Includes bibliographical references.Self-Reconfigurable Modular Robots are robotic systems consisting of a number of self-contained modules that can autonomously interconnect in different positions and orientations thereby varying the shape and size of the overall modular robot. This ground breaking capability is what in theory, makes self-reconfigurable modular robots more suitable for use in the navigation of unknown or unstructured environments. Here, they are required to reconfigure into different forms so as to optimise their navigation capabilities, a feat that is rendered impossible in conventional specialised robots that lack reconfiguration capabilities. However, the frequent development and use of self-reconfigurable modular robots in everyday robotic navigation applications is significantly hampered by the increased difficulty and overall cost of production of constituent robotic modules. One major contributor to this is the difficulty of designing suitably robust and reliable docking mechanisms between individual robotic modules. Such mechanisms are required to be mechanically stable involving a robust coupling mechanism, and to facilitate reliable inter-module power sharing and communication. This dissertation therefore proposes that the design and development of a functional low cost self-reconfigurable modular robot is indeed achievable by optimising and simplifying the design of a robust and reliable autonomous docking mechanism. In this study, we design and develop such a modular robot, whose constituent robotic modules are fitted with specialised docking connectors that utilise an optimised docking mechanism. This modular robot, its robotic modules and their connectors are then thoroughly tested for accuracy in mobility, electrical and structural stability, inter-module communication and power transfer, self-assembly, self-reconfiguration and self-healing, among others. The outcome of these testing procedures proved that it is indeed possible to optimise the docking mechanisms of self-reconfigurable modular robots, thereby enabling the modular robot to more easily exhibit efficient self-reconfiguration, self-assembly and self-healing behaviours. This study however showed that the type, shape, functionality and structure of electrical contacts used within the docking connectors for inter-module signal transfer and communication play a major role in enabling efficient self-assembly, self-reconfiguration and self-healing behaviours. Smooth spring loaded metallic electrical contacts incorporated into the docking connector design are recommended. This study also highlights the importance of closed loop control in the locomotion of constituent robotic modules, especially prior to docking. The open loop controlled locomotion optimisations used in this project were not as accurate as was initially expected, making self-assembly rather inaccurate and inconsistent. It is hoped that the outcomes of this research will serve to improve the docking mechanisms of self-reconfigurable modular robots thereby improving their functionality and pave the way for future large scale use of these robots in real world applications
