Mechanical design for an autonomous robot built for the National Engineering Robotics Contest (NERC) 2024, one of Pakistan’s most prestigious robotics competitions. The design focused on modularity, weight optimization, and integration with sensors and electronics to support autonomous navigation, obstacle avoidance, and object manipulation.
- Year: 2024
- Industry: Agricultural Robotics
- Client: University (NERC entry)
- Duration: 5 months
The competition required designing a robot capable of:
- Navigating autonomously across dynamic tracks
- Avoiding obstacles in real-time
- Performing object manipulation & task-specific actions
- Operating reliably within strict arena dimensions & limited time The challenge was to create a lightweight, robust, and modular chassis that could house the control hardware, sensors, and actuation mechanisms without sacrificing balance or performance.
- Designed in SOLIDWORKS for modularity & rapid assembly
- Included four motor mounts, sensor brackets, sliding payload trays
- Aluminum frame construction with <5 kg weight cap
- Balanced center of mass within 15 cm radius of geometric center
- Performed stress analysis on load-bearing joints to prevent failure under rapid maneuvers
- Lightweight design iterations reduced overall weight by 15%
- Mounting for ultrasonic sensors, IR detectors, and line-following modules
- Built-in wiring channels & protective housings for electronics
- Integrated servo-actuated arm for precise gripping and object manipulation
- Worked with 2 software engineers and 2 electronics engineers
- Ensured mechanical layouts aligned with programming logic and electrical constraints
- Actively participated in iterative testing cycles, detecting and fixing mechanical–electrical mismatches
🥇 Best Design at NERC 2024 — recognized for modularity, mechanical reliability, and innovation among national teams.
Completed 100% of the track, including:
- Complex turns
- Ramp climbing
- Object drop zones
- Achieved error-free mechanical performance over 5 trial rounds and final competition run
- 15% weight reduction → improved speed & stability
- Tool-less assembly for 80% of components → rapid maintenance in competition
- High modularity → major components detachable within 5 minutes
- CAD: SOLIDWORKS (chassis, mounts, payload modules)
- Analysis: Static stress analysis of joints and frames
- Prototyping: Aluminum + 3D-printed brackets for rapid iteration
- Testing: Multi-round trials under simulated arena conditions
This project delivered a robust, competition-tested mechanical platform that balanced speed, durability, and modularity.
- Hands-on mechatronics system design under high-pressure conditions
Iterative prototyping and real-time problem solving
Strengthened team collaboration & leadership in a multidisciplinary setup