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cot-uexkhyro.com

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Share videos and pictures of your project here to help Prof. Socarras and I keep up to date with your progress. We can also help with troubleshooting.

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This is the live version of the report. At any given moment it may contain some TODOs for us to fill in. Clean snapshots will be submitted through Canvas or Padlet

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Name: Josué A. Bouchard

Email: jbouchard6@mail.valenciacollege.edu

Name: Adriano Mena Duque de Estrada

Email: amenaduquedeestra@mail.valenciacollege.edu

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Specifications

All components selected for commercial availability, low cost, and university lab compatibility.

Mechanical Structure

Robotic Arm: 4-DOF desktop robotic arm frame (e.g., 3D-printed or acrylic kit)

DOF 1 — Base rotation (Z-axis, horizontal swing): positions arm between input conveyor, wax bath, and output conveyor

DOF 2 — Shoulder joint (vertical lift): lifts and lowers arm

DOF 3 — Elbow joint (reach extension): extends arm over conveyor or bath

DOF 4 — Gripper open/close: actuates end effector

4pcs 600mm T Slot 2020 Aluminum Extrusion European Standard Anodized Linear Rail for 3D Printer Parts and CNC DIY Black(23.6inch)

Actuation

Shoulder & Elbow Joints (dip axis): NEMA 17 Stepper Motor (e.g., 17HS4401, 1.7A, 40 Ncm holding torque)

Used for the vertical dip axis where precise depth control is critical

Step resolution: 1.8°/step (200 steps/rev); microstepped to 1/16 via driver for finer depth increments

Each step at 1/16 microstepping ≈ 0.001° of joint rotation → sub-mm depth resolution at typical arm link lengths

TB6600 stepper driver — 9–40 V input, up to 4 A output current, DIP-switch microstepping selection; one driver per stepper axis

Base Rotation Joint: MG996R Metal Gear Servo Motor

Torque: 9.4 kg·cm (4.8V) — sufficient for horizontal swing of arm + piece

Speed: 0.17 s/60°

PWM control via Arduino

Gripper: DS3225MG 25 kg·cm Waterproof Digital Servo

Waterproof rating — critical for wax bath proximity environment (splash, vapor, drips)

Metal gear, coreless motor — high durability for repetitive open/close cycles

Operating voltage: 4.8–6.8 V; Stall torque: 25 kg·cm at 6.8 V

PWM control: 500–2500 µs pulse width, 50–330 Hz

Sensing

Piece Detection (Input Conveyor): E18-D80NK IR Proximity Sensor

Modulated IR output — immune to ambient light and sunlight interference

Adjustable detection range: 3–80 cm (set via trim screw)

Output: NPN open-collector digital (active LOW on detection)

Supply: 5 V DC; interface directly to Arduino digital pin with INPUT_PULLUP

Piece Detection (Output Conveyor / Placement Confirm): Second E18-D80NK — confirms successful placement and signals conveyor advance

Dip Depth Feedback: Stepper step count (primary) — depth is derived from step count with a known steps-per-mm conversion; no additional encoder required for PoC

Optional upgrade: AS5600 magnetic rotary encoder on shoulder joint shaft for closed-loop position verification (12-bit, I2C, 0.0879°/LSB resolution)

Gripper State: Microswitch (e.g., Omron SS-5GL) — mounted inside gripper jaw to confirm full close contact with piece; prevents false "pick success" when gripper closes on empty conveyor (fault R12)

Control

Main Controller: Arduino Mega 2560

Selected over Nano/Uno for additional UART ports (logging + display), more digital I/O (multiple sensors, drivers, indicators), and hardware timer channels for servo PWM

Runs the main state machine: IDLE → DETECT → PICK → TRANSPORT → DIP → HOLD → RETRIEVE → DRIP → PLACE → LOG → IDLE

PID loop executes in software (Arduino PID Library by Brett Beauregard) at 50 Hz update rate, regulating dip descent speed based on step count vs. target depth profile

