Brain Corp Minuteman Troubleshooting Manual
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Brain Corp Minuteman Troubleshooting Manual

Steering troubleshooting guide for oem
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Steering Troubleshooting Guide
Date Published: 4/9/21
Steering
Troubleshooting
Guide for OEM
©2020 Brain Corporation. All rights reserved.

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Summary of Contents for Brain Corp Minuteman

  • Page 1 Steering Troubleshooting Guide Date Published: 4/9/21 Steering Troubleshooting Guide for OEM ©2020 Brain Corporation. All rights reserved.
  • Page 2 Steering Troubleshooting Guide Date Published: 4/9/21 This document contains information confidential and proprietary to Brain Corporation. It may not be transmitted, modified, duplicated, disclosed, or distributed without prior written permission of Brain Corporation. 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.

  • Page 3: Table Of Contents

    Steering Troubleshooting Guide Date Published: 4/9/21 Table of Contents Revision History Definitions, Acronyms, and Abbreviations Overview When To Use It 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+Error+Inv entory OEM Assist Code Doc The latest OEM error code document is located in the Zendesk Guide webpage...
  • Page 4 Steering Troubleshooting Guide Date Published: 4/9/21 Appendix B - Tech Solution Codes CALIBRATION-01 UJOINT-01 STENCODER-01 STENCODER-02 MOTOR-01 AMP-01 AMP-02 DOWNTRUNK-01 ANGLE-01 BCM-01 TRACTION-01 Appendix C - How to replace the Traction Encoder Appendix D - How to Replace the Steering Motor Appendix E –...

  • Page 5: Revision History

    Steering Troubleshooting Guide Date Published: 4/9/21 Revision History Revision Date Description Draft 4/9/2021 Submitted for Peer Review Initial Release Definitions, Acronyms, and Abbreviations Term Definition Brain Control Module Digital Multimeter Motor Amplification Module Down Trunk Cable harness that goes from the down port on the BCM Original Equipment Manufacturer Examples of commands Caution, this might cause serious system problems.

  • Page 6: Overview

    Steering Troubleshooting Guide Date Published: 4/9/21 Overview This guide provides information on how to troubleshoot steering related issues for any autonomous floor scrubbers powered by BrainOS. In order to effectively troubleshoot any issue, please review this troubleshooting guide in the order given to determine the proper resolution.

  • Page 7: Required Tool List

    Steering Troubleshooting Guide Date Published: 4/9/21 The following steps are intended to be performed in the exact order listed in this document. It is essential to collect pictures and take notes throughout the 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.

  • Page 8: Oem Diagnostics

    Steering Troubleshooting Guide Date Published: 4/9/21 OEM Diagnostics When replacing any steering component, tech must perform a steering calibration. ****Print and update the checklist!**** To assist with troubleshooting, there is a troubleshooting checklist in Appendix A. This checklist needs to be printed, filled out, and submitted along with the pictures and notes.

  • Page 9: Traction Encoder Failed Or Failing

    Steering Troubleshooting Guide Date Published: 4/9/21 Tennant Link: None Traction Encoder failed or failing 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.

  • Page 10: Wheel Slip

    Steering Troubleshooting Guide Date Published: 4/9/21 Tennant Link: ● https://tennant.prod.roc.braincorp.com/assists/3S5ERDYHVSHP7 H6C3WD48TPVVT Failed Traction Encoder ● This shows the machine from the start of the assist sitting still and the objects are moving in relation to the Robot. This indicates that the Traction Encoder or cable has failed.

  • Page 11: Loose Steering Encoder

    Steering Troubleshooting Guide Date Published: 4/9/21 Loose Steering Encoder Steering encoder is mounted incorrectly or has set screws loose. Costmap shows an adjusted corrective route compared to straight planned route after turns are not registered entirely or properly Tennant Link: None ●...

  • Page 12: Example Of An Assist With Customer Driving

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

  • Page 13: Tech Diagnostics

    Steering Troubleshooting Guide Date Published: 4/9/21 Tech Diagnostics Please use the Tech Steering checklist in Appendix A. Submitting this checklist is required. 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.

  • Page 14: Steering Motor Check

    4. Verify that ALL of the set screws are present - there are a total 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...

  • Page 15: Steering Encoder Check

    Steering Troubleshooting Guide Date Published: 4/9/21 Take pictures of the steering motor from both front and back, along with the steering connection to the motor amp and power. 6. See the pictures below for a reference. Steering motor – back and front view 7.
  • Page 16 Steering Troubleshooting Guide Date Published: 4/9/21 4. Inspect the steering encoder and ensure that is properly mounted. Steering encoder good condition/properly mounted NOTE: Ensure that 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.

  • Page 17: Steering Amplifier Check

    Steering Troubleshooting Guide Date Published: 4/9/21 b. If the wiring to the steering encoder is damaged, refer to solution code Downtrunk-01 Steering Amplifier Check 1. Remove the front cover from the machine to check the steering motor amplifier module (MAM). 2.

