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

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 10 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.
Sometimes there might be temporary items in the surroundings, e.g. people, cars or scaffolding.
These should be minimised as far as possible because they will be incorporated into the 3D model.
However, provided there aren’t too many temporary items the robot will still be able to localise its
position using the other information in the map.
Temporary items do not affect object avoidance because this is based on live LiDAR data that is
gathered during the ongoing mission. However, it should be remembered that object avoidance
isn’t perfect. The following conditions can hamper performance.
Condition
Description
Potential work-arounds
Drop-offs
Drop-offs are more difficult to detect than
obstacles because if the ground is very
reflective (for instance in heavy rain) there
might be false positives and steep downward
ramps cannot be reliably distinguished from
drop-offs using LiDAR alone.
Drop-offs are usually
permanent features and it’s
very serious if the robot drops
from a height. Robot routes
should avoid drop-offs or
barriers should be erected
around them.
Upwards
ramps
The robot will usually interpret these ramps
as an obstacle and stop.
Contact your account manager
to see if the software can be
adjusted.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 11 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.
Narrow gaps
The robot is designed to navigate 0.8 meter
wide gaps. However some conditions might
prevent this and/or customers may wish to
navigate narrower gaps.
Contact your account manager
to see if the software can be
adjusted.
Thin and small
obstacles such
as vertical
pipes.
Avoidance is optimised to avoid collisions
with a variety of objects. Very small objects
are not considered as increased sensitivity
increases the likelihood of false-positive
avoidance.
If there’s a risk of collision,
choose a different route or
enclose such items in a larger
“box”.
Avoid leaving small, temporary
items on the robot’s routes.
Sharp turns
The LiDAR cannot see low objects to the side
of the robot. If the robot turns sharply and
the object is within 0.85m of the front of the
robot it may not be detected.
Take this into account when
planning robot routes. Avoid
leaving low, temporary items
near sharp turns.
Reversing
The LiDAR cannot detect objects lower than
0.5m behind the robot and there’s a blind
spot behind the inspection module.
Only reverse over short
distances over which the robot
has recently driven forwards.
Overhead
obstacles
The LiDAR might not detect low items that
are close to the robot and that might hit the
inspection module. This is especially
significant during sharp turns and for thin
overhead items like cables.
Keep robot routes clear of such
items.
Shiny and low
reflection
objects.
These objects might be detectable only close
to the robot
Paint or cover these items.
Avoid leaving shiny, temporary
items on the robot’s routes.
Rain, steam
and snow
These will obstruct the LiDAR’s beam.
Localisation and object detection will be less
effective.
Provide remote human
supervision until you’ve
assessed the impact on the
robot’s autonomous navigation.
Clear materials
LiDAR will not detect objects like glass doors.
Facilities seldom contain such
items.
High contrast
environments
& inadequate
lighting
The LiDAR is not affected by light in the
visible range.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 12 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.
6. Cloud Software
Robots are operated and data is collected using the “cloud”. Access is granted as described in
Section 8.2. Six types of screens are available as described below. The software is continuously
being upgraded particularly:
▪As each screen is progressively migrated from User Interface Version 1 (UI-v1) to Version 2
(UI-v2)
▪Additional skills are added.
The latest upgrades will be documented in the Energy Robotics’support portal (Reference 6).
6.1. Fleet Management & 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.
The Fleet Status screen (see below) is accessed by clicking on the “navigation menu” icon to the top
left of the Fleet Management screen. When connected to a specific robot this menu also allows:
▪A User to navigate between the different screens.
▪Users to access “Site Config”. This is used to add a location name adjacent to the robot’s
serial number on the screen headers. It can also be used to enter E-Mail addresses to which
robot status notifications will be sent.
