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In the 1960s and 1970s, NASA spent a lot of time thinking about whether toroidal (donut-shaped) fuel tanks were the way to go with its spacecraft. Toroidal tanks have a bunch of potential advantages over conventional spherical fuel tanks. For example, you can fit nearly 40% more volume within a toroidal tank than if you were using multiple spherical tanks within the same space. And perhaps most interestingly, you can shove stuff (like the back of an engine) through the middle of a toroidal tank, which could lead to some substantial efficiency gains if the tanks could also handle structural loads.

Because of their relatively complex shape, toroidal tanks are much more difficult to make than spherical tanks. Even though these tanks can perform better, NASA simply doesn’t have the expertise to manufacture them anymore, since each one has to be hand-built by highly skilled humans. But a company called Machina Labs thinks that they can do this with robots instead. And their vision is to completely change how we make things out of metal.

The fundamental problem that Machina Labs is trying to solve is that if you want to build parts out of metal efficiently at scale, it’s a slow process. Large metal parts need their own custom dies, which are very expensive one-offs that are about as inflexible as it’s possible to get, and then entire factories are built around these parts. It’s a huge investment, which means that it doesn’t matter if you find some new geometry or technique or material or market, because you have to justify that enormous up-front cost by making as much of the original thing as you possibly can, stifling the potential for rapid and flexible innovation.

On the other end of the spectrum you have the also very slow and expensive process of making metal parts one at a time by hand. A few hundred years ago, this was the only way of making metal parts: skilled metalworkers using hand tools for months to make things like armor and weapons. The nice thing about an expert metalworker is that they can use their skills and experience to make anything at all, which is where Machina Labs’ vision comes from, explains CEO Edward Mehr who co-founded Machina Labs after spending time at SpaceX followed by leading the 3D printing team at Relativity Space.

“Craftsmen can pick up different tools and apply them creatively to metal to do all kinds of different things. One day they can pick up a hammer and form a shield out of a sheet of metal,” says Mehr. “Next, they pick up the same hammer, and create a sword out of a metal rod. They’re very flexible.”

The technique that a human metalworker uses to shape metal is called forging, which preserves the grain flow of the metal as it’s worked. Casting, stamping, or milling metal (which are all ways of automating metal part production) are simply not as strong or as durable as parts that are forged, which can be an important differentiator for (say) things that have to go into space. But more on that in a bit.

The problem with human metalworkers is that the throughput is bad—humans are slow, and highly skilled humans in particular don’t scale well. For Mehr and Machina Labs, this is where the robots come in.

“We want to automate and scale using a platform called the ‘robotic craftsman.’ Our core enablers are robots that give us the kinematics of a human craftsman, and artificial intelligence that gives us control over the process,” Mehr says. “The concept is that we can do any process that a human craftsman can do, and actually some that humans can’t do because we can apply more force with better accuracy.”

This flexibility that robot metalworkers offer also enables the crafting of bespoke parts that would be impractical to make in any other way. These include toroidal (donut-shaped) fuel tanks that NASA has had its eye on for the last half century or so.

Machina Labs’ CEO Edward Mehr (on right) stands behind a 15 foot toroidal fuel tank.Machina Labs

“The main challenge of these tanks is that the geometry is complex,” Mehr says. “Sixty years ago, NASA was bump-forming them with very skilled craftspeople, but a lot of them aren’t around anymore.” Mehr explains that the only other way to get that geometry is with dies, but for NASA, getting a die made for a fuel tank that’s necessarily been customized for one single spacecraft would be pretty much impossible to justify. “So one of the main reasons we’re not using toroidal tanks is because it’s just hard to make them.”

Machina Labs is now making toroidal tanks for NASA. For the moment, the robots are just doing the shaping, which is the tough part. Humans then weld the pieces together. But there’s no reason why the robots couldn’t do the entire process end-to-end and even more efficiently. Currently, they’re doing it the “human” way based on existing plans from NASA. “In the future,” Mehr tells us, “we can actually form these tanks in one or two pieces. That’s the next area that we’re exploring with NASA—how can we do things differently now that we don’t need to design around human ergonomics?”

