ExRobotics ExR-1 User manual

Robot System
Operating Guide
LET’S DEPLOY ROBOTS
TOGETHER
ExRobotics B.V.
Effenseweg 1 I 4838 BA Breda I The Netherlands
[email protected]

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
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Copyright 2021 ExRobotics B.V.
Responsible
[Person who is responsible for
writing the document, i.e.
author]
Name:
Ian Peerless
Job Title:
Director
Signature:
Date:
20th July 2021
Accountable
[Person who is accountable for
the quality, validity and
timeliness of the document, i.e.
Process Owner]
Name:
Ian Peerless
Job Title:
Director
Signature:
Date:
20th July 2021
Consulted on this document
version
[Persons who have endorsed the
document]
Names:
Ronald Schreurs
Dorian Scholz
Alberto Romay
Informed
[Persons who have been
informed of this version of the
document]
Names:
All ExR employees, ER employees
and fleet managers.

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Robot System
Operating Guide
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Copyright 2021 ExRobotics B.V.
Document Change Log:
Version
#
Date of re-
issue
Changes Made
Page
Author of
Change
1
2019-01-22
First draft
Ian Peerless
2
2019-03-25
Updated software description & completed Sections 7
and 8
Many
Ian Peerless
3
2019-03-26
Incorporated comments from Iwan & Dorian
Many
Ian Peerless
4
2019-04-09
Included customer comments
Many
Ian Peerless
5
2019-05-03
Updated gamepad information, track replacement,
and chili-tag positioning. Minor points of clarification
based on deployments.
5, 10 & 12
Ian Peerless
6
2019-05-31
Renamed document & added mission planning &
reporting
5
Ian Peerless
7
2019-07-16
Added fleet status screen, gas alarm adjustments,
gamepad blue button, autonomy junctions, mission
reports with videos/recordings/snapshots, questions
& answers.
6, 7, 9, 14,
16
Ian Peerless
8
2019-08-31
Revised use of the “Keep awake” button
Alarm if autonomous mission is interrupted
Launching an autonomous mission explained
“Spot turn” limitations expanded
Corrected docking station electrical connections
Simpler chili-tags at waypoints explained
Why doesn’t my controller work?
How do I wash a contaminated robot?
7
9
10
11
12
14
18
18
Ian Peerless
9
2019-10-16
Added video recording to remote control screen
Updated screen shots
Clarified how to set up waypoint tasks
Added how to set up junctions
Added new view options to Mission Report
Added ExR-1 specifications
7
7,11
9,10
10,11
11
20
Ian Peerless
Alberto Romay
10
2019-12-02
Updated how to launch a mission and explained “Site
Config” & “Feedback” options.
Added cold weather behaviour to Q&A
8,11
20
Ian Peerless
Alberto Romay
11
2020-03-31
Removed “hibernation” feature & refined charger
wording.
Added a remark about auto-immobilisation.
Added picture of docking station buffer bolt.
Added image and description of new “User
Management” screen.
Added typical data consumption & battery life.
Robot specifications updated.
5,6,8
12
13
14
19
21 - 23
Ian Peerless
12
2021-07-20
Added ExR-2 and full 3D navigation
Created a separate deployment manual
Updated the information throughout the manual.
Multiple
Alberto Romay
Ian Peerless

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Robot System
Operating Guide
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Contents
1. Introduction ..........................................................................................................................................5
2. Robots ...................................................................................................................................................6
3. Control Stations.....................................................................................................................................8
4. Docking Stations & Charging.................................................................................................................8
5. Cloud Software......................................................................................................................................9
5.1. Fleet Management and Fleet Status................................................................................................9
5.2. Driver Screen................................................................................................................................. 10
5.3. Mission Editor ............................................................................................................................... 13
5.4. Mission Report.............................................................................................................................. 13
5.5. Engineer Screen ............................................................................................................................ 13
6. Autonomous Missions........................................................................................................................ 14
6.1. Overview....................................................................................................................................... 14
6.2. Line Following Navigation............................................................................................................. 15
6.3. Tag Based Inspections................................................................................................................... 15
6.4. Full 3D Navigation......................................................................................................................... 16
7. Operating Robots............................................................................................................................... 20
7.1. Operative Training ........................................................................................................................ 20
7.2. Authorisation and Authentication ................................................................................................ 21
7.3. Customer support......................................................................................................................... 21
7.4. Software releases.......................................................................................................................... 22
7.5. Routine Maintenance ................................................................................................................... 22
7.6. Replacing tracks ............................................................................................................................ 22
7.7. Calibrating gas detectors .............................................................................................................. 23
7.8. Replacing ExR-2 batteries ............................................................................................................. 23
7.9. Changing ExR-2 SIM cards............................................................................................................. 24
7.10. Security .................................................................................................................................... 24
8. Questions and Answers...................................................................................................................... 25
8.1. What is my robot’s status............................................................................................................. 25
8.2. Why can’t I connect to a robot? ................................................................................................... 25
8.3. Why has my robot stopped working in cold weather?................................................................. 25
8.4. Why doesn’t my controller work? ................................................................................................ 26
8.5. How much data will the robot transfer over its wireless connection?......................................... 26
8.6. How long will the robot’s batteries last?...................................................................................... 26
8.7. Why am I surprised by the battery level reported by the cloud software? ................................. 26
8.8. How do I refresh my control screen?............................................................................................ 27

