TM-Family
Original instruction manual (en)
From serial number:
TMC300: 2.00265A210000420
TMR150: 1.00265A200000424
TML150: 1.00265A220000393
2022-05-17
TM-Family
Original instruction manual (en)
Revision: 1.19
Copyright and disclaimer
All rights reserved. No parts of this document may be reproduced in any form without the express written permission
of ROEQ ApS. ROEQ makes no warranties, express or implied, in respect of this document or its contents. In
addition, the contents of the document is subject to change without prior notice. Every precaution has been taken in
the preparation of this manual. Nevertheless, ROEQ assumes no responsibility for errors or omissions or any damages
resulting from the use of the information contained.
This document contains colors which are considered to be useful for the correct undestanding of the content. Users
should print this document using a color printer.
Copyright 2022, ROEQ ApS.
Contact the manufacturer:
ROEQ ApS
Glasvænget 9
DK-5492 Vissenbjerg
CVR: 38656872
Publicly available p. 2 of 100
TM-Family
Original instruction manual (en)
Revision: 1.19
Revision History
Rev. Date Comment Responsible Reviewer
1.17 2021/05/25 Document translated from v1.16 (in Word) and
rearranged to better follow ISO 20607
mju <reviewer>
1.18 2021/11/29 Updated S/N for products on front page to coincide
with new numbering scheme.
Added remarks on varying look of internal electronics,
depending on product model, following restructuring of
TMC300.
mju <reviewer>
1.19 2022/05/17 Added information for AM250.
Changed mentioning of the ROEQ Assist in instances
with old naming.
jlh <reviewer>
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TM-Family
Original instruction manual (en)
Revision: 1.19
Table of Contents
1 Introduction 7
1.1 About this product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Hazard specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Where to find information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety 8
2.1 Safety principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Emergency situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.1 Emergency stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4.2 Applicable fire-fighting equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Machine overview 12
3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Machine description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.1 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.2 Electric connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.3 Identification label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.4 Employed materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Environmental specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 Safety system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.1 Safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6.1 Cargo requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Transportation, handling and storage 20
4.1 Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5 Assembly and installation 21
6 Commissioning 28
6.1 Prepare the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Perform a risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3 Robot safety configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.1 Connecting to the Sick Safe laser scanner system . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.2 Setting up COM settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.3 Taking backup of existing scanner configuration (recommended) . . . . . . . . . . . . . . . . 32
6.3.4 Transfer ROEQ safety configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.4 Prepare load transfer zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.5 Prepare robot docking location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.6 Prepare robot parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.7 Verify cargo fitness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.7.1 Stability during transfer and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.8 Verify safety system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.9 Create cargo transfer missions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.10 Testing docking sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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Revision: 1.19
7 Operation 49
7.1 Integration with robot interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.2 Running Get and Return missions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.2.1 Operating status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.2.2 Error checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.3 Contingency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.3.1 No movement during safety stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.3.2 Manual soft-homing command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.3.3 Safety zone override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.4 Safety during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8 Maintenance, inspection and cleaning 53
8.1 Regular maintenance and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Verifying safety functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9 Decommissioning 55
9.1 Disabling and dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2 Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10 Troubleshooting 56
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10.1.1 ROEQ support portal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10.1.2 System diagnostic manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10.1.3 Register values and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10.2 Troubleshooting cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.2.1 Disable IPv6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.2.2 Update log-in credentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.2.3 Extract ROEQ Assist operating log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.2.4 Verify PLC operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.2.5 Inspect PLC and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.2.6 Emergency stop issued by product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10.2.7 Clean laser scanner covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.2.8 Verify safety field selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.2.9 Calibrating lifter and locking bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.2.10 Verify safety configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10.2.11 Adjusting global docking offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10.2.12 Calibrating laser scanners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.2.13 Adjusting position specific docking offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.2.14 Improve robot traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
A User groups and level of training 82
B Hazard specification 83
C Cargo specification 84
C.1 Cargo size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
C.2 Cargo weight, distribution, and securement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
D Top-Module Equipment 86
D.1 ROEQ carts and racks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
D.1.1 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
D.1.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
D.1.3 Custom attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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D.2 ROEQ docking stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
D.2.1 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
D.2.2 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
E Register description 90
F Safety system details 91
F.1 Safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
F.2 Safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
F.3 Testing of safety system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
G Measuring docking misalignment 94
Bibliography 99
Abbreviations 99
Glossary 99
Safety functions 100
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Section Table of Contents
TM-Family
Original instruction manual (en)
Revision: 1.19
1 Introduction
This document outlines the operational instructions of the ROEQ TMC300, TML150, and TML150, colloquially
referenced as “the Top-Module”, “the top-module”, or simply “the product”.
This manual contains notices to be observed to ensure personal safety and to prevent damage to property.
Read this document before operating the product.
Save this document for future reference.
This document contains instructions for several products that are largely similar in their operation and behavior. Some
minor differences do however exist e.g. in terms of available features, configuration options, operating procedures,
etc. These differences are either emphasized explicitly, or can be readily deduced from the context of the provided
information.
1.1 About this product
The Top-Module is a partly completed machinery w.r.t. the European Machinery Directive [1]. As such it is not
intended to be operated as a standalone unit, but rather as a component in a larger setup possibly involving a MiR
robot, other machinery, etc.
Read the manual of the robot carefully before commissioning the combined solution.
The safety related aspects of this document pertains only to the ROEQ product and, to some extent, the interplay
between the ROEQ product and other equipment. The integrator of the complete machine must consider any hazards
and required remedies not included in the scope of this document.
The expected lifetime of the product safety system is 20 years, which should not be exceeded.
All abbreviations used throughout are summarized in the back of this document on page 99, along with all citations
and elaborations of selected technical terms.
1.2 Target group
The instructions in this document are intended for integrators, operators, etc. w.r.t. the user groups defined in
Appendix A, depending on the potential interaction with the product.
1.3 Hazard specification
Throughout the document, several directions and instructions are provided concerning the use and behavior of the
product. The classification of the provided directions and instructions follows the outline in Appendix B.
1.4 Where to find information
The material provided in this document is occasionally supported by material from the accompanying usb stick.
References made to the usb, are indicated by the [ :/] symbol, including the referenced path within the usb.
General citations are presented as a number in square brackets, e.g. [2], and a complete overview of citations is
provided in the back of this document.
In addition to the information in this document; the partner portal (login required) within
www.roeq.dk [2], contains
a wide range of information e.g. software updates, user guides, safety configurations, 3D CAD files and more. Contact
ROEQ technical support for access.
Support request to ROEQ technical support can be submitted via the support portal, following the link below:
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Section 1 Introduction
TM-Family
Original instruction manual (en)
Revision: 1.19
2 Safety
The following provides general safety instructions for operating the product. These must be carefully read before
installation and operation of the product. The instructions are additional to the safety instructions for the robot,
which are not repeated here but should be heeded at all times.
Further, always follow any site specific instructions or legislation concerning, e.g.
• use of personal protection equipment,
• emergency procedures in the event of fire or similar,
• etc.
Site specific safety concerns, not relating specifically to the product, are not considered in this document.
In addition to the general remarks provided below, concrete safety remarks pertaining to specific scenarios of operating
the product, are provided within the relevant section of this document.
Deviations from the safety precautions outlined below and in the remainder of this document, compromises the safety
assumptions, tests and designs conducted by ROEQ.
The integrator or end user responsible for the final installation of the ROEQ product, MiR robot and possibly other
machinery, must always perform a risk assessment of the full installation, and act on any identified issues not covered.
2.1 Safety principle
The basic safety functionality of the robot is not modified, and all safety functions such as personell detection, speed
monitoring, Emergency Stops (E-stops), etc. remain unaltered when installing the ROEQ product.
ROEQ products incorporate additional safety functions that operate alongside the safety system of the robot, e.g.
switching of safety zones.
The safety system of the ROEQ product starts with the sensors installed in the product itself, and ends with the
connection interface with the robot, i.e. the plugs connecting the robot and ROEQ product.
Suitable safety operation requires the robot to be installed with the correct safety configuration, e.g.
• to react appropriately to safety signals from the ROEQ product,
• to provide the correct safety information to the ROEQ product.
For the products covered by this document, proper safety operation requires updating the robot safety configuration
with an extended safety configuration provided by ROEQ, as part of the commissioning process, Section 6.3.
For more information on the robot safety system, refer to the MiR user guide.
For more information about the ROEQ safety features, consult Section 3.5 of this document.
2.2 General safety precautions
Use a fully functioning and serviced robot for integration
The robot used for integration with the product must be fully functioning and serviced in
accordance with specifications from MiR.
Residual risk:
• personal injury from collisions caused by faulty robot.
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Section 2 Safety
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Follow the robot operating instructions and safety limitations
The safety of the Top-Module is based upon the safety of a correctly operated robot.
Residual risk:
• personal injury from faults/malfunctions caused by improper robot operation
Follow guidelines for correct handling
Follow the guidelines in the Section 4 for correct handling and transporting the product
Residual risk:
• personal injury from ergonomic overload due to incorrect handling.
Ensure proper installation and commissioning of the product
The product must be fully and correctly installed as per the procedure of Section 5.
The product must be fully and correctly commissioned as per the procedure of Section 6.
Residual risk:
• personal injury from overturning robot, falling load, incorrect operation, etc.
Ensure proper mounting of load during locomotion
The transported goods must be meet the stability requirements outlined in Section 7
Residual risk:
• personal injury from overturning robot or falling load during locomotion.
Only transport approved cargo
The Top-Module must only be used to transport the cargo types outlined in Section 3
Do not use the Top-Module to transport people.
Residual risk:
• personal injury due to falling load during locomotion
Inform personnel about load transfer zones
Load transfer zones must be set up as Operating Hazard Zones (OHZs), as described in
Section 6.4.
Personnel working near an OHZ must be aware of this, and instructed to stay clear of the
robot during load transfer.
Residual risk:
• personal injury from collisions with cargo and/or robot.
Ensure proper training of personnel
The personnel involved in each task involving the Top-Module must comply with training
guidelines for that task, as indicated in Appendix A.
People and personnel in rooms/areas where the product is set to operate must at the very
least be informed about the presence of the product, and its basic operating principle.
Risk:
• personal injury from incorrect interaction with the product due to lack of training
to complete a specific task
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Section 2 Safety
TM-Family
Original instruction manual (en)
Revision: 1.19
Driving area must be suitable for operation
Make sure the area in which the Top-Module is used, complies with the specifications of
Section 6.
Avoid large gaps, grooves, steps, debree, etc. in and on the floor, as the load may become
unstable if the robot drives across such obstacles.
Do not operate the robot/Top-Module on sloped floors, as the load may become unstable.
Wet and uneven surfaces may cause the robot to skid.
Residual risk:
• personal injury from dropped or tipping cargo.
Environment must be suitable for operation
Respect the environmental limitations for operating the product outlined in Section 3.
Residual risk:
• faulty operation due to malfunctioning electrical equipment
Avoid leakage of fluid during transport
Make provisions to avoid leakages when transporting fluids.
Residual risk:
• personal injury from leaking fluid
• malfunctioning electrical equipment
2.3 Residual risks
In addition to the residual risks summarized in the documentation for the MiR robot, ROEQ has identified the
following potential risks that integrators must inform personnel about, and take appropriate measures to prevent:
• Getting hands and fingers crushed/pinched during mounting of the product.
