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Introduction

1. a nnne nnns 23 3 3 6 1 DISCONNECTING poWer sees a se aerae sna as 23 3 3 6 2 Reconnecting power I reverse the above steps 23 3 3 7 Operation C7 Change Dattery 24 3 3 8 Operation C8 Change internal component 25 3 09 Operation G9 Change PC 25 3 3 10 Operation C10 Change video camera window 26 3 3 11 Operation C11 Purge hydraulic System 26 3 3 11 1 Disconnecting the hydraulic system 2 3 3 11 2 REMOVING pistons nnne nenne rase ne rna saei nuns 2 3 3 11 3 Purging the SyStem nenne rase r nasse saeua 28 3 3 11 4 Re assembly a nee saei aes r ie asi esr nasse nnus 29 4 Appendix es 30 4 1 User manual for batteries SAFT Li lon VL41M72V39ARh 30 4 2 User manual for charger EVE 72v 10A 671ED1051670 30 Table of figures robos Table of figures Figure 1 General view of the robuROC6 Figure 2 Gene
2. een 11 3 2 4 Operation P4 Clean fan filters i 12 3 2 5 Operation P5 Check rotation axes for foreign matter 14 3 2 6 Operation P6 Recharge batteries a a 15 3 2 7 Operation P7 Recharge remote control 15 3 2 8 Operation P8 Check tire preSS re aserne 15 3 2 9 Operation P9 Check tire Wear nennen nennen nennen nnns 15 3 2 10 Operation P10 Check tightness of lug bolts 16 3 2 11 Operation P11 Check rim condition 16 3 2 12 Operation P13 Control working of security elements 16 SDN Do Operation P14 Control hydraulic system oil levels 17 3 2 14 Operation P17 Synchronize hydraulic system 18 3 9 Corrective operations i 19 ood Operaio T CODE DOG oeque dum MM qM 19 dd CODI a u uuu s 19 DA O O e EE 19 3 3 2 Operation C2 Change wheel 20 o9 Operation C3 GANGES E sessies asasssssssssssssqssssssasasqssasqqassiawasansaawsqawsasassuqasqqaquss 21 3 3 4 Operation C4 Change security DUMPper 22 3 3 5 Operation C5 Change motor 22 3 3 6 Operation C6 Disconnect powWer
3. Roboti lt 3 3 6 Operation C6 Disconnect power x ar 30min bo A This operation must precede any work inside the robot Opening the pods as in procedure C1 must precede this operation Steps must be carried out strictly in the given order 3 3 6 1 Disconnecting power 1 Remove the fuse 1 in the front pod 2 Remove the fuse 2 in the rear pod 3 3 6 2Reconnecting power reverse the above steps 1 Manually tighten the fuse 2 in the rear pod 2 Put the fuse 1 back in the front pod 621058005 indE RobuROC6 Maintenance Manual Page 23 Introduction TONDE Robotics Solutions 3 3 7 Operation C7 Change battery x Tere 30min n Wrench 13mm A This operation may be carried out by integrator only after written agreement from Robosoft A Steps must be carried out strictly in the given order 1 Cutthe power and carry out operation C1 on all three pods Disconnect the electronics bus on all three batteries undo the steel clip and disconnect the black connector 3 You MUST carry out operation C6 disconnecting power 4 Remove battery holding straps 5 Disconnect the power cables on all three batteries with the wrench it may be necessary to slightly lift the batteries to have access to bottom terminals 6 Follow the above steps in reverse to replace battery A Never connect the battery terminals while removing nor while storing A short circuit will cause a very strong discharge w
4. 2 Push the emergency off button 3 Turn the general power off switch to the OFF position turn counter clockwise to the vertical position A Check that plugs are in place on any unused connectors A Carry out regular maintenance and control of the material according to intensity of use see chapter 2 5 A DO NOT WAIT UNTIL BATTERIES ARE COMPLETELY DRAINED BEFORE RECHARGING A Use only the charger supplied with the robuROCe A To limit wheel odometry errors check tire pressure weekly A Obstacle and sidewalk climbing should be carried out at slow speed 621058005 indE RobuROC6 Maintenance Manual Page 4 Introduction rono sgy Robotics Solutions 2 4 Nomenclature Figure 3 Rear view 621058005 indE RobuROC6 Maintenance Manual Page 5 Introduction 6 Emergency stop antenna 8 Frontinfraredligh 9 Frontultrasound Tow ring OFF JONER ON STOP Figure 4 User panel General power on off switch 621058005 indE RobuROC6 Maintenance Manual robosoft Robotics Solutions Page 6 Introduction robos ft f Supervisor PC and task modules on off button Supervisor PC and task modules light Optional Optional OO Brake switch 6 Joystick connector and protective cap 4 8 Lg 1 621058005 indE RobuROC6 Maintenance Manual Page 7 Introduction dir e ME Robott lt tast 2 5 Maintenance This chapter covers the following types of maintenance operati
