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Husky A300 Maintenance

Preventative Maintenance​

WARNING

Always follow the proper Lock-Out Tag-Out Procedure for Husky A300 when completing inspections or maintenance.

Access to live voltage inside Husky A300 may occur if the proper Lock-Out Tag-Out procedure is not followed. This may result in electric shock.


CAUTION

Always follow safe handling procedures when performing maintenance.

Sharp edges may exist inside the robot.


CAUTION

Always follow facility guidelines to clean up fluid spills.

These may present a slip hazard.

Weekly Prevenative Maintenance​

Perform the following tasks at least once every week.

Circle Check​

Perform a circle check around Husky daily to ensure no damage has occurred since its last usage. During this visual inspection, ensure the robot is turned on and verify that:

  • The Status Lights are functioning correctly by pressing an Emergency Stop button and checking for the Emergency Stop light pattern.
  • The robot was not damaged during the last operation.
note

Husky is an all-terrain IP54-rated robot, but it is not waterproof. Care should be taken that no part of the main chassis is ever submerged in water. When the chassis becomes wet or dirty, wipe it down with a damp cloth and dry with a towel.

If water is suspected to have entered the Husky chassis, power off the robot, open the top plate to ensure that any water has drained out through the drain plug, and allow Husky to dry fully (for a minimum of 24 hours) prior to putting it back into service.

Clean or Replace Air Filter​

The air filter is used to prevent dirt and dust from entering the robot at the front air intake. It must be cleaned or replaced on a regular basis. High-dust environments will require more frequenct maintenance.

note

The air filter is foam and can be washed, then reused.

Procedure:

  1. Remove the front Livery panel by loosening the quarter-turn latches and lifting the panel up. Be careful not to damage the Emergency Stop Button while removing the panel.
  2. Remove the air filter.
  3. Wash the filter with water and allow it to dry fully. (Alternatively, replace with a new filter.)
  4. Install the clean filter.
  5. Replace the front livery panel by aligning the pins and tighten the quarter-turn latches.

Full Battery Charge​

Husky is powered by LiFePO4 batteries. The function and health of these batteries is monitored by a Battery Management Unit (BMU) which is internal to the battery pack itself. It is recommended that the batteries be charged to 100% at least once per week.

Procedure:

  1. Power off the robot.
  2. Place the robot on a level surface.
  3. Connect the manual charger.
  4. Let the batteries charge until they reach a full charge, as indicated on the charger.

AMP Sensor Cleaning​

The AMP variant of Husky is equipped with additional sensors that should be inspected at least weekly (more often in high dust/dirt environments) and cleaned as needed.

LiDAR Lens Cleaning​
  1. Inspect LiDAR lens with a flashlight for any dust and/or debris.
  2. Using the Lens Cleaning Wipes (Clearpath p/n 015591), clear the LiDAR of any dust/debris.

CAUTION

Do not use abrasive items or solvents on the LiDAR assembly, as this will damage the LiDAR. Used and dirty cleaning cloths or wipes will scratch the window over time. The LiDAR window is a wear item but proper care and cleaning can significantly extend its life.

Camera Cleaning (clean with microfiber cloth or CPR-approved cleaning wipe if dirty)​
  1. Visually inspect the camera lenses and confirm there is no dust or debris on them.
  2. If necessary, carefully clean the lenses with a microfiber cloth or a Clearpath Robotics-approved cleaning wipe.

CAUTION

Do not apply excessive pressure to the camera lenses.

Monthly Preventative Maintenance​

Perform the following tasks once every month.

Tire Inspection​

Tire pressure may change with temperature and should be checked monthly with a pressure gauge. Inspecting tires, releasing pressure, and inflating tires are completed through the tire's inflation stem. Tire pressure should not exceed 137 kPa (20 psi), and lower pressure may be desired based on terrain requirements. A monthly visual inspection of the tire treads is also recommended. Replacement tires and tubes assemblies can be purchased from Clearpath Robotics and can be installed by the user.

tip

Husky's wheels can handle a range of different terrains, but work best when inflated to the proper pressure. Lower tire pressures, for example 68.5 kPa (10 psi), ensure better traction in rough and varied terrain, where rocks or other obstacles may be encountered. This has the adverse effect of lowering drivetrain efficiency and decreasing battery charge, so high pressures up to a maximum of 137 kPa (20 psi) should be used when driving on flat surfaces.

