{"id":11820,"date":"2020-08-28T07:00:00","date_gmt":"2020-08-28T11:00:00","guid":{"rendered":"https:\/\/blogs.sw.siemens.com\/solidedge\/?p=11820"},"modified":"2026-03-26T07:34:15","modified_gmt":"2026-03-26T11:34:15","slug":"new-connector-design-improves-robustness-and-flexibility-for-a-modular-robot-system","status":"publish","type":"post","link":"https:\/\/blogs.sw.siemens.com\/solidedge\/new-connector-design-improves-robustness-and-flexibility-for-a-modular-robot-system\/","title":{"rendered":"New connector design improves robustness and flexibility for a modular robot system"},"content":{"rendered":"\n<p><a href=\"https:\/\/www.robosynthesis.com\/\" target=\"_blank\" rel=\"noreferrer noopener\"><strong>Ross Robotics<\/strong><\/a> in the UK is a fast-growing developer of modular robots that are used for inspection and maintenance operations in a variety of industries. In a recent interview with Philip Norman, co-founder and director of research and development, we discussed their development of a new type of connector. Philip describes the challenge they faced: \u201dWe needed a means of connecting robot modules to one another that would provide both a robust physical connection and reliable power and data connectivity. Our robots are made up of modules that can be reconfigured to make different types of robot to perform different\u00a0tasks, so the connector between the robot modules is a critical design feature.\u201d<\/p>\n\n\n\n<div class=\"wp-block-image\"><figure class=\"aligncenter size-medium\"><img loading=\"lazy\" decoding=\"async\" width=\"600\" height=\"450\" src=\"https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/EXTRM-with-CLAWWS-IM2.1-600x450.jpg\" alt=\"\" class=\"wp-image-11826\" srcset=\"https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/EXTRM-with-CLAWWS-IM2.1-600x450.jpg 600w, https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/EXTRM-with-CLAWWS-IM2.1-1024x768.jpg 1024w, https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/EXTRM-with-CLAWWS-IM2.1-768x576.jpg 768w, https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/EXTRM-with-CLAWWS-IM2.1-1536x1151.jpg 1536w, https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/EXTRM-with-CLAWWS-IM2.1-1110x832.jpg 1110w, https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/EXTRM-with-CLAWWS-IM2.1.jpg 1933w\" sizes=\"auto, (max-width: 600px) 100vw, 600px\" \/><figcaption><strong>Ross Robotics EXTRM robot with 2 sensors connected using the slimline connector<\/strong><\/figcaption><\/figure><\/div>\n\n\n\n<p>Some of the requirements for the connector include:<\/p>\n\n\n\n<ul class=\"wp-block-list\"><li>Simple operation with no tools required<\/li><li>Ability to reposition rotationally<\/li><li>Support power transmission rates of 20 Amps continuous, 60 Amps transient<\/li><li>Reliable transmission of data with no loss of packets<\/li><li>Non-magnetic (no ferromagnetic components)<\/li><li>Extremely low mass penalty<\/li><li>Small form factor (ideally 50mm diameter and shallow, with a maximum depth of 9mm)<\/li><li>Designed for manufacturing at a low cost<\/li><li>Easily modifiable to suit a range of specific requirements<\/li><\/ul>\n\n\n\n<p>One interesting thing I learned in my conversation with Philip is that reliability is a major issue for robots that are deployed to perform a variety of tasks, often in uncontrolled environments. \u201cWe have seen data that showed a mean time between failures of just 30 minutes for some robot deployments. We spend a lot of time thinking about the robustness of our systems and building in redundancies and support for self-healing. For example, if a single drive motor fails the robot can still maneuver and perform necessary tasks.\u201d The connector is a prime example of a design challenge where reliability and robustness are major considerations.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Elegant design solution and manufacturing considerations<\/strong><\/h4>\n\n\n\n<p>Philip has come up with an elegant solution to meet these requirements. The \u201cSlimline\u201d connector is comprised of two discoid plates with coaxial ridges that engage with each other in a cone-to-cone mating configuration. He used <a href=\"https:\/\/solidedge.siemens.com\" target=\"_blank\" rel=\"noreferrer noopener\"><strong>Solid Edge<\/strong><\/a> 3D CAD software with <a href=\"https:\/\/solidedge.siemens.com\/en\/solutions\/products\/3d-design\/synchronous-technology\/\" target=\"_blank\" rel=\"noreferrer noopener\"><strong>synchronous technology<\/strong><\/a> to precisely model the subtle cone geometries that would ensure reliable\u00a0transmission of power and data. Philip said, \u201cSynchronous technology enabled me to rapidly experiment with different\u00a0parameters to find the sweet spot for the cone geometry. Using a history-based modeling system would have made this very onerous, and I probably would have tried fewer options, which would have meant a less thorough exploration of the critical parameters.