Green = test window (3 days). Every test must be targeted with clear pass/fail criteria.
| # | System | What's New | Design Failure Mode | Effect | S | O | D | RPN | Ship Blocker | Test | Pass Criteria | Cycles |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| B1.1 | PA Turntable | Kinco FD415P + SMK40S 100W + CRBH6013A bearing + tote rester | Turntable jams under bin weight mid-rotation | Bin stuck. Cannot present or return. Site down. | 10 | 4 | 5 | 200 | YES | Load max-weight bin (Jumbo, full). Rotate 180° → present → rotate 180° back. | 20 consecutive full rotations, zero jams, zero position errors. Motor current within rated spec. | 20 |
| B1.2 | PA Ball Screw Lift | Kinco FD425P + SMK80S 200W + THK HGW20 rails + ball screw | Lift jams or fails to reach presentation height | Bin stuck. Cannot present. | 10 | 4 | 5 | 200 | YES | Raise with max-weight bin → hold 60s → lower. | 20 consecutive lift-lower cycles, zero stalls. Position accuracy ±2mm. No backlash. | 20 |
| B1.3 | PA Combined Sequence | Full: bin on rester → rotate → lift → hold → lower → rotate back | Sequence fails at a transition | Bin dropped or mechanism collision. PA damaged. | 10 | 3 | 5 | 150 | YES | Full PA presentation sequence. Simulate user access (open door, 30s wait, close). | 20 full sequences. Load cell confirms bin at each stage. | 20 |
| B1.4 | Fork ↔ Turntable Transfer | Bin transfer from child fork to PA tote rester (new interface) | Bin doesn't seat in guide. Bin cocked on rester. | Turntable rotation throws bin. PA damaged. | 9 | 3 | 4 | 108 | YES | Fork extends, places bin, retracts. Reverse. Both bin sizes. | 20 transfers (10 Jumbo + 10 Large). Bin seats every time. Fork retracts clean. | 20 |
| B1.5 | Charging Dock — M100 | M100 IO module controls charge via PLC. Independent Mother/Child charging. | M100 fails to trigger charge. Silent failure. | Robot appears docked but doesn't charge. Dead by morning. | 10 | 4 | 7 | 280 | YES | Dock. Verify charge current within 60s. Monitor cell voltages. Disconnect/reconnect. | 10 dock-charge-undock cycles. Current confirmed every time. | 10 |
| B1.6 | FMS ↔ PLC MQTT | Brand new software interface — FMS commands PA via MQTT through PLC | FMS sends command, PLC doesn't execute | PA doesn't respond. Task hangs. | 10 | 4 | 5 | 200 | YES | Full command sequence: FMS → rotate → lift → door → ack. Inject 2s delay. | 20 sequences. All acks received. Timeout + retry logic works. | 20 |
| B1.7 | Bin-Level Tags | Child navigates to bin tag instead of rack level tag | Bin tag misread or damaged | Child can't locate target. Recovery kicks in. | 8 | 3 | 4 | 96 | No — fix at site | Read all bin tags. Obscure 2 tags to test recovery. | All read OK. Recovery works for obscured tags. | 1 |
| B1.8 | RC Module | Remote power cycle and hibernation | RC module doesn't connect | Cannot remote restart. Manual only. | 3 | 3 | 5 | 45 | No | Power cycle via RC. Hibernate and wake. | 3 successful cycles. | 3 |
| # | System | What Changed (V3 → Neo) | Design Failure Mode | Effect | S | O | D | RPN | Ship Blocker | Test | Pass Criteria | Cycles |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| B2.1 | Mother Drive Motors | 24V hub → Kinco iWMC 400W (48V, 8.2Nm) | Motor controller fault. Overheat. | Mother cannot navigate. Site down. | 10 | 3 | 4 | 120 | YES | Full route pattern with and without loaded Child. | 10 loaded runs. Temp below rated max. No faults. | 10 |
| B2.2 | Drive Wheels | 173mm rubber → 150mm PU + castor rocking | Traction loss. Ride height change. | Navigation drift, dock misalignment. | 7 | 3 | 4 | 84 | No — tune at site | Navigate test surface. Check slip. Verify dock alignment. | 10 runs. No slip. Dock OK. | 10 |
