Integration of a Low Profile, High Resolution Encoder within Tight Deadlines
Introduction
There is a phrase in Silicon Valley, ‘Fail and Fail Fast.’ The idea is that time is money, and if you can’t quickly scale up an idea to a prototype it will soon create so much debt that it is not a feasible business proposition. With that sense of urgency, when an emerging leader in humanoid robotics faced a critical challenge in finding the right rotary encoder for a joint on their prototype humanoid, they turned to Everight Position for a solution. This case study explores how Everight Position not only met these demands but also provided unwavering technical support that helped achieve deadlines and performance milestones.
The Challenge
The customer was in the final stages of developing a humanoid robot that required a sophisticated joint mechanism. The encoder initially selected was compact and low cost but lacked resolution and had too much noise on the output signal. Encoders are critical in humanoids as they not only provide position feedback on appendages, they can also be used in tandem to be torque sensors, helping the humanoid to determine if unexpected contact has been made with an object or person. The key challenge was sourcing a rotary encoder that would meet the following specifications:
- Low Profile: The encoder needed to fit within the compact design of the humanoid joint which had already been defined.
- High Resolution: Precision in movement was critical for the joint’s function, necessitating a high-resolution encoder.
- Absolute SSI/BiSS interface: In the chance that power was lost the encoder needed to know immediately where it was at startup. SSI and BiSS are based on RS-422 and open protocols, making them the defector standard in robotics.
- Short Lead Time: Units needed to be delivered within 4 weeks to meet the project’s tight deadline.
Limited Susceptibility to Noise: As noise had been an issue with the original encoder, the Team wanted a solution that could be packaged into the dense volume of motors and other electronics.
The Solution
The controls team approached Everight Position, renowned for their expertise and vast portfolio of sensors and encoders starting with NASA’s Robonaut 2 (R2). Everight Position took on the challenge with enthusiasm and dedication. Everight Position quickly assembled a portfolio of options representing not only different brands of encoders, but spreading across four different fundamental sensing technologies, each with their own strengths and weaknesses. These were defined with respect to the specific project’s needs allowing the customer to select the encoder(s) that were most appropriate. Had the customer tried to work with an OEM directly they would have only had access to a limited range of options and had to duplicate efforts in order to gain access to as many options.
Key Features of the Selected Encoder
- Low Profile Design: Ensured compatibility with the compact joint structure.
- High Resolution: Provided the necessary precision for the humanoid’s movements.
- Accuracy: Guaranteed reliable performance and consistency in readings.
Implementation and Support
What set Everight Position apart was not just the provision of the ideal encoder but their commitment to exceptional service. Recognizing the urgency of the project, Everight Position ensured the encoders were delivered within the 4-week timeframe, coordinating with the management and production teams of the chosen vendor. However, their support did not end there.
Everight Position’s technical team extended their assistance beyond traditional working hours, offering guidance and support as they integrated the encoders into their prototype. This level of support was crucial in addressing any issues that arose during the integration process, ensuring seamless implementation and functionality of the joint mechanism.
Conclusion
Everight Position’s role in this project highlights the importance of choosing a partner who not only provides the right product but also offers unwavering support throughout the implementation process. Their commitment to customer satisfaction and technical excellence ensured that the Team could overcome their challenges and achieve their project goals.
