Goal: Design and build an automated fabrication cell, cabable of creating customized short-run products with an easy-to-use user interface.
Creation of the workcell started with customer and stakeholder interviews, in order to determine the needs. From these early interviews, we discovered that quality was of utmost importance, followed next by cost, then lastly by speed.
Following this, the workcell was designed with a foremost focus on reliability and repeatability. We focused on the manufacturing of cork coasters, as it showcased the potential of the workcell concept, while working within the restrictive time and budget constraints of the project.
The workcell was creating using three dexArm robot arms- relatively low-cost 3-DOF robotic manipulators. The limitations in the accuracy (1mm) and degrees of freedom were key limitations which guided much of the design of the project.
Key design tasks included the layout and assembly of a modular, rigid base to mount arms and alignment jigs, reverse-engineering provided end effects to create custom attachments, and the improvements of the pre-exisitng laser cutter enclosure to enhance safety and reliability.
Skills: Mechanical design, mechatronic system integration, SolidWorks 3D modeling and simulation, Python programming, rapid prototyping, manufacturing process optimization, precision automation, Arduino programming, sensor integration, customer-driven design iteration, teamwork, and creative problem-solving.
Goal: Design a fully-functional arcade machine that uses mechanical principles blended with mechatronic systems to create a fun and engaging user experience.
Prior to construction, the entire machine chasis, alongside all of its electronics, were modeled and assembled virtually in Solidworks. This initial time investment proved to be incredibly valuable, as issues caught and resolved during the initial design helped to greatly streamline the manufacturing process.
Our unique take on the penny arcade was to add a prize-coin dispenser. The coin was designed to function as both a visually-appealing haptic-fidget toy and an easy-to-store keychain. The dispenser, as seen in the fourth image, stored the coins in a vertically-stacked magazine, allowing for a 32-coin capacity.
All of the functionality of the machine, including the coin reader and the prize dispenser, were controlled by an Arduino MEGA microcontroller.
Skills: Mechanical design, mechatronic system integration, Onshape 3D modeling, virtual assembly and simulation, manufacturing process optimization, Arduino programming, microcontroller-based system control, prototyping, creative problem-solving, haptic design, and teamwork.
Goal: Achieve hybrid-force control for a simulated 2DOF robotic manipulator, with support for non-planar surfaces
Simulations were performed in MATLAB SIMULINK, using the Robotics Toolbox for Matlab by Peter I. Corke.
The first photo shows an example trajectory of the 2DOF arm with pure dynamic control. The second photo is the desired vs. actual X-position of the arm, with a sinusoidal position command. The final photo is the Simulink workspace for the final algorithm, with switching matrices and force control implemented.
Skills: Hybrid-force control implementation, MATLAB Simulink simulations, Robotics Toolbox, 2DOF robotic manipulator trajectory optimization, dynamic control systems, switching matrix design, non-planar surface interaction modeling, prototyping simulation algorithms, technical documentation, algorithm analysis
Goal: Manufacture 300 laser engraved, light-up acrylic displays, with tight time constraints and high expectations for quality.
As part of an initiative to bring more manufacturing capabilities to the university's maker space, a commission was accepted to manufacture 200 acrylic signs, to be handed out as employee gifts at MAXAR.
Quality expectations were extremely high, given that these gifts were to represent the company. This offered unique challenges, due to the tight timeframe and lack of prior SOP's for manufacturing.
As an example, a miscommunication between parties led to a disconnect in the actual vs. expected quality, leading to an initial rejection rate upwards of 90%. After the implementation of new manufacturing procedures, refurbishment, and packaging, this rejection rate was brought down to 4%.
Skills: Communication, rapid prototyping, project management, teamwork, adaptability, quality control, graphic design, material selection, manufacturing process optimization, standard operating procedures (SOP) development.