Robot stopped in Recovery mode and system is Stopped


This article is intended for certified Pio Super Users who have completed Pio’s Super User course because it requires in-depth knowledge of Pio hardware.
It is dangerous to follow the instructions below if you are not a certified Pio Super User.
Please contact your manager to determine who can perform these steps in your company.

If the system stops due to a robot or bin issue, start by checking the Actions and Event log in Customer Console on the Service PC. The most common reason a robot is set to Recovery mode is when a bin is overfilled and the robots cannot grip it or lift it.

There can be different situations that need other solutions, but here is an example of how to get the system started to continue picking or storing with Pio.

Follow these steps to start the system

In this example, Port 2 is open and has requested bin ID 100101. Two robots have tried to fetch the bin, but they failed with the error message 'Wire failure' and both robots ended in Recovery mode: 

Open the Actions tab in the Customer Console Overview

Go to the Service PC and open the Customer Console. If an incident has occurred, you will find the reason why the system has stopped in the Actions tab:

If one or more robots are in Recovery mode because of a bin issue, you need to enter the grid to fix the issue at some point. It can be an overfilled bin with too much content or something that covers the gripper holes, making it impossible for the robots to pick up the bin.

Before we choose any of the options above, find the X,Y location of the cell where robots try to fetch the bin.

Open the Customer Console Viewer

In the Console Viewer, you can see where the robot(s) in Recovery are located. They will show in yellow when they are in Recovery mode. 

Select one of the robots to see the details of its position in the Info panel in the upper right corner.

Robot 1 went to Recovery first, and moved to the cell above the port, while robot 2 stopped above the issue cell. 

Take action to resolve the Incidents

Switch back to the Action tab in Console, and click to expand the details of the Incidents.

This will give you more details and options on how to resolve it:

Robot 1

The robot that moved away from the issue cell can be put back into Planner mode. This will make it ready for new tasks.

Robot 2

The robot that stopped in Recovery directly above the issue cell, can be put to Console mode. This robot will not move unless manually given commands in Console.

You can leave this robot in Console mode above the issue cell to prevent other robots from trying to fetch the same bin.

A Super User must at some point enter the grid and fix the root cause with the bin.

Start the system

When the Incidents have been resolved, the system can be started again. 

Note! This is only a workaround to get the system back to running as quickly as possible if the bin or cell with the issue can be left to fix at a later stage. If the system stops again, the bin must be fixed before continuing.

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