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8.9. Why does my robot “drift” to the left or right ............................................................................. 27
8.10. Why have I experienced unexpected behaviour while operating a robot? ............................ 27
8.11. How do I wash a contaminated robot? ................................................................................... 27
9. Robot and Docking Station Specifications ......................................................................................... 28
9.1. Worksite and Climate: ExR-1 Robot.............................................................................................. 28
9.2. Worksite and Climate: ExR-2 Robot & Docking Station................................................................ 28
9.3. Standard ExR-1 Specifications....................................................................................................... 29
9.4. Standard ExR-2 Specifications....................................................................................................... 30

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1. Introduction
This document is one of four that will help operators to use their robots safely and effectively:
▪ExR-1 Robot Operator Operating Instructions
▪ExR-2 and Docking Station Operating Instructions
▪Robot System Operating Guide.
▪Robot System Deployment Guide.
The instructions focus on the safe operation of the robots especially with respect to their use in
potentially explosive gas environments. The others provide additional information about the robot
systems and their use. If there’s a conflict between the documents, the instructions will always
prevail.
This operating guide:
▪Describes each key part of the robot system:
oRobots.
oControl stations that are used to communicate with the robot.
oDocking stations that recharge the robots’ batteries.
oCloud software that enables users to interact with robots.
▪Explains how to set up autonomous missions.
▪Recommends how robot operatives should be trained.
▪Provides advice for operating robots.
The guide will be updated and made available to robot fleet managers and first line support as new
robot hardware and software is deployed.

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2. Robots
Once deployed, users will have little reason to interact with robots. However, the major
components are shown on the drawings below. Robot specifications are included in Section 9.
ExR-1 Robot Platform
ExR-2 Robot Platform
The only controls mounted on each robot are the red emergency stop switch and the black on/off
switch. When the red emergency stop switch is pressed downwards it immobilises the drive
motors. The robot can’t be driven until the switch is released by rotating it and letting it spring

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upwards. When the black switch is rotated anticlockwise to the “off” position the power supply to
all components (except some circuits in the electronics box) is shut-off.
There’s a range of options that can be added to a robot:
Option
ExR-1
ExR-2
Comments
Extra drive camera
module
Not available
In the rear of the robot
Only one of these
options can be installed.
Extra inspection module
Not available
Facing upwards from
the rear of the robot
Inspection module
thermal
Facing forwards
Facing forwards or in
the inspection module
panning
It replaces the light in
the inspection module
panning.
Falco VOC module
Up to 3 of these options
can be installed on top
of the hull.
Up to 2 of these options
can be installed inside
the hull.
Honeywell toxic gas
module 3000 Mk II
Honeywell toxic gas
module Sensepoint XRL
Simtronics hydrocarbon
gas module
Eaton MEDC DB20
speaker
Not available
COMING SOON
Det-tronics acoustic
analyser module
Not available
Ex high power induction
charger & docking
station
Not available
Quick charger with
power socket module
Supplied as standard
instead of the induction
charger
WiFi
Can be combined with
4G LTE
GPS
Not available
Pepperl & Fuchs
switches
Installed when ambient
temperatures won’t
exceed 50C
Electronics box check
valve
Installed if there’s an
exceptional risk of water
entering the electronics
box
Elevating mast
Not available
Raises the inspection
module panning to
head height
COMING SOON
IR leak detection
module
On top of the hull.
Not available

