🚀 Industrial AMR Project - Power System Design

This repository documents the power system design and implementation for our industrial Autonomous Mobile Robot (AMR) project.
The AMR is designed to carry a 5 kg payload (total mass 25 kg) and navigate autonomously using SLAM with a Jetson Nano and LiDAR.

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🛠️ My Contribution

I primarily worked on:

• Performing detailed torque and power calculations.
• Designing the complete power distribution system.
• Selecting and integrating DC-DC converters (boost & buck) to meet system demands.

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⚙️ Motor & Motion System

Component	Model/Spec
Motor	24HS40-5004D-E1000 (4.0 Nm Closed-loop Stepper)
Driver	CL57T-V41
Gearbox	EG24-G10
Wheel Diameter	12.5 cm
Max Speed	0.6 m/s
Acceleration	0.6 m/s²

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📊 Torque & Power Calculations

🔩 Force & Torque

• Rolling friction force:

F_friction = μ * M * g = 0.02 * 25 * 9.81 ≈ 4.9 N

• Acceleration force: F_acceleration = M * a = 25 * 0.6 = 15 N

• Torque at constant velocity: Torque = (4.9 * 0.0625) / 2 ≈ 0.153 Nm

• Torque during acceleration:
  Torque = ( (15 + 4.9) * 0.0625 ) / 2 ≈ 0.62 Nm

⚡ Electrical Power

Component	Voltage	Current	Power
Motors	24 V	4 A	92 W
LiDAR	5 V	0.5 A	2.5 W
Jetson Nano	5 V	2 A	10 W

• Mapping operation:
  Total current ≈ 6.5 A, Total power ≈ 105 W

• Normal operation (~20% accel):
  Total current ≈ 3.5 A, Total power ≈ 49 W

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🔌 Power Distribution & Conversion

⚡ Power Distribution

We used a Power Distribution Board (PDB) 60A XT30 to safely distribute power.

Power Distribution Board Product

🚀 DC-DC Converters

• Boost converter to power motors (22.2V → 36V).
• Boost Converter
• Buck converter to supply Jetson Nano & LiDAR (22.2V → 5V).
• Buck Converter

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🔋 Battery & BMS

🔥 Battery Pack

Specification	Value
Type	Li-ion 6S (22.2V nominal)
Capacity	5 Ah
Max Discharge Current	~50 A (10C burst)

🧠 BMS: JK-JBD4A8S4P

Feature	Value
Cells Supported	4S–8S Li-ion/LiFePO4
Max Charging Current	Configurable, typical ~20 A
Balancing Current	~1.5 A active balancing
Communication	UART/Bluetooth App

✅ Functions:

• Cell balancing (during charging & standby)
• Overcharge & overdischarge protection
• Overcurrent & short circuit protection
• Bluetooth app for live cell voltages, current, cycle data.

📖 JK BMS Manual

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🔌 Battery Charging Process

We used the iMAX B6 Smart Balance Charger for charging our 6S Li-ion battery safely.

⚠️ Safety Notes

• Select correct battery type.
• Always use Balance Charge mode.
• Never leave charging battery unattended.
• Use a fireproof charging bag if possible.

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🪫 Charging Steps (with iMAX B6)

1. Connect Battery and Balance Lead

2. Power On Charger

3. Select Li-ion Balance Mode
   Navigate: Li-ion BATT → Li-ion BALANCE

4. Set Parameters

   • Battery Type: Li-ion
   • Cell Count: 6S
   • Voltage: 21.6V
   • Current: 0.5C (max)

5. Start Charging

   • Hold ENTER to start.
   • Confirm cell count and press again.

6. Monitor the Charging Process

   • Total voltage should reach < 25.2V
   • Check individual cell voltages
     

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🔋 Charging Profile Summary

Setting	Value
Battery Type	Li-ion (6S)
Max Voltage	25.2 V
Charge Current	< 0.5 C
Mode	Li-ion Balance

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📚 References & Calculations

• Rolling friction (Engineering Toolbox)
• Stepper motor torque guide (Portescap)
• Voltage & current impact on stepper motors (Mechtex)

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📝 Acknowledgments

This work was completed as part of a team project for building an industrial-grade AMR with SLAM.
My primary responsibility was designing the complete power system, performing electrical & torque analysis, and integrating converters and distribution hardware.

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📷 Future Work

✅ Add wiring diagrams & power schematics
✅ Include BOM (Bill of Materials)
✅ Upload photos of actual power setup on the robot

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✨ Thanks for checking out this project!

Feel free to fork, open issues, or contribute!