ergoCub 1.1 S/N:001 – Torso Roll does not calibrate

[LoreMoretti]

Robot Name 🤖

ergoCub 1.1 S/N:001

Request/Failure description

When starting the robot the torso roll does not calibrate.

Detailed context

At the end of the calibration procedure, if I open the yarpmotorgui, I see:

The related error message in the yarprobotinterface is the following:

[ERROR] from BOARD 10.0.1.5 (torso-eb5-j0_2) time=1176s 65m 898u :  MC: hard limit reached. The joint position is outside its hardware boundaries. (Joint=torso_roll (NIB=0))

Additional context

No response

How does it affect you?

Cannot use the robot.

[filippoborgogni]

Hi @LoreMoretti ,
today I worked to solve this issue.
I could see, by trying to start the robot, that the problem was not the position reading given by the AMO sensor (and leading to a hard limit reached as described in the issue); what triggered the hardware fault was the fact that the TDB board of the torso roll joint could not receive data on I2C channel.
I checked the wiring and realized that the problem was not the cable connecting the 2foc board (label 5B0) to the I2C board, but the cable connecting the I2C board directly to the TDB board. As can be seen in the photo below, the cable in question (label WE2) passes internally to the torso mechanics, making it impossible to fix it without disassembling the mechanical assembly.

To work around the problem I therefore disabled the temperature sensor in the robots-configuration of the robot (link to the commit).
Now, as seen in the video below, the robot works properly and the joint is able to move throughout its range of motion.

WhatsApp.Video.2025-05-27.at.11.41.41_b99fb162.mp4

This issue remains open, since to rehabilitate the temperature sensor it will be necessary to disassemble the torso and check the wiring.

cc @AntonioConsilvio