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Yujin Robot GoCart250 Service Manual

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YUJIN AMS
GoCart250
Service Manual
Revision: 1.4
Date: 2023/03

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Summary of Contents for Yujin Robot GoCart250

  • Page 1 YUJIN AMS GoCart250 Service Manual Revision: 1.4 Date: 2023/03...
  • Page 2 All logos and trademarks in this document are legally protected as part of the intellectual property rights of Yujin Robot. No part of this document may be reproduced in any form without the explicit written consent of Yujin Robot. The appearance and specifications of the product are subject to change without notice for product improvement.
  • Page 3 Disposal of Waste Equipment Waste electrical and electronic equipment often still contains valuable materials. However, they also contain harmful substances that were necessary for their function and safety. In residual waste or in the event of incorrect treatment, they can harm human health and the environment. For this reason, do not dispose of your old device in the residual waste.
  • Page 4 GoCart250 Service Manual Change History The following table provides version information for this document and a history of significant changes. Version Date of Writing Changes V1.0 26/04/2021 First Creation The battery quantity is changed from 1ea to 2ea (see "6. Replacing V1.1...

  • Page 5: Table Of Contents

    Table of Contents Table of Contents 1. Introduction 1.1 Product Introduction 1.2 About this Document 1.3 Manual Introduction 2. Important Safety Instructions 2.1 Definition 2.2 General Safety 3. Tools Required 4. Periodic Maintenance Schedule 4.1 Daily Check 4.2 Periodic Maintenance 5. Replacing Electrical Components 5.1 Disassembling Covers 5.2 Checking Electrical Components Position 5.3 Replacing Electrical Components 5.4 Wiring Diagram 6. Replacing Battery 6.1 Replacing Battery on Rear of Robot...
  • Page 6 GoCart250 Service Manual 7.3.3 ③ UNIT_LED_ASSY 7.4 Sensors Attached on Left Cover 7.4.1 ① UNIT_CLIFF SENSOR (ToF) 7.4.2 ② UNIT_SONAR_SENSOR (W238) 7.4.3 ③ UNIT_LED_ASSY 7.5 Sensors Attached on Rear Cover 7.5.1 ① UNIT_SONAR_SENSOR (W238) 7.5.2 ② UNIT_SONAR_SENSOR (HC-SR04) 7.5.3 ③ UNIT_LED_ASSY 7.6 Sensors Attached on Rear Bottom Cover 7.6.1 ① UNIT_CLIFF_SENSOR (PSD) 8. Replacing Switches and External Ports...

  • Page 7: Introduction

    GoCart250 includes the driving unit with independent type suspension, 3D sensors, LiDAR sensors, emergency stop, and equipped with output interfaces to communicate with conveyors. In addition, GoCart250 system is compliant with ISO 13482 PL d level safety to assure safety of the robot when operating in a public environment.

  • Page 8: Important Safety Instructions

    GoCart250 Service Manual 2. Important Safety Instructions 2.1 Definition The following instruction is to ensure user’s safety and prevent any property damage. Please read the following texts and use the system with care. Warning Users must follow the instructions to avoid potentially hazardous situations that could cause serious injury or death.

  • Page 9: Tools Required

    Tools Required 3. Tools Required Item Picture Hex wrench set (meter) Power up Handle Adjustable wrench Screw Driver (PH2, +) Table 1: Tools Required...

  • Page 10: Periodic Maintenance Schedule

    GoCart250 Service Manual 4. Periodic Maintenance Schedule Fig. 1: Product Part Information ① (x2) 3D Lidar ② (x8) Cliff Sensor (Tof) ③ (x8) Sonar Sensor (W238) ④ (x2) Window camera (3D ⑤ (x1) Window camera (Astra ⑥ (x1) Docking Terminal RealSense) Camera) ⑦...

  • Page 11: Daily Check

    Periodic Maintenance Schedule 4.1 Daily Check Emergency switch. • Check the LED light in the emergency switch when pushing the switch. • 4.2 Periodic Maintenance Cleaning: The following table provides a summary of cleaning steps. Item Tasks Period Remove dirt and hairs with a wet Drive Wheel &...

  • Page 12: Replacing Electrical Components

    GoCart250 Service Manual 5. Replacing Electrical Components 5.1 Disassembling Covers To replace electrical components, remove ①②③④⑤ covers to perform maintenance. Fig. 2: Disassemble Covers ① COVER_RIGHT_ASSY ② COVER_FRONT_ASSY ③ COVER_LEFT_ASSY ④ COVER_REAR_ASSY ⑤ PLATE_TOP_CONTAINER...

