Brain Corp Minuteman, Troubleshooting Manual

Page 1: ...Steering Troubleshooting Guide Date Published 4 9 21 2020 Brain Corporation All rights reserved Steering Troubleshooting Guide for OEM ...

Page 2: ...ation This document may only be viewed by third parties under an active non disclosure agreement NDA with Brain Corporation covering the scope of the information herein If you received or obtained this document outside of these requirements please destroy all copies and report this error to legal braincorp com 2020 Brain Corporation All rights reserved Brain Corporation Corporate Headquarters Cont...

Page 3: ... Code Doc The latest OEM error code document is located in the Zendesk Guide webpage 6 How To Use It 6 Required Tool List 7 OEM Diagnostics 8 Assists 8 U Joint 8 Traction Encoder failed or failing 9 Wheel Slip 10 Loose Steering Encoder 11 Steering Encoder Malfunction 11 Example of an assist with customer driving 12 Tech Diagnostics 13 Hardware Inspection 13 U Joint Check 13 Steering Motor Check 14...

Page 4: ...ENCODER 01 32 STENCODER 02 32 MOTOR 01 33 AMP 01 33 AMP 02 34 DOWNTRUNK 01 34 ANGLE 01 35 BCM 01 35 TRACTION 01 36 Appendix C How to replace the Traction Encoder 36 Appendix D How to Replace the Steering Motor 38 Appendix E U Joint Replacement 45 Appendix F Steering Amplifier MAM replacement 51 Appendix G Steering Encoder replacement 52 Appendix H Down Trunk Cable replacement 60 ...

Page 5: ...Peer Review 01 Initial Release Definitions Acronyms and Abbreviations Term Definition BCM Brain Control Module DMM Digital Multimeter MAM Motor Amplification Module Down Trunk Cable harness that goes from the down port on the BCM OEM Original Equipment Manufacturer Examples of commands Caution this might cause serious system problems Stop and ensure you understand what is being asked ...

Page 6: ... 218 224 40002 40004 40006 60400 60461 Errors 501 502 504 20003 20009 40007 Startup 5010 For more information on the error codes please refer to the OEM Error Code Reference Document Brain Internal Assist Codes https braincorporation atlassian net wiki spaces TS pages 298582085 Error Codes and Err or Inventory OEM Assist Code Doc The latest OEM error code document is located in the Zendesk Guide w...

Page 7: ...process Required Tool List The following is the list of tools needed to service the Steering related issues for any autonomous floor scrubbers powered by BrainOS Item Image Details Hex Drivers 2 mm 2 5 mm 3 mm 7 mm socket wrench Digital Multimeter DMM Fluke 101 Model or equivalent Fine Test Leads Model MICTL 013 or equivalent or back probes Cable Tie Cutter Probing Adaptors Optional https www amaz...

Page 8: ...cific machine When reviewing each assist it is really important to look at the images and assist replay to see what triggered this assist to happen By reviewing assists it allows us to get a better understanding of what type of issues the machine could be having For the latest list of assist codes please reference the most updated error code document Make sure to watch the playback as it gives a b...

Page 9: ...ling When viewing these assists you will notice that the scrubber sits still while the environment is moving This will indicate that the traction encoder or cable has failed Failing Traction encoder This shows the traction encoder working then at the end of the video the traction encoder stops working This indicates that the Traction Encoder or cable has failed ...

Page 10: ...iled Tennant Link https tennant prod roc braincorp com assists 2VPKCPXWRBMB FCK11KNKMJ9SXC https tennant prod roc braincorp com assists 4WAKMQ30AMXX02WB C9QY2J4M9F Wheel Slip In the below assists we have an example of Wheel Slip You can see places where the Robot thinks it has moved but the shelving moves and stays ahead of the scrubber We have seen worn pads and broken scrub deck springs cause th...

Page 11: ... screws loose Costmap shows an adjusted corrective route compared to straight planned route after turns are not registered entirely or properly Tennant Link None Steering Encoder Malfunction The adjusted route blue line shows no suggestions remains straight while the planned route green line becomes more mismatched in relation to the body of the scrubber Encoder is not registering turns ...

