AchieVe LPPT25 series pressure transmitters offer great value for general industrial applications. These pressure sensors feature a compact stainless steel construction, are ideal for space-limited applications, and are extremely affordable.
• Pressure ranges from vacuum to 5000 psig
• 4 to 20mA output
• 4-pin M12 quick-disconnect
Potable Water Pressure Transmitters
• 1/4 inch NPT male threaded process connection
• IP67 protection rating
Transmitters
Starting at $485.00
Endress+Hauser Ceraphant® PTP31B series digital pressure sensors provide dual process connections and are available in measuring ranges up to 6000 psig. The PTP33B series offers measuring ranges up to 600 psig and features a sanitary tri-clamp process connection for Food and Beverage applications.
• 4-20 mA analog, N.O./N.C. selectable, or IO-Link output options
• Built-in 4-digit LCD display
• IO-Link v1.1 compatible
• 316L stainless steel housing and process isolating diaphragm
• IP67 protection rating
Miniature Linear Motion Products
BIG ON ACCURACY & SPEED
THK is a leading manufacturer of high quality and ultra precise miniature linear guides, ball screws, cross roller rings and actuators for a wide range of industries, including industrial automation, medical, aerospace, semiconductor, machine tool and robotics.
LM Guides - SRS Series - Featuring patented THK Caged Technology, the SRS Miniature LM guides perform with smooth and quiet motion, long-term maintenance free operation, increased speed and accuracy, low dust generation and a long life.
Cross Roller Rings - RAU Series - THK Micro Cross Roller Ring Series RAU are compact and lightweight and even more rigid than a double row angular contact ball bearing type. Spacer retainers enable smooth movement and high rotation accuracy.
Ball Screws - BNK and MTF Series - BNK with finished shaft ends and MTF Roll-Formed screw shaft are known for their high accuracy, low noise, smooth movement and long-term maintenance free operation.
Actuators - KR Series - KR Actuators consist of LM guide units on the ends and ball screw unit in the center making them highly rigid and highly accurate in a minimal space.
To learn more, call us at 847-310-1111 or visit www.thk.com.
RAU
Adding to your career knowledge
One of the most exciting things we’ve experienced over the past year has been Design World’s steady growth, especially around our acquisition of Engineering.com, with its excellent coverage in areas such as design and design software, 3D printing, simulation, digital transformation, and manufacturing. Our work together with their staff provides you even more avenues (and connections) online when you visit either their website or our own designworldonline.com.
As part of our work together, we’ve identified several areas where we see a need in the engineering community for additional resources. So, over the coming year, we’ll be rolling out a variety of special reports together, all aimed at keeping you informed. Along with our annual Engineering Diversity + Inclusion issue, these special reports will include a focus on some future engineering leaders you need to know about and a comprehensive salary survey. There will also be stories covering the various details surrounding corporate job satisfaction for engineers, an innovative and all-new listing of the best places to engineer, and details on what the engineer of the future may look like.
We’re also finalizing a career development webinar series aimed at people in different stages of their careers. We’ll have information for students on scholarships, fellowships, and topics for degreed engineers, such as the importance of Professional Engineer licensure. But there will also be presentations on master’s degrees and why some mid-career engineers should consider going back to school. For example, engineers with master's degrees may earn as much as an additional 20% compared to their bachelor-degreed colleagues. They are also more likely to do innovative work, receive promotion opportunities, and stay in higher demand.
But we’re also seeking your feedback: What other content do you want from our editorial team? What stories and data would help you to solve problems at work? What do you need to advance in your career in the direction you most desire? We’re always looking for your insights and want to hear about your pain points. Please drop me a note at the email below and let’s talk. DW
Driving automation forward
Manufacturers are tailoring offerings for specific application needs and enhancing their networking capabilities.
The fundamentals of miniature gearing
Miniature gearing in Module-0.2 and Module-0.3 variations finds use in medical, haptic, and laboratory equipment.
Maximizing robot ROI through seventh-axis-enabled collaboration
Cobots require transfer units capable of maintaining compliancy to be safe around humans.
NOW ONLINE!
Help us honor the companies that have provided the most leadership in engineering
It has been a fascinating decade for all businesses, including manufacturers. We’ve seen the difficult supply chain issues brought on by the worldwide pandemic, along with a shortage of qualified workers and the strong reshoring trends in many industries. If nothing else, this helps to show how resilient manufacturers can be.
These companies represent the best and brightest, and they reflect the continued vision, integrity, and creativity of their design (and manufacturing) engineers.
We think they deserve recognition from you, too. Vote online for one or more of the companies listed through October.
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1949 - 2024: From sewing machines to drivers of innovation in cybertronic drive technology
Founded in 1949 – initially as a maker of double chainstitch machines with an innovative cutter for the production of ladies’ gloves – the family business has constantly evolved ever since, repositioning itself several times over three generations.
Today, the WITTENSTEIN group is a driver of innovation in cybertronic drive technology with an annual turnover of more than EUR 500 million and around 2900 employees at over 40 sites worldwide. The international high-tech group develops customized products, systems and solutions for highly dynamic motion, maximum-precise positioning and smart networking.
www.wittenstein-us.com |
AI-enabled counting tool automates quality control
Assembly verification and quantity checks can be time-consuming and error-prone. To automate counting tasks and improve accuracy, Cognex added an AI-enabled tool to its In-Sight Snapp vision sensor. The solution helps count challenging part types, including objects of similar size, reflective and distorted parts, and objects with varying contrasts and shapes.
The company aims to help manufacturers ensure consistent quality control without complex programming. Image-based training, guided setup, and embedded AI allow operators of all skill levels to solve counting tasks quickly and effectively, eliminating the need for complex setups or extensive training.
Suitable for numerous industries, the counting tool can be set up in minutes to perform various tasks. For example, food and beverage producers can count the number of products in the final packaging to ensure completeness. Pharmaceutical companies can verify the correct count of vaccine vials or count pills in a blister pack. Automotive manufacturers can quickly count modules in an EV battery pack tray to confirm proper assembly and avoid recalls.
Cognex released the In-Sight Snapp vision sensor in September 2023 to solve common quality control tasks, including presence and absence detection, basic inspections,
classification, and now counting. Earlier this year, the company also released the In-Sight L38 3D Vision System, which combines AI, 2D, and 3D vision technologies for various inspection and measurement applications. The system creates projection images that combine 3D information into a 2D image for simplified training and reveals features not visible with traditional 2D imaging. AI tools detect variable or undefined features, while rule-based algorithms provide 3D measurements to deliver reliable inspection results. DW
Cognex www.cognex.com
Design For Industry
POWER TRANSMISSION RETAINING DEVICES & maintenance &
Eccentric encoders no longer need backups
Encoder eccentricity, caused by off-center scale mounting and bearing runout, is a common source of angular error. Two encoders are often employed to compensate for the error, increasing cost and power consumption. Celera Motion’s Aura encoders solve this problem with a built-in compensation algorithm, eliminating the need for a second encoder.
The company recently announced the new Aura P, an extension to the Aura series of precision rotary and linear optical encoders with MicroE technology. Aura P offers high-resolution accuracy, high run speed, and wide alignment tolerances. It has a super compact form factor in a connectivity-ready PCBA package (12 x 14 x 7.4 mm), BiSS-C communication, and 90 mA current consumption. It currently cannot be daisy-chained and weighs 0.9 g. This compares to the original Aura, with an SMT package (9 x 7 x 1.2 mm), BiSS-C, SSI, SPI, ABZ communication, and 45 mA current consumption that can be daisy-chained and weighs 0.15 g.
Aura P is a suitable solution for high-volume OEM applications, including surgical robots; medical robotics, devices, and instruments; lab and diagnostics; metrology; cobots, robot joints, and grippers; advanced industrial and semiconductor; and linear stages. DW
Celera Motion www.celeramotion.com/aura-series/
WHITTET-HIGGINS manufactures quality oriented, stocks abundantly and delivers quickly the best quality and largest array of adjustable, heavy thrust bearing, and torque load carrying retaining devices for bearing, power transmission and other industrial assemblies; and specialized tools for their careful assembly.
Visit our website–whittet-higgins.com–to peruse the many possibilities to improve your assemblies. Much technical detail delineated as well as 2D and 3D CAD models for engineering assistance. Call your local or a good distributor.
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SEMICONDUCTOR
Measuring down to the micrometer
LED micrometers measure extremely small distances and dimensions to ensure the accuracy and quality of semiconductor components. They typically project a beam of light that either passes through or reflects off the object being measured. The amount of light that reaches a detector is used to calculate the distance or thickness of the object. For example, semiconductor manufacturers use LED micrometers to measure wafer thickness to ensure uniformity and adherence to tolerances.
The new optoControl 2700 high-performance LED micrometer by Micro-Epsilon enables accuracy for such measurement tasks. It can measure thickness, gaps, edges, and segments of small objects from 0.3 mm with a linearity of less than 1 µm and a digital resolution of 10 nm. This LED micrometer is used in semiconductor production, the automotive industry, aerospace, and medical technology.
The telecentric optics illuminate the measuring object evenly, and the real-time inclination correction ensures accurate results even at an angle or tilt, making orthogonal alignment of the measuring object unnecessary. The micrometer optimizes measurements for highly reflective objects, such as rollers, or transparent objects, such as glass wafers. Integrated contamination detection proactively identifies foreign bodies on the measuring surface, helping avoid errors and improving the measurement quality.
This LED micrometer has an integrated controller configured through a web interface accessed via Ethernet. Six presets enable quick and easy setup for the measurement task. The web interface also offers a scalable black-and-white image for easy alignment, enabling optimal graphical positioning. DW
To boost supply chain resiliency and sustainability efforts, battery manufacturers are exploring recycled and engineered cathode materials as an alternative to internationally mined sources. As a bonus, cathode materials from recycled battery metals can help EV battery manufacturers qualify for U.S. tax credits under the Inflation Reduction Act (IRA).
Ascend Elements uses a patented process called Hydro-to-Cathode direct precursor synthesis to manufacture cathode active materials (CAM) and nickel-manganese-cobalt precursor CAM (NMC pCAM) from used lithium-ion batteries and battery manufacturing scrap. The closed-loop process eliminates up to 15 intermediary steps in the traditional cathode manufacturing process and provides significant economic and carbon-reduction benefits. A recent life cycle assessment conducted by an independent third party found that Ascend Elements’ Hydro-to-Cathode process produces EV battery cathode material with a 49% reduction in carbon emissions compared to traditional cathode manufacturing processes. By 2030, the company aims to achieve a 90% reduction in carbon footprint for its decarbonized cathode products. Additionally, several peerreviewed studies have shown that its recycled battery materials perform as well as similar materials made from virgin (or mined) sources.