Machina Labs’ ‘robotic craftsmen’ work in pairs to shape sheet metal, with one robot on each side of the sheet. The robots align their tools slightly offset from each other with the metal between them such that as the robots move across the sheet, it bends between the tools. Machina Labs

The video above shows Machina’s robots working on a tank that’s 4.572 m (15 feet) in diameter, likely destined for the Moon. “The main application is for lunar landers,” says Mehr. “The toroidal tanks bring the center of gravity of the vehicle lower than what you would have with spherical or pill-shaped tanks.”

Training these robots to work metal like this is done primarily through physics-based simulations that Machina developed in house (existing software being too slow), followed by human-guided iterations based on the resulting real-world data. The way that metal moves under pressure can be simulated pretty well, and although there’s certainly still a sim-to-real gap (simulating how the robot’s tool adheres to the surface of the material is particularly tricky), the robots are collecting so much empirical data that Machina is making substantial progress towards full autonomy, and even finding ways to improve the process.

An example of the kind of complex metal parts that Machina’s robots are able to make.Machina Labs

Ultimately, Machina wants to use robots to produce all kinds of metal parts. On the commercial side, they’re exploring things like car body panels, offering the option to change how your car looks in geometry rather than just color. The requirement for a couple of beefy robots to make this work means that roboforming is unlikely to become as pervasive as 3D printing, but the broader concept is the same: making physical objects a software problem rather than a hardware problem to enable customization at scale.

I’ve been reviewing robot vacuums for more than a decade, and robot mops for just as long. It’s been astonishing how the technology has evolved, from the original iRobot Roomba bouncing off of walls and furniture to robots that use lidar and vision to map your entire house and intelligently keep it clean.

As part of this evolution, cleaning robots have become more and more hands-off, and most of them are now able to empty themselves into occasionally enormous docks with integrated vacuums and debris bags. This means that your robot can vacuum your house, empty itself, recharge, and repeat this process until the dock’s dirt bag fills up.

But this all breaks down when it comes to robots that both vacuum and mop. Mopping, which is a capability that you definitely want if you have hard floors, requires a significant amount of clean water and generates an equally significant amount of dirty water. One approach is to make docks that are even more enormous—large enough to host tanks for clean and dirty water that you have to change out on a weekly basis.

SwitchBot, a company that got its start with a stick-on robotic switch that can make dumb things with switches into smart things, has been doing some clever things in the robotic vacuum space as well, and we’ve been taking a look at the SwitchBot S10, which hooks up to your home plumbing to autonomously manage all of its water needs. And I have to say, it works so well that it feels inevitable: this is the future of home robots.

A Massive Mopping Vacuum

The giant dock can collect debris from the robot for months, and also includes a hot air dryer for the roller mop.Evan Ackerman/IEEE Spectrum

The SwitchBot S10 is a hybrid robotic vacuum and mop that uses a Neato-style lidar system for localization and mapping. It’s also got a camera on the front to help it with obstacle avoidance. The mopping function uses a cloth-covered spinning roller that adds clean water and sucks out dirty water on every rotation. The roller lifts automatically when the robot senses that it’s about to move onto carpet. The S10 comes with a charging dock with an integrated vacuum and dust collection system, and there’s also a heated mop cleaner underneath, which is a nice touch.

I’m not going to spend a lot of time analyzing the S10’s cleaning performance. From what I can tell, it does a totally decent job vacuuming, and the mopping is particularly good thanks to the roller mop that exerts downward pressure on the floor while spinning. Just about any floor cleaning robot is going to do a respectable job with the actual floor cleaning—it’s all the other stuff, like software and interface and ease of use, that have become more important differentiators.

Home Plumbing Integration

The water dock, seen here hooked up to my toilet and sink, exchanges dirty water out of the robot and includes an option to add cleaning fluid.Evan Ackerman/IEEE Spectrum

The S10’s primary differentiator is that it integrates with your home plumbing. It does this through a secondary dock—there’s the big charging dock, which you can put anywhere, and then the much smaller water dock, which is small enough to slide underneath an average toe-kick in a kitchen.

