Finally, an actually robust USB to ethernet converter for drones and robots
Trillium Engineering is the industry-leading provider of actionable imagery for small UAS tactical operations.
The Challenge
Trillium Engineering approached BotBlox with a challenging request: to design and develop a highly compact yet rugged USB to Ethernet converter board. This solution needed to be small enough to integrate seamlessly into their advanced systems while being robust enough to withstand the harsh conditions their equipment often encounters, including high vibration, extreme temperatures, and demanding operational environments.
USB, while ubiquitous in commercial applications, often behaves unreliably in industrial settings, particularly when used in environments with motors and radio transceivers. This unreliability, especially when compared to Ethernet, can lead to significant integration challenges—often referred to as "integration hell"—when incorporating USB-based hardware into embedded platforms.
The Solution
At BotBlox, we recognized the need for a robust solution that could overcome these challenges, leading to the development of USBBlox—our answer to the reliability issues that plague USB in industrial applications.
Collaborating closely with the team at Trillium Engineering, we designed a miniature USB to Ethernet converter board that addresses these issues in three key ways:
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Industrial-Grade Chipset: Unlike most USB to Ethernet converters on the market that use the commercial-grade RTL8153 chipset, USBBlox is built with the LAN7800, an industrially rated chipset from Microchip. This ensures greater reliability and performance in demanding environments.
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Vibration-Resistant Connectors: Standard USB connectors are non-locking, making them prone to disconnection in vibrating environments. USBBlox utilizes Molex PicoClasp positive locking connectors, which prevent contact issues due to vibration, ensuring a stable connection even in high-vibration scenarios.
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EMI Shielding: USB is highly sensitive to electromagnetic interference (EMI) and performs poorly when unshielded. To combat this, we designed a USB to Molex PicoClasp cable that integrates a shield, coupled with a grounding scheme on the board. This encapsulates the USB circuitry inside the cable shield, both on the board and using a custom EMI shield, providing superior protection against EMI.
Additionally, we are proud to announce that in May 2024, USBBlox successfully passed the EMC test, further validating its reliability and suitability for use in demanding environments. You can view the test report here.
The Result
The collaboration with Trillium Engineering led to the successful development of USBBlox—the world's most compact, rugged USB 3.0 to 10/100/1000M Ethernet Converter. This converter seamlessly integrates into their systems, offering the perfect balance of size and durability. It’s specifically designed for conversion between USB devices and Ethernet networks inside drones, robots, and other space-limited applications, where reliability is paramount.
This project was a great example of what can be achieved when two teams come together with a shared commitment to innovation and excellence. Working with Trillium Engineering allowed us to push the boundaries of what’s possible in compact, rugged networking solutions.
Looking Ahead
We are thrilled with the outcome of this partnership and look forward to future opportunities to collaborate with Trillium Engineering. This project underscores our belief that great ideas often come from teamwork, and we are excited to continue driving innovation together.