Earlier this year, Ascend Elements shipped decarbonized cathode materials to Freudenberg e-Power Systems for a commercial vehicle application. Since cathode material is the single largest contributor to a lithium-ion battery cell’s carbon footprint, the low-carbon cathode material will dramatically impact Freudenberg e-Power Systems’ batteries.
The companies worked closely for more than a year to engineer and manufacture the low-carbon cathode material to particularly high-performance requirements for lifetime, charge time, and safety.
Freudenberg tested Ascend Elements’ customized cathode product extensively and found it to have exceptional cycle-life results while achieving best-inclass safety. DW
Ascend Elements www.ascendelements.com
Freudenberg e-Power Systems www.freudenberg-eps.com
HANDHELD ENCLOSURES
Take a look at our huge range of designer handheld cases for today’s personal electronics, instrumentation and medical equipment. Options include battery compartments, display windows, integral cable glands and sealing up to IP 65.
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Propelling mobile machines with less energy
Propel solutions enable and control mobile machines’ movement (propulsion), including construction machinery, agricultural vehicles, material handling equipment, and other off-highway vehicles. Danfoss Power Solutions’ new ePanda eDrive for low-voltage applications is designed as a propel solution for mobile elevating work platforms. It is an integrated compact power system comprising an electric motor, microcontroller unit, and reduction gearbox aimed at maximizing efficiency, reliability, and safety.
The eDrive joins the ePowerpack in the company’s ePanda series of products for low-voltage electrification. Its permanent magnet synchronous motor maximizes propel system efficiency, reducing battery consumption and extending machine runtime. It offers a peak efficiency of 94% compared to 85% for competitive ac induction motor systems. It maintains high efficiency throughout its operating range, 17% to 31% higher system efficiency than ac systems at various speeds. The average efficiency improvement is 20%.
The ePanda eDrive’s integrated design has ingress protection ratings of IP67 (motor) and IP65 (controller), making it suitable for extreme environments. The braking system is durable and replaceable, and the gearbox in the leading position minimizes oil leakage risks.
With overspeed protection and inching control, the eDrive delivers a smoother, easier driving experience. It prevents rollback during hill starts and stops and enables gradeability of up to 30% and speeds of up to 6.4 kph. The eDrive is CE compliant and its safety stop and speed limitation functions meet ISO 13849 performance level D requirements, maximizing operational safety while ensuring suitability for use in global markets. DW
EDITED BY MIKE SANTORA
Automation advances help Texas children’s hospital
As part of routine maintenance, researchers feed the fruit flies by transferring them into vials containing fresh food every 30 days. A typical lab maintains around 20,000 vials and researchers spend about 20% of a workday “flipping flies” by placing a vial containing the fly stock over a vial with fresh food and tapping it to drop the flies.
ABB Robotics and the Jan and Dan Duncan Neurological Research Institute (Duncan NRI) at Texas Children’s Hospital, one of the largest pediatric hospitals in the US, have made an innovative medical breakthrough by creating an automated Drosophila melanogaster (Fruit Fly) transfer workstation, featuring ABB’s dual-arm YuMi cobot to aid the study of diseases including Alzheimer's, Huntington’s, and Parkinson’s.
This is the first automation solution that does not require the flies to be immobilized with anesthetics such as carbon dioxide before transfer, a tedious step in previous automation solutions, which can negatively impact the behavior of the flies and potentially the accuracy of study results.
ABB’s YuMi cobot performs the same movements as human researchers to tap and transfer the flies between vials, allowing
The robot’s advanced sensing technologies enable precise placement of vials within standard cardboard racks, granting researchers the option of continuing to use existing vial racks, reducing operational costs.
scientists to focus on mission-critical tasks such as discovering new pathways and testing the efficacy of new drugs in treating neurological disorders. This removes the need to anesthetize the flies before transfer, improving the accuracy of results and speeding up the transfer process.
“We have seen significant strides in lab automation over the years, yet
After passing UL’s Solid Particle Protection and Liquid Ingress Protection Tests per IEC Standard 60529 (Sec. 4.2, 13.4, and 14.2.4), Interpower’s C14 inlet Face Seal Kit as well as its Plug Seal Kit was given an Ingress Protection rating of IP54 per UL’s test report. The IP “4” rating (liquid ingress level) prevents liquids from “splashing” into the terminals causing possible arcing, which could lead to short-circuiting which may damage equipment, or possibly create fires or even electrocution. The plug seal kit offers both front and back side moisture protection.
Toll-Free Phone: (800) 662-2290 E-mail: info@interpower.com Business Hours:
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Bodine gearmotors with different degrees of water protection
Whether your application requires a gearmotor protected from light water splashing (IP-44) or heavy outdoor rain (IP-55 or IP-66) or washdown of a food processing machine (IP-69K), Bodine Electric Company has a product suited for that environment. And like all Bodine products, they are designed for long life, quiet operation, high quality, zero oil leakage, and reliable performance. Visit at bodine-electric.com
some crucial tasks are still performed manually which can impact results,” said Jose-Manuel Collados, Manager of ABB Service Robotics Product Line. “Our YuMi cobot’s arms work independently but in a coordinated way, making it possible to automate the complex task of transferring live flies between vials.”
Drosophila melanogaster, commonly known as the fruit fly, is well-established in the study of various aspects of biology, including genetics, development, and behavior. The fruit fly shares many genetic and developmental markers with humans and is used in studies on human neurological diseases globally.
As part of routine maintenance, researchers feed the fruit flies by transferring them into vials containing fresh food every 30 days. A typical lab maintains around 20,000 vials, and researchers spend about 20% of a workday “flipping flies” by placing a vial containing the fly stock over a vial with fresh food and tapping it to drop the flies. All attempts to automate the process involved exposing the flies outside the vials during transfer, hence requiring sedation.
ABB Robotics engineers collaborated with researchers at Duncan NRI to design and build a fly transfer workstation, including the YuMi cobot, a table stacked with vials for transfer, a barcode and labeling unit, and a trash chute.
“This innovative solution to accelerate biomedical research is a result of our close partnership of more than two years with ABB Robotics,” said Dr. Juan Botas, professor in the Department of Molecular and Human Genetics and the Department of Molecular and Cell Biology at Baylor College of Medicine and principal investigator at Duncan NRI.
ABB’s YuMi cobot performs the same movements as human researchers to tap and transfer the flies between vials, allowing scientists to focus on missioncritical tasks such as discovering of new pathways and testing the efficacy of new drugs in treating neurological disorders.
“Combining the fruit fly biology and high-throughput expertise of DNRI researchers led by me and Dr. Ismael-Al Ramahi, an assistant professor at Baylor College of Medicine and also a Duncan NRI investigator, with the automation expertise of ABB engineers, allowed us to design a cobot-based solution, which reduces time, eliminates strain loss, and allows for more experiments to be conducted in parallel.”
The YuMi handles the entire process of flipping fruit flies, which includes performing 10 pre-programmed steps in quick succession. Just like humans, the YuMi picks up a vial containing live flies, opens the protective cellulose acetate plug, places the vial over one with fresh food, taps the vials to transfer the flies, caps, labels, scans it; and finally stacks the vial in cardboard racks. The robot then discards the vials with the old food to avoid cross-contamination.
A significant technical feature integrated into the solution is the
capability to read barcodes and print labels, which are applied to the vials with strain and genotype information during the transfer. This feature ensures meticulous tracking and management of the Drosophila strains.
The robot's advanced sensing technologies enable precise placement of vials within standard cardboard racks, granting researchers the option of continuing to use existing vial racks, reducing operational costs.
More importantly, this robot is engineered to be cooperative and safe for human interaction. Its motion-sensing arms are equipped to detect nearby humans or objects, halting movement instantly to prevent accidents, thereby allowing for a safe collaborative workspace. DW
After passing UL’s Solid Particle Protection and Liquid Ingress Protection Tests per IEC Standard 60529 (Sec. 4.2, 13.4, and 14.2.4), Interpower’s C14 inlet Face Seal Kit as well as its Plug Seal Kit was given an Ingress Protection rating of IP54 per UL’s test report. The IP “5” rating (solid particle ingress level), prevents corrosive dust and solid particles from reaching the terminals, which could create loss of electrical continuity and disable machinery. Why not prevent an electrical arc from igniting any number of combustible dusts: metallic, chemical, plastic, carbonaceous, and others?
EDITED BY MIKE SANTORA
New technology for old school sculpting
In 1984, the Sterling Heights, Michiganbased company TARUS changed the automotive industry by introducing the Claymill. With full milling and scanning capabilities for the sculpting of concept vehicle designs, this CNC milling machine set the tone for how they still operate today.
When owners — and brothers — Dave and Doug Greig realized they needed to elevate and enhance the capabilities of their clay milling machines, they looked into SINUMERIK ONE machine control from Siemens.
“SINUMERIK ONE came at the right time,” said Dave Grieg. “We were looking to make a change that would bring added performance while also allowing us to keep our graphical user interface designed for clay modelers. That gives us our edge. With the Siemens control powering our machines, modelers can do things they never could do before.”
Finding another gear
“Timing was key to the TARUS-Siemens
partnership.” Scott Doyle of ElectroMatic, the technology partner for TARUS, knew his client’s needs.
“Understanding exactly what TARUS does and its superior motion control — a lot of what TARUS was doing was right up Siemens’ alley,” said Doyle, vice president of OEM sales at Electro-Matic.
“We took the SINUMERIK ONE package, we implemented it, and we tweaked it for our interface,” Doug said. “Now we have an extremely highperformance CNC machine control with our user interface.”
Boosting manufacturing performance TARUS and its customers are now realizing benefits across the production cycle, from machine setup and customization to machine performance and throughput.
Most important to Dave, Doug, and their customers was the familiar look and feel of the TARUS control. This was their biggest concern and biggest question when adapting TARUS machines to SINUMERIK ONE. The
process took about one year, involving collaboration between Siemens and TARUS staff.
“Nobody has the user interface like we have with the reliability of SINUMERIK ONE. That’s the secret sauce,” he said. “Because we already wrote our own software for our own control, we were able to make these two things work together for our customers’ benefit.”
Dave said customers who use TARUS machines as an extension of their own design sculpting teams are indeed achieving a higher-quality surface that rarely requires smoothing by hand.
“Our machines cut so precisely now that they don’t have to refine it,” he said.“It’s saving them valuable time.”
Faster cycle times
“In processing power alone, SINUMERIK ONE is 30% faster,” said Chris Grimm, OEM sales account manager at Siemens. Testifying to that claim, Doyle has seen the results first-hand
with TARUS’s internal machines. “Their throughput has increased tremendously,” he said.
Customers are saving even more time during the design and milling phase of the car models, as the TARUS software enables changes on the fly.
“With our software, customers have a choice. They can mill a car model, and if they want a small change, they can sculpt it by hand and then measure it. They can scan it with their scanning system; they can mill it on the other side of the model… There’s a lot of give-andtake with clay modeling. Our controls allow this to happen,” said Doug.
