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Millimeter-wave imaging inspection in real time

With its new quality and inspection R&S IMAGER millimeter-wave scanner, Rohde & Schwarz aims to simplify the industrial inspection of packaged products. The system sees through common packaging materials at production speed without using X-rays, protecting both products and operators. The high-contrast 3D images are used as digital twins and can be automatically integrated into AI-powered fault-detection systems. Sees through plastics, cardboard, and composites. Applications include food and beverage, pharmaceuticals, logistics.
Learn more.

What are single-loop process controllers?

PLCs are powerful, but complex control isn't always necessary. For standalone processes requiring single-variable monitoring -- like temperature, pressure, or flow -- a single-loop controller is ideal. See how single-loop controllers can streamline your next project.
Read the AutomationDirect tech tip.

Great Resources: Flexible circuit design guide

Tech-Etch uses advanced techniques to manufacture flex and rigid-flex circuits to exacting customer specs. Special processes include selective plating a single circuit with two different finishes, contoured circuits with variable metal thickness, semi-additive and subtractive techniques, open window or cantilevered contact leads, plus SMT for component assembly. Tech-Etch specializes in flexible circuits for medical, telecommunications, aerospace, semiconductor, and other high-reliability electronic applications.
Learn about flex circuits and get the guide (no registration required).

EMI Investigations: New immunity development system

Saelig Company announces the Langer E1 Immunity Development System for EMI investigations. This compact, affordable kit simulates burst and ESD interference to pinpoint layout weak spots down to IC pins. By eliminating "black box" guesswork early in development, engineers can efficiently identify coupling mechanisms, test measures, and resolve immunity issues before compliance failure.
Learn more and see it in action.

Battery packs for unmanned aerial vehicles

Re:Build Manufacturing has launched U.S.-assembled, NDAA-compliant lithium-ion battery packs for commercial, public safety, and defense UAV applications. Available in Core, Power, and Performance series, the packs use non-FEOC cells and are produced at Re:Build's advanced facility in New Kensington, PA. Re:Build also offers custom pack and battery management system development.
Learn more.

Easy-to-use precision measurement system

Optical Gaging Products has announced the StarLite S1, a compact, semi-automatic 3-axis video measurement system. It combines fully automatic video measurements with manual stage motion and features an IntelliCentric-S optical system for high-resolution images. Powered by Measure-X software, this system delivers fast, repeatable, high-accuracy results, making it ideal for both shop-floor and quality-control applications.
Learn more.

Why a soccer kick bends the ball path: SOLIDWORKS simulation

With SOLIDWORKS Flow Simulation, you can virtually test a ball's flight path and see the science behind its amazing trajectory. Visualize anything you want to test, including the physics that make a ball curve and dip, to optimize performance and reduce physical testing. See the SOLIDWORKS Flow Simulation study setup and learn about the Magnus effect where a spinning object moving through a fluid curves away from its straight path. [Credit: Screenshot courtesy of SOLIDWORKS]
View the video.

Lightning-fast in-line verification, high-performance barcode reading

The Omron VHV5 Barcode Reader now combines high-performance barcode reading and calibrated ISO verification in one device. Replacing offline sample checks, it delivers 100% inline verification at production speeds up to 1,200 parts per minute. With flexible lighting, the VHV5 easily inspects labels and Direct Part Marks, even on challenging curved or irregular surfaces.
Learn more.

How to choose the right industrial Ethernet switch

Antaira Technologies breaks down 10 mission-critical capabilities separating industrial-grade switches from commercial compromises. Even if you aren't in IT engineering, you will find valuable networking knowledge in this guide to protect vital infrastructure.
Read the full article.

New CAM software cuts robotic machining deployment

At Automate (Booth #4476), RoboDK will showcase RoboDK CAM, which generates robotic machining programs directly from CAD files. Designed for easy deployment, it cuts setup time by up to 40%. Live demonstrations will show users how to create collision-free robot motion straight from CAD data, eliminating manual line-by-line coding.
Learn more about RoboDK CAM.

AI Tools You Can Use: What is OpenClaw? How do I get it and use it?

OpenClaw is trending big time right now, but what is it? The YouTubers over at Create a Pro Website run through the basics of what you need to know and how to implement it. Basically, OpenClaw is a next-gen 24/7 AI assistant that lives on your computer and can perform actions for you. You talk to it through a chat app. You can set it up to do real work such as alert you to important emails, answer emails for you, manage your calendar and travel, and so much more. There is a great intro video here and also a longer, very thorough step-by-step video to setting up OpenClaw.
View the OpenClaw intro video.
View the OpenClaw setup video.