  • Page 18: Traction Encoder Check

    Steering Troubleshooting Guide Date Published: 4/9/21 If the wheel is hard to turn, unplug the steering amplifier connection. If the steering is easier, then it is usually a bad steering amplifier. Refer to solution code AMP-01. b. If there is a damaged left male connector that has missing pins, a broken connector housing or a broken retention clip, refer to solution code AMP-01.
  • Page 19 Steering Troubleshooting Guide Date Published: 4/9/21 2. Inspect the traction encoder cabling for damage (cut or torn). 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.

  • Page 20: Voltage / Continuity Testing/Swap

    Steering Troubleshooting Guide Date Published: 4/9/21 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 Brain Corporation Proprietary and Confidential Page...
  • Page 21 Steering Troubleshooting Guide Date Published: 4/9/21 Cable Pairs to check Component Component Connector Description D38999 Down Trunk Steering Encoder SPI3 CLK+ SPI3 CLK- SPI MISO+ SPI MISO- Traction Encoder ENC1_ACH+ ENC1_ACH- ENC1_BCH+ ENC1_BCH- Steering Motor Unused P4V3 PWM_3V3 DIR_3V3 Enable MTR driver Steer MTR DIS STEER_FLT STEER_CUR...
  • Page 22 Steering Troubleshooting Guide Date Published: 4/9/21 Brain Corporation Proprietary and Confidential Page...

  • Page 23: Ui Based Diagnostics (Os Version 3.1.X +)

    Steering Troubleshooting Guide Date Published: 4/9/21 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...
  • Page 24 Steering Troubleshooting Guide Date Published: 4/9/21 Tech can choose RUN on the main Steering menu which will run all tests for most steering components. 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.

  • Page 25: Sensor History

    Steering Troubleshooting Guide Date Published: 4/9/21 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 →...

  • Page 26: Steering Service Tests

    Steering Troubleshooting Guide Date Published: 4/9/21 Steering Service Tests 1. Navigate to the Service Tools Menu. (Settings→Service→Service Pin→Service Tools) 2. Select Steering 3. Press Run 4. Press Run All 5. Pres Yes 6. Follow steps to go through the seven steering tests 7.
  • Page 27 Steering Troubleshooting Guide Date Published: 4/9/21 4. Select Calibration > Steering Offset. Calibration > Steering Offset option The machine displays two configurations: current and candidate. • The top configuration is the current configuration, which is what the machine is using at the moment.
  • Page 28 Steering Troubleshooting Guide Date Published: 4/9/21 b. Walk up to the machine from each side and make sure the machine stops c. Place a stationary obstacle in the machine's route to make sure it goes around the obstacle d. Observe the machine to verify the following: ○...

  • Page 29: Appendix A - Tech Steering Checklist

    Steering Troubleshooting Guide Date Published: 4/9/21 Appendix A - Tech Steering Checklist Completed Description Results (Pass/Fail/Measurements) (Yes/No) 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...

  • Page 30: Appendix B - Tech Solution Codes

    Steering Troubleshooting Guide Date Published: 4/9/21 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 Brain Corporation Proprietary and Confidential...
  • Page 31 Steering Troubleshooting Guide Date Published: 4/9/21 NOTE: This is generally a required step after replacing parts or CALIBRATION-01 troubleshooting issues related to the steering system. 1. Train a route that is at least 5 minutes with minimal stopping. a. Be sure to teach a route that goes straight and has left turns, right turns, and u-turns.
  • Page 32 STENCODER-01 externally), perform the following steps: 1) Send any photos, notes, and/or a filled out Troubleshooting Checklist to Brain Corp using the e-mail address specified in the work order. 2) Place an order for the following part: Steering Encoder (ICE...
  • Page 33 Steering Troubleshooting Guide Date Published: 4/9/21 If the steering motor is leaking oil or has a damaged cable, perform MOTOR-01 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.
  • Page 34 Steering Troubleshooting Guide Date Published: 4/9/21 If there is a damaged left female connector that has any damaged wires or something stuck in the connector , perform the following AMP-02 steps: Send any photos, notes, and/or a filled out Troubleshooting Checklist to Brain Corporation using the e-mail address specified in the work order.
  • Page 35 Steering Troubleshooting Guide Date Published: 4/9/21 If the Steering Angle check is off, perform the following steps: ANGLE-01 1) Perform the steps in the Steering Calibration solution code CALIBRATION-01. 2) Perform the Steering Angle Check (again). 3) If the unit is unable to complete running the newly trained route or it fails the Steering Angle check again, proceed to the remaining Software Diagnostics: a) Manual Steering Check...

  • Page 36: Appendix C - How To Replace The Traction Encoder

    Steering Troubleshooting Guide Date Published: 4/9/21 If the traction value does not increase or decrease as expected, TRACTION-01 perform the following steps: 1) Place an order for the following part: Traction Encoder (ICE Part Number: 8350266), Traction encoder cable, Down trunk Harness.
  • Page 37 Steering Troubleshooting Guide Date Published: 4/9/21 1. Power down the unit and disconnect the red battery coupling. Turn the steering wheel so the encoder and brake assembly installed on the drive wheel assembly can be easily accessed. Disconnect the encoder cable from the wire harness. Note: Photo cable management you will be required to reproduce after replacement.