He also emphasized reliability as an essential customer benefit. Reliability means less downtime, which increases output, he said.
“The SINUMERIK ONE greatly improved reliability compared to our previous solution. Reliability translates into increased productivity for the customer, decreased warranty costs for TARUS, and greater confidence when selling these machines to new and existing customers.”
“SINUMERIK ONE is particularly helpful during machine setup and deployment, Doug said.” Using a process he calls “cloning” the TARUS team can program one machine and replicate it across multiple machines.
“We take the settings from one machine and put them on the next machine, turn it on, and it works,” he said. “Every machine acts just the same as the one we just built.”
Ensuring a productive future
Although Dave and Doug are focused on the here and now, they also are thinking long-term. That’s another reason the brothers felt comfortable switching from an in-house control. Siemens will support SINUMERIK ONE for many decades to come. TARUS and its customers will have no issues
The 5-axis kinematics capabilities of the SINUMERIK ONE control enable fluid and highly precise high-speed cutting paths, quickly achieving smooth surface finishes as the new car design begins to emerge from the modeling clay.
obtaining new parts or customer service — from both Electro-Matic and Siemens.
As beneficial as the switch to SINUMERIK ONE has been for TARUS, there’s room for more growth. The control package has features and options TARUS has only begun to explore, options that are particularly well-suited for other markets, including aerospace. Doug has already thought about expanding into manufacturing CNC machines for customers who make parts for the aerospace industry.
No matter the market, features of SINUMERIK ONE, such as the digital twin, can play a part. The digital twin is a virtual representation of a physical machine or process used to understand and predict the physical counterpart’s performance characteristics. Digital twins are used throughout the life cycle to simulate, predict, and optimize the product and production system before investing in physical prototypes and assets.
“Leveraging the digital twin and running parts virtually first before you actually put them on the machine so they can get accurate quotes for how long it might take for end-customers to do a mold or a die is a powerful option,” said Brian McMinn, business segment manager of Machine Tool Systems at Siemens. “Training benefits from the
digital twin as well. TARUS can train customers virtually before the machine even arrives at their location.” The possibilities are appealing to Doug, especially in terms of how TARUS supports its customers. “100% remote monitoring and repair of the machine is 100% possible,” he said. DW
Siemens Corporation siemens.com
The Siemens SINUMERIK ONE brings added processing power and reliability to the Gen 3 Claymill.
Quickly Building and Training Edge AI Multi-Sensor Smart Home Devices with Matter Connectivity
Smart home energy management systems, heating, ventilation, air conditioning (HVAC) controllers, smart locks, and more are being designed using the Matter connectivity standard. Many smart home systems need a variety of sensors for monitoring motion, sound, light, and environmental parameters like temperature, humidity, air quality, and air pressure merged into a sensor fusion platform.
That’s complex. Adding Matter connectivity or another wireless protocol like Bluetooth low energy (BLE), Bluetooth mesh, Wi-Fi, Thread, or Zigbee can increase
designers’ challenges. In addition to the needed hardware platform, the effort can be streamlined using an integrated development environment (IDE) that facilitates the process and boosts productivity.
Designers can benefit from using a prototyping platform that is pre-installed with firmware to work with the Edge Impulse mobile app to create and run embedded machine learning (ML) applications. Edge Impulse enables designers to build datasets, train ML models, and optimize libraries to run directly on edge and Internet of Things (IoT) devices.
This article presents the Nordic Thingy:53, a multi-sensor prototyping platform with Matter connectivity, embedded machine learning (ML), wireless IoT, and Edge AI devices from Nordic Semiconductor. It then presents an expansion board for implementing Wi-Fi 6 and reviews the benefits of related software development tools, including the nRF Programmer mobile app for flashing firmware on the go and nRF Edge Impulse mobile app for embedded ML and
The discussion closes by looking at Edge Impulse’s web-based interface, which enables developers with all levels of ML development experience to leverage TensorFlow and speed training.
Nordic Thingy:53 is based on the nRF5340 system on chip (SoC), for example, model NRF5340-CLAA-R, and includes sensors for motion, sound, light, and environmental parameters like temperature, humidity, and pressure. It’s designed to speed up the development of prototypes and build proofs of concept. Connectivity is important in edge AI/ML devices, and Thingy:53 lets designers select between various wireless protocols, including BLE, Bluetooth mesh, Thread, Zigbee, and Matter (Figure 1).
Firmware
In addition to comprehensive suites of sensors and connectivity, the nRF Edge Impulse mobile app is pre-installed on Thingy:53, along with the needed firmware to create and run embedded ML applications with Edge Impulse Studio.
The firmware simplifies the integration of the various sensors in applications
like voice recognition and movement pattern detection and recognition. In addition, the digital pulse density modulation (PDM) microphone and the accelerometer can be used to wake the SoC from sleep mode based on sound or motion events. Extending sleep mode until a trigger event occurs can be especially useful for saving power and extending operating life in battery-powered edge devices.
Processors, power, and RF
When the device is awake, the Arm Cortex-M33 application processor core of the nRF5340 SoC is clocked at 128 MHz to enable the Thingy:53 to handle heavy ML computational workloads and user applications without interfering with wireless connectivity. The 1 MB of Flash and 512 KB RAM provide plenty of room for application storage without consuming too much power.
Power consumption is also minimized by clocking the second Arm Cortex-M33 core of the nRF5340 used for wireless
connectivity at 64 MHz. That’s fast enough to support continuous connectivity with minimal power and relieves the main core from having to handle communication tasks. Key semiconductor devices on the Thingy:53 board include (Figure 2):
• nRF5340 SoC is the heart of the system and is on the top of the board.
• 128 MHz high-performance Arm Cortex-M33 application processor with 1 MB Flash and 512 KB RAM for application firmware
• Ultra-low-power Arm Cortex-M33 64 MHz network processor with 256 KB Flash and 64 KB RAM for protocol stack firmware
• Multiprotocol radio supports Bluetooth LE, Thread, Zigbee, Bluetooth Mesh, and proprietary 2.4 GHz protocols
• nPM1100 power management IC (PMIC) like the NPM1100-CAAAE-R on the bottom of the board.
Figure 1: The Nordic Thingy:53 multi-sensor prototyping platform for wireless IoT and edge AI/ML applications. (Image source: Nordic Semiconductor)
• High efficiency for improved battery life
• Full power path supports seamless switching between charging mode and battery operation
• nRF21540 front-end module (FEM) like the NRF21540-QDAA-R on the top of the board.
• RF front end for extended range
• Increases link robustness
Adding Wi-Fi 6
Nordic Semiconductor’s nRF7002 expansion board connects to the Thingy:53 and adds Wi-Fi 6 connectivity. The board plugs into an edge connector on the Thingy:53 and uses the Thingy:53’s nRF5340 SoC as a host device. A simple firmware upgrade enables Thingy:53 to communicate directly with the Edge Impulse Studio over Wi-Fi.
The NRF7002-EB enables the Thingy:53 to use Wi-Fi 6 features such as orthogonal frequencydivision multiple access (OFDMA)
for improving wireless network performance, beamforming, and target wake time (TWT) (Figure 3). It supports dual-band operation at 2.4 GHz and 5 GHz. With the NRF7002-EB, the Thingy:53 supports wireless protocols used in Matter, including Bluetooth LE (BLE) for commissioning, Wi-Fi for highthroughput, and Thread for low-power mesh.
Programmer app
The nRF Programmer app for the Thingy:53 is designed to speed the development of prototypes. The app allows users to update firmware using BLE directly from an Android
or iOS device without needing a PC. Developers can also upload precompiled firmware samples from the nRF Connect software development kit (SDK), including:
• Edge Impulse firmware
• Peripheral UART sample
• Mesh light, light switch, light fixture, and sensor samples
• Matter weather station example
• Zigbee weather station example
• ML examples
• Mobile app
Figure 2: Locations of major components on the Nordic Thingy:53 circuit board. (Image source: Edge Impulse)
Figure 3: Nordic Semiconductor Wi-Fi 6 expansion board for the Thingy:53. (Image source: DigiKey)
Nordic Thingy:53 comes with firmware that supports the nRF Edge Impulse mobile app. The app allows users to upload raw sensor data via a mobile device to the cloud-based Edge Impulse Studio (discussed below) and use BLE to deploy fully trained ML models to the Thingy:53.
The app lets users select between existing projects or create a new project. It can also collect sensor data from specific sets of sensors, including:
• Accelerometer
• Environment and inertial
• Inertial (accelerometer and magnetometer)
• Light
• Light and environment
• Light and inertial
• Magnetometer
• Microphone
• Temperature, pressure, humidity, and air quality
Edge Impulse IDE
Edge impulse is a cloud-based IDE that allows software developers to acquire and import sensor data and build, train, and test ML models, which can then be deployed and run efficiently on edge computing devices like Thingy:53 (Figure 4).
Edge Impulse fully supports Nordic’s Thingy:53, and Thingy:53 ships with Edge Impulse firmware. Users can choose between Edge Impulse Studio or the Nordic nRF Edge Impulse iPhone and Android over BLE apps.
The Edge Impulse IDE is compatible with microphones for audio data, cameras for images, vibrational sensors, and other sensory sources. Typical applications for the IDE include:
• Activity or pattern recognition.
• Anomaly detection.
• Audio detection for recognizing “wake-up words.”
• Image detection and object recognition.
Conclusion
Designers can turn to Nordic Thingy:53 to quickly design multisensor smart homes and other IoT devices with Matter connectivity. Thingy:53 is optimized to minimize power consumption in batterypowered edge devices. An expansion card can easily add Wi-Fi 6 capability, and Nordic offers extensive software
development tools, including the nRF Programmer mobile app for wirelessly flashing firmware and nRF Edge Impulse mobile app for embedded machine learning. Finally, Thingy:53 can communicate directly with the Edge Impulse Studio cloud-based IDE over Wi-Fi for ML application development and deployment. DW
Figure 4: Edge Impulse is a cloud-based IDE for edge ML development and deployment. (Image source: Edge Impulse)
Driving automation forward
Manufacturers are tailoring their offerings for specific application needs as well as enhancing their networking capabilities.
MILES BUDIMIR • SENIOR EDITOR
Drives
are electronic devices that interface between control signals and an electric motor or actuator. These days, digital drives have internal processing capabilities that allow them to not only manage position, velocity and torque loops but also take over high-level functions such as trajectory generation. Digital drives also allow tuning to be done via software, and they’re able to monitor internal functions and provide detailed fault diagnostics.
As drives continue to evolve, newer offerings are responding to broader industry trends in automation with new features and designs. They’re also finding use in new applications, particularly mobile e-vehicle designs.
Matching the correct drive to the type of motor in an application is critical for getting the optimal performance out of a system. A wide range of drives are available depending on the needs of the specific application and motor type.
