AGC Manual

IDC SALES CONTACTGinger Smigelski

(517) 646-0358

AUTO CRAFT SALES CONTACTMarianna Walters

(810) 765-1333Job # J9642

Rev. 1.0 Released 10/2010

AUTO-CART

AGCMODEL #

E500-TUG-CAM-S-CSB-BC25-FB-LS-A6-A8-B1

TECHNICAL MANUAL

3D Sales for

JCI RAMOS

3-D SALES, INC.* 604 SMITH STREET * ALGONAC, MI 48001-1441

(810) 794-8160 PHONE (810) 794-8165 FAX [email protected]

3-D SALES INC. is a CERTIFIED MINORITY BUSINESS

AUTO-CART SUPPORT HOT LINE for JCI

LAYOUT AND MECHANICAL SUPPORT CONTACTS: Office 7:00am – 4:30pm (810) 765-1333 Dave Benke (586) 615-2552 Tom Dudek (810) 650-6988 Michael DuVernay (586) 615-2580 CONTROLS SUPPORT CONTACTS Office 7:00 – 3:30 pm. (517) 646-0358 Jim Black (517) 648-2724 Pete Walacavage (517) 648-2719 Matt Robel (517) 648-2725 AFTER HOURS PHONE SUPPORT

Auto Craft Tool & Die



AGC AGC AGC

TECHNICAL MANUAL

TECHNICAL MANUAL

TECHNICAL MANUAL

J9642 J9642 J9642

JCI - SO

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E3500-TUG

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M-SR

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JCI - SO

UTH

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E3500-TUG

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M-SR

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6-A8-SP

JCI - SO

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E3500-TUG

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6-A8-SP

AUTO-CART

Section 00-01 Overview

TABLE OF CONTENTS

Rev 0 00-01 Auto-Cart Manual Table of Contents.docx Page 1 of 1

1. VEHICLE SIZE AND TYPE

2. GUIDANCE

3. CONTROLS

4. BATTERIES

5. OBSTACLE AVOIDANCE

6. MISCELLANEOUS OPTIONS

7. PREVENTATIVE MAINTENANCE

8. SPARE PARTS

9. MECHANICAL ASSEMBLIES

10. ELECTRICAL

11. TROUBLE SHOOTING

12. WARRANTY

AUTO-CART


AUTO-CART GENERAL OVERVIEW

Rev 1 00-02 Auto-Cart General Overview Rev 1-01.docx Page 1 of 2

The Auto-Cart is a battery operated automated delivery cart guided by a color camera. The cart is

designed to follow colored floor tape or a painted stripe path. The base cart is loaded with user-friendly

features that can provide a delivery route with just a few basic rules in path design. Step Control models

are step controlled, where each step in the path can have a host of parameters to set operating speed,

travel distance, guidance by left or right edge or center of the stripe, use various laser sensing patterns,

and control peripherals devices on the cart such as lifts and actuators. Each step also has a

communication interface to other carts to provide traffic control, allowing carts to share common paths

while avoiding collisions. This is all accomplished without having a master control.

Web interface allows any Laptop computer with Internet Explorer to view and change cart speed,

step values, camera settings and drive configurations. Carts are factory programmed to follow safety

orange color tape or paint. User may choose a new color that provides the best color contrast against

their floor using a color selection routine.

The cart is provided with an automatic speed control, based on tape width, or a particular

speed can be selected for each step. When selected to use tape width to control speed, widening the

tape will reduce cart speed. Placing wider tapelines in front of stopping areas such as load/unload

stations and corners will automatically slow down the cart to provide optimum guidance and to prevent

spilling payloads. The speed may also be selected in each step control. During that setting, the tape

width is ignored for speed control.

The cart is provided with a floor proximity sensor. Each time the cart senses a steel plate it will

initiate a slow down and stop. It is advisable to place 4-6 ft of widened tape in front of the stopping plate

to slow the cart speed before stopping. This will provide a more precise stopping location. Cart can be

programmed to recognize different length floor plates to be associated to a particular step in the

program. This will positively re-synchronize the cart to the correct step in its programmed path.

Anytime during operation the obstacle avoidance laser will stop the cart when an obstacle is

detected. The cart will resume operation when the obstacle is removed or cleared from its path. If an

obstacle was encountered suddenly very close, such as a person stepping directly in front, the brake will

be applied immediately to provide an emergency stop. At that time the cart must be re-initiated manually

by pressing the green button. During normal operation the cart may be stopped anytime by pressing the

Green start/stop button. Pressing the green button again will initiate the cart to go, resuming the current

step. Pressing the red button will remove power from the motor drives and immediately apply the brake.

AUTO-CART


AUTO-CART GENERAL OVERVIEW

Rev 1 00-02 Auto-Cart General Overview Rev 1-01.docx Page 2 of 2

The cart is provided with an alarm sounding alert horn and yellow alert light. The sound module

is usually set to play a melody when the cart is in motion. However each step has a choice of

continuous, pulsed on/off, or muted sound. The module will also ring to indicate when the cart is

blocked by an obstacle and sound a bell when the batteries are low.

The yellow beacon will change its flash sequence to alert the operator the following conditions.

Slow flash is normal operation when the cart is moving. Fast flash indicates that the cart is off the color

path or the color is not properly selected. The cart will not move in this condition. A double fast flash

followed by a pause indicates that the brake is not selected in the run position. The brake release handle

is located on cart back and must be in the operating position “run” (handle down).

The cart guidance servo system is provided with steering gain proportional to speed. This gives

the cart its ability to make tight turns at slow speeds and to smoothly follow a straight line at faster

speeds. There is a gain vs. speed table in the web page for “tuning” the cart. This table is factory set and

usually requires no additional changes.

The cart is provided with anti-runaway protection that will shut down the cart immediately upon

detection. Cart must be reset and restarted by powering with the power on/off selector switch. If problem

persists see troubleshooting.

Touch screen for information and Program Settings

Main Power On/Off

Cart Emergency Stop Button Push to stop Pull to Resume

Electronic Laser Bumper

Start/Stop Initiate

Audible warning Module (Optional Melody Module also available)

Operating Lamp with flash

annunciating Flash sequence

Brake Handle located in the Down (run) position for operation

Back of Cart

AUTO-CART

Section 01-00

AUTO-CART SIZE AND TYPE

Rev 0 01-00 Vehicle Size-Type E500 TUG.docx Page 1 of 1

AUTO-CART SIZE

1. Model E500

The Model E500 AUTO-CART can be used in Tugger, Tunnel or Unit Load applications. It has a

distributed deck capacity of 500 lbs., a towing capacity of up to 1,000 lbs. depending on traction

capabilities and towed cart wheel friction. Paint color is “Battleship Gray”.

AUTO-CART STYLE

2. “TUG” (TUGGER) STYLE

A TUGGER style AUTO-CART will tow carts using a wide variety of hitches, receivers, pins or

customer supplied hitch designs. The cart, being towed, must have a tongue length to allow the towed

cart to turn and not create a pinch point between it and the Auto-Cart or another towed cart. The total

combined weight of the cart(s) being towed cannot exceed the allowed towing capacity of the Auto-

Cart. A flexible bumper is provided in most application. CAUTION: The owner of a towed cart or a

load which is wider than the Auto-Cart deck is responsible for providing or advising this Auto-Cart

manufacturer which collision avoidance methods are to be used based on local requirements.

AUTO-CART

Section 01-00


Rev 0 01-00 Vehicle Size-Type.docx Page 1 of 1

AUTO-CART SIZE

1. Model E500


distributed deck capacity of 500 lbs., a towing capacity of up to 1,000 lbs. depending on traction


2. Model E3500


distributed deck capacity of 1,000 lbs., a towing capacity of up to 3,500 lbs. depending on traction


AUTO-CART STYLE

3. “TUG” (TUGGER) STYLE

A TUGGER style AUTO-CART will tow carts using a wide variety of hitches, receivers, pins or

customer supplied hitch designs. The cart, being towed, must have a tongue length to allow the towed

cart to turn and not create a pinch point between it and the Auto-Cart or another towed cart. The total

combined weight of the cart(s) being towed cannot exceed the allowed towing capacity of the Auto-

Cart. A flexible bumper is provided in most application. CAUTION: The owner of a towed cart or a

load which is wider than the Auto-Cart deck is responsible for providing or advising this Auto-Cart

manufacturer which collision avoidance methods are to be used based on local requirements.

4. “TUN” (TUNNEL) STYLE

A TUNNEL style AUTO-CART will tow carts using an electric actuator to attach the towed cart to

the Auto-Cart. The cart, being towed, must have a counter-weighted attachment to receive the Auto-

Cart actuator pin. The towed carts can be released, on command from the Auto-Cart controls.

Normally, only one (1) cart is towed. This style cart is used to perform cart exchanges (dropping off a

full cart and exchanging it for an empty cart). The total combined weight of the cart being towed

cannot exceed the allowed towing capacity of the Auto-Cart. A flexible bumper is provided.

CAUTION: The owner of a towed cart or a load which is wider than the Auto-Cart deck is

responsible for providing or advising this Auto-Cart manufacturer which collision avoidance

methods are to be used based on local requirements.

AUTO-CART

Section 01-01


Rev 0 01-01 Vehicle Size E500.docx Page 1 of 1

AUTO-CART SIZE

1. Model E500

The Model E500 AGC can be used in Tugger, Tunnel or Unit Load applications. It has a distributed deck capacity of 500 lbs., a towing capacity of up to 1,000 lbs. depending on traction capabilities and towed cart wheel friction. Paint color is “Battleship Gray”.

This document is Uncontrolled when printed. Rev.: 11172007

AUTO-CART STANDARD FEATURES:

• Drive and Steering: o 24 VDC differential transaxle w/ motor and an

electrically released, spring set, fail-safe brake; o 8”/208.4mm diameter Urethane drive wheels; o Linear position feed-back sensor; o High torque steering actuator; o 4” dia. spur gear driven Urethane steering wheel; o Steering position feed-back module;

• Guidance: o Digital video camera with custom algorithms; o Modulated, uniform, self-contained light source; o Guidepath tape re-teach or program new color; o Dead reckoning capable; o Loss of guidance sensing;

• Cart Controls: o A dedicated micro-processor core module

controls: speed, steering, guidepath imaging and the linear STEP program;

o Operator controls; o Obstacle detection and bumper control; o Diagnostics o Battery and charger management; o Web page control and interface; o Communication interfaces, when necessary; o Part present and Stop floor marker detection;

• Visible Diagnostics: o Battery condition, low; o Loss of guidepath; o Obstacle detected;

AUTO-CART STANDARD FEATURES:

• Speed Control: o Pulse Width Modulated (PWM) o High bred “Closed” loop o Automatic deceleration in curves and selected

straight sections without programming; o Programmable speeds o Automatic speed selection with the STEP

programming module;

• Battery and Charger: o (2) 12 VDC GEL @ 71 Amp Hour; o 24 VDC, motor operating voltage; o 25 amp “smart” charger, (3) auto charge levels; o Removable battery tray for easy recharging; o Quick connectors for faster battery exchange;

SPECIFICATIONS:

• Live load capacity (on deck)………..…….………...500 lbs

• Tugger Capacity……..……………………..Up To 1000 lbs

• Mule wt w/batteries and charger……………....…...250 lbs

• Max. Speed .…………………………………….…225 FPM

• Drive Voltage....……………………………………..24 VDC

• Stopping Accuracy .………………………..……..±.25 Inch

• Ground Clearance.……..……………………………..1 inch

• Min. Turn Radius (90°)..…………….25 inches @ 90 FPM

• Deck Dimensions.............…………...36” L x 24” W x 9” H

• Deck Material…Pre-Punched, Formed and Welded Steel

NOTES:

Please consult the factory for a list of options, price, delivery and AGC application assistance. Demo and proto-type vehicles may be

AUTO

Rev 0

AUTO-CART STYLE

“TUG” (TUGGER) STYLE A TUGGER style AUTO-CART or customer supplied hitch designs. The cart, being towed, allow the towed cart to turn and not create a pinch point between it and the Aanother towed cart. The total combined weight of the cart(s) being towed cannot exceed the allowed towing capacity of the A CAUTION: The owner of a towed cart or a load which is wider than the responsible for providing or advising this Amethods are to be used based on local requirements.

Examples:

E3500

E500

AUTO-CART

Section 01-02


01-02 Vehicle Type TUG.docx

“TUG” (TUGGER) STYLE

CART will tow carts using a wide variety of hitches, receivers, pins or customer supplied hitch designs. The cart, being towed, must have a tongue length to allow the towed cart to turn and not create a pinch point between it and the Aanother towed cart. The total combined weight of the cart(s) being towed cannot exceed the allowed towing capacity of the Auto-Cart. A flexible bumper is provided in most application.

The owner of a towed cart or a load which is wider than the Autoresponsible for providing or advising this Auto-Cart manufacturer which collision avoidance methods are to be used based on local requirements.

E500 E3500

E500 E3500

Page 1 of 1

will tow carts using a wide variety of hitches, receivers, pins must have a tongue length to

allow the towed cart to turn and not create a pinch point between it and the Auto-Cart or another towed cart. The total combined weight of the cart(s) being towed cannot exceed the

exible bumper is provided in most application.

Auto-Cart deck is manufacturer which collision avoidance

E3500

AUTO-CART

Section 02-01 Guidance

COLOR CAMERA

Rev 1_02 02-01 Guidance Cam.doc Page 1 of 1

CAM – COLOR CAMERA w/ TAPE GUIDANCE

The vehicles are guided by a commercially available color camera. They follow a

colored vinyl aisle marking tape. Inputs from the camera are processed and the resulting signals cause the drive steering motor to steer. The baseline steering heading is pre-programmed into the AGC controls.

The camera system can be adjusted, by the end user, to follow other tape colors besides the standard “orange” color. Gaps in the tape can be bridged by “dead reconning” across the gap. The length of travel across a “dead reconning” space is an end user defined variable. Tape can be laid on top of other tape, including magnetic guidepath. Damaged tape can be repaired easily witout any special tools. It is difficult to lift the tape from the floor but it can be cut by fork truck forks or racks/pallets and other dunnage being pushed across the tape. This technology allows camera system to provide other benefits such as: automatic slow-down in turns, a wider guidepath with regard to a “loss of guidance” stoppage.

AUTO-CART


CAMERA SETUP

Rev 1_02 02-02 Camera Set-Up Rev1_02.doc Page 1 of 6

Ver 2.xx, 3.xx, 4.xx and 5.xx

This program allows the user to select the color of the guidance stripe with background color to optimize tracking. This process must be done for each cart to optimize the cart guidance due to slight variations in camera exposures. Cart camera must be positioned on center of guidance stripe. Connect serial cable to Guidance processor 9-pin plug. Position the first toggle switch located next to serial plug for the camera to the PC position.

(2) Click on CMUcam2GUI Icon on your desktop

(3) Click OK if you are using the No. 1 serial port or type in your port number and click OK. Once connected the screem shown on the next page will open up.