The dock includes a pumping system that accesses clean water through a pressurized water line, and then squirts dirty water out into a drain. The best place to find this combination of fixtures is near a sink with a p-trap, and if this is already beyond the limits of your plumbing knowledge, well, that’s the real challenge with the S10. The S10 is very much not plug-and-play; to install the water dock, you should be comfortable with basic tool use and, more importantly, have some faith in the integrity of your existing plumbing.

My house was built in the early 1960s, which means that a lot of my plumbing consists of old copper with varying degrees of corrosion and mineral infestation, along with slightly younger but somewhat brittle PVC. Installing the clean water line for the dock involves temporarily shutting off the cold water line feeding a sink or a toilet—that is, turning off a valve that may not have been turned for a decade or more. This is risky, and the potential consequences of any uncontrolled water leak are severe, so know where your main water shutoff is before futzing with the dock installation.

To SwitchBot’s credit, the actual water dock installation process was very easy, thanks to a suite of connectors and adapters that come included. I installed my dock in between a toilet and a pedestal sink, with access to the toilet’s water valve for clean water and the sink’s p-trap for dirty water. The water dock is battery powered, and cleverly charges from the robot itself, so it doesn’t need a power outlet. Even so, this one spot was pretty much the only place in my entire house where the water dock could easily go: my other bathrooms have cabinet sinks, which would have meant drilling holes for the water lines, and neither of them had floor space where the dock could live without being kicked all the time. It’s not like the water dock is all that big, but it really needs to be out of the way, and it can be hard to find a compatible space.

Mediocre Mapping

With the dock set up, the next step is mapping. The mapping process with the S10 was a bit finicky. I spent a bunch of time prepping my house—that is, moving as much furniture as possible off of the floor to give the robot the best chance at making a solid map. I know this isn’t something that most people probably do for their robots, but knowing robots like I do, I figure that getting a really good map is worth the hassle in the long run.

The first mapping run completed in about 20 minutes, but the robot got “stuck” on the way back to its dock thanks to a combination of a bit of black carpet and black coffee table legs. I rescued it, but it promptly forgot its map, and I had to start again. The second time, the robot failed to map my kitchen, dining room, laundry room, and one bathroom by not going through a wide open doorway off of the living room. This was confusing, because I could see the unexplored area on the map, and I’m not sure why the robot decided to call it a day rather than investigating that pretty obvious frontier region.

SwitchBot is not terrible at mapping, but it’s definitely sub-par relative to the experiences that I’ve had with older generations of other robots. The S10 also intermittently freaked out on the black patterned carpet that I have: moving very cautiously, spinning in circles, and occasionally stopping completely while complaining about malfunctioning cliff sensors, presumably because my carpet was absorbing all of the infrared from its cliff sensors while it was trying to map.

Black carpet, terror of robots everywhere.Evan Ackerman/IEEE Spectrum

Part of my frustration here is that I feel like I should be able to tell the robot “it’s a black carpet in that spot, you’re fine,” rather than taking such drastic measures as taping over all of the cliff sensors with tin foil, which I’ve had to do on occasion. And let me tell you how overjoyed I was to discover that the S10’s map editor has that exact option. You can also segment rooms by hand, and even position furniture to give the robot a clue on what kind of obstacles to expect. What’s missing is some way of asking the robot to explore a particular area over again, which would have made the initial process a lot easier.

Would a smarter robot be able to figure out all of this stuff on its own? Sure. But robots are dumb, and being able to manually add carpets and furniture and whatnot is an incredibly useful feature, I just wish I could do that during the mapping run somehow instead of having to spend a couple of hours getting that first map to work. Oh well.

How the SwitchBot S10 Cleans

When you ask the S10 to vacuum and mop, it leaves its charging dock and goes to the water dock. Once it docks there, it will extract any dirty water, clean its roller mop, extract the dirty water, wash its filter, and then finally refill itself with clean water before heading off to start mopping. It may do this several times over the course of a cleaning run, depending on how much water you ask it to use, but it’s quite good at managing all of this by itself. If you would like your floor to be extra clean, you can have the robot make two passes over the same area, which it does in a crosshatch pattern. And the app helpfully clues you in to everything that the robot is doing, including real-time position.

