Date of Award

5-5-2025

Degree Type

Capstone Project

First Advisor

Bahram Nassersharif

Abstract

This project focuses on automating the repetitive task of loading and unloading #04 air bearings into a Haas EC-300 CNC machine at Hexagon Manufacturing Intelligence using a Universal Robots UR5e robotic arm equipped with specialized attachments. The primary objective was to eliminate the need for a machinist to perform this task every hour, thereby increasing operational efficiency and reducing manual labor. A vacuum gripper paired with a screwing mechanism was developed to allow the robot to seamlessly perform both gripping and fastening operations. A redesigned air bearing holding structure was also integrated to ensure enhanced compatibility, precision, and system reliability.

The project progressed through a structured design process, beginning with an analysis of operational constraints and customer requirements. A series of comprehensive proof-of-concept trials were conducted using a temporary end effector setup consisting of a parallel gripper and a custom-made screwing mechanism. More formalized trials were then conducted with the final designed end effector. These trials included time studies, repetition tests, and safety evaluations to ensure the system’s robustness and adherence to strict quality standards. Results from the time trials demonstrated significant reductions in manual intervention time, while repetition trials verified the system’s consistency and repeatability. Safety trials confirmed that the system operates within acceptable thresholds for human-robot interaction.

Overall, the system has successfully met all project objectives by providing a reliable, efficient, and safe automation solution. The final design not only improves productivity but also maintains the high quality requirements essential for air bearing machining. Future implementation will include improvements to the end effector, further optimizing performance and reinforcing the impact once it is fully implemented at Hexagon Manufacturing Intelligence.

Comments

Team Name: Team 18

Company Sponsor: Hexagon Manufacturing Intelligence

Sponsor Representative: Kevin Hilburn and Brian Malloy

Document Reference: URI-MCE-402-018-2025

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