Page 12: ...dential Page 12 of 64 Tennant Link https tennant prod roc braincorp com assists 1F9GQZ7QYP1K4 VYF71MZDQ86JB Example of an assist with customer driving This example shows the customer driving the scrubber You can tell this because there are not any red arrows nor pathing lines Tennant Link None ...

Page 13: ...ed Hardware Inspection U Joint Check 1 Remove the access panel to access the steering column Figure 0 Access Panel NOTE When inspecting the U joint ensure that the pin is not missing Take multiple pictures of the steering U joint that shows the pins on all sides 2 Inspect the U joint for damage set screws being loose or lost and other damage See the pictures below for a reference Example of a U jo...

Page 14: ...l of four on ICE and two on Minuteman The keys within the U joint also have to be present and in the proper location 5 If U joint is broken worn out or missing a pin refer to UJoint 01 Steering Motor Check 1 Remove both the front and back access panels Removing both access panels 2 Ensure that the steering motor cable and power connector are not loose or damaged 3 Ensure the presence of the ferrit...

Page 15: ...7 Steering motor common issues a If the steering motor is leaking oil refer to solution code MOTOR 01 b If the steering motor cable is damaged refer to solution code MOTOR 01 Steering Encoder Check 1 Inspect the steering encoder and the associated wiring for physical issues 2 Turn the steering wheel left and right to inspect that all set screws are installed and properly tightened 3 Unscrew the ca...

Page 16: ...at the steering encoder cable is not loose and the steering encoder is mounted like the picture above NOTE The steering encoder pictured above is rotated Encoder may or may not be broken 5 Take pictures of the steering encoder that show the overall condition condition of the wires and the set screws 6 Steering Encoder common issues a If the steering encoder is missing set screws not mounted proper...

Page 17: ...cover from the machine to check the steering motor amplifier module MAM 2 Inspect the steering amplifier and wires for damage 3 Unplug the connectors inspect the pins for damage and plug them back in Ensure the connectors lock into place 4 Take pictures of the steering amplifier and condition of the cables and pins 5 Examples a Example of a Good steering amplifier b Example of a Bad Steering amp D...

Page 18: ...here is a damaged right male connector that has missing pins refer to solution code AMP 01 e If there is a damaged left female connector that has any damaged wires or something stuck in the connector refer to solution code Downtrunk 01 Traction Encoder Check The Traction Encoder is responsible for tracking the movement distance traveled by the scrubber As the traction wheel spins the encoder count...

Page 19: ... or torn 3 Take pictures of the traction encoder and condition of the cables 4 Traction Encoder Common Issues a If the traction cabling is damaged the traction encoder will need to be replaced Refer to solution code TRACTION 01 b If the traction encoder itself is physically damaged then the traction encoder will need to be replaced Refer to solution code TRACTION 01 ...

Page 20: ...nfidential Page 20 of 64 Voltage Continuity Testing Swap If you suspect wiring use the Chart below to check voltage and continuity If continuity testing fails please Use Solution Code Downtrunk 01 Down Trunk BCM connector Notice Pin Numbering Traction Encoder connector Notice Pin Numbering ...

Page 21: ...ctor Description D38999 Down Trunk Steering Encoder 1 GND 15 2 P5V 21 3 SPI3 CLK 16 4 SPI3 CLK 24 5 SPI MISO 8 6 SPI MISO 9 Traction Encoder 1 ENC1_ACH 25 2 P5V 43 3 ENC1_ACH 26 4 ENC1_BCH 34 5 ENC1_BCH 35 7 GND 44 Steering Motor 1 GND 19 2 Unused 3 P5V 17 4 P4V3 18 5 PWM_3V3 6 6 DIR_3V3 5 7 Enable MTR driver 10 8 Steer MTR DIS 12 9 STEER_FLT 11 10 STEER_CUR 4 ...

Page 22: ...Steering Troubleshooting Guide Date Published 4 9 21 Brain Corporation Proprietary and Confidential Page 22 of 64 ...

Page 23: ...23 of 64 UI based diagnostics OS version 3 1 x Tech will need to click the following path to get to the steering tests Settings Service Service Tools Confirm to Launch Service tools Menu Settings Menu Service Menu Confirm Y N Brain Screen Service Tools Click Steering You will now see all the Steering tests ...

