The Industrial Challenge: High-Mix / Low-Volume production requires robots to adapt to parts that are never in the same position. In this project, the goal was to automate the assembly of multi-layered cylindrical components (Matrioshkas) with high dimensional variance and random orientation.
My Solution: I engineered a Vision-Centric Cell where the robot acts as the master. Instead of relying on rigid fixtures, I used Real-Time Visual Servoing to detect, align, and assemble parts on the fly.
Key Results:
The Problem: Calibrating a vision system usually requires manual grid placement, introducing human error and downtime.
The Innovation: I automated the calibration process. The robot mounts the target on its tool and autonomously maps the workspace.
Business Value: This "Self-Healing" capability means the machine can recalibrate itself after a collision or maintenance without needing a vision specialist on-site.
The Strategy: Parts arrive randomly in trays. Using standard "blob detection" isn't enough when parts overlap or touch.
The Logic: I implemented a Space-Awareness Algorithm. Before picking, the vision system checks not just the part's location, but the clearance around it for the gripper fingers. This prevents the "domino effect" of knocking over adjacent parts, a common cause of jams in bin-picking.
The Challenge: Aligning two rotating parts with +/- 22° misalignment without stopping the cycle.
The Solution: I implemented a parallel task: while the robot rotates the part, the camera triggers high-speed capture (Visual Servoing) to detect the alignment markers in real-time.
The Result: Perfect alignment achieved during the motion phase, effectively hiding the inspection time within the handling time (Zero-Cycle-Time Impact).
The Optimization: Traditional deburring moves the tool around the part (slow, complex path).
My Approach: I used One-Point Rotation. The robot holds the part and rotates it against a static tool. This simplifies the trajectory calculation to a single axis, ensuring 100% constant contact pressure and uniform finish quality.
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