Breadcrumbs

Error handling on the robot

Notification

Whenever the robot encounters a unforseen situation it will try to recover and resolve the issue automatically.

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Robot in error state

If the robot is unable to recover and manual intervention is required the robot indicates this by red constant or pulsating LEDs.

A robot with red LEDs requires manual intervention. If you see a robot in error state please recover the robot or notify responsible personell.

Tutorials

In error state the robot always shows the error message on the display.

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Error screen

Every error is also always accessible via the header bar.

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Header bar

Open an error to access the error tutorial. Each error tutorial is built up in the same way:

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Error tutorial structure

#

Name

Description

1

Graphic

Graphic representation of the error.

2

Error identifier

Error ID, error code and timestamp of the error - please provide this information to the Support if required.

3

Information

Error specific information and recovery instructions. Please follow the information displayed here to recover the robot from the error.

4

Recovery options

Select the correct recovery option based on the situation to recover from the error.

5

Error toggle

Toggle between multiple errors present at the same time.

Please follow the instructions on the tutorial to recover from the error.

Error recovery options

Some recovery options are only available in automatic or manual mode. If a recovery option button is greyed out please switch the mode with the key switch.

Warnings

Warnings can be identified by the yellow triangle warning symbol instead of the red circular error symbol.

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Warnings

In case of a warning there is no need to take any action on the HMI. Simply resolve the error and the robot will continue its operation automatically.

Continue Action (Acknowlege)

Resolve the situation and select Continue Action to acknowledge an error. The robot will attempt to continue its operation and retry the action.

Some error tutorials require you to move the robot manually to resolve the situation. Switch back to automatic to acknowledge the error afterwards.

Depending on error origin (safety-critical errors, basetruck errors) the universal button might need to be pressed. This is indicated by blinking universal button LEDs.

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Universal button

The universal button has to be pressed for at least 500ms to acknowledge an error.

Cancel order

When a transport job is active, the tutorial offers a Cancel Order option. Select Cancel Order and the robot will cancel its current transport job.

If the robot has already the load carrier onto the forks, the server will then reassign a new transport job to remove the load carrier from the forks (i.e. automatic transport to clearing station).

Remove LC

When a transport job is active and the robot already has lifted the load carrier onto the forks, the tutorial offers a Remove LC (Load carrier) option. Select Remove LC to delete the load carrier from the system and cancel the associated order.

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Remove LC tutorial

Follow the accompanying tutorial to remove the load carrier from the robot in manual mode. The user is responsible to further transport the load carrier to its target destination and manually book the transport in the WMS.

Warning
The recovery option Remove LC deletes the transport and the load carrier from the system database. At this stage the load carrier status is unknown to the system and there will be no further automatic transport issued for this load carrier as long as this is the case. The user has to make sure that the transport is completed manually and booked in WMS.

Moving the robot manually

Many error recoveries require the robot to be moved manually.

Switch to manual

Modes can be switched via the key switch.

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Key switch

The key switch offers three positions:

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Operating modes

 

Off

The robot is turned off.

Automatic mode

The robot is in automatic mode. The robot is connected to the server and receives and executes transport jobs automatically.

Manual mode

The robot is in manual mode. The robot does not receive transport jobs from the server and can be moved manually using the remote.

The operating mode of the robot is also indicated in the HMI header bar:

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Manual mode
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Automatic mode

In manual mode the robot aborts active transport jobs. However, if the state of the load carrier does not change during manual operation the server will re-assign and complete the transport automatically after switching back to automatic mode.

Moving the robot using the remote

In order to move the robot in manual mode the remote is required. The remote is located in the storage compartment unter the HMI of the robot.

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Storage compartment

Use the remote to maneuver the robot.

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Remote control

Danger
Safety fields are deactivated in manual mode. The robot can collide with persons and obstacles.

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Emergency stop
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Steering

Control the steering angle of the robot.
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Lift

Control the hydraulic lift of the robot to pick-up or put-down load carriers manually.
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Driving

Control the velocity of the robot to drive in load or drive direction.
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Enabling button

Enable manual control.