• Getting limbs pinned, crushed, or severed between robot and carts during docking operations.
• Getting crushed by cargo if the robot or cargo overturns during transport.
• Getting feet run over by cart as robot begins to move.
• Losing control of the Top-Module if accessed by unauthorized users
– Consult the IT security guidelines of the MiR robot.
• Cargo dropping or robot overturning due to hazardous robot movement.
• Cargo dropping or robot overturning due to faulty placement of cargo.
2.4 Emergency situations
Emergency situations are highlighted in the following.
2.4.1 Emergency stopping
The Top-Module stops all movement whenever the MiR robot is put into E-stop.
The Top-Module is equipped with dedicated E-stops, see Section 3, to be used in case of emergency.
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Section 2 Safety
TM-Family
Original instruction manual (en)
Revision: 1.19
Proper operation of the E-stops requires the correct safety configuration.
The installed E-stops do not provide any direct stop of moving parts. Rather, they provide
a signal path to communicate an E-stop to the robot. Any action based on any E-stop
being thrown, must be governed by the safety system of the robot.
The proper safety configuration must be programmed into the robot prior to operation,
to ensure proper operation of the product safety features.
2.4.2 Applicable fire-fighting equipment
In case of fire involving the Top-Module, employ fire-fighting equipment suitable for electric systems corresponding
to the electric specifications of the Top-Module.
Personnel working near the Top-Module must be trained in operating firefighting equipment.
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Section 2 Safety
TM-Family
Original instruction manual (en)
Revision: 1.19
3 Machine overview
This section provides a general overview of the Top-Module.
TM-Family products are originally developed for MiR100 and MiR200 robots, but may be
similarly used on MiR250 when installed with a ROEQ AM250 adapter module.
This document focus primarily on the original MiR100 and MiR200 integration and use
of the Top-Module. For integration and use with MiR250, the AM250 documentation is
also required in addition to this document.
3.1 Intended use
The TMC300 and TML150 products are accessories for the MiR100 or MiR200 robots, allowing the robots to
transport ROEQ carts and racks between ROEQ docking stations, see Figure 1.
Figure 1: Top: ROEQ cart (left) and rack (right). Bottom ROEQ docking stations for
floor mounting (left) and wall mounting (right)
The TML150 product is similarly an accessory for the MiR100 or MiR200 robots, but is not intended for transporting
carts or racks, but rather individual pieces of cargo, e.g. crates or similar.
The Top-Module works in conjunction with the software embedded on the robot and acts as an extension of the
autonomous capabilities of the robot.
After correct installation and commissioning, the Top-Module can be used in conjunction with a MiR100 or MiR200
robot can be used to transport cargo from location to location, as specified by the user.
Different types of cargo can be transported by the various members of the TM-Family:
• TMC300
– With a TMC300 installed the robot can dock underneath carts placed at a docking station, and extend a
set of locking bolts, thus attaching itself to the cart as illustrated in Figure 2
– Once attached, the cart will follow the robot as it moves to a destination, where the cart can be dropped
off
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Section 3 Machine overview
TM-Family
Original instruction manual (en)
Revision: 1.19
Figure 2: Robot with a TMC300 may dock underneath carts transport them to a destina-
tion.
• TMR150
– The TMR150 is equipped with locking bolts allowing it to move carts similar to the TMC300
– The TMR150 is further equipped with a lifting mechanism allowing it to move racks by first latching on
to the rack using the locking bolts, and then lifting the rack off the ground for transport
• TML150
– The TML150 is equipped only with a lifting mechanism but no locking bolts
– The TML150 cannot be used to move carts or racks, but the lifting mechanism allows it move e.g.
individual crates
– A robot with a TML150 installed can dock underneath cargo inside a custom cargo station, raise the lifter
to pick up cargo, and transport it to a given destination, as illustrated in Figure 3
Figure 3: Robot with a TML150 may dock underneath and lift individual crates to transport
them to a destination. Illustration is shown with TML150 Forks which is an optional
accessory.
Each ROEQ Top-Module is compatible with MiR100 hardware version 2.0 and MiR200 hardware version 1.1 and
newer.
The TMC300 and TMR150 are not designed or intended to be used with carts, racks, docking stations, outside the
ROEQ product portfolio. ROEQ carts and racks are however intended to be extended by custom cargo carrying
equipment on top. ROEQ carts, racks, and docking stations compatible with TMC300 and TMR150 are described
in detail by Appendix D.
The TML150 is less restrictive and may be used with custom docking stations, pallets racks, etc.
3.2 Machine description
3.2.1 Main components
Figure 4 and Figure 5 summarize the main components of the Top-Module in conjunction with Table 1 and Table 2.
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A detailed elaboration of the functional aspects of sensors, motors, and various operating means are elaborated in
Section 6 and Section 7.
Figure 4: Main components of the Top-Module (Top view)
Nr. Description Nr. Description
1 Emergency stop button 2 Protective guard
3 Mounting bolt access plug 4 Wifi antenna
5 Top plate 6 Inspection plate
7 Threaded mounting hole 8 Lock bolt (If present)
9 Protective side fender
Table 1: The main components of the Top-Module as illustrated in Figure 4.
Figure 5: Main components of the Top-Module (Bottom view)
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Nr. Description Nr. Description
1 Soft-homing button 2 Safety reset button
3 Cable access 4 Safety zone bypass button
Table 2: The main components of the Top-Module as illustrated in Figure 5.
3.2.2 Electric connections
The Top-Module is connected to the robot using the cables as outlined in Table 3 and illustrated in Figure 6.
Left well Right well
1 Wi-Fi antenna cable 2 Ethernet cable
3 Power cable 4 E-stop cable
Table 3: The cables connecting the Top-Module.
Figure 6: Cables connecting the Top-Module to the robot: Wi-Fi antenna cable, ethernet,
power (4 pins) and E-stop (10 pins).
3.2.3 Identification label
The Top-Module is delivered with an identification label, located underneath the right, rear corner of the rollers the
rollers, on the downfacing side of the bottom plate, as indicated in Figure 7.
Figure 7: Location of the identification label.
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The content of the identification label is exemplified in Figure 8.
Product: ROEQ ApS Partly
TR500 Auto Kobbervænget 5 completed
HW rev.: 2.00 DK-5492 Vissenbjerg machinery
Electric diagram: 2.3.5 Made in Denmark 2021 2006/42/EC
S/N: 2.00268A550000010
1
Figure 8: Example of the Top-Module identification label. The identification number
various between individual models and units.
The product serial number is read as follows
S/N: 2.00 269A5000 00100
Sequential identification number
Internal product number
Hardware version
3.2.4 Employed materials
No hazardous materials are used in the construction of the Top-Module:
• The main mechanical parts are made from steel: Powder coated, galvanized, and stainless
• Other minor mechanical parts are made from Polyoxymethylen (POM)
• All electronics are RoHS compliant
3.3 Environmental specification
The product is only intended to operate in indoor, industrial environments near informed people and personnel, as
per the specifications of Appendix A.
The Top-Module should not be installed or operated in areas open to the general public.
The ground must be even, without slopes, steps or grooves. Further, the ground must be without significant amounts
of dust, dirt, and debris such as gravel, rocks, screws, etc.
Avoid placing docking stations on slopes.
Avoid driving in areas with obstacles and always keep all drive paths clean and free for obstacles.
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Only use product indoor.
The electronics of the Top-Module are not protected for outdoor operations.
The robot safety system is not designed for outdoor operation.
Risks:
• collision due to faulty robot safety system
• rain, snow and excessive dust or dirt may damage the product
Only use product in the intended environment.
Slopes, large gaps, grooves or obstacles on the ground may compromise the stability of
the Top-Module and cargo during locomotion.
Risks:
• cargo dropping to the floor
• robot turning over
Do not use Top-Module in explosive environments, sterile environments, etc.
The Top-Module is not designed to operate in these special conditions.
3.4 Foreseeable misuse
Any use or application deviating from the intended use stated in this document, is misuse of the product and must
be avoided.
This includes, but is not limited to:
• Incomplete commissioning of the robot and Top-Module
– Each step of the commissioning process described in Section 6 must be carefully followed, including the
safety system test, the validation of the cargo and environment, and the potential calibration of the
sensors.
• Omitting to make a risk assessment of the full installation
– ROEQ products are partly completed machines. As such, the final installation of the Top-Module, robot
and, potentially, other equipment, may pose site- or installation specific hazards that have not been
considered in the design and construction of neither robot nor ROEQ product. To comply with the
European machinery directive [1], a full risk assessment and CE-marking must be made after the final
machine installation is complete.
• Failure to maintain a suitable operating environment
– A suitable environment is crucial for safe and stable operation of the installation. The environmental
specification provided in Section 3.3 must be accommodated at all times.
• Attempting to transport inappropriate cargo or inappropriately packed cargo
– The safety measures and features incorporated in the Top-Module depends upon the transported cargo
obeying to the requirements of Section 3.6 and Appendix C
• Integration of TMC300 or TMR150 with non-ROEQ equipment
– Part of the safety surrounding the Top-Module lies in the joint design of Top-Module, carts/racks, and
docking stations. Using custom designed carts/racks or docking stations with a ROEQ Top-Module, is
outside the intended use.
• Omitting to test the safety system
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– To ensure continued operation of the installed safety features, the safety system of the robot as well as
the Top-Module must be tested yearly, as per the specifications of Section 8.2
• Failing to maintain the Top-Module
– Safe operation of the Top-Module is conditioned by the maintenance specifications of Section 8.
• Disregarding the proper training/information for people and personnel
– Proper training of people and personnel is an important aspect of the safety sorrounding the ROEQ
products. Proper training of people interacting with the Top-Module in different situations must therefore
always be ensured.
• Using the wrong safety configuration for the robot
– The safety of the Top-Module builds on the safety of MiR, so the correct safety configuration must be
running in the robot.
• Using the E-stops for anything other than emergency stops
– Unnecessary use of the E-stops incurs wear and tear which may affect their functionality in actual emer-
gency situations.
– Exception: Yearly verification of safety system must be conducted at as described by Section 8.2
• Lifting the product incorrectly by hand
– The product is heavy and should be handled acordingly. Use appropriate lifting techniques and equipment
for installing and dismantling the product.
Additional elements of foresseable misuse relating specifically to the robot, are summarized in the manual provided
by MiR.
3.5 Safety system
The Top-Module has an integrated safety system that functions alongside that of the robot.
The Top-Module safety system governs all identified, unacceptable risks relating to the product.
Risk reduction is obtained via the following Safety Functions (SFs), each with the indicated Performance Level (PL)
level with respect to DS/EN ISO 13849-1 [3].
Any residual risks related to the operation and use of the Top-Module, not governed by the safety system, is
summarized elaborated in this document, Section 2, 6, and 7.
3.5.1 Safety functions
• SF1: Extended safety zones - PL-level d
When transporting carts or racks, the safety zones of the robot are extended to account for the increased
footprint.
• SF2: Emergency stops - PL-level d
Contingency fail-safe.
3.6 Technical specifications
The physical properties of the Top-Module are summarized in Table 4, and the electrical properties are presented
in Table 5.
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Dimensions
Total length 800 mm
Total width 606 mm
Total height 75 mm/100 mm1
Total Weight (without load) 35 kg
Table 4: Top-Module technical specifications
Electric properties
Nominal operating voltage 24 V
Maximum steady current draw ≤ 10 A
Minimum operating temperature 5
∘ C
Maximum operating temperature 40∘ C
Maximum operating humidity (Non condensing) 85 %
Table 5: Top-Module electrical specifications and requirements.
