Technical Portfolio
Technical Portfolio
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Machine Vision for inspection of Neptunium Oxide and Aluminum pellets
This project supports the NASA Plutonium-238 Supply Program, which utilizes Pu-238 in radioisotope thermoelectric generators (RTGs) for deep space missions. To produce this fuel, Neptunium oxide and aluminum pellets, fabricated at ORNL, must be inspected before they are irradiated in the High Flux Isotope Reactor (HFIR). The traditional inspection process was highly inefficient, relying on operators to manually inspect each pellet one at a time. This approach resulted in low throughput and exposed glovebox workers to high radiation doses. This project aimed to replace this manual, time-consuming process with an automated machine vision solution that could perform simultaneous inspections, adhering to ALARA (As Low As Reasonably Achievable) principles, maximizing throughput, and generating detailed documentation.
To validate the core concepts of the proposed machine vision process, I designed and built a robust, modular test bed that simulated the glovebox environment. This automated and repeatable platform utilized 80/20 aluminum extrusion and incorporated a Vention ball-screw linear actuator with 360mm of travel for precise scanning. The structure was designed to be modular and easily changeable, allowing for future improvements. This initial test bed proved that the proposed process could simultaneously perform visual defect and metrology inspections on a batch of up to 52 pellets. This capability established the project's viability to drastically reduce radiation exposure and increase throughput compared to the manual, single-pellet inspection method.
A critical step involved hardware evaluation, where I determined the initial Cognex Insight 3D L4050 camera's resolution was insufficient for the required 0.003 inch pellet diameter tolerance gap, only allowing for approximately 1.5 pixels. This led to the specification of the Keyence LJ-X 8060 as the alternative, which is capable of providing ≈19 pixels for the same tolerance gap. To prevent project delays, I strategized and implemented Dynamic Similitude by 3D-printing scaled mock pellets to match the new camera's resolution, allowing Python code development and testing to continue immediately. I developed custom Python scripts that utilize Photogrammetry and OpenCV to convert the laser-scanned point cloud data into 2D height maps for automated dimensional analysis and defect detection.
The project successfully proved the viability of the automated process, yielding a 98% success rate for dimensional measurements during initial mock pellet tests. Beyond dimensional checks, the solution provides increased quality assurance through AI/ML integration. This included collaborating on applying an Autoencoder to identify anomalies and testing a commercial Large Language Model (LLM) (4o-mini) for defect classification, proving the process could be leveraged for future AI applications. All project findings, design details, and process flows were meticulously documented and presented at both the AGS Conference and a dedicated AI/ML conference at Los Alamos National Laboratory. Current efforts have shifted to designing a more robust system to be integrated into the current radiological glovebox in the near future.
Summer 2023 SULI Intern Deliverables Miller, Noah-Final.pdfAutomation Advancements in Np-237 Pellet Inspection 3_5 [Autosaved].pdfAGS_Enhancing_NepO2_Pellet_Inspection_ver3.pdfDifferential Swerve Drive
rotating assembly v5.aviDesigned to be utilized in FIRST robotics, a differential swerve drive is a holonomic drive that combines two motors to control module steering and wheel control. On a typical swerve drive, wheel movement and module steering are independently controlled by separate motors, however, in a differential swerve, the wheel movement and module steering are determined by the difference in the output speeds of the the two motors. The differential swerve designed allows for the torque of both motors to be used in both rotation of the modules and in moving the robot. The designed differential swerve utilizes as many off the shelf parts as possible to reduce the machining load on teams. This module was designed to be compact while still being robust and easily serviceable. This module was designed using Autodesk Fusion 360.
Designed to be utilized in FIRST robotics, a differential swerve drive is a holonomic drive that combines two motors to control module steering and wheel control. On a typical swerve drive, wheel movement and module steering are independently controlled by separate motors, however, in a differential swerve, the wheel movement and module steering are determined by the difference in the output speeds of the the two motors. The differential swerve designed allows for the torque of both motors to be used in both rotation of the modules and in moving the robot. The designed differential swerve utilizes as many off the shelf parts as possible to reduce the machining load on teams. This module was designed to be compact while still being robust and easily serviceable. This module was designed using Autodesk Fusion 360.
