Skip to main content

Batteries

This section instructs on replacement of core components on the battery.

Part DescriptionPart #Qty
PIN PLATE1010651
PIN PLATE SCREWS1012616
LIFTING PIN1012591
LIFTING PIN SCREW1012601
CONTACT PLATES1020162
CONTACT PLATE SCREWS1022104
BATTERY NFC1015621
BATTERY NFC SCREWS1012644

XL Version Note​

The “XL” battery variant is longer (by about 5.5”), however it uses the same components as the standard size battery. Battery Contact Plates, Pin Plates, and Battery NFC boards are identical (with identical firmware).

The only difference between the Standard and XL versions are physical length, weight, energy capacity, and a small magnet located on the standard size battery used to indicate the battery should be treated differently when operating in a mixed system.

XL Actuator / Magnet​

The XL battery utilizes a magnet (102658) attached to the pin plate with an M3x12 FHT screw (102658) so the system can detect the battery’s size when moving and placing the battery. The XL battery should cause an error in the system when trying to move it without the magnetic actuator.

the magnetic actuator.the magnetic actuator.
Part DescriptionPart #Qty
MAGNET ACTUATOR1026581
ACTUATOR SCREW1026581

Pin Plate/Pin​

The pin plate is the adapter plate that the gripping pin attaches to located on the front of the battery above the fans.

Repair / Maintenance​

The pin plate is required to be free of debris to perform its function. The front surface, top edge, and top-center bolt hole are used to calculate the plane and position of the pin when gripping onto the battery. The top edge of the pin plate should be free of damage and not chamfered.

Significant scratching or debris built up on the pin plate should be removed to prevent bad or failed scans while removing or auditing in the rack. Discoloration may cause the pin plate to not be detected by the imager and can result in a “truck not located” (or similar) error.

The pin should be free of scratches or debris that could become lodged or stuck in the gripper. Some discoloration and surface rust is acceptable from humid or salty

environments, however deeper damage must be addressed. Additional coatings may be applied to pins located in cold storage environments to prevent rust and damage from water condensation.

Replacement​

If the pin plate is damaged beyond repair, it can be replaced. Special care should be taken to install and torque the bolts properly , as damaging the threads on the battery can result in considerable repair effort.

danger

When the bolts are removed from the pin plate, the battery cells may be exposed so DO NOT insert any sharp or metallic objects in those holes.

danger

Use ONLY the specified bolts when installing the pin plate.

  • Shallow Pin Plate (0.75” thick) uses M10 x 25 SHCS

  • Standard Pin Plate (1.5” thick) uses M10 x 40 SHCS

Figure 34 Battery Front View

Follow the instructions below for replacement:

  1. CAUTION: The plate is heavy – be prepared for the weight.

  2. Remove the six (6) M10 screws from the front of the plate. The plate should now be free. Torque to 60 N.m upon re-installation.

  3. CAUTION: DO NOT grip the pin edges with a vise or tool of any kind . Damaging the edges of the pin can damage the gripper and lead to costly repairs.

    • a. IF A PIN IS DAMAGED, DO NOT INSTALL ONTO A BATTERY . That damage may be transferred to the gripper leading to much more costly damage.

    • b. It’s better to replace a $200 part than an $8,000 part.

  4. When removing the pin, remove it by using the M16 SHCS located in the end of the pin.

  • a. To re-install the pin, the pin plate (not the pin) can be placed in a vise or a 17mm hex can be inserted into the pin to keep the pin from rotating

  • b. The M16 bolt must be torqued to 262 N.m .

    1. Re-install the pin plate using a diagonal tightening scheme.
    • a. Pin plate bolt torque:

Contact Plate Replacement​

The contact plates (102978) are the electrical conductors from the battery to the rack and the cradle. Follow the instructions below for replacement:

danger

Battery terminals SHOULD be open circuit while the battery is out of the cradle. Verify terminal voltage is 0V with a multimeter.

  1. Turn off the battery by holding the power button for 3-4 seconds (more than 2, less than 10). Confirm battery is “off” when the power light is constant-off.

  2. With the battery turned off, remove the (2

    • ea) M5 x 12 FHT (Flat Head Torx) screws

    • (102210) on the contact plates with a T25 bit .

      • a. In some cases, an M5 x 12 FHS hex screw is used to secure the contact

Figure 35 Contact Plates

  • plates. These should be replaced with FHT (Torx) if desired for ease of removal in the future.

  1. The contact plate is now free and can be removed.

    • a. If hot, the contact plate can stick into the plastic housing.

    • b. A flat-head screwdriver can be used to gently rotate the top surface out of the plastic red/black housing. Use a twisting motion when setting the screwdriver into the corner made between the plate and plastic housing.

    • c. DO NOT DAMAGE THE CONTACT SURFACE of the battery OR contact plate.

      • i. If damaged, deburr the surface with an emery cloth or similar tool.

  2. Inspect the interface between the contact plate and the battery terminal for damage, discoloration, or excessive heat buildup.

    • a. Remove excess material between contact plate and battery terminal. Ensure a good electrical connection and very flat connection.

    • b. Apply a thin layer of Penetrox A or E to the joint to improve electrical conductivity and reduce the chance for oxidation.

  3. Apply blue Loctite to fasteners, install contact plate(s) and torque to 5 N.m .

Battery NFC Replacement​

The battery NFC is the antenna that allows the battery to communicate with the cradle and rack. To replace the battery NFC follow these instructions:

  1. Remove the battery from the charging rack or cradle using the “Service Battery” function or Manual Cart.

  2. If service mode is available, use that method and follow these instructions:

    • a. Locate the HMI on the primary rack and tap the tap left corner 10 times in 5 seconds or until the service menu comes up.

    • b. Select the battery from the rack that

Figure 36 Battery NFC

  • you want to service and tap

  • “Service” at the bottom of the HMI.

  • i. NOTE: The robot needs to be at the “home” position for this option to be available.

  • c. The robot will locate the battery and bring it into the hallway. d. After the robot has paused motion with the battery in the hallway, break the hallway light curtain .

    • i. If the curtains are not tripped the robot will put the battery back into the rack after 10s.

  • e. The battery can now be serviced.

    • i. When the work is complete, return to the HMI and press the green flashing button. The robot will replace the battery in the same location from which it was removed.

  1. Remove the (4) M4 FHT (Flat Head Torx) screws. The NFC should now be free but is still connected to the harness.

    • a. In some cases these are M4 FHS (Flat Head Socket) screws. Use a 3mm allen for these screws.

  2. Locate the tab on the harness at the top of the connector, press it down and pull it away from the NFC. The NFC can now be removed.

danger
  • a. Do not pull, mangle, or damage the wiring connected to this board. Do not allow this board to touch any metal surfaces while plugged into the harness. Live (fused – 3A) battery voltage exists in this connector and on this PCBA even when the battery is “off.”

  1. Locate the new NFC assembly, plug in the harness to the connector on the PCB (should click in), and confirm power is good by seeing the green LED on the board before reinstalling.

  2. With the connector pointed downward (on the bottom of the assembly), install the NFC assembly with the (4) screws and torque to 3 N.m.