Project Overview
This project focused on designing and developing a multi-bay drop testing system to evaluate the durability and impact performance of cushioning foam used in package handling within the SureSort robotic sorting system. In operation, packages weighing up to 25 lbs are dropped onto conveyors during sorting, requiring the foam to withstand repeated impact loading without degradation.
The objective was to create a robust, repeatable test system capable of simulating real-world conditions over extended cycles while ensuring operator safety and reliable data collection.
Design & System Implementation
I designed and built a four-bay drop testing fixture, where each bay independently tested a foam sample under cyclic loading. The system was engineered to repeatedly drop 25 lb weights onto test samples, replicating the worst-case operational conditions of the sorting system.
Key design challenges included:
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Ensuring structural durability under repeated high-impact loading
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Maintaining consistent drop conditions across all test bays
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Preventing system-level failure during long-duration testing
To address these, I redesigned structural components and machined custom parts to reinforce critical load paths and improve system stiffness. The fixture was designed to be stable, repeatable, and capable of sustaining continuous operation across all bays simultaneously.
A cycle-counting mechanism was integrated to track the number of drops per bay, enabling controlled testing and consistent comparison between samples.
Fault Detection & System Reliability
A critical addition to the system was a vibration-based fault detection mechanism designed to monitor abnormal behavior during operation. Given the high-energy impacts and long-duration testing cycles, there was a risk of component loosening, misalignment, or structural degradation within the fixture.
To mitigate this, I implemented a system that monitored vibration signatures and automatically stopped the test when deviations from normal operation were detected. This ensured:
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Protection of the test system from catastrophic failure
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Prevention of invalid test data caused by fixture degradation
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Safe operation during unattended or long-duration testing
This transformed the system from a simple test fixture into a self-monitoring validation platform.
Results & Impact
The final system provided reliable, repeatable impact testing across multiple samples simultaneously, significantly improving throughput and consistency of material validation. The integration of automated fault detection ensured safe operation and maintained data integrity over extended test cycles.
This project enabled accurate evaluation of foam durability under realistic conditions, directly supporting material selection and system reliability in the SureSort platform. It also demonstrated the importance of designing test systems that account for both mechanical loading and long-term operational stability.
Key Takeaways
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High-cycle impact testing requires careful consideration of fixture durability and load paths
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Test systems must be designed to prevent self-induced failure modes
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Vibration monitoring can serve as an effective method for real-time fault detection
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Reliable validation depends on both consistent test conditions and system integrity