▪Engineers to enable “Maintenance Mode”. This option is used when a robot is taken off-site.
It prevents users from accessing and controlling the robot.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 13 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.
6.2. 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 driver 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.
▪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.
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 pressing the
green button on the controller).
oDriving –the robot is in motion.
oGas Detectors On –The gas detectors are powered up (they have individual warm-up
times, the gas displays will only start showing measurements when they’ve warmed up).
oManual Control –the robot is being controlled from this control station by a driver.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 14 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.
▪Using the cursor to activate the "Stop” button has the same effect as pressing the emergency
stop switch on the controller. The drive motors are isolated until the switch is released. This
is done by using the green button on the controller or recommencing an autonomous
mission.
▪There’s a drop down list that’s accessed via the “Robot power icon”. 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). There’s an option to keep the gas detectors
on at all times so that they don’t need to warm up before a mission can commence. The light
switch is also located in this drop-down menu.
▪The teleoperation options at the bottom right of the screen allow drivers to switch between
Xbox, keyboard and touch controls to drive the robot.
▪The microphone can be muted at the control station by toggling on the “Microphone”
window. The robot still transmits its sound to the cloud.
▪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.
▪Snapshots are displayed in “Recorded media” once they’ve 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...”.
▪The icons at the top of “Recorded media” 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.
▪All video and LiDAR streams are displayed on the control station. Clicking on the “Expand
icon”of any window moves it to the largest
window.
▪To take a snapshot, hover the cursor over any
video stream and click on the “Area of interest
icon”that appears in the top-left corner. Then
use the cursor to frame the area of interest and
click on the “Accept” button to capture the
image. Alternatively, you can take a full-size
picture by clicking on the “Full screen icon”.
▪To take a video, hover the cursor over any video stream and click on the “Video icon” 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...”.
▪The LiDAR screen displays a point cloud with a 3 dimensional representation of the robot’s
environment. A mouse or trackpad can be used to rotate, expand, and reduce the image –
See Section 7.3.1.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 15 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 autonomy controls are grouped together. They duplicate those on the “Click and Inspect”
screen (Section 7.3.4). Select a mission using the drop-down box. To launch or stop the
mission click the buttons underneath. Missions will be started from the docking station.
▪Hovering over an icon or text will often provide more information.
A typical controller is illustrated below:
▪The green “A” button activates remote control by enabling the controller and drive motors. It
typically takes 30 seconds for the motors to be activated.
▪The yellow “Y” button deactivates remote control by disabling the controller.
▪The red “B” button on the controller stops the robot and isolates the motors, identical to the
“Stop” icon on the Driver Screen.
▪The analogue joysticks are used to drive (LSB) and steer (RSB) the robot.
▪Holding down the LB/RB buttons changes speed mode (slowest - no buttons pressed, fastest -
both buttons pressed).
▪If the LT button is held down, the RSB controls whichever PTZ and elevating mast combination
that’s fitted to the robot. Remember some robots do not have a tilting PTZ or mast. Push the
RSB button:
oLeft to rotate the field of view (FoV) anticlockwise.
oRight to rotate the FoV clockwise.
oForwards to raise the FoV or mast.
oBackwards to lower the FoV or mast.
oDown to reset the camera (point it forwards).
For safety reasons, robots cannot be remotely controlled when the driver is using another
application on their control station. A pop-up will appear with a warning. Clicking on the pop-up will
re-enable remote control.
FORWARDS

