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Summary of Contents for Otto 750
- Page 1 OPERATION AND MAINTENANCE MANUAL OTTO 750 Document ID OMM-000083 Revision A Release Date 19 Sep 2019...
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Page 2: Disclaimer
In no event shall OTTO Motors be liable for any costs or damages arising from the use of this document or the hardware and software described within. The reference documents listed in this manual shall be applicable at the latest revision in effect. -
Page 3: Contact Information
OTTO 750 Operation and Maintenance Manual • Rev. A CONTACT INFORMATION OTTO Motors is committed to your success and satisfaction. We are located in Kitchener, Ontario. If you have any questions or concerns, visit our support knowledge base for more information, or get in touch with our support team. -
Page 4: Table Of Contents
OTTO 750 Operation and Maintenance Manual • Rev. A CONTENTS Disclaimer ........................... 2 Safety ............................2 Contact Information ........................3 Revision Table ..........................3 Contents ............................. 4 List of Figures ..........................6 List of Tables ..........................7 1 Introduction ..........................8 1.1 Included Items ...................... - Page 5 OTTO 750 Operation and Maintenance Manual • Rev. A 5.3 Charging OTTO ....................38 5.4 Pendant Controller ....................39 6 Attachment..........................41 6.1 Mechanical Interface Specifications ..............41 6.2 General Attachment Interface Signals ..............42 6.3 24 volts vs. 48 volts Power Outputs ..............43 6.4 Attachment Safety ....................43...
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Page 6: List Of Figures
Figure 7: Live Voltage Locations ....................17 Figure 8: OTTO 750 Drive System ....................18 Figure 9: Minimum Safety Distance...................30 Figure 10: OTTO-Charge 1500 ....................38 Figure 11: Pendant Controller ....................40 Figure 12: OTTO 750 showing mechanical and electrical interface locations......41 Figure 13: Attachment Interface Port ..................42... -
Page 7: List Of Tables
OTTO 750 Operation and Maintenance Manual • Rev. A LIST OF TABLES Table 1: Revision Table ......................3 Table 2: Reference Documentation .................... 8 Table 3: Abbreviations and Acronyms ..................9 Table 4: Emergency Stop Conditions ..................19 Table 5 OTTO 750 Status Indication ..................21 Table 6: OTTO 750 System Specifications ................23... -
Page 8: Introduction
OTTO 750. This document provides important information pertaining to the operation and use of an OTTO 750 and is organized into sections pertaining to system components and overview, robot safety, system operation, attachment interfacing and details on maintenance. -
Page 9: Abbreviations And Acronyms
OTTO 750 Operation and Maintenance Manual • Rev. A Abbreviations and Acronyms The following table lists abbreviations and acronyms used throughout this document. Table 3: Abbreviations and Acronyms Abbreviation/Acronym Phrase E-Stop Emergency Stop LIDAR Combination of "light" and "radar" Battery Monitoring System... -
Page 10: Getting Started
This section will outline the basic manual pendant control and first time bring-up instructions for OTTO 750 to get the system up and running upon arrival at the facility. Please continue review the entire manual for the correct safety procedures and precautions as well as operating conditions for the OTTO 750 system. -
Page 11: First Robot Bring-Up
The pendant connection port is found behind the hinged plate found on the starboard side of OTTO 750. To access the port, remove the one screw and open the plate door. Remove the pendant port terminator plug to use the port. Ensure to return the plug prior to changing the system into autonomous mode. - Page 12 For detailed instructions regarding this procedure, refer to the S3000 Operating Instructions Manual. 4. Trip OTTO 750 into an emergency stop state by fully depressing one of the four E- stop buttons on the port or starboard sides of the vehicle.