  • Page 13: Checking Electrical Components Position

    Replacing Electrical Components 5.2 Checking Electrical Components Position After disassembling the covers of GoCart, check the position of electrical components. Refer to the figure below for more information. Fig. 3: Electrical Components Position ① PCB_FUSA_PWR_V001 ② LAN_HUB_ASSY ③ SBC_ASSY_TOTAL ④ MAGNETIC CONTACTOR (MC-22b ⑤...

  • Page 14: Replacing Electrical Components

    GoCart250 Service Manual 5.3 Replacing Electrical Components For maintenance of electrical components, refer to the following procedures. 1. Disconnect cables of electrical parts to perform maintenance. 2. Remove screws from the corresponding part. 3. Replace the part with a new one.

  • Page 15: Wiring Diagram

    Replacing Electrical Components 5.4 Wiring Diagram A wiring diagram is a simplified visual representation of the physical connections and physical layout of an electrical circuit. It shows the components of a circuit as simplified shapes and where fixtures and components may be connected to the system. Also, it shows how the electrical wires are interconnected between the devices.
  • Page 16 GoCart250 Service Manual LAN Hub1 LAN Hub2 Fig. 5: Wiring Diagram...

  • Page 17: Replacing Battery

    Shut off to front battery, and Supply to rear battery shut off both front and rear batteries For battery maintenance, refer to the following procedures. Warning Replace the battery only with one provided by Yujin Robot. • Follow proper Electrostatic discharge (ESD) procedures during removal and • replacement.
  • Page 18 GoCart250 Service Manual 2. Turn off ② main switch. 3. Turn off ③ rear battery trigger switch (rear-right position). Rear Battery Trigger Switch (Rear-right Position) Fig. 7: Turn off Main and Rear Battery Trigger Switch 4. Detach ⑤ battery bracket by removing fixing bolts (2 ea).

  • Page 19: Front Battery Replacing

    Replacing Battery 6. Take out by pulling the battery assembly. 7. Insert a new battery in place. It recommends replacing in assembly units. 8. Connect power cable connector to the new battery then turn on the trigger switch and main switch. 6.2 Front Battery Replacing 1.
  • Page 20 GoCart250 Service Manual 4. Detach ④ front cover by removing fixing bolts (10 ea). 5. Detach ⑥ battery bracket by removing fixing bolts (2 ea). ⑥ Battery Bracket Fig. 12: Detach Front Cover and Battery Bracket 6. First, Unplug ⑤ power cable connector on the right panel of battery.
  • Page 21 Replacing Sensor Refer to the type of cables on the front battery. ① Power Cable Connector ② Trigger Wire Harness (red-yellow) Not Available. RS-485 Wire Harness (red-blue) Type Description ① Power Cable Connector For power supply Trigger Wire Harness ② For powering front battery (red-yellow) RS-485 Wire Harness...

  • Page 22: Replacing Sensor

    GoCart250 Service Manual 7. Replacing Sensor 7.1 Sensors Attached on Frame 7.1.1 ① UNIT_ASSY_3D_LIDAR 1. Disconnect 2 connectors inside the frame. 2. Release 2 screws. 3. Pull down the unit to disassemble. 4. Replace the unit with a new one by following the disassembly steps in reverse order.

  • Page 23: Sensors Attached On

    Replacing Sensor 7.2 Sensors Attached on Front Cover 7.2.1 ① UNIT_CLIFF SENSOR (ToF) 1. Disconnect 2 connectors to the sensor. 2. Release 4 screws. 3. Pull up the unit to disassemble. 4. Replace the unit with a new one by following the disassembly steps in reverse order. 7.2.2 ②...

  • Page 24: Unit_Docking_Terminal

    GoCart250 Service Manual 7.2.6 ⑥ UNIT_DOCKING_TERMINAL 1. Disconnect the connector to the sensor. 2. Release 4 screws. 3. Pull up the unit to disassemble. 4. Replace the unit with a new one by following the disassembly steps in reverse order. Fig. 17: Sensors Attached on Frame...

