Troglotech T815 Gebrauchsanweisung

Troglotech T815 Crawler Workshop Manual Page 1

WORKSHOP MANUAL — T815 CRAWLER

Troglotech Ltd Phone +44(0)1730 711240

Unit 1, 3 Penns Road Phone +44(0)1730 711240

Petersfield Fax +44 (0)1730 711240

Hampshire Email info@troglotech.com

GU32 2EW Web www.troglotech.com

Troglotech T815 Crawler Workshop Manual Page 2

T815 CRAWLER - OVERVIEW

T815 Crawler Overview—Motor Drives

MECHANICS:

The mechanical construction of the T815 crawler enables quick disassembly and

is simple to repair and maintain. NOTE: See https://youtu.be/H5bHqfwd2yg for

video of assembly instructions

The diagram above shows the plain chassis and the two motor/gearbox drive

units. These are manufactured by Troglotech and are not serviceable, in the

unlikely case of malfunction they can be replaced as assemblies and the failed

unit returned to Troglotech for investigation.

The motor drives contain a 3-phase brushless motor and a Troglotech-designed

cycloid gearbox to attain the torque requirements and available volume.

The drive units can be replaced by removing the side metalwork (containing the

drive axles, seals and idler gear) and PCB’s—Note that the drive units are

connected to the Motor Drive PCB’s by a flexible Kapton lead with a ZIF

receptacle at the end—this is disconnected by sliding the lock on the PCB—this

is best done with the Motor Drive PCB still fitted to the chassis

Troglotech T815 Crawler Workshop Manual Page 3

T815 CRAWLER- OVERVIEW

T815 Crawler Overview—PCB’s

The diagram above shows the PCB positions the numbered balloons show the

order in which the PCB’s must be removed, they are connected in such a way

that only the correct order will allow them to be removed without damage.

NOTE: Removal of the Motor Drives (3 and 8) requires the disconnection of the

Kynar flexible connection from the ZIP sockets—be careful as these can be

damaged easily. Disconnection requires that the clasp is pushed towards the

flexible ribbon by around 2mm before it can be removed.

NOTE: Add a small amount of silicon grease between the motor drive PCB and

the pocket in which it is housed to conduct heat away from the driver whenever a

motor drive PCB is replaced

Troglotech T815 Crawler Workshop Manual Page 4

T815 CRAWLER - OVERVIEW

T815 Crawler Overview—PCB’s

The diagram above shows the PCB positions the numbered balloons show the

order in which the PCB’s must be removed, they are connected in such a way

that only the correct order will allow them to be removed without damage.

NOTE: Removal of the Motor Drive (3) requires the disconnection of the Kynar

flexible connection from the ZIP sockets—be careful as these can be damaged

easily. Disconnection requires that the clasp is pushed towards the flexible ribbon

by around 2mm before it can be removed

NOTE: Add a small amount of silicon grease between the motor drive PCB and

the pocket in which it is housed to conduct heat away from the driver whenever a

motor drive PCB is replaced

Troglotech T815 Crawler Workshop Manual Page 5

T815 CRAWLER- OVERVIEW

T815 Crawler Overview—PCB’s

The diagram above shows the PCB positions the numbered balloons show the

order in which the PCB’s must be removed, they are connected in such a way

that only the correct order will allow them to be removed without damage.

NOTE: Removal of the Motor Drive (4) requires the disconnection of the Kynar

flexible connection from the ZIP sockets—be careful as these can be damaged

easily. Disconnection requires that the clasp is pushed towards the flexible ribbon

by around 2mm before it can be removed

NOTE: Add a small amount of silicon grease between the motor drive PCB and

the pocket in which it is housed to conduct heat away from the driver whenever a

motor drive PCB is replaced

Troglotech T815 Crawler Workshop Manual Page 6

T815 CRAWLER - OVERVIEW

T815 Crawler Overview—Drivetrain and External Parts

DRIVETRAIN:

The picture below shows the T815 drivetrain and external parts. The drivetrain

consists of six individual axles with integral gears and two Idler Gears. These parts

are attached to, or held in place by the Tractor Sides which are secured by 12

Allen bolts

To release the Tractor Sides it is good practice to loosen the Front Cover as this

can put force on the sides. The Rear Cover contains the Swivel Connection and

the Sonde Transmitter, it also has apertures for the rear camera and lighting

(both of which are fitted to the Processor/VID PCB)

The Front Cover contains the Camera Pogo PCB, this connects to the camera

(which can be either the T812 Pan & Tilt or the Forward View Camera)

The Connector Block connects to the inserted battery pack and is the input for

all electronics within the Tractor. This, along with the sonde assembly are the

only wired components, all other connections are connector pairs

Troglotech T815 Crawler Workshop Manual Page 7

T815 CRAWLER- OVERVIEW

T815 Crawler Overview—Electronic Operation

The electronic operation of the Crawler is controlled by the Processor/VID PCB

(TC81511011). With a Battery Pack fitted to the Crawler the battery power is

disconnected from all PCB’s apart from the Processor and the TC81510011

Power Control PCB. The latter provides power to the Processor PCB via a 1K

resistor called ‘BAT SAFE’

BAT SAFE is regulated on the Processor PCB to provide a low-current 5V supply

for a sensing circuit as seen below. When the Display Unit is switched ON the

small voltage on Video+ve that is present at the end of the cable is detected by

this circuit. The detected voltage produces a HIGH level on ‘WAKE’ and this is

conducted to the Power Control PCB to switch ON the battery supply to the

complete electronics.

