Automated Flashlight Assembly with UR5

Tools & Technologies: UR5, RoboDK, Python, Cartesian & joint-space motion planning, pneumatic clamping

• Programmed a UR5 collaborative robot via the RoboDK Python API to autonomously assemble a three-part flashlight (head, battery, endcap) without human intervention.
• Defined 15 Cartesian targets for pick-and-place, insertion, and fastening operations; used joint-space motion for fast transits and Cartesian linear motion near contact points to prevent collisions.
• Implemented a multi-stroke pre-threading routine followed by torque-controlled final tightening, coordinated with a pneumatic chuck and optical sensor for stable part fixturing.
• Completed the full assembly sequence in 1 minute 39 seconds, within the 110-second requirement.