Lower tire pressuses also reduce the effective diameter of the wheel, and will impact your odometry readings. Odometry is calculated using the average diameter of a tire inflated to 137 kPa (20 psi).

Tire inspection procedure:

  1. Power off the robot.
  2. Place the robot on a level surface.
  3. Using a tire pressure gauge, check the pressure on each tire to confirm it is 68.5 - 137 kPa (10 - 20 psi). Add or remove air as needed to ensure each tire is in the proper range. If leaks persist, change the tire tube.
  4. One wheel at a time, slowly roll Husky through full wheel revolution while inspecting the tire for excessive wear, cuts, or punctures. If any damage is detected, replace the tire.

Drivetrain Inspection​

It is recommended that an auditory inspection of the robot drivetrain be performed once per month. Take note of any clicking, grinding or irregular skipping sounds while the robot is moving. Note that some clicking in the gearheads is normal during stops and starts, due to backlash between the gears.

Annual Preventative Maintenance​

Perform the following tasks once every year.

Safety Function Checks​

note

No planned maintenance of the safety system is required. The checks below ensure that the safety systems remain operational.

Emergency Stop Buttons Check​
  1. Confirm that the robot can be driven normally and then stop driving.
  2. Press the front emergency stop button, attempt to drive the robot again, and confirm that it does not move.
  3. Clear the front emergency stop and confirm that the robot can be driven again normally.
  4. Repeat the steps above for the rear emergency stop button and any wireless emergency stop buttons.
Debug Panel Door Check​
  1. Confirm that the robot can be driven normally and then stop driving.
  2. Open the rear debug panel door, attempt to drive the robot again, and confirm that it does not move.
  3. Close the rear debug panel door, clear the emergency stop condition, and confirm that the robot can be driven again normally.
Emergency Stop Braking Check​
  1. On a robot with no payload, while driving the robot at 1.0 m/s on flat ground, press one of the emergency stop buttons.
  2. Measure the stopping distance and confirm it is less than 40 cm.

36-Month Preventative Maintenance​

Perform the following tasks once every thirty-six months.

Battery Health Check​

Husky's batteries are expected to last for at least 36 months of continuous operation. The actual lifetime experienced will vary greatly depending on the usage and operating environment. Contact Support for an in-depth assessment of the battery's health if you have any concerns.

Hardware Maintenance​

Common Replacement Items​

note

This does not cover the full bill-of-materials for your robot. These items are things we consider critical, so you may want to keep spares on hand. You can get any replacement part by contacting <support@clearpathrobotics.com>, including parts not listed here.

DescriptionWhat Subsystem Is This Used In?CPR ItemManufacturerManufacturer Item
Fuse, 10 ASystem Interface Assembly,
and System Interface Assembly's Standby Power Cable		018897Littelfuse0297010.WXNV
Fuse, 20 ASystem Interface Assembly032295Littelfuse0297020.U
Fuse, 40 APower Distribution's Large VBAT Contactors023567Littelfuse142.5631.5402
Fuse, 50 APower Distribution's Manual Charger029139Littelfuse142.5631.5502
Fuse, 60 ABatteries,
Power Distribution's Mobility Contactors,
Power Distribution's Shunt Brake		029140Littelfuse142.5631.5602
Fuse, 150 ABatteries029145Littelfuse142.5631.6152
Air FilterFans032403Clearpath Robotics-
TireMobility000269Carlisle5100201
Tire's Inner TubeMobility000435Carlisle323790

Critical Items​

info

These items are unlikely to fail in normal use. We are providing this data because some customers want spares on hand for anything that could impact their schedule.

