What

A real-time computer vision system to automate rack detection and decision-making for autonomous mobile robots in Toyota Boshoku's manufacturing plant. The system processes a live RTSP camera feed, applies homography and distortion correction to generate a consistent bird's-eye view of the workspace, and uses HSV colour segmentation with configurable detection regions to determine rack occupancy.

How

The system integrates with Allen-Bradley PLCs over Ethernet/IP — detection results are converted into structured boolean arrays and sent directly to trigger AMR actions. I built an interactive calibration interface with live tuning for colour thresholds, detection sensitivity, and geometric transformations, with save/load functionality for fast redeployment. A multithreaded camera pipeline eliminates frame latency and maintains stable real-time operation in a production environment.

Impact

Replaced manual operator input with a fully automated system, allowing AMRs to make real-time decisions based on actual rack availability. The system reliably moved over 100 racks per day, reduced operator workload, and minimized production delays.

What

Human-machine interface displays for multiple machines and robotic systems across the production plant. Interfaces show real-time servo speed and torque data for sonic weld robots during clip installation, track total screws and clips installed, and allow operators to selectively bypass vision-based defect detection for specific screws when needed.

How

Built using FactoryTalk View Studio and Studio 5000. Ladder logic captures and stores real-time production and diagnostic data in the Allen-Bradley PLC, communicated to the HMI through structured tags and arrays. Layouts were designed to ensure operators and maintenance staff can quickly interpret system status and act without needing to dig into raw PLC data.

Impact

Improved visibility into robot performance, enabling faster fault diagnosis and better maintenance scheduling. Tool usage tracking allowed proactive part replacement before failures, reducing unexpected downtime. Operator-controlled bypasses reduced unnecessary production stoppages without compromising quality control.

What

A spacer jig designed to align push bar holes for accurate, repeatable drilling on the UWFE race car chassis.

How

Measured the necessary dimensions directly from the driveline SVN master assembly, modeled the spacer in SolidWorks to fit the push bar geometry, then 3D-printed the jig for immediate use.

Impact

Team members could drill holes accurately and repeatably without manual measurement each time, improving manufacturing consistency and reducing setup time.

What

A motor template jig to improve alignment and repeatability of chassis hole and insert manufacturing for the UWFE driveline.

How

Modeled the jig in SolidWorks using measurements taken from the SVN driveline master assembly. Drafted a full engineering drawing with GD&T specifications and had it validated by a senior team member for manufacturability. Water-jetted the aluminium base to dimension, then milled holes to ±0.1 mm tolerance.

Impact

Standardized hole alignment across driveline machining operations, enabling team members to work faster and with greater accuracy.

What

An accurate CAD replica of the physical cooling system radiator for integration into the UWFE driveline assembly model.

How

Measured all key radiator dimensions using calipers, then recreated the geometry in SolidWorks with matching form and mounting features. Committed the finished model to the team's TortoiseSVN master assembly.

Impact

The model served as a key component in completing the cooling system design, allowing the team to verify spatial packaging and fitment in the full driveline assembly before fabrication.

What

A real-time computer vision guitar interaction system using a webcam feed to detect hand and finger movements and translate them into musical input. The left hand selects chords based on finger positions; the right hand triggers individual notes. Visual overlays display chord diagrams and fingertip indicators in the live feed.

How

Built custom hand-tracking logic on top of MediaPipe, interpreting finger states by comparing landmark positions to determine which fingers are raised or pressed. Detected gestures map to chord and note audio files via Pygame. An event-based playback system only fires on new finger presses — preventing repeated audio from a held position. Optimized frame processing to maintain sub-frame latency from a live camera feed.

Impact

This project was the entry point into real-time computer vision — showing that a standard webcam could drive a low-latency interactive system with meaningful accuracy. The core ideas around frame processing, gesture mapping, and real-time performance directly informed the approach taken on the AMR CV system at Toyota Boshoku.

What

An autonomous checkers-playing robot built to compete against a human player. The system scans the board with optical and distance sensors, identifies piece locations, determines a legal move, and physically executes it using a motorized claw and X-Y gantry mechanism — all under strict hardware and size constraints.

How

C++ firmware represents the board as a 2D array, handling piece detection, legal move generation, promotion logic, and game-over detection. The X-Y motion system positions the claw over target squares and the claw mechanism picks and places pieces. Multiple prototype iterations improved chassis stability, reduced jamming, refined claw and sensor alignment, and adjusted the checkers pieces themselves for more reliable detection.

Impact

The final robot reliably played a complete game of checkers — scanning the board, selecting legal moves, and executing them. Demonstrated end-to-end integration of mechanical design, sensors, and embedded software. Strengthened skills in prototyping iteration, debugging under physical constraints, and full-system mechatronic design.

What

A 2D survival shooter built from scratch in Java using JavaFX. The player controls a spaceship, dodges randomly spawned asteroids, shoots aliens, and survives as long as possible. Includes a full menu flow, health tracking, enemy combat, collision handling, and a game over screen with persistent high-score statistics.

How

Object-oriented architecture with separate classes for each entity type — spaceship, aliens, asteroids, projectiles, health bar, and stat tracker. Real-time gameplay is driven by a JavaFX AnimationTimer loop handling movement, spawning, collision detection, and scoring. Smooth held-key movement uses a key-state map instead of single key events. Directional projectile motion is calculated from normalized velocity components toward mouse-click targets; enemy shots track the player. Stats persist between sessions via file I/O.

Impact

Built and shipped a complete, playable application end-to-end — from architecture to gameplay loop to persistent state. Developed a solid feel for managing multiple interacting real-time systems and clean OOP design under a tight game loop.