Mechatronics Projects

Project Overview:

For my final-year Capstone Design course, my team collaborated with Attabotics, a Calgary-based robotics company specializing in automated storage and retrieval systems (AS/RS). We were tasked with designing a proof-of-concept actuator capable of reliably storing and retrieving heavy bins within their robotic system, while meeting strict spatial constraints.

Project Requirements:

• Compact actuator design to fit within the limited robot form factor

• High load capacity to lift bins exceeding 120 lbs

• Exploration of alternative actuator mechanisms beyond Attabotics' existing designs

• Optional integration of bin detection sensors to enhance retrieval reliability

• Development of a fully functional prototype suitable for physical testing

Key Features & Outcomes:

• Designed a spool-based telescoping actuator, inspired by surgical robotics mechanisms, but heavily modified to meet industrial load requirements

• Addressed key engineering challenges, including compactness, load handling, and integration with existing robot architecture

• Prototyped a bin detection system using an 8x8 Time-of-Flight (ToF) sensor array, demonstrating potential for closed-loop retrieval operation

• Developed multiple iterations, with the final prototype consisting of:

• Custom sheet metal components for structural integrity

• Carbon-fiber 3D printed parts for strength and weight reduction

• Full electronics integration for actuator control and sensor feedback

• A complete 100+ part assembly, fully designed and manufactured by the team

• Successfully demonstrated the actuator's functionality and sensor integration during project evaluations

Skills Demonstrated:

Mechanical design, actuator development, system integration, sensor prototyping, rapid prototyping, teamwork, and practical application of mechatronics principles.

Capstone Fair Poster

Manufactured Prototype

Project Overview:

Designed a fully 3D-printable 6 Degrees of Freedom (DOF) robot arm as a personal project to improve rapid prototyping skills and gain experience with robotics hardware and control systems.

Key Features & Outcomes:

• Hybrid Actuation: 3 NEMA-17 stepper motors and 3 servo motors for full 6-DOF movement

• Mechanical Design: Belt-driven linkages with a 6:1 gearing ratio to meet torque requirements

• Focused on improving printability, ease of assembly, and mechanical robustness

• Future plans include a custom driver board and full ROS/ROS2 integration with a proper URDF model

Skills Demonstrated:

Mechanical design, prototyping, actuator integration, gearing, and robotics software fundamentals.

This project was a small challenge in conjunction with my other project in "Hardware Section" where I created my "Pelican" general robot controller board. My hardware was intended for 2-4 DC motors with quadrature encoders so I decided to whip up a quick test platform to demonstrate the usage of my board. I decided it would also be fun to design/CAD a "as-simple" as possible robot platform in the shorted amount of time and easy to manufacturer and assemble with standard parts or easy to 3d print.

My "15 minute bot" consists of 5 printed plastic parts, 2 motors with quadrature encoders, a USB power bank, and my custom Pelican hardware board. The robot featured a castor wheel that was simple and easy to manufacture where you slot a marble in as the castor wheel to provide support for the robot to pivot.

Hoping to revise my 15 minute robot and potentially utilize it's application as a cheap, open-source, and basic "Turtle-Bot" for education and STEM purposes.

CAD Model Stage

3D Printed Prototype

For my third-year mechatronics class and amidst the pandemic, we were given generic robot car kits for our remote class. We were given various tasks to do basic control structure and logic for the robot car including driving, utilizing the ultrasonic sensor for obstacle detection, and demonstrating other introductory Arduino skills.

For a bonus task, we were challenged to attempt a PID loop to follow a wall utilizing just the ultrasonic sensor. These sensors are typically inaccurate and usually provide noisy feedback on the distance it detects. Because of this, it was quite a challenge to tune the PID loop and write robust code to have the robot follow the wall at a certain distance. This required understanding of the course content regarding control loops, but also a knowledge of real-life variances and practicality regarding choosing the feedback and effector of a control system and developing a robust loop based on the properties of the components.

Robot in 3 Days (Ri3D) is a national competition where post-secondary students across North America attempt to build a robot in only 3 days for the FIRST Robotics Challenge. In 2019 I was the Project Lead for Ri3D and organized the event for over 50 students. I was also in charge of designing the intake mechanism which utilized a 775 motor and pneumatic actuators. As Project Lead, I was also in charge of the project management and ensuring that the robot was finished in only 3 days. 

Team Photo

In 2018 I participated in the FIRST Robotics Competition on my high school team. I was in charge of sponsorship as well as certain mechanical aspects of the robot such as intake. We were very fortunate to be on the winning alliance for the Canadian Rockies Regional and qualified to participate in the world championships in Houston, Texas. We were able to represent Canada as a Canadian team at Worlds which saw over 400 teams across the world.