Inspiration
While the current production line for customized industrial lens manufacturing is highly automated, the delicate polishing stage remains a manual bottleneck. We saw an opportunity at StarkHacks to leverage AMD LeRobot and Ford pneumatic components to bridge this gap and complete the automation loop for high-precision optics.
What it does
Our system utilizes a dual-arm AMD LeRobot setup to automate the lens polishing workflow:
The 12V Arm: Acts as the precision handler, equipped with a pneumatic suction assembly to pick lenses from the inlet.
The 5V Arm: Acts as the craftsman, wielding the polishing tool to perform the actual finishing.
Vision-Guided Workflow: Independent vision systems on both arms use AprilTags for spatial localization and distance calculations, allowing the system to autonomously move lenses from inlet to outlet after a polishing cycle.
How we built it
Brain & Brawn: Controlled via an STM32 F103RB managing the pneumatic network logic (PNL) and a custom OLED status UI.
Pneumatics: A DC vacuum pump driven by an L298N H-Bridge, using PWM to fine-tune suction force.
Vision: Integrated AprilTag tracking for high-accuracy coordinate mapping between the two independent arms.
Industrial UI: A real-time OLED dashboard and full-color RGB LED strips providing vacuum telemetry, system status, and visual warnings.
Challenges we ran into
The biggest hurdle was the lack of solenoid valves for vacuum release. We faced a "sticky" situation where lenses wouldn't drop even after the pump stopped. We solved this with a "Bleed Hole" hack—precision-drilling a micro-vent in the tubing to balance pressure, and implementing a reverse-polarity vibration pulse in the STM32 code to shake the lens free. Additionally, pivoting from FPGA to STM32 mid-competition due to cable constraints tested our rapid prototyping limits.
Accomplishments that we're proud of
The "Zero-Valve" Release: Achieving sub-second lens release using only physics and clever code.
Dual-Arm Coordination: Synchronizing two arms with different voltage requirements and independent vision systems.
Professional UI: Developing a centered, industrial-grade OLED interface that provides clear feedback during the polishing cycle.
What we learned
We gained deep insights into pneumatic physics—specifically, vacuum residual pressure. We also mastered AprilTag integration for real-time kinematic adjustments and learned that in a high-stakes hackathon, Engineering Intuition (like the bleed hole) is just as important as the code itself.
What's next for Grey Squad
The current prototype is a success, but we have a roadmap for "Aero-Optics 2.0":
Closed-Loop Suction: Integrating pressure sensors and solenoid valves to implement PID control for vacuum stability.
Force-Feedback Polishing: Adding force sensors to the 5V arm to maintain constant polishing pressure via PID, ensuring perfect optical clarity every time.
Industrial Optimization: Improving system stability for mass production, reducing manufacturing costs, and further integrating electronic components for a streamlined design.
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