DescriptionWhat Subsystem Is This Used In?CPR ItemManufacturer
BatteryBatteries025047Clearpath Robotics
Battery Manual ChargerSpare Parts032729Clearpath Robotics
Main PCBASystem Interface Assembly030449Clearpath Robotics
BLDC Motor Controller PCBASystem Interface Assembly030377Clearpath Robotics
Common Core PCBA, (MCU)System Interface Assembly030446Clearpath Robotics
12 V DC-DC PCBASystem Interface Assembly030430Clearpath Robotics
24 V DC-DC PCBASystem Interface Assembly030433Clearpath Robotics
GearmotorMobility031514Clearpath Robotics
FanFans031356Clearpath Robotics
ComputerComputer032741,
or 032742		Clearpath Robotics
Network SwitchNetwork Switch033443Clearpath Robotics

Tire and Inner Tube​

CAUTION

Place the robot up on blocks prior to replacing the tire or inner tube. The robot may become tip over if you remove a wheel without stabilizing the chassis.


To replace the tire and inner tube:

  1. Shut off the robot's circuit breaker.

  2. Remove the six M8×1.25 screws holding the wheel to the motor.

  3. Deflate the tire by pressing on the Schrader valve's core.

  4. Remove the six M4×0.7 screws and nuts that hold the split rim together.

  5. Remove the outer rim.

  6. Remove the tire and tube from the inner rim.

  7. Replace the tire and/or tube as needed with new parts. Make sure the tire's chevron treds are facing the correct direction, as the left and right wheels have different tred orientations. Ensure that the tube is installed in the tire and inflated only far enough that it takes its shape. Inflating further will make reassembly difficult.

  8. Place the tire—(with inner tube)—onto the inner rim, aligning the valve stem with the notch in the rim.

  9. Place the outer rim on top, aligning the value stem with the notch in the rim.

  10. Reinstall the six M4×0.7 screws and nuts, tightening them in a star pattern to 2 N·m.

    note

    It may be necessary to use three longer M4×0.7 screws on a temporary basis to help pull the inner and outer rims together and ensure alignment, allowing the first three standard M4 screws to be installed. Then, the temporary M4×0.7 screws can be removed and the standard ones installed. As you tighten the screws, ensure that the valve stem is not being pinched.

  11. Inflate the tire to 140 kPa (20 psi).

  12. Place the wheel on the motor and reinstall the six M8×1.25 screws, tightening them in a star pattern to 20 N·m.

Replacing Circuit Boards​

Husky's System Interface Assembly, including DC-DCs, BLDC controllers, Common Core, and fuses

Husky has several circuit boards—(PCBAs). It is uncommon for a PCBA to fail during operation, but could occur from physical damage during a maintenance task. If a failure occurs, usually only one board needs to be replaced, rather than the full System Interface Assembly.

ESD Protection

PCBAs are sensitive components and can be damaged easily through electrostatic discharge—(ESD). Be sure to follow proper ESD protection measures prior to handling any circuit boards.

WARNING

Confirm that Husky's Emergency Stop System is functioning after changing any of the circuit boards.


Procedure for replacing the DC-DC and BLDC circuit boards

  1. Turn off the robot's circuit breaker.

  2. Remove the 7 screws that fasten the Top Plate to the chassis and remove the Top Plate.

  3. Remove the cable brush holder.

  4. Remove the heat shield covering the DC-DC or BLDC circuit boards.

  5. Remove the failing circuit board by gently lifting the board up. These circuit boards have many pins, so a large amount of force is requred.

  6. Install the new circuit board by aligning the connector and gently sliding it into place.

  7. Reinstall the heat shields.

  8. Reinstall the cable brush holder.

  9. Put the Top Plate back in place and finger tighten the 7 screws. Note that the screw with the sealing washer goes in the inner location, and the remaining 6 screws are installed around the perimeter. Tighten all screws to 3 N·m.

Procedure for replacing the Common Core circuit board

  1. Turn off the robot's circuit breaker.

  2. Remove the 7 screws that fasten the Top Plate to the chassis and remove the Top Plate.

  3. Remove the Common Core by removing the 2 retaining screws, pushing out on the retaining clips, and then gently pulling the board out horizontally.

  4. Install the new circuit board by gently sliding it into place horizontally, ensure that the retaining clips are secured, and that the two screws have been installed.

  5. Put the Top Plate back in place and finger tighten the 7 screws. Note that the screw with the sealing washer goes in the inner location, and the remaining 6 screws are installed around the perimeter. Tighten all screws to 3 N·m.