(1)To view camera via software position the toggle switch to the PC position. This disconnects the camera from the processor and connects it to the computer.

Connect PC to this serial port with a standard serial cable.

AUTO-CART


CAMERA SETUP


(4) Click the Config button and the next screen will pop up.

CMUcam type 2 Version 6

This message indicates that

the computer recognizes the

camera.

AUTO-CART


CAMERA SETUP


(5) Select all of the following: Color Space-YCrCb White Balance-Off Auto Gain-Off Camera Resolution-High

(9) Click Camera View to view the image stripe.

(6) Type 10 to crop upper window edge.

(7) Type 110 to crop lower window edge.

174 10

(8) Click on Set Window.

110

AUTO-CART


CAMERA SETUP


(12) Type 25 for typical tolerance. The wider the value the more color range the camera will track.

(13) Select Grab Frame This will initiate a “snapshot” of the Camera view. (Next page)

(10) Type in CR 0 8 (Camera Gain range 4 thru 63) and click the send box to the right. Then type CR 6 128 (Camera brightness range 1 thru 255) and click the send box again. Keep one space between each number. Note these values may need to be adjusted depending on color and floor background.

(11) Click the Send button to transmit each "CR" command (see item 10) to the camera. Repeat for the CR 6 128 command.

AUTO-CART


CAMERA SETUP


A color strip will be visible after the "Grab Frame" button is clicked. In YcrCb mode the colors may not appear normal, but you should be able to clearly distinguish the stripe.

(14) Place the curser over the desired area (usually in the center of the bright spot) and Click. A light blue highlighted area will be automatically selected. You may select different areas to achieve as much solid highlight area over the stripe as you can, as shown. If any blue highlighted areas are visible outside the stripe, or if you can't achieve solid highlighting, you may need to change camera brightness and gain setting (step 10/11), then repeat steps 12-14 to test your changes.

(15) After Light Blue highlighted area is satisfactorily selected, Click on the Color tab and the next screen will appear.

AUTO-CART


CAMERA SETUP


After clicking on the color track button below, (See step 16), this blue highlighted area will appear. This is the tracking window that will produce the position error signal to the guidance processor.

(17) These 6 groups of numbers are the color values selected by the camera. They must be documented and entered in the WEB page for “Color Stripe Setup” Note: Min and Max values are entered in the Min and Max values on the WEB page. Don’t transpose entry.

(16) Click on the Track Color button and a dark blue window will appear. Moving the cart from left to right of the stripe will show the tracking. The dark blue stripe should be steady and visible across the whole window when the cart is moved from left to right of stripe. With the blue stripe visible you may test run the cart by simply switching the toggle switch on the guidance processor to RUN. These values are not saved so don’t kill the cart during the test. You should copy the six min and max numbers, along with the brightness and camera gain values which you set up in step 10. Once satisfied with values enter the Min and Max colors values, camera brightness and gain via the WEB interface under the Color Setup. Note: the CMU camera viewer program may not resume operation if you switch the camera back to the PC port with the toggle switch; it may be necessary to use Task Manager to quit the program and start over. If so, you will need to re-enter all of your settings and parameters as the viewer program initializes the camera to a default condition upon startup.

Red Green Blue Min

Red Green Blue Max

AUTO-CART

Section 03-02 Controls

STEP PROGRAMMING MANUAL

Rev 1_02 03-02 Step Programming Manual Rev 1_02.docx Page 1 of 25

Table of Content Page

Section 1 - Step Description…………………………………………….…………. 3

Section 2 - Basic Step Components……………………………………….............. 3

2.1 Step Initiation………………………………………………………………. 3

2.1.1Go Mode……………………………………………………………… 3

2.2 Step Action…………………………………………………........................ 4

2.2.1 Function……………………………………………………………… 4

2.2.2 Speed & Speed Mode………………………………………………... 4

2.2.3 Direction and Navigation…..………………………………………... 3

2.2.4 Size………………………………………………………………….. 4

2.2.5 Obstacle Avoidance (Scanner)..……………………………..………. 4

2.2.6 Loss of Guidance…………………………………..………………... 5

2.3 End of Step………………………………………………………………... 5

2.3.1 End Mode……………………………………..……………………... 5

2.3.2 Next Step…………………………………...……………….….......... 5

2.3.3 End Action…………………………………………………………… 5

2.4 Examples of Basic Steps………………...………………………………… 6

2.4.1 Basic Steps………………………………………………….….......... 6

2.4.2 90 deg. Intersection……...……………………………………........... 8

2.4.3 Intersection (Y) ………………………………………….…………... 9

2.4.4 Basic Loop…………………………………………………………… 10

Section 3 - Advanced Step Controls….…………………………………………… 12

3.1 Delay for Warning…………………………………………………………. 12

3.2 Sound……………………………………………………………………… 12

3.3 Next Step…………………………………………...……………………… 13

3.4 Initiation Triggers………………….………………………………………. 14

3.5 Hardwired Outputs………………………………………………………… 15

3.6 Plate Recognition…………………..………………………………………. 19

3.7 Occupied Step………………………...…………………………………… 20

3.8 Routes……………………………………...…………………………….… 21

Appendix A - Important Terms…………………………………………………… 22

Table of Figures Page

Figure 1-1 Basic Step Layout………………………………………………...... 2

Figure 2-1 Basic Step Example 1………………………………………............ 6

Figure 2-2 Basic Step Example 2………………………………………............ 6

Figure 2-3 Basic Step Example 3………………………………………............. 7

Figure 2-4 Example of 90 deg. Intersection……………………………............ 8

Figure 2-5 Example of an Intersection………………………………….............9

Figure 2-6 Basic Loop Example…….…………………………………............ 10

AUTO-CART




Table of Figures (cont’d) Page

Figure 3-1 Next Step Example………………………....………………............ 12

Figure 3-2 Initiation Triggers using Hardwired Inputs...…………………........ 14

Figure 3-3 Initiation Triggers using Radio Inputs…......…………………......... 15

Figure 3-4 Outputs Example 1………………………....…………………........ 16

Figure 3-5 Outputs Example 2………………………....…………………........ 18

Figure 3-6 Occupied Step List Example…………....………………….............. 20

AUTO-CART




1 Step Description 1

The Auto-Cart is programmed to navigate a path using a Step Program. This program allows the path to

be broke down into smaller sections. Each section allows the AGC to be setup to carry out a different

function that can range from navigating corners and intersections to raising and lowering lifts. Each

section contains the need information for the AGC to complete a portion of the path. As these sections,

or “steps”, are put together in sequence, the AGC uses the supplied information to navigate the entire

path

A step contains three main components; initiation, action, and end. The initiation portion of the step

informs the cart how to determine when to start the step. The AGC will wait until the initiation

conditions are satisfied prior to starting the step. Once the step has been initiated, the cart will use the

data stored in the action portion of the step to determine which functions to perform. This data contains

information ranging from the step’s speed and size to how to perform obstacle avoidance. As the cart

approaches the end of the step, the end portion of the step tells the cart how to determine that it is at the

end of the step and what actions to take. To achieve a seamless transition between two steps, the end

action of one step has to be set to work with the initiation of the next.

Figure 1-1 Basic STEP Layout

2 Basic Step Components 2

2.1 Step Initiation

2.1.1 Go Mode

The Go Mode is used by the AGC to determine when to initiate a step. The cart will wait for the

initiation condition to be true prior to placing the cart into cycle for the step. The options

available for this parameter are:

• Operator Release – The AGC will initiate cycle when the Master Start pushbutton is

pressed.

• Automatic – If the AGC is already in cycle upon transition into the step, the AGC

will continue to run. Otherwise the Master Start pushbutton will have to be pressed to

release the cart.

• Input Triggers – The AGC will wait until the entire input trigger conditions are true

prior to initiating the step. This option will be discussed in Section 3.4.

Initiate Action End

AUTO-CART




2.2 Step Action

2.2.1 Function

The step Function is used by the AGC to determine what actions to carry out during the step. The

options available for this parameter are:

• Set Outputs, Forward – The AGC will set the hardwired and radio outputs to the step's

programmed settings and travel the distance set in Step Size.

• Set Outputs Only -The AGC will set the hardwired and radio outputs to the step's

programmed settings and then go to the next step.

• Set Outputs, Delay -The AGC will set the hardwired and radio outputs to the step's

programmed settings and delay the time set in Step Size.

2.2.2 Speed & Speed Mode

The Speed and Speed Mode parameters are used by the AGC to set the speed that it will travel

during the step. The speed uses units of inches per second. In Single Speed mode the cart will

maintain the programmed speed. In Proportional Speed mode, the programmed Speed will be

achieved on standard width tape and straight steering, but the AGC will automatically slow down

if it sees wider tape or enters a turn. The AGC will determine which state to use based on the

setting in the Speed Mode. The options available for this parameter are:

Speed Mode

Proportional to Line Width – The maximum speed that the AGC will run will be the

speed set in the Speed parameter. It will slow from this speed as the tapes width

increases or when a turn is entered.

Single Fixed Speed – The AGC will run the speed set in the Speed parameter.

Speed

• Speed Units – Inches/Second

• Speed Limits – 0 to 33

AUTO-CART




2.2.3 Direction and Navigation

The AGC uses the Direction and Navigation to decide how it will steer through the step. In most

cases the cart should be set to follow the tape; in this mode the cart will use the Direction

parameter to determine what portion of the tape to follow -Left edge, Right edge, or Center. The

other option allows the cart to run without tape; it will move straight, or execute a maximum turn

left or right depending on the Direction parameter. The options available for the parameters are:

Navigation

• Normal Guidance – The AGC will follow the tape based on the setting set in

Direction.

• Dead Reckon – The AGC will not follow the tape and will head in the direction set in

Direction.

Direction

• Direction when Normal Guidance is used:

o Left – The AGC will follow the left side of the tape.

o Center – The AGC will follow the center of the tape.

o Right – The AGC will follow the right side of the tape.

• Direction when Dead Reckon is used:

o Left – The AGC will turn to the left.

o Center – The AGC will travel straight.

o Right – The AGC will turn to the right.

Direction Programming Recommendations:

• Follow the center of the tape when able.

• When transitioning from one side of the tape to the other, pass through a short step that

uses the center of the tape. This will reduce the appearance of the cart jumping from one

side to the other.

• If any paths must cross, have the tape cross at ninety degrees when able.

2.2.4 Size

The AGC uses the Size parameter to determine the length of the step. The way that this is used is

based on the setting in the Function parameter. Bellow is how this parameter affects the units of

the parameter.

• Set Outputs, Forward – When this function setting is used, the Size parameter will use the

unit of inches.

• Set Outputs Only – When this function setting is used, the Size parameter is ignored.

• Set Outputs, Delay -When this function setting is used, the Size parameter will use the

unit of seconds.

• Size Limits – 0 to 9999

*

AUTO-CART




2.2.5 Obstacle Avoidance (Scanner)

The Obstacle Avoidance parameter, also referred to as Scanner, is used by the AGC for selecting

the obstacle detection modes. The value set in this parameter will correspond to the areas setup

in the scanner’s software. Refer to the area settings in this software to determine the appropriate

area to use.

Limits

• STI limits: 1 & 2

• Hokuyo limits: 1 – 15

AUTO-CART




2.2.6 Loss of Guidance

The AGC will use the value set in Loss of Guidance to determine how far it is allowed to travel

after the guidance tape is lost. This feature is used to help accommodate missing portions of the

tape. This value will be ignored when using Navigation Setting of Dead Reckon.

• Loss of Guidance Units – inches

• Loss of Guidance Limits – 6 to 24

2.3 End of Step

2.3.1 End Mode

The End Mode is used by the AGC to trigger the end of the step. When the End Mode setting is

satisfied, the cart will load the step set in Next Step and perform the End Action. The options

available for this parameter are:

• Distance – The AGC has reached the end of the step after it has traveled the distance that

is set in the Size parameter.

• Marker – The AGC has reached the end of the step after it has traveled over a marker, or

exhausted the Distance parameter.

• Time -The AGC has reached the end of the step after it has delayed for the time period

that is set in the Size parameter.

2.3.2 Next Step

The AGC uses the Next Step parameter to sequence the steps. Once the End Mode is satisfied,

the cart will load the step set in this parameter. If this is set to zero, the steps will be loaded

consecutively. Refer to Section 3.3 for more details on how this parameter is used.

• Next Step Limits – 0 to 99

2.3.3 End Action

The End Action is used by the AGC to determine whether to remain in cycle for the next step.

This parameter, along with the Go Mode of the next step, will determine how the AGC will

respond during the transition to the next step. The options available for this parameter are:

• Stop – The AGC will load the step set in Next Step and then wait for a signal to continue.

This is usually used in conjunction with the next steps Go Mode setting of Operator

Release or Input Triggers.

• Merge -The AGC will load the step set in Next Step and then continue to run that step.

This is usually used in conjunction with the next steps Go Mode setting of Automatic.

AUTO-CART




2.4 Examples of Basic Steps

2.4.1 Basic Steps

Example 1

In this example, the cart will be programmed to run a straight path of 310 inches. It will require an

operator to release the cart, and once it has reached the end, it will stop. The cart’s speed is not critical

so it will be set to a lower speed of ten inches per second. The step will be programmed as follows.

310”

Figure 2-1 Basic STEP Example 1

Step Initiation

• Go Mode – Operator Release

Step Action

• Function – Set Outputs, Forward

• Speed Mode – Single Fixed Speed

• Speed – 10

• Navigation – Normal Guidance

• Direction – Center

• Size – 310

• Loss of Guidance – 12

End of Step

• End Mode – Distance

• End Action -Stop

Example 2

In this example, the cart will be programmed to run a straight path of 100 inches maximum, but

instructed to stop when it encounters a floor marker plate any time within the 100 inch move, to

provide precision alignment with some external fixture. It will require an operator to release the

cart, and once it has found a floor marker, it will stop. The cart's speed is not critical so it will be

set to a low speed of ten inches per second. The step will be programmed as follows.

100”

Figure 2-2 Basic Step Example 2

AUTO-CART




Step Initiation


Step Action



• Speed – 10



• Size – 120


End of Step

• End Mode – Marker

• End Action – Stop

The Step size was set twenty inches longer than the actual step size to allow the cart to have the

distance to travel over the marker.

!

AUTO-CART




Example 3

In this example, the two steps from the first two examples will be put together. Example one will

become step one and example two will become step two. The cart will travel at a moderate speed

of twenty inches per second through step one and then slow to eight inches per second in step

two to prepare for a stop at an operator station marked by a floor marker. It will be assumed that

the scanner has area 1 set for high speed travel and area 2 programmed to be narrow for slower

speed steps near operator stations. The step program for these two steps will appear as follows.