5. 005 indE RobuROC6 Maintenance Manual Page 20 Introduction robos ft Re b tie 5 slut ions 3 3 3 Operation C3 Change tire gt KCANA min Hex key A Do not use a tire iron you will damage the fiberglass rim 1 Follow the steps of operation C2 for removing a wheel 2 Deflate the inner tube not shown 3 Undo the 12 nuts 4 5 6 4 Remove the fiberglass rim 3 5 Remove the tire 2 and inner tube 6 Replace the defective tire or inner tube 7 Mount the tire by reversing the above steps 8 Inflate the tire to 2 bar for positioning on the rim 9 Deflate the tire depending on the axle on which the wheel is mounted see operation P8 10 Mount the wheel according to operation C3 621058005 indE RobuROC6 Maintenance Manual Page 21 Introduction robosgft Roboti lt 3 3 4 Operation C4 Change security bumper x ar 30min Cutting pliers soapy water Carry out procedure C1 Carry out procedure C6 Cut the two branch wires at the connector Remove the rubber part of the bumper by pulling it out of its groove Mount the new bumper by slipping it into the groove the soapy water will help Reposition the cable and the connector Close the covering plate as for C1 D DS E E I 3 3 5 Operation C5 Change motor gt IO MAU MT comin F I e The robot must go back to workshop e Contact Robosott 621058005 indE RobuROC6 Maintenance Manual Page 22 Introduction robosgit
6. anual Page 26 Introduction peas a V Robotics Solution A This operation may be carried out by integrator only after written agreement from Robosoft A It will be necessary to completely take down the hydraulic system 3 3 11 1 Disconnecting the hydraulic system 1 Lift the middle pod as far as possible with the hydraulic system 2 Open the middle pod and remove the battery see C1 C6 C7 3 Remove the hydraulic system motor 3 3 11 2 Removing pistons 1 Remove the 4 shoulder bolts 2 Remove the 8 articulated axes using the screwdriver 3 The middle pod must be raised as far as possible for this operation in order to gain access to the internal axes raise by hand if necessary 621058005 indE RobuROC6 Maintenance Manual Page 27 Introduction robosoft Robotics Solutions 3 3 11 3 Purging the system Installing material 1 a b C d The pistons should be placed in plastic trays to contain the purged hydraulic oil 1 The compressed air tank 2 is used to charge the hydraulic system with oil see operation P14 for oil grade The air pressure regulator ensures constant charge pressure Oil is injected via the filler plug 4 The tank should be full to avoid introducing air into the hydraulic circuit 5 2 T pistons coop Hold piston with plug end up Unscrew all piston plugs Check that oil is flowing normally without air bubbles Tighten plugs while allowing oil to conti
7. em x L 10min Hex key 6mm Hydraulic pistons control the pitch of the middle pod with respect to the other pods the angle should be the same fore and aft Through internal leakage it is possible that this synchronization may drift with the following consequences Inclinaison du pode central x T To realign this angle 1 Open the synchronization valves 1 with the 6mm hex key 2 2 Manually level the pod 3 Close the valve 621058005 indE RobuROC6 Maintenance Manual Page 18 Introduction robosoft Robotics Solutions 3 3 Corrective operations 3 3 1 Operation C1 Open pod x var 30min Hex key 3 3 1 Cut power with the general power on off switch Undo the holding screws Remove covering plate Disconnect the task module connectors Disconnect the bumper and fans Remove the bumper and fan holder 3 3 1 2Closing 1 Reverse the above steps 2 Lightly lubricate the holding screws to avoid lock up 3 Tighten the M4 screws to a maximum torque of 2 Nm ora N 621058005 indE RobuROC6 Maintenance Manual Page 19 Introduction robosgjt 3 3 2 Operation C2 Change wheel x ar 5min Hex key The wheel is attached by 7 lug bolts 2 and lock washers 1 Raise the pod and place it on blocks Undo the log bolts Put the new wheel into place Tighten the lug bolts don t forget the lock washers Place the robuROC6 back on the ground Mr ON ES 621058