Tailoring drives to applications
It’s common for drive manufacturers to tailor designs to specific applications, while at the same time integrating drives with other components and offering complete drive systems.
For instance, the ePanda eDrive from Danfoss Power Solutions is designed specifically for low-voltage applications.
Designed as a propel solution for mobile elevating work platforms, the ePanda eDrive is an integrated compact power system comprising an electric motor, microcontroller unit, and reduction gearbox that maximizes efficiency, reliability, and safety.
The drive’s permanent magnet synchronous motor maximizes propel system efficiency, reducing battery consumption and thereby extending machine runtime. The drive offers peak efficiency of 94% compared to 85% for competitive ac induction motor systems. It maintains high efficiency throughout its operating range, with system efficiency 17 to 31% higher than ac systems at various speeds, with an average efficiency improvement of 20%.
The ePanda eDrive also simplifies machine integration and installation. Compared to the next best alternative, the eDrive is 20% shorter in length and 23% lower in weight. As a fully integrated solution, the eDrive reduces the number of parts and labor hours required for installation.
Plus, the integrated design provides high durability and reliability. Ingress protection ratings of IP67 (motor) and IP65 (controller) make it suitable for extreme environments. The braking system is durable and replaceable, and by having its strong gearbox in the leading position mimimizes the risk of oil leakage.
With overspeed protection and inching control, the eDrive delivers a smoother, easier driving experience for operators. Its high controllability prevents rollback during hill starts and stops, while its high power enables gradeability of up to 30% and speeds
Aerotech’s Enhanced Scanner Control, or ESC, feature for the Automation 1-GL4 2-axis laser scan head drives is a passive control loop enhancement that ensures higher accuracy during the most dynamic motion.
of up to 6.4 km/hr. The eDrive is CE compliant and its safety stop and speed limitation functions meet ISO 13849 performance level D requirements, maximizing operational safety while ensuring suitability for use in global markets.
Other applications have different demands. Case in point; as the demand for laser processes with higher throughput is increasing across industries, quality standards are being tightened. As a result, conventional laser scanning systems quickly reach their limits. Aerotech is addressing this issue by upgrading AGV laser scan head performance through a powerful controller feature, Enhanced Scanner Control, or ESC. The new ESC feature for Automation 1-GL4 2-axis laser scan head drives is a totally passive control loop enhancement that ensures higher accuracy during the most dynamic motion.
Aerotech’s 2-, 3- and 5-axis laser scan heads all benefit from this feature, which allows higher accelerations with less tracking error so users see significant enhancement in laser process throughput.
A wide range of laser applications are already benefiting from ESC. Some of those include percussive laser drilling for electronics and semiconductor applications. Here, ESC delivers increased hole drilling efficiency with strict hole profile quality requirements. Another use is laser cutting and micromachining of display glass for automotive and mobile applications. In this case, increasing cutting velocity without sacrificing on-edge quality means higher throughput and steady quality yields. There’s also laser welding of medical devices. In this situation, higher frequency wobble motion during welding profiles enables higher weld quality and minimizes post processing.
The ePanda eDrive from Danfoss is an integrated compact power system comprising an electric motor, microcontroller unit, and reduction gearbox.
Networking and communication features
For newer machinery with the most advanced automation features, networking and communication plays a key role in attaining optimal performance. For instance, ACS Motion Control recently debuted a new compact single-axis EtherCAT Mini Drive Module for OEM machine designers. The MDMst is the first member of the Mini-universal Drive Module (MDM) series of EtherCATbased drives. Its small form factor allows OEMs with demanding motion control applications to develop even more compact machines. Controllable by any ACS SPiiPlus Platform EtherCAT master, it leverages powerful servo control algorithms to maximize motion system performance, while its universal servo drive technology provides the system designer flexibility to control most types of motors or stages.
Key features of the MDMst include a PCB mount or non-enclosed panel mount options as well as universal motor and encoder support for maximum motor/stage flexibility. The units feature maximum drive current to 5 A continuous, and 10 A peak, and a
drive supply input of 12 to 48 Vdc. There is one feedback channel (for AqB, SinCos, or Absolute) as well as analog and digital I/O.
The MDMst’s small form factor allows it to be mounted close to the axis being controlled, reducing cabling. Or it can fit in smaller systems where cabinet space is limited or non-existent, like in table top equipment.
Examples of common applications include ones where fast Z-axis motion is essential, in applications such as voice coil stages or BLDC motor stages, autofocus in inspection machines, step and measure in biotech applications, pick and place in electronics assembly machines, and soft touch landing for contact testing. Fast, compact theta axis comes in handy for fast rotary alignment, but also in biotech tabletop lab equipment.
Another key requirement for networking infrastructure is interoperability between the many protocols used in industry. Manufacturers are continually evaluating and upgrading their networking options to meet these requirements.
Case in point is Kollmorgen’s latest update to its AKD2G servo drive. With the introduction of these new features, Kollmorgen’s latest update to its AKD2G servo drive includes new features such as support for PROFINET IRT and Ethernet/IP with CIP Sync alongside CANopen, EtherCAT, and FSoE time-synchronized communication protocols.
Kollmorgen has broadened its offerings to additionally support PROFINET IRT and Ethernet/IP with CIP Sync alongside CANopen, EtherCAT, and FSoE timesynchronized communication protocols. Each protocol is rigorously tested with a variety of motion controllers and certified by industry standards organizations.
The AKD2G servo drive update allows for synchronized motion between multiple drives using a wide variety of control architectures. Thanks to its flexibility and high performance, AKD2G is the ideal drive for use in applications that require highly precise coordination across multiple axes of motion.
The drive features industry-leading power density in a compact package and is easy to mount — with one- and two-axis variants available. Engineers can leverage single-cable Smart Feedback Device (SFD) or HIPERFACE DSL connections or choose from a wide range of other feedback devices.
Finally, the drive features an optional SafeMotion Monitor (SMM) firmware with a safety level of SIL3/PLe to meet functional safety needs and enable a wider range of applications.
The AKD2G paired with AKM2G motors is part of the 2G Motion System, a suite of motion products designed to work together for ultimate ease of setup and higher performance. Engineers also can take advantage of the drive’s compatibility with a wider range of controllers and feedback devices — or with other motors, as needed. DW
Danfoss Power Solutions www.danfoss.com
Aerotech www.aerotech.com
ACS Motion Control www.acsmotioncontrol.com
Kollmorgen www.kollmorgen.com
The MDMst is the first member of the Mini-universal Drive Module (MDM) series of EtherCAT-based drives from ACS Motion Control. Its small form factor allows OEMs with demanding motion control applications to develop even more compact machines.
LISA EITEL • EXECUTIVE EDITOR
Fundamentals of miniature gearing
Miniature
and microgearing with high precision and tight tolerances is used to deliver accurate low-backlash power transmission complementing small electric motors in:
• Medical devices and surgical tools
• Aerospace rovers and satellites
• Small motorized electronics.
Such gearing is most often paired with small dc motors that are either brushed or brushless — with coreless permanent-magnet motor types increasingly common in these applications.
Consider a specific haptic application — that of electronic fly-by-wire flight control. In these systems, a pilot’s steering movements aren’t transferred via conventional mechanical or hydraulic actuators. Instead, electronic transmission occurs via force-feedback feeling through the motor assembly in a joystick control column. Such hapticsgenerating motor-driven designs benefit from miniature gearing capable of smooth backdrivability and simultaneously generating torque and force based on joystick position.
Gear arrangements in these and other miniature and microdesigns are often customized with specialty
mounting geometries, tooth profiles, diameters, and integrated sensing or other components.
What’s more, such miniature gears are usually constructed from high-strength materials to maintain overall design compactness. Subcomponents of stainless steel, titanium, and specialized plastics and composites are common where the gearing is destined to be implanted in the human body due to these materials’ corrosion resistance and biocompatibility; for the latter, additional surface treatments are sometimes applied to gear housings to discourage bacterial growth. Gears made of noncorrosive materials are often customized by component suppliers using precision molding and machining capabilities in controlled settings to satisfy FDA medical-manufacturing requirements.
Dreamstine
Expressions of miniature gear sizing
Gear modules are a unit of measure defined by the International Organization for Standardization (ISO) expressing geartooth size or pitch, spacing, and how the gearset assembly meshes. Defined as the gear pitch diameter divided by the number of teeth, this module relates overall gear size to that gear’s number of teeth. Sets of gears must have matching modules.
Miniature gearsets having 0.2 modules feature a 0.2-mm pitch diameter for each tooth. This makes for very fine and small teeth to operate in watches, micromotordriven electronics, and small medical devices … though these gearsets can only be produced through advanced manufacturing approaches. Module-0.3, 0.4, and 0.5 gearing in contrast is common where more power is needed — as in small pumps and autonomous consumer electronics. Module-0.8 to 1.0 gearsets (at the high end of what’s generally considered miniature) deliver more torque than the smallest gears can provide for small automotive, medical, and robotics applications.
Applications in medical settings
Miniature and microgears for medical devices must meet regulatory requirements and exacting standards to ensure patient safety. Satisfaction of additional sterilization, RoHS, biocompatibility, and MTBF requirements may also be necessary. Manufacture of these gearsets is often executed in cleanroom settings to ensure the substantial engineering, customization, and applied material science is expressed in the final component assembly. Machined and molded subcomponents are typically pre-integrated by the supplier for the same reason. That’s true whether a miniature gearset is produced for prototyping quantities or full production runs.
In servodriven applications where load inertia is high compared to motor inertia, miniature gearing can reduce settling time. Dreamstine
In laboratory automation, miniature and microgears in dc gearmotors are used in blood and gas analysis machinery, genomic testing equipment, cytometers, and automated diagnostic systems. The smallest gearsets find use in analyzers and centrifuges where exacting control over speeds ensures properly processed biological samples.
Miniature and microgears are used medical robotics as well. Module 0.2 gears in particular find use in surgical robots to allow for accurate motion control over minimally invasive procedures. The compactness of such gearsets allows for the smallest possible robotic end effectors to delicately maneuver through and manipulate small-scale structures in the human body. Linear performance characteristics make motorized systems featuring these gears suitable for applications requiring tight motion
control. Case in point: Ophthalmic surgical and diagnostics tools (for which accurate control is paramount) often incorporate module-0.3 gears to facilitate fine positioning of tools on delicate and complex eye structures.
Cardiorespiratory equipment as well as other medical fans and pumps also make copious use of miniature and microgears. Module-0.2 gears in micropump motorized designs (including those for renal care and drug-delivery systems) allow for precise control over fluids to ensure dosing is accurate. In contrast, the most common wearable insulin pumps (for which patient safety and treatment efficacy are paramount) feature precision module-0.3 gears. Other implantable medical devices such as cardiac-assist devices, neurostimulators, and implants feature miniature and microgears primarily designed for long-term reliability.