STEP 2: 100”

STEP 1: 310”

Figure 2-3 Basic Step Example 3

Step 1

Step Initiation


Step Action


• Speed Mode – Single Fixed

Speed

• Speed – 20 •



• Size – 310

• Obstacle Avoidance -1


End of Step End of Step


• End Action -Merge

Step 2

Step Initiation

• Go Mode – Automatic

Step Action


• Speed Mode – Single Fixed

Speed

• Speed – 8



• Size – 120

• Obstacle Avoidance - 2


End of Step End of Step


• End Action - Stop

In step two, the Speed Mode parameter was set to Proportional to Line Width to have the ability

to add a second width of tape to help slow down for the plate if needed. The step would have

cycled properly if it was left at Single Fixed Speed.

To have the two steps run as one step, the End Mode of step one was set to Merge and the Step

Initiation of step two was set to Automatic. By setting the steps this way, the cart will transition

between the two steps without stopping.

!

!

AUTO-CART




2.4.2 90 deg. Intersection

This example will be the same as example one of section 2.4.1 except that another path crosses it

at ninety degrees. In this example, the step will be programmed exactly the same way. In order

for the cart to travel through the intersection properly, the AGC’s direction must be set to center.

310”

Figure 2-4 Example of 90 deg. Intersection

Step Initiation


Step Action



• Speed – 10


• Direction – Center (Must be set to Center)

• Size – 310


End of Step



!

AUTO-CART




2.4.3 Intersection

This example will be the same as example one of section 2.4.1 except that another path turns off

of this path to the left. The cart will travel straight past the intersection. In this example, the steps

will be programmed similarly. The only change that will need to be made is to have the

navigation Direction follow the right side of the tape.

310”

Figure 2-5 Example of an. Intersection

Step Initiation


Step Action



• Speed – 10


• Direction – Right (Must be set to Right)

• Size – 310


End of Step



To have the cart follow the path to the left, the cart’s direction would need to be set to the left.

!

*

AUTO-CART




2.4.4 Basic Loop

In this example, the cart will be programmed to navigate the loop shown in Figure 2-6. The cart

will leave operator station one in step one traveling at fifteen inches per second and head toward

the operator station two. Along the way, it will come to an intersection where the AGC will have

to choose between three directions. The cart will travel straight through the intersection and on to

step two where the cart will slow to eight inches per second to prepare to stop on the floor

marker.

After operator is complete with the cart at the second station, the operator will release the cart to

travel back toward the first station. The cart will then need to navigate though two intersections.

The first one will require the cart to navigate to the left. The second intersection will require the

cart to navigate to the center of the tape. The cart will travel at fifteen inches per second through

these two sections. As the cart approaches the first station, it will use double width tape to slow

from twelve inches per second to prepare for the stop at another marker.

Operator Station 1

Step 5: 200” Step 4: 100” Step 3: 450”

Step 1: 650” Step 2: 100”

Operator Station 2

Figure 2-6 Basic Loop Example

AUTO-CART




Step 1

Step Initiation • Go Mode – Operator Release

Step Action • Function – Set Outputs, Forward


• Speed – 15



• Size – 650

• Obstacle Avoidance - 1


End of Step • End Mode – Distance

• End Action –Merge

Step 3




• Speed – 15


• Direction – Left

• Size – 450





Step 5

Step Initiation • Go Mode – Automatic


• Speed Mode – Proportional to Line Width

• Speed – 12



• Size – 230



End of Step


• End Action -Stop

Step 2




• Speed – 8



• Size – 120



End of Step • End Mode – Marker

• End Action - Stop

Step 4




• Speed – 15



• Size – 100





The direction in step five is set to follow the

left side of the tape so that it won’t appear to

run toward the right on the double wide

tape.

!

AUTO-CART




3 Advanced Step Controls

3.1 Delay for Warning

The Delay for Warning is used by the AGC to determine how long to wait between the step initiation

and the start of motion. At any point when motion has been stopped during this step, the cart will

execute this delay prior to restarting. During the delay, the cart will activate the sound module. If the

cart is already in cycle due to transitioning from another step, then this parameter will be bypassed

and the cart will continue to run the step.

• Delay for Warning Units – Seconds

• Delay for Warning Limits – 0 to 5

3.2 Sound

The Sound parameter is used by the AGC to determine how the sound module is used during the

step. The options available for this parameter are:

• Silent – The sound module is not used while the AGC is in motion. This is not recommended

where personnel may be present.

• Continuous – The sound module is held on continuously while the AGC is in motion.

• Pulsed – The sound module will be turned on and off while the AGC is in motion.

3.3 Next Step

The Next Step is used by the cart to sequence the steps. This allows the step numbers to be non-

consecutive. For example, this allows steps to be added into a preexisting path without affecting

other steps.

-Example:

Using the example in section 2.4.4 Basic Loop, the steps could have been programmed in the

following sequence.

Step 1 : 200” Step 3: 100” Step 5: 450”

Step 4: 650” Step 2: 100”

Figure 3-1 Next Step Example

AUTO-CART




Step 1




• Speed – 12



• Size – 230




• Next Step – 4

Step 3




• Speed – 15



• Size – 100



• End Action – Merge

• Next Step – 1

Step 5




• Speed – 15



• Size – 450


End of Step



• Next Step – 3

Step 2




• Speed – 8



• Size – 120




• Next Step – 5

Step 4




• Speed – 15



• Size – 650




• Next Step – 2

AUTO-CART




3.4 Initiation Triggers

If Initiation Triggers are selected for the Go Mode, the AGC will use it’s hardwired and radio inputs

to place the cart into cycle for the step. This allows the cart to initiate off of signals sent by a remote

device. In order for this function to operate properly, all of the hardwired and radio inputs have to be

set correctly. Any unused input must be set to N/A to inform the cart that the state of this input is not

critical for a release. Otherwise, the input must be set as On or Off. It is recommended that the steps

that use input triggers as their Go Mode are set to use a short distance or to be set as a delay step.

When radio input triggers are used, the ID number for the remote station must be set in the Target

Radio for the step.

-Example 1:

The AGC is to be released from an operator station when an operator steps on a pedal that reveals a

reflector that will activate a photoeye mounted on the AGC. The photoeye will be wired into input

one. Step one will be set to delay three seconds and then transition into step two where the AGC will

travel one hundred inches at fifteen inches per second and then stop.

Step 2 100”

Step 1 Delay

Figure 3-2 Initiation Triggers using Hardwired Inputs

Step 1

Step Initiation • Go Mode – Input Triggers

Hardwired Input 1 = On

Hardwired Input 2-10 = N/A

Radio Input 1-16 = N/A

Step Action

• Function – Set Outputs, Delay


• Speed – 0



• Size – 3

• Obstacle Avoidance – 1


End of Step

• End Mode – Time


Step 2


Step Action



• Speed – 15



• Size – 100



End of Step


• End Action –Stop

• All non-motion steps are shown as a red line.

• Speed Mode, Navigation, Direction, Obstacle Avoidance, and Loss of Guidance settings are not

critical for step one.

!

!

AUTO-CART




-Example 2:

The AGC is to be released from a remote operator station that will communicate to the carts over the

radio communications. The remote operator station is setup to transmit using the ID of fifty. When

an operator presses the release button on the station, then the station turns on the cart’s third Radio

Input. Once Radio Input three turns on, the AGC will initiate step one where the cart will travel five

inches and then transition into step two. The AGC will travel sixty inches at twenty-eight inches per

second in step two and then stop.

Step 1 : 5 2 : 60”

Figure 3-3 Initiation Triggers using Radio Inputs

Step 1



Radio Input 1 & 2 = N/A

Radio Input 3 = On


• Target ID – 50

Step Action



• Speed –28 •



• Size – 5



End of Step



Step 2


Step Action



• Speed –28



• Size – 60



End of Step



AUTO-CART




-Example 3:

In this example, the cart will execute the same as in Example 2 except that the AGC also must see

the pallet present prox that is wired into the hardwired input five Off prior to releasing in step one.

The cart will now release only when both hardwired input five is off and radio input three is on at the

same time.

Step 1



Hardwired Input 5 = Off


Radio Input 1 & 2 = N/A

Radio Input 3 = On


• Target ID – 50

Step Action



• Speed – 28



• Size – 5



End of Step



Step 2


Step Action



• Speed – 28



• Size – 60



End of Step



3.5 Hardwired Outputs

Each step has the ability to turn on or off the hardwired outputs. This gives the cart the ability to

control lifts, photoeye senders, additional lights and sound modules, and so on. The available options

for the outputs are:

• On – Turns the output on when the step is initiated.

• Off – Turns the output off when the step is initiated.

• N/A – Leaves the output in its current state.

-Example 1:

The AGC has an additional warning light to be used when crossing isle ways. This light is wired into

output six and is used in step two which crosses an aisle way.

AUTO-CART




Example 1 (cont’d)

Step 1 : 25” Step 2 : 95” Step 3 : 45”

Figure 3-4 Outputs Example 1

Step 1



• Outputs –

Outputs 1-5 = N/A

Output 6 = Off

Outputs 7-10 = N/A


• Speed – 20



• Size – 25





Step 3



• Outputs –

Outputs 1-5 = N/A

Output 6 = Off

Outputs 7-10 = N/A


• Speed – 20



• Size – 45





Step 2



• Outputs –

Outputs 1-5 = N/A

Output 6 = On

Outputs 7-10 = N/A


• Speed – 15



• Size – 95





AUTO-CART




-Example 2:

An AGC uses a pin lift to transport part racks to and from the operator stations. When the AGC

enters the drop off station, it will push the empty rack forward until the AGC reaches the operator

station. The AGC will then turn on output two to lower its lift pin so that the full rack will be left at

the operator station. The cart will then start to pull under the empty rack. When it is clear of the link

mechanism of the full rack, the AGC will turn on output one to raise its lift pin which will then

engage the empty rack as it is passing by.

Step 1: 25” Step 3: 20” Step 4: 53”

Step 2:

Outputs Only

Figure 3-5 Outputs Example 2

Step 1



• Outputs –

Output 1 = On

Output 2 = Off

Outputs 3-10 = N/A


• Speed – 8



• Size – 25





Step 2



• Outputs –

Output 1 = Off

Output 2 = On

Outputs 3-10 = N/A


• Speed – 0



• Size – 5



End of Step • End Mode – Time


Empty

Cart

Loaded

Cart

Operator

Station

AUTO-CART




Step 3

Step Initiation


Step Action


• Outputs –

Output 1 = Off

Output 2 = On

Outputs 3-10 = N/A


• Speed –8



• Size – 20



End of Step



Step 4

Step Initiation


Step Action


• Outputs –

Output 1 = On

Output 2 = Off

Outputs 3-10 = N/A


• Speed – 8



• Size – 53



End of Step



3.6 Plate Recognition

The Plate Recognition table utilizes floor marker plates of different lengths to orient the AGC to

certain locations in a path. After the cart has traveled over a floor marker, the cart will compare the

measured plate length to the data set in the Plate Recognition Table. If there is a step number entered

for that length, the cart will load that step and then perform the action set in the associated End

Action parameter (the End Action acts in the same manner as the step End Action). If the step

number for that plate length is set to zero, the cart will treat that plate as a generic plate length. Each

route has its own Plate Recognition Table and will only load the steps within that route.

Length

• The length of the plate in inches.

Step

• 0 – Plate will be treated as a generic floor marker.

• 1-99 -After the cart has traveled over the plate, this step number will be loaded (within the

current route).

End Action

• Stop – The AGC will load the step set in Next Step and the wait for a signal to continue. This

is usually used with a Go Mode setting of Operator Release or Input Triggers.

• Merge -The AGC will load the step set in Next Step and then continue to run that step. This

is usually used with a Go Mode setting of Automatic.

Plate Recognition Programming Recommendations:

• Allow 2” and 4” plates to be generic plate lengths.

• Avoid using recognition plates on corners.

• Set a recognition plate at the point in the path were carts will be introduced to the path.

*

AUTO-CART




3.7 Occupied Step

The Occupied Step List is used with Cart-to-Cart communications to set step priority amongst the

carts. When another cart transmits a current step number that is in the step list, the cart will hold

until the step is clear.

-Example:

In the path below there is an intersection where Cart-to-Cart communication is used to set the step

priority. In this example, cart one (in steps 50-52) has priority over cart two (in steps 1-3). If the two

carts were to come to the intersection at the same time, the cart in step fifty would continue and the

cart in step one will stop and wait until the intersection is clear to continue. However, if cart two has

already entered step two, cart one will hold until the intersection is clear.

Step 52

Step 1 Step 2 Step 3

Step 51

Step 50

Figure 3-6 Occupied Step List Example

Step 1

Occupied Step List

• 2

• 50

• 51

Step 2

Occupied Step List

• 2

Cart 2

Cart 1

AUTO-CART




• Avoid having two steps that would block each other. If step fifty above had step one in it

Occupied Step List, then when a cart is setting in step one and fifty, neither cart would move.

3.8 Routes

Routes are used by the AGC so that it can have multiple paths of up to ninety nine steps per route.

This option is best utilized when a Main Cart Control Panel (MCCP) is used to control the cart

system or the carts need the ability to travel several different paths.

AUTO-CART




Appendix A -Important Terms

AGC – Automated Guided Cart

Companion Cart – An additional structure that supports the weight of the material and is transported by

a mule is referred to as a Companion Cart.

HMI – Human Machine Interface

Marker - A floor plate used to mark the end of a step. Also refer to Stop Plate and Recognition Plate.

MCCP – Main Cart Control Panel

Mule – An AGC that transports a cart (Companion Cart) that carries the majority of the payload is

referred to as a Mule.

Occupied Step – Each step has an occupied step list. If any AGC that is running the same path is

transmitting that it is in one of the steps in the occupied step list, than that AGC is in an occupied step.

While the AGC is in this step, the AGC with this occupied step list is not allowed to run.

Recognition Plate – A floor plate used to mark the transition point of steps and is associated to a specific

step in the Plate Recognition data table is referred to as a Recognition Plate. When an AGC travels over

a Recognition Plate, it will automatically load the associated step. Also refer to Marker and Stop Plate.

Route – A route can contain up to 99 steps and a AGC can have multiple routes. This feature allows a

complicated AGC path to be broken down into multiple sections (or routes). It divides the path down

into smaller, easier to manage individual paths. This also allows for easier path modifications without

potentially affecting other areas of the overall path.

RSSI – Received Signal Strength Indication – This is used as a generic term for the received signal

strength for the AGC’s.

Step – A step contains the needed information for an AGC to manipulate a small portion of an overall

path. This information contains data such as speed, distance to travel, guidance direction, and much

more. The number of steps needed to put a path together depends on the complication of the overall

path.

Stop Plate -A floor plate used to mark the end of a step which typically causes the AGC to stop. Also

refer to Marker and Recognition Plate.

AUTO-CART


XBEE RADIO INTERFACE

Rev 1_01 03-03 XBee Radio Interface Rev 1_01.docx Page 1 of 5

AGC Communications

The carts communicate with each other and/or a fixed base station using MaxStream XBee Pro Radios.