The app does and excellent job of showing where the robot has cleaned. You can also add furniture and floor types to help the robot clean better.Evan Ackerman/IEEE Spectrum

I’m pleasantly surprised by my experience with the S10 and the water dock. It was relatively easy to install and works exactly as it should. This is getting very close to the dream for robot vacuums, right? I will never have to worry about clean water tanks or dirty water tanks. The robot can mop every day if I want it to, and I don’t ever have to think about it, short of emptying the charging dock’s dustbin every few months and occasionally doing some basic robot maintenance.

SwitchBot’s Future

Being able to access water on-demand for mopping is pretty great, but the S10’s water dock is about more than that. SwitchBot already has plans for a humidifier and dehumidifier, which can be filled and emptied with the S10 acting as a water shuttle. And the dehumidifier can even pull water out of the air and then the S10 can use that water to mop, which is pretty cool. I can think of two other applications for a water shuttle that are immediately obvious: pets, and plants.

SwitchBot is already planning for more ways of using the S10’s water transporting capability.SwitchBot

What about a water bowl for your pets that you can put anywhere in your house, and it’s always full of fresh water, thanks to a robot that not only tops the water off, but changes it completely? Or a little plant-sized dock that lives on the floor with a tube up to the pot of your leafy friend for some botanical thirst quenching? Heck, I have an entire fleet of robotic gardens that would love to be tended by a mobile water delivery system.

SwitchBot is not the only company to offer plumbing integration for home robots. Narwal and Roborock also have options for plumbing add-on kits to their existing docks, although they seem to be designed more for European or Asian homes where home plumbing tends to be designed a bit differently. And besides the added complication of systems like these, you’ll pay a premium for them: the SwitchBot S10 can cost as much as $1200, although it’s frequently on sale for less. As with all new features for floor care robots, though, you can expect the price to drop precipitously over the next several years as new features become standard, and I hope plumbing integration gets there soon, because I’m sold.

The water column is hazy as an unusual remotely operated vehicle glides over the seafloor in search of a delicate tilt meter deployed three years ago off the west side of Vancouver Island. The sensor measures shaking and shifting in continental plates that will eventually unleash another of the region’s 9.0-scale earthquakes (the last was in 1700). Dwindling charge in the instruments’ loggers threatens the continuity of the data.

The 4-metric-ton, C$8-million (US $5.8-million) remotely operated vehicle (ROV) is 50 meters from its target when one of the seismic science platforms appears on its sonar imaging system, the platform’s hard edges crystallizing from the grainy background like a surgical implant jumping out of an ultrasound image. After easing the ROV to the platform, operators 2,575 meters up at the Pacific’s surface instruct its electromechanical arms and pincer hands to deftly unplug a data logger, then plug in a replacement with a fresh battery.

This mission, executed in early October, marked an exciting moment for Josh Tetarenko, director of ROV operations at North Vancouver-based Canpac Marine Services. Tetarenko is the lead designer behind the new science submersible and recently dubbed it Jenny in homage to Forrest Gump, because the fictional character named all of his boats Jenny. Swapping out the data loggers west of Vancouver Island’s Clayoquot Sound was part of a weeklong shakedown to test Jenny’s unique combination of dexterity, visualization chops, power, and pressure resistance.

Jenny is only the third science ROV designed for subsea work to a depth of 6,000 meters.

By all accounts Jenny sailed through. Tetarenko says the worst they saw was a leaky O-ring and the need to add some spring to a few bumpers. “Usually you see more things come up the first time you dive a vehicle to those depths,” says Tetarenko.

Jenny’s successful maiden cruise is just as important for Victoria, B.C.–based Ocean Networks Canada (ONC), which operates the NEPTUNE undersea observatory. The North-East Pacific Time-series Undersea Networked Experiments array boasts thousands of sensors and instruments, including deep-sea video cameras, seismometers, and robotic rovers sprawled across this corner of Pacific. Most of these are connected to shore via an 812-kilometer power and communications cable. Jenny was custom-designed to perform the annual maintenance and equipment swaps that have kept live data streaming from that cabled observatory nearly continuously for the past 15 years, despite trawler strikes, a fault on its backbone cable, and insults from corrosion, crushing pressures, and fouling.