Page 24: ...ponents Or the tech can choose the specific tests he wants to re run if necessary Both menus where steering tests can be run on and the confirmation screen for running the tests History screen of related steering events done on this machine along with a screen of the tests completed Note Please ignore the Navigation File Verification test This shows as failed but can be ignored without issue for r...

Page 25: ...f 64 Note If a test fails there are three tabs of information Error Details and HW Faults Sensor History Provides a history of the sensor including replacements disconnects other issues and normal events Settings Service Service Tools Confirm to Launch Service tools Steering Select the STEERING Sensor History ...

Page 26: ...g them Note Please ignore the Navigation File Verification test This shows as failed but can be ignored without issue for right now Calibration IMPORTANT This is a REQUIRED procedure to be performed after any steering component change This calibration verifies that the steering is properly aligned Settings Service Service Pin Calibration Steering offset Click to swap 1 Go to the Home Screen Teach ...

Page 27: ... to the case NOTE If the candidate configuration is not displayed on the screen train a new route that is at least 5 minutes 5 Press the middle of the screen to swap the candidate and current configuration Moving the new configuration to the top ensures that the latest candidate calibration is being used 6 Key the unit off and back on 7 Go back to the Service menu 8 Select Calibration Steering Off...

Page 28: ...obstacle d Observe the machine to verify the following Steering is controlled as expected The robot drives straight does not drift to one side or snake back and forth The robot navigates around obstacles as expected The robot does not have any unexpected path blocked assists There are no steering related faults The turn signals are working properly e Pause and start the machine using the Start Pau...

Page 29: ...ements Hardware Inspections Check the U Joint Check the Steering motor Check the Steering Encoder Check the Steering Amp Check the Traction Encoder UI touch screen Diagnostics Check the steering angle Check the manual steering Check manual navigation Check automated steering Gyro Noise Test Record Traction Values Perform Steering Calibration Note This is a REQUIRED step when any component is repla...

Page 30: ...Confidential Page 30 of 64 Appendix B Tech Solution Codes The following tables are provided as individual solutions for issues that were identified in the preceding document Tech Solution Codes Detailed Replacement instructions are located in the Appendix Solution Code Recommended Actions ...

Page 31: ...t off and back on 5 Run the newly trained route and monitor for any anomalies 6 Take a picture of the Route Complete or Route History screen 7 Send any photos notes and or a filled out Troubleshooting Checklist to Brain Corporation using the e mail address specified in the work order UJOINT 01 If a u joint is broken worn out or missing a pin perform the following steps 1 Send any photos notes and ...

Page 32: ... for the part 4 Replace the steering encoder 5 For this service always perform the required steering calibration in solution code CALIBRATION 01 STENCODER 02 If the Manual Navigation Check fails perform the following steps 1 Send any photos notes and or a filled out Troubleshooting Checklist to Brain Corporation using the e mail address specified in the work order 2 Place an order for the followin...

Page 33: ...ng calibration for more information on how to perform a steering calibration refer to the Steering calibration section 6 For this service always perform the required steering calibration in solution code CALIBRATION 01 AMP 01 If any of the following occur perform the following steps The steering wheel is hard to turn There is a damaged left or right male connector The left or right male connector ...

Page 34: ...CE Part Number 8350430 3 Schedule an estimated service date to replace the steering motor 4 Replace the steering motor 5 For this service always perform the required steering calibration in solution code CALIBRATION 01 DOWNTRUNK 01 If there is a damaged right female connector and or any damaged wires or something stuck in the connector perform the following steps 1 Send any photos notes and or a f...

Page 35: ...ined route or it fails the Steering Angle check again proceed to the remaining Software Diagnostics a Manual Steering Check b Manual Navigation Check c Automated Steering Check d Gyro Noise Test BCM 01 If the BCM has failed the Gyro Test multiple times perform the following steps 1 Send any photos notes and or a filled out Troubleshooting Checklist to Brain Corporation using the e mail address spe...

Page 36: ... back to the Software Diagnostic Traction Check section to view Traction Reading i If the traction encoder reading does not change replace the Downtrunk Harness and repeat step 4a ii If the traction encoder reading does change un tether the traction encoder cable and plug it into the new traction encoder and attempt to get a traction encoder reading iii If a reading is registered with the new enco...

