Rover Robot: Terrain Adaptation & Suspension Control

📌 Overview

This project implements a Rover Robot capable of traversing uneven terrain using:

• Dynamic suspension control with servo motors
• IMU (MPU6050) for pitch/roll stabilization
• ToF Sensors (VL53L5CX via TCA9548A I²C multiplexer) for terrain profiling
• ESP32 (Arduino IDE + FreeRTOS) as the controller

The system ensures stable movement over rocky or sloped surfaces by adapting suspension angles in real-time.

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⚙️ Features

• Multi-mode terrain handling:
  • Flat Mode → stiff control for smooth surfaces
  • Rocky Mode → adaptive compliance for bumpy terrain
  • Step Mode → aggressive leveling for obstacles
• PID control with limits & smooth transitions
• Automatic mode switching based on IMU + VL53L5CX sensors
• Fail-safe: stop or revert to safe posture if tipping or sensor failure is detected
• Modular FreeRTOS-based firmware for scalability

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🛠️ Hardware

• ESP32-WROOM / ESP32-S3
• MPU6050 IMU
• VL53L5CX ToF sensor(s) (via TCA9548A I²C multiplexer)
• Servos (suspension adjustment)
• Rover chassis with 4-wheel suspension

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📂 Firmware Structure

/src
  ├── images/
  |    ├──  block_diagram.svg
  |    └──  Servo_Suspension_System.jpg
  |
  ├── main.ino              # FreeRTOS task creation & system entry
  ├── config.h              # Pins & constants
  ├── imu.cpp/.h            # IMU reading (pitch/roll)
  ├── control.cpp/.h        # PID control & suspension servo outputs
  ├── modes.cpp/.h          # Terrain mode manager
  ├── vl53_manager.cpp/.h   # VL53L5CX ToF management via TCA9548A
  └── actuators.cpp/.h      # Actuators (Servo Motors) control

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                           +-----------------------------+
                           |       TCA9548A (I2C)        |
                           |      (I2C Mux @ 0x70)       |
                           +----+----+----+----+----+----+
                                |    |    |    |    |
      MPU6050 (CH0) <-----------+    |    |    |    +----> VL53_RR (CH4)
                                     |    |    +----> VL53_RL (CH3)
                                     |    +----> VL53_FR (CH2)
                                     +----> VL53_FL (CH1)

            +---------------------------------------------------------------+
            |                      ESP32 (FreeRTOS)                         |
            |                                                               |
            |                                                               |
            |  IMU Task  ---> reads MPU6050                                 |
            |  VL53 Task ---> cycles mux & reads VL53 devices               |
            |  Control Task ---> PID (pitch & roll) & Mode Manager          |
            |  Actuator Task ---> LEDC PWM outputs to servos (GPIO16..19)   |
            |  Safety Task ---> tilt detection, actuator monitoring         |
            |  Telemetry ---> Serial/Wi-Fi: pitch, roll, PID output, ToF    |            
            |                                                               |
            +---------------------------------------------------------------+

Power:
  - Battery -> Servo rail (5-7.4V)
  - Battery -> 3.3V regulator -> ESP32 + sensors

Telemetry/UI:
  - UART0 (Serial) or Wi-Fi web UI / REST endpoint for live tuning

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🚀 Getting Started

1. Clone repository:

   git clone https://github.com/<your-username>/rover-robot-suspension.git

2. Open in Arduino IDE or PlatformIO.

3. Install required libraries:

   • SparkFun VL53L5CX

   • Adafruit MPU6050

   • ESP32 board package

4. Compile & upload to ESP32.

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📊 Testing & Deployment

• Test track: gravel, sand, small steps

• Load test: measure max weight before suspension loses stability

• Telemetry: observe PID outputs, IMU angles, ToF maps

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🔮 Future Enhancements

• Machine learning for adaptive terrain classification

• LIDAR-based 3D mapping

• Remote monitoring dashboard via Wi-Fi

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📜 License

This project is licensed under the MIT License. wasarwad.raj@gmail.com