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Page 13: Overview
OVERVIEW This section provides the user with a functional and mechanical overview of the entire OTTO 750 system. Figure 4 and Figure 3 give a tour of the key components of OTTO 750. Figure 3: OTTO 750 Port and Front Figure 4: OTTO 750 Starboard and Rear ©... -
Page 14: Components
Section Error! Reference source not found.. Power Switch 3.1.2 The Power switch on OTTO 750 is a simple two-state switch that allows the user to turn OTTO 750 on and off. Manual Charge and Pendant Connector Bay 3.1.3... -
Page 15: Figure 5: Wireless Antennas Clearance
The manual bypass screws are two screws which allow the user to disengage the drive wheels from the floor and manually move OTTO 750 using the 4 swivel castor wheels. The user must pay very close attention to OTTO 750 when using the manual bypass screws because there will be no active braking when the drive wheels are disengaged from the floor. -
Page 16: Figure 6: Manual Disconnect Switch
This system consists of four corner light panels, each with two LED Light Stacks. There is also one LED Light Pipe which wraps around the entire body of OTTO 750. These LEDs indicate the behaviour or intended behaviour of OTTO 750 for users to understand and predict how OTTO 750 will move around the workspace. -
Page 17: Figure 7: Live Voltage Locations
Power System 3.1.10 OTTO 750 is powered by a 51.2V (nominal) 100Ah battery pack. This battery pack is connected in series though a Battery Monitoring System (BMS). In addition, a 12V lead-acid battery is connected to the BMS to provide state-of-charge and error code data when the system is powered off. -
Page 18: Sensors
Hoist Locations 3.1.12 The four hoist points, with or without the load cell option are used to hoist OTTO 750 for transporting to another location. Refer to document: Attachment Interface, OTTO 750 for the exact specifications of these four hoist points. -
Page 19: System Architecture
Emergency Stop System 3.2.5 There are two (2) forms of Emergency Stops on OTTO 750 which are defined in Table 4. When the emergency stop state is triggered, the system will immediately apply the brakes and cut all power to the drive motors. If an attachment is connected, a stop signal will be relayed to the attachment. -
Page 20: Status Indicators
(and attachment accessories if connected). Status Indicators OTTO 750 is equipped with four sets of light stack panels (one on each corner) and one light pipe which encircles the entire robot. The colour of the lights illuminated and the frequency of the flashing are used to indicate the state of OTTO 750. -
Page 21: Table 5 Otto 750 Status Indication
OTTO 750 Operation and Maintenance Manual • Rev. A Table 5 OTTO 750 Status Indication Audible Light Pipe Light Panels Notification Status Port Starboard Front Side Rear Front Side Rear Blue Blue Blue Blue Blue Blue Powering Up None Filling... - Page 22 OTTO 750 Operation and Maintenance Manual • Rev. A Power Down Fade Fade Fade Fade Fade Fade Fade Indicating Next Motion Changing Direction Red to White to Red to White to to Forward White White Changing Direction White to Red to...
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Page 23: Specifications
OTTO 750 Operation and Maintenance Manual • Rev. A Specifications Key specifications of OTTO 750 are shown in Table 6. All specifications do not include additional sensors or sensing systems. Table 6: OTTO 750 System Specifications Size and Weight Length... - Page 24 OTTO 750 Operation and Maintenance Manual • Rev. A Interfacing and Communication Attachment Control Systems Power 24 VDC, regulated, unswitched, 5A Attachment Power Unregulated battery power, 50A switched Supplies with safety circuit 2 general purpose inputs and outputs 1 Ethernet 1 USB 2.0...
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Page 25: Safety
OTTO 750 Operation and Maintenance Manual • Rev. A SAFETY Clearpath Robotics is committed to the safety of our users. Please be advised that OTTO 750 is designed for use in industrial production facilities and should not be used for other purposes outside of this environment. -
Page 26: Table 8: Specific Hazards
OTTO 750 Operation and Maintenance Manual • Rev. A Failure to follow instructions may result in INJURY or DAMAGE to the charge system and or property. Table 8: Specific Hazards Severity Classification Description Suggested Avoidance Impact with When OTTO 750 is enabled, it individuals. - Page 27 OTTO 750 Operation and Maintenance Manual • Rev. A Undefined Footprint. Always maintain the correct footprint for OTTO 750. Should a payload OTTO 750 has been over-extend the footprint, OTTO 750 loaded with an will be unable to navigate safety and...
- Page 28 OTTO 750 Operation and Maintenance Manual • Rev. A Objects caught in Keep hands and other objects clear. space between vehicle frame and the floor. Pinch Point Objects caught in Docking stations have a human space between vehicle exclusion zones and warning symbols and docking bay.
- Page 29 Like most applications using batteries with Lithium technology, special precaution should be taken to handle this type of material. The battery pack on OTTO 750 should only be handled by trained personnel to ensure proper handling of these materials. Also be aware of the operating environments for OTTO 750 and more specifically the battery pack, refer to section 7.4 for specific battery pack details.
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Page 30: Figure 9: Minimum Safety Distance
(less than 1% grade) and the drive wheels should never be manually bypassed on a ramp condition. OTTO 750 should also never be driven onto curbs or across gaps in the floor that may damage the drive system. -
Page 31: Lock-Out Tag-Out
The best way to ensure safety of life and equipment around OTTO 750 is to keep a safe distance from OTTO 750 when it is performing its operations. All individuals working around OTTO 750 should be familiar with the OTTO 750 status indicators and emergency stop button locations. -
Page 32: Safety Features
Normal Mode is applied during typical operation in regular transit zones under standard traffic rules. The applied LIDAR Field Set is dynamically adjusted based on the OTTO 750 speed as reported by the encoders through the SICK EFI. Six Field Sets are defined by velocity bins, and as a worst-case-scenario assumption, the actual velocity is always less than the maximum velocity of the current bin. - Page 33 Navigation 4.5.2 OTTO 750 is guided by two safety rated LIDARs, one on the front and another on the rear. These guide OTTO 750 around obstacles and will stop the vehicle if an object is detected within the safety zone, refer to Appendix B. The protective zone will change size and distance based on how fast OTTO 750 is moving to better prepare for an emergency stop.
