EnCata

An autonomous smart IoT plant growing system Fito Slim for urban farming. The product designed around a “plant and forget” philosophy, outperforming conventional soil and hydroponic solutions. The product allows users to manage the indoor plantation via a mobile application.

We designed, engineered, and manufactured a prototype for the home farming market relying on N.F.T. and flood and drain hydroponics technologies. The development reached as far as TRL-5 and passed engineering validation tests, which allowed the client to move into design validation, refinements, and alpha-tests (aka DVT). 

Work with EnCata allowed our customer to concentrate on core agriculture technology development and the developed prototype became a bench for testing the crucial software and AI/ML algorithms. Importantly, EnCata provided the company with essential hardware engineering, IoT and consumer product development expertise, which allowed the client to focus their precious time on their core activities.

Hyper-realistic simulations with the maximum level of immersion using VR with a full-body tracking suit and tactile feedback system​. Surgical training and simulation VR platform integrates a software and hardware complex which is used in carrying out collaborative operations and tool skills training with the help of VR-technologies.

The most advanced Virtual Reality trainer available for surgeons in the healthcare industry. The first alpha prototype (TRL-5) is a fully developed laparoscopic simulations platform. The secret sauce is a core technology that can be applied to training across industries, from astronauts to neurosurgeons.

The Piston Vault is secure electronic custody safe for Spark™ wallets. The safe design provides storage and reliable connectivity, ready to control and execute blockchain-enabled safe transactions.
EnCata delivered the hardware design of the safe Piston Cylinder™ containing 32 Piston Valve™ systems, connected to 8194 Spark™ hardware self-custody wallets. Overall, steel-clad Piston Cylinders ™ have multiple security features designed to prevent unauthorized access to Spark™ wallets. 

The project design is a unique combination of hardware and blockchain technologies bringing transaction and electronic signature security to a new level. 

The 600 kg prototype was designed, produced and assembled in EnCata, packed, and shipped to Singapore. Our work allowed the client to successfully showcase his solution at a conference and to continue work with embedded software.

A MULTIFUNCTION GATE WITH INNOVATIVE BACTERICIDAL DISINFECTION SYSTEM

A Gate|0 system is designed to help identify virus symptoms in order to reduce the level of infected people in crowded places

Perfectly suited for crowded places (airports, railway

stations, office buildings, manufacturing plants,

shopping malls, cafes, bars, restaurants, etc)

Automated - staff will be distanced from potentially infected people

Disinfects a person with flows of ionized air * and cold steam with ozonized water sprays*, disinfectant sprays

Helps to identify people with virus symptoms

The first affordable professional reusable medical respirator for protection against viruses and bacteria.

Imagine the only mask that not only stops the entry of pathogens into the respiratory tract, but also actively kills them.

A virus or bacteria settling along with large aerosols on the surface of a BDC-Air Cu35 primary filter (copper), as well as some viruses and smaller aerosols passing through BDC-Air Cu35 filter, meet with BDC-Air Bioactive filter and are destroyed.

Bacteria exhaled by humans do not multiply on the inner surface of the BDC-Air Cu35 fabric because a primary filter is installed which prevents the growth of bacterial colonies.

The mask is made of medical plastic with the addition of antibacterial additives that prevent the growth of bacteria on surfaces. A patch (obturator) made of soft rubber is comfortable to wear and forces any inhaled air entirely through the filter material (also made with the addition of antibacterial additives).

A fully automated drone hatch for Arctic and desert environment. The hangar was designed and manufactured from scratch. The hangar equipped with the advanced drone positioning system, custom drone chargers and smart HVAC system.

EnCata took the leading role in engineering the concept, which led us to the development of several important subsystems:

• battery charger,
• commanding electronics with wireless interface
• precision mechanics system for automated hatch opening and closing
• automated landing ‘table’ for positioning drone for charging after it landed in
• HVAC system that sustains a wide range of temperatures: from -50 deg. C to +60 deg. C

Precision mechanics for hangar opening/closure, drone positioning table sub-systems and a custom 200 A charger were the particular engineering challenge while TRL-5 development phase. The assembled and tested prototype (TRL-6) then went for field tests with the customer’s drone system and telecommunication software and successfully passed tests (qualified as TRL-7), which qualified the prototype for further batch production and TRL-8 technology.

An autonomous warehouse robot with 50 kg payload. The robot has IP-53 protection mark to operate both inhouse and outside (temporarily). EnCata refined the startup’s concept and delivered the industrial design, DFM and produced the prototype with all the documentation. The robot plays on the same field as KIVA robots from Amazon and QUICKTRON from Alibaba.

A startup company engaged in industrial robot automation approached EnCata with a POC (TRl-4) prototype. The startup’s team comprised prominent software and electrical engineers and they wanted to refine their concept and move further with the industrial design, optimize BOM and implement DFM approach to start low-volume production and proceed to multiple pilot projects.

We have started the project from both refinings the concept and doing work on robot carriage/suspension simulations to ensure its stability and effectiveness in a variety of situations.

Having completed a multitude of various kinematic simulations and user-cases EnCata’s engineers proceeded to finalize the concept and the industrial designers gave the robot a fashionable touch.

We tried to get away from typically chunky straight lines of industrial robots and suggested nice and clean robot shape while having the DFM in mind. So the industrial design phase left the customer with the design of the covers which are made with vacuum forming technology in order to reduce the robot production costs.

We closely worked with the startup team on the electrical side, BOM optimization and components procurement. The robot implemented several essential components such as:

• reliable motor wheels
• lidar system
• wireless charger
• sensor system

Finished with the CAD design, DFM and documentation/drawings release phase we proceeded to components sourcing, tooling design and prototype manufacturing.