| B2.3 | Mother-Child Dock | Redesigned: aligner tracks + compliant top plate | Child doesn't seat properly | Child unstable during transit. | 9 | 3 | 4 | 108 | YES | Dock/undock loaded. Offset Mother by 5-10mm. Shake test. | 10 cycles. Seats with offset. Zero play. | 10 |
| B2.4 | Fork Motor | SM8524BL (85kgcm) → SM260BL (260kgcm, EtherCAT) | Overtorque damages bin. Undertorque can't pick. | Bin damaged or pick fails. | 8 | 3 | 4 | 96 | YES | Pick/place with heaviest bin. Verify torque limits. | 10+10 operations. No damage. No overload. | 10 |
| B2.5 | Battery + BMS (Mother) | 24V/8.4Ah Li-ion → 48V/5.0Ah LFP. New BMS. | BMS rejects charge. Premature shutdown. | Robot dies mid-shift. | 10 | 3 | 5 | 150 | YES | Full charge → run until low-battery. Measure cycles, charge time, cell balance. | 2 full cycles. Cell delta <50mV. Runtime ≥ target. | 2 |
| B2.6 | Battery + BMS (Child) | 48V/4.2Ah Li-ion → 48V/5.0Ah LFP. New BMS. | Same as B2.5 | Same as B2.5 | 10 | 3 | 5 | 150 | YES | Run as part of integrated test. | 2 full discharge-charge cycles. | 2 |
| B2.7 | Dock Connector | Staubli 172357 → 195771 (LMFB feedback pins) | Connector doesn't engage. False feedback. | No charge or false "docked" signal. | 8 | 3 | 3 | 72 | Part of B1.5 | Covered by charging dock test B1.5. | LMFB feedback matches physical state. | — |
| B2.8 | Connectors (LP-24, YM-20) | All inter-module connectors changed | Intermittent connection. Doesn't seat. | Random subsystem faults. | 7 | 3 | 6 | 126 | YES | Wiggle test all connectors. 1hr continuous soak. | All pass wiggle. Zero faults in 1hr. | 1hr |
| B2.9 | E-Stop | Green toggle → Pizzato dual-channel + 90° switch | Doesn't cut power. Or false triggers. | Safety system failure. | 10 | 2 | 2 | 40 | YES — safety | Hit E-stop during operation. Verify cut + recovery. | 5 activations. 100% cut every time. | 5 |
| # | System | Status | Test Needed |
|---|---|---|---|
| B3.1 | Climb motor (Kinco MD60) | Same motor family | Smoke test as part of integrated run |
| B3.2 | Latch motor (Cubemars AK70-10) | Confirmed same as V3 | Smoke test only |
| B3.3 | QR tag navigation logic | Same localization system | Smoke test only |
| B3.4 | Ultrasonic obstacle detection | Same sensors | Smoke test only |
| B3.5 | Bin RFID reader (Superlead CD20DE) | Same reader | Smoke test only |
| B3.6 | Load cell (Scaime) | Same model | Calibrate at site |
| B3.7 | MQTT protocol (VDA5050) | Same — but architecture bugs remain | Site commissioning. Not a ship blocker. |
| Priority | Item | Test | Cycles | Est. Time |
|---|---|---|---|---|
| 1 | Electronics box integration | Parts arrive Mar 13. Wiring + power-on. | — | Day 1-2 |
| 2 | PA full sequence (B1.1-B1.3) | Turntable + lift + combined with bin | 20 combined | ~3 hrs |
| 3 | Fork ↔ turntable transfer (B1.4) | Both bin sizes | 20 transfers | ~2 hrs |
| 4 | FMS ↔ PLC integration (B1.6) | Full command loop | 20 sequences | ~2 hrs |
| 5 | Charging dock + M100 (B1.5) | Dock-charge-undock | 10 cycles | ~4 hrs |
| 6 | Drive motors loaded nav (B2.1) | Route runs with Child | 10 runs | ~1 hr |
| 7 | Mother-Child dock (B2.3) | Dock/undock with offset | 10 cycles | ~1 hr |
| 8 | Fork motor (B2.4) | Pick/place heavy bin | 10+10 | ~1 hr |
| 9 | Battery runtime (B2.5-B2.6) | Full discharge-charge | 2 cycles | ~8 hrs overnight |
| 10 | E-Stop (B2.9) | Emergency stop from various states | 5 activations | ~15 min |
| 11 | Connector soak (B2.8) | Wiggle test + 1hr run | 1hr soak | ~1.5 hrs |
| Total active testing + overnight battery cycling | ~24 hrs | |||
The biggest risk to March 18 isn't any individual subsystem — it's the electronics box wiring arriving March 13 and needing 1-2 days to integrate. If integration takes longer than expected:
Recommendation: Prep everything while waiting — mechanical assembly, firmware flash, PLC programming, FMS config. Wiring arrives → plug and test, not plug and debug.