Serial output at 115200 baud for debugging

Servo Driver: PCA9685 16-Channel PWM Driver (I2C, 0x40)

Offloads PWM generation for MG996R (base) and DS3225MG (gripper) from Arduino

12-bit resolution per channel

Stepper Drivers: 2× TB6600

One per stepper (shoulder, elbow)

DIR/STEP/EN signals from Arduino Mega digital pins

Input voltage: 12–24 V DC from bench supply

Data Logging & Display

SD Card Module (SPI) — logs cycle data (cycle #, dip depth, hold time, dip speed, fault code) to a .CSV file on a standard microSD card

SPI interface: CS, MOSI, MISO, SCK → Arduino Mega SPI pins

0.96" OLED Display (SSD1306, I2C, 0x3C) — shows current state, cycle count, last dip parameters, and active fault codes

Status LEDs (×3):

Green — system READY / cycle running normally

Yellow — DRIP / WAIT state

Red — FAULT condition active

Power Supply

12V / 5A DC bench power supply — powers stepper drivers (12V rail) and servos via LM2596 buck converter (5V/3A regulated output)

LM2596 Buck Converter Module — steps 12V down to 5–6V for servo and logic power

Communication paths:

E18-D80NK sensors → Arduino Mega (digital GPIO, NPN active-LOW)

Gripper microswitch → Arduino Mega (digital GPIO)

Arduino Mega → 2× TB6600 (DIR + STEP + EN signals, digital GPIO)

TB6600 → NEMA 17 steppers (bipolar stepper phases A+/A−/B+/B−)

Arduino Mega ↔ PCA9685 (I2C, 0x40)

PCA9685 → MG996R (PWM) + DS3225MG (PWM)

Arduino Mega ↔ SSD1306 OLED (I2C, 0x3C)

Arduino Mega ↔ SD card module (SPI)

Arduino Mega → Status LEDs (GPIO digital out through resistors)

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As a team, develop at least THREE project objectives. You can work out those objectives here. Objectives should follow SMART guidelines.

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Work out your project ideas, title, and description here. Use these prompts for guidance.

Problem Statement: What problem does the project solve?

Motivation: Why is this project important or useful?

Project Description: Provide a brief overview of the proposed project.

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This is a place for team members to discuss ideas, issues, ask questions, and communicate with faculty facilitators. Please be respectful and practice professional engagement.

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Identify your project's major tasks to create a plan and timeline.

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This is an area to keep track of and share your research (articles, videos, etc) with each other.

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Identify possible risks, safety issues, and constraints

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Identify possible risks, safety issues, and constraints

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Work through issues with the project proposal that could create risk, safety issues, deadline issues, etc.

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Identify technologies that may be involved in your project

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Identify technologies that may be involved in your project

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Use APA 7 reference citations. Everything you use for the final proposal needs a reference (papers, articles, videos, websites, etc). I recommend using this website, Free APA Citation Generator [Updated for 2026], to help generate the citations.

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Generate citations in APA format quickly and automatically, with MyBib!

🤔 What is an APA Citation Generator?

An APA citation generator is a software tool that will automatically format academic citations in the American Psychological Association (APA) style.

It will usually request vital details about a source -- like the authors, title, and publish date -- and will output these details with the correct punctuation and layout required by the official APA style guide.

Formatted citations created by a generator can be copied into the bibliography of an academic paper as a way to give credit to the sources referenced in the main body of the paper.

👩‍🎓 Who uses an APA Citation Generator?

College-level and post-graduate students are most likely to use an APA citation generator, because APA style is the most favored style at these learning levels. Before college, in middle and high school, MLA style is more likely to be used. In other parts of the world styles such as Harvard (UK and Australia) and DIN 1505 (Europe) are used more often.

🙌 Why should I use a Citation Generator?

