Berkshire Grey

Mechanical Engineering Co-op
July-December 2024

Berkshire Grey is a robotics company that uses AI to automize supply chain and fulfillment operations. During my 6 months as a co-op for this company, I worked on 2 different projects: RPSi (Robotic Package Sortation with identification) and RPU (Robotic Package Unloader). RPSi autonomously sorts and tracks large volumes of small sized packages. RPU automizes the long and tiring task of unloading delivery trucks with varying sizes, weights, and shapes of packages. Here are some of the projects that I worked on as a mechanical engineer on these projects!

Disclaimer: Some of the projects that I worked on at this company will have missing information or will not be included all together due to request of the company.

Linear Sort Wing Shuttle Bucket
RPSi

Context: The shuttle bucket is a bucket that moves along a linear rail and transfers packages to their assigned bags.

Task: Redesign the shuttle bucket to be easier to assemble and test the assembly on the machine.

Contributions:

Made final adjustments in CAD to make sure everything fit and is manufacturable
Created part and assembly drawings for the redesigned parts
Worked with manufacturers to get the parts made and ordered any additional components
Assembled the new Shuttle Bucket and took note of any assembly issues
Adjusted the CAD according to the discoveries made while assembling

Tools and skills:

SolidWorks
Part and assembly drawings

Linear Slide Testing for a Sweeper
RPSi

Context: A sweeper runs on a linear slide to push boxes into the shuttle bucket on the RPSi. The current linear slide being used is very expensive, so the team is looking to replace it with something cheaper.

Task: Test a new linear slide to determine its force and speed capabilities, test its different functionalities, and ultimately decided if it is worth using for the RPSi machine.

Contributions:

Set up the linear slide for testing
- Adjusted the shelf that the motor is mounted to, and added a plastic flooring to simulate the machine
- Added an 8020 frame to the sweeper to allow it to easily and consistently push boxes of different weights
- Mounted a counter for life-cycle testing
Learned how to use the application to control the linear motor, and updated the instructional wiki
Tested varying speeds and weights with the motor while also adjusting the settings to optimize results
Worked with the vendors to resolve issues in the app
Created test plans for weight vs. speed, stalling, and life-cycle testing

Tools and skills:

Collaborating with vendors
Testing new systems

Conveyor Sensor Brackets
RPU

Context: Originally, the conveyors used lidar sensors to detect when boxes got stuck. The brackets for these were too flimsy and boxes often got stuck on it. Additionally, the lidar sensors were already very big, so most brackets got in the way when the conveyors were folded. Eventually, the lidar sensors were changes to 3, much smaller distance sensors.

Task: Redesign the lidar sensor brackets to be easily manufacturable, not get in the way of the machine when the conveyors are folded up, and be strong enough to withstand the impact of heavier boxes.

When we shifted to smaller distance sensors, my task was to created new brackets for the 3 sensors with given positional constraints.

Contributions:

Redesigned sheet metal lidar brackets to be easily manufacturable with limited mounting holes to the conveyor
Designed new sheet metal brackets for 3 differently positioned sensors
Tested the brackets on the machine and made changes based on any issues
- Round 1 of testing: boxes got jammed along the sides, so rollers mounted at an angle were added to prevent this
- Round 2 of testing: boxes got stuck on a corner, so the corner was cut flat
- Round 3 of testing: a box got jammed, bending the thick stainless-steel brackets, so an additional bracket support was added

Tools and skills:

Sheet metal design
SolidWorks
Iterative design

Original Lidar brackets

Lidar sensor bracket redesign

Distance sensor brackets original design

Distance sensor brackets redesign

Final distance sensor design

Distance sensor brackets support

Lagging bracket
RPU

Task: Redesign many different variations of a bracket that mounts to a system and lags to the floor, fits given size constraints, and can withstand 1000lb of force 27in above the bracket

Contributions:

Designed 5 different brackets using sheet metal, welding, and tubes that attach to a system and lag to the floor
Ran FEA on every bracket at 2-3 different orientations
Compared the deformation and stress results for each bracket

Final lagging bracket tube design

FEA of original design

FEA of sheet metal with welds design

Tools and skills:

Sheet metal design
Weld design
Tube design
FEA
SolidWorks

Conveyor Testing
RPU

Task: Do testing on a conveyor to compare speed vs. weight and determine when it stalls. Use this data to determine if the conveyor is fit to replace one that is currently being used.

Contributions:

Designed and built an 8020 frame to mount the conveyor at a 20-degree angle
Tested the motor with varying weights on it and recorded the changes in speed with the increase in weight
Increased the weight until the motor stalled and recorded the value
Concluded that the conveyor was not strong enough for the given application