3.6.1 Cargo requirements
The overall requirements for the cargo that may be transported by the Top-Module are summarized in Table 6.
Additional detailed requirements that must also be fulfilled are summarized in Appendix C
General cargo requirements
Maximum length 800 mm for all configurations
Maximum width 800 mm on carts and racks (Within cart/rack footprint)
606 mm directly on Top-Module (Within Top-Module footprint)
Maximum weight2 ROEQ cart (TMC300, TMR150): 150 kg (MiR100), 300 kg (MiR200 and
MiR250)
ROEQ rack (TMR150): 50 kg (MiR100), 150 kg (MiR200 and MiR250)
Individual crates (TML150): 50 kg (MiR100), 150 kg (MiR200 and MiR250)
Weight distribution Evenly across loading surface
Center of Mass (COM) in accordance to robot documentation
Table 6: General requirements to all types of cargo transported by the Top-Module
1Height is 100 mm for TML150 when raised, 75 mm for TML150 when lowered. For all other TM-Family products, the height is
75 mm
2Transporting and accurately docking with maximum weight may require additional effort or customization of robot or carts/racks -
See Section 10.2.14
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4 Transportation, handling and storage
The Top-Module must be transported, handled, and storred as described below.
4.1 Transportation and storage
The product must be transported within the provided transport box, or an equivalent enclosure.
During transport and storage, the environmental conditions of Section 3.6, Table 5, must be obeyed.
4.2 Handling
With respect to the training levels outlined in Appendix A, handling of the Top-Module
must be performed by authorized personnel, or trained personnel under supervision of
authorized personnel.
The Top-Module may be lifted and moved by hand, but care should be taken to employ correct lifting and carrying
techniques, and keep the Top-Module close to the body while carrying it.
Employ the appropriate Personal Protective Equipment (PPE), e.g. safety shoes, gloves,
etc. while handling and moving the Top-Module.
Do not lift the Top-Module by E-stops
The E-stops are likely to break if the Top-Module is lifted by pulling the E-stop knob.
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5 Assembly and installation
The process outlined in the following details the installation process of the Top-Module.
Be sure to read and follow the instructions of each step carefully.
If the Top-Module is being installed on a MiR250, the AM250 needs to be installed first. Consult the AM250
documentation for these steps.
For TMC300 and TMR150 on MiR100 or MiR200 it is recommended to install a ROEQ
Spring Kit and Weight Kit on the robot. If the payload on the cart exceeds 100 kg, the
ROEQ Spring Kit Plus should be used instead. For high payload, slippery floor or cargo
larger than cart footprint, the ROEQ Wheel Kit is recommended for the carts.
For TMC300 and TMR150 on MiR250 with AM250 it is recommended to install a MiR
Traction Kit. For high payload, slippery floor or cargo larger than cart footprint, the
ROEQ Wheel Kit is recommended for the carts.
With respect to the training levels outlined in Appendix A, assembly and installation
must be performed by authorized personnel, or trained personnel under supervision of
authorized personnel.
Installing top module
Step Instruction and Illustration
1. 1. Remove the foam sheet from the top of the Top Module and remove the inspection plate by un-
screwing the T20 bolts highlighted on the illustration.
2. When the inspection plate has been dismounted, remove the yellow cable tie to free the 4 Top
Module cables.
• The layout of the internal electronics underneath the inspection plate varies between product
models, and may not coincide completely with the presented illustrations.
Never lift the Top Module up by using the Emergency Stop. Due to the size and weight of
the Top Module it is recommended two persons to lift the Top Module up from the packaging
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2. • Carefully lift the Top Module from the crate and place it on an elevated platform (e.g. a table or
pallet) to access the underside of the Top Module.
3. • Remove the 4 bolt-access cover plugs by using a large flat-tip screwdriver.
4. • Remove the 4 white plastic M10 top nuts from the pre-mounted M10 bolts.
5. 1. Turn off the robot
2. Disconnect the battery
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6. 1. Place the Top Module on top of the robot
2. To connect the 10-pin connector and Wi-Fi antenna cable, the Top Module must initially be placed
slightly towards the front of the robot, when installed on a MiR100 or MiR200, as illustrated until
adequate accessibility has been obtained.
When installed on a AM250, the Top Module can be placed directly on top of the AM250.
7. • When the two cables have been properly connected, carefully slide the Top Module towards the rear
end of the robot until the ethernet- and 4-pin connectors align with the Top Module base plate
cut-out as illustrated.
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8. 1. Fasten the Top Module to the robot by tightening the four pre-mounted M10 bolts highlighted on
the illustration using 6mm hex key.
2. Carefully connect the 4-pin and ethernet connector to the robot interface.
9. • After tightening the bolts and mounting all cables reinstall the 4 bolt-access cover plugs into the
holes in the top plate and remount the inspection plate.
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10. • After installation of the Top Module, the safety reset button, emergency stops and Wi-Fi antenna
are now accessible from the front and rear of the Top-Module
11. • Reconnect the robot battery
• The robot can be turned on when needed
Installing docking stations
ROEQ docking stations must be installed at all locations where the robot/Top-Module is intended to pick up or drop
off carts/racks/cargo.
The process for installing ROEQ docking stations, both floor and wall mounted (see Appendix D), is described below.
Step Instruction and Illustration
1. Fasten the docking station firmly to floor or wall.
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2. For floor mounted docking stations:
• The docking station must be anchored to an even and smooth surface
• The docking station must be installed parallel to the floor and leveled vertically
3. For wall mounted docking stations:
• The docking station must be anchored to an even wall
• The docking station must be leveled vertically
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4. • The bottom plate of the docking station has 6xØ8,2 mm anchor holes.
• To access these, the back plate of the Docking Station must be removed.
5. If manual undocking is needed, turn the two handles on the back of the Docking Station 180∘
and pull
the Cart away from the Docking Station.
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6 Commissioning
The commissioning process is an important part of setting up the Top-Module and verifying that it operates in the
desired manner, and that all safety features function as intended.
With respect to the training levels outlined in Appendix A, commissioning must be per-
formed by authorized personnel, or trained personnel under supervision of authorized
personnel.
The mandatory steps of the commissioning are:
• Section 6.1 - Prepare the environment
• Section 6.2 - Perform a risk assessment
• Section 6.3 - Robot safety configuration
• Section 6.4 - Prepare load transfer zones
• Section 6.5 - Prepare robot docking location
• Section 6.6 - Prepare robot parameters
• Section 6.7 - Verify cargo fitness
• Section 6.8 - Verify safety system
• Section 6.9 - Create cargo transfer missions
• Section 6.10 - Testing docking sequence
6.1 Prepare the environment
Inspect the environment in which the Top-Module and robot are intended to operate. Remedy any deviations from the
intended environment outlined in Section 3.3, while also respecting the environmental requirements and constraints
of the MiR documentation.
It must also be verified that openings, doorways, etc. has an appropriate width and height to allow for sufficient
clearance when the robot passes. This must account for the height of the robot itself, as well as the height of
Top-Module and transported cargo.
6.2 Perform a risk assessment
As the Top-Module is a partly completed machine, it is necessary to make an overall risk assessment of the complete
application within which the Top-Module is integrated, as well as the environment it will be operated in.
This is to maintain safety when all individual components are joined together in an overall installation.
The final risk assessment is the responsibility of the commissioner.
ROEQ does not take any responsibility for the performance of the risk assessment, but
we provide information and guidelines that may be used in this section.
It is recommended that the commissioner follows the guidelines in DS/EN ISO 12100:2011 [4], or a similar relevant
standard to conduct the risk assessment.
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The risk assessment must be used to determine any additional safeguards, markings, access restrictions, etc. required
in addition to what is already provided by the product, in order to ensure safety of the personnel around the Top-
Module.
The risk assessment should at least consider the need for:
• Access restrictions around load transfer zones
• Safety distances around the Top-Module
• Additional markings or pictograms or warning signs
• Information for users and where to keep it
6.3 Robot safety configuration
To allow the robot to to transport carts and racks, the safety configuration of the robot must be updated to the
safety configuration provided by ROEQ.
This is both to prevent collisions caused by the increased size of the robot when attached to a cart/rack, but also to
prevent the legs of the cart/rack to trigger the default safety zones of the robot, and force it into safety stop.
Updating the safety system is only relevant for TMC300 and TMR150.
The TML150 does not require an update of the safety system since this cannot be used
to transport carts and racks.
The steps in section Section 6.3 goes through the setup for MiR100 and MiR200, for
MiR250 with AM250 follow the guide located on the ROEQ Partner Portal or enclosed
on the USB-drive:
[ :/SICK/ROEQ_ safety/]
When the robot safety system is updated, the ROEQ top module will automatically change the safety zones during
operation, in the sense that when the robot drives without cart or rack, the standard safety zones are used, but when
driving with cart or rack, a set of enlarged safety zones are used.
The default and modified safety zones are illustrated in Figure 9.
Updating the robot safety system
The safety system of the Top-Module requires that the SICK safety configuration of the
robot is updated to incorporate additional features exposed by the Top-Module.
Read this section carefully and be sure to perform the safety system update as described.
The process of updating the safety configuration is illustrated in a video enclosed on the USB-drive:
[ :/Video/]
6.3.1 Connecting to the Sick Safe laser scanner system
The robot laser scanners are interfaced with proprietary software.
Therefore, to access the scanners and robot safety system in general, the programs “Sick Flexi Soft Designer” and
“Sick CDS” must be installed on the PC used for the updating the safety configuration.
All software necessary for the implementation of the Top-Module is included on the enclosed USB-drive.
6.3.2 Setting up COM settings
This section describes the procedure for getting connected to the Sick Safe laser scanner system.
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Figure 9: Left: The default safety zones of the robot. Right: The extended safety zones
activated when transporting carts/racks.
Step Instruction and Illustration
1. Turn on the intended MiR robot and log onto the corresponding WiFi network.
2. Copy the content of the USB-drive to the hard-drive on the PC.
3. From the SICK folder copied in step 2, install Flexi Soft Designer and CDS
4. Start the program Sick Flexi Soft Designer from the PC.
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5. A connection must be configured to connect the PC to the scanners.
Start the connection setup by clicking “Com settings”.
6. The connection settings window will appear. A TCP/IP connection is required between the PC and
the scanners.
Click “Add TCP/IP connection profile”.
7. To create the new profile, fill out the entry name and set the IPv4 address to 192.168.12.9, which is
the IP of the scanners.
Click “OK”.
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8. Click the check mark to test the connection. When the connection is accepted, mark the connection
as default by double clicking the connection.
Click “OK” to terminate the setup.
6.3.3 Taking backup of existing scanner configuration (recommended)
This section describes the procedure for taking backup of existing Sick configurations before transferring the ROEQ
Sick configuration from the enclosed USB-drive to the Sick Safe laser scanner system.
It is highly recommended to back up existing safety zones from the Main Module and
both Front- and Rear laser scanners before transferring the new safety zones.
Step Instruction and Illustration
1. Click “Connect” to connect to the main Module.
When the connection is done (takes some time), the SICK main Module will be ready for doing the
backup.
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2. Select YES to: Do you want to upload the configuration on “SICK Flexi Soft main module FX3-CPU1”?