Like almost every other citation style, APA style can be cryptic and hard to understand when formatting citations. Citations can take an unreasonable amount of time to format manually, and it is easy to accidentally include errors. By using a citation generator to do this work you will:

Save a considerable amount of time

Ensure that your citations are consistent and formatted correctly

Be rewarded with a higher grade

In academia, bibliographies are graded on their accuracy against the official APA rulebook, so it is important for students to ensure their citations are formatted correctly. Special attention should also be given to ensure the entire document (including main body) is structured according to the APA guidelines. Our complete APA format guide has everything you need know to make sure you get it right (including examples and diagrams).

⚙️ How do I use MyBib's APA Citation Generator?

Our APA generator was built with a focus on simplicity and speed. To generate a formatted reference list or bibliography just follow these steps:

1. Start by searching for the source you want to cite in the search box at the top of the page.

2. MyBib will automatically locate all the required information. If any is missing you can add it yourself.

3. Your citation will be generated correctly with the information provided and added to your bibliography.

4. Repeat for each citation, then download the formatted list and append it to the end of your paper.

5. Done!

MyBib supports the following for APA style:

⚙️ Styles

APA 6 & APA 7

📚 Sources

Websites, books, journals, newspapers

🔎 Autocite

Yes

📥 Download to

Microsoft Word, Google Docs

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Free APA Citation Generator [Updated for 2023]

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Generate APA style citations quickly and accurately with our FREE APA citation generator. Enter a website URL, book ISBN, or search with keywords, and we do the rest! Updated with APA 7th Edition!

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May still need more research, but seems to point that an X-Y gantry model may be cheaper than using an XYZ hand, especially if we are just making just a gantry with just one horizontal axis.

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Pro's and cons of using a robot or an X-Y gantry for picking and placing

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Pro's and cons of using a robot or an X-Y gantry for picking and placing... SPTechnology explain the important considerations...

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While super raw, it's a first draft of the idea... a gantry picking objects from the input conveyor belt, diping them in the waxing vase, and putting them in the output conveyor belt.

I'm not sure if we'll do the conveyor belt, or just the outputs lights...

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Location: Zoom

Date: 06/08/2026 - 5:00 pm
Led by: Dr. Mayra Socarras and Dean Lara Sharp
Purpose: First meeting outlining an initial pass of the Senior Proposal

1. Scheduling Issues

1. Some students raised concerns about the time switch.

2. Proposed solution: move classes from face-to-face to Zoom.

3. While the moving to zoom was an accepted measure, it didn't solve everyone's problems. Therefore, a poll will be sent to be completed this week to define the new date and time of the meetings.

2. This Week's Task

1. Create a Padlet using the provided template: https://padlet.com/larasharp2002/eet4910-draft-template-nep8y6kfvvyrirce

2. Write the problem statement

3. Conduct research

4. Start the systems document

5. Identify possible constraints and challenges

6. Begin drafting the project timeline

3. New Approach This Semester

1. There won't be multiple proposals per group, just the one to be completed.

2. Conduct a SWOT analysis (Strengths, Weaknesses, Opportunities, Threats) to determine that project.

3. Post results on Padlet, or schedule an appointment with Sharp and Socarras.

4. The professor will provide feedback asynchronously via padlet.

4. All Required Assets

1. System-level diagram with interfaces

2. System requirements (per IEEE standard)

3. System specification (limitations/requirements for correct system performance)

4. Web page

5. Key Deadlines

1. First version of concept: June 29th

2. Project proposal report: July 26th

3. Project proposal presentation: July 31st

6. Other useful information

1. Lara Sharp's office location: Building 9-140

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Limitations

Wax bath temperature regulation is external — the system only interfaces with an already-heated bath; it does not control bath temperature, heating elements, or thermal sensors in this phase.

The prototype operates on a benchtop-scale mock conveyor, not full industrial hardware (no full-length industrial belt).

