mechanical design engineer
overview
Brain Corp has a successful autonomous driving OS product for industrial floor scrubbers. To further develop the efficiency and capability of these cleaning robots in stores like Sam's Club or Walmart, we were tasked to add the capability of scanning store shelfs for inventory keeping. This job involved working in conjunction with the software and electrical engineering team to add appropriate adjustable lidar sensors and cameras to the robot.
task
prototype a way to mount an angle adjustable lidar sensor and cover it with a shroud.
team
Joseph Cognato
Daniel Vandewiele
tools
SolidWorks, 3D Printing,
Sheet Metal DFM,
Rapid Prototyping
brainstorming
Initially we used foamboards and 2040 aluminum extrusions to prototype a folding tower that keeps a low profile when not needed for scanning, but this idea was later replaced with a short permanent tower that doesn't go beyond human height.
prototyping
Our design constraints for incorporating the LiDAR sensor focused on three key requirements:
Adjustability – The sensor needed to accommodate varying angles and positions for optimal performance in different scenarios.
Robustness – The design had to ensure durability and reliability, even in challenging environments.
Non-intrusiveness – The sensor had to be visually unobtrusive and seamlessly integrated without impairing the usability of the product.
Sheet Metal Mount
Using SolidWorks' Sheet Metal CAD tools, I designed a mount that attaches directly to the vehicle chassis. This approach ensured a robust and reliable attachment without relying on modifications to other parts in future iterations. The design file was thoroughly reviewed before being sent to a third-party metal manufacturer for production.
Installing the Mount
A significant part of this task involved disassembling and reassembling our OEM robots. One full day was dedicated to carefully dismantling the robot to access the chassis and securely install our custom mount.
3D Printing the Cover
Due to the limited build plate size of our in-house 3D printers, I designed the cover in SolidWorks as four separate sections. These sections were later assembled using precision jigsaw joints and secured with M3 bolts, ensuring a seamless and sturdy final product.
Assembling the Cover
One of the key challenges in designing the shroud was incorporating an acrylic window that allowed the sensor to operate at the precise angle required. Since the window was off-axis in all three planes, creating a single body with six different axes proved to be a complex task.
Seamless Integration with Existing Shroud
To achieve a visually seamless addition of the LiDAR sensor, I utilized the Boolean tool in CAD to work directly against the surface mesh of the pre-existing injection-molded shroud of the tower. This approach ensured the new design blended perfectly with the original structure.
The whole mount and shroud was then replicated to be attached to all 15 different robots.
testing
Thermal Testing of Electronic Components
To assess the performance of heat-sensitive components, such as the motherboard connected to the cooling fan, we conducted a two-week thermal test in a heat chamber. This allowed us to monitor the system’s ability to handle elevated temperatures and ensure reliable operation under stress.
final thoughts
Although my time as an intern was just a small part of this robot's development journey, I am proud of my contributions across various stages: design, manufacturing, testing, and even redesigning the in-house workshop for improved productivity. Seeing the product evolve in different forms—such as the version with a foldable tower for a specific OEM—makes my work feel even more meaningful. I'm grateful for the opportunity to have been part of the team at Brain Corp.