8. from Robosoft All three pods must be opened and one of the batteries must be removed to gain access to the video camera compartment 1 Cut the power and carry out operation C1 on all three pods 2 Disconnect the electronics bus on all three batteries undo the steel clip and disconnect the black connector You MUST carry out operation C6 disconnecting power Remove battery holding straps Disconnect the power cables on all three batteries with the wrench It may be necessary to slightly raise the batteries to have access to bottom terminals Unscrew the camera attached to the struts 6 taking care not to change the lens adjustment Unscrew the four screws 5 Remove the front cover 1 and o ring 2 10 Check the o ring and replace if necessary 11 Replace window 3 12 Follow the above steps in reverse to re install video camera ensuring that the o ring is properly in place 13 Before closing pods check that video camera is working correctly BONO OSS 3 3 11 Operation C11 Purge hydraulic system x Naser 120min Hex keys screwdriver SAE15 30 grade hydraulic oil compressed air tank plastic tray compressed air regulated at maximum 0 3 bar power supply at 24V 3A paper towels alcohol thread lock The robuROGS6 is equipped with a system to synchronize the pitch joints Any air bubbles in the system will lead to play in the joint resulting in oscillation of the middle pod 621058005 indE RobuROC6 Maintenance M
9. ghts with damp sponge and water with non corrosive cleaning product eg window cleaner 3 Rinse with clean water and sponge 4 Dry with soft cloth A Do not use a scraper or any corrosive substance which might scratch or damage surfaces 3 2 3 Operation P3 Clean video camera window x ki 10min Sponge water without corrosive cleaning products soft cloth A Shut robot down before cleaning Turn general power on off switch to vertical position to ensure that robot power is off 1 Put protective cap on general power connector Clean front and back video camera windows with damp sponge and water with non corrosive cleaning product eg window cleaner 3 Rinse with clean water and sponge 4 Dry with soft cloth A Do not use a scraper or any corrosive substance which might scratch or damage surfaces 621058005 indE RobuROC6 Maintenance Manual Page 11 Introduction robosoft Robotics Solutions 3 2 4 Operation P4 Clean fan filters x var 20min Hex key A Shut robot down before cleaning Turn general power on off switch to vertical position to ensure that robot power is off Fan air intakes are covered with foam fiters which must be cleaned regularly to ensure proper cooling of the robot These filters are located 1 Under front and rear bumpers 2 On both sides of the middle pod 621058005 indE RobuROC6 Maintenance Manual Page 12 Introduction robosgft v e Roboti lt 1 On the f
10. hich may severely damage the battery or make it explode A For any battery maintenance storage or shipping operations see the SAFT manual included as an appendix to this document 621058005 indE RobuROC6 Maintenance Manual Page 24 Introduction robos ft I D 3 3 8 Operation C8 Change internal component X Tere 30min n D A This operation may be carried out by integrator only after written agreement from Robosoft Steps must be carried out strictly in the given order 1 Cut the power and carry out operation C1 on all three pods Disconnect the electronics bus on all three batteries undo the steel clip and disconnect the black connector 3 You MUST carry out operation C6 disconnecting power 4 It may be necessary to remove one of the batteries as in operation C7 in order to gain access to component 5 Remove the component according to the specific instructions supplied by Robosoft 6 Follow the above steps in reverse to replace component 3 3 9 Operation C9 Change PC x var 30min A This operation may be carried out by integrator only after written agreement from Robosoft This operation must be carried out the same as for operation C8 621058005 indE RobuROC6 Maintenance Manual Page 25 Introduction oT IV Roboti lt 3 3 10 Operation C10 Change video camera window x Na sa P 30min n Hex key wrench A This operation may be carried out by integrator only after written agreement
