Industrial service robotics: smart navigation, safety and control with TE Connectivity’s connector solutions
Industrial service robots (Figure 1) are improving productivity and efficiency in manufacturing, logistics, and automated warehouses in multiple industries. While these robots boast vast networks of sensors, processors, actuators, and communication systems all working together to achieve autonomous operation, a critical, yet often overlooked component is connector solutions that enable them to function in industrial environments. TE Connectivity’s interconnect solutions address the reliability challenges manufacturers face when building industrial service robots as off-the-shelf connectors typically fail to meet requirements for miniaturization, durability, and performance. Enabling autonomous movement and situational awareness Navigation and safety systems in service robots use arrays of sensors like LiDAR, ultrasonic detectors, vision cameras, and inertial measurement units to achieve holistic environmental awareness. A key requirement is for each sensor to continuously generate data streams to be transmitted without loss or corruption to CPU for real-time analysis and decision-making. The ERNI MicroCon ™ Series connector (Figure 2) fully meets the requirements with its industry- leading 0.8 mm pitch and sturdy,
robust construction that allows designers to have the dense sensor integration necessary for environmental monitoring. The miniaturized 0.8 mm pitch spacing delivers space savings compared to 1.27 mm alternatives, which enables robot designers to integrate additional sensors into limited spaces. The MicroCon connector’s dual- beam female contact design provides exceptional reliability for sensor connections via its 1.9 mm wipe length for consistent electrical connectivity under continuous vibrations. Additionally, the wider contact surface in the dual- beam design, helps to minimize contact resistance variations that can potentially introduce noise to sensitive sensor signals. The connectors support data transmission rates of up to 3 Gbit/s, suitable for high-resolution camera systems and advanced LiDAR units that generate massive data volumes. Operating temperature range is from -55 to +125°C ensuring reliable performance whether the robot operates in sub- zero temperature environments or near industrial heat sources. Safety systems in service robots also need fail-safe connectivity to maintain signal integrity under adverse operating conditions. The MicroCon connector’s blind- mate pre- centering capability with ±0.7 mm misalignment tolerance is especially useful in modular robot designs where sensor modules
Figure 2: The ERNI MicroCon series connector Source: TE Connectivity
require frequent replacement for maintenance or reconfiguration.
Central control units: supporting precise command and coordination In the control units of industrial service robots, power distribution efficiency and high-density signal routing capabilities are critical. These systems are responsible for coordinating motor controllers, processing sensor inputs, managing communication interfaces, and maintaining real- time control loops using battery power or industrial power supplies. Entrelec ™ DBL Power Distribution Blocks can be integrated to optimize power management in control units. These blocks utilize a 3-in-1 configuration system that consolidates a single-pole splitter, multi-pole splitter, and grouping configurations into a single product family. With current ratings ranging from 80 A to 550 A, DBL blocks can meet a broad range of power needs of industrial service robots, from
Figure 1: Warehouse robots Source: Adobe Stock
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