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 16 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.
6.3. “Click and Inspect”& Mission Editor
These screens enable planners to plan and edit autonomous missions as described in Section 7.
6.4. 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 and acoustic analyser values are displayed on the adjacent graphs.
▪The plan will be green where the values 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 6.2 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.
▪Return to default scale by double-clicking.
7. Autonomous Missions
7.1. Overview
A robot mission is typically a circuit that starts and finishes at a docking station. During the circuit
the robot will record tasks when it’s stationary at a waypoint:
▪A typical task is to record a video, snapshot, sound, or sensor reading.
▪Tasks 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

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 17 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.
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 or tilt). There can be more than one task at a POI.
▪Waypoints are 2D locations from which POIs are observed. There can be multiple POIs
associated with a waypoint.
▪There can be multiple waypoints on a mission.
When in autonomous mode, by default the robot will stop if the connection to the robot
supervisor’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.
Human robot supervisor’s will typically monitor several simultaneous autonomous missions. We
recommend that this is initially limited to two simultaneous missions. This can be progressively
increased as the supervisor gains experience and the challenges of each mission are better
understood. The control station will require a separate screen for each pair of robots.
If a supervisor needs to stop a mission, they can:
▪Press the red button on the controller which will stop all of the robots that they’re
supervising.
▪Click on the “Stop” button on the individual robot’s screen.
Missions may be interrupted for a number of reasons other than supervisor intervention e.g.:
▪Loss of wireless connection to the robot.
▪Collision detected.
▪Motor over-loaded.
▪Loss of locational awareness.
▪Gas detected.
A pop-up will usually appear to explain the interruption. The supervisor then has the option to take
control or restart the mission, sometimes from a different point. The robot will locate its position
and resume its autonomous mission even after a short detour.
7.2. “Teach & Repeat” & “Line Following”Navigation
These forms of navigation are being superseded by “Click and Inspect” navigation. However, they
may still be used for special situations or for robots that were deployed before “Click and Inspect”
was widely available. Instructions for using these forms of navigation screen are available in Version
2 of this Operating Guide.

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 18 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.
7.3. “Click and Inspect” Navigation
7.3.1. The Click and Inspect Screen
Click and Inspect missions are programmed and executed using this screen.
When the screen is opened, the control panel and video/sensor panels are not visible. They appear
when you click on the pulsating robot icon that is at the robot location. They disappear when you
switch off focus mode using the Sidebar menu. The Settings tab in that menu allows you to adjust
the graphics to suit your control station and gives an explanation of the controller buttons. The
other Sidebar options are self-explanatory.
Expanding the video/sensor panels and capturing videos/snapshots are essentially the same as
when doing so in remote control mode (Section 6.2).
The point cloud image can be adjusted as follows:
▪Left click and drag to rotate the map around its central pivot point.
▪Right click and drag to pan the map.
▪Zoom in and out using the mouse wheel
More information about this screen and its use is available in an Energy Robotics’ presentation
(Reference 2).

ExRobotics B.V.
ExR-2 Robot
Operating Guide
Document No.:
20220412IP1
Version No.: 3
Owner:
Ian Peerless
Date:
2023-07-25
Page 19 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 “Click and Inspect” screen is the first that’s been released in the migration to Energy Robotics’
User Interface Version 2 (UI-v2). It’s characterised by its “Site centric” approach – instead of viewing
the World from the perspective of the robot you see the site as a whole. This offers a number of
advantages compared with UI-v1:
▪POIs are clearly shown on the site model. POI tasks can be quickly grouped in new
combinations to create new missions. New POIs and tasks can be added to the site model at
any time.
▪As the robot is driven around a site it creates a “green line” around its route. This line
represents the area through which the robot is permitted to travel. It can be extended during
future missions.
▪The robot chooses a route between the docking station and POIs that stays within the green
line. It has more freedom of movement than the old “teach and repeat” approach.
▪The model, POIs and tasks can be linked to a customer’s digital twin of the site with assistance
from Energy Robotics.
▪In future it will be possible to add “No go zones” and multiple robots/docking stations to the
same model. It will also be possible quickly to swap a robot for another whilst still maintaining
the programmed missions.
7.3.2. Extending the Point Cloud Model & Adding Tasks
The permitted robot route (green line) and tasks on the “Click and Inspect” screen are created using
the Mission Editor screen. Having opened the screen, click on the “Open Editor” button under the
“Click & Inspect” label. This will reveal this view.
Click on the “extend map” button while the robot is on its docking station. Then drive around the
site and capture snapshots/videos/recordings at POIs using remote control navigation as described
in Section 6.2. Each POI task should be given a name which will often include a TAG number. The
software will:
▪Improve/extend its point cloud model using information from the robot’s LiDAR.
Other manuals for ExR-2
1
Table of contents
Other ExRobotics Robotics manuals