11. nd try to move it I it should not move If there is any play the lug bolts are loose Tighten the lug bolts see operation C2 3 2 11 Operation P11 Check rim condition The wheel rims are made of fiberglass Check that there are no nicks or cracks which may have been caused by excessive shock If the rim is damaged go to operation C2 for how to change a wheel 3 2 12 Operation P13 Control working of security elements Li EY W K 1 Start the robot Use the joystick to control the robot Test the security elements they must all be tested one by one a Front tactile bumper b Reartactile bumper c Emergency off button on the robot d Emergency off button on the remote control The vehicle should stop Reactivate the vehicle Repeat to test the remaining security elements N D ois 621058005 indE RobuROC6 Maintenance Manual Page 16 Introduction kranser 3 2 13 Operation P14 Control hydraulic system oil levels x Na sa P 10min n Hex key funnel SAE 15 30 grade hydraulic oil 1 The hydraulic system forms a closed circuit however a slight drop in the oil level may be noticed This is normal As needed top up the circuit with SAE 15 30 grade hydraulic oil Open the plug 1 Top up the circuit with oil Close the plug the plug is not air tight DI 621058005 indE RobuROC6 Maintenance Manual Page 17 robosoft Introduction advance Solutions 3 2 14 Operation P17 Synchronize hydraulic syst
12. nue flowing seal is ensured by a rubber gasket and BS screw 621058005 indE RobuROC6 Maintenance Manual Page 28 Introduction robosQft f Do this operation for all 8 plugs upper and lower chambers of each cylinder 3 Check a To check the result it may be necessary to run the hydraulic pump in both directions b Use a power supply stabilized at 24V and with current limited to a maximum of 3A c Raise and lower the hydraulic cylinders by manually switching the solenoid valve 3 3 11 4 Re assembly 1 Clean the cylinders with the paper towels optionally doused with alcohol Reassemble the hydraulic cylinders e Reverse the order of the above disassembly steps e Use normal strength thread lock e g Loctite 243 to ensure tightness 3 Re install battery and pod covers as in C7 C6 C1 621058005 indE RobuROC6 Maintenance Manual Page 29 Introduction robosgit 4 Appendixes 4 1 User manual for batteries SAFT Li Ion VL41M72V39Ah 4 2 User manual for charger EVE 72v 10A 671ED1051670 621058005 indE RobuROC6 Maintenance Manual Page 30
13. ons e Preventive Vehicle maintenance e Corrective Repairs to vehicle damage After maintenance operations have been carried out ensure that all operating conditions are satisfied see chapter 2 3 2 5 1 Preventive operations and schedule Preventive maintenance operations are as follows 1 Clean robot l Clean infrared lights I Clean video camera window Clean fan filters Check rotation axes for foreign matter Recharge batteries 7 Recharge remote control Check tire pressure X 9 ere er 1 gt 30 foxista O Cm mex mcm OOO TTT Check working of security 12 X elements sowon Pa ow jewwewswiessm X EE Den 621058005 indE RobuROC6 Maintenance Manual Page 8 Introduction robos ft m oot 2 5 2 Corrective operations In the following table e C indicates operations which may be carried out by client e indicates operations which may be carried out by integrator e R indicates operations undertaken by Robosoft or by integrator under special authorization from Robosoft After carrying out one of the following operations it is recommended to carry out all the preventive operations above to ensure that the robuROCE6 is in working condition In case of doubt do not hesitate to contact Robosoft ov On fir 4 nenge sei iumpe A _ 5 Cn A 6 Disconet power In 7 Cebu A 8 chango ema componen R 40 change video camera window IR i Pure more tem a If a co
14. ons book Ref 1 0 ind A 621058005 indE RobuROC6 Maintenance Manual Page 2 Introduction robosgft Robotics Solutions 2 2 Overview The robuROCe has been optimized for stability and for obstacle climbing It is perfectly suitable for use on uneven ground Figure 1 General view of the robuROC6 621058005 indE RobuROC6 Maintenance Manual Page 3 Introduction robosQft f 2 3 Operating conditions 2 3 1 Security rules A Read this manual before using the platform AN For maximum security we recommend following the instructions in this manual A The vehicle operator must at all times have visibility of platform maneuvers A Keep a safe distance from moving platform A Always keep the remote control within easy reach in case of