My internship at Honda of Canada Manufacturing (HCM) consisted of several projects that were different from typical "engineering" work. Considering that I was in a manufacturing setting, a lot of the work I did was on the floor, where I worked with associates., got hands on, and worked with PLC logic, installations, panel builds, CAD Design, and some COGNEX Vision.
Something that really stuck with me through this internship is the importance of vision. Although I did not get to work on vision very much here and learned some introductory Cognex, it piqued my interest in the intersection of robotics and AI. Working in the Weld department, there are 300+ sealer and spot weld robots. However, not a single one of them solely employs vision in the actual robot. Essentially, it is a static and methodical system. I have looked into companies that work on this intersection, and I want to explore this space.
In manufacturing, there can certainly be improvements and I think that there is space for efficiency. I want to pursue a thesis for my undergrad that touches on the Robotics X Vision space.
Here are my mini projects that I have contributed to over the course of my time at HCM.
My team and I developed the SynthBoard, an innovative audio synthesizer that combines a 4x4 button matrix with 8 potentiometers to control real-time audio generation and waveform manipulation. The project integrates a variety of components and technologies to create a versatile and interactive music tool.
Key highlights of the project include:
Audio Synthesis: STM32F407G microcontroller programmed using C++ to handle the audio output via a Digital-to-Analog Converter (DAC), as well as SPI-driven LED control and user inputs from buttons and potentiometers.
Hardware Design: I designed and 3D printed the external casing using Fusion360, optimizing the user interface layout within the space constraints. I also soldered and assembled the button/knob grid and the LED array, overcoming challenges like keyboard ghosting.
User Interface and Testing: Tested the system extensively, including pitch range, harmonics, polyphony, and LED visibility under different conditions to ensure functionality and usability.
This project is a blend of hardware, software, and user-centric design, creating a hands-on, customizable synthesizer.
I designed and built an adjustable low-voltage DC power supply as part of the MIE366 course, combining both hardware and software elements for precise control and display of voltage and current.
Key aspects of the project include:
Microcontroller Integration: I programmed an STM32 microcontroller using C to control the power supply's output and provide an interface on an LCD panel for real-time voltage and current monitoring.
Circuit Design: I iterated multiple circuit designs using SPICE simulation to ensure the power supply met the required performance and reliability standards.
PCB Design: I designed a multi-layer PCB layout using EAGLE, optimizing for minimal signal interference and power loss, ensuring efficient operation.
Assembly: I assembled and soldered all circuit components, ensuring the physical integrity and accuracy of the final PCB design.
Testing and Validation: I performed extensive testing to verify the power supply's functionality, stability, and precision under varying loads.
This project required a deep understanding of electronics, programming, and circuit design, resulting in a reliable and adjustable DC power supply.
First time soldering and learning how to connect traces.
This project is what really made me realize the impact and the responsibility of an engineer to the world -- inspiring me to major in robotics. My team and I (6 total individuals) were challenged to find a way to improve the lives of Ghanaian citizens through the approach of plastic cleanup. We could scope this project in any way (i.e. landfill, plastic organization, transportation, etc.). However, we decided to look into into the idea of a plastic collection in water. We did our due diligence and research in order to justify this, and we found that there was a "hole" in the opportunity space, since water cleanup was not a high focus for Ghana. We looked into the livelihood of Ghanaian culture to also realize that citizens are losing their lives literally by slipping on plastic masses. Furthermore, a good portion of the economic situation in Ghana relies on fishing. Hence, we felt that exploring this opportunity space would be the best way to approach the plastic crisis.
Now, when it came to designing a prototype, we were completely directionless. This is why we formulated a set of requirements in order to constrain ourselves to a criteria that was feasible in the scope of our abilities. After researching several designs and iterating through different brainstorming methods, we finally came up with our champion design. We decided to create a contraption that can easily integrate into the daily lives of fishermen, where the device would attach to the boat and collect plastic.
Several layers of complexity were involved when attempting to put together the contraption. There were also several design problems that we did not account for that we later fixed in the building process. For example, some of the laser-cut wood was not cut to the correct diameter, so I learned to use power tools and machinery, such as the drill press, to adjust the hole. We also needed to create a "spinning brush" motor which was made of a dowel and some tubing (see in images below). However, it was difficult to find a way to connect the dowel to the tubing, so I conducted measurements with the vernier caliper and created my own CAD model of a "dowel coupler" that would allow the tubing to be easily attached to the dowel. This was one of my first experiences with CAD and it made me want to challenge myself to become a better learner and creator. Moreover, I got to learn more about using the Raspberry Pi Pico microcontroller to set up basic circuits and experience using force sensors and actuators. In the design video below, the button press initiates the movement of the piston, where the force sensing resistor allows the piston to stop at a certain point such that the plastic is enclosed.
Finally, when it came to testing our prototype, the collection of plastics was successful and proved our design concept. Although there were some design flaws and more complexity that could be integrated, the design was made over a very short span of 4 months and I am very proud of the work my team and I accomplished. Overall, this project has allowed me to recognize the work and effort engineers put into designing for the real world and the positive implications it can create, such as sustainability. I want to be a part of the solution and contribute through the use of technology!
Dowel Coupler CAD I worked on (top image) and the final result (bottom image).
Brainstorming with my group - dimensions and components of the prototype.
Front of the design
Functioning Design
In this project, I was first exposed to a building for the first time as an engineering student. And what I learned in this course was how to improvise when there is little time and high stakes. For some context, in my CIV 102 course, I learned so much about bridge construction and design and the analysis of free-body diagrams. Resultantly, my team and I were faced with the challenge of building a bridge out of matboard material that carried a weight of 400 Newtons [N].
To create an optimal design for a bridge, we were supposed to iterate through several designs and support them through calculations. I hand calculated samples of the different bridge designs (for parameters relating to locations of shear stresses, bending moments, and more). Additionally, this project also involved the use of MATLAB in order to create bending moment diagrams and shear forces diagrams to help create an optimal bridge design (as hand calculation over every iteration is timely and inefficient).
However, due to an error, the MATLAB code was not developing properly for the diaphragm placement and there was not enough time to locate the placement of the supports. On the bright side, I proposed a method to simulate the process physically by using fingers as "supports" and having one team member add force the bridge to see where support was required. This would help to see locations of where most support was required. Ultimately, his worked quite successfully as the placement of our diaphragms were the most crucial part of the structure -- the bridge passed the 400 N test!
My hand calculations for a bridge design - compression/ tension stresses, moments.
Example of MATLAB plots created to find points of failure and causes.
Testing for diaphragms -- I am holding my fingers as potential diaphragm placeholder.
Final placement of the brige diaphragms based off of the testing.