3. Double click the front laser (S300.CPU1[0].EFI1.1)
4. Select “Read configuration from device”
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5. Double click the rear laser (S300.CPU1[0].EFI2.1) and repeat step 4 to take backup of the rear scanner
configuration
6. Finally select “Save as” in the project drop down window and save the original configuration on the
PC.
6.3.4 Transfer ROEQ safety configuration
This section describes the procedure for transferring ROEQ configurations from the enclosed USB-drive to the Sick
Safe laser scanner system.
It is highly recommended that the files stored on the enclosed USB-drive are saved in a local folder on the PC used
for the SICK setup, before continuing with the following step.
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The steps described in the following may vary depending on the hardware version of
the robot. Therefore, deviations from the outlined process may not constitute an error
scenario.
Read any pop-up messages - Usually the provided information is sufficient to determine
how to proceed.
Step Instruction and Illustration
1. From the SICK folder copied previously, unzip the safety configuration suitable for your robot model
and serial number.
2. From within the Flexisoft Designer, open the provided ROEQ safety configuration for the SICK system:
Project → Open → choose the project unzipped above.
The correct file to upload must be chosen based on robot model and serial number.
3. Click “Connect” to connect to the main Module. When the connection is done, the SICK main Module
will be ready for transferring the desired safety zones.
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4. Click “Transfer the configuration” to transfer the new safety zones to the main Module and the two
S300 laser scanners.
5. Make sure that both S300 scanners and the main Module are marked and click “OK”.
For older robots, the default password for uploading safety configurations is: SICKSAFE
For newer robots, a custom password is provided with the robot documentation
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6. Verify the configuration protocol carefully for both scanners and proceed by clicking “Release”. These
can be saved if needed.
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7. Click “yes” to download the new configuration and run the new head device.
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8. Verify the new checksum by clicking “yes”.
9. Mark the option for Authorized Client user group and click “OK”.
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10. Select “Upload and verify result” and “Yes” to finalize the process.
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11. Select “Disconnect” before closing down the program.
The robot safety system has now been configured with the ROEQ safety configuration.
6.4 Prepare load transfer zones
As described in the summary in Section 2.3, there is an increased risk of getting crushed, pinned, etc. around the
Top-Module and external conveyor system during load transfers.
As per DS/EN ISO 3691-4:2020 [5] the area around the load transfer zones is classified as OHZs and must be clearly
marked with signs, paint, floor-tape etc. as exemplified in Figure 10.
Figure 10: Load transfer areas must be marked as OHZs, e.g. using tape, paint, signs,
etc. The image is illustrative and does not represent an actual, compliant OHZ.
Further, personnel must be instructed to stay clear of operating hazard zones when a robot is approaching for
Top-Module cargo transfer.
The OHZ must have an escape route of at least 50 cm on both sides to other fixed obstacles, walls, etc., as illustrated
in Figure 11.
The specific size of the OHZs should be based on the risk assessment c.f. Section 6.2.
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Operating hazard zone
Escape route
Escape route
Walls/Obstacles
Walls/Obstacles
Robot w.
Top Module
Docking station
Figure 11: There must be a suitable escape route around the load transfer zones, both
when approaching docking stations to pick up and drop off cargo.
6.5 Prepare robot docking location
For the robot to automatically pick up carts/racks/cargo, the installed ROEQ docking stations must be made available
in the robot map, by the following procedure:
Step Instruction and Illustration
1. • Drive the robot manually to the desired docking station.
– The robot needs to be within approximately 1 meter of the VL-marker installed in the docking
station.
2. • Use the built-in MiR function to create a marker
– The icon can be found at the top of the MiR map.
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3. • Under “Type” choose VL-marker
• Use the “Detect marker” button in the bottom of the window to detect the VL-marker.
• Add a name to the marker of the form: roeq_docking <position name> <position type>
– The name must start with “roeq_docking”
– The name must end with a position type, e.g. “cart”, “rack” or “lifter” depending on
the type of installed equipment
– The <position name> can be an explanatory name of the position
– Example: ROEQ_Docking warehouse cart
6.6 Prepare robot parameters
For having a functional installation a few parameters needs to be adjusted in the robot interface as described in the
following. s
Step Instruction and Illustration
1. • Log on to the robot Wi-Fi
• Access the robot web interface through a browser at either
http://mir.com or alternatively
• Log in using an account with “distributor” permissions
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2. In the robot interface, navigate to
• System → Settings → Docking
• Click “Show advanced settings”
3. • Type in the value 2 under “Distance to marker for disabling collision checks.”
• This will allow the robot to dock to a Docking Station when equipment is attached.
4. • Type in the value 0.01 under “Parameter for driving more straight during docking”
• This will ensure that the robot drives more straight while docking.
5. • Type in the value 1.5 under “Relative move target when docking to markers.”
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6. Only for MiR250/AM250 installations:
• Type in the value 1.5 under “Distance to VL-marker before muting front protective fields”
• This will mute the front safety zones before the robot drives under the cart/rack.
• This is required, since the smallest safety zone is wider than the cart/rack.
6.7 Verify cargo fitness
Before using the Top-Module to transport cargo, the cargo itself must be verified to be suitable for transport in terms
of the requirements laid out by Section 3.6.
6.7.1 Stability during transfer and transport
Verify that the mechanical properties of the cargo is within the specified limits.
Verify that the load distribution are within the COM specifications of MiR.
Verify that the load is sufficiently secure and stable to not tip over during locomotion.
6.8 Verify safety system
The funtionality of the safety system in terms of the SFs introduced in Section 3.5.1, must be verified as part of the
commissioning of the Top-Module.
The test procedure along with acceptance/rejection criteria are summarized in Appendix F.
The functionality of the safety system must be verified prior to first use of the product.
6.9 Create cargo transfer missions
Operating the Top-Module from the MiR interface, requires missions to be called for load and unload operations are
the locations prepared in Section 6.5.
The process of generating the individual missions, has been fully automated using the ROEQ mission tool “ROEQ
Assist”, as described below.
To generate missions on the robot the ROEQ tool must employ the correct login creden-
tials.
Consult Section 10.2.2 if the default login credentials of the robot have been modified.
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Step Instruction and Illustration
1. • Log on to the robot WiFi
2. • Run the ROEQ program supplied in the USB stick
3. • Choose “Add new docking station”
4. • Select the appropriate product in the drop down menu
• Click “Create equipment”
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5. • Select the desired station from the drop down list
– The list shows the docking positions within the active map of the robot, that complies with
the naming convention of the selected product
• Click the “Create docking station” to generate missions for the selected docking position
• Alternatively, select “Create all stations” to generate missions for all docking positions
• Be careful not to select “Delete all stations” as all missions will be removed from robot
6. • Redo steps 3 through 5 for each docking position
• Alternatively, use the “Create all stations” option in step 5
The docking station (docking points) generated here are only stored in the active map on the MiR
robot. If multiple maps are used docking points must be generated in the individual maps/sites.
6.10 Testing docking sequence
To achieve the precise dockings required to pick up and return a cart, the global offsets
for the robot needs to be adjusted. The global offsets are individual for all robots.The
steps of updating the offsets are covered in Section 10.2.11. To automatically calculate
the offsets with the ROEQ Assist, the misalignment needs to be measured following the
steps in Appendix G.
When docking positions have been created (Section 6.5), robot parameters have been adjusted (Section 6.6), cargo
missions have been created (Section 6.9) and the global offsets have been adjusted (Appendix G), it is recommended
to verify that the docking procedure for getting and returning cargo functions as desired.
The process is as follows:
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Step Instruction and Illustration
1. • Drive the robot to a random position a few meters away from the VL-marker.
• Use the joystick function of the robot interface
2. • Make sure a cart or rack is present in docking station to be tested
• Run the “Get” mission for the docking station - See Section 7.2
• The robot will get the cart/rack
– Wait for the robot to finish the “Get” mission
3. • Drive the robot to a random position a few meters away from the VL-marker.
• Use the joystick function of the robot interface
4. • Make sure that no cart or rack is present in docking station to be tested
• Run the “Return” mission for the docking station - See Section 7.2
• The robot will get the cart/rack
– Wait for the robot to finish the “Return” mission
If either “Get” or “Set” mission fails, consult Section 10 for troubleshooting assistance.
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7 Operation
Following installation and commissioning of the Top-Module, it may be put to use through the missions generated
in Section 6.9.
With respect to the training levels outlined in Appendix A, operation may be conducted
by authorized or trained personnel.
7.1 Integration with robot interface
The process completed in Section 6.9 generates a number of missions and mission groups in the MiR interface as
illustrated in Figure 12. These missions must be used when operating the Top-Module.
Figure 12
Depending on the types of equipment interfaced by the installed Top-Module, a total of up to 4) new mission groups
are created.
1) “ROEQ TMC300”
This group contains all missions for getting and returning carts. For each docking position created in Section 6.9,
there will be a “Get” and a “Return” cart mission.
2) “ROEQ TMR150”
This group contains all missions for getting and returning racks. For each docking position created in Sec-
tion 6.9, there will be a “Get” and a “Return” rack mission.
3) “ROEQ TML150”
This group contains all missions for getting and returning individual creates. For each docking position created
in Section 6.9, there will be a “Get” and a “Return” mission.
4) “ROEQ Utility”
This group contains missions that are needed for the Top-Module to function, but does in general not need to
be called directly by the user
Notice that
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• “cart” missions will only operate the locking bolts of the top-module. These missions can thereby be executed
by TMC300 as well as TMR150, even though the missions are only present in the “ROEQ TMC300” mission
group.
• “rack” missions will operate both locking bolts and lifting mechanism. These missions can thereby only be
executed by TMR150
• “lifter” missions will only operate the lifting mechanism of the top-module. These missions can thereby be
executed by TML150 as well as TMR150, even though the missions are only present in the “ROEQ TML150”
mission group.
7.2 Running Get and Return missions
The generated “Get” and “Return” missions contains the following elements:
1. Navigate to the intended docking station
2. Pick up or drop off the cargo: Cart, rack, or crate
3. Adjust the footprint
4. Un-dock from docking station
Since the missions include an initial navigation procedure, they can be called from anywhere in the map.
The footprint adjustment in Step 3 is to let the robot navigation algorithm account for the correct dimensions of the
robot and cargo, when planning a path around the map. This means that:
• The footprint is increased when picking up carts or racks
• The footprint is shrunk when dropping off carts or racks.
7.2.1 Operating status
The status of the operation is reflected in several of the robot Programmable Logic Controller (PLC) registers,
accessible through the robot interface via: System → PLC registers.
The use and meaning of the various registers is summarized in Appendix E.
7.2.2 Error checking
The TMR150 and TMC300 are both equipped with a cargo sensor to detect whether a cart is present before extending
the locking bolts. The sensor is located on the right side of the top-module, towards the rear.
The sensor is illustrated in Figure 13.
If a “Get cart” or “Get rack” mission is called for a location where no cart or rack is present, the Top-Module will
issue an error.
7.3 Contingency operation
In addition to the intended operation outlined in Section 7.1, the following elements of contingency operation should
be noted.
7.3.1 No movement during safety stop
The Top-Module is designed so that power to the motors driving locking bolts and lifting mechanism is disconnected
while the robot is either emergency stopped or safety stopped, e.g. if the laser scanners are obstructed.
In that way, no movement of neither lifter nor locking bolts should be expected when a safety exception is stopping
the robot.
