Automatic Sandbag Feeding System
Project Overview
Developed a bag feeding subsystem for an automatic sandbag filling machine by Brigade Automation (BaggerBot). Exceeded project sponsor specifications by achieving 220% increase in speed and 95% reliability.
What?
Designed, fabricated, and optimized an automatic bag feeding system.
Led a team of 7 and communicated with sponsor.
Utilized design matrix, risk assessment, and over 50 performance analysis trials to optimize system.
How?
Designed within SolidWorks to create and design 3 prototypes.
Coded C++ (Arduino) and Python (Adafruit nRF52840 - initial prototype) to automate the entire process using a state machine model.
Introduced pneumatics and AK60-6 actuator (CAN/UART protocol) to achieve high speeds.
Utilized Unistrut and flux core welded steel tubing to achieve rigidity, robustness and reliability.
Results
Improved speed from 3.75 bags/min to 12 bags/min (220% speed increase compared to previous 4 iterations).
Improved reliability (sucess rate) from 38% to 95% (compared from test trial 1 to trial 35).
Successfully designed a reloadable cassette capable of holding 600 sandbags at a time, reducing BaggerBot downtime during operation.
Designed and built a frame capable of interfacing with the BaggerBot to achieve full automation.
Created an electronic and pneumatic control system, within weather resistant enclosures, for rough environments.
Brigade Automation & San Jose State University
This Automatic Sandbag Feeding System was my two-semester senior project for my B.S. in Mechanical Engineering. Special thank you to Brigade Automation (BaggerBot - Tom and Ginger Burns) for sponsoring the project and San Jose State University (SJSU) for the opportunity.
Electronic/Pneumatic Components
Arduino Uno (C++)
AK60-6 Motor (UART/CAN Protocol)
CAN-BUS Arduino Shield
x4 Pneumatic Linear Actuators
x4 Venturi Vacuum Generators
x3 5/2 Solenoids
x2 2/2 Solenoids
x5 5V Relays
24V Power Supply
DC-DC Converter
x1 Limit Switch
x1 Toggle
CAD (SolidWorks) Process
Initial Project Designs
Mid-Project Designs
Final Project Designs
Prototype Fabrication
Initial (Wooden) Prototype
Mid-Fabrication Process
Final (Unistrut + Steel) Prototype
C++ Code (Arduino Sketch)
State Machine Diagram
Circuit Diagram
Block Diagram
Design Decision Matrix
Risk Matrix
Potential Future Work
Integrate subsystem onto BaggerBot
Adjust Unistrut as needed
Convert Arduino into programmable logic controller (PLC) for increase robustness and industrial capabilities
Explore machine vibrations and potential long-term wear onto components
Switch mechanical relays to solid state relays
Consider dampening linear actuation to reduce vibration
Design for manufacturability
Consider alternate materials other than Unistrut
Redesign custom fabricated prototype components to be manufactured easily and at lower costs