NEPTUNE remains one of the world’s largest installations for oceanographic science despite a proliferation of such cabled observatories since it went live in 2009. ONC’s open data portal has over 37,000 registered users tapping over 1.5 petabytes of ocean data—information that’s growing in importance with the intensification of climate change and the collapse of marine ecosystems.

Over the course of Jenny’s maiden cruise, her operators swapped devices in and out at half a dozen ONC sites, including at several of NEPTUNE’s five nodes and at one of NEPTUNE’s smaller sister observatories closer to Vancouver.

Inside Jenny

ROV Jenny aboard the Valour, Canpac’s 50-meter offshore workhorse, ahead of October’s NEPTUNE observatory maintenance cruise.Ocean Networks Canada

What makes Jenny so special?

• Jenny is only the third science ROV designed for subsea work to a depth of 6,000 meters.
• Motion sensors actively adjust her 7,000-meter-long umbilical cable to counteract topside wave action that would otherwise yank the ROV around at depth and, in rough seas, could damage or snap the cable.
• Dual high-dexterity manipulator arms are controlled by topside operators via a pair of replica mini-manipulators that mirror the movements.
• Each arm is capable of picking up objects weighing about 275 kilograms, and the ROV itself can transport equipment weighing up to 3,000 kg.
• 11 high-resolution cameras deliver 4K video, supported by 300,000 lumens of lighting that can be tuned to deliver the soft red light needed to observe bioluminescence.
• Dual multibeam sonar systems maximize visibility in turbid water.

Meghan Paulson, ONC’s executive director for observatory operations, says the sonar imaging system will be particularly invaluable during dives to shallower sites where sediments stirred up by waves and weather can cut visibility from meters to centimeters. “It really reduces the risk of running into things accidentally,” says Paulson.

To experience the visibility conditions for yourself, check out recordings of the live video broadcast from the NEPTUNE maintenance cruise. Tetarenko says that next year they hope to broadcast not only the main camera feed but also one of the sonar images.

3D video could be next, according to Canpac ROV pilot and Jenny codesigner, James Barnett. He says they would need to boost the computing power installed topside, to process that “firehose of data,” but insists that real-time 3D is “definitely not impossible.” Tetarenko says the science ROV community is collaborating on software to help make that workable: “3D imagining is kind of the very latest thing that’s being tested on lots of ROV systems right now, but nobody’s really there yet.”

More Than Science

Expansion of the cabled observatory concept is the more certain technological legacy for ONC and NEPTUNE. In fact, the technology has evolved beyond just oceanography applications.

ONC tapped Alcatel Submarine Networks (ASN) to design and build the Neptune backbone and the French firm delivered a system that has reliably delivered multigigabit Ethernet plus 10 kilovolts of direct-current electricity to the deep sea. Today ASN deploys a second-generation subsea power and communications networking solution, developed with the Norwegian international energy company Equinor.

ASN’s “Direct Current/Fiber Optic” or DC/FO system provides the 100-km backbone for the ARCA subsea neutrino observatory near Sicily, in addition to providing control systems for a growing number of offshore oil and gas installations. The latter include projects led by Equinor and BP where DC/FO networks drive the subsea injection of captured carbon dioxide and monitor its storage below the seabed. Future oil and gas projects will increasingly rely on the cables’ power supply to replace the hydraulic lines that have traditionally been used to operate machinery on the seafloor, according to Ronan Michel, ASN’s product line manager for oil and gas solutions.

Michel says DC/FO incorporates important lessons learned from the Neptune installation. And the latter’s existence was a crucial prerequisite. “The DC/FO solution would probably not exist if Neptune Canada would not have been developed,” says Michel. “It probably gave confidence to Equinor that ASN was capable to develop subsea power and coms infrastructure.”

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