No vision system — piece detection and positioning rely entirely on TOF and/or ultrasonic sensors and fixed-position arm coordinates; no camera-based guidance.

No multi-axis simultaneous motion — the arm executes sequential joint movements (not coordinated interpolated paths), which limits cycle speed.

No wax bath level monitoring — bath depletion or overflow is not measured or flagged by the system.

No safety interlocks for human proximity — the prototype is intended for unobstructed lab operation; no light curtains or safety PLCs (maybe add a detection system to it?)

Single piece per cycle — the system processes one part at a time; no parallel or pipelined processing of multiple pieces.

Fixed arm mounting — the arm base is stationary; it does not translate along more than a rail or gantry.

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Industrial waxing processes require repetitive, precise handling of components — picking pieces from a conveyor, dipping them into wax at a controlled depth and speed, retrieving them, and placing them on a cooling conveyor. The current use of it in Siemens Energy FAST Warehouse is less than ideal  regarding the EHS safety protocols, but the lack of options to solve this problem have left an unsafe, inefficient and costly process to do it. This process is currently labor-intensive and inconsistent, exposing workers to heat( wax besides being around 200 F it’s also sticky, a bad combination) and fumes while introducing variability in coating thickness and quality. No low-cost, task-specific automated solution exists at the prototype scale that integrates conveyor detection, closed-loop dip control, and pick-and-place mechanics into a single deployable system.

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References

1. E18-D80NK IR Proximity Sensor with Arduino — Circuit Digest

https://circuitdigest.com/microcontroller-projects/interfacing-e18d80nk-ir-proximity-sensor-with-arduino

2. E18-D80NK Project on Instructables

https://www.instructables.com/Project-on-E18-D80NK-IR-Proximity-Sensor-With-Ardu/

3. TB6600 Stepper Motor Driver — RobotShop

https://www.robotshop.com/products/tb6600-stepper-motor-driver

4. TB6600 + Arduino + NEMA Motor Wiring Tutorial — YouTube

https://www.youtube.com/watch?v=nLV0fjUWI-g

5. DS3225MG 25KG Waterproof Digital Servo — DSPowerServo

https://www.dspowerservo.com/high-speed-metal-gear-coreless-waterproof-digital-servo-ds3225-25kg-servo-product/

6. DS3225MG Review — YouTube

https://www.youtube.com/watch?v=6Re_6vCxcgw

7. Pick and Place Robotic Arm — Instructables

https://www.instructables.com/Pick-and-Place-Robotic-Arm/

8. Robotic Arm for Automated Pick and Place Operations — IJRPR

https://ijrpr.com/uploads/V6ISSUE5/IJRPR44762.pdf

9. Pick and Place Robots: An In-Depth Guide — Wevolver

https://www.wevolver.com/article/pick-and-place-robots-an-in-depth-guide-to-their-functionality-and-applications

10. Robotics in Investment Casting: Uses and Benefits — Impro Precision

https://www.improprecision.com/robotics-in-investment-casting-uses-and-benefits/

11. Robotic Installation for Investment Casting Wax Assembly — Ecrimesa Group

https://ecrimesagroup.com/robotic-installation-for-investment-casting-wax-assembly/