The default network parameters for the AGC are:

PAN ID 18301 (0x477D)

MY ID Assigned by cart prompt

In normal operation each cart broadcasts its status as a block of 18 bytes as follows:

Byte 0 Current Step Most Significant Byte

Byte 1 Current Step Least Significant Byte

Byte 2 RF Coils Most Significant Byte (Coils 9-16)

Byte 3 RF Coils Least Significant Byte (Coils 1-8)

Byte 4 AGC Voltage MSB

Byte 5 AGC Voltage LSB

Byte 6 AGC Current MSB

Byte 7 AGC Current LSB

Byte 8 Current Route MSB

Byte 9 Current Route LSB

Byte 10 Distance Traveled MSB

Byte 11 Distance Traveled LSB

Byte 12 AGC Inputs 9-16


Byte 14 AGC Outputs 9-16


Byte 16 Fault Code MSB

Byte 17 Fault Code LSB

AUTO-CART




When this is received by an XBee radio operating in API mode with the same PAN ID, the radio outputs

the following packet structure:

Byte 0 Start of Frame, 0x7e

Byte 1 High Byte of Frame Length

Byte 2 Low Byte of Frame Length

Byte 3 API Command Code (0x81)

Byte 4 High Byte of sender’s MY ID (0)

Byte 5 Low Byte of sender’s MY ID (Cart No.)

Byte 6 Received Signal Strength, abs(-dB)

Byte 7 Option Byte (2 = broadcast within PAN)

Byte 8 Current Step MSB

Byte 9 Current Step LSB

Byte 10 RF Coils 9-16

Byte 11 RF Coils 1-8

Byte 12 AGC Voltage MSB

Byte 13 AGC Voltage LSB

Byte 14 AGC Current MSB

Byte 15 AGC Current LSB

Byte 16 Current Route MSB

Byte 17 Current Route LSB

Byte 18 Distance Traveled MSB

Byte 19 Distance Traveled LSB





Byte 24 Fault Code MSB

Byte 25 Fault Code LSB

Byte 26 8-bit checksum

• “RF Coils” refers to the RF Output bits programmed for each step.

• “AGC Inputs” refers to the discrete inputs into the expander board.

• “AGC Outputs” refers to the outputs on the expander board programmed for each step.

• AGC Fault Codes:

o 0 = No Fault

o 1 = Illegal Step Number

o 2 = Laser Scanner Blocked

o 3 = Blocked By Radio

o 4 = Master Off

o 5 = Loss Of Guidance

o 6 = Step Cycle On

o 7 = Waiting For Triggers

o 8 = Charging

o 9 = Low Battery

AUTO-CART




o 10 = Brake Disabled

All receivers get this information for every transmitter in range. As part of the parameters for each step

in the cart’s program, any individual cart can be instructed to “listen to” a particular sender (defined by

the RF Target ID item in the step program), mapping that sender’s RF Coils to the receiver’s RF Input

bits.

This information is transmitted approximately once a second starting from the time the cart powers up

and completes initialization, so they are random to start with. In addition, each transmitter implements

some random delay from the last received packet, so the net effect is that the packets arrive with random

timing.

Each cart is equipped with a display as shown below. This allows the operator to see status of the

communications and the current route, step, and relative signal strength for each cart. The cart number

display is used to show the status of the corresponding watchdog timer. The communications are OK

when the background is white, and communications is lost when black.

Figure 1: AGC Communications Status Display

AUTO-CART




MCCP Communications The multi-route carts are designed to receive a one word command from the Main Cart Control Panel

(MCCP). When the AGC receives a transmission from the MCCP, the cart extracts its individual

command word and separates it into the five command components shown in the table below.

Bits: 1-8 Step #

Bits: 9-13 Route #

Bit: 14 Jump to Step

Bit: 15 Control Stop

Bit: 16 Remote Start

• Step and Route #: The Route and Step number commands are used by the AGC when the Remote

Start or Jump to Step command signals are received. When the Remote Start command is received,

the AGC will verify that its current Route and Step number equal that of the commanded Route and

Step number before initiating the current step. For the Jump to Step command, the AGC will load

the Route and Step number.

• Jump to Step: This bit is used to instruct the cart load the corresponding Route and Step numbers

from the above commands.

• Control Stop: While this bit is held high, the AGC will cease all motion and display a radio block

alarm.

• Remote Start: The AGC will initiate cycle when this bit goes high as long as its current Route and

Step numbers match the above Route and Step numbers.

The packet sent to the radio should be in the form of:

Byte 0 Start of Frame, 0x7e

Byte 1 High Byte of Frame Length

Byte 2 Low Byte of Frame Length

Byte 3 API Command Code (0x01)

Byte 4 Disable Response Frame (0x00)

Byte 5 Broadcast MSB (0xFF)

Byte 6 Broadcast LSB (0xFF)

Byte 7 Disable ACK (0x01)

Byte 8 AGC 1 Command MSB

Byte 9 AGC 1 Command LSB





Byte [(* x 2) + 6] (*=AGC#) AGC * Command MSB (Max. * = 50)

Byte [(* x 2) + 7] (*=AGC#) AGC * Command LSB (Max. * = 50)

Byte [(* x 2) + 8] (*=Last AGC#) 8-bit checksum

Note: This packet format can transmit up to fifty cart command words.

AUTO-CART




Note that a transmitting device should follow the Xbee Pro API mode instructions for transmitting data,

as the radio uses API mode for both transmit and receive packets. The API mode allows sending

commands to set the protocol addresses, as well as many other control parameters. It is up to the

designer whether to fix the PAN ID and MY ID through the modem configuration utility, in which case

they don’t need to be initialized by the controller, or let controller do the configuration upon startup.

The advantage to the latter approach is that the MY ID, for instance, could be changed dynamically

should such a need arise. The other advantage is that an off-the-shelf radio would automatically be

configured when attached to the system, without need for special setup before deployment, reducing

spare part inventory and simplifying replacement procedures. One thing to take note of, though, is that

the units come from the factory in ASCII mode, so regular “AT” commands must be sent first to put it

into API mode.

The default network parameters for the MCCP are:

PAN ID 18301 (0x477D)

MY ID 150 (0x96)

It is suggested that a monitoring or control system store the received information in an array, indexed by

the sender ID’s. A corresponding watchdog timer per cart is also recommended, so that loss of

communication with any one cart can be detected. If a controller is designed to transmit to the carts, it is

suggested that a 1-second transmit interval is appropriate.

In the event that a large number of carts need to operate in a given area in different subsystems, groups

of different carts with different PAN ID’s could be configured to isolate them from each other. In this

case, it is conceivable that a central control/monitoring system could either use multiple radios with

different PAN ID’s or dynamically switch PAN ID’s to selectively monitor/control more than one

subsystem.

Although the Xbee radios are capable of mesh networking to extend the range beyond the reach of a

single pair, this is not presently implemented for throughput reasons. If a situation should arise where

carts can’t talk to each other directly because of physical limitations such as plant walls, etc., then a

central controller could act as a relay by operating so that carts on either side of the barrier would talk to

the controller, and the controller would relay the information, preferably selectively based on some

combination of cart ID and step locations. Should this situation arise, further discussion would be in

order.

AUTO-CART


RFBASE UNIT USER GUIDE

Rev 1_02 03-04 RFBase Unit User Guide Rev 1_02.docx Page 1 of 17

Introduction

The AutoCart RF Base unit provides a bidirectional radio link between a system of AutoCarts and a

stationary control system, such as robots, automatic doors, loaders, lifters, etc. To minimize cost and

spare parts requirements, it utilizes the same hardware as the AutoCarts themselves with a special

program suited for the purpose.

In general terms, the RFBase Unit receives the broadcast status information from all nearby AutoCarts,

and using the program setups outlined below it reports 8 status bits from relevant carts to its host device

via 24 V DC open-collector (a.k.a. sinking) outputs, which can be interfaced to various controllers, relays,

etc. At the same time, it accepts 8 input bits from 24 V DC Sourcing devices and broadcasts these status

bits to all AutoCarts in range, so that those carts can use the information to trigger various actions

according to their step sequence programs.

The unit has numerous configuration options that are configured using Web pages on a built-in Ethernet

connection. More detail on how this actually works is found below in the description of the setup web

pages.

The unit is housed in an industrial enclosure, as shown in the photo below:

AUTO-CART




Physical mounting information is shown in the drawing below:

AUTO-CART




Terminal hookups for user use are shown in this drawing:

All configuration and setup is performed by built-in web pages via common internet browser software.

For one-on-one connection with a computer a crossover cable is needed, or the user may connect the

device to a standard ethernet switch to enable remote access. If the device is connected to the a

customer's general network it is strongly recommended that the user should consider security issues in

their environment and take appropriate steps to prevent unauthorized access to the unit.

The RF Base is supplied with a standard IP address as shown in the following screen documents, although

the address can be changed in the field – consult the factory for help in changing the address if so desired.

AUTO-CART




Login Screen

(appearance may vary depending on your browser)

This screen should appear when you type the IP address of the RF Base Unit into the address bar of your

browser.

The user name is “user”, and the password is “password”

Upon successful login, the Main Page will appear as shown below.

AUTO-CART




Main Menu Page

Click any of the links to go to the corresponding page.

AUTO-CART




Status Viewer: Note that this screen will take a few seconds to fully display the status table.

The Radio Pan ID and Radio Unit ID are readouts of the configuration entered in the Radio Setup editor,

detailed later in this document.

AUTO-CART




The Hardware Input, Hardware Output and RF Source ID items display the current state of the hardware

I/O for diagnostic use. Note that hexadecimal format is used to allow determination of the state of each

I/O bit.

Table Column explanations are:

Unit ID is the “Cart ID” of the transmitting cart. The table is sorted by this column, so if you want to see

what Cart 10 is doing, for example, you would look at the line for Unit ID 10.

Silence Timer is a count of seconds since the Cart on a particular line has been heard from. If this time

exceeds a time limit indicating that the unit is out of range or off the air, then this cell will be highlighted

in red, and the Route and Step information will be cleared. This allows the system to clear itself if a cart

is turned off, for example.

Current Route reports the latest Route information from each cart. This is part of the selection process

used to choose which cart's status information is be reported on the hardware outputs.

Current Step reports the latest Step information from each cart. This is part of the selection process used

to choose which cart's status information is be reported on the hardware outputs.

Current RF Coils is a hexadecimal readout of the “Radio Coils” programmed for each cart as an item in

the step controls. It is reported here primarily for diagnostic purposes. Refer to the Receiver Mapping

Page description for an explanation of how and when this information will be relayed to the host

hardware.

Current RSSI is an indicator of Radio Signal Strength for the particular cart: the higher the number, the

stronger the signal.

AUTO-CART




Receiver Mapping Page: note that this page can take a while to load because it is preparing a very

large set of choices for you to select from.

This is the heart of the system for relaying status bits from one or more carts to the base unit's Output

bits.

The base unit is continuously listening to status broadcasts from every cart within radio range. However,

it only has a fixed number of hardware outputs to report this information to its host control system. To do

so, it sorts through all the received status information from all of the carts, and when it finds that a cart is

in a location that is of concern to its host system, as specified by the route and step combinations in this

table, it can select that cart's RF Coils to be mapped to the hardware outputs.

Since there could be several steps, or several carts, in the area of the base unit that need to interlock with

the local control system, two options are available to choose which cart's information is passed on.

AUTO-CART




Priority Mode

The simplest mode is Priority mode, where the first cart found in the specified list of Route & Step

combinations takes full control of all available outputs to the base machine. When that Route/Step slot is

vacated by the cart, the rest of the list will be searched until a lower-priority site is found to be occupied;

the cart at that location will then get its coils copied to the hardware outputs. If none of the Route/Step

combinations listed here are occupied, then all outputs will be turned off. In this scenario, there can be

only one cart at a time controlling all outputs to the base machine. This is the only appropriate mode if an

MCCP (Master Cart Control Panel) is chosen to control the outputs.

Mask Mode

An alternative Bit Masked mode is available that can allow the available hardware outputs to be

distributed amongst carts in several locations simultaneously. In this mode, when a cart is found to be in

the specified Route/Step combination for line 1, for instance, its outputs (that is, the RF Coils

programmed in its step table) will be logically ANDed with the bit mask specified in column 3 and held

in an accumulator. The 2nd

line will then be scanned, and the outputs of any cart in that location will

again be ANDed with the 2nd

line's bitmask specification, then that result will be logically ORed with the

previously mentioned accumulator. This continues through all lines in the table. Thus, certain bits from

each line can be combined with bits from the other lines. The accumulation of all these bits will be

output on the hardware.

For readers less familiar with “programmerese”, the following explanation of the aforementioned logical

“AND” and “OR” operations may be helpful.

First it is necessary to understand the mapping of bits to a value in order to understand how to specify the

Bit Mask. This is accomplished by “place value” mapping, just like ordinary decimal arithmetic except

that the place values are all powers of 2 instead of 10. The first input bit has a value of 1, the 2nd

has a

value of 2, the third has a value of 4, etc.; each bit has double the value of the next lower bit. A summary

table for the 8 input bits available can be expressed as follows:

Bit NumberPlace Value when ON

11

22

34

48

516

632

764

8128

Any combination of bits can be expressed by adding up the table values for the bit. The result will be

somewhere between 0 and 255. For example, if bits 3 and 4 are ON, then the resulting value is 12.

AUTO-CART




In the AND operation, any bit that is ON in the bitmask will allow the corresponding bit of the cart's RF

Coil data to be passed on the the Accumulator, while any bit that is OFF in the bitmask will be blocked

from the accumulator for that particular cart. So, to allow bits 3 and 4 to be controlled by the cart in the

Route/Step combination from Line 2, for instance, the bitmask value of 12 would be specified in Line 2.

Keep in mind that the AND function described above is applied to each individual line. After that, the

OR function is applied between lines. In the OR operation, any bit that is On in either input value will be

ON the result. For example, if the cart in line 1 has bits 1 & 2 ON with a value of 3 in the Line 1

bitmask, and the cart in line 2 has bits 2 & 3 on with a value of 12 in the Line 2 bitmask, then the result

will be Bits 1, 2, and 3 ON. In this example Bit 4 will be OFF; this happens because the AND operation

in line 2 allowed bits 3 and 4 to be controlled by that cart, and the cart sent bit 4 OFF so that result

appeared in the accumulator. This example is presented in a table format below:

Row Description Bit 4 Bit 3 Bit 2 Bit 1 Numeric

Value

Explanation

#1 Bit Mask 0 0 1 1 3This would be entered in the Bit Mask

column of the setup page, Line 1

#1 Cart Coils 1 0 1 1 11This value isn't displayed anywhere, but is

shown just as a further example of place

value calculations

#1 AND Result 0 0 1 1 Only Bits 1 & 2 pass through the AND

mask

#2 Bit Mask 1 1 0 0 12This would be entered in the Bit Mask

column of the setup page, Line 2

#2 Cart Coils 0 1 1 0 6This value isn't displayed anywhere, but is

shown just as a further example of place

value calculations

#2 AND Result 0 1 0 0 4Only Bits 3 & 4 pass through the AND

Mask

#1 AND Result 0 0 1 1 Only Bits 1 & 2 pass through the AND

mask

#2 AND Result 0 1 0 0 4Only Bits 3 & 4 pass through the AND

Mask

#1 OR #2, output to

hardware

0 1 1 1 7 Any ON bit passes through to OR result

And so on: the AND operation applies to each line in the table individually, then the OR operation

combines all the individual line results into a final 8-bit output sent to the hardware outputs.

