Botmind Maintenance App

Fault & Incident Playbook

Robot Fault and Incident Handling Procedures · v1.1 · Author: Nicholas Ng

Critical Faults

Robot is not controllable from the C2 console or poses a safety risk. Auto-stops and reports a fault + error message.

9 entries
failToEstop

Fail to E-Stop

Emergency stop command or mechanism fails to activate when triggered.

Recommended Action

Ground-level recovery

  • Attempt manual assisted control via wireless joystick (line-of-sight).
Clear Condition
  • Technical Support: Manual clear after fault-free E-stop test.
failToLowerMast

Fail to Lower Mast

Obstruction or failure during mast lowering.

Recommended Action

Ground-level recovery

  • Attempt manual assisted control via wireless joystick (line-of-sight).
Clear Condition
  • Technical Support: Manual clear after fault-free test.
failToMove

Fail to Move

Robot is unable to move autonomously or respond to teleoperation commands.

Recommended Action

Ground-level recovery

  • Attempt manual assisted control via wireless joystick (line-of-sight).
Clear Condition
  • Technical Support: Manual clear after robot mobility restored and verified.
navigationError

Navigation Error

Localization or path planning failure preventing safe autonomous navigation.

Recommended Action

C2 Operator

  • Teleoperate to designated charging station.
  • Send a charging task.
  • Escalate to ground recovery if unresolved.

Ground-level recovery

  • Attempt manual assisted control via wireless joystick (line-of-sight).
Clear Condition
  • Robot: Auto-cleared after successful re-localisation when charging.

If robot does not auto-clear

  • Technical Support: Manual clear after fault-free test.
sensorFailure

Sensor Failure

One or more critical sensors not functioning.

Recommended Action

Ground-level recovery

  • Robot halts due to sensor failure — attempt manual assisted control via wireless joystick under line-of-sight.
  • Use a dedicated recovery mode with safety functions disabled.
Clear Condition
  • Technical Support: Manual clear after fault-free test.
cpuOverload

CPU Overload

Sustained high CPU utilization affecting performance but without thermal risk.

Recommended Action

C2 Operator

  • Stop patrol task; send a new task for the robot to go charge.
  • Inform Technical Support.
  • If the situation worsens it will trigger cpuOverheat — refer to that fault.
Clear Condition
  • Robot: Auto-cleared when CPU stabilises.
cpuOverheat

CPU Overheat

CPU temperature exceeds safe operating limits, indicating cooling failure, airflow obstruction, or environmental risk.

Recommended Action

Ground-level recovery

  • Power down the robot and manually move it to a safe location.
Clear Condition
  • Technical Support: Manual clear after physical inspection and confirmed thermal stability under load.
motorFault

Motor Fault

Motor controller reports a hardware or safety-related fault.

Recommended Action

Ground-level recovery

  • Power down the robot and manually move it to a safe location.
Clear Condition
  • Technical Support: Manual clear after fault-free test.
unexpectedReboot

Unexpected Reboot

Robot experiences an unexpected reboot or shutdown during operation.

Recommended Action

Ground-level recovery

  • Attempt manual assisted control via wireless joystick (line-of-sight).
Clear Condition
  • Technical Support: Manual clear after stability confirmation.

Non-critical Faults

Robot remains controllable from the C2 console. No immediate on-site recovery required; Technical Support is informed.

11 entries
failToCharge

Fail to Charge

Charging unsuccessful or charge rate stagnating.

Recommended Action

C2 Operator

  • Stop / retry the docking task.
  • Teleoperate to a safe location.
  • Inform Technical Support for follow-up.
Clear Condition
  • Robot: Auto-cleared after stable charging resumes.
batteryFault

Battery Fault

Battery health or protection circuitry reports a hardware-level issue without immediate safety risk.

Recommended Action

C2 Operator

  • Limit operation.
  • Teleoperate to a safe location.
  • Inform Technical Support for follow-up.
Clear Condition
  • Technical Support: Manual clear after battery health check.
failToDock

Fail to Dock

Robot fails to align with or physically connect to the charging dock.

Recommended Action

C2 Operator

  • Retry the docking task.
Clear Condition
  • Robot: Auto-cleared after successful dock.
failToLiftMast

Fail to Lift Mast

Mast extension is obstructed or fails, affecting task execution but not base mobility.

Recommended Action

C2 Operator

  • Abort task.
  • Teleoperate to a safe location.
  • Inform Technical Support.
Clear Condition
  • Technical Support: Manual clear after fault-free test.
cameraFault

Camera Fault

Camera stream unavailable or capture failure affecting surveillance or teleconference only.

Recommended Action

C2 Operator

  • Inform Technical Support.
Clear Condition
  • Technical Support: Manual clear after fault-free test.
nvrFault

NVR Fault

NVR offline, recording stopped, or storage unavailable.

Recommended Action

C2 Operator

  • Stop operation.
  • Inform Technical Support.
Clear Condition
  • Technical Support: Manual clear after storage or service recovery.
displayFault

Display Fault

One or more onboard displays not functioning.