12. Arduino PID Library — Brett Beauregard / GitHub

13. Universal Robots UR3e Product Page

14. Epson T3 SCARA Robot

15. Yaskawa MotoMini

16. amazon.com/Aluminum-Extrusion-European-Standard-Anodized/dp/B08Y8LWW4R/ref=sr_1_4?crid=RD9IDPMKWNEW&dib=eyJ2IjoiMSJ9.WsUtEi2eRhuBYmbXiV6sBGacXMK5Ldadkbz9sLp1BWV5TwWJbHK-pIsa761OEQOGWf8Z7Gn5yIfMOXcPgJHliPQHbUKAgDIifqNf_xmCCQzv8IbXpeqC40HdwlHpvKCjDagFDM-DROm5B1D9Bj_b_iJHFom0KRcOdMLY1NtgoiAkRy3ztlCnMOxa6yCnkOFUZoGoNDAP2MWkndH3nNKct_EZlMKa4uzutWCUmysJdR23Bz-rkF2jmSRcDdu8XIixokHCg0z8LUJ91VL0FNkCx__3oIRJOGtT9cyuT7yTJhQ.UJlY2ZZzE3H_5X1RdUnBlwUlSYUO5UVjXuvjdZBf46M&dib_tag=se&keywords=2pcs+600mm+T+Slot+2020+Aluminum+Extrusion+European+Standard+Anodized+Linear+Rail+for+3D+Printer+Parts+and+CNC+DIY+Black%2823.6inch%29&nsdOptOutParam=true&qid=1782242300&s=industrial&sprefix=2pcs+600mm+t+slot+2020+aluminum+extrusion+european+standard+anodized+linear+rail+for+3d+printer+parts+and+cnc+diy+black+23.6inch+%2Cindustrial%2C109&sr=1-4

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4pcs 400mm T Slot 2020 Aluminum Extrusion European Standard Anodized Linear Rail for 3D Printer Parts and CNC DIY Black(15.75inch)

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4pcs 400mm T Slot 2020 Aluminum Extrusion European Standard Anodized Linear Rail for 3D Printer Parts and CNC DIY Black(15.75inch): Amazon.com: Industrial & Scientific

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1. Detect incoming pieces — sense the presence of a part on the input conveyor belt using an IR proximity sensor (Ex: E18-D80NK).

2. Pick up the piece — actuate a servo-driven gripper to grasp the part at a fixed pick position on the conveyor.

3. Transport to wax bath — move the robotic arm to the wax bath position using stepper-motor-driven joints with a system of pulleys and a encoder-verified positioning.

4. Execute PID-controlled dip — lower the piece into the wax bath at a controlled dip speed, hold it at a target depth for a programmed duration, all regulated by a PID controller reading a linear encoder or stepper step count as process feedback.

5. Monitor dip parameters — continuously track dip depth, hold time, and dip speed during the immersion phase via closed-loop feedback.

6. Retrieve and enforce drip interval — raise the piece out of the bath at a controlled retrieval speed and hold it above the bath for a timed drip period before transfer.

7. Place onto the output conveyor — move the arm to the output position and release the piece onto the cooling conveyor belt( use maybe a replaceable cover like a piece of paper into the conveyor to minimize the maintenance?)

8. Log cycle data — record cycle count, dip depth achieved, hold time, dip speed, and any fault flags to onboard memory (SD card) and serial output.

9. Detect and flag faults — identify and flag conditions such as missed pick, conveyor empty timeout, depth-not-reached error, and gripper open/close failure.

10. Indicate system state — display current operating mode, cycle count, and fault status on an LCD/OLED display and via LED indicators.

11. Have an emergency button — in case the process for any reason needs to be immediately suspended

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Industrial E-Stop Systems: Hardwired Safety Best Practices - Industrial Monitor Direct

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Hardwired E-stop circuits remain mandatory for industrial safety. This guide covers fail-safe wiring, safety relay requirements, and legal liability.

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Still in review... dependent on scale of accomplishing desired, especially for servos and controllers

Limit $500

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# Prototype System Overview

- The system shall move only in two directions: horizontal and vertical.

- (TBD) The claw of the system shall tolerate high temperatures and wax-resistant.

# Dipping process

- The system shall detect incoming pieces on the input conveyor using a time of flight sensor.

- When a piece is detected, the system shall position itself above the piece, pick the piece with a servo-actuated gripper.

- When the piece is picked, the system shall move the piece horizontally above the wax bath.

- When the piece is moved above the wax bath, the system shall execute a dip sequence into the wax bath at a programmed depth and hold time.

- After the dip sequence, the system shall move the piece to the output conveyor and wait for the next piece.

