When Trillium Engineering, a leader in actionable imagery solutions for small tactical unmanned aerial systems (sUAS), sought to solve a critical reliability issue, they turned to BotBlox. Read more >>
The task was to develop a USB-to-Ethernet converter compact enough tointegrate seamlessly into Trillium’s systems while maintaining durability under the extreme conditions their products face.
This collaboration gave rise to USBBlox, a miniature, rugged USB-to-Ethernet converter purpose-built for drones, robots, and other mission-critical systems operating in challenging environments.
The Problem: Reliability Under Pressure
For tactical sUAS and robotic systems, USB is often an unreliable choice for data connectivity. Its susceptibility to disconnections in high-vibration settings and interference from nearby radio transceivers or motors creates what engineers term “integration hell”.
In contrast, Ethernet provides a more robust and reliable communication protocol. However, integrating Ethernet into a platform designed for USB presents its own challenges. For Trillium Engineering, the need was clear: a durable, compact USB-to-Ethernet converter that could overcome these limitations and integrate seamlessly into their compact systems.
BotBlox’s Approach: Building USBBlox
Recognizing the high stakes of this project, BotBlox set out to create a converter that not only solved these integration challenges but also surpassed the durability expectations of conventional designs. The result, USBBlox, is a highly specialized device engineered with three core features to ensure reliability in the field.
1. Industrial-Grade Chipset
Unlike most USB-to-Ethernet converters that use the commercial-grade RTL8153 chipset, USBBlox incorporates Microchip’s industrial-grade LAN7800 chipset. This ensures exceptional reliability and performance even in environments with extreme temperatures or high vibrations.
2. Vibration-Resistant Connectors
Traditional USB connectors lack locking mechanisms, making them prone to disconnections in vibrating conditions. To counter this, USBBlox employs Molex PicoClasp positive-locking connectors, ensuring a stable connection even in the most demanding operational scenarios.
3. Advanced EMI Shielding
USB circuits are particularly vulnerable to electromagnetic interference (EMI), especially in environments with motors and radio transceivers. BotBlox addressed this by incorporating a USB-to-Molex PicoClasp cable with integrated shielding. Combined with a custom EMI shield and grounding on the board itself, this design ensures superior EMI protection, guaranteeing consistent performance.
In May 2024, USBBlox successfully passed rigorous EMC testing, validating its reliability in the toughest environments.
The Result: Compact and Rugged Connectivity
The collaboration between Trillium Engineering and BotBlox resulted in the creation of the world’s most compact, rugged USB 3.0 to Gigabit Ethernet converter. Designed for space-limited applications like drones and robots, USBBlox balances compact form with exceptional durability.
For Trillium Engineering, this solution seamlessly integrates into their tactical systems, ensuring reliable and high-speed data transfer while standing up to extreme environmental conditions. This project exemplifies how tailored engineering solutions can address complex technical challenges without compromising on performance or durability.
The Future of Tactical Networking
The successful partnership between BotBlox and Trillium Engineering highlights the power of collaboration in advancing tactical technologies. With USBBlox, BotBlox has set a new benchmark for rugged, space-efficient connectivity solutions in unmanned systems.
This project underscores BotBlox’s commitment to innovation in industrial-grade networking, and the team is eager to explore new challenges and partnerships in the unmanned systems and robotics sectors.
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