Telescoping Elevator
Telescoping Elevator
normal_6279b3759fc9b.mp4normal_6279ad379d802.mp4telescopingElevator.mp4Designed around specific game requirements, this elevator was used to lift a 150 lb robot off the ground at attachment points as high as 84 inches. Overall size of the mechanism had to remain within the perimeter of the robot without going over a certain height, so the elevator is designed to rotate from its stowed position to its climbing position. Once extended, it retracts until it hits a locking mechanism on the base stage, where a limit switch signals for the motor to stop. If an unexpected error occurred, a ratchet positioned on the gearbox is used to stop the robot from dropping. This Elevator was designed and manufactured using Autodesk Fusion 360.
Designed around specific game requirements, this elevator was used to lift a 150 lb robot off the ground at attachment points as high as 84 inches. Overall size of the mechanism had to remain within the perimeter of the robot without going over a certain height, so the elevator is designed to rotate from its stowed position to its climbing position. Once extended, it retracts until it hits a locking mechanism on the base stage, where a limit switch signals for the motor to stop. If an unexpected error occurred, a ratchet positioned on the gearbox is used to stop the robot from dropping. This Elevator was designed and manufactured using Autodesk Fusion 360.
Ball Intake Mechanism
Ball Intake Mechanism
normal_6279d5964c9ce.mp4
normal_6279d5841b08c.mp4Designed around specific game requirements, this intake was used to pick up 13" diameter balls. The design utilizes a common shaft to rotate the arms of the intake, while also delivering power to the wheels to pick up the balls. Power to the wheels is transmitted through chain inside the 2x1 tubing of the arm from the motor connected to the base plate. Another motor drives the rotation of the arms through rotating a sprocket connected directly to the arms. Once a ball has been intake, the arms rotate up, delivering the ball to the next subsystem to be scored. This intake was designed to be rigid, allowing for full speed wall impacts, while still being able to be functional after. This intake was designed and manufactured using Autodesk Fusion 360.
Designed around specific game requirements, this intake was used to pick up 13" diameter balls. The design utilizes a common shaft to rotate the arms of the intake, while also delivering power to the wheels to pick up the balls. Power to the wheels is transmitted through chain inside the 2x1 tubing of the arm from the motor connected to the base plate. Another motor drives the rotation of the arms through rotating a sprocket connected directly to the arms. Once a ball has been intake, the arms rotate up, delivering the ball to the next subsystem to be scored. This intake was designed to be rigid, allowing for full speed wall impacts, while still being able to be functional after. This intake was designed and manufactured using Autodesk Fusion 360.
Cube Intake Mechanism
Cube Intake Mechanism
normal_6279ce536c477.mp4normal_6279d0f07e5ad.mp4This intake mechanism was designed to pick up 13" x 13" x 11" boxes. The intake utilizes two articulating arms connected to two static arms. The articulating arms allow for the boxes to be centered ensuring proper control over the game piece. The articulating arms also allow for better control over box trajectory, as when the arms are extended parallel, it allows for better contact with the box on expulsion from the intake, allowing for further shots. The intake itself is mounted on a pivoting base which keeps the mechanism inside the frame perimeter of the robot and allows for higher arching shots. This intake was designed and manufactured using Autodesk Fusion 360.
This intake mechanism was designed to pick up 13" x 13" x 11" boxes. The intake utilizes two articulating arms connected to two static arms. The articulating arms allow for the boxes to be centered ensuring proper control over the game piece. The articulating arms also allow for better control over box trajectory, as when the arms are extended parallel, it allows for better contact with the box on expulsion from the intake, allowing for further shots. The intake itself is mounted on a pivoting base which keeps the mechanism inside the frame perimeter of the robot and allows for higher arching shots. This intake was designed and manufactured using Autodesk Fusion 360.
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