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Standards & Regulations

Team D: CuBi

16682 MRSD Project II

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Standards & Regulations

UL-2054

Standard for Household and Commercial batteries

UL-1740-BULLETINS-2006 (Third Edition)

Robots and Robotic Equipment

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UL-2054 Scope

Requirements for portable batteries (single or multiple cells, rechargeable or not) for use as power source in products
Objective is to reduce risk of fire or explosion of batteries during use in a product or during removal and transportation
Does not cover exposure to toxic elements of a battery
Separate standard for Lithium cells UL 1642

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UL-2054 Scope

Kiwibot delivery robot catches fire on UC Berkeley campus after 'human error'.

Defective battery installed. Dec/2018

Source: https://www.bbc.com/news/technology-46593190

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UL-2054 Industries Applicable

Any entity shipping products with batteries or batteries by themselves should follow these standard

Consumer products
Commercial products
Industrial products

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UL-2054 CuBi

This standard applies to our product as we will shipping CuBi to households with a battery included in the packaging. It also guides our design decisions for improved safety of the battery enclosure, connectors and easy accessibility.

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UL-2054 Construction

Requirements		CuBi
Casing & Enclosure	Strength and rigidity to resist possible abuses to reduce risk of fire or injury	Protect the cells from excessive exposure by designing a proper enclosure rigid and with no flex.
Electrolyte	Not contain pressurized vapor of liquid that expels when punctured	Communicate requirement to manufacturer. Sample batteries from stock 1/1000 and puncture it to test it
External battery pack connectors	Constructed to prevent short circuiting	Recess and insulate terminals. Also use terminals that can only connect correctly. We use Amass XT-30

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UL-2054 Electrical Tests

Requirements: Battery should not explode, catch on fire, and no chemical leaks from cracking, rupturing battery casing		CuBi
Short-Circuit Test	Short circuit fully charged battery, record temperature, complete discharge.	Request test from manufacturer. Sample 1/1000 batteries and run test internally
Abnormal Charging Test	Use batteries discharged to manufacturer’s rated capacity. Charge it with three times the specified Ic current for minimum 7 hours.	Request test from manufacturer. Sample 1/1000 batteries and run test internally
Abusive Overcharge Test	Charge battery at 10 times C5 amp rate capacity	Request test from manufacturer. Sample 1/1000 batteries and run test internally
Forced-Discharge Test	Connect fully charged multi-cell pack with fully discharged multi-cell pack	Request test from manufacturer. Sample 1/1000 batteries and run test internally
Battery Pack Surface Temperature Test	Subject fully charged battery pack to constant resistive load set to just under operating limit	Perform test internally and check that temperature does not exceed 75 Celsius if no temperature marking

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UL-2054 Mechanical Tests

Requirements: Battery should not explode or catch on fire		CuBi
Crush Test	Battery is to be crushed between two flat surfaces until a force of 13 KN is reached	Request test certificate from manufacturer. Set up a hydraulic arm or arbor press internally and perform test every 1/1000 samples
Impact Test	Drop a 9.10Kg weight, from 610mm on a bar laying across on a battery	Replicate the test internally sampling 1/1000
Vibration Test	Subject samples to simple harmonic motion with amplitude 0.8mm, frequency from 10 to 55 hertz in three perpendicular directions	Request certificate from manufacturer. Hire third party test lab as needed for quality control.

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UL-2054 Battery Enclosures

Requirements		CuBi
250 N Steady Force Test	Apply steady force for 5 seconds, on top, bottom and sides of battery pack enclosure over a 30mm circular plane surface. Examine after 6 hours. Shall not vent or leak.	Perform test internally 1/1000 sample
Mold Stress Relief Test	Place samples in a circulating air-oven at 70 Celsius for 7 hours. Shall show no evidence of mechanical damage: crack, warp, or melt	Hire external lab for test
Drop Impact Test	Drop each sample three times from a one-meter height so it strikes a concrete surface. Shall not explode or catch on fire or show cracks	Hire external lab for test
Markings & Instructions	Manufacturer’s name/ Model Electrical Rating Manufacturing date / Hazards	Inspect batteries for marking as they are received in inventory

