous lab and field tests. A notable achievement was a successful deployment in a Mine Campaign, marking the first time a robot autonomously navigated a muck pile in an operational mine, demonstrating key performance indicators (KPIs).

Program milestones

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Mobility Platform design and in-action

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In this endeavor, I led the mechanical design and integration of the OffWorld Surveyor Bot from its conceptual stage. 
 
As the principal designer and CAD manager, I delivered the complete drawing package for the first unit within four months. Subsequently, I transitioned the SolidWorks-created digital twin into the Siemens Teamcenter environment to streamline the Product Lifecycle Management (PLM) processes. I supervised the fabrication of over 100 custom parts for the initial Surveyor Bot unit, including collaborating with local machine shops to manufacture traditional metal parts, utilizing in-house equipment for 3D-printed components, and modifications of Commercial Off-The-Shelf (COTS) parts. I personally machined and modified more than 10 parts in-house, balancing tight schedules with cost reduction.

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In-house fabrication

Milling EE boxes

Machine shop visit

machine shop

As the integration lead, I also built an integration schedule, following which the first round of mechanical assembly of the Surveyor Bot was completed within two weeks upon receiving all the parts. My role extended to supporting the electrical engineering team for full robot integration and further assisting in-lab unit testing, subsystem & system-level testing, and field testing campaigns, both in Southern California and at international customer sites. 

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Lab integration

Lab assembly

Local quarry testing

Local quarry testing

In late 2023, I took on the role of Technical Program Manager (TPM) of the Surveyor program. In this capacity, I was in charge of organizing the development work for the next iteration of the robot, focusing on enhancements and multi-unit production.

Dev team with Surveyor

team photo (me sitting on bot)
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