Automatic Cigarette Rolling Machine Development

Designed and delivered a complete embedded control system for a fully automated preroll manufacturing machine — autonomously handling the entire production cycle from material crushing and mixing through to final rolling.

Built around an ATmega2560 MCU, the firmware concurrently orchestrates 20 stepper motors, 4 oscillators, and a vacuum motor within a tightly sequenced control loop with RTOS — each responsible for a distinct stage of the production pipeline. Achieving reliable simultaneous control across this many actuators demanded careful interrupt management, precise timing architecture, and efficient resource allocation within the firmware. Full-circuit simulation in Proteus was completed before any hardware was manufactured, catching timing conflicts and component sizing issues early.

Component selection was backed by proper electrical calculations, and a comprehensive documentation package — including full wiring diagrams and component specifications — was delivered alongside the hardware for client-side maintenance and future scaling.