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3. Control Stations
Robots are controlled with a:
▪PC with a screen resolution of at least 1920 x 1080 and Google Chrome.
▪Gamepad for driving the robot (Xbox is recommended).
▪Mouse or trackpad for operating the cursor on the PC’s screen.
It’s important that there are no intrusive firewalls between the control station and the cloud
software (see below).
Port
Protocol
IP
3478
UDP
Will be given to you by Energy Robotics
4. Docking Stations & Charging
The robot automatically charges itself using the induction charger built into its docking station. In
autonomy mode the robot will automatically undock and redock. At the end of a remote control
mission the operative should approach the docking station in “slow speed” mode and in the
direction indicated in the diagram below. Provided the robot is reasonably straight and central
when approaching the docking station, the robot will automatically align the induction charging
plates using the plastic strips under its hull. To facilitate robot alignment, the robot should
approach the docking station in a straight line for at least 3 meters.
Once the front of the robot’s hull is pressing against the front of the docking station the operative
should stop driving forwards and switch off the motors by pressing the red button on the gamepad.
The robot will “go to sleep” (to reduce power consumption) and begin to charge using the induction
charger. There can be a delay of up to 120 seconds before this happens.
Once the induction charger is connected, the “Wireless Charger” and “Charging” boxes on the cloud
software will be checked. Hovering the cursor over the charging box will reveal the charging
current. It takes approximately 6 hours to recharge fully an empty ExR-1 battery pack and 12 hours
for an ExR-2 battery pack.

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The docking station should be powered up at all times since charging may be disrupted if it’s
switched on when the robot’s already docked. Also, it’s best not to switch off the robot (using the
black On/Off switch) when the robot is in the docking station since this too can disrupt charging. If
this happens pull the robot 30cm back and switch it off and on again.
When a driver checks the “Wake Up” box the robot video streams will typically appear within 1
minute. The robot is then ready to use although it’s best to allow some gas sensors 30 minutes to
warm up before starting a mission (see their instructions).
A power socket module (when fitted) enables the robot to be charged within 3 hours. This requires
the robot to be manually plugged into a power supply using a quick-charger that can be ordered
with the robot. The quick-charger’s lead is typically 3 meters long. If the robot is docked you should
first switch off power to the induction charger. When inserting the quick-charge plug, rotate the
entire body clockwise before tightening the ring around its base. You can check the status of the
charging using the LEDs and instructions on the quick charger.
5. Cloud Software
Robots are operated and data is collected using the “cloud”. Access is granted as described in
Section 7.2. Six types of screens are available as described below.
5.1. Fleet Management and Fleet Status
Fleet Management is the first screen that appears when users log on. It allows them to connect to
any robot to which they’ve been granted access. Scrolling down reveals more robots.

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The Fleet Status screen (see below) is accessed by clicking on the “navigation menu” icon to the top
left of the fleet management screen.
5.2. Driver Screen
Once a user has connected to a robot, most of the display information is intuitive:
▪The major functions are summarised in the picture below.
▪For safety reasons, only one operative can control a robot at any given time. The logo towards
the top right of the screen will show who that is. To take over control, click on that icon.
▪All video and LiDAR streams are displayed on the control station. Clicking on the “Expand”
icon of any video stream window moves it to the largest window.
▪To take a snapshot, hover the cursor over any video stream and then click on the Point of
Interest (POI) icon that appears in the top-left corner. Then use the cursor to select the area
of interest and click on the “Accept” button to capture the image. Alternatively you can take a
full-size picture without selecting the POI icon.
▪Snapshots are displayed in the “Media Log” once they have been uploaded to the server (this
happens automatically after taking them) and can be viewed in large scale by clicking on
them. From there they can be saved to the local machine by right clicking the full-sized
picture and selecting “Save As...”.
▪To take a video, a mission must be active. This is done by undocking the robot and driving to
the location of interest (Videos are currently only recorded if the robot status is “Mission
Active”). Once ready, hover the cursor over any video stream and click on the “Video” icon
(small circle) that appears in the top-left corner. The message “recording” will appear. To stop
recording click the “Video” icon again.
▪Videos will be available only after the robot is back in the docking station (to save bandwidth
when driving, videos are not uploaded immediately). Videos are displayed in the Mission
Report website under “Recorded Media” and can be viewed in large scale by clicking on them.
From there they can be saved to the local machine by right clicking the full-sized picture and
selecting “Save As...”.