\u201d<\/p>\n\n\n\n<p>The two halves of the connector are created from just two parts. The total mass is 20gm, and the mated connectors are less than 8mm deep. The connectors are 3D printed, then selectively metallized to produce a sequence of conductors and insulators. The same device conventionally manufactured would require between twenty and thirty separate parts and a lot of assembly. When they move to higher volume production, Philip plans to use injection molding for the manufacturing process.<\/p>\n\n\n\n<div class=\"wp-block-image\"><figure class=\"aligncenter size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"958\" height=\"362\" src=\"https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/slimline5.jpg\" alt=\"\" class=\"wp-image-11824\" srcset=\"https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/slimline5.jpg 958w, https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/slimline5-600x227.jpg 600w, https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/slimline5-768x290.jpg 768w\" sizes=\"auto, (max-width: 958px) 100vw, 958px\" \/><figcaption><strong>Slimline connector during the metalization process, and detail of the locking mechanism<\/strong><\/figcaption><\/figure><\/div>\n\n\n\n<h4 class=\"wp-block-heading\"><strong>Testing and future plans<\/strong><\/h4>\n\n\n\n<p>The connector has been tested informally to demonstrate that it can carry 20 Amps continuous; it will next go through formal testing. The Slimline connectors are installed with a plug and socket arrangement that ensures a progressive interference fit and an easy locking action using a threaded collar for tool-free connection. Philip has also developed an actuated locking device to support one of the challenging goals of their modular robot system, enabling robots&nbsp;to build robots.<\/p>\n\n\n\n<p>The next steps in the development of the Slimline connector are likely to include using <a href=\"https:\/\/solidedge.siemens.com\/en\/solutions\/products\/electrical-design\/\" target=\"_blank\" rel=\"noreferrer noopener\"><strong>Solid\u00a0Edge Harness Design<\/strong><\/a> software to configure and optimize the connection of wire harnesses to the Slimline connector. A gigabit version of the Slimline connector is also under development and Philip is aware of potential applications in adjacent industries such as oil &amp; gas, nuclear decommissioning and aerospace. In fact anywhere where a lightweight, extremely compact connector is required and especially one which does not require precise alignment before mating.<\/p>\n\n\n\n<p>You can read a complete case study about the design of the Robosynthesis\u00ae modular platform using Solid Edge <a href=\"https:\/\/www.plm.automation.siemens.com\/global\/en\/our-story\/customers\/ross-robotics-solid-edge\/70414\/\" target=\"_blank\" rel=\"noreferrer noopener\"><strong>here<\/strong><\/a>.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Ross Robotics in the UK is a fast-growing developer of modular robots that are used for inspection and maintenance operations&#8230;<\/p>\n","protected":false},"author":57666,"featured_media":11826,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"spanish_translation":"","french_translation":"","german_translation":"","italian_translation":"","polish_translation":"","japanese_translation":"","chinese_translation":"","footnotes":""},"categories":[1],"tags":[193,9],"industry":[],"product":[439],"coauthors":[],"class_list":["post-11820","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news","tag-computer-aided-design-cad","tag-startup","product-solid-edge"],"featured_image_url":"https:\/\/blogs.sw.siemens.com\/wp-content\/uploads\/sites\/8\/2020\/08\/EXTRM-with-CLAWWS-IM2.1.jpg","_links":{"self":[{"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/posts\/11820","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/users\/57666"}],"replies":[{"embeddable":true,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/comments?post=11820"}],"version-history":[{"count":5,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/posts\/11820\/revisions"}],"predecessor-version":[{"id":11843,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/posts\/11820\/revisions\/11843"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/media\/11826"}],"wp:attachment":[{"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/media?parent=11820"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/categories?post=11820"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/tags?post=11820"},{"taxonomy":"industry","embeddable":true,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/industry?post=11820"},{"taxonomy":"product","embeddable":true,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/product?post=11820"},{"taxonomy":"author","embeddable":true,"href":"https:\/\/blogs.sw.siemens.com\/solidedge\/wp-json\/wp\/v2\/coauthors?post=11820"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}