Page 37: ...ssembly installed on the drive wheel assembly can be easily accessed 3 Disconnect the encoder cable from the wire harness Note Photo cable management you will be required to reproduce after replacement 4 Loosen the hex screw which locks the traction encoder to the axle 5 Remove the screws that hold the traction encoder 6 The Traction encoder may be difficult to remove and a gear puller will help 7...

Page 38: ...ct the red battery coupling and the seat sensor connection 2 Make sure the front wheel is oriented straight ahead This will be our point of reference 3 Remove the access panel to access the Steering Column 4 Remove the front fascia As shown at right also be sure to remove the six hex screws holding on the main fascia two on each side and two at the bottom Note there may also be additional smaller ...

Page 39: ... Guide Date Published 4 9 21 Brain Corporation Proprietary and Confidential Page 39 of 64 5 Loosen the collar 2 hex screws and slide it down 6 Remove the two set screws indicated below then pull the steering wheel straight up ...

Page 40: ...e 40 of 64 7 Next unplug the 12 pin connector on the left side of the steering motor amp module MAM Ensure the replacement steering motor has both the same 12 pin connector and a ferrite core shown 8 Undo all steering motor bolts Take care to retain all washers bolts and the mounting plate for reassembly ...

Page 41: ...nect them to mounting plate 19 Note bolts 6 and 23 may not be present in the Gen2 scrubber 10 When re tightening the four steering motor bolts follow a star pattern similar to when changing a tire on a four bolt car wheel 11 Installed steering motor as viewed from the front of the scrubber with BCM immediately above and steering motor amp module MAM located below Note 12 pin ...

Page 42: ... the steering motor into the MAM 12 Push the steering wheel down to move the shaft into place It should move through the steering motor and lock into the U joint below Make sure the keys all line up and the wheel is pushed all the way down before re securing the four set screws Raise the collar back up and tighten the hex screws ...

Page 43: ...ht and the steering wheel logo is misaligned the steering wheel may be removed and repositioned 14 To do this use a 3 mm hex to remove the three screws that reside on the underside of the steering wheel Do not remove the Phillips screws 15 Use a 7 8 socket wrench to remove the nylon nut and washer that secures the steering wheel Wiggle the steering wheel back and forth and pull up to remove Once f...

Page 44: ...Steering Troubleshooting Guide Date Published 4 9 21 Brain Corporation Proprietary and Confidential Page 44 of 64 Note Diagram of Keys and trough ...

Page 45: ... to get to the U Joint Parts required for this service 2 5 mm hex 5 mm hex Replacement U joint 3 mm hex optional Turn the key to power off the scrubber Raise the seat and disconnect the red battery coupling and the seat sensor connection Make sure the front wheel is oriented straight ahead This will be our point of reference Remove the access panel to access the Steering Column ...

Page 46: ...ng Guide Date Published 4 9 21 Brain Corporation Proprietary and Confidential Page 46 of 64 Loosen the collar 2 hex screws and slide it down Remove the two set screws indicated below then pull the steering wheel straight up ...

Page 47: ...ng Troubleshooting Guide Date Published 4 9 21 Brain Corporation Proprietary and Confidential Page 47 of 64 Remove the set screws from the bottom of the U joint so the component can be removed from the shaft ...

Page 48: ...stalled either way as long as the keys match up The shaft U joint and keys should be configured to resemble the images below See end of document for a high res image Push the steering wheel down to move the shaft into place It should move through the drive motor and lock into the U joint below Make sure the keys all line up and the wheel is pushed ...

Page 49: ...4 all the way down before re securing the four set screws Raise the collar back up and tighten the hex screws Verify that the wheel is straight and the logo on the steering wheel lines up properly If the wheel is straight and the steering wheel logo is misaligned the steering wheel may be removed and repositioned ...

Page 50: ...e on the underside of the steering wheel Do not remove the Phillips screws Use a 7 8 socket wrench to remove the nylon nut and washer that secures the steering wheel Wiggle the steering wheel back and forth and pull up to remove Once freed realign and reassemble Reconnect the red battery coupling Turn the key to power on the unit to ensure proper start up and system operation ...