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▪The icons at the top of the “Media Log” can be used to filter the time of the last events e.g.
images from the last 4 hours. Additionally, the “cloud download” icon to the right can be used
to download a complete set of recordings as a zip file.
▪The audio stream of the microphone can be started and paused by clicking on the
“Microphone” window.
▪The screen shows the gas levels for those gas detectors that are fitted to the robot. The gas
alarm levels for the robot can be adjusted by clicking on the icon to the top right of each gas
display window. An audio/visual alarm is emitted when the alarm level is exceeded.
▪The autonomy controls are grouped together. When the "Keep Awake” box is ticked the
robot won’t sleep. If it’s unticked the robot will save 4G costs and battery power by sleeping
(whether or not it’s docked).
▪Select a mission using the drop-down box. To launch the mission, click on the “Play” button
to the left of the mission drop-down box, to cancel the mission press the button again.
Missions will usually be started when the robot is in a docking station. However it’s also
possible to launch “line-following” missions when the orange line is visible in the down-facing
camera.
▪Using the cursor to activate the "Stop” button has the same effect as pressing the emergency
stop switch on the gamepad. The drive motors are isolated until the switch is released. This is
done using “Auto” or the green button on the gamepad.
▪The gas detectors and lights controls are accessed by clicking on “More”.
▪The top right of the screen shows the robot’s status. A tick adjacent to each item indicates:
oMission Active –robot has been commanded to move and it’s not charging anymore.
oWireless Charger–the robot’s coil is connected to that in the docking station.
oCharging –current is flowing into the battery pack.
oE-Stop Released –the robot’s emergency stop has been released ready to drive.

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oMotors Enabled –the robot’s motors are not isolated anymore, so the robot can be
driven manually or autonomously (this takes a few seconds to change after checking the
“Auto” box or pressing the green gamepad button).
oDriving –the robot is in motion.
oGas Detectors On –The gas detectors are powered up (they have individual warm-up
times and only after this time the gas displays will start showing measurement values).
oManual Control –the robot is being controlled from this control station by a driver.
▪Hovering over an icon or text will often provide more information.
▪Drivers can change the robot location on the screen by clicking on the “Site Config” option in
the navigation menu to the top left of the screen. They can report issues to our engineers
using the “Feedback” option in the user menu to the top right of the screen.
The gamepad controls are illustrated below:
▪The green button activates remote control by enabling the gamepad and drive motors.
▪The blue button switches from remote control to autonomous driving.
▪The yellow button deactivates remote control by disabling the gamepad.
▪The red button on the gamepad stops the robot and isolates the motors, identical to the
“Stop” icon.
▪The analogue joysticks are used to drive (left stick) and steer (right stick) the robot.
▪For ExR-2, the right stick rotates the inspection module panning if the button under the LB
button is held down.
▪Holding down the LB/RB buttons changes speed mode (slowest - no buttons pressed, fastest -
both buttons pressed).
When in autonomous mode, the robot will stop if the connection to the driver’s control station is
broken for more than 5 seconds. This means that an active control station is required for the robot
to be operational in autonomous mode. The robot will also stop if it loses sight of the orange line.
In this situation an audio/visual alarm will be triggered on the robot control screen.

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5.3. Mission Editor
This screen enables planners to construct and edit autonomous missions as described in Section 6.
5.4. Mission Report
A typical mission report screen is as follows.
The data for a mission is displayed by clicking on the relevant block to the left of the screen.
▪The gas detector values are displayed on the adjacent graphs.
▪The plan will be green where the gas levels were below the lower alarm level, amber
where they were between the two alarm levels, and red where they were above the upper
alarm level. Section Error! Reference source not found. describes how to set the alarm
levels.
▪Other information that has been gathered at Waypoints is displayed in the right-hand part
of the screen.
▪Snapshots and gas readings are uploaded immediately. Other recordings are uploaded
when the robot returns to its docking station. Video and sound recordings are limited to 2
minutes for each action.
To study a chart in more detail:
▪Hover the cursor over a point on the chart to get a digital reading.
▪Zoom in with the mouse wheel or by left-clicking and dragging.
▪Pan by using the shift key, left-clicking and dragging.
5.5. Engineer Screen
This screen is used by ExRobotics and Energy Robotics and will not usually be used by customers.

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6. Autonomous Missions
6.1. Overview
A robot mission is typically a circuit that starts and finishes at a docking station. During the circuit
the robot will perform actions for points of interest when the robot is located at a waypoint:
▪A typical action is to record a video, snapshot, sound, or sensor reading.
▪Actions are targeted at points of interest (POIs). This is a 3D location at which the appropriate
camera or sensor is targeted. Examples of POIs are valves, flanges and pumps. To target the
POI the robot will usually need to change its azimuth (rotate) and in some cases will require a
camera to lift its field of view (elevate). There can be more than one action at a POI.
▪Waypoints are 2D locations from which POIs are observed. There can be multiple POIs at a
waypoint. In Line-following navigation, waypoints are defined by an array of chili-tags.
▪There can be multiple waypoints on a mission.
Robots perform their missions using orange lines on the ground (line following navigation), chili-
tags (tag based inspections) and/or a virtual model created by the a robot’s LiDAR module (full 3D
navigation). The deployment guide describes how to establish the required infrastructure. This
manual describes how to use that infrastructure using this mission editor screen.
Robot control
Add Action
Save Mission