In either mode, the Timeout parameter is used to decide that the given Route/Step is unoccupied. In

Priority mode, this will allow lower priority lines to be searched when the specified timeout expires; if all

AUTO-CART




rows are timed out then the outputs will be cleared. In OR mode a timed out state will clear the Cart Coil

bits for that particular line.

The choice between these two modes is implemented via the “Multiple Received Data Selection Mode”

combo-box. This choice must be made first; the rest of the table can then be filled in as needed to

accomplish the user's I/O objectives.

Note that the RF Base unit regularly broadcasts its hardware inputs from its host machine to all carts in

radio range. This means that any cart within range can be programmed with the Base Unit's Radio ID as

the “Target Radio” in any number of steps; this will allow such steps to use Radio Trigger bits from the

Base Unit to trigger actions on the cart.

When the parameters are set up as you want them, then you can either Apply them without saving or Save

and Apply in one step. The difference is that if you Apply them they will take effect immediately, but

won't survive a power-down: if you cycle power the previously saved parameters will be restored. After

an Apply action you can also revert to the previously Saved settings if you decide to do so by clicking the

“Reload last settings” button and clicking the Submit button. You may also choose to revert to factory

defaults, but that may not be practical on this page.

Once you've got it set up and chosen your action, click the Submit button to actually implement your

choices.

AUTO-CART




Radio Address parameter page:

There are two critical parameters that determine how these radios operate. First, all inter-operating Carts

and RF Base units must have the exact same PAN network code. This must be a number between 1 and

65535. It doesn't really matter what this code is, as long as they're all the same, but different from

unrelated AutoCart systems (or other Zigbee radio networks).

Second, each radio in the system must have a UNIQUE Radio ID. The system currently allows buffers

for 50 radios in a given network. While it's not critical, it is slightly more efficient to use the lower

numbers for Carts and the next available numbers for Base units.

The Radio Sequencing Delay is a parameter that is helpful to optimize radio throughput when a Master

Cart Control Panel is in use. Usually this is a PLC-based system, and depending on the brand of PLC

deployed there may be speed limits in it’s receive buffer, and this parameter allows slowing the carts

down to a rate that can be reliably received by the particular PLC. Generally, the carts and RF Base units

broadcast their status information at some interval - with no MCCP the broadcasts are not synchronized,

but are broadcast at interval specified in the Block Transmit delay described below. When an MCCP is

AUTO-CART




used, however, it is most efficient to have the broadcast packet from the MCCP trigger a sequential

transmission from each cart and/or base unit. This is accomplished by the use of a transmit delay that is

determined by this parameter and the unit's Radio ID; each starts a timer with the preset based on this

parameter times its own radio ID, and when that timer is done it transmits. This scheme eliminates

packet collisions and allows controlling the transmission rate so the host PLC can't be overrun. In order

for this to work, all Carts and RF Base Units associated with a particular MCCP must be set to the same

delay factor as well as having unique IDs.

The Block Transmit Delay is used if an MCCP is not present or fails to transmit. In this case each cart

and RF Base unit will broadcast status at this interval, unsynchronized with respect to each other. When

an MCCP is deployed, this value must be somewhat larger than the MCCP's transmit interval so that

collisions with the MCCP “pulse” don't occur. If the system includes no MCCP, then this parameter

should be set system-wide to some value such as the number of system radios divided by 10. Note that

there is an implied decimal in the drop-down menu: the value 150 is 15.0 seconds, for example.

When the parameters are set up as you want them, then you can either apply them without saving or Save


won't survive a power-down: if you cycle power the previously save parameters will be restored. You

may also choose to revert to factory defaults, but if you do then you should promptly fix the Radio ID to

avoid conflicts with other units.


parameters.

AUTO-CART




Input-to-coil Mapping page:

This page is best understood by referring to the sample ladder diagram displayed at the top of the page,

keeping in mind the notion that the ladder rung applies to each row of the table.

A key concept here is that each hardware input corresponds one-to-one with a bit broadcast to all listeners

as a “radio coil”. Input 0 maps to Radio Coil 0, etc. Each row of the setup table allows additional

features to be applied to the input as follows.

AUTO-CART




The Echo to Output option allows any particular hardware to be echoed (with or without the latch and/or

flash options described below) to one of the hardware Outputs. This may be used to drive a pushbutton

acknowledgement light, for example. The Output choices are selected via a drop-down menu as follows:

It is the user's responsibility to avoid assigning one output to multiple inputs. In every case the Radio

Output is automatically mapped, so the choice is merely whether and which hardware output will be

attached.

The Latch option can be used to remember a momentary input, such as an operator pressing a

pushbutton, until it is cleared by some subsequent control signal specified in the Unlatch Trigger column.

The No option will keep the input from latching, which may be useful for inputs that will remain on until

externally reset, such as a robot or machine cycle complete which is reset externally at the start of the

next cycle. The Yes option will cause the input to be remembered: if this is chosen, then it is important

to also choose the Unlatch Trigger or else the radio coil (and any hardware echo) will remain on until

power is reset.

AUTO-CART




The Flash option applies only when an output echo is chosen. If set to Yes then the specified output will

flash about once a second when the coil (latched or unlatched) is On.

The Unlatch Trigger option applies when the Latch option is On, and specifies what will unset the

Latched coil. Valid choices are indicated in the drop-down menu:

When the chosen trigger comes ON, the latch will be reset. The Radio Inputs, if used, are as mapped out

on the Receive Data to Output Mapping page, described above.

When the parameters are set up as you want them, then you can either Apply them without saving or Save


won't survive a power-down: if you cycle power the previously save parameters will be restored. You

may also choose to revert to factory defaults, but if you do then you should promptly fix the Radio ID to

avoid conflicts with other units.


parameters.

AUTO-CART




HMI Configuration Screen

The RF Base Unit supports an optional HMI panel for programming and diagnostic uses. At present two

brands are supported, which can be selected here.

The previously detailed Action and Submit functions apply similarly here.

AUTO-CART


WEB PAGE CONFIGURATION

Rev 1_02 03-05 WEB Page Configuration Rev 1_02.docx Page 1 of 16

Utilizing an Ethernet connection with a crossover cable and Internet Explorer allows you to access

operating data, enter colors from the camera viewer program and set the cart operating speeds. The

following pages are available for setups. Note that most of this information is also available on the touch-

screen, as detailed in a following section.

AUTO-CART




Main Page:

AUTO-CART




Status Viewer:

AUTO-CART




Steering & Speed Setup Page:

AUTO-CART




Color Stripe Setup Page:

AUTO-CART




Radio Setup Page:

AUTO-CART




Step Editor: Step selection

AUTO-CART




Step Initiation Edit Page:

Radio Trigger Mask Choices

Go Mode Choices:

Input Trigger Mask Choices:

Target Radio Choices:

AUTO-CART




Alternate Step Hardware Input Mask:

Alternate Step Radio Input Mask:

Alternate Step Number Entry Field (0-99):

AUTO-CART




Step Action Editor Overview:

Step Function Choices:

Speed Mode Choices:

Navigation Mode Choices:

Navigation Directions Choices:

Sound Mode Choices:

AUTO-CART




Audible Warning Delay Choices

Loss of Guidance Choices:

AUTO-CART




Cart-to-cart Zone Blocking setup:

AUTO-CART




Laser Scanner Area Choices:

Set Hardware Output Choices:

MCCP selection allows Master Cart Control Panel to take

over control of an output bit for the duration of this step.

Can be used, for example, to control an audio signaling

device from a master timer.

Set Radio Output Choices:


Rev 1_02 03-05 WEB Page Configuration Rev 1_02.docx

NOTE: with Version 3.44, there exists a choice between the Hokuyo Laser scanner and an infrared

Optical Scanner made by Sunx. With this version the menu choices are renamed Optical Scan, instead of

Laser Scan. When used with the Laser, the patterns are completely selectable via separate scanner

software.

When used with the Sunx sensor, the area choices are fixed accordin

Codes 0 & 8 must not be used:

Here, "Full Range Code" uses the set pattern for the range configured with the adjusters within the Sunx

sensor. "Short Range Code" refers to the scaled

potentiometer on the IDC Scanner Interface Board insi

make sure you have loaded a step with code 15 so that you are testing the sensor itself at full range. You

can then switch to code 7 to adjust the IDC potentiometer.

NOTE: these patterns apply only to the E

is used for a Controlled Stop, and seems only to apply to the center beam. Zone 2 is attenuated

proportionately when using the Short Range codes.

For more details on the basic Sunx sensor, visit

http://www.sunx-ramco.com/SunxPDFFiles/PX_2.pdf

End Of Step Parameter Editor Overview

AUTO-CART



05 WEB Page Configuration Rev 1_02.docx Page 14


Sunx. With this version the menu choices are renamed Optical Scan, instead of


When used with the Sunx sensor, the area choices are fixed according to the following table.

Short Range Code: Full Range Code:

0

1

2

3

4

5

6

7


sensor. "Short Range Code" refers to the scaled-back settings where the scale factor is set by a

potentiometer on the IDC Scanner Interface Board inside the panel. When adjusting the Sunx sensor,


can then switch to code 7 to adjust the IDC potentiometer. Codes 0 & 8 must not be used

patterns apply only to the E-Stop zone. The "Zone 2" setting described in the Sunx manual


proportionately when using the Short Range codes.

on the basic Sunx sensor, visit

ramco.com/SunxPDFFiles/PX_2.pdf

End Of Step Parameter Editor Overview

of 16


Sunx. With this version the menu choices are renamed Optical Scan, instead of


g to the following table. NOTE:

Full Range Code:

8

9

10

11

12

13

14

15


back settings where the scale factor is set by a

de the panel. When adjusting the Sunx sensor,


Codes 0 & 8 must not be used

Stop zone. The "Zone 2" setting described in the Sunx manual


AUTO-CART




AUTO-CART




End Trigger Mode Choices:

End Action Choices:

Auto-Cart


ProFace HMI

Rev 1_04 03-06 ProFace HMI Rev1_04.docx Page 1 of 28

Main Screen

(Not Logged In)

Current Step This is a numeric input that

displays the step that the AGC is

currently running. This value

should be set after the Current

Route has been set. (Input

Range: 1-99)

Current Route

The Current Route is a numeric

input that displays the route that

the AGC is running. This value

should be entered prior to

entering the Current Step.

(Input Range: 1-15)

Distance to Go

This numeric display

shows the distance

(inches) or time

(seconds) that the AGC

has remaining in the

current step.

My ID

This is the numeric

display for the AGC’s

identification number.

This should be a

unique number for all

carts that utilize cart to

cart communications.

Cart Communications

Go to the cart

communications screen.

Input Status

Go to the cart input

status screen.

Information

Go to the AGC

information screen.

Manual

Go to the cart manual

control screens.

Log In

This allows the operator to log into the

AGC. Once logged in, the operator will

be able to access the screens to edit the

steps.

The green callouts are used to explain the screen navigation pushbuttons.

The blue callouts are used to explain the interactive screen controls. They include the

pushbuttons and numeric entries.

The orange callouts are used to explain the screen indicators. They include the numeric displays

and discrete indicators.

Battery

The Battery display

shows the AGC’s

battery Voltage.

Auto-Cart


ProFace HMI


My ID

This is the numeric

display for the AGC’s


This should be a

unique number for all

carts that utilize cart to

cart communications.

Information

Go to the AGC

information screen. Edit Step

Go to the carts edit

step screens.

Logout

Logout of AGC.

Cart Communications

Go to the cart

communications screen. Manual

Go to the cart

manual control

screen.

Input Status

Go to the carts

input status screen.

Current Step

This is a numeric input that displays

the step that the AGC is currently

running. This value should be set

after the Current Route has been

set. (Input Range: 1-99)

Current Route

The Current Route is a numeric

input that displays the route that

the AGC is running. This value

should be entered prier to

entering the Current Step.

(Input Range: 1-15)

Main Screen

(Logged In)

Battery

The Battery display

shows the AGC’s

battery Voltage.

Distance to Go


shows the distance

(inches) or time (seconds)

that the AGC has

remaining in the current

step.

Auto-Cart


ProFace HMI


Edit Step

Plate Recognition

Go to the carts plate

recognition screen.

Step Action

Go to the carts step

action screen.

Initiation Triggers

Go to the cart

initiation triggers

screen.

Main

Go to the main AGC

screen.

Occupied Steps

Go to the carts occupied

step list screen.

Alternate Triggers

Go to the carts alternate

step triggers screen.

Set Outputs

Go to the AGC’s output

settings screen.

Save

Apply and save the

changes made to the

current step being edited

to the AGC memory.

These values will remain

until the step is edited

again.

Apply

Apply the changes made

to the current step being

edited. These values will

not be saved to memory

and the values will be lost

when the carts power is

cycled.

Next Step

Next Step is a numeric

input used to instruct the

carts which step to run

after this step is complete.

Target Radio

This input is used to set

the ID number of the radio

that will be used for the

initiation triggers.

Step to Edit

This is used to load the

step that will be edited.

Only steps contained in

the route displayed above

can be edited.

Route

This numeric display shows the

route number that contains the

steps that are being edited.

Alt. Step- is a numeric

input used to instruct the

carts which step to run

after current step is

complete and input

condition is satisfied for

a jump step sequence.

Auto-Cart


ProFace HMI


Edit Step (Cont.)

Go Mode

The Go Mode is used by the AGC to

determine when to start the step. When the

AGC is running this step and the

conditions in this parameter are satisfied,

the AGC will start the step.

Operator Release-The step is initiated

when the Master Start button is pressed.

Automatic-When the step is entered from

a previous step, the cart will execute this

step without stopping.

Input Triggers-The cart will initiate the

step when the hardwired and radio input

conditions are satisfied.

Op Release w/ Alt Steps-Upon Operator

Release, the cart will choose the current

step or an alternative step based upon

specific input states

Auto w/ Alt Steps- Upon entering this step

from a previous step, or upon Operator

Release if this step was just selected from

the Main Screen, the cart will choose either

the current step or an alternative step based

upon specific input states.

Trigger w. Alt Steps- When Step Cycle is

ON (by entry from a previous step or

Operator Release) the cart will wait for the

Trigger Conditions to be met before

continuing: if the primary Trigger

Condition are met this step will be

executed, but if the Alternate Trigger

conditions are met first then it will run the

specified Alternate Step.

