Create an autonomous method for counting reciprocating saw blades, to improve efficiency, ergonomic comfort, and allow implementation into future automated solutions.

There were also a few requirements we had to follow when designing the machine. Those included:

• Hold 200 of each blade type

• Adapt to future blade profiles

• Cycle time of 8 seconds

• Volume below 85 dBA

• Compact Footprint

• Ergonomically present specific number of blades

The solution to this problem starts with the magazines. These consist of 4 individual magazines mounted on drawer slides for easy access. Each one is equipped with a stepper motor that raises the lifting plate, ensuring the top of the blade stack can always be reached by the pneumatic system. Sensors are used to determine when the motor needs to be raised as well as when to reload the magazines.

3D printed parts (red components) are used to mount a lot of the previously named features. 3D printing was also used to make the handles and brackets as well for mor intricate parts. MGN rails are uses to make linear motion smooth. Sheet metal parts in all sections were ordered pre cut to save on machining cost and labor time.

The last step of the machine is how to present the blades to the operator. A 3D printed blade holder is translated by a belt driven motor system with an auto-homing feature to ensure consistent alignment within the different systems. Slots in the presentation carriage hold the collected blades to keep them from moving too much during motion. A large channel was also designed into the carriage for operators to have an easy and ergonomic method to pick blades from the machine.

Through our best efforts as described here, we won 2nd place for best video, and 1st place for best project! I am so happy and thankful the mentor, the industry supporter, and most important the team. This project taught me so much, and I am so glad I got to have a part in this.