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
Page 1 of 30
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
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.

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
Page 2 of 30
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
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

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
Page 3 of 30
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2021 ExRobotics B.V.
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

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
Page 4 of 30
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2021 ExRobotics B.V.
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

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
Page 5 of 30
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2021 ExRobotics B.V.
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.

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
Page 6 of 30
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2021 ExRobotics B.V.
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

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
Page 7 of 30
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2021 ExRobotics B.V.
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

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
Page 8 of 30
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2021 ExRobotics B.V.
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.

ExRobotics B.V.
Robot System
Operating Guide
Document No.:
20190122IP1
Version No.: 12
Owner:
Ian Peerless
Date:
2021-07-20
Page 9 of 30
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2021 ExRobotics B.V.
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.