Procedure for replacing the Main circuit board

  1. Turn off the robot's circuit breaker.

  2. Remove the 7 screws that fasten the Top Plate to the chassis and remove the Top Plate.

  3. Disconnect all cables from the Main circuit board.

  1. Remove the Main circuit board by removing the screws and then lifting out the board.

  2. Place the old and new Main circuit boards on an ESD mat.

  3. Move the funcational DC-DC, BLDC, and Common Core circuit boards from the old Main circuit board to the new Main circuit board by following the procedures above.

  4. Install the new Main circuit board tighten the retaining screws to 1 N·m.

  5. Reconnect all cables, noting that the labels on the cables should match those on the board.

  6. Put the Top Plate back in place and finger tighten the 7 screws. Note that the screw with the sealing washer goes in the inner location, and the remaining 6 screws are installed around the perimeter. Tighten all screws to 3 N·m.

Replacing the Computer​

CAUTION

Circuit boards are sensitive components and can be damaged easily through electrostatic discharge (ESD). Be sure to follow proper ESD protection measures prior to handling any circuit boards.


info

If the existing computer is still operational, a backup of any important data should be made prior to its replacement.

Procedure:

  1. Follow the Lock-Out Tag-Out procedure.
  2. Remove the seven screws that fasten the Top Plate to the chassis and remove the Top Plate.
  3. Disconnect all cables from the computer.
  4. Remove the computer by removing the four retaining screws and lifting it out of the robot.
  5. Install the new computer and tighten the four retaining screws to 1 Nm.
  6. Reconnect all cables.
  7. Put the Top Plate back in place and finger tighten the seven screws that were removed in Step 2. Note that the screw with the sealing washer goes in the inner location and the remaining six screws are installed at the perimeter. Tighten all seven screws to 3 Nm.
  8. As needed, reinstall any custom configuration that has been backed up.

Motors​

Husky's Gearmotor, With Power And Data Cables
To remove the motors:
  1. Shut off the robot's circuit breaker.
  2. Remove the cable gland cover on the side of the robot. This cover is held with 5 socket head screws.
  1. Disconnect the both sets of motor power and cables from the chassis on the side of the robot with the motor being replaced. The thick power cables are removed by pulling on the cable. The thiner data cables have a latch on the connector; press on the latch and then pull on the connector.
  1. Remove the suspension beam from the chassis by removing the four nuts and washers.
  1. Remove the wheel from the motor (see above).
  2. Remove the motor from the suspension beam by removing the four M8×1.25 screws.
note

When reinstalling the motor and suspension:

  • Torque the motor's 4 screws to 20 N·m.
  • Torque the wheel's 6 screws to 20 N·m.
  • Torque the suspension beam's nuts to 30 N·m. Torque these slowly, in a star pattern. Exceeding 30 N·m will damage the Husky's aluminum chassis.
  • Each motor has 2 cables. Make sure both related cables go to the related connectors on the robot's chassis.
  • Torque the cable gland cover's screws to 1 N·m.

Replacing Batteries​

DANGER

Battery terminals and connected cables / busbars may be live. Follow proper safety procedures when performing any maintenance on the batteries.

Only trained personnel authorised by Clearpath Robotics shall perform maintenance on the batteries.

Ensure proper personal protective equipment is used when performing battery maintenance.

