This project involved the complete, end-to-end design, fabrication, and commissioning of a small-scale Flexible Manufacturing System (FMS). The system consists of a custom-designed 3DOF robotic arm and a motorized rotary indexing table.
I managed the entire project lifecycle, starting with the mechanical design and 3D modeling in SolidWorks. After client approval, I generated DXF files for sourced CNC-machined components and 3D-printed the remaining plastic parts in PLA on my own 3D printer. I then sourced all mechanical/electronic components, built the full robot, and fabricated a custom control box to operate the system.
The section shows the mechanical design of different the different parts of the system.
The mechanical system was fully modeled in SolidWorks for design verification. The 3DOF arm provides X (linear traverse), Z (vertical lift), and gripper axes. The Z-axis is driven by a NEMA stepper motor on a lead screw and guided by linear rods. The rotary table is also stepper-driven to allow for precise, indexed part presentation. A key part of the design phase was researching and sourcing the correct bearings, lead screws, and NEMA stepper motors to meet the system's load and precision requirements.
I built a custom, standalone control box to house the system's electronics. The core of the system is an Arduino Mega, which controls all axes via a CNC Shield. This shield simplifies the management of the stepper motor drivers. For the user interface, I integrated a 16x2 LCD screen with a rotary encoder. This allows the operator to select different routines and run the FMS without needing to connect a computer. I was responsible for all programming, from basic motor control to developing the full operational logic and the menu on the LCD.
Rotary Encoder with printed knob
Used CNC-shield
This section shows the skills I developed/improved working on this project.
Mechanical Design & CAD: Full system and component design from scratch in SolidWorks.
Design for Manufacturing (DFM): Generating DXF files for CNC machining and STL files for 3D printing.
Rapid Prototyping: Utilizing my own 3D printer with PLA material for part fabrication.
Mechatronic Assembly: Full physical assembly and wiring of the robot and control box.
Component Sourcing: Researching and selecting appropriate bearings, NEMA motors, and electronic components.
Electronics Integration: Designing and building a custom control box with an Arduino Mega, CNC Shield, and HMI.
Microcontroller Programming: Programming the Arduino Mega to control multiple axes and read user inputs.
Embedded UI/UX: Creating a functional user menu system using a 16x2 LCD and rotary encoder.
Client Relations: Managing a project from design proposal and approval through to final delivery.