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Figure 13: The cargo sensor used to detect whether carts and racks are present before
pick up.
If the Top-Module is conducting a movement involving either lifting mechanism or locking bolts as the power is
disconnected, the PLC inside the Top-Module will perform a “soft-homing” operation when the power is restored.
Soft-homing entails that the locking bolts or lifting mechanism is slowly contracted or lowered respectively.
7.3.2 Manual soft-homing command
If for whatever reason the bolts or lifter needs to be contracted or lowered, respectively, a soft-homing operation can
be issued manually. This is done by pressing and holding the “Soft-homing button” indicated in Figure 5.
7.3.3 Safety zone override
When the locking bolts are not fully contracted, the robot safety system is triggered to enable a larger set of safety
zones to account for the increased size and braking distance of the robot while transporting carts and racks.
If necessary, the safety zone selection can be overridden to allow the robot to employ the regular safety zones even
though the bolts are extended. This is achieved by pressing and holding the “Safety zone bypass button” indicated
in Figure 5.
The zone override is only active as long as the button is pressed. As soon as the button is released, the safety zones
will be selected following the actual position of the bolts.
7.4 Safety during operation
The safety system of the robot as well as the safety functions described in Section 3.5 will override operation of the
robot and Top-Module, in any situation where safety is compromised.
This includes, but is no limited to the scenarios outlined in Table 7.
Ensure stability and load distribution of the transported cargo
The Top-Module cannot measure the position or stability of the cargo, neither on top of
carts, racks or the top-module itself.
The user must verify that cargo allows for stable locomotion, also in case of turns or
abrupt stopping.
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Scenario System responese
An E-stop is thrown at any time The E-stop is mitigated from robot to Top-Module, and
vice versa.
A person steps in front of the robot while driving The safety scanners detect the person and stops the
robot.
The robot has increased braking distance when driving
with heavy carts or racks
The ROEQ safety configuration has extended safety
zones designed for increased stopping distance while
driving with carts/racks.
Table 7: Exemplified fault scenarios governed by the safety system of the robot and Top-
Module.
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8 Maintenance, inspection and cleaning
8.1 Regular maintenance and cleaning
With respect to the training levels outlined in Appendix A, regular cleaning must be
performed by authorized or trained personnel.
Turn off the robot and disconnect the battery before cleaning the product.
Avoid aggressive or abrasive cleaning agents.
Avoid excessive amounts of water when cleaning.
Part Procedure Interval
Top Module
General Clean on the outside with a damp cloth.
Do not use compressed air or pressure cleaning.
As needed
Side wear
protection plate
Inspect for damage.
Consult ROEQ for replacements
Every month / as needed
Carts
General Clean on the outside with a damp cloth.
Do not use pressure cleaning.
As needed
Wheels Remove dirt with damp cloth.
Make sure the wheel rotation is not hindered.
Inspect wheel for damages and deformations
Every month/as needed
Locking
mechanism
Ensure correct functionality of the internal spring
activated lock arm.
Every month/as needed
Racks
General Clean on the outside with a damp cloth.
Do not use pressure cleaning.
As needed
Adjustable feet Remove dirt to ensure level placement on the
floor.
Every month/as needed
Docking stations
General Clean on the outside with a damp cloth.
Do not use pressure cleaning.
As needed
Table 8: Regular maintenance and cleaning of the Top-Module and carts/racks.
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8.2 Verifying safety functionality
With respect to the training levels outlined in Appendix A, safety system verification
must be performed by authorized personnel, or trained personnel under supervision of
authorized personnel.
A test of the safety functions presented in Section 3.5.1 must be conducted yearly to verify continued functionality
of the various safety measures.
The test procedure along with acceptance/rejection criteria are summarized in Appendix F.
If a safety functionality has been inadverdently activated as part of day-to-day operation,
that function may be excempted from additional verification, e.g. if an E-stop is known
to have been used during an emergency.
As none of the installed safety measures are intended to be activated by normal operation,
it is however expected that all safety functions should undergo yearly verification.
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9 Decommissioning
The procedures to follow during decommissioning of the product are provided in the following.
With respect to the training levels outlined in Appendix A, decommissioning must be
performed by authorized personnel, or trained personnel under supervision of authorized
personnel.
9.1 Disabling and dismantling
Turn off the robot and disconnect the battery, as similarly described for the installation process in Section 5.
The Top-Module can then be dismantled and removed by following the reverse procedure for installation as detailed
in Section 5.
9.2 Scrapping
The Top-Module must be discarded in accordance with the applicable legislation at the time and location of where
the product is being scrapped, with respect to the materials comprising the product as outlined in Section 3.2.4.
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Original instruction manual (en)
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10 Troubleshooting
This section is provided in support of Section 6 and Section 7 to provide additional troubleshooting suggestions in
case of contingency events.
With respect to the training levels outlined in Appendix A, troubleshooting may be con-
ducted by authorized or trained personnel.
10.1 General
This initial section provides information about the general support tools:
• The ROEQ support portal: For submitting request to ROEQ technical support
• The Top-Module System Diagnostic Manager (SDM): For easy access to general system inforation and logs
10.1.1 ROEQ support portal
Technical questions and support requests can be submitted via the ROEQ support portal:
10.1.2 System diagnostic manager
ROEQ employs a web-interface native to the PLC integrated in the Top-Module, to obtain further diagnostic infor-
mation about the system state.
The SDM allows the user to:
• Obtain basic information about the system, product type, product version
• Inspect individual inputs and outputs of the PLC
• Inspect product logs
• Extract a system dump for ROEQ support.
The SDM is illustrated in Figure 14, and can be accessed from the robot network, via the web address:
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Figure 14: Frontpage of the SDM. The menu to the left allows the user to obtain detailed
information about the system.
The various elements of the SDM are accessed via the left menu shown in Figure 14.
Acessing logs
The logs are accessed via the “Logging” button in the menu of Figure 14.
From the drop-down of the resulting “Logging” screen, all the logs of the top module can be accessed - See Figure 15
Figure 15: Logger page of the SDM.
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Extracting a system dump
ROEQ technical support would typically request a system dump to diagnose any errors or misbehavior of the Top-
Module. The system dump includes all information about the system, including all the log files.
To extract a system dump go through the following procedure:
Step Instruction and Illustration
1. • Connect to the robot Wi-Fi
– It must be the robot Wi-Fi as the PLC cannot be reached from e.g. a fleet network
2. Click the button labelled System Dump
3. 1. Click Ok
2. In the pop-up select Parameters + Data-files, and click Ok
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4. 1. Choose Upload from target
2. Save the generated file, and include it in the ROEQ support ticket
Inspecting IO values
The value of each input and output of the PLC can be inspected via the SDM.
This can for instance be used to check sensor values or logical outpus governing motor operation etc.
Step Instruction and Illustration
2. Click the button labelled “Hardware”
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2. 1. Within the hardware tree, expand the “IF6” group to show all installed modules
• The number and type of installed modules vary greatly between ROEQ products and may not
be as illustrated in the image
2. Select a given module for which IO information is needed
3. In the bottom of the screen, click the “+” sign next to “IO Info”
3. 1. In the expanded “IO Info” frame information is available for e.g.
• Value of digital inputs (DigitalInputXX)
• Value of digital outputs (DigitalOutputXX)
2. Use the scrolbar to the right to scroll through all available information
10.1.3 Register values and error codes
All communication between robot and the Top-Module goes through the PLC registers of the robot interface.
The use and meaning of each register is presented in detail in Appendix E.
For troubleshooting it is sometimes helpful to examine any potential error code (register 3) and cross reference with
the description of each error in Appendix E.
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10.2 Troubleshooting cases
Table 9 outlines some general troubleshooting scenarios and suggested approaches for resolving various issues.
Users are always welcome to submit support request through the ROEQ support portal (Section 10.1.1), although
in some cases, a faster solution or narrowing of the issue can be obtained by going through the suggestions provided
below.
Therefore, it is recommended to attempt the suggestions provided below when experiencing a given issue, and include
any experiences of doing so if a support ticket is submitted.
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Sympton Potential cause Potential remedy
Cannot connect to robot safety system IPv6 confusion Disable IPv6 - Section 10.2.1
ROEQ Assist connection issue Modified distributor account Update credentials - Section 10.2.2
Unspecified error Extract log file - Section 10.2.3
ROEQ product does not respond PLC is in not in RUN mode Verify operating mode - Section 10.2.4
Modified distributor account Update credentials - Section 10.2.2
Cabling issue Inspect PLC and cabling - Section 10.2.5
Lost calibration Calibrate top module- Section 10.2.9
Robot stuck in E-stop E-stop button pressed Release E-stops - Section 10.2.6
Safety zones obstructed Clean scanner covers - Section 10.2.7
Incorrect fields selected Ensure correct field selection - Section 10.2.8
Wrong safety configuration Ensure that the correct safety configuration is
used - Section 10.2.10
Docking fails when picking up or dropping off
carts/racks
Global docking parameters need adjustment Adjust parametes for global docking - Sec-
tion 10.2.11
Laser scanners needs recalibration recalibrate the laser scanners - Section 10.2.12
Position specific docking offsets need adjsut-
ment
Adjust offsets for affected positions - Sec-
tion 10.2.13
Issues with traction Improve traction of robot - Section 10.2.14
Table 9: The most common troubleshooting scenarios and references to possible remedies.
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10.2.1 Disable IPv6
If Flexi-Soft cannot find the Safety PLC with the “Scan devices” function, it may be required to disable IPv6 in the
properties of the network adapter.
The process of doing so depends on the version and language of windows, but the following outlines the regular
approach in Windows 10:
1. Go to Control Panel→Network and Internet→Network Connections
2. Right click on the network adapter connected to the robot
3. Select “Properties” and de-select “Internet Protocol Version 6 (TCP/IPv6)”
4. Select “OK”.
Then try to “Scan devices” in Flexi-Soft again.
10.2.2 Update log-in credentials
Both ROEQ Assist and the PLC inside the top module require distributor level access to the robot in order function.
By default it is assumed the the distributor:distributor account is available, but if the username or password
has been modified, the credentials needs to be updated in ROEQ Assist and PLC as well.
Identification
This issue may be identified in several ways:
• When launching ROEQ Assist, incorrect login credentials are illustrated by a warning message as exemplified
in Figure 16.
• When accessing the logs in the SDM, a warning message indicating an HTTP error number 401 will be printed
– Depending on the age of the specific product, the warning may be printed in either the “roeq” log, or
the “roeq_ComS” log
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Figure 16: ROEQ Assist detects when the default credentials are incorrect.
Solution
From the ROEQ Assist, the correct username and password can be provided in the login screen illustrated in Figure 16
Remark: If the updated credentials should be stored in the top module PLC, the “Also update PLC” option must
be activated.
10.2.3 Extract ROEQ Assist operating log
In case of unspecified errors or issues involving the ROEQ Assist, a log file should be extracted and included in the
support ticket sent to ROEQ support.
The logs are extracted as follows:
Step Instruction and Illustration
1. Navigate to the location of the ROEQ Assist “.exe” file
2. Open the adjacent “Resources” folder
3. The folder contains up to 5 log files:
• roeq_log_1.txt: Log file for the most recent use of the program
• roeq_log_2.txt: Log file for the second to last time the program was used
• . . .
• roeq_log_5.txt: Log file for the fifth from last time the program was used
4. Include roeq_log_1.txt in the ROEQ support ticket.
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10.2.4 Verify PLC operating mode
For proper operation, the PLC inside the top module must remain in “RUN” mode. Various events may cause the
PLC to enter an alternative operating mode.