In handheld medical tools such as dental drills and portable handheld instruments for emergency medical services, precision module-0.2 gears are widely used to maintain the design accuracy of lightweighted equipment. Many endoscopic and laparoscopic devices integrate miniature module-0.3 gears in tool end effectors that execute the precise cuts associated with biopsies and other manipulations.
Bearings are key to miniature and micro gear designs
Even the smallest gearsets require shaft bearings to allow gears to turn. Some include simple steel pins to serve as plain bearings. Others include modestly more rugged ceramic pins for plain bearings to satisfy high torque and life as well as low noise and backlash requirements. Still others incorporate FDA-compliant miniature ball bearings
and pillow block bearings made of engineered plastic. However, the most demanding applications may benefit from needle roller bearings.
High-performance miniature products complete with miniature needle bearings on which the tiny gears spin allow backdriving and maximize efficiency, which is especially important on small battery-powered designs.
Consider haptics-reliant surgical robots for minimally invasive microsurgeries and telesurgeries. Doctors performing surgery via these robots dynamically and instantaneously feel forces equivalent to those exerted by the robot end effectors. Here, gearboxes with smooth backdrivability are essential. Miniature gearsets with needle roller bearings deliver on this parameter even on axes needing gear ratios necessitating two or three stages. Traditional gearing exhibiting uneven or sticky backdrivability is mechanically noisy and unusable in these robots.
Considering miniature gear lubrication
Miniature gearing either employs oil or grease lubrication or features selflubricating elements compatible with the destination setting. Where oil or grease are used, cooler operation can significantly extend lubricant life (and gearset life with it) because there’s less thermal stress. So, gear teeth
are slower to shed abrasive particles and the lubricant is slower to exhibit chemical breakdown. Of course, medical devices require the use of nontoxic and biocompatible lubricant.
The special case of planetary gearing
Miniature planetary gearsets offer advantages over other miniature gearsets including multiple kinematic combinations, power density, big reductions from compact setups, and pure torsional reactions. With precision sets, losses never exceed a few percent per stage. That’s helpful for boosting overall design efficiency and keeping assemblies cool — a key objective where miniature gear and motor pairings drive handheld tools.
Some miniature planetary gearing with multiple stages can get efficiencies to 90% — far better than the 70% or so of comparable designs. So, if fitted with an otherwise identical motor and controller, a system with this gearing can output 30% more power or consume 20% less input to deliver a given output. If the design happens to use a brushed motor, that extends the brush and overall system life. Plus, more efficient gearing lets the motor operate at higher on the efficiencytorque curve or (with the help of control electronics) allow use of a smaller and lighter motor.
Miniature planetary gearing efficiency is particularly useful in battery-powered medical devices and other miniature designs because it’s key to helping them operate longer between charges and battery swaps.
Miniature gearsets featuring rollingelement bearings mentioned earlier are especially well suited to haptic force-feedback applications because their smooth-turning planet gears allow repeatable backdriving from the system output. So, torque feedback via the gearset to the motor on the gearing’s input is consistently proportional to the load. Traditionally built planetary gearheads can’t guarantee smooth backdrivability or consistent load interpretation through the gearbox. That’s because of their fluctuating efficiency, variable tolerance stackup between gearbox internals, and the potential cocking of planet gears. DW
In the burgeoning field of motorized prosthetics and exoskeletons, module-0.3 gears integrate into motorized joints mimicking natural movements. Dreamstine
MAXIMIZING
COBOT ROI
MOST robot arms have six axes of motion, fewer than a human arm, but still plenty of range to automate complex industrial operations with speed, precision and consistency unattainable by humans. Although the cost of implementation has dropped dramatically over the years — from hundreds to tens of thousands of dollars — a robot is still a capital investment needing a solid
Robot transfer units have become increasingly important to automated settings. Now, transfer units with collision detection pair with collaborative robots for human-centric technology enabling previously unimagined levels of productivity.
THROUGH SEVENTH-AXISENABLED COLLABORATION
KYLE THOMPSON PRODUCT INNOVATION MANAGER
THOMSON INDUSTRIES
CHRIS DIAK
SOUTHEAST AUTOMATION MANAGER MOTION
business case. Adding a seventh axis to a traditional six-axis robot helps make that case by simplifying the transport of a single robot to multiple locations, functioning as robot transfer units or RTUs. By design, the cobot segment within the robotics category provides collision protection to avoid human injury. When adding a seventh axis to extend robot arm capabilities, encompassing the
collision protection for the seventhaxis controls strengthens the business case with a safer RTU design. With the collision protection included in the system, the RTU has now become a cobot transfer unit or CTU.
The benefits of a seventh axis While six-axis robots are usually fixed to a single location, a seven-axis system mounts the arm on a carriage attached
Ball Splines
• 6 Nut Shapes
No Backlash No Vibration Higher Loads
• 16 Shaft Diameters (4 – 100mm)
• Custom Modi cations Twice As Fast
• 10X Load Capacity*
• Longer Travel Life*
• Nut and Shaft Available in Stainless Steel
Oil hole to oil channel.
No backlash because precisely ground (not drawn) raceways conform to shape of ball in nut and shaft so opposing raceways have same angles of contact.
Wiper Seal.
Anti-rotation torque transmission.
Spline shaft is straighter than competitions’ – eliminating rotational vibration.
Greater ball contact in nut permits compact single shaft applications.*
*When compared with ball bushings.
All ball tracks are in contact with racewaysonly half of competitions’ are in contact in any one direction.
to an actuation element. This moves the robot along an axis as long as 10 meters, dramatically extending the range of operation as shown in Figure 1.
A movable robot opens many possibilities for cost efficiency, enabling the arm to extend its reach beyond the capabilities of a standard six-axis robot. This extra degree of freedom makes it easier for the robot to navigate around obstacles, reach into tight spaces or serve larger work areas.
Adding a seventh axis combined with motion profile recipes for each part per workstation allows the user to program one robot to act like multiple robots. An assembly application might juxtapose four milling stations in a row. When the milling targets arrive, the arm selects one and serves it to the machine. Then, instead of idling in wait for the next part, the arm would move along the seventh axis to the next workstation, repeating the operation. Most robots can free drive, which simplifies the initial training. Some seventh-axis systems also have a free-drive mode, making the whole station training easy and flexible. A robot can work with larger part trays due to its extended reach capabilities. This enables it to do more in less time, perhaps working in an envelope holding a day’s worth of millwork while refreshing the base parts overnight.
When one reviews the initial cost of $50,000 to $100,000 per robot to serve each milling station, consider that one seventh-axis robot could move between comparable operations to accomplish all the work. ROI on a single robot could justify the purchase, delivering the traditional benefits with the highest efficiency. Factoring in the possibility of labor shortages further justifies the cost because a single robot solution could accomplish work that might be reprioritized. This reprioritization could be due to a lack of trained labor or low part demand, increasing the assigned labor cost in the first place.
The human touch
Should the milling application example incorporate a cobot, it could be useful to have a human reviewing the full process. The program can be revised for optimization and checking the milled parts for quality. However, the need to tend multiple machines in such areas would make it difficult to address all the safety demands of operating machines and humans in such proximity per the risk assessment.
Installing cages or other guard technology can degrade operational efficiency. A balance to meet the risk assessment and production requirements might let plant personnel run operations more slowly, but this might diminish throughput. Another approach is to consider collision detection monitoring on the CTU as part of the overall risk assessment, combined with guarding or safety devices appropriate for the application.
CTU designers can afford such a capability by deploying collision detection paddles on both sides of the carriage, where an operator might instinctively put a hand as shown in Figure 2. Forces as low as 13 N — about
the force used in a computer keystroke — would be enough to signal the system to stop at once. A combination of current limit and position error monitoring would enable the detection, complementing similar sensing that may already be embedded into the joints of the robot arm. In all cases, users can adjust the sensitivity of both the seventh axis and the cobot arm. They should do this based on a risk assessment that considers the motion profile, moving materials and other application aspects.
Working with the robotic arm
In a CTU, the robots would handle the heavy lifting, precision welding and assembly tasks. At the same time, humans perform quality control, fine-tuning and complex decisionmaking processes, which can increase production speed and quality. Following are some applications that might benefit from human-robot collaboration. Machine tending: In addition to the milling example mentioned earlier, machine-tending CTU applications include CNC, injection molding and presses, where one person can tend multiple machines with the same robot. Material handling: Bin picking, packaging or palletizing could benefit by moving the robot arm to extend the human’s reach for heavy products in tight spaces.
that enables transfer of the arm to multiple locations, allowing one robot to do the work of various robots. Thomson Industries
Welding: Human control and monitoring of the arc of motion can enable longer welds.
Assembly: Human monitoring of insertion, nut driving, riveting and screw driving at multiple work locations can help maintain consistency.
Quality inspection, measurement, and testing: Shared control of quality inspection devices, such as cameras and scanners, highlights and helps fix inefficiencies.
Dispensing: With automated dispensing of dense/sticky materials such as glue or sealants, humans could enable longer beads by monitoring for consistency and regulating accordingly.
Only the beginning for robotic installations
Whether one wants to increase robot ROI in applications or design a new robotbased system, CTUs can provide quicker ROI and pay for themselves many times over.
First, they let manufacturers to address those dirty, dull, and dangerous applications (the Three Ds) more efficiently, with one cobot doing the work of many.
Second, CTUs can fill gaps in staffing, letting manufacturers reach production quotas that are otherwise impossible. Finally, they improve ROI by balancing human/robot collaboration. Humans provide planning, monitoring and decisionmaking capabilities, and the robots enforce efficiency in the Three Ds.
CTUs however are still a relatively new technology and becoming more affordable, easier to use, and essential to a highly dynamic industrial market. They will likely be key enablers in what industry watchers call the Fifth Industrial Revolution or Industry 5.0. These terms describe human-centric and robot technology combined with AI to bring previously unimagined levels of productivity and value to automation. As engineers innovate to meet the demands of emerging markets, the greatest benefits of human-robot collaboration are yet to come. DW
2. Thomson’s MovoTrak CTU uses collision detection paddles to sense unplanned loads from accidental human contact and stop motion. The robot arm is also sensitive to accidental human contact. Thomson Industries Motion motion.com
Figure
eVtoL future
wing designs Airbus accelerates with the help of software platforms
The aircraft maker’s Wing of Tomorrow program leverages 3DExperience tools to cut months from the development cycle.
Tereza Pultarova
Airbus is reinventing the wing to make it fit for the age of carbon-neutral aviation. The company’s engineers are taking advantage of a 3D digital “co-architecture” environment that enables them to optimize the wing design and the manufacturing process in one go.
