TASK: As part of the hard disk fabrication process, the disks travel from one automated process to another in cassettes with 25 slots. At one point, they emerge with only 13 disks per cassette. We were tasked to develop a robotic device to fill in the missing slots and return all empty cassettes to their source. The final system needed to integrate with the clients existing conveyor lines.

SOLUTION: When a cassette enters the machine, it is driven into position by a tractor belt. All thirteen disks are removed by a custom vacuum pickup head. The empty cassette is then driven into a transfer shuttle where it is moved to an exit conveyor. The 13th disk is placed in one of 12 positions on a storage rack. The remaining 12 disks are then placed in the empty slots of the next cassette, which is allowed to continue. When there are 12 disks in the storage rack, they are placed in the next cassette. The goal of a full cassette leaving every 2 seconds was met.