Page 51: ... and Confidential Page 51 of 64 Steering Calibration Required after U joint replacement please see UI based Diagnostics Section Appendix F Steering Amplifier MAM replacement 1 Turn off the unit and disconnect the red battery coupling 2 Remove the front cover and place it to the side ...

Page 52: ...two black plugs and remove the Motor Amplifier Steering AMP 4 Connect the new motor and reverse your steps Appendix G Steering Encoder replacement Parts required for this service 2 5 mm hex 5 mm hex Replacement Steering Encoder 3 mm hex optional Turn the key to power off the scrubber Raise the seat and disconnect the red battery coupling and the seat sensor connection optional ...

Page 53: ...ietary and Confidential Page 53 of 64 Make sure the front wheel is oriented straight ahead This will be our point of reference Remove the access panel to access the Steering Column Spin the wheel to provide access to these two set screws Loosen them but do not remove completely ...

Page 54: ...shed 4 9 21 Brain Corporation Proprietary and Confidential Page 54 of 64 Loosen the collar 2 hex screws and slide it down Unplug the Steering Encoder connector Remove the two set screws indicated below then pull the steering wheel straight up ...

Page 55: ...Steering Troubleshooting Guide Date Published 4 9 21 Brain Corporation Proprietary and Confidential Page 55 of 64 ...

Page 56: ...haft and replaced with a new one The set screws on the steering encoder need to be aligned with the threaded holes on the steering shaft Since the holes can t be seen when the encoder is in place it is useful to indicate their location s by scratching or marking the shaft The shaft U joint and keys should be configured to resemble the images below See end of document for a high res image ...

Page 57: ...ge 57 of 64 Push the steering wheel down to move the shaft into place It should move through the drive motor and lock into the U joint below Make sure the keys all line up and the wheel is pushed all the way down before re securing the four set screws Raise the collar back up and tighten the hex screws ...

Page 58: ...he wheel is straight and the logo on the steering wheel lines up properly If the wheel is straight and the steering wheel logo is misaligned the steering wheel may be removed and repositioned To do this use a 3 mm hex to remove the three screws that reside on the underside of the steering wheel Do not remove the Phillips screws ...

Page 59: ...teering wheel Wiggle the steering wheel back and forth and pull up to remove Once freed realign and reassemble Reconnect the red battery coupling Turn the key to power on the unit to ensure proper start up and system operation Check the Steering Encoder functionality and alignment from the Steering Angle Screen The Steering value should change as the steering wheel is rotated left and right ...

Page 60: ... when the wheel is straight If these two conditions aren t met they must be corrected before the steering may be calibrated and the unit used autonomously A steering calibration must be performed after the Steering Encoder has been replaced Appendix H Down Trunk Cable replacement 1 The Downtrunk is a wiring bundle that connects the BCM to numerous sensors encoders and indicators throughout the low...

Page 61: ...unit remove the front plastic shield 5 mm and the screws that hold the control panel 2 mm in place 3 Remove the Downtrunk connector by spinning it counter clockwise 4 Remove any zip ties that secure any of the Down trunk cables 5 The Down Trunk connects to the following devices 1 START_PAUSE 2 ESTOP 3 SP_ETH SSH Port 4 ENC_TRACT1 6 STEERING 7 LIDAR_HRZ_ETH ...

Page 62: ...Steering Troubleshooting Guide Date Published 4 9 21 Brain Corporation Proprietary and Confidential Page 62 of 64 8 LIDAR_HRZ_PWR 9 ENC_ABS Steering Encoder ...

Page 63: ...Steering Troubleshooting Guide Date Published 4 9 21 Brain Corporation Proprietary and Confidential Page 63 of 64 6 Remove the access panel opposite the seat and route the ENC_ABS cable as shown below ...

Page 64: ...any modification to the sensor s position may result in a necessary recalibration of machine sensors 9 Reverse the steps outlined in this document to reassemble the scrubber after replacing the Downtrunk then power on the machine 10 To verify unit functionality following the Downtrunk replacement Ensure that the UI screen can display Planar LIDAR signal the Start Pause button and E stop buttons fu...