New! 6-digit programmable display/controller

Bristol Instruments has released the OM 403UNI Series displays/ controllers, allowing users to monitor two or three simultaneous functions. Configured via OM Link software or front-panel buttons, they feature four- or six-digit displays with +/-0.05% of f.s. range accuracy. They function as numeric/bar-graph displays, controllers, data recorders, or accumulators. Additionally, they detect and alert users to error conditions like broken sensor wires.
Learn more.

Mini edge AI systems for vision, generative AI

As enterprises transition from PoC to real-world edge AI deployment, Aetina has launched its Mini Series Edge AI systems. Powered by NVIDIA Jetson Orin Nano and NX modules, these compact, fanless systems deliver high-performance vision and generative AI inference. Engineered for demanding industrial environments, they offer flexible camera connectivity, space-saving designs, and long-term reliability to accelerate smart infrastructure.
Learn more.

Thermal imaging on the quality control line

On a high-speed food and beverage line, what you can see is not always what is happening. Thermal imaging adds a different layer of control. Instead of relying on surface appearance, it measures heat distribution as seals are formed and products move through the line, providing continuous, 100% in-line inspection instead of just sampling.
Read the full article.

Built for the test bench, ready for the field

FUTEK's IDC150 Signal Conditioner packages high-performance signal conditioning in a rugged aluminum enclosure. Built for engineers needing accurate, synchronized data from strain gauge sensors, it fits prototyping and lab environments. The device connects seamlessly to existing setups and pairs with SENSIT software and Python APIs. It is ideal for compact, high-performance digital sensor evaluation.
Learn more.

Communications system achieves fastest laser link from space yet -- 1,000 times better

By Ariana Tantillo, MIT Lincoln Laboratory

In May 2022, the TeraByte InfraRed Delivery (TBIRD) payload onboard a small CubeSat satellite was launched into orbit 300 miles above Earth's surface. Since then, TBIRD has delivered terabytes of data at record-breaking rates up to 100 gigabits per second -- 100 times faster than the fastest internet speeds in most cities -- via an optical communication link to a ground-based receiver in California. This data rate is more than 1,000 times higher than that of the radio-frequency links traditionally used for satellite communication, is the highest ever achieved by a laser link from space to ground, and is made possible by a communications payload that is quite small -- roughly the size of two cereal boxes stacked together.

MIT Lincoln Laboratory conceptualized the TBIRD mission in 2014 as a means of providing unprecedented capability to science missions at low cost. Science instruments in space today routinely generate more data than can be returned to Earth over typical space-to-ground communications links. With small, low-cost space and ground terminals, TBIRD can enable scientists from around the world to take advantage of laser communications fully to downlink all the data they could ever dream of.

The TBIRD communications payload, pictured above, is showcasing unprecedented data rates for space-to-ground laser communications. [Credit: Photo courtesy of Lincoln Laboratory]

 

 

Designed and built at Lincoln Laboratory, the TBIRD communications payload was integrated onto a CubeSat manufactured by Terran Orbital as part of NASA's Pathfinder Technology Demonstrator program. NASA Ames Research Center established this program to develop a CubeSat bus (the "vehicle" that powers and steers the payload) for bringing science and technology demonstrators into orbit more quickly and inexpensively. Weighing approximately 25 lb, the CubeSat was launched into low-Earth orbit (LEO) aboard Space X's Transporter-5 rideshare mission from Cape Canaveral Space Force Station in Florida in May 2022.

The optical ground station is located in Table Mountain, CA, where most weather takes place below the mountain's summit, making this part of the sky relatively clear for laser communication. This ground station leverages the one-meter telescope and adaptive optics (to correct for distortions caused by atmospheric turbulence) at the NASA Jet Propulsion Laboratory Optical Communications Telescope Laboratory, with Lincoln Laboratory providing the TBIRD-specific ground communications hardware.

"We've demonstrated a higher data rate than ever before in a smaller package than ever before," says Jade Wang, the laboratory's program manager for the TBIRD payload and ground communications and assistant leader of the Optical and Quantum Communications Technology Group. "While sending data from space using lasers may sound futuristic, the same technical concept is behind the fiber-optic internet we use every day. The difference is that the laser transmissions are taking place in the open atmosphere, rather than in contained fibers."

From radio waves to laser light
Whether video conferencing, gaming, or streaming movies in high definition, you are using high-data-rate links that run across optical fibers made of glass (or sometimes plastic). About the diameter of a strand of human hair, these fibers are bundled into cables, which transmit data via fast-traveling pulses of light from a laser or other source. Fiber-optic communications are paramount to the internet age, in which large amounts of data must be quickly and reliably distributed across the globe every day.