Recommended Action

C2 Operator

  • Inform Technical Support.
Clear Condition
  • Technical Support: Manual clear after display recovery.
speakerFault

Speaker Fault

Audio output unavailable.

Recommended Action

C2 Operator

  • Continue operation.
  • Inform Technical Support.
Clear Condition
  • Technical Support: Manual clear after speaker test.
BlinkerFault

Blinker Fault

Blinkers not functioning.

Recommended Action

C2 Operator

  • Continue operation.
  • Inform Technical Support.
Clear Condition
  • Technical Support: Manual clear after functional check.
cordonLightFault

Cordon Light Fault

Cordon lights not functioning.

Recommended Action

C2 Operator

  • Continue operation.
  • Inform Technical Support.
Clear Condition
  • Technical Support: Manual clear after light recovery.
headLightFault

Head Light Fault

Head lights not functioning.

Recommended Action

C2 Operator

  • Continue operation.
  • Inform Technical Support.
Clear Condition
  • Technical Support: Manual clear after light recovery.

Incidents

Safety or security events caused by external interaction. Robot auto-stops; operator acknowledgement is mandatory.

5 entries
eStopActivated

E-Stop Activated

Emergency stop triggered (e.g. button press).

Recommended Action

Initial response

  • C2 Operator answers the teleconference call (triggered by the robot when the e-stop button was pressed).
  • Ground-level staff inspect the robot and surrounding area.

If accidental activation

  • Reset the physical E-stop and inform C2 Operator to resume operation.

If non-benign trigger

  • Enforce stop authority and treat the robot as unsafe until recovery is completed.
  • Escalate to Technical Support for inspection and follow-up actions.
Clear Condition

Accidental activation

  • Physical E-stop reset completed.
  • C2 Operator manual acknowledgement and resume operation.

Non-benign trigger

  • Ground-level verification confirms safe operating condition.
  • C2 Operator manual acknowledgement required.
Collision

Collision

Physical impact detected (e.g. bumper hit).

Recommended Action

Initial response

  • Ground-level staff inspect the robot after impact.

Classification

  • Minor contact — no visible damage, misalignment, abnormal behaviour, or new faults.
  • Major impact — visible damage, misalignment, abnormal behaviour, or any associated fault or incident.

If minor contact

  • Inform C2 Operator to resume operation.

If major impact

  • Enforce recovery and treat the robot as unsafe until recovery is completed.
  • Escalate to Technical Support for inspection and follow-up actions.
Clear Condition

Minor contact

  • Ground-level verification completed.
  • C2 Operator manual acknowledgement and resume operation.

Major impact

  • Recovery and required hardware servicing are completed.
  • C2 Operator manual acknowledgement required.
Tampering

Tampering

Suspicious motion or force suggesting interference.

Recommended Action

Initial response

  • Ground-level staff assess the robot and surrounding area for signs of interference.

Classification

  • Minor interference — accidental contact with no damage, abnormal behaviour, or new faults.
  • Major interference — forced or repeated interaction, visible damage, abnormal behaviour, or any associated fault or incident.

If minor interference

  • Ground-level staff inform C2 Operator to resume operation.

If major interference

  • Ground-level staff enforce recovery and treat the robot as unsafe until recovery is completed.
  • Escalate to Technical Support for inspection and follow-up actions.
Clear Condition

Minor interference

  • Ground-level verification completed.
  • C2 Operator manual acknowledgement and resume operation.

Major interference

  • Recovery completed and ground-level verification confirms safe operating condition.
  • C2 Operator manual acknowledgement required.
Intrusion

Intrusion

Forced or unauthorized access detected.

Recommended Action

Ground-Level Staff

  • Secure the robot and surrounding area.
  • Prevent further interaction and do not resume operation.
  • Observe and report any signs of intrusion.

C2 Operator

  • Acknowledge the incident and keep the robot stopped.
  • Escalate to Technical Support and site security.
  • Preserve logs and recordings.

Technical Support

  • Inspect hardware and software for compromise.
  • Perform required recovery or reimaging.
  • Approve redeployment only after integrity is confirmed.
Clear Condition
  • Technical Support completes integrity verification and security clearance is granted.
  • C2 Operator manual acknowledgement required.
fallDetected

Fall Detected

Robot has tipped over or fallen.

Recommended Action

Ground-Level Staff

  • Secure the area and physically recover the robot to an upright position.
  • Do not resume operation.

C2 Operator

  • Acknowledge the incident and keep the robot stopped.
  • Escalate to Technical Support.

Technical Support

  • Inspect mechanical, sensor, and structural integrity.
  • Perform required servicing and validation.
Clear Condition
  • Physical recovery is completed and Technical Support confirms safe operating condition.
  • C2 Operator manual acknowledgement required.

Botmind © 2026 · Playbook sourced from Robot Fault and Incident Handling Procedures v1.1