ExRobotics ExR-2 User manual

ExRobotics B.V.
Delftechpark 26, 2628 XH, Delft, The Netherlands
[email protected]
ExR-2 Robot
Operating Guide

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 2
Owner:
Ian Peerless
Date:
2022-04-30
Page 1 of 39
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2022 ExRobotics B.V.
Responsible
[Person who is responsible for
writing the document, i.e.
author]
Name:
Ian Peerless
Job Title:
Director
Signature:
Date:
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:
Consulted on this document
version
[Persons who have endorsed the
document]
Names:
Stefan Kohlbrecher
Jeroen Mostert
Alberto Romay
Dorian Scholz
Ronald Schreurs
Daan Hitzbleck
Informed
[Persons who have been
informed of this version of the
document]
Names:
All ExR employees, ER employees,
first line support, and fleet
managers.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 2
Owner:
Ian Peerless
Date:
2022-04-30
Page 2 of 39
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2022 ExRobotics B.V.
Document Change Log:
Version
#
Date of re-
issue
Changes Made
Page
Author of
Change
1
2022-04-12
First draft derived from Robot System Operating
Guide 20190122IP1 Version 12
All
Ian Peerless
2
2022-04-30
Included Energy Robotics comments and additional
details about battery replacement
Various
Ian Peerless

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 2
Owner:
Ian Peerless
Date:
2022-04-30
Page 3 of 39
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2022 ExRobotics B.V.
Contents
1. Introduction ..........................................................................................................................................5
2. Robots ...................................................................................................................................................6
3. Control Stations & Communication ......................................................................................................7
4. Docking Stations & Charging.................................................................................................................8
5. LiDAR Based Navigation, Object Detection and Object Avoidance ......................................................9
6. Cloud Software................................................................................................................................... 12
6.1. Fleet Management and Fleet Status............................................................................................. 12
6.2. Driver Screen................................................................................................................................. 13
6.3. Mission Editor ............................................................................................................................... 16
6.4. Mission Report.............................................................................................................................. 16
6.5. Engineer Screen ............................................................................................................................ 17
7. Autonomous Missions........................................................................................................................ 17
7.1. Overview....................................................................................................................................... 17
7.2. Line Following Navigation............................................................................................................. 18
7.3. Tag Based Inspections................................................................................................................... 18
7.4. Teach and Repeat Navigation....................................................................................................... 19
7.5. Skills .............................................................................................................................................. 23
7.6. Click and Inspect ........................................................................................................................... 23
8. Operating Robots............................................................................................................................... 23
8.1. Operative Training ........................................................................................................................ 23
8.2. Authorisation and Authentication ................................................................................................ 24
8.3. Customer support......................................................................................................................... 25
8.4. Software releases.......................................................................................................................... 25
8.5. Routine Maintenance ................................................................................................................... 25
8.6. Replacing tracks ............................................................................................................................ 25
8.7. Opening the hull............................................................................................................................ 26
8.8. Calibrating gas detectors .............................................................................................................. 27
8.9. Replacing batteries ....................................................................................................................... 27
8.10. Changing SIM cards.................................................................................................................. 30
8.11. Security .................................................................................................................................... 31
9. Questions and Answers...................................................................................................................... 32
9.1. What is my robot’s status............................................................................................................. 32
9.2. Why can’t I connect to a robot? ................................................................................................... 32
9.3. Why has my robot stopped working in cold weather?................................................................. 32
9.4. Why doesn’t my controller work? ................................................................................................ 32

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 2
Owner:
Ian Peerless
Date:
2022-04-30
Page 4 of 39
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2022 ExRobotics B.V.
9.5. How much data will the robot transfer over its wireless connection?......................................... 33
9.6. How long will the robot’s batteries last?...................................................................................... 33
9.7. Why am I surprised by the battery level reported by the cloud software? ................................. 33
9.8. How do I refresh my control screen?............................................................................................ 33
9.9. Why does my robot “drift” to the left or right ............................................................................. 33
9.10. Why have I experienced unexpected behaviour while operating a robot? ............................ 33
9.11. How do I wash a contaminated robot? ................................................................................... 34
10. Robot and Docking Station Specifications ......................................................................................... 35
10.1. Environment ................................................................................................................................. 35
10.2. Terrain and Manoeuvrability ........................................................................................................ 35
10.3. Availability..................................................................................................................................... 36
10.4. Standard Hardware & Software.................................................................................................... 36
10.5. Sensing & Audio Options .............................................................................................................. 37
10.6. Charging Options........................................................................................................................... 38
10.7. Connectivity & Navigation Options............................................................................................... 38
10.8. Cloud-Based Reporting & Analysis Options.................................................................................. 39
10.9. Noses for Honeywell 3000 Mk II................................................................................................... 39

