Optimization of Wheel Design for PLC-controlled Four-wheel Drive Systems

Abstract

Wheeled mobile robots (WMRs) are extensively deployed across industrial, autonomous, and defense sectors owing to their high mechanical efficiency and terrain mobility. The operational performance of WMRs is critically dependent on the design of wheel profiles; however, conventional design approaches relying on iterative trial-and-error methods are both time-intensive and suboptimal in accuracy. This study presents a systematic, statistically-driven methodology for optimizing wheel profiles in four-wheel drive WMR systems to enhance traction, stability, and energy efficiency. Response surface methodology (RSM) is applied to define and analyze key design parameters, enabling the construction of accurate predictive models for system performance. Computer-aided design (CAD) tools are employed to develop detailed three-dimensional models of the chassis, wheel assembly, and drive components, while MATLAB-based simulations validate the dynamic behavior of the drive system under varying operational conditions. A programmable logic controller (PLC)-based control architecture is integrated to achieve precise motor coordination and adaptive terrain response. The optimized system demonstrates measurable improvements in traction, energy consumption, and terrain adaptability compared to conventional configurations. This approach significantly reduces design development time and provides a robust, scalable solution for high-performance WMR applications.