WARNING
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.
The Pio Robot Swap makes it easy to replace a robot on the grid, even with the system running at all times.
If you are adding a new robot to the grid, please schedule a time with your support provider for pairing of the new robot before adding it to the grid.
Follow the instructions below to safely add a new robot to the grid. If a robot is going to be swapped, start by adding the new robot first. This way, you will free up the pallet and can reuse it to park the robot that will be sent back.
1. Unpack the robot
When the new robot arrives in the warehouse, start by unpacking it to get it ready.
Remove the pallet collars safely:
- Grab the surface of the pallet collars facing the front of the robot
- Tilt upward and backward to easily remove from packaging
- Remove the external straps used for transportation
NOTE
Keep the straps and pallet for the return of the robot later on.
2. Prepare the Service Tower lift
Make sure the lift is in the lower position. If the lift is in the upper position, press and hold the down button until it reaches the lower position. See the Service Tower Control panel for details.
Press the padlock button to unlock the doors, and open the front door. The doors will be automatically locked after 20 seconds of inactivity.
NOTE
When unlocking the doors, both the front door and the side door are unlocked. When opening one of the doors, the other door will automatically lock.
3. Lower the Service Tower ramp
Manually lift and lower the ramp. The tracks should now be ready for the pallet to be positioned in front of it.
4. Position the pallet with the robot
Check the robot direction on the grid and in Customer Console, and position the pallet with the robot in the same direction. There are no options to turn the robot's direction when it is added to the system. Most robots should be south-facing in Pio.
Use a pallet jack to position the pallet in front of the Service Tower. The tracks should be positioned near the edge of the pallet (not onto the plywood base)
Align the placement of tracks from the ramp to the edge of the plywood, and lower the pallet onto the floor.
5. Connect the batteries
Open the robot's top cover. The batteries are usually transported inside the robot, but with the cables unplugged. Start by connecting the cables to the batteries.
If the batteries are transported outside of the robot, carefully insert them into the robot before connecting them.
More details are available here: How to install and remove robot batteries
Put the top cover back on the robot.
7. Trackshift the wheels
On the robot control panel, press "Offline" to set it to manual mode. Then short-press the "track shift" button upward to lift the wheels and make it ready for forward/backward movement.
More details are available here: Robot's control panel
6. Add the robot in Customer Console
Go to the Service PC and open the Customer Console app. Navigate to the Robots page to find the robot icons in the upper right corner:
- Press "Add Robot"
- Type in the number of your robot, and select North or South-facing robot
- Click "Continue"
If the robot hasn't been active in the system previously, it requires pairing with the system by Pio Support.
Please connect with your support provider to schedule a time slot for adding the new robot to the system.
7. Move the robot into the lift
Align robot wheels with crossing tracks corresponding to the robot's direction in the Service Tower. Carefully roll the robot off the pallet and onto the Service Tower ramp.
When moving the robot into the service tower, be aware that there is no physical stopper inside the lift, so make sure to move it slowly and stop once it is inside, and the ramp can be lifted back up.
NOTE
Do not roll the robot beyond the crossing tracks!
Be careful not to damage the track sensor and ensure good alignment before rolling the robot off.
8. Close the Service Tower robot door
When the robot is safely placed inside the Service Tower, lift and close the ramp, and close the robot door.
9. Park the robot inside the lift
Press the padlock button on the Service Tower control panel to unlock the doors again. This time, open the side door/service hatch to park the robot safely:
- Fine-tune the robot placement so that the tracks align with all tracks
- Short-press the "track-shift" button downward to lower the wheels
- Set the robot in Mode "Online" and close the Service Tower door
NOTE
Double-check that all eight wheels are aligned and touching the tracks.
10. Move the lift to the top position
The robot should now be parked inside the lift, with all 8 wheels down and in Mode: "Online", all doors closed, and ready to be lifted to the grid level.
Press and hold the "up-arrow" on the Service Tower control panel until the lift has stopped at the top level
The white light on the control panel of the Service Tower will illuminate when the lift is at the top level.
11. Drive the robot onto the grid
The last step is to move the robot from inside the lift and onto the grid. Go back to the Service PC and follow the instructions in the Customer Console.
In the end, the robot should be set to Planner mode and be ready for use.
Related articles
Robot Swap - Removing a robot from the grid using the Service Tower
Service Tower Control panel