  • Page 38: Appendix D - How To Replace The Steering Motor

    Steering Troubleshooting Guide Date Published: 4/9/21 Appendix D - How to Replace the Steering Motor 1. Turn the key to power off the scrubber. Raise the seat and disconnect 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. Remove the access panel to access the Steering Column Remove the front fascia As shown at right, also be sure to remove the six hex screws holding on the main fascia...
  • Page 39 Steering Troubleshooting Guide Date Published: 4/9/21 Loosen the collar (2 hex screws) and slide it down Remove the two set screws indicated below, then pull the steering wheel straight up. Brain Corporation Proprietary and Confidential Page...
  • Page 40 Steering Troubleshooting Guide Date Published: 4/9/21 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. Undo all steering motor bolts. Take care to retain all washers, bolts and the mounting plate for reassembly Brain Corporation Proprietary and Confidential Page...
  • Page 41 Steering Troubleshooting Guide Date Published: 4/9/21 Connect bolts 16 through the replacement drive motor and connect them to mounting plate 19. Note, bolts 6 and 23 may not be present in the Gen2 scrubber. When re-tightening the four steering motor bolts, follow a star pattern similar to when changing a tire on a four-bolt car wheel.
  • Page 42 Steering Troubleshooting Guide Date Published: 4/9/21 connector from the steering motor into the MAM. 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.
  • Page 43 Steering Troubleshooting Guide Date Published: 4/9/21 13. 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 To do this, use a 3 mm hex to remove the three screws that reside on the underside of the steering wheel.
  • Page 44 Steering Troubleshooting Guide Date Published: 4/9/21 Note: Diagram of Keys and trough Brain Corporation Proprietary and Confidential Page...

  • Page 45: Appendix E - U-Joint Replacement

    Steering Troubleshooting Guide Date Published: 4/9/21 Appendix E – U-Joint Replacement See appendix D. This outlines steps 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.
  • Page 46 Steering Troubleshooting Guide Date Published: 4/9/21 Loosen the collar (2 hex screws) and slide it down Remove the two set screws indicated below, then pull the steering wheel straight up. Brain Corporation Proprietary and Confidential Page...
  • Page 47 Steering Troubleshooting Guide Date Published: 4/9/21 Remove the set screws from the bottom of the U joint so the component can be removed from the shaft. Brain Corporation Proprietary and Confidential Page...
  • Page 48 Steering Troubleshooting Guide Date Published: 4/9/21 The replacement U joint can be installed 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.
  • Page 49 Steering Troubleshooting Guide Date Published: 4/9/21 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 Steering Troubleshooting Guide Date Published: 4/9/21 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. 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.

  • Page 51: Appendix F - Steering Amplifier (Mam) Replacement

    Steering Troubleshooting Guide Date Published: 4/9/21 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 Remove the front cover and place it to the side. Brain Corporation Proprietary and Confidential Page...

  • Page 52: Appendix G - Steering Encoder Replacement

    Steering Troubleshooting Guide Date Published: 4/9/21 Loosen the four 3mm hex screws above the eyelets, decouple the 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...
  • Page 53 Steering Troubleshooting Guide Date Published: 4/9/21 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 Steering Troubleshooting Guide Date Published: 4/9/21 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 Brain Corporation Proprietary and Confidential Page...
  • Page 55 Steering Troubleshooting Guide Date Published: 4/9/21 Brain Corporation Proprietary and Confidential Page...
  • Page 56 Steering Troubleshooting Guide Date Published: 4/9/21 The Steering Encoder can now be slid off from the bottom of the steering shaft 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.
  • Page 57 Steering Troubleshooting Guide Date Published: 4/9/21 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.
  • Page 58 Steering Troubleshooting Guide Date Published: 4/9/21 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 59 Steering Troubleshooting Guide Date Published: 4/9/21 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.

  • Page 60: Appendix H - Down Trunk Cable Replacement

    Steering Troubleshooting Guide Date Published: 4/9/21 The green line should move left and right as the steering wheel is rotated and should orient straight up 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.
  • Page 61 Steering Troubleshooting Guide Date Published: 4/9/21 To replace this component, power down the unit, remove the front plastic shield (5 mm) and the screws that hold the control panel (2 mm) in place. Remove the Downtrunk connector by spinning it counter-clockwise. 4.
  • Page 62 Steering Troubleshooting Guide Date Published: 4/9/21 8. LIDAR_HRZ_PWR 9. ENC_ABS (Steering Encoder) Brain Corporation Proprietary and Confidential Page...
  • Page 63 Steering Troubleshooting Guide Date Published: 4/9/21 Remove the access panel opposite the seat and route the ENC_ABS cable as shown below. Brain Corporation Proprietary and Confidential Page...
  • Page 64 Steering Troubleshooting Guide Date Published: 4/9/21 To disconnect the START_PAUSE and ESTOP coupling. 8. Use caution when handling the LIDAR_HRZ_ETH and LIDAR_HRZ_PWR cables. When connecting them to the LIDAR sensor, be gentle, as any modification to the sensor’s position may result in a necessary recalibration of machine sensors. 9.

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