# Safety measures

- When the E-stop is pressed, the system shall get to a home position before de-energizing actuator power. If this cannot be confirmed within 10 seconds or less then all power shall be cut regardless and the fault shall be logged.

# Communications

- The system shall communicate its current state and any errors or faults to the operator via:

- Safe default: Serial structured communication

- Safe Extension option: MQTT

- Full Extension option: Modbus TCP

- (Optional) The system shall provide a dashboard which will display the current state, and any errors or faults to the operator

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Docs: https://lonelybinary.com/en-us/blogs/tinkerblock/tk50_01_ultrasonic-sensor

It's 3.3v and supports 1-wire mode or SPI, which could reduce the amount of pins used.

Operational temp: -40°C to 90°C

Blind zone of 2-3cm

its recommended and most reliable operating range is between 2 cm and 200-300 cm (2 to 3 meters)

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Lonely Binary 5-Pack HC-SR04 Ultrasonic Sensor I2C UART for Arduino & ESP32 | 4 modes: I2C, UART, 1-Wire, GPIO; gold PCB; brick adapters + storage case; solderless; 3.3V/5V

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Lonely Binary 5-Pack HC-SR04 Ultrasonic Sensor I2C UART for Arduino & ESP32 | 4 modes: I2C, UART, 1-Wire, GPIO; gold PCB; brick adapters + storage case; solderless; 3.3V/5V: Amazon.com: Industrial & Scientific

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Some notes:

A lot of this will be clearer once we establish the scope, and therefore the strength of the servos, and with that the servos.

The Ethernet adapter is still a TBD. It depends on how communications will be performed.

Servo controllers may be ommitted if the servos already include the controller (common for smaller servos).

E-stop is not drawn yet, as power requirements will also come once scope is fully defined.

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What is the Modbus Protocol & How Does It Work?

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Modbus is an industrial protocol that makes communication possible between automation devices. Get an in-depth view of the Modbus Protocol at ni.com.

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STEPPERONLINE Nema 23 Stepper Motor 2.4Nm(339.79oz.in) 4.0A 8mm Shaft 57x57x82mm 4 Wires

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STEPPERONLINE Nema 23 Stepper Motor 2.4Nm(339.79oz.in) 4.0A 8mm Shaft 57x57x82mm 4 Wires - Amazon.com

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25KG High Torque RC Servo Digital Servo Full Metal Gear Waterproof with 2 25T Servo Horn Compatible with 1/6，1/8, 1/10, 1/12 RC Car Crawler Robot Control Angle 180°

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Buy 25KG High Torque RC Servo Digital Servo Full Metal Gear Waterproof with 2 25T Servo Horn Compatible with 1/6，1/8, 1/10, 1/12 RC Car Crawler Robot Control Angle 180°: Servos - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

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LewanSoul Mechanical Robot Arm Claw/Gripper Robot Gripper (Black Mechanical Claw Without servo)

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Buy LewanSoul Mechanical Robot Arm Claw/Gripper Robot Gripper (Black Mechanical Claw Without servo): Science Kits & Toys - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

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Spring jaw, so if power goes off it will keep the pice inside. Likely need to modify a claw for that.

Proper Fail-Safe Solutions

Option 1 — Spring-loaded jaws (best for your case)

Design the jaw so a spring naturally closes it. The motor/stepper only works to open the jaw. When power cuts, the spring snaps it shut.

Zero power needed to hold grip

Instant fail-safe closure on any power loss

Simple mechanical design — just a torsion or compression spring in the jaw linkage

The stepper/servo only fights against the spring to open

Very common in industrial grippers for exactly this reason

Option 2 — Electromagnetic brake (NEMA 17/23 with brake)

You can buy NEMA steppers with a built-in spring-engaged electromagnetic brake — the brake is held OPEN by power, and springs CLOSED when power cuts. Same fail-safe principle.