End Mode

End Mode is used by the AGC to

determine when to transition to the next

step. When the conditions set in this

parameter are satisfied, the AGC will

load the step set in Next Step.

Distance-The AGC travels the preset

distance set in the Size parameter.

Marker-The AGC searches for a floor

marker.

Time-The AGC delays the preset time

set in the Size parameter.

End Action

The End Action, along with

the Go Mode, is used by the

AGC to determine how to

handle the transition to the

next step.

Stop-The AGC will stop

and wait to be reinitiated by

the Master Start or Input

Triggers.

Merge-The AGC will stay

in cycle for the start of the

next step.

Auto-Cart


ProFace HMI


Step Actions

Edit Step Go to the cart's main

edit step screen.

Scanner This will select the

scanner area that the AGC

will use during the step.

Refer to the settings in the

scanner to determine the

appropriate scanner area.

(Input Range: STI: 1or 2,

Hokuyo: 1-15)

Loss of Guidance

The distance (inches) the

AGC will travel without

guidance tape. This is

used to accommodate

damaged tape. (Input

Range: 6-24)

Speed The speed the AGC will

travel during the step.

(Range: 0-33

inches/second)

Delay for Warning

The number of seconds the

AGC will delay and sound a

warning before the initiation

of cycle. If the AGC

transitions from another step

and does not stop, this setting

will be bypassed. (Range: 0-

5)

Direction

The guidance direction is

used by the cart to

determine which side of

the tape the AGC will

follow.

Left-The AGC will follow

the left side of the tape.

Center- The AGC will

follow the center of the

tape.

Right- The AGC will

follow the right side of the

tape.

Route This numeric display shows

the route number for the


Step This numeric display

shows the step number for

the step that is being

edited.

Size The distance (inches) the

AGC will travel or the time

(seconds) that the AGC will

delay during the step. (0-

9999)

Auto-Cart


ProFace HMI


Step Action (cont.)

Beginning with Version 8.01, there are additional screens to accommodate various Obstacle Avoidance

sensors, including the Laser Scanners and the Ultrasonic Modules.

The screens are as follows:

This current setting display is a text display; typical readouts are, for example:

Text Explanation

Unrecognized!!! An invalid selection (never set for this step)

Scanner Mode 5 Laser Scanner selected, Pattern # 5

Scanner Disabled Laser Selected, but disabled (cart may not move)

Sonic Left = 44 Left Ultrasonic sensor, brake at 44 inches for any speed

Sonic Left <= 44 Left Ultrasonic sensor, brake at 44 inches, less for low speed

Sonic Both = 44 Alternate left & right sonic sensors, fixed 44 Inch range

Sonic Disabled Disable Ultrasonic sensors (not recommended)

See the Obstacle Avoidance section of the manual for more information about the Laser Scanner area

patterns and ultrasonic capabilities.

The green Obstacle Avoidance button takes the user to the next screen:

Illustration 1: Version 8.01 Step Action Screen,

with Obstacle Avoidance readout and screen

button

Displays current

Obstacle Avoidance

Setting

Go To Obstacle Avoidance

Main Selection Screen

Auto-Cart


ProFace HMI


Obstacle Avoidance Primary Selection Screen

Go to Ultrasonic Setup screen

Return to Step Action Screen

Go to Scanner Setup Screen

Displays current

Obstacle Avoidance

Setting

Auto-Cart


ProFace HMI


Scanner Set Up Screen

Current Setting text,

described above; updates

when one of the numbered

pattern buttons is pressed.

Press a numbered button to

select a laser pattern for the

step being edited

Return to Obstacle Avoidance

Primary Selection Screen

Auto-Cart


ProFace HMI


Ultrasonic Setup Screen

“Fixed” column:

Range number is

stop threshold in

inches, for any

cart speed.

Left button

selects left

sensor,

Right button

selects right

sensor,

Both selects

alternating

sensors

“Variable” column:

Range number is stop

threshold at full speed;

range is reduced as cart

slows or stops, down to

20 inches at 0 speed.

Left button selects left

sensor,

Right button selects

right sensor,

Both selects alternating

sensors

Displays current Obstacle

Avoidance Setting; updates

when buttons pressed or

new range entered.

Touch here to enter the

distance (in inches) at

which an obstacle stop

should begin.

Disables Ultrasonic sensor:

use only in restricted areas!

Return to

Obstacle Avoidance

Primary Selection Screen

Auto-Cart


ProFace HMI


Step Actions (Cont.)

Function

The Function parameter is

used by the AGC to

determine the actions to

perform during the step.

The AGC hard wired and

radio outputs will be set

for all options.

Set Output, Forward-

The AGC will travel the

speed set in the Speed

parameter until it satisfies

the End Mode.

Set Outputs Only-The

AGC will set the outputs

and then transition to the

next step.

Set Outputs, Delay-The

AGC will delay for the

time set in the Size

parameter.

Navigate

The Navigate parameter is

used by the AGC to

determine how to navigate

through the step.

Normal Guidance-The

AGC will follow the

guidance tape.

Dead Reckon-The AGC

will not use the guidance

tape to navigate through

the step. The AGC will

travel according to the

setting in the Direction

parameter.

Left-Turns to the Left

Center-Travels Straight

Right-Turns to the Right

Speed

The Speed parameter sets how the

AGC speed is determined.

Proportional to Line Width-The

AGC will adjust its speed based on

the width of the tape. The AGC

speed will increase as the tapes width

decreases until it reaches the speed

set in the other Speed parameter.

Single Fixed Speed-The AGC will

run the speed set in the other Speed

parameter.

Sound

The Sound parameter sets how the

audible alarm sounds during the step.

This will take affect after the Delay for

Warning is complete.

Silent-No audible alarm will be used.

Not recommended where personnel

may be present.

Continuous-The audible alarm will be

held on continuously while the AGC is

in motion.

Pulsed-The audible alarm will be

turned on and off while the AGC is in

motion.

Auto-Cart


ProFace HMI


Occupied Step

Route

This numeric display shows



Step


the step number for the step

that is being edited.

Edit Step

Go to the cart edit step

screens.

Occupied Steps

While the AGC is in this step (the step that is being edited) and any AGC is transmitting

that it is in a step that is in this list, the cart will stop and hold until the step is clear. The

step numbers on this screen are set as four digit words (XXYY). The first two digits

(XX) represent the route number and the second two (YY) are the step number. Below

are some examples on how to enter the route and step numbers into the Occupied Step

list.

Example:

Route 2, Step 50 – Enter 250




Auto-Cart


ProFace HMI


Plate Recognition

Edit Step

Go to the

cart edit

step

screens.

End Action

This is similar to the End Action that was

described earlier. This informs the AGC what

action to take after it travels over the

corresponding plate size.

Merge-The AGC will load the appropriate

step and run the step.

Stop-The AGC will load the appropriate step

and stop.

Step

After an AGC travels over

a floor plate in the Length

column, it will load the

corresponding step set in

the Step parameter and

perform the End Action

associated to it. If the

Step parameter is set to

“0”, the plate will be

treated as a general floor

marker. Each route has its

own Plate Recognition

Table.

Save

Apply and save the

changes made to the

Recognition Plate Table

to AGC memory. These

values will remain until

the Recognition Plate

Table is edited again.

Apply


to the Recognition Plate

table. These values will


and the values will be

lost when the carts power

is cycled.

Edit Step

Go to the remainder of

the Plate Recognition

Table.

Route


shows the route number for

the plates that are being

edited.

Auto-Cart


ProFace HMI


Plate Recognition (Cont.)

Edit Step

Go to the

cart edit

step

screens.

End Action

This is similar to the End Action that was

described earlier. This informs the AGC what

action to take after it travels over the

corresponding plate size.

Merge-The AGC will load the appropriate

step and run the step.

Stop-The AGC will load the appropriate step

and stop.

Step

After an AGC travels over

a floor plate in the Length

column, it will load the

corresponding step set in

the Step parameter and

perform the End Action

associated to it. If the

Step parameter is set to

“0”, the plate will be

treated as a general floor

marker. Each route has its

own Plate Recognition

Table.

Save

Apply and save the

changes made to the

Recognition Plate Table

to AGC memory. These

values will remain until

the Recognition Plate

Table is edited again.

Apply


to the Recognition Plate

table. These values will


and the values will be

lost when the carts power

is cycled.

Edit Step


the Plate Recognition

Table.

Route



plates that are being edited.

Auto-Cart


ProFace HMI


Initiation Hardwired Input Triggers

Edit Step


screens.

Radio Trigger

Go to the radio initiation

trigger edit screens.

Route


shows the route number

for the steps that are

being edited.

Step


shows the step number

for the step that is being

edited.

Initiation Hardwired Input Triggers

Input triggers are used when the Go Mode parameter is set to Input Triggers. The hardwired input

triggers allow the cart to be initiated by discrete switches such as photoeyes, prox switches and similar.

The input triggers can be setup to initiate the cart based on several different signals at the same time.

N/A-The input can be in either the On or Off state.

On-The input has to be On.

Off-The input has to be Off.

Auto-Cart


ProFace HMI


Initiation Radio Input Triggers

Radio Trigger

Go to the remainder

of the radio initiation

Edit Step


screens.

Route




being edited.

Step




edited.


Input triggers are used when the Go Mode parameter is set to Input Triggers. The radio input triggers

allow the cart to be initiated by discrete radio signals from a remote station. The AGC will only look at

the signals sent by the radio identified by the Target Radio parameter specified on the main Step Edit

screen.. The input triggers can be setup to initiate the cart based on several different signals at the same

time.




Initiation Trigger

Go to the hardwired

initiation trigger edit

Auto-Cart


ProFace HMI


Initiation Radio Input Triggers (Cont.)

Radio Trigger Go to the remainder of the

radio initiation trigger edit

screens.

Edit Step


screens.

Route




being edited.

Step




edited.


Input triggers are used when the Go Mode parameter is set to Input Triggers. The radio input triggers

allow the cart to be initiated by discrete radio signals from a remote station. The AGC will only look at

the signals sent by the radio identified by the Target Radio parameter specified on the main Step Edit

screen.. The input triggers can be setup to initiate the cart based on several different signals at the same

time.




Initiation Trigger

Go to the hardwired

initiation trigger edit

screens.

Auto-Cart


ProFace HMI


Alternate Step Input Triggers

Alternate Step Radio Triggers

G

Alternate Radio Triggers

Go to the radio initiation trigger edit

screens.

Edit Step

Go to the cart edit

step screens.

Route




being edited.

Step




edited.

Alternate Step


shows the Alternate step

number that will be

initiated if the input

combination specified

here occurs.

Alternate Step Triggers

Go to initiation trigger edit

screens.

Route




being edited.

Step




edited.

Alternate Step


shows the Alternate step

number that will be

initiated if the input

combination specified

here occurs

Edit Step

Go to the cart edit

step screens.

Auto-Cart


ProFace HMI


Set Hardware Output

Edit Step


screens.

Route




being edited.

Step




Radio Outputs

Go to the radio output

edit screens.

Charger

Sets the charger

contactor (if present)

to be on or off for the

given step.

Set Hardwired Outputs

The hardwired outputs on the I/O Expander can be turned on and off for each step. The output state

will be set as soon as the step is loaded, without waiting for Cycle Start to begin executing the step.

N/A-Leaves the output in its current state.

On-Turns the output on.

Off-Turns the output off.

MCCP- The Master Cart Control Panel is allowed to control the output by radio command.

Auto-Cart


ProFace HMI


Set Radio Output

Edit Step


screens.

Route This numeric display shows the

route number for the steps that are

being edited.

Step

This numeric display shows the

step number for the step that is

being edited.

Hardwired Outputs

Go to the hardwired

output edit screens.

Radio Outputs


the radio output edit

screens.

Set Radio Outputs The radio outputs can be turned on and off for each step. The outputs are broadcast to all listening carts and base stations,

and may be used to pass trigger conditions to base units or carts.




Auto-Cart


ProFace HMI


Set Radio Output (Cont.)

Edit Step


screens.

Route




Step




Hardwired Outputs

Go to the hardwired

output edit screens.

Set Radio Outputs

The radio outputs can be turned on and off for each step. The outputs are broadcast to all listening

carts and base stations, and may be used to pass trigger conditions to base units or carts.




Radio Outputs


the radio output edit

screens.

Auto-Cart


ProFace HMI


Apply Step Data Confirmation

Save Step Data Confirmation

Yes

The data for the step that is currently being edited will

be temporarily activated, but not saved. If editing the

current operating step, then the current step counter

position will be retained. Unless later saved, the new

data will be lost if a new Route is selected or the AGC

power is cycled.

No

The data for the step that is

currently being edited will not be

implemented (or saved).

Yes

The data for the step that is currently being

edited will be saved. This data will be

retained through a power cycle.

No

The data for the step that is currently being

edited will not be saved.

Auto-Cart


ProFace HMI


Apply Plate Data Confirmation

Save Plate Data Confirmation

Yes

The plate recognition table will be

temporarily applied, but not saved. This

data will be lost if the AGC power is cycled

or a different Route is selected..

No

The plate recognition table will not be

updated.

Yes

The plate recognition table will be saved.

This data will be retained through a power

cycle.

No

The plate recognition table will not be

saved.

Auto-Cart


ProFace HMI


Manual Control for Outputs

Manual Control Pushbuttons

The manual control pushbuttons are

used to control the corresponding

outputs. The master circuit has to be

enabled for the outputs to operate.

Manual


the carts manual control

screen.

Output Name Display

The string displays are

used by the AGC to

display the name of the

output. The cart controller

will send an ASCII string

to the HMI to name the

output.

Main

Go to the main AGC

screen.

Charger

The charger buttons are used to

control the charger contactor (if

present). The master circuit has

to be enabled for the contactor

to operate.

Auto-Cart


ProFace HMI


Manual Control for Outputs

(Continued)

Manual Control Pushbuttons

The manual control pushbuttons

are used to control the

corresponding outputs. The

master circuit has to be enabled

for the outputs to operate.

Output Name Display

The string displays are used

by the AGC to display the

name of the output. The cart

controller will send an ASCII

string to the HMI to name the

output.

Main

Go to the main AGC

screen.

Manual

Go to the remainder of the

carts manual control.

Auto-Cart


ProFace HMI


Input Status

Input Status Indicators

The input indicators show the

status of the carts hared wired

inputs. Input Name Display


used by the AGC to


input. The cart controller



input.

Input Status


the carts input status.

Main

Go to the main AGC

screen.

Auto-Cart


ProFace HMI


Input Status

(Continued)

Input Status Indicators

The input indicators show the

status of the carts hared wired

inputs.

Input Status


the carts input status.

Main

Go to the main AGC

screen.

Input Name Display


used by the AGC to


input. The cart controller



input.

Auto-Cart


ProFace HMI


Cart Communications

Information

Go to the AGC

information screen.

Main

Go to the main AGC

screen.

