ExRobotics ExR-2 User manual

ExR-2 Robot
Operating Guide

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 1 of 69
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2023 ExRobotics B.V.
Responsible
[Person who is responsible for
writing the document, i.e.
author]
Name:
Ian Peerless
Job Title:
Director
Signature:
Date:
25th July 2023
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:
25th July 2023
Consulted on this document
version
[Persons who have endorsed the
document]
Names:
Siebren Lemmers
Vassilis Georgoutsos
Informed
[Persons who have been
informed of this version of the
document]
Names:
ExR employees, ER employees,
supply chain partners, and first line
support.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 2 of 69
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2023 ExRobotics B.V.
Document Change Log:
Version
#
Date of re-
issue
Changes Made
Pages
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
3
2023-07-25
Added new robot configurations/options arising from
recertification in June 2023 and planned for early
2024.
6
Ian Peerless
Replaced line-following, tag-based and “teach and
repeat” autonomy by “click and inspect” autonomy.
17 –22
Added skills that are in “Beta” release
23 –28
Added more information about roles, deployment
support and transporting robots.
29 –33
Provided more detail on routine robot servicing tasks.
34 –54
Added operational risk assessment table
64 –68
Added a list of referenced material
69
Refined document to reflect recent experience and
minor updates.
Various

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 3 of 69
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2023 ExRobotics B.V.
Contents
1. Introduction.............................................................................................................................5
2. Robots......................................................................................................................................6
3. Control Stations & Communication.........................................................................................7
4. Docking Stations & Charging ...................................................................................................8
5. LiDAR Based Navigation...........................................................................................................9
6. Cloud Software ......................................................................................................................12
6.1. Fleet Management & Fleet Status ....................................................................................12
6.2. Driver Screen.....................................................................................................................13
6.3. “Click and Inspect” & Mission Editor ...............................................................................16
6.4. Mission Report..................................................................................................................16
7. Autonomous Missions ...........................................................................................................16
7.1. Overview ...........................................................................................................................16
7.2. “Teach & Repeat” & “Line Following” Navigation ............................................................17
7.3. “Click and Inspect” Navigation..........................................................................................18
7.4. Skills...................................................................................................................................23
8. Deploying & Operating Robots.....................................................................................................29
8.1. Roles & Training ................................................................................................................29
8.2. Security, Authorisation & Authentication.........................................................................31
8.3. Deployment Support.........................................................................................................32
8.4. Operating Support ............................................................................................................32
8.5. Software Releases.............................................................................................................33
9. Servicing, Maintaining & Transporting Robots......................................................................34
9.1. Inspecting & Cleaning .......................................................................................................34
9.2. Recovering Lost Communications.....................................................................................34
9.3. Replacing Tracks................................................................................................................35
9.4. Opening the Hull ...............................................................................................................39
9.5. Changing SIM cards...........................................................................................................41
9.6. Calibrating Gas Detectors .................................................................................................46
9.7. Replacing Batteries ...........................................................................................................47
9.8. Maintaining Robots...........................................................................................................54
9.9. Handling & Transporting Robots.......................................................................................54
10. Questions & Answers.............................................................................................................55

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 4 of 69
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Copyright 2023 ExRobotics B.V.
10.1. What is my Robot’s Status ...........................................................................................55
10.2. Why Can’t I Connect to a Robot?.................................................................................56
10.3. Why has my Robot Stopped Working in Cold Weather? .............................................56
10.4. How much Data will the Robot Transfer over its Wireless Connection?.....................56
10.5. How Long will the Robot’s Batteries Last?...................................................................56
10.6. Why am I Surprised by the Battery Level Reported by the Cloud Software?..............56
10.7. How do I Refresh my Control Screen? .........................................................................57
10.8. Why does my Robot “drift” to the Left or Right ..........................................................57
10.9. How do I Wash a Contaminated Robot?......................................................................57
11. Robot & Docking Station Specifications ................................................................................58
11.1. Environment.................................................................................................................58
11.2. Terrain & Manoeuvrability...........................................................................................58
11.3. Availability & Recovery.................................................................................................59
11.4. Basic Hardware & Software .........................................................................................59
11.5. Hardware Options ........................................................................................................61
11.6. Noses for Honeywell 3000 Mk II ..................................................................................63
12. Risk Assessment & Reduction................................................................................................64
13. References to Supporting Material .......................................................................................69