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6.2. Line Following Navigation
A planner will:
For undocking, define the exit direction of the robot when leaving the docking station. When the
robot “undocks” it drives in reverse until the middle point between the “Dock 1” and the “12:00”
tags. Then the robot will rotate and exit the docking station to start following the line in one of
three possible directions: 03:00 (robot rotates 90 degrees clockwise), 06:00 (robot rotates 180
degrees), or 09:00 (robot rotates 90 degrees counter-clockwise).
▪From the Mission Editor screen select action “Undocking”
▪Select the Exit Direction (e.g. 09:00)
▪Write a name in Select Action Name e.g. “Undock”
▪Click “Save”
For waypoints that are used as junctions where a robot selects between alternative routes.
▪From the Mission Editor screen select action “Junction”
▪Select Exit Direction (e.g. 06:00).
▪Select the waypoint number for the Junction (the number on the chili-tag).
▪Give the action a name e.g. “Junction 1”
▪Click “Save”
6.3. Tag Based Inspections
1. Launch an autonomous mission from the Robot Control screen and stop the mission a few
meters before the waypoint at which actions are to be performed (with the orange line visible
from the floor cam).
2. Open the Mission Editor screen.
3. Click on “Create Mission” and give a name
4. Click on “Add new action” and press the play button. The robot will drive to the tag and stop
between it and the 12:00 tags.
5. Rotate the robot (and elevate the camera) using the left/right icons on the mission editor
until the sensor is pointing at the POI.
6. Select from the drop-down menus the desired action, sensor, waypoint number and give a
recognisable name (e.g. equipment TAG number) to the action.
7. If “Full-size” is not selected, a region of interest ROI needs to be selected and a photo must be
taken. For this, hover the mouse over the image and use the buttons that appear in the top-
left corner.
8. Click on “Add Action”.
9. Repeat steps from step 5. for all actions that might be required at that waypoint.
10.Drive manually to the line and repeat steps from 4. for other waypoints.
11.Finally, click on the yellow “Disk” icon on the bottom-right to save the mission.
All inspection actions (e.g. Photo) can also be defined and executed at junction waypoints. For this
you just need to add the actions that you require to the waypoint number as described previously
and then add a “Junction” action to the same waypoint number.

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Actions are listed by waypoint in the right-hand column of the mission editor. Planners can create
missions by ticking the actions to be performed and saving the mission using a recognisable name.
When a mission is to be performed, select and launch the mission from the Robot Control screen
(see Section Error! Reference source not found.). Actions will be recorded in the mission report.
6.4. Full 3D Navigation
This is only available for ExR-2 robots. The robot can drive without the need of physical guidance
such as a line. Using its 3D sensors, the robot can extract geometrical information of the
surrounding environment. The robot can be used to record this environment so that it can learn
how to reach points of interest.
To teach a mission, the following steps need to be taken:
1. Open the Mission Editor which you can find by clicking on the burger menu on the top-left
corner
2. Press the green button on your gamepad to enable motors
3. Undock and drive back at least 1m away from the docking station (see image below)
4. Turn in the direction you want to drive

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5. Click on yellow button "Create Mission"
6. Give a unique name and click "Create"
7. Add a new route by clicking on the grey button "Add new route"

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
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8. Give a unique name and click the black circle icon to start recording
9. The button will turn red indicating that recording is in progress
10. Start navigating through the environment until you reach your first waypoint.
11. You have three options: photo, video or waypoint.
12. For photos and videos, you may need to rotate the inspection module panning as described
in Section 5.2. Once the POI is in the Field of View (FoV), you can take a video, a full-size
picture, or a framed picture as described in Section 5.2. Then give a name to the POI
(possibly a tag number) and click on “Add action”.
13. For a waypoint, give a name to your waypoint and click the yellow button "Add action".
14. Actions will appear in a list below.
15. Repeat these steps until you’ve covered all of the POIs.
16. Drive back to the docking station and stop 1m before the docking station, see image.

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
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Copyright 2021 ExRobotics B.V.
.
17. Click on the red button to stop recording the mission
18. Accept the confirmation dialog
19. Your mission is now saved
20. Drive over the docking station to charge the robot and wait for the "Mission Active" box the
get unticked
For the robot to repeat the taught mission:
1. Change to the “Driver Screen”
2. Select the mission from the “Robot Control” list
3. Click the “Play” icon.