The operating mode can be determined from the frontpage of the SDM as illustrated in Figure 17.
Figure 17: Operating mode of the top module PLC
The PLC must be in “RUN” mode to function. If it enters eitehr “SERV” or “DIAG” mode, it will not communicate
with the robot.
In this case the robot must be rebooted the get the PLC back into regular operation.
Contact ROEQ support if the issue reoccurs.
10.2.5 Inspect PLC and cables
To inspect the cables and the PLC itself, follow the procedure:
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Step Instruction and Illustration
1. Remove the inspection plate from the top module
The layout of the internal electronics underneath the inspection plate varies between product models,
and may not coincide completely with the presented illustrations.
2. Inspect all cables and wires:
• There should be no loose wires or cables
• All cables should be firmly connected
3. Inspect the PLC Light Emitting Diodes (LEDs):
• The “R/E” light should be solid Green
• The “IF2/ETH” light blink green
10.2.6 Emergency stop issued by product
The Top-Module is installed with E-stops that may prevent the robot from moving if any of the E-stop buttons on
the Top-Module are activated.
This situation may be identified in the MiR interface under the menu:
“Monitoring ⇒ Hardware health ⇒ Safety system ⇒ Emergency stop”
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In case of an emergency stop, the MiR interface will read:
“Robot is in Emergency stop (Shared E-stop engaged)”,
or alternatively:
“Robot is in Emergency stop (Release button needs to be pressed)”,
if the E-stop has been released but the reset button has not been pressed. Both scenarios are illustrated in Figure 18.
Figure 18: Messages in the MiR inteface when the Top-Module enforces an E-stop: Top:
When the E-stop is still mechanically activated. Bottom: When the E-stop is released,
but the reset button needs to be pressed.
For reference, if either of the E-stops installed on the robot itself are activated (instead of those installed on the
Top-Module), the message in the robot interface will be:
“Robot is in Emergency stop (E-stop button pressed)”,
Recovery procedure
To lift an E-stop, all of the red E-stop actutors installed on the robot and Top-Module must be in their released
state. An active E-stop is released by rotating the actuator clock-wise.
When all E-stops are released, the “reset” but on the robot will start flashing and must subsequently be pressed.
The E-stop condition will then be lifted and the robot will be operational, provided that no other safety stops are
enforced, e.g. by the Top-Module or from the laser scanners.
Remarks
During a E-stop, power cannot be restored to the any movable parts within the Top-Module, so in this case, all
E-stops must be resolved before any movement can be obtained.
10.2.7 Clean laser scanner covers
If the cover of the laser scanners get dirty or dusty, the edge of the safety fields may get “blurry” and accidentally
trigger a safety stop of the robot.
Use a dry or damp cloth to clean the scanner covers, all the way around - Refer to the robot documentation.
10.2.8 Verify safety field selection
If the wrong safety zones are activated at a given time, the robot will go into safety stop in seemingly unexplainable
situations.
This may happen in different ways:
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• If the “regular” safety zones are activated while driving with a cart/rack, the robot will exhibit “jerky” behavior:
– When accelerating, the robot will be safety stopped
– When the robot stops, the safety stop is lifted and the robot may start to drive
• If the “cart” zones are activated while driving without a cart the robot will be safety stopped whenever
– It docks underneath a cart/rack that should be picked up
– It undocks from underneath a cart/rack it has just placed
Identification
The problem can be identified by the following procedure:
Step Instruction and Illustration
1. Log on to the robot Wi-Fi
2. Open the Sick configuration software “Flexi Soft”
3. Click “Connect” to connect to the main Module.
• If no connection has been configured, follow the process outlined in Section 6.3.2
4. Select “YES” to when prompted:
Do you want to upload the configuration on “SICK Flexi Soft main module FX3-CPU1”?
5. In the robot interface, run the ROEQ_Docking bolts in from the ROEQ Utility mission group
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6. When the bolts have moved in:
• In Flexi Soft: Verify that the I5 signal on the safety PLC is High - Green light turns on
7. In the robot interface, run the ROEQ_Docking bolts out from the ROEQ Utility mission group
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8. When the bolts have moved out:
• In Flexi Soft: Verify that the I5 signal on the safety PLC is Low - Green light turns off
If the above behavior cannot be achieved, the zone switching is not conducted correctly.
Solution
Issues relating to the “I5” signal not reaching the robot safety PLC may be ralted to hardware issues in either the
top module or the robot itself.
The following outlines the process for investigating if the issue resides inside the top module:
Step Instruction and Illustration
1. • Log on to the robot Wi-Fi
2. In the robot interface, go to Setup → Missions and select the ROEQ Utility mission group
• Run ROEQ_Docking bolts in
• Wait for the missions to complete
3. Turn off the robot
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4. Remove the inspection plate from the top module
5. Detach:
• The ethernet cable
• The 4 pole power cable.
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6.
1. Remove the cover from the 4 mounting points of the top module
2. Unscrew the 4 bolts mounting the top module to the robot
7.
1. Lift the top module slightly (1-2cm) and move it gently towards the front of the robot
• The 10 pole connecter must be visible through the inspection panel as illustrated
2. Disconnect the 10-pole connector
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8. 1. Using a volt meter, measure the continuity between pin 8 and 10 in the 10-pole connector
• When the docking bolts are in, there should continuity between pin 8 and 10
9. Reconnect the 10-pole connector
10. • Gently lift the top module slightly (1-2cm) and move it gently towards the rear of the robot
– The 4-pole and ethernet plugs must be visible
• Reconnect the 4-pole and ethernet connectors
11. Turn on the robot and wait for it to be fully ready
12. In the robot interface, go to Setup → Missions and select the ROEQ Utility mission group
• Run ROEQ_Docking bolts out
• Wait for the missions to complete
13. 1. Repeat steps 3 through 8
2. When the bolts are out, there should not be continuity between pins 8 and 10, in the 10-pole
connector.
If the continuity test fails, there is a hardware error in the top-module - Consult ROEQ support for further assistance.
If the continuity test passes, the zone-switching issue resides inside the robot - Consult MiR support for further
assistance.
Following the continuity test, the top module must be correctly re-mounted before further
use.
10.2.9 Calibrating lifter and locking bolts
The lifter and locking bolts may occasionally losse their calibration, in which case an error code will be issued whenever
commands are sent to the top module.
The bolts and lifter may be recalibrated by the following procedure:
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Step Instruction and Illustration
1. • Log on to the robot Wi-Fi
2. In the robot interface, go to Setup → Missions and select the ROEQ Utility mission group
• Run ROEQ_Calibrate lock bolts to calibrate the locking bolts
• Run ROEQ_Calibrate lifter to calibrate the lifter
• Wait for the missions to complete
10.2.10 Verify safety configuration
Step Instruction and Illustration
1. Log on to the robot Wi-Fi
2. Open the Sick configuration software “Flexi Soft”
3. Click “Connect” to connect to the main Module.
• If no connection has been configured, follow the process outlined in Section 6.3.2
4. Select “YES” to when prompted:
Do you want to upload the configuration on “SICK Flexi Soft main module FX3-CPU1”?
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5. Double click a laser scanner:
• Front: S300.CPU1[0].EFI1.1
• Rear: S300.CPU1[0].EFI2.1
6. Select “Read configuration from device”
7. Select “Field sets” in the menu
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8.
• Verify that the three “Extra” sets have been added.
– The naming, order and specific shape of each set might vary slightly from the image
– There should be a visible “cut-out” allowing the leg of carts/racks to not trigger a safety
stop
9. Perform steps 5 through 8 for the other scanner
10. If the “Extra” scanner fields are not present as described, the ROEQ safety configuration has not been
correctly transferred to the robot
10.2.11 Adjusting global docking offsets
If the robot exhibits a general poor performance when docking to any ROEQ docking station, it may be required to
adjust the global VL-marker offsets for the robot.
Adjusting the global docking offsets, affects the docking procedure for any VL-marker,
V-marker or L-marker in the map, not just VL-markers related to ROEQ equipment.
Before modifying offset, make a note of their current values for easy recovery if desired
later on.
The global docking offsets can be adjusted directly in the robot interface or by using the ROEQ Assist.
Enter offsets directly in robot interface
The process for direct manipulation in the robot interface is:
1. Log on to the robot Wi-Fi and go to the robot web interface
2. Go to “System → Settings → Calibration”
3. Modify, as needed, the values entered in:
• “Global V,L,VL marker docking offset X”
• “Global V,L,VL marker docking offset Y”
• “Global V,L,VL marker docking offset orientation”
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4. Click “Save changes”
Provide offset using the ROEQ Assist
Alternatively, the ROEQ Assist may be used to automate the above process as follows:
Step Instruction and Illustration
1. • Log on to the robot Wi-Fi
• Launch the ROEQ Assist
2. • In the top menu, select “Adjust global offsets”
• Select either:
– “Manually”: Type in desired offsets manually - Go to step 3
– “By calculation”: The ROEQ Assist calculates optimal offsets based on provided measure-
ments - Go to step 4
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3. For manual entries
• Type in the desired “X”, “Y”, and “orientation” offsets
• Click “Update docking stations global_offset”
4. For calculating entries
• The offsets are automatically calculated based on measurements of the actual docking perfor-
mance.
• Go through the process outlined in Appendix G and find the mean value coefficients “a”, “b”,
and “c”
• Type in the mean values in their respective fields
• Click “Calibrate docking stations global_offset”
10.2.12 Calibrating laser scanners
If the robot cannot dock precisely, it may in rare instances require a recalibration of the laser scanners. This would
however typically only be the case following a repair or replacement of robot safety components, e.g. a replacement
of a laser scanner, the robot safety PLC, or the robot main computer.
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MiR provides a guide on how to calibrate the laser scanners, but it should not be attempted until other potential
remedies for improving the docking position has been exhausted.
Contact ROEQ support for recommendations.
10.2.13 Adjusting position specific docking offsets
In some cases the robot/Top-Module may dock fine at most docking positions, but local conditions may cause the
docking to become in acccurate at a few specific positions.
Largely the same process as outlined in Section 10.2.11 may be used to let the ROEQ Assist automatically adjust
the docking offsets for specific locations:
Step Instruction and Illustration
1. • Log on to the robot Wi-Fi
• Launch the ROEQ Assist
2. • Select “Update existing docking station”
• In the drop-down menu, select the intended docking position
– Take care in selecting the right docking position w.r.t. both name and equipment type
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3. • Select among the options as needed:
– “Update station offsets manually”: If you wish to manually adjust the offsets used for
docking - Go to step 4
– “Calibrate station”: If you wish to let the ROEQ Assist calculate optimal offsets based on
provided measurements - Go to step 5
• The final option “Update station position manually” is not related to the docking offsets, but
instead provides a way to move the docking station to a different location in the map
4. For manual entries
• Type in the desired “X”, “Y”, and “orientation” offsets
• Click “Update docking station <station name>”
5. For calculated entries
• The offsets are automatically calculated based on measurements of the actual docking perfor-
mance.
• Go to the process outlined in Appendix G and find the mean value coefficients “a”, “b”, and “c”
• Type in the mean values in their respective fields
• Click “Calibrate docking station <station name>”
10.2.14 Improve robot traction
Driving with cargo that weighs close to maximum of what the Top-Module can carry, requires that there is proper
traction between the floor and the robot.
