Autonomous navigation in high-risk environments requires precise sensor technology.

The transition from experimental research and development to the mass deployment of autonomous platforms is accelerating. Autonomy has expanded beyond the predictable laboratory or controlled environments.

Engineers and innovators are pushing the boundaries of what machines can achieve by deploying autonomous systems in some of Earth's most inhospitable environments—from the crushing pressure of the deep sea to the dangerous, unpredictable terrain of remote industrial sites. Add to that the growing demand for autonomous spacecraft and robotics, and the potential is enormous.

For these machines to operate successfully without human intervention, they need more than just spatial awareness. They must understand the physical forces acting upon them in real time in order to make safety decisions in a matter of seconds. They require precise sensor capabilities suitable for use in hazardous environments are designed.

Interface offers robust load cells and multi-axis force technologies that are integrated into operational systems to expand the applications of autonomous platforms in extreme environments. As in our latest case study Autonomous systems in harsh environments require precise force measurement. As described, autonomy has a wide range of use cases in various industries beyond driverless cars.

Autonomous platforms in extreme environments

Where are autonomous platforms being developed, tested, and actually deployed today? Here are examples of these systems, which are known to Interface.

Underwater energy and infrastructure

• Pipeline integrity: swarms of autonomous underwater vehicles (AUVs) They continuously monitor deep-sea oil and gas pipelines to detect cracks or leaks using real-time force and visual data.
• Shaft head maintenance: Autonomous systems perform skillful repairs and valve adjustments on underwater equipment where high hydrostatic pressure prevents human diving.

Nuclear decommissioning and energy

• Radiation mapping: Ground vehicles equipped with multi-axis sensors navigate autonomously through contaminated zones to map alpha, beta, and gamma radiation without endangering operators.
• Reactor inspection: Small-scale robots navigate through the interior of nuclear reactors to inspect structural tiles and support systems in high-temperature and high-radiation zones.

Mining and underground exploration

• Autonomous drilling: Large-format robotic drilling platforms use force sensors to optimize drill pressure and borehole placement during deep drilling operations.
• Search and Rescue Services (SAR): Walking robots explore unstable, smoke-filled, or collapsed tunnels to locate survivors and map dangerous underground terrain after industrial accidents.

Aerospace and space research

• Planetary Rovers: Autonomous platforms navigate across irregular, low-gravity terrain to collect geological samples and perform structural tests on extraterrestrial surfaces, as in our application. Rover wheel torque monitoring highlighted.
• High-altitude weather sensors: Autonomous UAVs measure extreme updrafts and wind speeds near volcanic activity to improve atmospheric forecasts and disaster prevention.

Industrial decontamination

• Handling of hazardous waste: Autonomous mobile manipulators identify, lift and transport chemical or biological waste in sealed environments and ensure precise load distribution to prevent spills.
• Refinery security: Autonomous “robot dogs” patrol hazardous processing plants to monitor for gas leaks and structural fatigue in areas with limited human access.

Exploring the challenges and solutions of autonomous platforms

Maritime autonomous rescue vehicles

In search and rescue operations, autonomous underwater vehicles (AUVs) must withstand extreme hydrostatic pressure while maintaining precise propulsion. The challenge lies in the unpredictability of the environment. Propellers and thrusters encounter varying water resistance and hydrodynamic loads, which can lead to mechanical fatigue or catastrophic failure if not monitored.

To solve this challenge, engineers use the Interface T2 Ultra Precision Shaft Style Rotating torque transducer. This sensor is designed for contactless data transmission and enables torque measurement during high-speed engine operation (up to 15.000 RPM) with a combined error of 0,1%. In combination with the SI-USB4 4-channel USB interface module The system delivers a high-resolution 16-bit data stream directly to the AUV's control unit. This real-time feedback enables the autonomous system to optimize energy consumption and dynamically adjust engine power to ensure mission success across the vast ocean. Read more: Water rescue robot.

Terrestrial inspections require stability in hazardous areas

The oil and gas industry is increasingly relying on autonomous four-legged "robot dogs" to inspect refineries and offshore platforms. These environments are characterized by uneven steel gratings, steep stairs, and slippery surfaces, where a single misstep could lead to the loss of expensive equipment or a safety hazard.

Engineers have the Interface LBM Compression Load Button Load Cell Integrated into the feet of these robotic explorers, these stainless steel sensors, despite their compact design, can handle capacities of up to 50.000 lbf and provide important data on ground contact forces and weight distribution.

Using the WTS-AM-1E Wireless Strain Bridge Transmitter keeps the robot completely wireless. The data is transmitted via a WTS-BS-6 Wireless Telemetry Dongle The data is sent to a remote monitoring station, allowing the robot's onboard AI to instantly adjust its gait and balance when transitioning from smooth concrete to rough industrial terrain. Learn more in the application note. Autonomous robot dog.

The hybrid transformation for validating multi-axial loads

One of the most complex advances is the rise of hybrid humanoid robotThese machines can switch between fully autonomous and remotely controlled modes. They must perform high-stress mechanical operations, such as turning stubborn underwater valves or operating heavy salvage equipment. The stress on the robot joints during these transitions is immense and multidirectional.

To manage this complexity, Interface offers the 6A55RI 6-axis robot flange force torque sensorUnlike standard sensors that measure a single force, the 6A55RI captures simultaneous data across three force axes and three torques. Integrated directly into the robot's limb flanges, it uses an EtherCAT P interface to transmit power and high-speed data over a single cable. The sensor ensures the robot's control system has a comprehensive map of the mechanical load at each joint, preventing overtorque and extending the platform's service life. Learn more: Underwater humanoid robot.

Developing a reliable autonomous future

The of Interface load cells, torque transducers and multi-axis sensors for hazardous environments The delivered data is specifically designed for the requirements of extreme environments and autonomous platforms. By integrating these robust technologies, developers shorten development cycles and increase the reliability of mission-critical applications.

TIP: Learn more in our Hazardous Locations ATEX 101.

Whether it's an underwater drone or a terrestrial inspector, the goal remains the same: to provide the physical data needed for autonomy to flourish and reduce the risk to humans and our world.