Why is the MCU_3_Degraded & AUX Battery Spurious?

RMP 210, 220, 440LE, 440SE, 440 Omni
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brittjh
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Joined: Mon Dec 14, 2015 6:53 pm
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Why is the MCU_3_Degraded & AUX Battery Spurious?

Post by brittjh » Thu Jan 07, 2016 8:50 pm

1) Platform: RMP440LE w/ the “External Power Supply”
2) Currently has a payload of 60lbs and the robot is effectively “on blocks” such that the drive wheels do not touch the ground for testing of joystick.
3) Modifications
a. Inverted gearboxes from factory
b. 5V, 12V, & 48V dc/dc converters from factory.
c. Two additional batteries mounted internally of RMP440LE enclosure
d. Rear (by default bare) panel modified for panel mount connectors to access additional batteries
e. The two 5V power and 5V return lines have been crimped into the same Powerpole connectors to make a single 5V power and 5V return line
f. 12V and 48V power lines have had Powerpoles attached.
4) We are using a Segway provided OCU and one based off of example code…
5) Fault log, see attached .zip file
6) Issue:
With the robot on blocks, the 5V, 12V, and 48V lines are powering a BeagleBone, an HRI remote/Wireless Estop, and a POE hub effectively. The BeagleBone interprets the HRI joystick commands and sends them to the Segway via the hub. Turn robot on, test joystick, everything works as expected, after roughly 5min of the Segway being on an audible “Beep Beep Beep” occurs. Not knowing what this indicates we turn the Segway off via the front switch and then back on. The “Beep Beep Beep” has stopped. The remote no longer functions and we can no longer ping the Segway. We attempt power cycling a few more times and cannot ping the Segway. Upon connecting the Segway via USB to a laptop and running the RMP DEMO OCU, the demo OCU indicates that the AUX battery is at 0%. The other battery indicator I think read roughly 90%. Additionally the wheels will turn via the app. We turn the robot off again via front switch and connect the “External Power Supply” to charge the robot. Once charging commences the Battery3 LED indicator is solid red with all other LED indicators are green including the AUX indicator. After charging for 10 minutes, we repeat the remote test, everything functions as expected, after a few minutes we again here the “Beep Beep Beep” and power the robot off via front switch. Upon checking connecting again with the RMP DEMO OCU the AUX battery indicates it is now over 90% charged. Connect the charger again, and the Battery 3 indicator LED is still solid red.
1) What could be the issue causing Battery 3 to indicate that the “MCU_3_is_DEGRADED”?
2) Why does the AUX battery provide spurious measurements of charge?
3) What should I do to better narrow down the problem?
4) Does anyone know of a solution to these issues?
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ChrisC
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Re: Why is the MCU_3_Degraded & AUX Battery Spurious?

Post by ChrisC » Wed Jan 20, 2016 3:41 pm

brittjh wrote: 1) What could be the issue causing Battery 3 to indicate that the “MCU_3_is_DEGRADED”?

Battery 3 is connected to MCU_3. Since the charging status LED indicator for Battery 3 is solid red during charging (indicates no communications between charger and pack), the MCU_3_is_DEGRADED fault is likely due to: Battery 3 not installed properly or, Battery 3 pack voltage is too low to enable charging.
Try removing the battery and measuring the pack voltage. If it’s <65V it may be unable to charge or, power the MCU and will need to be replaced.

2) Why does the AUX battery provide spurious measurements of charge?

If the RMP is powered ON via the USB connection (rather than turning it on with the primary power toggle switch), the AUX battery board will not turn ON and therefore isn’t able to report SOC over the communications interface.

3) What should I do to better narrow down the problem?

Try powering the RMP ON using the toggle switch before connecting the USB interface. You should now be able to monitor the AUX battery status.

4) Does anyone know of a solution to these issues?
Answers in blue inline above.
Let us know if you need any additional assistance.

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