Since 2016, teams at the European aerospace giant’s Wing Technology Development Centre (WTDC) in Filton, U.K., have been playing with unconventional ideas that could change how aircraft-makers approach wing design. Pressed by the need to eliminate the carbon footprint of aviation by 2050, in line with international commitments to fight climate change, Airbus is experimenting with lighter composite materials to reduce weight. The company also wants to make wings longer and leaner to increase lift and lower fuel consumption. The goal of the research program, called the Wing of Tomorrow, is to offer a menu of different technology solutions “to enable the development of the next-generation wings,” Airbus says. The work has already produced results, and the first demonstrators are being built to undergo testing next year.
Yann Lewis, the Wing of Tomorrow’s head of engineering, says Airbus has built the demonstrators using a novel approach that relies on advanced digital tools
allowing engineers, designers, and manufacturing experts to interact with each other in the same 3D digital environment in real time.
“When we came to assemble the Wing of Tomorrow wing boxes, we had very few instances where there was a clash with manufacturing requirements,” Lewis said. “We were able to get it right the first time, which I haven’t seen in many other Airbus programs before. That’s of great value because in any sort of serial production environment, if something doesn’t work right the first time, it takes a long time to fix it.”
Finding paths for automation
A wing box is the load-bearing structure of an aircraft wing to which other components, such as flaps and wingtip devices, attach. Assembling these structures has traditionally been a tedious, manual process, says Lewis. Technicians must at times climb inside tight fuel tanks located inside the wing boxes to install fasteners and fuel pipes. In the future, Airbus hopes to make the assembly process more automated to speed it up and make it more comfortable for the personnel. The collaborative digital design approach trialed as part of the Wing of Tomorrow program helps the engineers identify which tasks could be taken over by robots and how to redesign the factory to optimize workflow.
“If you look at the wing assembly process of the single-aisle A320
The Wing Technology Development Centre’s goal is to develop a menu of technology solutions that can feed new wing designs.
aircraft [Airbus’s flagship narrow-body aircraft manufactured since 1984], it’s very manual,” said Lewis. “As part of the Wing of Tomorrow program, we are looking for opportunities for automation, the use of robots for positioning parts, clamping parts, drilling. It’s quite a big step change.”
Lewis added that although the design changes may seem subtle, the engineers wouldn’t be able to identify them without working in a common environment with the manufacturing experts from the start.
“We would likely have encountered problems or clashes between robots and structure later on during the build when it is too late to change the design,” he said.
AExxxPGA Family
Ultra-low Loss Power Inductors
This step change in the way aircraft are built is called for. According to the International Civil Aviation Organization, demand for air transport is on the rise and will continue to grow over the next 20 years at a rate of 4.3% per year. For Airbus, currently the world’s biggest manufacturer of passenger planes, that means the need to build more aircraft and build them faster, in addition to ensuring that this new aircraft produces less carbon emissions
A platform for possibilities Airbus has been using computer-aided design (CAD) and computer-aided engineering (CAE) tools for more than four decades, pretty much since the technology was introduced in the 1970s.
• Offer up to 40% lower DCR than previous best-in-class inductors
• Meet NASA low outgassing specifications
• Pass vibration testing to 80 G and shock testing to 1000 G
• Currently offered in eight sizes with inductance values from 0.11 to 47 µH and current ratings up to 38 A
| Airbus / Neil Phillips Photo and Film Ltd.
For more than twenty years, the firm has been relying mostly on the Catia CAD and CAE software suite developed by French company Dassault Systèmes. However, Airbus’s adoption of Dassault’s 3DExperience software platform, which integrates Catia with Delmia (manufacturing), Enovia (PLM) and other tools, opened new possibilities for Airbus.
“We can collaborate and come up with designs that are lightweight, efficient, and perform well structurally,” said Lewis. But we can also be more sympathetic to the manufacturing process. We can visualise the proposed solution and model the type of tooling that we might need to create certain attachments, see whether there is enough space and whether it’s going to be ergonomic.”
The simulations are instantly fed data from completed hardware tests to compare accuracy of the predictions with real-life performance and, in turn, improve fidelity of future simulations. The 3D CAD model also automatically links with the finite element analysis (FEA) model that engineers use to analyze the resiliency of the assembled wing boxes. The linking of the CAD and FEA models means that any updates in the design are immediately reflected in the simulation, shortening the development cycle by “months of time,” said Lewis.
“We’re able to run and show the results of any simulations within the same environment, as well as capture data from the tests that we do and any manufacturing steps that we have,” said Lewis. “We can pull all that data into the same environment, which means that we have a much better understanding not only of how to design [the product] in the first place, but also as we move it through the design and manufacturing cycle”
Simulation advances wing testing
In early 2025, the team at Filton plans to take one of their perfected wing boxes and attempt to break it. Attached to a test airframe inside a giant hangar, the wing will be pulled up and down by a system of levers with a gradually increasing force until it cracks. Before breaking the wing for real, the engineers will simulate each of the 12 tested load scenarios digitally.
“Thanks to the simulation, we have a first confident view of how that wing is going to behave during the test,” said Lewis. “That means we can identify areas of interest where something interesting is going to happen on a particular load case. That allows us to put the right instrumentation onto the test specimen to monitor and capture the behavior.”
Over the years, the engineers have conducted many smaller-scale test, the results of which were captured by simulation software, giving the team high confidence in the results of the simulations. Such experiments have been part of Airbus’ testing procedures for decades, but only recent advances in computer technology allowed them to model the entire wing-breaking process.
“It started off with pitifully small and simple models,” said Lewis. “Like three or four rib bases, because we didn’t have the computing power to resolve more. Now we have a simulation model that covers the whole of the wing in a way that predicts the types of behavior that in the past were limited to those smaller models.”
Lewis says that simulations will never fully replace hardware tests but will reshape the “testing pyramid” in a way that proves various design solutions more quickly and earlier in the process.
“You can do more and more quickly, explore a wider design space and also compress some of the timescales,” said Lewis.
In the future, Lewis foresees many of the tasks performed by engineers today being taken over by artificial intelligence. Data collected in the collaborative simulation environment could help Airbus begin experiments and train algorithms that could be used to design wings beyond the Wing of Tomorrow program.
The demonstrators developed as part of the Wing of Tomorrow project are not yet intended for any existing or planned aircraft line and might take decades to take to the skies. The engineers are proposing, for example, to add four-meter-long folding wing tips to the wing boxes to increase their lift while at the same time maintaining the aircraft’s dimensions within the limits required by existing airport infrastructure. AD
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How Joby Aviation created its
low-noise flying taxi
The eVTOL diminishes its decibels one rotor blade at a time.
Joby Aviation’s eVTOL is 100 times quieter than a helicopter of similar mass, thanks in part to its propeller design. | Joby Aviation
Tereza Pultarova
Flyingcars have been a staple of science fiction for decades. Soon, they might be whisking wealthy city dwellers from point to point while common folk idle in traffic jams below.
California-based Joby Aviation hopes to obtain a license from the Federal Aviation Administration (FAA) for its hexacopter-like vehicle to shuttle paying passengers around America’s busiest cities as early as next year.
The electric vertical take-off and landing (eVTOL) aircraft can carry four passengers and a pilot, fly 100 miles on one battery charge and reach speeds of 200 mph. During the aircraft's 15 years of development, Joby engineers had a major problem: making the aircraft so quiet that it wouldn’t bother city dwellers.
“From day one, we considered a low acoustic footprint to be a core design requirement for the Joby aircraft,” said Didier Papadopoulos, president of Joby’s Aircraft OEM division. “We knew that in order for electric flight to become an accepted mobility tool in and around cities, our aircraft would have to be orders of magnitude quieter than today’s helicopters – and that is exactly what we’ve achieved.”
As quiet as a conversation
There's no missing a helicopter hovering above a city. The noise of its rotor blades interacting with the surrounding air thunders compared to the background noise of an urban environment.
The sound of an air ambulance rushing to save a life, a police chopper on the hunt for a fugitive or the occasional politician on their way to a high-profile event is considered a fact of life in the city. But hundreds of helicopters carrying people across the city solely for convenience will almost surely spark public outrage. Furthermore, transport noise pollution is a significant health hazard, with studies showing that exposure to consistently elevated levels of noise frequently causes disturbed sleep and stress, increasing the risk of heart disease and diabetes.
Joby, therefore, set out to make its eVTOLs barely perceptible “against
the ambient environment of cities.” That goal was achieved two years ago when a NASA-led test campaign proved that the sleek air produces sound of about 45 weighted decibels (the relative loudness perceived by a human ear) when flying overhead at a distance of 500 meters. That’s quieter than a regular human conversation. An average helicopter hovering 300 meters away generates nearly 80 dB, nearly a thousand times louder than the Joby aircraft. Papadopoulos says Joby’s aircraft is 100 times quieter than a helicopter of a similar weight. The company compares its sound to the rustle of leaves in a breeze.
“Our aircraft’s low noise profile is the result of more than 10 years of hard engineering focused on acoustics, ranging from the design of our motors and propellers to the overall architecture of the aircraft,” Papadopoulos says. “There are numerous aspects of the aircraft’s design that have been selected and optimized to both reduce the magnitude of the sound produced during flight and improve the quality of that sound.”
Minimizing blade-vortex interaction
The Joby aircraft can be piloted remotely, but the company plans to fly passengers with a pilot on board to improve comfort and safety. The eVTOL's six propellers are arranged roughly hexagonally and draw power from four battery packs similar to those used in electric cars, with each motor drawing power from two of the packs to reduce the chance of failure.
But Papadopoulos said that swapping an internal combustion engine for an electric one doesn't solve the helicopter noise problem because most noise results from the rotor blades moving through the air. Joby's engineering team countered this by perfecting the design and positioning of the six propellers and each of their blades.
“Many aspects of Joby’s configuration were carefully selected to minimize or eliminate noisy adverse interactions between air flows produced by our six propellers in all stages of flight,” said Papadopoulos. “This
includes maximizing the distance between each propeller, the placement of propellers relative to the airframe, and the raised tail rotors."
Each propeller can also independently adjust its rotation speed, tilt, and the pitch of its blades. That, Papadopoulos explains, enables the aircraft to minimize the interactions between the blade tips of one propeller and the aerial vortices caused by the blade tips of another. Since the rotor blade tips slice the air at half the speed of sound, suppressing these vortices is extremely important.
The amount of noise each blade produces is also proportional to the weight it lifts. “We made careful decisions around the number of propellers our aircraft has — six larger propellers instead of more, smaller propellers — and five large-area blades per propeller,” Papadopoulos said. “This directly correlates to noise through the tip speeds of the rotor blades.”
However, the Joby vehicle is not purely a giant drone. The aircraft also features an 11.6-meter wing that takes over most of the lifting work once the vehicle is aloft. According to Papadopoulos, that means the propellers must provide only about a tenth of the force needed by a helicopter of a similar size when in cruise mode.
