Autonomous Robotics: From Intermittent Failure to Reliable Deployment

The Challenge

A global logistics automation company was experiencing reliability problems with autonomous ground vehicles operating within a large warehouse environment.

The robotic system had been engineered for automated material movement, but electromagnetic interference within the operating environment was affecting reliable performance. The problem was particularly challenging because the robots themselves were sophisticated engineered products; determining why they were not operating reliably required looking beyond conventional product troubleshooting.

ELEXANA was brought in to investigate the problem after previous efforts had not produced a satisfactory solution.

Looking Beyond the Robot

ELEXANA approached the investigation differently.

Rather than assuming the problem existed exclusively within the autonomous vehicle, James Finn examined the robot as part of a larger electromagnetic system—including the vehicle, its electronic architecture, communications, electrical infrastructure, and the environment in which it was expected to operate.

This distinction proved important.

An electronic system can satisfy its individual design and compliance requirements yet still experience reliability problems when deployed into a complex real-world electromagnetic environment.

The objective therefore was not simply to identify the presence of EMI. It was to determine why the interference was affecting operation and what needed to change to make the system reliably functional in its intended environment.

Engineering Investigation

ELEXANA conducted field measurements and system-level investigation of the operating environment while evaluating potential electromagnetic interactions affecting the autonomous vehicles.

Multiple hypotheses were evaluated rather than assuming that the first observed electromagnetic anomaly was responsible for the failures.

The investigation ultimately identified electromagnetic compatibility conditions contributing to the operational problems and provided engineering design recommendations intended to increase the system’s immunity to those conditions.

Importantly, the solution did not depend upon eliminating every electromagnetic source within a massive industrial facility.

The system itself needed to be capable of operating reliably in the environment for which it was intended.

The Result

ELEXANA’s investigation and design contributions helped resolve the electromagnetic compatibility problems affecting the autonomous ground vehicles.

The resulting design improvements enabled the robotic platform to operate reliably across deployment environments and contributed to achieving full system functionality.

The project became an important example of a principle that continues to guide ELEXANA’s work:

EMC compliance and electromagnetic reliability are not necessarily the same thing.

Passing standardized testing demonstrates performance under defined test conditions. Real-world electromagnetic integrity requires understanding how equipment, infrastructure, communications, power systems, and the surrounding electromagnetic environment interact as a complete system.

That is the problem ELEXANA was engaged to solve.

Electromagnetic Integrity Engineering™

Today, autonomous systems, robotics, medical equipment, advanced manufacturing systems, and other mission-critical technologies operate within increasingly complex electromagnetic environments.

When those systems fail without an obvious cause, replacing components or repeating conventional troubleshooting may never reveal the underlying mechanism.

ELEXANA investigates the complete electromagnetic system to identify the root cause and engineer practical solutions.

Where troubleshooting ends, our work begins.