One aspect of this is to keep the floors clean, since build-up of dust and dirt may cause slippage of the wheels as
the robot starts to drive, which ultimately deteriorates the maneuverability of the robot and precision of the docking
sequence.
To further improve tracking, ROEQ provides a number of modification options to the carts and robot:
• Robot spring kit: Installing weights and springs inside the robot can substantially improve the traction with
the floor
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• Cart wheel kit: Installing an extra wheel on each side of the cart can substantially reduce the force required to
turn the cart, and improve the maneuverability for turning and docking.
Consult ROEQ support for further details about either option.
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Section 10 Troubleshooting
TM-Family
Original instruction manual (en)
Revision: 1.19
A User groups and level of training
The operation instructions in this document are intended for the personnel groups presented in Table A.1.
Personnel group Training Level Intended product interaction
Integrators Authorized personnel Integrating the Top-Module into the overall machine installation, e.g.
w.r.t.
• Unpacking, handling and installation
• Commissioning
• Maintenance and decommissioning
Operators Trained personnel Practical interaction and day-to-day operation and troubleshooting
of the Top-Module.
Nearby people Informed personnel Anyone working or occupying the area around the Top-Module during
operation, without direct interaction.
Table A.1: Personnel groups interacting with the product.
The training levels listed above refer to the level of information, experience, and training a personnel group must
receive before participating in the listed activities involving the product. The training levels are elaborated in Table A.2.
Training
Level
Experience/Training activities
Authorized
personnel
Able-bodied persons, at least 18 years of age, with in-depth experience and understanding of the
robot operation, design, and construction, including the safety system.
In-depth understanding of the construction and operating principle of the Top-Module, including
the operating interface in terms of functional and safety behavior.
Authorized personnel is expected to have access to, and have read, read the documentation
of both the robot and Top-Module, and have possibly received technical training for installing,
operating or servicing the respective products as per. the guidelines of MiR or ROEQ.
Trained
personnel
Able-bodied persons, at least 18 years of age, with practical experience in operating the robot,
including basic understanding of the operating principle.
Trained personnel is assumed to have read the documentation for the product, and that this
documentation is readily available.
Trained personnel have received supervised instructions in operating the robot and Top-Module,
e.g. from authorized personnel.
Informed
personnel
Must be informed by trained or authorized personnel of the presence of any robots incorporated
with the Top-Module.
Must further be informed about the basic behavior of the robot and Top-Module as well as
the safety precautions when being near the robot and Top-Module, including the location of
emergency stops, and location and identification of OHZs.
In case of impeding physical, sensory or mental handicaps, interactions and working distance to
the Top-Module must be limited/adjusted accordingly.
Table A.2: Training levels for interacting with the product.
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Section A User groups and level of training
TM-Family
Original instruction manual (en)
Revision: 1.19
B Hazard specification
Throughout the document, several directions and instructions are provided concerning the use and behavior of the
product. The classification of the provided directions and instructions follows the outline provided below.
Table B.1 outlines the severity and potential consequence of a hazard, or failure to follow the provided guidelines and
specifications, concerning ROEQ products.
Indicates an immanently hazardous situation that will result in death or severe personal
injury if proper precautions are not taken.
Indicates a potentially hazardous situation that could result in death or severe personal
injury if proper precautions are not taken.
Indicates a situation that could result in minor personal injury or damage to the equipment
if proper precautions are not taken.
Indicates general information without direct safety relevance, but could be important to
ensure proper operation, integration, etc.
Table B.1: Classification of different hazards and notifications.
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Section B Hazard specification
TM-Family
Original instruction manual (en)
Revision: 1.19
C Cargo specification
The cargo transported by the Top-Module must comply with the details provided in the following.
C.1 Cargo size
When transporting cargo on carts/racks, the cargo must not extend beyond the physical size of the cart/rack. The
same goes for custom attachments installed on top of ROEQ carts/racks.
When transporting cargo directly on the top module, e.g. crates or similar, the cargo must not extend beyond the
physical size of the robot.
In essence these requirements imply that the cargo dimensions must satisfy:
• Maximum length: 800 mm for all configurations
• Maximum width:
– 800 mm when cargo is on carts/racks (Within cart/rack footprint)
– 606 mm when cargo is directly on Top-Module (Within Top-Module footprint)
Additionally, when placed on top of the robot/Top-Module, the cargo must not have a height in excess of 1800 mm.
The height of the cargo must be accounted for when setting up the robot to prevent it
from traveling through doorways and similar, with insufficient clearance.
Violating the maximum cargo dimensions compromises the safety maintained by the laser
scanner safety zones and increases the risk of collisions between cargo and personnel.
C.2 Cargo weight, distribution, and securement
The allowed weight of the cargo depends on the Top-Module, which equipment is transported, and which type of
robot is employed.
The maximum weight limit is as follows:
• ROEQ cart transported by TMC300 or TMR150
– MiR100: 150 kg
– MiR200: 300 kg
– MiR250: 300 kg
• ROEQ rack transported by TMR150
– MiR100: 50 kg
– MiR200: 150 kg
– MiR250: 150 kg
• Individual crates or similar transported by TML150 or TMR150
– MiR100: 50 kg
– MiR200: 150 kg
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Original instruction manual (en)
Revision: 1.19
– MiR250: 150 kg
When moving carts with TMC300 or TMR150 on MiR100 or MiR200 it is recommended
to install a ROEQ Spring Kit and Weight Kit on the robot. If the payload on the cart
exceeds 100 kg, the ROEQ Spring Kit Plus should be used instead. For high payload,
slippery floor or cargo larger than cart footprint, the ROEQ Wheel Kit is recommended
for the carts.
When moving carts with TMC300 and TMR150 on MiR250 with AM250 it is recom-
mended to install a MiR Traction Kit. For high payload, slippery floor or cargo larger
than cart footprint, the ROEQ Wheel Kit is recommended for the carts.
Transporting and accurately docking with maximum weight may require additional effort
to provide sufficient traction to accurately maneuver the robot, carts and racks.
When packing or stacking the cargo, it must be ensured that:
• The weight must be evenly distributed across the surface of the cart/rack or top-module, respectively
• The cargo COM should be placed centered and as low as possible
– Eccentric loading can cause undesirable performance unacceptable maneuvering
• The COM placement must in any case comply with the requirements of the robot
• The cargo must be secured to prevent it from sliding during transport
Make sure to obey the COM restrictions
Inappropriate location of the COM may cause the cargo or robot to tip over during
transport
Secure the cargo in a robust fashion
When transporting several units of cargo, each unit must be securely fixated to avoid
sliding or being thrown off during turning or abrupt braking of the robot. The stability of
the cargo must be validated during commissioning of the system.
During commissioning of the Top-Module it must be verified the load stays at the intended
position and satisfies the robot COM specifications.
This also applies when cargo is transportet using custom attachments on top of carts and
racks.
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Section C Cargo specification
TM-Family
Original instruction manual (en)
Revision: 1.19
D Top-Module Equipment
This section describes the ROEQ equipment to be used when creating installations with a ROEQ Top-Module.
Carts and racks are described in Section D.1.
Dockign stations are described in Section D.2.
The equipment described here is not compatible with TML150.
Only TMC300 and TMR150 can be used with the described equipment.
D.1 ROEQ carts and racks
The ROEQ carts and racks are illustrated in Figure D.1.
ROEQ carts may be towed by robots installed with either a TMC300 or a TMR150. Carts have wheels and are not
intended to be lifted during transport.
ROEQ racks can only be transported by robots installed with a TMR150. Racks do not have wheels and must be
lifted during transport.
Figure D.1: ROEQ cart (left) and rack (right).
D.1.1 Main components
The components comprising ROEQ carts and racks are summarized in Figure D.2 and Table D.1.
Figure D.2: Main components of a ROEQ cart. A ROEQ rack consists of the same
components, but with “feet” instead of wheels
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Section D Top-Module Equipment
TM-Family
Original instruction manual (en)
Revision: 1.19
Nr. Description Nr. Description
1 Caster wheel 2 Main frame
3 Docking bolt interface (Optional) 4 Corner attachment point
5 Locking mechanism attachment point 6 Ball docking interface (optional)
Table D.1: The main components of the Top-Module as illustrated in Figure 5.
D.1.2 Technical specifications
The technical details are collected in Table D.2.
Property Value
Length 800 mm
Width 800 mm
height 484 mm
Weight (Unloaded) 25 kg (Cart)
22 kg (Rack)
Color Silver gray (RAL7001)
Corner attachment points M10x1.5 mm
Maximum cargo weight3 Cart: 150 kg (MiR100), 300 kg (MiR200)
Cart: 50 kg (MiR100), 150 kg (MiR200)
Cargo weight distribution Payload shall be evenly distributed around the
centre of the cart/rack.
Table D.2: Technical details for carts and racks.
D.1.3 Custom attachments
ROEQ carts and racks are intended to be installed with custom attachments, e.g. cabinets, shelves, etc. for
customized cargo transport.
Custom attachments must be mounted in the corner attachment points described in Figure D.2 and Table D.1.
Custom attachments must be installed in all four attachment points using the screws indicated in Table D.2.
The integrator of the custom attachments must ensure that the attachments are securely fixed, and that the attach-
ment is able to withstand the forces experienced during operation, without deformation, wear down etc.
Custom attachments must be designed and installed in a fashion that prevents them from
coming loose during operation, either from bolts, screws, etc. coming loose, or from
structural tears or deformation.
Further, when installing custom attachments, the same limitations outlined in Appendix C must be satisfied as for
any other type of cargo transported by a ROEQ Top-Module, e.g. size, weight, COM placement, etc.
In particular, the weight of a custom attachment must be deducted from the allowed maximum weight of the payload.
3Satisfactory operation with maximum cargo weight may depend on external aspects such as floor surface material, dirt accumulation,
etc.
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Section D Top-Module Equipment
TM-Family
Original instruction manual (en)
Revision: 1.19
D.2 ROEQ docking stations
The ROEQ docking stations can be floor mounted or wall mounted as illustrated in Figure D.3.
Figure D.3: Floor mounted docking station (Left) and wall mounted station (Right).
D.2.1 Main components
The components comprising ROEQ docking stations are summarized in Figure D.4 and Table D.3.
Figure D.4: Main components of a ROEQ docking station.
Nr. Description Nr. Description
1 Docking bolt 2 Docking bolt housing
3 Docking bolt release handle 4 Docking station front plate
5 Locking mechanism attachment point 6 Geometric marker for robot docking
Table D.3: The main components of the docking stations as illustrated in Figure D.4.
D.2.2 Technical specifications
The technical details of wall- and floor mounted docking stations are summarized in Table D.4 and illustrated in
Figure D.5 and Figure D.6, respectively.
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Section D Top-Module Equipment
TM-Family
Original instruction manual (en)
Revision: 1.19
Property Value
Length Floor mounted: 250 mm (383 mm including docking bolts)
Wall mounted: 82 mm (238 mm including docking bolts)
Width 800 mm
height Floor mounted: 430 mm
Wall mounted: 505 mm
Weight (Unloaded) Floor mounted: 18 kg
Wall mounted: 14 kg
Color Silver gray (RAL7001)
Anchor points Floor mounted: 6x8.5 mm
Wall mounted: 6x12.5 mm
Table D.4: Technical details for docking stations.
Figure D.5: The dimensions of wall mounted docking stations.