For satellites, however, a high-speed internet based on laser communications does not yet exist. Since the beginning of spaceflight in the 1950s, missions have relied on radio frequencies to send data to and from space. Compared to radio waves, the infrared light employed in laser communications has a much higher frequency (or shorter wavelength), which allows more data to be packed into each transmission. Laser communications will enable scientists to send 100 to 1,000 times more data than today's radio-frequency systems -- akin to our terrestrial switch from dial-up to high-speed internet.

From Earth observation to space exploration, many science missions will benefit from this speedup, especially as instrument capabilities advance to capture larger troves of high-resolution data, experiments involve more remote control, and spacecraft voyage farther from Earth into deep space.

However, laser-based space communication comes with several engineering challenges. Unlike radio waves, laser light forms a narrow beam. For successful data transmission, this narrow beam must be pointed precisely toward a receiver (e.g., telescope) located on the ground. Although laser light can travel long distances in space, laser beams can be distorted because of atmospheric effects and weather conditions. This distortion causes the beam to experience power loss, which can result in data loss.

For the past 40 years, Lincoln Laboratory been tackling these and related challenges through various programs. At this point, these challenges have been reliably solved, and laser communications is rapidly becoming widely adopted. Industry has begun a proliferation of LEO cross-links using laser communications, with the intent to enhance the existing terrestrial backbone, as well as to provide a potential internet backbone to serve users in rural locations. Last year, NASA launched the Laser Communications Relay Demonstration (LCRD), a two-way optical communications system based on a laboratory design. In upcoming missions, a laboratory-developed laser communications terminal will be launched to the International Space Station, where the terminal will "talk" to LCRD, and support Artemis II, a crewed program that will fly by the moon in advance of a future crewed lunar landing.

"TBIRD heralds a new approach with the potential to further increase data rate capabilities; shrink size, weight, and power; and reduce lasercom mission costs," says Wang.

One way that TBIRD aims to reduce these costs is by utilizing commercial off-the-shelf components originally developed for terrestrial fiber-optic networks. However, terrestrial components are not designed to survive the rigors of space, and their operation can be impacted by atmospheric effects. With TBIRD, the laboratory developed solutions to both challenges.

Commercial components adapted for space
The TBIRD payload integrates three key commercial off-the-shelf components: a high-rate optical modem, a large high-speed storage drive, and an optical signal amplifier.

All these hardware components underwent shock and vibration, thermal-vacuum, and radiation testing to inform how the hardware might fare in space, where it would be subject to powerful forces, extreme temperatures, and high radiation levels. When the team first tested the amplifier through a thermal test simulating the space environment, the fibers melted. As Wang explains, in vacuum no atmosphere exists, so heat gets trapped and cannot be released by convection. The team worked with the vendor to modify the amplifier to release heat through conduction instead.

To deal with data loss from atmospheric effects, the laboratory developed its own version of Automatic Repeat Request (ARQ), a protocol for controlling errors in data transmission over a communications link. With ARQ, the receiver (in this case, the ground terminal) alerts the sender (satellite) through a low-rate uplink signal to re-transmit any block of data (frame) that has been lost or damaged.

"If the signal drops out, data can be re-transmitted, but if done inefficiently -- meaning you spend all your time sending repeat data instead of new data -- you can lose a lot of throughput," explains TBIRD system engineer Curt Schieler, a technical staff member in Wang's group. "With our ARQ protocol, the receiver tells the payload which frames it received correctly, so the payload knows which ones to re-transmit."

Another aspect of TBIRD that is new is its lack of a gimbal, a mechanism for pointing the narrow laser beam. Instead, TBIRD relies on a laboratory-developed error-signaling concept for precision body pointing of the spacecraft. Error signals are provided to the CubeSat bus so it knows how exactly to point the body of the entire satellite toward the ground station. Without a gimbal, the payload can be miniaturized even further.

"We intended to demonstrate a low-cost technology capable of quickly downlinking a large volume of data from LEO to Earth in support of science missions," says Wang. "In just a few weeks of operations, we have already accomplished this goal, achieving unprecedented transmission rates of up to 100 gigabits per second. Next, we plan to exercise additional features of the TBIRD system, including increasing rates to 200 gigabits per second, enabling the downlink of more than 2 terabytes of data -- equivalent to 1,000 high-definition movies -- in a single five-minute pass over a ground station."

Lincoln Laboratory developed the TBIRD mission and technology in partnership with NASA Goddard Space Flight Center.

Published December 2022

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