NEMA 23 with brake: ~$35–60

Automatically locks the shaft on power loss

Works without any software or controller intervention

Option 3 — Worm gear drive

A worm gear is self-locking — the load cannot back-drive it. Once the jaw closes, it physically cannot open without the motor turning it, even with zero power.

Add a worm gear between the motor and jaw mechanism

Any small motor works since the worm gear multiplies torque and self-locks

No springs needed, no brake needed

Downside: slower open/close speed

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1910.124 - General requirements for dipping and coating operations. | Occupational Safety and Health Administration

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An official website of the United States government.

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1. Lead Screw

A lead screw operates on sliding friction, converting rotational torque into linear force via matching threads (like an optimized nut and bolt).

Mechanical Advantage: Extremely High. The shallow angle of the threads acts as a continuous wedge or ramp. A small amount of motor torque is multiplied into a massive linear lifting force.

Speed: Low. Because it only advances by its lead distance (e.g., $2\text{ mm}$ or $8\text{ mm}$) per full motor revolution, the motor must spin at high RPMs to achieve fast travel.

Length Limits: Short (Under 1 Meter). Over long spans, a thin lead screw will sag under its own weight and begin to wobble violently at high RPMs—a destructive phenomenon called screw whip.

Self-Locking: Yes (if single-start like a Tr8x2). Friction prevents back-driving.

Best Fit for Your Gantry: Your Vertical Z-Axis (30 cm). It perfectly handles the heavy 10 kg vertical lifting load without skipping steps, easily fits within the short travel length, and natively locks in place when power is cut.

2. Timing Belt Drive

A timing belt drive uses a flexible, reinforced rubber loop wrapped around a geared pulley on the motor shaft and an idler pulley at the far end.

Mechanical Advantage: Low. One turn of a typical 20-tooth GT2 pulley moves the axis $40\text{ mm}$. This large distance means the motor acts against a long lever arm, drastically reducing its linear pushing force.

Speed: Extremely High. Because of the large travel distance per revolution, a belt drive can easily achieve blazing travel speeds (over $500\text{ mm/s}$) at very low motor RPMs.

Length Limits: Moderate (Up to 2-3 Meters). Belts span long distances easily, but if the belt is too narrow, it acts like a giant rubber band—stretching slightly under high loads, which causes positioning errors and structural "bounciness."

Self-Locking: No. It is incredibly smooth and back-drives instantly under weight.

Best Fit for Your Gantry: Your Horizontal X/Y Axis (1 Meter) if you use a heavy-duty, steel-reinforced, wide belt (9mm or 15mm width) paired with a high-torque NEMA 23 motor. It provides fast, quiet, and smooth travel across your 1-meter span.

3. Rack and Pinion

A rack and pinion turns rotational motion into linear motion by running a circular gear (the pinion) directly along a long, flat track of gear teeth (the rack).

Mechanical Advantage: Low to Moderate. Similar to a belt drive, one turn of a standard pinion moves the carriage a large distance (typically $60\text{ mm}+$ per turn), sacrificing torque for speed. However, you can couple the motor to a small gearbox reduction to regain that lost torque.

Speed: High. It offers excellent high-speed travel capabilities across massive distances.

Length Limits: Infinite. Unlike screws that whip or belts that stretch, racks can be bolted end-to-end indefinitely. The rigidity of a steel rack remains identical whether the axis is 1 meter or 10 meters long.

Self-Locking: No. A heavy gantry can easily back-drive a standard pinion gear when the motor is disabled.

Best Fit for Your Gantry: Your Horizontal X/Y Axis (1 Meter). Because your horizontal carriage must move a combined weight of around 13–14 kg (the vertical motor, rails, and the 10 kg object), a rack and pinion offers zero-stretch mechanical rigidity across that 1-meter span.