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Page 34: Table 10: Emergency Stop Conditions
Emergency Stop System 4.5.3 There are two (2) forms of Emergency Stops on OTTO 750 which are defined in Table 4. When the emergency stop state is triggered, the system will immediately apply the brakes and cut all power to the drive motors. If an attachment is connected, a stop signal will be relayed to the attachment. - Page 35 LED Light Panels as well as an LED Light Pipe which extends around the entire body of OTTO 750. There are also two speakers on the system, one at the front and one at the rear.
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Page 36: Transport
OTTO 750 is equipped with four hoisting points as seen in Figure 3. Only these points should be used to lift or orient the platform. Lifting OTTO 750 in any manor other than that specified (such as a forklift below the platform) may result in permanent damage. Care should be taken to ensure that the OTTO 750 does not shift or move during any hoisting or lowering activities. -
Page 37: System Operation
System Start Up Prior to starting OTTO 750, inspect the area surrounding the vehicle as well as the space that OTTO 750 will be operating in to ensure that there are no hazards or obstacles present. After inspection, perform the following steps to activate the system. -
Page 38: Charging Otto
OTTO 750, refer to the OTTO-Charge 1500 Operation and Maintenance Manual. Note that when the OTTO 750 battery pack is exhausted less then 10%, OTTO 750 will not turn on and therefore cannot charge using the OTTO-Charge 1500. It will have to be charged with the manual charger until the battery pack has reached at least 25%. -
Page 39: Pendant Controller
Manual Charge 5.3.2 Manual Charge for the OTTO 750 can be done at any time. This process involves using the manual charger and connecting it to OTTO 750 for the duration of the charge. OTTO 750 is done charging when it is indicated on the manual charger and App interface. -
Page 40: Figure 11: Pendant Controller
The pendant connection port is found behind the hinged plate found on the starboard side of OTTO 750. To access the port, remove the one screw and open the plate door. Remove the pendant port terminator plug to use the port. Ensure to return the plug prior to changing the... -
Page 41: Attachment
OTTO 750 Operation and Maintenance Manual • Rev. A ATTACHMENT The attachment interface sits between OTTO 750 base platform and the attachment subsystem. The base robotic platform is designed to interface with several different attachments; therefore, the interface includes detection and handshaking of the attachment to ensure that the base platform is aware of the attachment being used. -
Page 42: General Attachment Interface Signals
The attachment umbilical cable must be terminated with connectors that conform to the electrical specifications in Attachment Interface, OTTO 750. In general, the electrical umbilical of the attachment should have sufficient flex to allow the attachment to be mechanically mounted and then the electrical interface cables plugged into the Attachment Connector on the chassis afterward. -
Page 43: 24 Volts Vs. 48 Volts Power Outputs
The 48VDC line from the chassis is switched by the master control relay on OTTO 750 so it is the primary means for the hazardous motions of the attachment, if any, to be deactivated. If the attachment is equipped with emergency stop input devices, then these devices can trigger an emergency stop on OTTO 750. -
Page 44: Footprint Safety
OTTO 750 Operation and Maintenance Manual • Rev. A Footprint Safety It should be noted that the overall footprint of OTTO 750 must remain within the current configuration for each robot. Depending on which attachment has be mounted on OTTO 750, the footprint may have to be adjusted to suit the attachment. -
Page 45: Maintenance Schedule
Degradation in autonomy performance may result. Manual Bypass of the Drive Wheels In the event of having to manually bypass the drive wheels on OTTO 750, the manual bypass screws should always be accessible, including when there is an attachment in place. -
Page 46: Storage
OTTO 750 out of storage. It is also recommended that OTTO 750 is stored with a full battery charge and if possible, discharged once a month and recharged. This will help maintain the life of the battery pack. -
Page 47: Maintenance Schedule
Performing checks on the following components is integral and required to maintain a valid warranty. For a list of spare parts available for the OTTO 750 system, refer to document SPL-000013. Table A-1: OTTO-Charge 1500 Maintenance and Inspection Schedule Maintenance Cycle from Time of Installation... -
Page 48: Appendix A Glossary
A sequence of goals, plans, or other actions which serve to complete a task. Attachment A subsystem attachment that is mounted to the top of OTTO 750 in order to perform a specific material handling activity. Refer to section 6. -
Page 49: Appendix Blidar Field Sets
OTTO 750 Operation and Maintenance Manual • Rev. A The LIDAR used on OTTO 750 is a S3000 Safety Laser Scanner manufactured by SICK AG. It provides ranging and obstacle detection within a rectangular zone in front of the sensor. There are two types of fields the LIDAR reports, protective and warning.
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