NASA and DARPA tools aided blade design
Joby has been flight-testing its first full-scale prototype aircraft since 2017. At that time, the noise generated by the prototype was considerably lower than that by a conventional helicopter –but the engineers believed it could be lower still. They began fine-tuning the propulsion system, focusing especially on the shape of the blades.
“We started with a CAD design of the blades,” Papadopoulos said. “We then used rapid composite prototyping to build the blades, test them, process the results, and design a new blade. We build many blades to improve our understanding of the noise sources to design new, quieter blades.”
The team used a range of highfidelity tools developed by NASA
Joby Aviation’s commercial air-taxi operation should be off the ground in Dubai by late 2025, said CEO JoeBen Bevirt on an earnings call in August 2024. | Joby Aviation
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and the U.S. Defense Advanced Research Projects Agency (DARPA) to model the acoustic behavior of the propellers. They then tested the prototypes in a wind tunnel and on a special test circuit they built near Joby’s headquarters in Santa Cruz, Calif. Nicknamed the Whirly, the test track allows the engineers to send a propeller attached to a rig around at a speed similar to the Joby aircraft's cruising speed and measure its aerodynamic behavior in conditions akin to those of an actual flight.
The experiments showed, for example, that wide blades produce less noise than narrow ones. Subsequent flight tests showed the redesign further reduced the loudness of the propulsion system by 3 dB while delivering the same thrust.
“Generally speaking, our blades have much more surface area than helicopter blades, allowing for lower tip speeds, but not too much area, which can increase other noise sources,” said Papadopoulos. “We have found that careful optimization of the airfoil design and blade shape can balance the noise sources, allowing for a sound that more closely resembles leaves in a breeze than the strong whopwhop of a helicopter.
Joby Aviation's commercial air-taxi operation should be off the ground in Dubai by late 2025, said CEO JoeBen Bevirt on an earnings call in August 2024. (Image: Joby Aviation)
In May, Joby announced the completion of more than 1,500 flights covering more than 33,000 miles, including 31 flights in partnership with the FAA to demonstrate “the aircraft’s operational characteristics and precision landing capabilities.” Pilots were on board for more than 100 of those flights.
The company plans to commence further testing with the FAA soon to obtain final certification to start commercial operations. If all goes well, Joby could ferry its first paying customers in 2025. AD www.koford.com Contact us at mail@koford.com
Scott Miller • Director of Product Management • Cinch Connectivity Solutions
eVtoL future The is counting on interconnect
For a sky full of flying cars to become reality, they’ll have to lighten up. Smart selection of cables and connectors will play a big role.
Whenit comes to getting from one place to another, current modes of transportation cover almost all environments, whether by land, sea, or air. Despite these vectors being conquered, numerous emerging technologies provide new options. One such method of transportation takes its inspiration from quadcopter drone technologies, which show extraordinary amounts of freedom, safety, and potential for automation.
Electric vertical takeoff and landing vehicles, or eVTOLs, can fly like common commercial drones, taking off and landing without requiring long airstrips. While drones typically have blades affixed to motors pointing directly upward, more modern eVTOLs can take advantage of movable engines
that allow for more forward thrust, thereby improving efficiency. Cables and connectors play a surprisingly important role in the viability of eVTOLs and their impact on overall mass. Knowing how the right connectors and cables will aid in design can help engineers create viable and sustainable eVTOLs.
Compared to helicopters, which are notoriously difficult to pilot, such vehicles are far easier to manage due to simplified controls. Additionally, the vast amount of software and hardware already developed to create autonomous drones means that eVTOLs are ripe for deploying autonomous flight systems, thus eliminating pilot error.
Most airspace above urban zones is virtually unused, so eVTOLs could move around at high speed, significantly
reducing transportation times between locations. Thus, eVTOLs could ferry people and cargo within urban environments, reducing road dependency and making highways more ideal for transporting heavy goods.
Bridges and tunnels can increase road and rail traffic capacity, but the massive infrastructure cost makes such projects hard to justify. eVTOLs would merely need landing pads and charging stations. This not only reduces costs for taxpayers but also lowers maintenance expenses, as roads will experience less traffic if pedestrians use eVTOLs.
While they offer many benefits, eVTOLs face many design challenges if they are to become an effective mode
of transportation. In this article, we’ll discuss these challenges while focusing on the interconnect design and its importance in the development of efficient and effective eVTOLs.
What challenges do eVTOLs face?
Despite all the advantages that eVTOLs present, they are still more of a concept than an actual solution that can be deployed in a commercial environment, and this reality comes down to numerous challenges that they face.
The first, and arguably the most critical factor, is weight. Because eVTOLs are entirely electric, they must carry hefty batteries. Compared to fossil fuels, batteries have far less energy density, meaning that any battery is far heavier than a tank of gasoline with the same energy capacity. For comparison, the energy density of gasoline is 47.5MJ/kg compared to lithium-ion batteries at 0.3MJ/kg.
Due to the need for heavy batteries, the rest of an eVTOL needs to be as light as possible. While modern materials such as carbon fiber can achieve this, they come at an added price and design complexity.
If eVTOLs become autonomous, communication between each eVTOL will be essential due to the severity of possible collisions. eVTOLs will need to be able to see the flight path of all other vehicles and plot a safe route accordingly. Such a network would need to handle vast amounts of data in real time with significantly reduced latency. According to researchers at KAUST, latencies down to 10 ms will be needed for autonomous flight control.
At a minimum, an eVTOL network would need to work on top of a 5G network, using edge computing to have data immediately routed to other vehicles (i.e., not pass through ISPs). However, integrating cellular communication systems and onboard artificial intelligence for autonomous flight introduces additional systems and components, further increasing weight and reducing the energy available to the craft for flight. Energy efficiency is of paramount importance, and designers must reduce the weight of any and every component. Depending on the size and complexity of the
High-density modular connectors like those in Cinch’s C-ENX series reduce the footprint and weight of RF, power, digital, and optical connections.
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vehicle, electronics typically account for 10-20% of an eVTOL’s total weight.
What’s the role of connectors and cables?
Cables and connectors may not seem as critical as other components in the design of eVTOLs, but their importance is quickly realized when exploring each aspect.
Connecting and powering the various eVTOL systems requires long cabling lengths, sometimes adding up to miles, which can account for a significant portion of the aircraft’s total weight. Power cables alone can account for close to 1% of the total weight of a 5,000-lb. craft. The signal and data cables further increase this number. Power cable weight is seen as such a significant weight contributor that aerospace engineers at NASA have studied how the design of power cables can be optimized to minimize weight.
Since eVTOLs are entirely based on electricity, electrical stress can be extremely high, with high voltages and currents present. This means that any cable and connector used to deliver power from the batteries to the motors needs to handle such power levels safely and have sufficient insulation to provide adequate protection, which tends to lead to large, bulky cables. Ensuring the optimal conductor and insulation materials can help limit power cables’ impact on overall weight. Many engineers designing eVTOLs opt for solutions commonly found in aviation platforms, including aluminum cables that are designed with these concerns in mind.
Whether high voltage or current is chosen, the final cable and connector choice must reduce weight as much as possible. Any extra weight in an eVTOL will increase the difficulty of takeoff and limit its range.
Such connectors must operate safely in extended temperature ranges while retaining a high IP rating to prevent damage during poor weather conditions. Consider, for example, the connectors found in the landing gear, rotary motors, antenna systems for GPS, and radar for eVTOLs. Most of these systems have some or much exposure to the environment. When landing in cities such as Dubai these connections may face weather conditions that include sandstorms, extreme temperature changes, sudden torrential rain, and high winds.
Finally, as all these connectors and cables are being used in an environment subjected to shock and vibration generated by motors and landing/ takeoff, any connector used must resist accidental disconnects over extended use. As such, simple screw terminals or clips will likely be insufficient, requiring locking nuts, press-fit connections, and unique mating mechanisms.
How can RF connectors help power the future of eVTOLs?
A wide range of compact RF connector styles and mounting options is available to satisfy the various RF needs of an EVTOL. This includes connectors down to 1.0 mm, which can operate at frequencies up to 110 GHz. This makes them suitable for all aviation tracking systems, including ADS-B and Pilot Aware. They can also be used with cellular systems, including 4G, 5G, and mmWave bands of 5G.
For designs that require communication speeds beyond copper’s capabilities, a range of optical connectors can help engineers achieve
extremely high inter-device speeds across the entire eVTOL and do so at significantly reduced weight due to the use of tiny fiber-option cables. Such cables are also immune to electromagnetic interference, making them far safer for use in autonomous environments where sensor data cannot be compromised.
Not all connectors can be replaced with RF or fiber optics. For such applications, micro-D connectors become invaluable. Their design allows for either shielded or unshielded cables to be used. In cases where EMI is not a concern, the absence of shielding can help reduce size, weight, and cost. Their specific D shape also makes them polarized. Compared to standard D-sub connectors, micro-D connectors are significantly lighter and take up to 80% less space while offering the same performance in the harshest environments.
Conclusion
While there is a lot of hype surrounding eVTOLs, they are still in their infancy, and any existing systems are more of a concept than an actual viable design that could be supported economically. The extreme technical challenges faced by eVTOLs and endless amounts of legislation present numerous roadblocks to engineers when trying to get such ideas to take off. However, the industry has growing confidence that the necessary infrastructure can be built and that technological roadblocks, such as battery density, will be overcome.
Scott Miller is the Director of Product Management at Cinch Connectivity Solutions. For much of his 25-plus-year career in electronic components, Scott has worked with manufacturers of interconnect devices for harsh environments.
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OBVIUS ROBOTICS CERTA ACCESS SYSTEM EARNS FDA BREAKTHROUGH NOD
OBVIUS Robotics Inc. recently said that the U.S. Food and Drug Administration has granted breakthrough device designation for its Certa Access System for central venous catheterization, or CVC.
CVC procedures require access to one of the great veins — internal jugular, subclavian, or femoral — to place a multi-lumen catheter for rapid replacement of blood volume, administration of emergency medicines and analgesics, and hemodynamic monitoring.
Complication rates can range from 4% to 11%, noted Obvius Robotics. The Sunrise, Fla.-based company said this underscores a significant need for better and more consistent outcomes.
“CVC procedures are required for a wide variety of conditions and patients for life-saving care every single day,” said William Cohn, M.D., chief medical officer of Obvius Robotics.
“Despite this fact, the procedure still has high complication rates, and many health systems lack the expertise to reliably conduct the procedure on critically ill patients in a timely manner,” he added. “A breakthrough is truly needed to improve care.”
Obvius said it designed Certa to incorporate robotics as well. It aims to improve the accuracy, safety, and consistency of accessing targeted anatomy.
For CVC procedures, the company said that its system could aid clinicians of varying levels of training and experience. Obvius said it will assist in safely and effectively achieving vascular access.
| Postmodern Studio, Adobe Stock
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Certa remains investigational as Obvius readies a submission to the FDA for market clearance. The company completed initial clinical cases for the handheld device in June 2023. It says the system allows users to quickly visualize the target vessel and advance a needle to the target location in seconds.