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 2
Owner:
Ian Peerless
Date:
2022-04-30
Page 5 of 39
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2022 ExRobotics B.V.
1. Introduction
This document is one of three that will help operators to use their ExR-2 robots safely and
effectively:
▪ExR-2 and Docking Station Operating Instructions
▪ExR-2 Robot Operating Guide.
▪ExR-2 Robot Deployment (Quick Start) Guide.
All of these documents and some explanatory videos can be downloaded from Downloads |
ExRobotics
The instructions focus on the safe deployment, operation and servicing of robots and docking
stations. The guides provide additional information about robot systems and their use. The guides
don’t usually replicate important information that’s in the instructions so it’s essential that robot
users read and understand the instructions. 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.
oObject detection and avoidance.
▪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.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 2
Owner:
Ian Peerless
Date:
2022-04-30
Page 6 of 39
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Copyright 2022 ExRobotics B.V.
2. Robots
ExR-2 robots are assembled from a number of modules mounted on a skeleton that is clad in sheet
steel. Many of these modules are optional. The full range of modules is identified in these clad and
unclad pictures. More detailed robot specifications are included in Section 10.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 2
Owner:
Ian Peerless
Date:
2022-04-30
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Copyright 2022 ExRobotics B.V.
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
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.
▪When the emergency stop switch is released and the robot is switched on, the robot is held in
position by its motors.
▪When the emergency stop switch is pressed down and/or the robot is switched off, there’s no
power to the motors so the robot moves freely. This means it will roll down a slope under the
influence of gravity.
3. Control Stations & Communication
Customers are responsible for providing control stations. By default, robots are controlled with a:
▪PC with a screen resolution of at least 1920 x 1080 and Google Chrome or Microsoft Edge.
▪Xbox gamepad for driving the robot.
▪Mouse or trackpad for operating the cursor on the PC’s screen.
Should a customer prefer to control their robots with “tablets” (without gamepads) they should
perform a risk assessment because there will be no physical emergency stop on the control station.
In the near future customers will then be able to adapt the user interface for use with tablets.
However, at the moment they should contact their account manager.
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
Robots transfer data and receive instructions via wireless networks. This might be a public 4G
network, a private 4G network, or a WiFi network. They also have a short-range WiFi network that
can be used to correct faults if the main communications network fails. 4G networks are secured
using VPN technology.
The wireless network will connect the robot to a server which might be a private server, or a service
provided by a third party company such as Amazon (AWS) or Microsoft (Azure). This server will host
the cloud software (see Section 6) and transfer data to other servers.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 2
Owner:
Ian Peerless
Date:
2022-04-30
Page 8 of 39
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2022 ExRobotics B.V.
4. Docking Stations & Charging
A robot automatically charges itself using the induction charger built into its docking station. It can
also autonomously dock and undock as described in Section 7. If the robot is being remotely
controlled, the operative should approach the docking station in “slow speed” mode and in the
direction shown in the picture 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.
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 8 hours to recharge a battery pack from 10% to 90% charge.
When the robot is fully docked it will “go to sleep” and begin to charge using the induction charger.
There can be a delay of up to 120 seconds before this happens. When the robot is asleep, many of
its components are switched off to reduce power consumption and speed charging. However:
▪The gas detectors remain on so that they don’t need to “warm up” before commencing the
next mission.
▪It continues to communicate so that it can quickly be woken up.
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.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 2
Owner:
Ian Peerless
Date:
2022-04-30
Page 9 of 39
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Copyright 2022 ExRobotics B.V.
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.
A power socket module (when fitted) enables the robot to be charged within 4 hours. This requires
the robot to be manually plugged into a power supply using a quick-charger that’s supplied with the
socket. 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. This video provides more detail:
https://exrobotics.global/media/uploads/mp4/5/8/58_instruction-how-to-connect-the-quick-
charger.mp4
5. LiDAR Based Navigation, Object Detection and Object Avoidance
ExR-2 robots are usually supplied with a LiDAR module. This is at the heart of autonomous
navigation (see Section 7.4), object detection (which also works during remote controlled missions)
and object avoidance.
It’s useful to understand how the LiDAR works before performing missions. It scans the
environment around the robot as indicated in this diagram.