At switch ON the 5V power supply becomes active and is used to keep ‘WAKE’ at

a high level for a few seconds via C89—this period is long enough to allow the

Processor to start and hold ‘KEEP AWAKE’ high whilst the cameras produce video

and TTDS communications are established to ensure that the power remains ON.

Once the 5V supply is operational Video+ve will drop in DC voltage as the video

signal is transmitted.

Troglotech T815 Crawler Workshop Manual Page 8

T815 CRAWLER - OVERVIEW

T815 Crawler Overview—Electronic Operation Continued

The picture below shows the battery switching section of the Power Control PCB.

If there is a high level on ‘WAKE’ then power is made available at Motor+ve via

IC11 which supplies power for the complete crawler including the Motor Drive

PCB’s and the PSU which provides the 5V and 15V supplies.

The picture below shows the Power Supply (TC81509011) which produces 5V and

15V from the Power+ve rail—it’s source is the Motor+ve supply from the Power

Control PCB—Motor+ve and Power+ve are kept separate through the Interconnect

PCB’s from the Power Control PCB to reduce electronic noise which may affect the

video picture.

This Power Supply is the voltage source for all the electronics and cameras on the

crawler, however the Motor+ve supply is used as a raw supply for the Motor Drives

and additional lighting (large lighthead and reversing lights). The voltage from the

battery can drop below 13V which is unsuitable for the T815 camera head which is

why a separate 15V supply is available.

Troglotech T815 Crawler Workshop Manual Page 9

T815 CRAWLER- OVERVIEW

T815 Crawler Overview—Electronic Operation Continued

Once the Power Supply is established, the Processor continually communicates

with the Display Unit of the Cable Drum via TTDS signals that are present on

Video+ve. As long as TTDS data is stable and the data contains the

’KEEP_ALIVE_BIT’ (this is set as long as the Display Unit has the correct crawler/

drum software) the processor will hold ‘KEEP AWAKE’ high, which, in turn, holds

‘WAKE’ high. TTDS only works when either the front or rear camera is in

operation, TTDS needs a video signal to operate.

If data is not available the crawler will switch back OFF again. If this cycling

continues, it indicates that the voltage on Video+ve is present but TTDS data is

incorrect or missing. This behaviour will be seen if the software for the Display Unit

(both MAIN and COMMS) has not been updated; pre-T815 software does not

include the ’KEEP_ALIVE_BIT’ bit on TTDS data.

Once TTDS communications are established and the correct data is received the

processor will start communicating with the internal parts via IIC serial bus

The processor has a number of tasks:

 Continually send/receive TTDS data

 Initialise all IIC devices

 Initialise the T812 camera head (if fitted)

 Initialise the two motor drives to a safe state

 Communicate with the Display Unit via TTDS

 Select the video source between front and rear cameras

 Switch ON/OFF rear lights

 Switch ON/OFF large lighthead

 Initialise the accelerometer

 Read the accelerometer to get inclination data

 Transmit the inclination to Display Unit via TTDS

 Switch sonde ON/OFF

 Read EEPROM to get calibration data

 Get pressure sensor data and calculate true pressure

 Get IIC data from current/voltage monitors

 Calculate true voltage/current

 Transmit voltage/current to Display Unit via TTDS

 Calculate crawler orientation for auto-steering

 Determine maximum motor speed from voltage data

Troglotech T815 Crawler Workshop Manual Page 10

T815 CRAWLER - OVERVIEW

T815 Crawler Overview—Electronic Operation Continued

Once the processor has initialised all PCB’s and the T812 camera it will operate

the crawler speed, direction and camera orientation and selection via commands

from the Display Unit via TTDS:

 Continually send/receive TTDS data

 Control the T812 camera head

 Control the motor drives speed and direction

 Select the video source between front and rear cameras

 Switch ON/OFF rear lights

 Switch ON/OFF large lighthead

 Read the accelerometer to get inclination data

 Switch ON/OFF the sonde

 Get pressure sensor data and calculate true pressure

 Get IIC data from current/voltage monitors

 Return Voltage/Current data via TTDS

 Calculate crawler orientation for auto-steering

 Determine maximum motor speed from voltage data

T815 Crawler Integration with AUTO DRUM:

The T850 Auto Drum system is designed to be a transparent addition to a

standard crawler system. However, the crawler changes its behaviour if the

Auto Drum is set to ‘AUTO’ and the crawler direction is set to reverse:

 The Auto Drum sends a ‘crawler passive’ command via TTDS

 The Display Unit accepts the ‘crawler passive’ command

 The Display Unit sends out a ‘crawler passive’ command to the crawler

 The crawler does not engage reverse and switches OFF the brakes

The behaviour above requires software to be upgraded in:

 The Crawler

 The MAIN Display Unit software

 The COMMS Display Unit software

Without these software upgrades the crawler will enable its motor drives in reverse

and the Auto Drum will pull the crawler slightly faster than the wheel speed, this

substantially increases the Auto Drum current demand.

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