  • Page 25: Sensors Attached On Right Cover

    Replacing Sensor 7.3 Sensors Attached on Right Cover 7.3.1 ① UNIT_CLIFF SENSOR(TOF) 1. Disconnect 2 connectors to the sensor. 2. Release 4 screws. 3. Pull up the unit to disassemble. 4. Replace the unit with a new one by following the disassembly steps in reverse order. 7.3.2 ②...

  • Page 26: Unit_Led_Assy

    GoCart250 Service Manual 7.4 Sensors Attached on Left Cover 7.4.1 ① UNIT_CLIFF SENSOR (ToF) 1. Disconnect 2 connectors to the sensor. 2. Release 4 screws. 3. Pull up the unit to disassemble. 4. Replace the unit with a new one by following the disassembly steps in reverse order.

  • Page 27: Unit_Led_Assy

    Replacing Sensor 7.5 Sensors Attached on Rear Cover 7.5.1 ① UNIT_SONAR_SENSOR (W238) 1. Disconnect the connector to the sensor. 2. Release 4 screws. 3. Pull up the unit to disassemble. 4. Replace the unit with a new one by following the disassembly steps in reverse order. 7.5.2 ②...

  • Page 28: Sensors Attached On Rear Bottom Cover

    GoCart250 Service Manual 7.6 Sensors Attached on Rear Bottom Cover 7.6.1 ① UNIT_CLIFF_SENSOR (PSD) 1. Remove the ① cover bottom rear parts by removing 8 screws. 2. Disconnect each of the 2 connectors of the ②sensor assembly that needs replacement. 3. Release 4 ③screws.

  • Page 29: Replacing Switches And External Ports

    Replacing Switches and External Ports 8. Replacing Switches and External Ports Fig. 22: Switches and External Ports ③ EMERGENCY_SWITCH_K22- ① CHARGER POWER CONNECTOR ② UNIT SPEAKER ASSY 87R-N29 ⑥ HDMI_ LS-HDMI-SMF-2M_HDMI_ ④ NEXT-306UHP_USB_HUB ⑤ LAN_NMC-U610FZ_1M_LAN_CABLE CABLE ⑦ UNIT_MIC_EIM001 ⑧ SWITCH_MAIN_ASSY ⑨ UNIT_OP_PANEL ⑨-①...

  • Page 30: Charger Power Connector

    GoCart250 Service Manual 8.1 ① CHARGER POWER CONNECTOR 1. Disconnect the connector to the unit. 2. Release 4 screws. 3. Pull down the unit to disassemble. 4. Replace the unit with a new one by following the disassembly steps in reverse order.

  • Page 31: Hdmi_ Ls-Hdmi-Smf-2M_Hdmi_Cable

    Replacing Switches and External Ports 8.6 ⑥ HDMI_ LS-HDMI-SMF-2M_HDMI_CABLE 1. Disconnect the connector to the unit. 2. Release 2 screws. 3. Pull up the unit to disassemble. 4. Replace the unit with a new one by following the disassembly steps in reverse order. 8.7 ⑦...
  • Page 32 GoCart250 Service Manual For BRAKE SWITCH, SOFT SWITCH, START_SWITCH maintenance, refer to the ⑨-①, ⑨-②, ⑨-③, ⑨-④, ⑨-⑤ following procedures. 1. Push the side hook as shown in the below figure and disconnect cables. 2. Loosen a nut fixed switch on the rear of the cover.

  • Page 33: Replacing Wheel And Motor

    Replacing Wheel and Motor 9. Replacing Wheel and Motor Fig. 27: Wheels Parts ① MOTOR DRIVE ASSY ② WRENCH SCREW M6X16 ③ CASTER_AVMU-110SF ④ CASTER_AVMU_75RF ⑤ WRENCH SCREW M8X20...

  • Page 34: Caster Replacement

    GoCart250 Service Manual 9.1 Caster Replacement 1. Bring a block (height 70 mm ~ 80 mm) that can withstand the weight of the robot. Place the side of the robot on the block carefully. Fig. 28: Caster Replacement (1) 2. After removing ①SCREW from a caster, replace it with a new caster.

  • Page 35: Wheel Replacement

    Replacing Wheel and Motor 9.2 Wheel Replacement 1. Bring 2 blocks (height 70mm ~ 80mm) that can withstand the weight of the robot. Place the front and rear of the robot on the blocks carefully. Fig. 30: Wheel Replacement (1) 2. Remove ①②COVER of ③WHEEL. 3.

