Structural Analysis and Topology Optimization of a Mobile Robot Chassis for STEM Education

Abstract

This study investigates the structural analysis and topology optimization of a Theo Jansen mechanism-based mobile robot chassis, developed to help primary school students learn engineering fundamentals. Finite element analyses were performed in ANSYS, including static and modal analyses, followed by topology optimization to reduce mass while preserving strength. The pre-optimization model showed 0.2597 mm deformation and 3.5248 MPa stress, whereas the optimized design had 0.4885 mm deformation and 3.7745 MPa stress. Optimization reduced mass by 37% in simulation (15.625 g to 9.8925 g) and 26.3% after 3D printing (10.31 g to 7.60 g). Modal analysis revealed six natural frequencies, used to guide motor selection and avoid resonance. Results were simplified for students through ratio, proportion, and percentage exercises, supported by visuals and models. Future work includes applying the activities to larger groups and evaluating learning outcomes using artificial neural networks and fuzzy logic.