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 5 of 69
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2023 ExRobotics B.V.
1. Introduction
This document is one of two that will help customers to use their robot operators safely and
effectively. The documents are the “Operating Instructions” and the “Operating Guide”. The former
focuses on the safe deployment, operation and servicing of robots and docking stations. This guide
provides additional information about robot systems and their use. It doesn’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 guide contains most of the information that 1st Line Support Teams should need to assist all
types of robot user (see Section 8.1). Those users will also benefit from understanding the sections
of the guide that apply to them. It’s accessible via Downloads | ExRobotics
In future we expect field engineers, customer success teams, supply chain partners, and customers
to augment the material in this guide. If these additions are shared with ExRobotics’ Quality Owner
they’ll be shared more widely and will inform future versions of the guide. Existing supporting
material is referenced in Section 13 of this document.
This version of the guide has been released to coincide with the shift from “Teach and Repeat” to
“Click and Inspect” autonomy. It also includes hardware upgrades that will be commercially
available in 2023 and early 2024.
The 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 robot’s batteries.
oLiDAR based navigation that underpins the robot’s autonomy.
oCloud software that enables users to interact with robots.
▪Explains how to set up autonomous missions.
▪Recommends how robots should be deployed and operated.
▪Details how robots should be serviced, maintained and transported.
▪Provides additional technical and operating detail.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 6 of 69
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2023 ExRobotics B.V.
2. Robots
ExR-2 robots are assembled from a number of modules mounted on a skeleton that’s clad in sheet
steel. Many of these modules are optional. The main features of our basic robot are identified on
this picture of a clad robot.
Additional options are identified on this image of the robot’s skeleton.
More detailed robot specifications are included in Section 11.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 7 of 69
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Copyright 2023 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.
▪Logitech F310 or Xbox Series X controller for driving the robot.
▪Mouse or trackpad for operating the cursor on the PC’s screen.
Should a customer prefer to control their robots without controllers (using laptops, phones or
tablets) they should perform a risk assessment because there will be no physical emergency stop on
the control station. Section 6.2 explains how these options can be enabled.
Robots and control stations communicate via a server as shown in this diagram.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 8 of 69
This document is considered an uncontrolled copy when printed. Always ensure that you print and use a current version.
Copyright 2023 ExRobotics B.V.
The server will usually be provided by a third party company such as Amazon (AWS) or Microsoft
(Azure) and will be located in the same geographical region as the robot to reduce latency. For
larger fleets of robots the server might be private to the customer. The server hosts the cloud
software described in Section 6 and transfers data to other servers via an API.
The customer must ensure there are no intrusive firewalls between the control station and the
server by enabling the connections shown in the above diagram.
4G and 5G robot communications are preferred to WiFi because they require less access points and
the handover between access points is reliable. Whichever network is chosen, the robot has a
short-range WiFi system that enables it to connect to the server via a phone hotspot. This can be
used when diagnosing and correcting communications faults.
4. Docking Stations & Charging
A robot charges itself autonomously 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 driver should approach the docking station in “slow speed” mode and in the
direction shown in the picture below (which shows one of several docking station configurations).
It’s best to use the drive camera which unlike the inspection camera is on the robot’s centre line.
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 and the approach area should be at least 3 meters wide. Once the front of the
robot’s hull is pressing against the front of the docking station, the driver should stop driving
forwards and switch off the motors by pressing the red button on the controller.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 9 of 69
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Copyright 2023 ExRobotics B.V.
It will take up to 3 minutes for the induction charger to connect. The “Wireless Charger” and
“Charging” boxes on the cloud software will then 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 charging it will “go to sleep”. Many of its components are then switched off to
reduce power consumption and to 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.
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.
Never use the quick charger if the robot’s batteries are fully depleted because this can seriously
damage the robot’s electronics. If the robot is docked, you should first switch off power to the
induction charger before connecting the quick charger.
When inserting the quick-charge plug, rotate the 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. There’s a video with more detail – Reference 1.
5. LiDAR Based Navigation
ExR-2 robots are usually supplied with a LiDAR module. This is at the heart of autonomous
navigation and object avoidance (see Section 7). Object avoidance doesn’t work when the robot is
being remotely-controlled by a driver.
It’s useful to understand how the LiDAR works before performing missions. It scans the
environment around the robot as indicated in the diagram below.
The LiDAR is tilted down towards the front of the robot so that it can detect the ground close to the
robot in its usual direction of travel.
The tilted LiDAR also means that it can see higher objects behind the robot so it can build a 3D
model of the surroundings with more relief than a horizontally mounted LiDAR. The robot builds
this model as it performs its first remote controlled mission. The robot then uses this model to
navigate during subsequent autonomous missions.