Radio Input Status

Go to the carts radio

input status screen.

My ID

This is the numeric entry

for the AGC’s


This should be a unique

number for all carts that

utilize cart to cart

communications. This can

only be changed while the

operator is logged in.

Cart

This column is a row header for

the Radio ID data to in the other

columns. If the indicator has a

white background than that

radio has been heard from

recently. A black background

means that radio has not been

heard recently.

Route

The route indicator displays the

route number that the

corresponding AGC is reporting

that it is in.

Step

The step indicator displays the step

number that the corresponding AGC

is reporting that it is in.

RSSI

(Received Signal Strength Indicator)

This indicator is used to display the

relative signal strength for the

corresponding AGC. The larger the

RSSI number the stronger the signal

strength.

Target ID

This indicator shows the

radio ID number that this

AGC is watching for

Trigger info, if used.

Auto-Cart


ProFace HMI


Radio Input Status

Information

Main

Go to the main AGC

screen. Radio Input Status Indicators

The input indicators show the status of the

carts radio inputs. A white background

indicates the input is on and the input is off

when the background is black.

Main

Go to the main AGC

screen.

Firmware Version

This will display the

controller software version

number.

Screen Version


screen software version

number.

IP Address


controller IP address.

Subnet Mask


controller subnet mask

for the IP address.

Main

Go to the

main AGC

screen.

AUTO-CART

Section 04-00 CSB

Rev 1 04-00 CSB_Customer_Supplied_Battery.docx Page 1 of 1

CSB – Customer Supplied Battery

05_02Laser Scanner with Flexible Bumper

The laser scanner has fifteen programmable areas to be used for obstacle avoidanceand cart stacking. The areas are selected by the AGC based on the settings in thestep program. When an object is detected within the detection area, the AGC willperform a controlled stop and will resume motion when the object is clear of thedetection area.

The flexible bumper is used by the AGC to perform an emergency stop. A dual photo-switch and a reflector are used to sense a collapse in the bumper and will turn off themaster circuit when the bumper is deformed.

• Add DP to the end of the selection to receive (2) photoeyes with the flexiblebumper (LSDP).

05_02_Laser Scanner with Flexible Bumper_1.01

Illustration 1: Typical Scanner & Bumper Arrangement


Illustration 2: Typical Dual Photo-switch and reflector arrangment

Basic Concepts

There are several models of laser scanners available from different manufacturers. The most popular is the

Hokuyo brand, which allows the cart to select one of 15 preset patterns in any given step. This scanner is the

lowest cost, however it is doesn't have redundant safety features so some users are unwilling to accept it. In

that case, other models with redundancy features may be considered at higher cost.

All of the laser scanners use the same basic principal: an infrared laser beam is swept in a horizontal circular

plane. Objects that the beam encounters reflect some of the light back to the scanner's receiver, which can

measure the distance to the object by the time between transmitting the beam and receiving the reflection. This

develops an image of items in the scanner's view that can be visualized on a computer screen. While the details

vary between different models, the illustration below is typical:

In this particular view, the gray area is unoccupied, while the white areas are “occupied” by some obstacle.

Notice that a nearby obstacle obscures the view of anything beyond it in a radial direction, however this is

generally not a concern since the distance to the nearest object is the important measurement in an obstacle

avoidance application. Notice also that the measurements are centered around the sensor itself, which is

typically located at the center of the front of the cart.

The colored zones in this display illustrate boundaries that have been set up for this particular protection

pattern, designated in this scanner model by the label “Area 1”. The outer 2 boundaries are used by the cart for

path blockage detection, causing the cart to execute a controlled deceleration and stop when these areas are

occupied by any obstacle. The innermost red area can be configured to cause an Emergency stop, where power


Illustration 3: Sample Scanner View with 3 object detection zones

is removed from the drives and the brake sets immediately whenever an object is detected in this zone. In

many instances, however, users opt to rely on the bumper for E-Stop function and use the laser for cycle stops,

at least when a non-redundant scanner is used. This usage must be discussed and agreed upon when ordering

Carts, as it determines certain hardware configurations.

The sections that follow will illustrate features and usage for specific laser scanner models. For specifications

and literature for these models the user is encouraged to consult the particular manufacturer for more

information: this manual will specifically address the AutoCart use of the scanners


Hokuyo UBG series Laser Scanner

This scanner features 31 active protection patterns, of which one of the first 15 may be selected by the

AutoCart in any given Step. Hokuyo provides a software utility to configure the units, save the configuration

to a computer and upload/download configurations to copy from one unit to another. Unfortunately they have

not, as of this writing, provided good documentation on how to use it, so this manual will attempt to cover the

basics, with specific application to the AutoCart system.

Connecting to the scanner

The software connects to the scanner with an RS-232 serial port. It supports either a real hardware serial port

or a USB to Serial adapter. A connector is provided inside the cart control panel to let the PC talk to the

scanner while in operation, as shown in this photograph:

Note that it is necessary to have the cart power on and the red E-Stop PB raised to provide power to the scanner

for programming purposes.


Illustration 4: Serial Cable connection for Hokuyo scanner, in cart's control enclosure

The Hokuyo utility shortcut is similar to the following, where the actual disk path may be different:

Of particular note are the desktop icon and the application file name; the user may edit the displayed name of

the shortcut to something more easily recognized.

When the Hokuyo software starts, it will search the available serial ports for an active scanner and

automatically connect (if if doesn't you'll see a message and have an option to work off-line). When the

scanner is connected you'll see a screen something like this:


Illustration 5: Hokuyo UBG series Software Utility

Shortcut, illustrating Icon and Application File Name

This is a live image of the scanner's view of the world. By default the gray area is open; white areas indicate

an area that is obscured from view by some object. In this particular case a briefcase is parked at the back left

edge of the field of view, approximately in line with the left edge of the cart assembly to provide an on-screen

reference for setting up the protection zones in the following steps.

Reading Area Patterns from the scanner

At this point the PC software does not yet know how the protection zones are configured in the scanner. To

view the settings configured in the scanner, use the Communication menu and select the “Area Read” function

- confirm the operation to read the areas from the scanner. This will result in a view something like the

following:


Illustration 6: Typical UBG scanner view upon initial connection, before loading scanner Area setups

This operation loads all 32 areas from the scanner into the PC memory. Using the dropdown menu box at the

top of the screen, the user can overlay any of these existing patterns on the current scan.

Notable features of this display and edit screen include:

• On-screen measurement grid

• Mouse position readout (in mm) at the bottom of the screen

• Grab handles to graphically adjust outermost pattern area

• Grab Bars to adjust interior patterns relative to the outer pattern, discussed below.

• Area Number drop-down menu box at the top of the screen

• Sub-area shape selection drop-down menu box near the top of the screen, discussed below.

Note that all measurements are relative to the center of the scanner, which is usually located at the center of the

front of the cart.

Viewing and editing protection patterns

A variety of typical patterns are illustrated below, with further discussion to follow:


Illustration 7: Typical UBG scanner view after reading Area Patterns

In this case, the pattern is quite wide (almost 2 meters, or nearly 6 feet) because the application being illustrated

includes a wide “companion cart” attached to the base cart, so it is important to have the pattern protect the full

width of the payload. This remains true for the rest of the illustrations in this section, although some users

without a wide payload will want to use a narrower pattern.

This low-speed pattern looks forward far enough to allow the cart to decelerate nicely and stop without

collision when an obstacle is encountered.

Note that this is Area 1, identified on the screen by the drop-down menu at the top and the message in the

bottom status bar. This will be used by the cart when executing any step with the Scanner parameter set to 1,

which would be most straight, low-speed moves. For example, Route 1 Step 1 would be set up on a cart like

this (note this illustration is for AutoCart firmware Version 5.xx - see also V8.xx firmware update at the end of

this document):


Illustration 8: Typical scanner setup for straight, low speed moves

Next is a slightly different pattern:

This pattern is appropriate for a heavy payload traveling at higher speeds: in this situation the stopping

distance is increased, so it is necessary to detect obstacles at longer range.

Note that this is Area 3, identified on the screen by the drop-down menu at the top and the message in the

bottom status bar. This will be used by the cart when executing any step with the Scanner parameter set to 3,

which would be most straight, high-speed moves.


Illustration 9: Typical scanner setup for straight, high speed moves


The following pattern, Area 6, is typical for use where the cart will be making a left turn, and would be

specified only for a step that is actually executing such a turn. In this scenario, because the cart is actually

turning away from objects near its front right corner, this corner of the pattern can be pulled back. On the other

hand, since the cart is turning toward any obstacles that might be off to its left, the pattern is extended in that

direction to provide advance notice of obstacles in time to stop for them.

Notice also the additional corner points established by the square “grab handles” around the perimeter. Up to

seven such handles are available; in the simpler patterns above, the unused handles are “stacked” at location 0,0

- they can be deployed by grabbing the handle at the center and dragging it out the periphery. Such peripheral

vertices can, if desired, be removed by dragging one vertex handle onto another, whereupon they will merge

together and one will disappear (or be relocated to 0,0).

Notice also the selection of the “Ratio” menu at the top of the screen: this is used to make the interior detection

patterns follow the general outline of the outermost pattern, which is most useful for asymmetrical patterns like

this. The ratio between the internal and outermost patterns is adjusted by grabbing the color bars on the central

axis of the scanner and moving them up or down.

.

The actual actual contour of the right corner is a function of the sharpness and speed of the turn; this means it

may be appropriate to have several “left turn” patterns for various ranges of turning radius in the path. They

are deployed in the cart by specifying the appropriate scanner pattern number in each individual step.


Illustration 10: Typical scanner setup for low speed left turns, using Ratio option for zones 2 & 3

The following pattern, Area 8, is typical for use where the cart will be making a right turn, and would be

specified only for a step that is actually executing such a turn. In this scenario, because the cart is actually

turning away from objects near its left corner, this corner of the pattern can be pulled back. On the other hand,

since the cart is turning toward any obstacles that might be off to its right, the pattern is extended in that

direction to provide advance notice of obstacles in time to stop for them.

Notice also the additional corner points established by the square “grab handles” around the perimeter. Up to

seven such handles are available; in the simpler patterns above, the unused handles are “stacked” at location 0,0

- they can be deployed by grabbing the handle at the center and dragging it out the periphery. Such peripheral

vertices can, if desired, be removed by dragging one vertex handle onto another, whereupon it they will merge

together and one will disappear.

Notice also the selection of the “Ratio” menu at the top of the screen: this is used to make the interior detection

patterns follow the general outline of the outermost pattern, which is most useful for asymmetrical patterns like

this. The ration between the internal and outermost patterns is adjusted by grabbing the color bars on the

central axis of the scanner and moving them up or down.

Shown below is a special case that was used to allow the cart to maneuver into close quarters with a stationary

machine, approaching from a tight right turn and continuing into a work cell. In this particular instance the


Illustration 11: Typical scanner setup for low speed, moderate right turns, using Ratio option for zones 2 &

3

work cell had equipment that was below the companion cart, so both sides of the pattern were pulled inward to

allow the cart core to enter between the cell machinery. In addition, because of the right-turn approach, the left

front corner was trimmed back to just clear the equipment while entering the cell.

In cases like this, the scanner should be considered as protecting the cart from physical crashes: in this

particular instance personnel must take responsibility to keep clear of the outer portions of the payload.

Alternatively, external protection devices could be used to prevent the cart from entering the area with

personnel present.

Another special case is shown below: this illustrates the adjustment made to allow the cart to drive into an on-

line charging station which sits close enough to the path that it can make contact with the right side of the cart.

Hence, the right side is trimmed to allow passing the charger shoes. Like the pattern above, this limits operator

protection for the right side of the cart, so other precautions must be observed to protect personnel.


Illustration 12: Example setup for tight right turn into close quarters with machinery

Saving the Detection Area:

The above represent typical scenarios that can be created for an application. At this point in the process, the

patterns exist on the PC, but if any editing has been done, then they may not match what is actually in use in

the scanner. It is highly recommended that the user should use the file menu to save the setup, as shown here:


Illustration 13: Special setup for approaching an on-line charger on the right side of the cart, at low speed

Chose an appropriate location and file name. Note that the program will not over-write an existing file name;

if you try, it will report an error and not save anything. Therefore you must either create a new name or delete

an existing name before trying to use it again. It is suggested that sequential file names be use, to maintain a

backup path in case of error.

Once an area has been saved, the file menu's “Open Area File” can be used to read it back into the system from

the PC's storage, as an alternative to loading it directly from a scanner. This can allow a user to initialize a new

scanner, for instance, with a saved setup. This procedure is described below.

Writing the area setup to the scanner to make it effective

When the PC has an appropriate set of patterns established, whether by direct editing or by opening a stored

Area file, the areas must be written to the Scanner to take effect. The patterns may have been uploaded from an

existing scanner, edited on-line, or read back from a file that was previously saved. In any case, the operation

to write update the scanner to use these patterns is the same, as shown here:


It doesn't matter which area pattern is in view when writing: the operation will write all Area patterns to the

scanner. Immediately after the write, the scanner will utilize the patterns that were written.


Specifying the Area Pattern for a step (AutoCart Firmware Version 5.xx)

As briefly mentioned above, the patterns reside in the scanner itself. Which pattern it uses at any particular

moment is controlled by a numeric code sent from the carts step control system. Part of the definition process

for each step in the cart program is to decide which Area Pattern is appropriate for the operation. Once the

Area Number has been defined in the scanner and selected for a particular application step, then it must be

entered as one of the parameters for that step. This is accomplished through the HMI edit screens, which are

detailed elsewhere. For purposes of this discussion, however, it is appropriate to show how a particular area

number gets entered into the system for a given step. Observe the “Scanner” data entry field in the display

below:

The number entered into the Scanner field will be the Area number used for the step. This must be set up for

each step, of course.

It is suggested that users should establish some pattern to the area numbers so that they are not difficult to

remember. For example, Area 1 could be used for slow, straight moves, with areas 2 & 3 also straight but at

progressively higher speeds. In the same vein, Areas 4 - 6 could be a sequence of left turn patterns in some

progression such as speed of motion or increasing turn radius; a similar sequence could establish a progression

of right-turn patterns in Areas 7-9. Areas 10 & up could be used for relatively rare special cases such as

illustrated above.