The robot then first was assembled as a ‘skeleton’ chassis with components, electronics and wires added later. In parallel, a mold for vacuum forming was manufactured.

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Work with EnCata allowed the startup to focus on what they do best: embedded robot systems and warehouse/enterprise level software integration. We have brought different pieces to deliver a reliable and cost-effective robot, such as:

• Concept refinement
• Kinematic simulations
• Industrial design
• Design for manufacturability (DFM)
• BOM optimization
• Prototype manufacturing

"ADAM" is a humanoid robot specially designed for educational purposes. The robot is paired with proprietary VR software that enables motion control. EnCata has come with the startup the whole way from refining the concept and making a new industrial design - to DFM, tooling design and manufacturing. The robot is now introduced for robotics and programming classes in schools and universities.

A robotics startup dealing with an educational robotic platform came to EnCata with a POC (proof-of-concept prototype) of a new humanoid robot. The TRL-4 robot prototype was already paired with a startup’s proprietary educational software platform via its electronics.

The challenge was to make robots look nicer, friendlier and more futuristic while bringing both the BOM and manufacturing cost down.

EnCata’s team of design engineers started to rethink the concept with newer components and electronics in place. Eventually, several variants of the industrial design were suggested, which were reflecting the preliminary robot composition and dimensions.

In order to lower down robot mass-production costs and increase the reliability, we suggested to use the whole metal frame made almost entirely with sheet metal. While robot plastic covers were made from vacuum-formed plastic. All these DFM decisions lead to a radical decrease in production costs (only 12% of the components cost).

While startup was concentrated on software development, they came with their electrical layouts and preliminary BOM for electronic components. EnCata took this BOM further for refinement and optimisation, followed by components procurement and robot prototyping and assembly.

Here is a brief list of activities EnCata engaged on this project:

• Concept refinement
• Design engineering with DFM
• Industrial design
• Electronics and BOM optimisation
• Tooling manufacturing
• Industrial prototyping

A high precision body scanner for fashion retail. The scanner design is a rotating platform with a set of digital cameras measuring body parameters with cameras. Digital images then transferred via Wi-Fi interface to a PC and undergo realtime conversion into a digital 3D model.

The customer came to EnCata with a proof-of-concept prototype (TRL-4). The startup wanted to push its hardware technology towards batch production and focus all internal resources on developing custom 3D scanning software for the fashion retail business.

EnCata started the project from the engineering concept development followed by custom PCB design. The scanner system then undergoes industrial design which took into account a wide range of human body weight and ease of enclosure manufacturing with vacuum forming. ​

Having completed the DFM process we delivered a complete set of drawings and produced a TRL-7 prototype (all in-house) including a mold for vacuum forming which passed field tests and was ready for batch-production (TRL-8).

• Conceptual design
• Custom PCB electronics
• Custom electrics
• Full mechanical design with stress and kinematic simulations
• DFM (design for manufacturability)
• Vacuum mould design
• Scanner prototype ready for batch/mass production (TRL-8).

A continuously variable frictionless transmission prototype (proof-of-concept) with high torque was developed and manufactured, based on the customer’s patented invention. The prototype went for static testing and further R&D.

Following-up on the development of the multifunctional IoT device for personal airspace AitZen, EnCata has developed a web and mobile app (IOs and Android) that allow users to monitor air quality. The app is connected to an online store and allows in-app consumables purchase.

EnCata suggested the startup to go beyond a conventional IoT mobile application experience and ease post-sales user experience by having an opportunity to purchase in-app all necessary consumables, expendable parts and aroma fragrances.

By offering users such service in mobile phones, startup resolves the pain of customers searching the market for miscellaneous essential elements, creating a whole ecosystem within it’s IoT product.

Overall, the customer received a full service EnCata, leaving with both the hardware product (we helped to launch mass production) and the mobile application with e-commerce features, giving the startup a competitive edge over potential competitors through a user-friendly interface and IoT connectivity.

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SmartCup is an innovative device that makes coffee, tea and baby formula preparation a more convenient, time-saving and healthy process. This gadget can boil and cool liquids; maintain required temperature; as well as brew coffee, tea and other beverages in a standalone mode. SmartCup offers all these features without any loss in taste or the health-giving benefits of a beverage. 

This gadget went on Kickstarter and it was a turnkey crowdfunding campaign delivered by the EnCata Marketing team.

5S tool board systems empowered with machine vision AI neural network to control tool availability. Such that no item can be checked-out or missing from its place in a workshop. The solution can be transferred to other industries requiring ongoing object recognition.

A manufacturing company formulated a rather innate problem, suffered by any workshop or a lab: missed tools problem. In LEAN manufacturing approach, such problem is circumvented by using 5s visualisation boards. However, in spaces with access to multiple users 5s boards typically fail to keep tools in its place.

EnCata’s AI team suggested to move further and add machine vision (MV) to 5S boards, helping to control the presence of tools in its place. EnCata’s developers created an artificial neural network (NN), which was able to capture the live image from the camera, hanging above the 5s board, and compare the ‘missing tool image’ to the fully equipped board. The NN went through a supervised learning routine of image recognition, taking into account camera lens distortions.

Now any user, taking a tool from the 5s board had to either check in the taken item (via QR code scanning). In case when any tool is taken from the board without checking it in, an ‘Andon’ signal makes a sound+visual alarm. The neural network recognized all the objects/tools on the 5s board and understands which tool is missing, enabling dual control of the items displacement.

The client, in particular, received a very powerful solution for their workshop, tremendously reducing time for items searching. Developed AI-based solution enables a plethora of other applications involving object recognition. The manufacturer further plans to couple the MV software with its inventory management system by using the NN to recognize inventory Kanban stock and create an automated alert for component procurement.

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