ALFRED: Requirement-driven development of an open-source mobile manipulator for long-term plant monitoring

Tracking seasonal change in crops and forests requires observing the same plants repeatedly. Ground robots can do this at close range, and a manipulator gives their sensors more viewpoints. Yet the robots behind long-term field datasets are rarely released with their design files, and how a robot's own structure limits arm reach and occludes its sensors is seldom compared between builds. We present ALFRED, an open-source mobile manipulator built from commercially available components. It carries a six-degree-of-freedom arm, LiDAR, RGB-D cameras, RTK GNSS and an IMU on an Ackermann-steered base, all mounted on a reconfigurable aluminium strut frame, and runs containerised ROS software. It was developed through four builds against six requirements for repeated outdoor deployment: durability, modularity, repairability, sensing reach, endurance and reproducibility. Model-based analysis of the last three builds shows the usable share of the arm's reachable poses rising from 34.0% to 60.0% and then 66.1%, and ray casting shows that only the final build keeps the frame-mounted LiDAR's horizontal view clear both forwards and backwards. ALFRED completed a year of monthly forest surveys (528 traversals) without missing a scheduled collection. This was despite battery degradation, reconfiguration for another researcher's study, and the parallel development of ALFRED 2.0 for autonomous crop-row operation, with each switch between builds taking about six hours. The deployment also showed that mechanical modularity is only as dependable as the robot description that tracks it.