Bullen Ultrasonics’ patented connector is reported to enable safer, faster tool changes and support lights-out manufacturing in Industry 4.0 environments.
EATON, Ohio—Precision machining company Bullen Ultrasonics reported it was awarded a U.S. patent for a new electrical connector that enables fully automated, hands-free tool changes to eliminate downtime, boost safety, and advance lights-out manufacturing.
Designed specifically for high-performance, automated manufacturing, the patented connector enables robots to automatically pick up and drop off high-power, high-voltage tooling, such as Bullen’s ultrasonic machining attachments, while keeping operators safely distanced from ergonomic hazards, high-voltage components, and sharp edges, according to a release from Bullen Ultrasonics.
“This patent highlights our focus as a company on addressing real-world manufacturing challenges,” said Tim Beatty, president of Bullen Ultrasonics, in the release. “It represents our continued effort to develop practical, forward-looking solutions that support the evolving needs of the industry. We’re excited to create new technologies that deliver real value for our customers and help advance the future of precision manufacturing.”
Bullen Ultrasonics provides precision machining of advanced ceramics, glass, and specialty materials using proprietary ultrasonic and laser-based technologies. The company’s non-thermal processes are reported to enable micron-level accuracy and reduce the risk of microcracks, contamination, or structural damage, supporting the production of intricate features in components across high-performance applications.
In automated manufacturing, connectors must withstand repeated use, align without human input, and handle high voltages safely. Bullen’s patented design reportedly does all three while improving uptime and reducing maintenance.
Bradley Jeffries, senior design engineer, and Eric Norton, research and early innovation manager, developed the innovation in response to the harsh conditions of ultrasonic machining, where abrasive materials can corrode traditional components. Bullen’s team engineered a compact, spring-loaded connector that self-aligns and locks into place, even amid vibration, dust, or misalignment. It eliminates manual wiring, enabling seamless tool changes that are said to increase machine uptime and support safer operation.
The Bullen connector was developed as part of a fully automated production cell. In addition to robotic automation, the cell incorporates machine-to-machine data integration, creating a connected feedback loop that enhances yield and operational performance. Every part and process is tracked through a centralized system that enables proactive troubleshooting and continuous improvement. These capabilities position Bullen to integrate artificial intelligence and further advance its Industry 4.0 vision of a fully connected, data-driven factory, the company said in the release.
“As the manufacturing sector moves toward fully autonomous operations, innovations like our new smart connector are key to unlocking safer, more efficient, 24/7 production,” said Beatty. “By removing a long-standing friction point in automation, this innovation is the kind of practical, scalable advancement that modern factories need to stay competitive.”
Bullen applied this innovation to all of its ultrasonic machines in its robotic cell. The company is also exploring commercialization opportunities and strategic partnerships to expand the reach of its innovation, building on its decades of experience in supporting precision manufacturing in mission-critical sectors.
Bullen Ultrasonics stated in the release that its vertically integrated operations, including in-house tool design and custom automation, help streamline production from prototype through high-volume manufacturing. The company holds certifications to ISO 9001, AS9100, and ITAR, reflecting its alignment with quality and traceability standards. Bullen supports numerous industries, including aerospace, defense, automotive, medical, semiconductor, and micro-electromechanical systems (MEMS).