problem A In case of problem immediately stop the robot using either of the emergency off buttons on the robot or on the remote control 2 3 2 Operating rules A There are three elements for stopping the vehicle in case of problem 1 The remote control unit The batteries of the remote control should always be charged Power can be restored to the robot using the remote control 2 An emergency off button on the robot 3 A general battery power off switch A To start the vehicle all three stopping elements must be activated see the quick start chapter of the user manual A To turn the vehicle off deactivate all three elements in the following order 1 Push the remote control off button
15. ower wheels organized into three pods with pitches and roll linkages between them The kinematics allows the platform to adjust to different types of terrain and to climb over obstacles larger than its wheel radius 2 1 Technical specifications of the robuROC6 Parameter Indoors and outdoors Type of terrain City uneven ground Obstacles Slope e 6 independent wheels Geometry e 2 passive articulations roll and 2 active Better obstacle climbing hydraulic articulations pitch Stairs Weight O Q Load capacity 100 kg Evenly distributed on each Not dependent on load over Maximum speed 13 68 km h with fully charge batteries flat terrain dependent on available battery voltage o D Overall dimensions in mm Dimensions e 6wheel configuration 1660 x 800 x 530 mm I x w x h e 4wheel configuration 1610 x 800 x 910 mm e Ground clearance 110 mm Autonomy 3 to 5h Depending on type of use Energy source Li ion batteries Protected against water Water resistance streams from any direction NF EN 60529 Humidity e Storage 10 50 C 10 C with pre heating On board computer Programming Odometry Joystick Inclinometers Ultrasound Video Tactile bumpers Microphone Loudspeakers Temperature User panel User interface e Remote emergency stop ask module interface Supa eo RS232 link interface mode According to specifications interface Color Green RAL 7034 Sensors D Specificati
16. ral view Figure 3 Hear VIeW 5 Figure 4 User panel robosoft Introduction 1 Introduction 1 1 Document objectives This manual is intended to supply information necessary for the maintenance of the robot to keep it in good working order However as routine maintenance of the robot involves different areas of expertise e g mechanics electronics and informatics we recommend consulting qualified personnel 1 2 Glossary C cb555 Robosoft controller card based on the Motorola MPC555 microcontroller Up pitch Upward angle of the front pod with respect to the middle pod H Button that must be maintained pushed during robot movement in manual mode Dead man Releasing the button will immediately stop all movement This is an anti panic device Roll Longitudinal roll angle between one pod and the others T Up and down pitch angle between one pod and the others P Supervisor PC PC that sends frame sequences to the cb555 Down pitch Downward angle of the front pod with respect to the middle pod Unit consisting of an axle and associated electronics the robuROC6 consists of three pods 621058005 indE RobuROC6 Maintenance Manual Page 1 Introduction robos ft f 2 About the robuROC6 The robuROC6 is a mobile robot designed for research and exploration applications in an outdoor environment It is an articulated platform with six independent p
17. robos ft Maintenance manual FCIRE a1 Robotics 09 03 2010 Solutions robu ROC6 Author reviewed by Approved by Aida Sarr Nicolas Gu rineau Pierre Pomiers Pierrick Herv Georges Henri Bourgade Georges Henri Bourgade Document versions and distribution ODO Versions C D Action Pages changed Completed document Date LO ee Rereading LO 22 07 2008 Rereading 09 03 2010 Distribution list Name Compny Date UTIAS 22 07 2008 Copyright ROBOSOFT SA 1995 2006 All rights reserved Table of contents D f bot 1 Introduclion eee 1 1 1 Do umenton o u gt i 1 1 2 SV 1 2 About the robuROG6 cei 2 2 1 Technical specifications of the robUROCE 2 2 2 ONE EN iii 3 2 3 Operating conditions a nnne nnn nn nnn nnns nnns nna nnn nn 4 1 UNNE 4 20 2 Opera Mo tiles 4 2 4 NTE au 5 2 5 MARC 8 2 5 1 Preventive operations and schedule 8 AG 0 10 0 1 399 162198 CTI mm uk att ma na 9 3 Operation details 10 3 1 Lei e 10 3 2 Preventive operations ei 10 21 peraton Pi CleantoboL 0a 10 3 2 2 Operation P2 Clean infrared lightS sees 11 3 2 3 Operation P3 Clean video camera window
