Technical documentation for engineering review and integration partners
Technical Documentation
Comprehensive technical specifications, architecture details, and integration guidelines for engineering teams and development partners.
System Architecture
High-Level Architecture Diagram
• Force sensors
• Position encoders
• Environmental sensors
• Decision algorithms
• Motion planning
• Safety monitoring
• Actuator systems
• Tool interfaces
• Feedback loops
The Helixa system employs a three-layer architecture that separates perception, control, and execution concerns. This modular design enables independent optimization of each subsystem while maintaining tight integration through standardized interfaces.
Data flows from sensors through the perception layer, which performs real-time processing and feature extraction. The control layer receives processed sensor data and generates motion commands based on current state, desired outcomes, and safety constraints. The execution layer translates high-level commands into precise motor control signals with continuous feedback.
Control Logic & State Management
State Machine Architecture
Control Loop Hierarchy
Decision Algorithm Framework
The adaptive control system employs a hierarchical decision-making framework that balances reactive responses with planned behavior. At each control cycle, the system evaluates current sensor data against expected values, computes error metrics, and determines appropriate corrective actions.
Data Flow & Processing Pipeline
Vision Processing Pipeline
Multi-camera sync
Color normalization
Texture analysis
Point cloud generation
Sensor Fusion Architecture
Multiple sensor modalities are integrated using an Extended Kalman Filter (EKF) framework that provides optimal state estimates by combining measurements with different characteristics, noise profiles, and update rates.
Performance Specifications
Latency Characteristics
| Component | Latency |
|---|---|
| Vision processing | <50 ms |
| Decision algorithm | <10 ms |
| Motion planning | <20 ms |
| Motor response | <5 ms |
| Total system latency | <85 ms |
Mechanical Specifications
| Parameter | Value |
|---|---|
| Positioning accuracy | ±0.5 mm |
| Repeatability | ±0.2 mm |
| Force resolution | 0.01 N |
| Maximum velocity | 500 mm/s |
| Workspace volume | 400×400×300 mm |
Safety Architecture
Multi-Layer Safety System
Independent hardware watchdog monitors system state and can trigger emergency stop through dedicated safety-rated circuits. Force limiters provide mechanical protection against excessive loads. All safety-critical components use redundant sensors with cross-checking.
Continuous evaluation of sensor data against safety envelopes. Position limits, velocity constraints, and force thresholds are enforced at 1000 Hz. Any violation triggers immediate motion cessation and operator alert.
Forward simulation predicts system behavior over the next 100ms. If predicted trajectory violates safety constraints, motion is modified or halted preemptively. Reduces reliance on reactive safety measures.
Human operator maintains supervisory control with ability to pause, adjust, or override system at any time. Emergency stop buttons provide immediate physical intervention capability.
Safety Constraints
- Maximum force: 5N (configurable per operation)
- Maximum velocity: 500 mm/s with adaptive limiting
- Workspace boundaries enforced with 10mm safety margin
- Collision detection with 50ms prediction horizon
- Thermal monitoring prevents component overheating
Fault Handling
- Sensor failure: Switch to degraded mode with reduced capability
- Communication loss: Immediate safe stop and state preservation
- Constraint violation: Motion halt with detailed diagnostic logging
- Power anomaly: Controlled shutdown with position retention
- All faults logged with timestamp and system state snapshot
Repeatability & Accuracy
Measurement Methodology
System accuracy and repeatability are characterized through standardized test protocols. A calibrated reference target is positioned at multiple locations within the workspace. The system is commanded to move to each target position 100 times, and actual position is measured using external metrology equipment (laser tracker with 0.01mm resolution).
Accuracy Metrics
Accuracy measures the difference between commanded position and actual position. Systematic errors are characterized and compensated through calibration procedures.
Repeatability Metrics
Repeatability measures variation when returning to the same commanded position multiple times. This is the primary metric for consistent operation.
Long-Term Stability
Extended operation testing demonstrates maintained performance over time. System was operated continuously for 8-hour sessions over 30 days, with periodic accuracy measurements. No significant degradation was observed, confirming mechanical stability and effective thermal management.
Integration Guidelines
Communication Interfaces
Control API
RESTful API for high-level system control and configuration. Supports operation mode selection, parameter adjustment, and status monitoring.
Telemetry Stream
WebSocket connection provides real-time telemetry at 10 Hz. Includes position, force, system state, and diagnostic information.
Environmental Requirements
Operating Conditions
- • Temperature: 15-30°C
- • Humidity: 20-80% RH (non-condensing)
- • Vibration: <0.5g at 10-200 Hz
- • Lighting: 200-1000 lux ambient
- • Power: 110-240V AC, 50-60 Hz, 1500W max
Installation Requirements
- • Stable mounting surface (vibration isolated)
- • Minimum clearance: 500mm all sides
- • Network: Gigabit Ethernet connection
- • Dedicated 20A circuit recommended
- • Emergency stop accessible within 1m
Maintenance Schedule
Technical Support
For integration assistance, technical questions, or partnership inquiries, contact our engineering team.