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UL-1740-BULLETINS-2006 �(Third Edition)

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Scope

It is a pretty general standard that applies to Robot rated 600V or less in indoor and outdoor applications

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Markets

Paint Spraying

Mobile

Surgical

Book-keeping

Refueling

Cubi

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Part 7: Frames & Enclosures

“Robot equipment shall be constructed and assembled to have the strength and rigidity necessary to resist the ABUSES of the environment”

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Part 7: Frames & Enclosures

“Robot equipment shall be constructed and assembled to have the strength and rigidity necessary to resist the ABUSES of the environment”

Standard:

Necessary Rigidity

Cubi:

Rigid cover that does not deform when �100 Kg are placed on it

Closed position where Cubi is more protected

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Part 7: Frames & Enclosures

“Robot equipment shall be constructed and assembled to have the strength and rigidity necessary to resist the ABUSES of the environment”

Standard:

Partial collapse of system does not cause injuries to persons

Cubi:

Fail-safe mechanism if the arm falls off

Protected wires

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Part 7: Frames & Enclosures

“Robot equipment shall be constructed and assembled to have the strength and rigidity necessary to resist the ABUSES of the environment”

Standard:

Environment chemicals

Cubi:

Plastic covers to avoid metallic shock

Cover electronics to avoid wear

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Part 7: Frames & Enclosures - Key Takeaways

Robot not only needs to be safe when assembled, but also when “partially collapsed”
Be safe in a variety of environments where it may be subject to

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Part 36.1: Moving Parts - Robot Arm

“When the drive power is available to the robot arm, a yellow or visual indicator shall be provided on the manipulator to let other know that the robot is operating or motion is possible.”

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Part 36.3: Moving Parts - Robot Arm

“The robot control system shall be provided with user-connected inputs, outputs, or both, that reliably function to automatically stop the robot when safety gates, guards or the like are activated during robot operation”

Dynamixel motors physically connected to OpenCR board for information flow
Removing the physical connection will stop the motors from functioning

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Part 8: Mounting

8.1: “Robotic Equipment that is intended to be fastened in place shall have provision for mounting it securely in positions. Bolts, screws, or other parts used for mounting the equipment shall be independent of those used to secure components of the equipment to the frame, base, or panel.”��
8.2: “Portable robotic equipment shall not be provided with means for permanent mounting. If the equipment is mounted in a manner that permits removal without the use of tools, a cord connected means for electrical termination may be employed.”

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Part 8: Mounting

8.1: “Robotic Equipment that is intended to be fastened in place shall have provision for mounting it securely in positions. Bolts, screws, or other parts used for mounting the equipment shall be independent of those used to secure components of the equipment to the frame, base, or panel.”

Lots of holes for mounting in the mobility base
Custom 3D printed secure mounts for various robotics equipments, motors and sensors
Different screws, nuts and bolts for different mounts as per the application
Mounting parts (screws, nuts, etc.) different from components of equipements

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Part 8: Mounting

8.2: “Portable robotic equipment shall not be provided with means for permanent mounting. If the equipment is mounted in a manner that permits removal without the use of tools, a cord connected means for electrical termination may be employed.”

Custom 3D printed secure mounts for various robotics equipments, motors and sensors
Adjustable height + pitch angle mounting for camera
Removal mounting for LiDAR
Remove and plug cord connected electrical connectors for sensors, motors, battery, main power, peripherals.

Removable connections for motors and main power

Removable connectors for batteries �and peripherals

Adjustable sensors + Removable connectors

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Part 32: Use with Lasers, X-Radiation

“Equipment which employs laser or x-radiation shall be provided with documentation of compliance, as applicable, with the Federal requirements 21 CFR Part 1040 (Lasers); or 21 CFR 1020 (Ionizing Radiation) of the Department of Health and Human Services (DHHS).”

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Thank you!

Q&A