18. ront and rear pods Unscrew the holding screws Rinse the foam filters using plenty of water Air dry Rescrew into place 2 On the middle pod Unscrew the holding screws Rinse the foam filters using plenty of water Air dry Re screw into place 621058005 indE RobuROC6 Maintenance Manual Page 13 Introduction Visually examine the rotation axes and remove any foreign matter if necessary ES i Check for foreign matter in these zones 621058005 indE RobuROC6 Maintenance Manual Page 14 Introduction robosQft f 3 2 6 Operation P6 Recharge batteries ES T Z Battery charger AN Do not wait until batteries are completely drained before recharging Turn general power on off switch to vertical position to ensure that robot power is off Plug charger into platform see Figure 4 Turn general power on off switch so that robot power is on Plug charger into power source The green light on the charger should turn on After charging unplug charger from the platform and from the power source LP ab Dp IS A For maintenance storage and shipping operations see the SAFT manual included as an appendix to this document 3 2 7 Operation P7 Recharge remote control S TT Hits Hemote control battery charger AN Do not wait until batteries are completely drained before recharging AN Do not use the remote control while it is charging Push the emergency off button on the remote con
19. rrective maintenance operation is not included in the above list contact Robosoft for instructions and authorization 621058005 indE RobuROC6 Maintenance Manual Page 9 Introduction robosQft f 3 Operation details 3 1 Legend X Time taken for operation In minutes In hours Variable kj Level of difficulty var l Easy no particular care yy Middle proceed carefully YYY Difficult needs special care p E Number of people necessary f em 7 e SE Specific tools for this operation 3 2 Preventive operations 3 2 1 Operation P1 Clean robot x var 30min Water hose soft cloth A Shut robot down before cleaning Turn general power on off switch to vertical position to ensure that robot power is off 1 Put protective cap on all connectors Remove any large foreign material likely to damage robot paying particular care not to damage hydraulic system 3 Hose down robot 4 Dry with soft cloth AN Do not use a scraper or any corrosive substance which might scratch or damage surfaces 621058005 indE RobuROC6 Maintenance Manual Page 10 Introduction robos ft f 3 2 2 Operation P2 Clean infrared lights x L 10min Sponge water without corrosive cleaning products soft cloth A Shut robot down before cleaning Turn general power on off switch to vertical position to ensure that robot power is off 1 Put protective cap on general power connector Clean front and back li
20. trol Plug charger into power source Place the remote control on its charger While charging the red light on the remote control is continuously on the green light indicates the level of charging e Blinking green light fast charging e Fixed green light slow or maintenance charging charge gt 60 SAN During use of the remote control a low level of charge charge lt 10 is indicted by a rapidly flashing red light This warns the operator that the remote control will soon stop working in under 15min 3 2 8 Operation P8 Check tire pressure x ki 20min Filtered dry air compressor 1 Check tire pressure when cold Normal pressure is 0 5 to 1 bar for the front and rear wheels 1 to 2 bar for the middle wheels to be adjusted for load conditions and type of obstacle climbing If the tires are warm do not deflate if the measured pressure is higher than normal Inflate if the pressure is lower than normal Never inflate to more than 2 bar If frequent inflation is necessary have the wheel checked by a specialist See operation C3 for changing or fixing an inner tube 25 09 I9 3 2 9 Operation P9 Check tire wear Some Y 621058005 indE RobuROC6 Maintenance Manual Page 15 Introduction robosgit lt lt 1 Check the tire wear indicators between the tire treads A quick visual check may determine the cause ol tire wear 3 2 10 Operation P10 Check tightness of lug bolts W Grab a wheel a

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