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Multi-Robot Work Cell
(Collision Prevention)
Multi-Robot Work Cell
(Collision Prevention)
I designed and implemented the PLC/HMI software and electrical systems for a large-scale automated workcell integrating four robots, multiple molding presses, and auxiliary equipment. The system performs high-throughput overmolding operations, coordinating material handling, inspection, and part finishing across several interconnected subsystems.
The work cell automates the full production cycle: inserts are fed into the system, overmolded, inspected using machine vision, and either routed forward for finishing or automatically rejected. Accepted parts are trimmed and conveyed for downstream handling, enabling continuous, high-volume production (~70 second cycles, always improving).
A key engineering challenge was coordinating multiple robots operating within a shared workspace. To address this, I implemented software-enforced collision prevention cooridinated between the PLC and robot programs, ensuring safe and deterministic interaction between all robotic elements.
Additional system complexity included RFID-based tool verification to ensure correct pairing between molds, end-of-arm tooling, nests, and vision programs, as well as integrated safety systems spanning multiple machines and access points.
Outcomes:
Successfully deployed a fully integrated 4-robot automated production system
Implemented software-based collision prevention for safe multi-robot coordination
Enabled automated quality inspection and part routing using machine vision
Ensured tooling and program consistency through RFID-based verification
Integrated safety systems across presses, robots, feeders, and access points
Delivered a cost-effective solution relative to vendor-quoted alternatives
Additional Work Cells
Additional Work Cells
More information coming soon!
Automated Clip Assembly Station
Automated Clip Assembly Station
I designed a semi-automated workstation to improve consistency and efficiency in installing clips onto molded parts. The system guides the operator through a simple load-and-actuate process while verifying correct setup prior to actuation.
The operator loads clips into sensor-equipped retaining fixtures, places the part, and initiates the cycle. The system verifies clip presence before actuating a pneumatic cylinder, which drives a custom plate with compliant rubber bumpers to press the clips into place while accommodating part geometry.
To ensure safe operation, the design incorporates light curtains and fast-response pneumatic components to prevent unintended actuation during operator interaction. A machine vision system (Keyence IV-2) was later integrated to verify that clips were not pre-installed on incoming parts, adding an additional layer of quality control.
The workstation was modeled in Fusion 360 and designed using commercially available components, including pneumatic and control hardware, to enable practical fabrication and deployment.
Outcomes:
Designed a cost-effective, semi-automated solution for consistent clip installation
Integrated sensor-based verification to prevent incomplete or incorrect setups
Improved operator safety through light curtains and controlled actuation
Added machine vision to detect pre-existing clips and prevent process errors
Developed a practical, manufacturable design using off-the-shelf components
Valve Gate Controllers
Valve Gate Controllers
I designed and implemented custom valve gate control systems to retrofit older injection molding machines that lacked native support for valve gate sequencing. The solution utilized compact PLCs (AutomationDirect CLICK) with HMIs (C-more) to provide flexible, operator-configurable control over gate timing.
The systems interface directly with existing machine signals, including clamp state and screw operation, and support both time-based and position-based control strategies. For machines equipped with linear position sensors, gate sequencing can be driven by screw position, while simpler configurations rely on timed delays and durations.
The HMIs were designed to allow mold technicians to quickly configure and adjust gate behavior per job, reducing setup complexity and improving process flexibility. Variants of the system were deployed across multiple facilities, with configurations tailored to machine capabilities and process requirements.
These controllers provided a cost-effective alternative to upgrading or replacing legacy equipment, extending the usable life of existing machines while enabling more advanced molding processes.
Outcomes:
Extended functionality of legacy injection molding machines without major capital investment
Enabled flexible valve gate sequencing using both time and position based control
Provided operator-friendly HMI interfaces for rapid job setup and adjustment
Reduced tooling and upgrade costs through targeted control system retrofits
Successfully deployed across multiple machines with varying capabilities
End of Arm Tooling
End of Arm Tooling
Top-Loading
Top-Loading
Small End-of-Arm tool for a top-loading robot attached to an automated injection mold press. Removes four parts from the press and loads them into a fixture for adhesive application.
Assembled in Fusion360.
Components from Piab.
6-Axis
6-Axis
Here you'll find a simple EoA for a small 6-axis robot (UR3e, Universal Robots). While the robot has basic digital and analog I/O, what most excites me about these robots are the more advanced communications offered by the RS-485 serial communication line to the EoA. This could allow a seperate system
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