Design and Performance Evaluation of PLA-based Umbrella Wheels for Stair-Climbing Robotic Applications

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Year : 2026 | Volume : 14 | 03 | Page :
    By

    Penta Srinivas,

  • G.Yedukondalu,

  • Bondili Harshith Singh,

  1. Research Scholar, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, GreenFileds, Vaddeswaram, Andhra Pradesh, India
  2. Associate Professor, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, GreenFileds, Vaddeswaram, Andhra Pradesh, India
  3. B. Tech Student, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Green Fileds, Vaddeswaram, Andhra Pradesh, India

Abstract

Staircase climbing robots require a complex design capable of navigating various stair configurations. A crucial component of such robots is the wheel mechanism. This paper focuses on the umbrella wheel mechanism and its application in staircase climbing robots. In this study, a PLA–based umbrella wheel structure is developed and fabricated using fused deposition modeling (FDM) for application in stair-climbing robots. The umbrella wheel geometry enables transformation from a circular rolling configuration on flat surfaces to an expanded segmented profile for step climbing. A mathematical model describing the kinematics of the four-segment umbrella wheel mechanism is formulated to predict segment positions, velocities, and accelerations during operation. The kinematic model was compared with ADAMS multibody simulation results and qualitatively examined using a 3D-printed prototype during stair-climbing tests. Structural performance of the 3D printed PLA-based wheel is evaluated using finite element analysis in ANSYS to determine stress distribution under stair-climbing and flat-surface loading conditions. Simulation results reveal that peak von Mises stresses occur near the junctions of long and short arms, while remaining within safe limits for the selected PLA-based material. The combined results show that the 3D printed PLA-based umbrella wheel can achieve sufficient mechanical strength, stable deformation behavior, and good step engagement, which can be used for the purpose of stair climbing. The proposed approach identifies the potential of additively manufactured structures in lightweight, customizable and functionally adaptive robotic mobility systems.

Keywords: Umbrella wheel mechanism, Staircase, Climbing robot, Mathematical Modelling, ADAMS, Structural Analysis, 3D Printer, PLA.

How to cite this article:
Penta Srinivas, G.Yedukondalu, Bondili Harshith Singh. Design and Performance Evaluation of PLA-based Umbrella Wheels for Stair-Climbing Robotic Applications. Journal of Polymer & Composites. 2026; 14(03):-.
How to cite this URL:
Penta Srinivas, G.Yedukondalu, Bondili Harshith Singh. Design and Performance Evaluation of PLA-based Umbrella Wheels for Stair-Climbing Robotic Applications. Journal of Polymer & Composites. 2026; 14(03):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=243881


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Ahead of Print Subscription Review Article
Volume 14
03
Received 13/04/2026
Accepted 23/04/2026
Published 14/05/2026
Publication Time 31 Days
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