  • Page 36: Motor Drive Assy Replacement

    GoCart250 Service Manual 9.3 Motor Drive Assy Replacement Fig. 32: Motor Drive Assy Replacement (1) ① MOTOR DRIVE ASSY ② WRENCH SCREW 6X16 ③ WRENCH SCREW 8X12 ④ MOTOR_R_Cable_power ⑤ MOTOR_R_Cable_signal ⑥ Motor_R_Brake_power ⑦ Encoder_R_Connector ⑧ MOTOR_L_Cable_power ⑨ MOTOR_L_Cable_signal ⑩ Motor_L_Brake_power...
  • Page 37 Replacing Wheel and Motor 1. Disassemble ④⑤⑥⑦⑧⑨⑩⑪ connectors of a ①motor drive assembly. 2. Bring a block (height 70 mm ~ 80 mm) that can withstand the weight of the robot. Place the side of the robot on the block carefully. Fig.

  • Page 38: Running Test Program

    GoCart250 Service Manual 10. Running Test Program Execute the test program to check that the robot is in a normal state. 10.1 Preparation for Test The following devices are required to run the test program. Reserve a space with two adjacent walls 3 meters long for testing.

  • Page 39: Led Colors And Robot Status

    The LED light band around the robot indicates the robot’s current operational state. Refer to the following table for more details. Front Front GoCart180 GoCart200 Omni GoCart250 Fig. 35: LED band position of robot (1~8) Fig. 36: Status of LED light color...

  • Page 40: Error Handling

    GoCart250 Service Manual 12. Error Handling Robot checks its own error states. Below is the error list. Each errors have its severity and behavior. 12.1 Severity and Behavior LOG_ERR • The lowest priority Normal errors Keep its work after error becomes normal Publishing and Notifying error info >...

  • Page 41: Error Codes

    Error Handling 12.2 Error Codes Index Error Code Error Severity Description 10108300 LOG_ERR CPU reached the limitation. 10208300 LOG_ERR Memory is over the limitation. 10305500 LOG_ALERT Failed to open the system information file(/proc/stat). 10408800 LOG_ERR Disk space is over the limitation. 10608300 LOG_ERR Process is using high memory.
  • Page 42 GoCart250 Service Manual 202025nn LOG_ERR TiM510 data is empty. 202031nn LOG_ERR TiM510 cannot get available storage block. 202051nn LOG_ALERT Cannot get the TiM510 parameter file. 20205200 LOG_ALERT There is no TiM510 extrinsic data. 202053nn LOG_ALERT TiM510 reads wrong value. 203011nn LOG_ERR Cannot connect to the TiM571.
  • Page 43 Error Handling 216014nn LOG_CRIT FuSa TiM510 wakeup error. 216095nn LOG_CRIT FuSa TiM510 stops by category 0. 216096nn LOG_CRIT FuSa TiM510 stops by category 2. 216051nn LOG_ALERT Cannot get the FuSa TiM510 parameter file. 216053nn LOG_ALERT FuSa TiM510 reads wrong value. 21605200 LOG_ALERT There is no FuSa TiM510 extrinsic data.
  • Page 44 GoCart250 Service Manual 30108700 LOG_ERR SLAM failed to sync the map file. 30113100 LOG_ERR SLAM failed odometry interpolation. 30205100 LOG_ALERT Localization needs to set filename. 30205300 LOG_ALERT Localization needs to check extrinsic data. 30206400 LOG_ERR Localization failed to send pose requesting.
  • Page 45 Error Handling 50602800 LOG_ALERT Cannot move without destination point. 50702200 LOG_ERR Starting point is out of global grid map. 50702500 LOG_ERR Path planner got empty data. 50704200 LOG_ERR The global path was not planned within expected time. 50712100 LOG_ERR Path planner failed to get global path. 50802200 LOG_ERR Planner got abnormal pose in local map.

  • Page 46: Appendix

    GoCart250 Service Manual 13. Appendix. 13.1 Appendix A. How to Attach Visual Marker Sticker (using Marker Jig) 1. Prepare the provided Visual Marker Sticker and Marker Jig. 2. Align the Marker Jig with the Charging Terminal on the charging station and then insert it.
  • Page 47 Yujin Robot Co., Ltd. Harmony-ro 187 beon-gil 33, Yeonsu-gu, Incheon (Songdo-dong) www.yujinrobot.com TEL +82 32 550 2300 FAX +82 32 550 2301...

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