  1. Follow the Lock-Out Tag-Out procedure.
  2. Remove the cable gland brackets on both sides of the robot by removing five screws on each.
  3. Disconnect all motor power and encoder cables from the chassis.
  4. Remove the seven screws that fasten the Top Plate to the chassis and remove the Top Plate.
  5. Locate the V+ connector and pull the handle to disconnect it.
  6. Disconnect all cables at the front of the electronics tray, at a minimum the red Ethernet cable highlighted in the image.
  7. Disconnect all cables at the rear of the electronics tray.
  8. Remove the four screws used to fasten the electronics tray to the side of the robot.
  9. Remove the electronics tray to expose the batteries.
  10. Disconnect and remove the positive battery busbar by removing the two fuse covers, disconnecting the terminals, and lifting up the busbar.
  11. Disconnect and remove the negative battery busbar by removing the two screws. This also disconnects the battery ground cable.
  12. Disconnect any CAN bus cables (RJ45 connectors) at the batteries.
  13. Remove the battery to be replaced and the battery to which its terminals were facing. Note that batteries are installed in pairs.
  14. Move the terminal connectors from the old battery to the new battery.
  15. Align the pair of batteries so that their terminals are facing and slide the pair of batteries into the robot. A temporary locking strap to hold the two batteries together may make this step easier.
  16. Reconnect the CAN bus cables (RJ45 connectors).
  17. Re-install the negative battery busbar and ground cable. Tighten the two screws to 5 Nm.
  18. Re-install the positive battery busbar by placing it across the two fuses and tightening the two nuts to 3 Nm.
  19. Replace the two fuse covers.
  20. Put the electronics tray back into position and tighten the four screws used to fasten the tray to the side of the robot to 3 Nm.
  21. Reconnect all cables at the front and rear of the electronics tray.
  22. Locate the V+ connector handle and re-install the connector.
  23. Put the Top Plate back in place and finger tighten the seven screws that were removed in Step 2. Note that the screw with the sealing washer goes in the inner location and the remaining six screws are installed at the perimeter. Tighten all seven screws to 3 Nm.
  24. Reconnect all motor power and encoder cables on the chassis.
  25. Re-install the cable gland brackets on both siders of the robot, tightening the five screws on each to 1 Nm.

Replacing Fuses​

In the unlikely event that a fuse fails, refer to the table below for the required replacement fuse.

Circuit Board DesignatorFuse Type and RatingPart Number
F1, F2, F3, F4, F5, F8125 V, 3 A, fast-blowLittlefuse 0453003.MR
F6, F10125 V, 5 A, slow-blowLittlefuse 0454005.MR
F7, F9125 V, 8 A, fast-blowLittlefuse 0453008.MR
F52, F53, F54, F55, F56, F57, F5832 V, 10 A, MINI BladeLittlefuse 0297010.WXT

Software Maintenance​

Getting New Packages​

note

If you are upgrading your robot from an older version of ROS, please refer to our upgrade instructions for upgrading to ROS 1 Melodic, ROS 1 Noetic and ROS 2.

Clearpath Robotics robots are always being improved, both its own software and the many community ROS packages upon which it depends! You can use the apt package management system to receive new versions all software running on the platform.

Each robot leaves the factory already configured to pull packages from http://packages.ros.org as well as http://packages.clearpathrobotics.com. To update your package and download new package versions, simply run:

sudo apt-get update
sudo apt-get dist-upgrade

MCU Firmware Update​

Refer to firmware update instructions. Be sure to select the ROS 2 distribution that matches the ROS 2 distribution installed on your robot.

Motor Controller Firmware Update​

Use the following command to update the firmware on the motor controllers, using the serial number of your robot rather than xxxxx.

caution

Do NOT power off the robot while this command is running.

ros2 action send_goal /a300_xxxxx/platform/motors/update clearpath_motor_msgs/action/LynxUpdate {} -f

Once all four motor controllers have been updated, power cycle the robot.

Motor Controller Calibration​

The motor controllers are configured in the factory and do not normally to be reconfigured in the field. If you have been instructed by Clearpath Support to recalibrate, use the command below, using the serial number of your robot rather than xxxxx.

caution

Do NOT power off the robot while this command is running.

info

Ensure that the robot does not have its Emergency Stop engage while running this command.

info

Ensure that the robot is on a level surface with at least 1 metre of clearance in all directions before running this command.

ros2 action send_goal /a300_xxxxx/platform/motors/calibrate clearpath_motor_msgs/action/LynxCalibrate {} -f

Support​

Clearpath is committed to your success. Please get in touch with us and we will do our best to get you rolling again quickly: <support@clearpathrobotics.com>.

To get in touch with a salesperson regarding Clearpath Robotics products, please email <research-sales@clearpathrobotics.com>.

If you have an issue that is specifically about ROS and is something which may be of interest to the broader community, consider asking it on Robotics Stack Exchange. If you do not get a satisfactory response, please ping us and include a link to your question as posted there. If appropriate, we will answer on Robotics Stack Exchange for the benefit of the community.

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