In order to be able to drive the enabling button has to be pressed constantly. The enabling switch is fitted with a deadman switch as well as panic release functionality. This means the button has to be held in the middle position while the robot drives. If the button is released or pressed through the robot will stop immediately.

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Enabling button on remote backside

For better ergonomics there is also a second Enabling button located on the backside of the remote.

After moving the robot please put the remote back into the storage compartment.

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Magnet grip

If you plan to continue using the remote it can also be attached to the robot housing using the integrated magnet grip.

Switch to automatic

Use the key switch to switch back to automatic operating mode.

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Permission to move dialog

Confirm the Permission to move dialog on the robot HMI so that the robot can restart automatic operation.

Examples

Some typical errors encountered in live operation could be:

Error

Tutorial

Troubleshooting

Source empty!
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  • Ensure correct load is at the source.

  • Ensure the device is positioned correctly at the source.

  • Press Continue action to acknowledge the error.

 

  • Alternatively press Cancel order to abort the transport job.

Destination occupied!
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  • Ensure the destination is empty.

  • Press Continue action to acknowledge the error.

 

  • Alternatively press Cancel order to transport the load automatically to the clearing station.

  • Alternatively press Remove LC to delete the transport and manually deal with the order.

Navigation failed!

(Warning)
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  • Check for possible obstacles in the driving lane.

  • Ensure the device can drive independently.

Source not reachable!
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  • Ensure the source is reachable (e.g., remove obstacles).

  • Press Continue action to acknowledge the error.

 

  • Alternatively press Cancel order to abort the transport job.

Destination cannot be reached!
image-20250327-125858.png

  • Ensure the destination is reachable (e.g., remove obstacles).

  • Press Continue action to acknowledge the error.

 

  • Alternatively press Cancel order to transport the load automatically to the clearing station.

Load carrier moved during pick-up!
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  • Position the load correctly at the source.

  • Use manual mode if necessary to position the robot in front of the station.

  • Press Continue action to acknowledge the error.

 

  • Alternatively press Cancel order to abort the transport job.

Special errors

Recover Localization (Re-Initialisation)

The robot navigates based on contour detection of its surroundings with the top laser scanner which it compares to the recorded map. If the robot robot recognizes the contours of its surroundings it localises itself in the space (i.e. the robot knows its position). Reasons for the robot to loose localisation could be:

  • The robot has been driven outside its mapped working area and does not recognize its surroundings.

  • The robot has been moved manually while being turned off.

  • Incorrect version of the environment which does not match the surroundings of the robot.

In case the robot has lost its localisation the robot will show the Device position unknown tutorial.

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Robot delocalised

Select Establish device position to recover from the error. The robot will display the Restore localisation dialog:

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Restore localisation

To restore localisation the robot has to be manually moved to a modelled charger within the working area of the robot. Position the robot in a short distance from the charger with the carging contact pointing at each other. The charging contacts should not have contact to each other.

Select the correct charging station in the drop down menu and confirm Device is positioned. The robot will automatically detect the charging station with its laser scanners and thereby re-establish its position within the environment.

Errors without specific tutorials

Unknown errors

Errors that have not been mapped to a specific tutorials will show a generic Unknown error tutorial.

Internal errors

Internal software errors will show a generic Internal error tutorial.

Basetruck errors

Basetruck errors will show a generic Basetruck error tutorial highlighting the respective error codes. Basetruck errros are also highlighted by a blinking universal button LED.

In order to resolve basetruck errors the universal button has to be pressed in most cases.

No errors

Any error not covered by any of these categories will be shown by red LEDs only.

Recovery options

In order to recover from these errors a restart of the software might be required. There are two possible restart options:

  • Basetruck powercycle
    Turn the key switch to the Off position and wait for approximately 10 seconds before turning the robot back on again. The HMI will stay active during this time.

  • Restart robot
    Turn the key switch to the Off position and wait until the HMI has turned off (approximately 60 seconds). Then turn the robot back on again.