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https://www.amazon.com/Sydien-Pillow-Flange-Bearing-Self-Alignment/dp/B07C4Y7P2C

or

https://www.amazon.com/Sydien-Pillow-Block-Flange-Bearing/dp/B07C5MTB5X

$10 each

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The system must cost a maximum of $500 and its components must be accessible in the market by anyone

The system must be modular and easy to assemble (1h maximum assembly time) on a wax pot or tank of about 40 cm maximum diameter

The system must be capable of operating with the voltage/frequency supplied in United States outlets (110V and 60Hz)

The system must be capable of being operated from a computer and it must give the user information on:

How the system is behaving

The system’s electrical consumption

If any error has occurred

Control the depth of the dip to better control how much coating is desired, with a limit to minimize maintenance (cleaning) of the magnet

The system must be able to detect an object on the conveyor, pick it up with an error margin of 2 to 3 cm and move it to the designated area to be picked up by the gripper within a period of 3 min

The system must be able to lift the object (max 10kg) and be able to submerge it in hot Wax of around 250 F and resist that temperature without suffering damage

The system must be capable of waiting the necessary time (1 to 3 min depending on the client’s set up)

The system must be capable of positioning the object with the wax coating on the output conveyor in the indicated position with an error margin of 2 to 3 cm within a period of 3 min

The system must have an EMERGENCY STOP and stop all operation immediately and proceed to execute the “Release the load safely” protocol within a period of 10 seconds. This will consist of moving the load (if present) to the designated area, thus preventing it from being released over the hot wax pot.

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Safe-Dip: An Automated Hot-Dip Pick-and-Place System

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Safe-Dip: An Automated Hot-Dip Pick-and-Place System

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Hot-dipping is a widely used industrial process for coating, treating, and finishing parts in manufacturing, plating, and dip-molding. However, manual handling near these hot baths exposes operators to risks of burns and repetitive strain. Safe-Dip is an automated pick-and-place system that removes operators from this hazard zone by handling the load-dip-unload cycle with minimal human interaction. Safe-Dip aims to reduce burn-related injury risk while adding safety measures, such as fault logging and emergency stops, that make the process safer and more auditable for small manufacturers.

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System requirements converted into SMART goals

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System requirements converted into SMART goals

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Objective 1: Motion System

The system shall use a two-axis stepper-driven motion system to pick up parts, dip them in the wax bath, and place them at the output station, achieving positional accuracy within ±1 cm on both axes. This will be confirmed by commanding each axis to a known target and measuring the offset with a ruler. NEMA 23 motors paired with compatible stepper drivers provide enough torque and control resolution to meet this accuracy target given the payload and travel range involved. Reliable, accurate motion is essential to completing the pick-dip-place cycle without dropping or misplacing parts, and this objective shall be completed and validated before final system integration testing begins.

Objective 2: Control and Sensing Reliability

The system shall use a microcontroller-based state machine that reads ultrasonic and limit switch inputs to safely sequence motor and end-effector actions, with correct part detection at the input station and correct motion stop at each axis limit confirmed through direct testing of each sensor. The selected microcontroller has sufficient GPIO, processing speed, and I/O compatibility to handle all required sensors and outputs, making this objective achievable within the current hardware design. Reliable sensing and state control are necessary to prevent collisions, missed parts, and unsafe operation, and this objective shall be completed, with sensor integration and state machine testing finished, before end-effector integration begins.

Objective 3: Safety and Communication

The system shall include a hardware emergency stop and an Ethernet-based Modbus TCP reporting system that communicates system state, position, and faults, with the E-stop confirmed to cut power immediately when actuated and require manual reset, and all state transitions and faults confirmed to appear correctly in Modbus TCP output during a full operating cycle. A normally-closed E-stop rated for peak current and an SPI-compatible Ethernet module both integrate directly with the existing power and control architecture, making this objective achievable without major redesign. Operator safety and system visibility are required for safe operation and effective troubleshooting, and this objective shall be validated during the final safety and communications review before project completion.

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