The company wants Certa to become the new standard of care for CVC access, said Russell Seiber, president and CEO of Obvius.
“We are excited that the FDA has recognized the potential of the Certa access system to be a breakthrough for patients and clinicians,” he said. “We believe this technology could improve care critical care settings by democratizing vascular access procedures.”
Obvius Robotics was founded in 2020. Seiber said he conceived the idea for Obvius Robotics when an emergent liver-failure patient required a central line placed to stabilize very low blood pressure. This is a life-saving procedure that can be challenging for physicians.
Despite significant expertise in placing these lines, the critical care physician could not successfully gain vascular access with the difficult anatomy of the patient. While the line was eventually placed, Seiber wanted to find a system to address this common problem.
Over 20 million central lines are placed globally each year, making it one of the most common medical procedures in the world, said Obvius. However, between 200,000 and 550,000 patients currently suffer from preventable complications each year, it noted. RR
www.obviusrobotics.com
Scan the QR code to watch how doctors use the Certa Access System
Obvius Robotics says its Certa system enables quick visualization of target vessels, allowing surgeons to quickly and accurately place central lines.
Robotic surgery to benefit from ADVANCED PROCESSORS AND ARTIFICIAL INTELLIGENCE
Eugene Demaitre • Editorial Director
AMD said its processors enable robotic surgery such as with Intuitive Surgical’s da Vinci system. AMD
THE need for robotic surgery is well established, but most systems are still costly to purchase, operate, and maintain, noted Advanced Micro Devices Inc. The company said its technologies can help control those costs, and AMD is already working with leading surgical robot providers.
In 2021, almost 644,000 robotic surgeries were performed in the U.S., and that number could reach 1 million in 2028, according to the National Library of Medicine (NLM).
The global market for robot-assisted surgery could grow to $83 billion by 2032, predicted Noah Medical. However, many technical and regulatory hurdles remain to increasing
autonomy, noted MDPI Sensors, and cost is a major consideration for adoption.
AMD positions itself in the healthcare tech stack
“AMD is one of the fastest-growing semiconductor companies and has grown substantially in the healthcare space,” said Subhankar Bhattacharya, lead for healthcare and sciences at AMD. “We have a wide portfolio of processors, FPGAs, GPUs, CPUs, SoCs, PLCs, and programmable I/Os. They’re used in industrial automation,
Surgical robots and related technologies are moving along Gartner’s “hype cycle.”
| MDPI Sensors
“The FDA used to be very conservative, but it has started a new group for software as a medical device to consider these products in medical devices, which were previously under OEM’s perspective,” he told The Robot Report. “That opens up the technology, making artificial intelligence appears in almost every phase of the industry, from the devices themselves and ECR [electronic case reporting] to surgical robots.”
automotive, gaming, servers and data centers, and increasingly in healthcare.”
Bhattacharya has an electrical engineering background and worked for Intel, Sun, and PMC. He later worked on software-as-a-service (SaaS) for hospitals; with pharmaceutical company Novartis on medical devices; and with GE Digital on the Internet of Things (IoT), healthcare, and cybersecurity.
After working at Xilinx, which AMD acquired in 2022, Bhattacharya has seen the applicability of high-performance computing to robotic surgery.
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Pandemic propels telemedicine, robotic surgery
“COVID-19 was a major marketchanger,” said Bhattacharya. “If you looked at emerging trends in PoC [point-of-care] for AI, remote patient monitoring, telemedicine, and robotic surgery, they were projected in 2012 to grow, but it wasn’t happening. COVID gave a boost to these, and people saw with their own eyes how effective something like point-of-care ultrasound could be in saving lives.”
He cited the example of Clarius, an AMD customer that built a handheld
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device with AI capabilities for local physicians without sonography experience. They can now check complaints of back pain for potential cancer and then refer patients as needed to hospitals in cities.
“AMD is building adaptive SoCs [system-on-chips] that have low latency and high-speed data processing from the edge,” Bhattacharya said. “Once AI developers have trained models, they can do a lot more with inferencing with smaller devices.”
Intuitive Surgical robots get improved sensing, controls
“Diagnostic medical imaging has been AMD’s strength — in cart-based care, ultrasound, diagnostic endoscopy, and signal processing,” said Bhattacharya. “In robotics, we’re the market leader, and we’ve been working with Intuitive Surgical since 2010.”
The company‘s Xilinx unit worked with Intuitive Surgical to design the second-generation da Vinci robotic surgical system. Last year, more than 7,500 da Vinci systems were in use in 69 countries, said the NLM.
“Intuitive has built up its IP [intellectual property] with design and reuse potential,” Bhattacharya said. “In its surgeon side-cart AR/VR [augmented/virtual reality] system, a visualization system processes the image signal and makes it available for the next set of modules.”
“On the multi-arm robot side, nurses control the technologies with SoCs, and back-end video systems use not just one or two of our products but 30 to 50 per each da Vinci X or Xi multiport and single-port system,” he said. “The da Vinci 5 is a significant step forward in terms of haptic feedback.”
Xilinx reported favorable results, and the da Vinci 5 this year obtained U.S. Food and Drug Administration and European CE clearance.
Processors enable a range of medical devices
Reliable data processing is not only necessary for high-end surgical robots,
but it can also help less-expensive devices, said Bhattacharya.
“Capable hardware allows customers to scale software as they build up — we’ve provided SoCs to $10,000 to $150,000 machines,” he said. “For small and midsize enterprises, the ability to build and reuse app code is the secret sauce for developers.”
Bhattacharya touted the density of AMD’s FPGA (field-programmable gate array), its fast memory access, and the ability of adaptive SoCs to partition-load to various blocks for programmability and upgradeability.
“For example, a large CT or ultrasound scanner can acquire signals with an analog/digital interface, then use beamforming to move the data to the host for rendering and visualization,” he explained.
The right processors can reduce latency and help accelerate development of medical devices such as endoscopes and surgical robots. AMD said its heterogeneous approach to specialized and adaptable computing allows developers to choose from a range of systems for real-time visualization and multi-axis robot controls.
“With a bigger device and our Embedded+ offering — an x86 processor next to one of our highend Versal adaptive SoCs with PCI Express in between — we can help cut
10 months off development time and provide software for moving data and partitioning,” Bhattacharya said. AI to improve the quality of robotic surgery
“Robot-assisted surgery provides a clear advantage of smaller incisions and faster recovery,” said Bhattacharya. “The preferred approach of the FDA is to use AI to improve productivity while minimizing risk, so we still see a lot of assistance rather than AI making decisions.”
In addition to diagnostics, AI and machine learning can improve contrast or add filters for surgical robot displays, which don’t require FDA approval, he noted. Ultrasound also provides guidance on how to position a probe.
“Another use of is AI is for training. I was at a radiological conference, and a demo showed the layman where to put a device to take a report on the carotid artery,” Bhattacharya recalled. “Improving PoC training is low-hanging fruit, but it’s extremely important for medicine.”
Another area where AMD’s processors can enable AI and improve care is in imaging of small lesions to detect skin cancer at early stages, he said.
In the future, AI could even enable PoC surgery, but cybersecurity and surgeon oversight are still necessary for robotic and laparoscopic procedures, acknowledged Bhattacharya. RR
AMD makes processors for data centers, gaming, PCs, and increasingly embedded computing such as surgical robots. | AMD
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By Mark Jones
The perils of scale in software and ice cream
Mistakes happen. But small mistakes create big impacts when perpetrated by enormous companies. The largest IT meltdown ever occurred because a small mistake took down 8.5 million computers. Scale made it a big problem, just like a recent ice cream issue.
The pictures of airport concourses with bright blue screens on kiosks as far as the eye could see served as a stark reminder that we all use computers even when we aren’t directly using a computer. BSOD greeted travelers thanks to CrowdStrike’s flawed updating of a computer security program. Airlines, hospitals, banks, manufacturing, government services, and more were brought down by an upgrade. Someone pushed enter on a keyboard, a small string of bits ricocheted around the internet, and mayhem followed.
CrowdStrike, a company new to most, is the top enterprise security company with a 24% market share. The company’s most recent yearly revenue was a bit more than $400 for each crashed computer, $3.65 billion. Healthy 80% margins are evidence of how being big has its advantages. Size also made this the largest computer outage ever. It comes on the heels of another kind of meltdown, this one in ice cream. BSODs are bad, but don’t injure or kill. Eat tainted ice cream, and you can get sick. You can even die.
A recent headline read, “Ice cream sold nationwide recalled for listeria risk.” It sounds very biological, yet there is considerably more to the story, more technology. It is a reminder of the unseen supply chains we all use.
A little reading showed my first impression, that there was widespread contamination of many facilities, was
completely wrong. The Listeria problem was due to only one plant. One plant in Maryland was contaminated with Listeria monocytogenes, a potentially fatal bacterium. That one plant is operated by Totally Cool Inc. Like CrowdStrike, the company isn’t a recognized name. It packages ice cream for other brands, including Hershey’s, Friendly’s, Chipwich, and Jeni’s. The Listeria had tainted pints of ice cream and sorbet, as well as ice cream cakes, sandwiches, cones, and packaged products. More than 60 products were recalled from around the nation.
Let that sink in. A single plant run by a company that no one has heard of produces ice cream distributed around the nation. It is incredibly counterintuitive. These aren’t trucksized vats of ice cream being produced and transported; they are bars and containers that fit in your hand. They melt. A frigid supply chain is required. It doesn’t seem like a business where scale would be a huge advantage, but it is. It doesn’t seem like a business where long, challenging supply chains make sense, but it is.
Cryogenic tunnels, cooled by liquid nitrogen, are the important technology. They transform ice cream making from a batch to a continuous process. Before tunnel coolers, ice cream cakes took 24 hours in a big freezer. After implementation of the new technology, 30 minutes. With four tunnel freezers, up to 1.5 million ice cream cakes, pints, and cups per month are made in a single facility.
The global cold chain is adding capacity at 14% per year by some estimates. Energy intensive as it is, it remains a modest contributor to the total ice cream GHG footprint.
The production of the milk and other ingredients account for well more than half of the emissions.
Technology enabled both the biggest computer outage and a large, maybe the largest, ice cream recall. CrowdStrike’s tech is largely virtual. Totally Cool’s technology is more physical. We trust that the food we purchase isn’t tainted. People sue when trust is betrayed. There are many reported lawsuits for food poisoning, many with large settlements. There are surprisingly few in software. Software comes with something ice cream doesn’t, a terms of service agreement. CrowdStrike users agree not to use the software if there is a chance of injury or death. I explored the ice cream aisle at the grocery store. There were some nut warnings, but I found nothing remotely like a terms of service agreement. With ice cream, I am assuming the risk. DW
| Paul J. Heney
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