Figure D.6: The dimensions of floor mounted docking stations.
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Section D Top-Module Equipment
TM-Family
Original instruction manual (en)
Revision: 1.19
E Register description
The Top-Module is interfaced through the robot “PLC registers”. All operations involving the Top-Module are handled
by writing various numeric codes to a selection of registers.
The general use of each register is summarized in Table E.1. The descriptions of the appertaining numeric codes of
each register are outlined in the following sections.
Register Purpose Value Function
1 Command register 61
62
68
69
71
72
78
79
Docking bolts in (Lock function)
Docking bolts out (Lock function)
Docking bolts soft homing (Lock function)
Docking bolts hard home( Lock function)
Lower lift (Lift function)
Raise Lift (lift function)
Soft home lift (lift function)
Hard home lift ( lift function)
2 General status 0
1
2
3
Done
Busy
Starting up
Homing or adjusting position
3 Error code 0
11
12
13
14
15
19
OK
Module not ok
Startup failed
Lost position
Did not reach position
Switch error
Passed a switch
4 Homing register 0
1
Docking bolts are out
Docking bolts are in
5 Cart detection register 0
1
Cart present
No cart present
10 Interface register 1 0
1
Ready
Getting or returning cart
11 Interface register 2 0
1
Ready
Moving docking bolts
Table E.1: Overview of the registers involved in the operation of the Top-Module.
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Section E Register description
TM-Family
Original instruction manual (en)
Revision: 1.19
F Safety system details
This section provides details concerning the safety system to elaborate on the information given in other parts of this
document.
F.1 Safety functions
The safety functions as listed in Section 3.5.1 are:
• SF1: Extended safety zones - PL-level d
• SF2: Emergency stops - PL-level d
F.2 Safety components
The components comprising the Top-Module safety system are:
• E-stop buttons and switches installed in the top module
• The robot safety system including laser scanners, safety PLC, etc.
F.3 Testing of safety system
The following outlines the procedure for verifying the integrity of the safety system with respect to the safety functions
outlined in Section 3.5.
Test of the safety system must be conducted during commissioning of the Top-Module. It is further required to go
through the tests once every year.
Provide a safe setting for conducting the tests
The test of each safety function deliberately introduces contingency scenarios that does
not occur in regular operation.
In order to do so in a safe manner, the tester must remove any cargo from the Top-Module
that may pose a hazard, and bring the robot/Top-Module to a confined area, that may
be cleared, marked, restricted, etc. in way that is found appropriate to ensure that no
unacceptable risk occurs during tests.
The process outlined here does not validate the safety system of the robot.
Testing the robot safety system is a separate process that must be conducted as per the
specifications of MiR.
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Section F Safety system details
TM-Family
Original instruction manual (en)
Revision: 1.19
SF1 - Extended safety zones
Test process Not relevant for TML150
1. The robot/Top-Module must be operational, i.e. without any safety stops or E-stops
2. Place the robot in an area with adequate free floor space
3. Make sure the bolts are fully contracted
• Either by running the “contract bolts mission” - See Section 6.9
• Or by typing in the value “61” directly into PLC register 1 of the robot
4. Put an object next to the robot
• The robot should have “small” zones
• The object should be able stand closely next to the robot without triggering the
scanner zones
5. Remove the object
6. Extract the bolts fully
• Either by running the “extend bolts mission” - See Section 6.9
• Or by typing in the value “62” directly into PLC register 1 of the robot
7. Put an object next to the robot
• The robot should have “large/cart” zones
• The object should trigger the laser scanner safety zones when closer than approx-
imately 16 cm of the robot
• The robot goes is safety stopped when the safety zones are triggered
8. Remove the object
• The safety stop is lifted
Pass criteria • The robot goes in and out of safety stop as indicated
Actions in
case of fail
Contact ROEQ support
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Section F Safety system details
TM-Family
Original instruction manual (en)
Revision: 1.19
SF2 - Emergency stops
Test process 1. The robot/Top-Module must be operational, i.e. without any safety stops or E-stops
2. Press one of the E-stops on the Top-Module
3. Verify that the robot and Top-Module goes into E-stop
4. Release the E-stop by rotating the knob clockwise
5. Verify that the robot reset button starts flashing
6. Press and release the robot reset button
7. Verify that the robot and Top-Module goes out of E-stop
8. Repeat the process in step 2 through 7 for all E-stops on the Top-Module
Pass criteria • The robot/Top-Module goes in and out of E-stop as indicated
Actions in
case of fail
Contact ROEQ support
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Section F Safety system details
TM-Family
Original instruction manual (en)
Revision: 1.19
G Measuring docking misalignment
When docking a robot installed with a TM-Family Top-Module, towards any ROEQ docking station, the final position
of the robot needs to be accurate to get the desired interaction with carts and racks. This require careful calibration
of the docking offsets used by the robot for docking.
Any docking misalignment and required offset adjustment for the robot can be calculated based on the measurement
conducted in the process described below.
Three adjustment coefficients, a, b, and c, must be determined. To minimize the effect of measurement variations, the
underlying measurements are conducted 5 times each, and average values are subsequently used for offset adjustment.
The measurement process is as follows:
Step Instruction and Illustration
1. • Log on to the robot Wi-Fi
• Go to the robot web interface
• Bring up the map of the environment
2. Without a cart attached, dock the robot at a configure ROEQ docking station
• Click the intended docking station on the Map
• Click “GO TO”
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Section G Measuring docking misalignment
TM-Family
Original instruction manual (en)
Revision: 1.19
3. Mark the center of the docking station
4. Mark the center of the Top-Module
5. Use a straight profile, e.g. a ruler, and place it flush with the front of the Top-Module
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Section G Measuring docking misalignment
TM-Family
Original instruction manual (en)
Revision: 1.19
6. Measure the “a” value as:
• The distance from Top-Module front edge to the docking station front panel at the robot front
left corner (Robot x-direction)
7. Measure the “b” value as:
• The distance from Top-Module front edge to the docking station front panel at the robot front
right corner (Robot x-direction)
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Section G Measuring docking misalignment
TM-Family
Original instruction manual (en)
Revision: 1.19
8. Measure the “c” value as:
• The distance from Top-Module center to the docking station center (Robot y-direction)
Offset along positive robot y direction - Positive c-value
Offset along negative robot y direction - Negative c-value
9. Undock the robot/Top-Module from the docking station
10. Repeat steps 2 through 9, five times to obtain a set of measurements as exemplified below
11. Calculate the mean values as
x =
1
5
∑︁
5
i=1
xi
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Section G Measuring docking misalignment
TM-Family
Original instruction manual (en)
Revision: 1.19
Note:
Perfect docking alignment is obtained when:
• a = b = 70 mm
• c = 0 mm
In this case, the docking offset adjustments would not be corrected.
The mean values found through the above process can be used by the ROEQ Assist to automatically calculate the
appropriate docking offsets for both the global robot docking parameters, as well as local docking parameters for
specific docking stations.
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Section G Measuring docking misalignment
TM-Family
Original instruction manual (en)
Revision: 1.19
Bibliography
[1] European Parliament and Council. Directive 2006/42/EC of the European Parliament and of the Council of 17
legal-content/EN/TXT/?uri=CELEX%3A32006L0042.
[3] DS/EN ISO 13849-1. Safety of machinery - Safety-related parts of control systems - Part 1: General principles
for design.
[4] DS/EN ISO 12100:2011. Safety of machinery - General principles for design - Risk assessment and risk reduction.
[5] DS/EN ISO 3691-4:2020. Industrial trucks - Safety requirements and verification - Part 4: Driverless industrial
trucks and their systems.
Abbreviations
CAD Computer Aided Design p.: 7
COM Center of Mass p.: 19, 45, 85, 87
E-stop Emergency Stop p.: 8, 10, 11, 15, 18, 20, 52, 54,
62, 66, 67, 91–93
IT Information Technology p.: 10
LED Light Emitting Diode p.: 66
MiR Mobile Industrial Robots Aps. p.: 7, 8, 10, 18, 28,
42, 45, 49, 66, 67, 73, 79, 82, 91
OHZ Operating Hazard Zone p.: 9, 41, 82
PL Performance Level p.: 18
PLC Programmable Logic Controller p.: 50, 51, 56, 58–
60, 62–66, 69, 70, 78, 91, 92
POM Polyoxymethylen p.: 16
PPE Personal Protective Equipment p.: 20
ROEQ ROEQ Aps. p.: 7, 8, 10, 12, 13, 17–19, 25, 28,
29, 35, 41, 42, 45, 52, 53, 56, 58–62, 64, 65,
73, 76, 79–82, 84, 86–88, 92–94, 99
RoHS Restriction of Hazardous Substances p.: 16
SDM System Diagnostic Manager p.: 56–59, 63, 65
SF Safety Function p.: 18, 45
USB Universal Serial Bus p.: 29
Glossary
AM250 ROEQ adapter module for MiR250 allowing installation of TMC300, TMR150, TML150, or TMC300Ext p.:
12, 21, 23, 29, 45, 85
CE An administrative marking that indicates conformity with health, safety, and environmental protection standards
for products sold within the European Economic Area p.: 17
L-marker Marker consisting of a plate with a specific geometric "L" design that the robot is able to dock against. p.:
76
MiR100 MiR robot with 100 kg. maximum payload. p.: 12, 13, 19, 21, 23, 29, 84, 85, 87, 100
MiR200 MiR robot with 200 kg. maximum payload. p.: 12, 13, 19, 21, 23, 29, 84, 85, 87, 100
MiR250 MiR robot with 250 kg. maximum payload. p.: 12, 19, 21, 29, 45, 84, 85, 99, 100
ROEQ Assist Tool provided by ROEQ to support the setup of various products, and automated generation of
missions in the robot interface p.: 45, 47, 62–64, 76, 77, 79, 80, 98
TM-Family Family of ROEQ TM modules, comprised of TMC300, TMC300Ext, TMR150, and TML150. p.: 12,
19, 94
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Section Glossary
TM-Family
Original instruction manual (en)
Revision: 1.19
TMC300 ROEQ top module for dragging carts with a payload of up to 300 kg., for installation on MiR100, MiR200,
or MiR250. p.: 1, 7, 12, 13, 17, 19, 21, 29, 50, 84–86, 99
TMC300Ext Extended ROEQ top module for dragging carts with a payload of up to 300 kg, with a cargo carying
area corresponding to a standard EU pallet. For installation on MiR100, MiR200, or MiR250. p.: 99
TML150 ROEQ top module for lifting crates with a payload of up to 150 kg., for installation on MiR100, MiR200,
or MiR250. p.: 1, 7, 12, 13, 19, 29, 50, 84, 86, 92, 99, 100
TML150 Forks ROEQ pallet forks that may be optionally installed on a TML150 for transport of pallets or similar. p.:
13
TMR150 ROEQ top module for lifting racks with a payload of up to 150 kg., for installation on MiR100, MiR200,
or MiR250. p.: 1, 13, 17, 19, 21, 29, 50, 84–86, 99
V-marker Marker consisting of a plate with a specific geometric "V" design that the robot is able to dock against
with high precision. p.: 76
VL-marker Marker consisting of a plate with a specific geometric "VL" design that the robot is able to dock against
with high precision. p.: 42, 76
Safety functions
SF1: Extended safety zones - PL-level d 18, 91, 92
SF2: Emergency stops - PL-level d 18, 91, 93
Publicly available p. 100 of 100
Section Safety functions