Specifying the Area Pattern for a step (AutoCart Firmware Version 8.xx)

As briefly mentioned above, the patterns reside in the scanner itself. Which pattern it uses at any particular

moment is controlled by a numeric code sent from the carts step control system. Part of the definition process

for each step in the cart program is to decide which Area Pattern is appropriate for the operation. Once the

Area Number has been defined in the scanner and selected for a particular application step, then it must be

entered as one of the parameters for that step. This is accomplished through the HMI edit screens, which are

detailed elsewhere. For purposes of this discussion, however, it is appropriate to show how a particular area

number gets entered into the system for a given step. Version 8.xx supports either Ultrasonic or Laser sensors

as a user selection for each step. To accommodate these options the HMI screens have been redesigned as

shown here:

The textbox above the “OBSTACLE AVOIDANCE” button displays the currently selected obstacle avoidance

mode for the step being edited. To change this parameter, press the green Obstacle Avoidance button to

advance to the screen below:


This screen (above) again displays the current setting, and allows further selection between Ultrasonic sensors

or Laser Scanner, with subsequent setup screens for those two types - obviously the appropriate hardware must

be installed for the mode selected. As we are addressing the laser scanner usage in this document, press the

“Optical Scanner Setup” to advance to the following screen:

On this screen you can choose the scanner pattern number by pressing the appropriate button. The textbox at

the top of the screen will update to confirm the selection.

Note that option 0 technically exists to turn the scanner off, though the cart will not move in that state. This

could theoretically be used to save a small amount of battery power in a step that is merely waiting for

something to happen externally. There is a startup delay before the scanner will resume operation, which

would have to be allowed for in the subsequent step. This concept is hypothetical and unproven as of this

writing.

Once the appropriate pattern is chosen, use the yellow “Previous” buttons (on this screen and the previous one)

to get back to the Step Function screen, where the Obstacle Avoidance textbox will now display your selected

pattern which will be the Area number used for the step. This must be set up for each step, of course.

It is suggested that users should establish some pattern to the area numbers so that they are not difficult to

remember. For example, Area 1 could be used for slow, straight moves, with areas 2 & 3 also straight but at

progressively higher speeds. In the same vein, Areas 4 - 6 could be a sequence of left turn patterns in some

progression such as speed of motion or increasing turn radius; a similar sequence could establish a progression

of right-turn patterns in Areas 7-9. Areas 10 & up could be used for relatively rare special cases such as

illustrated above.

Documenting the Scanner Setup

The edit utility can print the patterns as displayed on the screen. It only prints the currently selected pattern,

however. A useful method of documenting the patterns it to paste screen grabs of the patterns into a document

or spreadsheet, which can then be printed in a single step.



UBG-05LNLASER RANGE-FINDER TYPE OBSTACLE DETECTION SENSOR

WIDE SCANNING ANGLE ! SUPER-SMALL SIZE ! General/Feature * Long range detection(5m) * High accuracy with semi-conductor laser(+/- 20mm at 1m) * 31 kinds of detecting area can be made Structure(Light scanning image) Application

NNNEEEWWW PPPRRROOODDDUUUCCCTTTSSS

Obstacle detection sensor on AGV

AGV

UBG

Power/input/ output

Scanning angle : 180°Max. step : 500 Resolution : 0.36°

Max. 5m

Max. 4m

AGV’s control

device

Specifications Model No. UBG-05LN Power source 24VDC±10%(Startup voltage range 18 to 30VDC) Current consumption 150mA or less(Rush current 300mA) Light source Semiconductor laser diode(wavelength 785nm), Laser safety class 1(FDA) Detection distance 0.01 to 5m(White sheet with 125×125mm) Accuracy ±20mm at 1m or less, ±2% of measurement, Repeatability ±10mm

Hysteresis Values specified while setting area patterns(Default 6.25%) 6.25% of detecting distance(not less than 60mm) 3.17% of detecting distance(not less than 30mm)

Output Output 1 to 3, trouble output, Photo-coupler/NPN open-collector output(30VDC 50mA Max)Scanning angle 180°(Resolution 0.36°) Scanning time 100msec/scan Response time Less than 210msec(Scanning time 100msec/1 rev.) Indicators Output lamp 1 to 3(orange), Power lamp(green) Connection method Lead wire 1m long Ambient light resistance Halogen/mercury lamp : 10000lux or less, Fluorescent lamp : 6000lux(Max.)

Ambient temperature/ humidity -10 to +50, 85%RH or less(Not condensing)

Vibration resistance 10 to 55Hz, double amplitude 1.5mm Each 2 hour in X, Y and Z directions Impact resistance 196m/s2(10G) Each 10 time in X, Y and Z directions Protective structure IP64 Weight Approx. 185(260 with cable) Life 5 years during normal condition(motor life) Material Front case : polycarbonate, rear case : ABS

External dimension

UBG-05LN

PPHHOOTTOO SSEENNSSOORR,, LLAASSEERR SSEENNSSOORR,, MMIICCRROOWWAAVVEE SSEENNSSOORR,, CCOOUUNNTTEERR,,AAUUTTOOMMAATTIICC DDOOOORRHOKUYO AUTOMATIC CO.,LTD.1-10-9 Niitaka, Yodogawa-ku, Osaka 532-0033,Japan Tel(06)6394-2102 Fax(06)6394-2339 http://www.hokuyo-aut.jp E-mail:[email protected]

No.RS-1

Approved Checked Drawn Designed T i t l e

No.

Symbol Amended Reason Page Date Corrector

Obstacle Detection Sensor UBG-05LN Specifications

C – 42 – 3404 1／7

Date：2006.05.18

DISTANCE MEASURING TYPE Obstacle Detection

Sensor UBG-05LN

Specifications

MORI

SANTOSHSUEKUNIMORI

名称図番UBG-05LN Specifications C – 42 – 3404 2／7

1. Outline 1. Operating Principle

UBG-05LN is an obstacle detection sensor with 785nm wavelength laser light source. It detect objects in the predefined area by scanning 180°semicircle and calculates the coordinates of the detected object by measuring its distance and angle. The product is laser class 1 safe.

2. Area Setting 31 different area patterns and their coordinate points can be set using application software and serial communication RS232C. 3-step outputs can be selected for each area.

3. Area Switching Bit input at terminal points switches the predefined area patterns.

4. Malfunction Output Self-diagnostic functions continuously check laser radiation and motor rotation and supplies malfunction output upon error detection.

2. Structure (Scan Image)

Non-radiated area: 180º

AGVControl

AGV

Max. 10m

Max. 5mMax 8m with special reflector.

Power Supply Input/Output Connections

Scan Angle: 180º Max. Step: 500 Resolution: 0.36º


３．Specifications

Model UBG-05LN Light source Semiconductor laser diode (λ=785nm)

Laser safety Class 1 (FDA) Laser power:0.8mW or less(Scanning satishfies the laser Class 1 safety.)

Power source 24V DC ±10% (Startup voltage range 18~30V) Current consumption 150mA or less (Rush current 300mA)

Detection distance 100mm ~ 5000mm* (White sheet 125×125 mm or more) 100mm ~ 8000mm* (Specific reflector 250×250 mm or more)

Accuracy Distance 100 ~ 1000mm： ±20mm* Distance 1000 ~ 4000mm： ±2% of measurement* Repeatability ±10mm*

Hyteresis Values specified while setting area patterns (Default: 6.25%) 6.25% of detection distance (not less than 60 mm) 3.17% of detection distance (not less than 30 mm)

Outputs Photo coupler open collector output (DC 30V, 50mA max.) Output 1: Turns OFF during object detection inside area. Output 2: Turns OFF during object detection inside area. Output 3: Turns OFF during object detection inside area. Malfunction Output: Always ON during normal operation. (Note: All the outputs turn OFF during malfunction)

Scan Angle 180°(Resolution 0.36°) Scan Time 100msec/scan

Output Less than 210 msec Response Time (Note: Additional delay of max. 100 msec (1 scan time) will occur

during area switching) Start up Time Within 10 sec after power supply. (Varies with startup conditions) Light Display Power supply (Green): Flashes during startup or sensor malfunction

Output 1 (Orange): Switches on during object detection inside area Output 2 (Orange): Switches on during object detection inside area. Output 3 (Orange): Switches on during object detection inside area.

Connection Flying lead cable (1m) Ambient Light

Resistance Halogen/Mercury light: 10000Lx or less Fluorescent Light: 6000 Lx (max.) (Note: Direct sunlight or strong light source may cause misdetections)

Ambient Conditions Temperature:

-10 ~ 50ºC

Humidity: 85% or less (non-condensing) Storage temperature -25 ~ 75ºC Vibration Resistance Double amplitude 1.5mm 10 ~ 55Hz, 2 hours XYZ direction, and

98m/s2 55Hz ~ 200Hz in 2 minutes sweep, 1 hours in XYZ directionsImpact Resistance 196 m/s2 (10G), 10 times in XYZ directions

Weight Approx. 185g (260g with cable) Protection Class IP64

Case Front: Polycarbonate / Back: ABS External dimension 60 W×60 H×75 D mm

*Under standard test conditions.


3. Specifications (continue)

Area Setting Output1 setting: Area with maximum 7 points form 0 to 5000mm Output2 setting: Straight : Fan Shape : Percentage of Output1 area points Output3 setting: Same as Output2

Inputs and Area Selection

Photo coupler input (Anode common, supply current to switch on the inputs = 4mA) Area Switching: Set area numbers with [Input1][Input2] [Input3][Input4][Input5] Laser radiation stops with all inputs ON. High: OFF Low: ON

[Input1] [Input2] [Input3] [Input4] [Input5] Area Patterns ON ON ON ON ON Laser OFF OFF ON ON ON ON Area 1 ON OFF ON ON ON Area 2 OFF OFF ON ON ON Area 3 ON ON OFF ON ON Area 4 OFF ON OFF ON ON Area 5 ON OFF OFF ON ON Area 6 OFF OFF OFF ON ON Area 7 ON ON ON OFF ON Area 8 OFF ON ON OFF ON Area 9 ON OFF ON OFF ON Area 10 OFF OFF ON OFF ON Area 11 ON ON OFF OFF ON Area 12 OFF ON OFF OFF ON Area 13 ON OFF OFF OFF ON Area 14 OFF OFF OFF OFF ON Area 15 ON ON ON ON OFF Area 16 OFF ON ON ON OFF Area 17 ON OFF ON ON OFF Area 18 OFF OFF ON ON OFF Area 19 ON ON OFF ON OFF Area 20 OFF ON OFF ON OFF Area 21 ON OFF OFF ON OFF Area 22 OFF OFF OFF ON OFF Area 23 ON ON ON OFF OFF Area 24 OFF ON ON OFF OFF Area 25 ON OFF ON OFF OFF Area 26 OFF OFF ON OFF OFF Area 27 ON ON OFF OFF OFF Area 28 OFF ON OFF OFF OFF Area 29 ON OFF OFF OFF OFF Area 30 OFF OFF OFF OFF OFF Area 31

Input Response Time Input reading frequency: 1 scan time (100msec) (Note: Input reading frequency is 1msec when Laser is switched offexternally)


4. Lead cable color and signals

Color Signal Black Output1 White Output2 White (Blue) Output3 Orange Malfunction Output Gray Output common minus Red Input common plus Green Input1 Yellow Input2 Purple Input3 White (Yellow) Input4 White (Purple) Input5 Brown +V IN Blue -V IN Yellow (Red) Serial Input (RXD) Yellow (Green) Serial Output (TXD) Yellow (Black) Serial Ground (GND)

Note: 1. Leave the unused input terminals open or connect to input common plus (red). 2. Leave the unused output terminals open or connect to input common minus (gray). 3. Colors inside ( ) suggest wires with colored lines on either sides. 5. Installation Notice

When mounting the device make sure to provide sufficient space for light window. Sensor will not operate normally if its view is blocked leading to serious injuries or property damage. Note For Long Term Use: It is necessary to readjust/reset sensors operating for more than one year to maintain the absolute accuracy.


6. Light Display Position UBG Output1Output2Output3 Power Supply (Flashes on malfunction) 7. Area Setting Range and Shape

Output1 Area

Output2 Area

Output3 Area

Straight Fan Shape Ratio

UBG UBG UBG

4m

Area Setting Range

OBJECT: 5m White Kent sheet 300×300mm placed perpendicular to the sensor’s vertical axis within 100~5000mm from sensor axis

Or Specific Reflector 200×200mm placed perpendicular to the sensor’s vertical axis within 100~8000mm form sensor axis

UBG


8. Input/Output Circuit

Load

I/O Powe Supplyr

Output 1

Output Common -

Power Supply Circuit

VIN +

Main Circuit

4.7KΩ

1KΩ

+ -

FG Power

Supply To Sensor

Output 4

Load

Input Common +

Input 1

1KΩ

4.7KΩ

Input 5

VIN -

06_Warning_Light_With_Adjustable_Mast_Rev_1.01

06 Warning Light With Adjustable Mast

Yellow warning light will indicate that the cart is on and running. The cart will annunciate with a different flash rates that indicate the following diagnostic functions. Steady On lamp indicates that the cart is powered up and ready to run. Slow flash is normal operation when the cart is moving. Fast flash indicates that the cart has lost guidance and will not move. Two fast flashes followed by a pause indicate that the brake is not in the run position. The optional warning light can only be added to Tugger Carts.

Yellow Status Beacon shown with Adjustable Mast

Yellow Status Beacon

AUTO-CART

Section 07-00

PREVENTIVE MAINTENANCE

Rev 2_00 07-00 AGC Preventative Maintenance Rev2_00.doc Page 1 of 5

SCHEDULE EVERY 2 WEEKS

1. CAMERA:

• INSPECT AND CLEAN THE CAMERA LENS WITH A SOFT CLOTH. DO NOT USE ANY

CLEANING AGENTS OR CHEMICAL CLEANERS. DEPENDING ON THE AMOUNT OF

CONTAMINATION, INSPECTION AND CLEANING MAY BE REQUIRED MORE OFTEN.

• DO NOT REMOVE CAMERA OR CAMERA BOARD.

• IF CAMERA IS LOOSE, CONTACT THE FACTORY FOR INSTRUCTION ON REPLACEMENT

AND/OR RE-ALIGNMENT.

• CHECK CAMERA AND BOARD CONNECTORS.

• IF CAMERA BOARD IS LOOSE, TIGHTEN.

2. CASTERS:

• CHECK STABILIZER BALL TRANSFERS FOR WEAR & DAMAGE.

• CHECK URETHANE STEERING MOTOR CASTER WHEEL FOR WEAR, DAMAGE AND

BONDING SEPARATION WITH THE WHEEL HUB.

• CHECK DRIVE AXLE URETHANE CASTER WHEELS FOR WEAR, DAMAGE AND BONDING

SEPARATION WITH THE WHEEL HUB.

• REPLACE DEFECTIVE WHEELS

3. STEERING/DRIVE:

• MAKE SURE THAT THE DRIVE IS SECURELY ATTACHED TO VEHICLE FRAME

• CHECK WIRING FOR BROKEN SOLDER JOINTS AND WEAR.

• INSPECT STEERING MOTOR. REPLACE IF DAMAGED.

AUTO-CART

Section 07-00



4. BATTERIES:

• CHECK FOR LOOSE BATTERY CABLE TERMINAL CONNECTIONS.

• CHECK CABLES FOR CHAFFING.

• IF BATTERY IS NOT HOLDING A CHARGE, CHECK THE BATTERY CHARGER FOR

PROPER OPERATION.

• IF BATTERY IS NOT HOLDING A CHARGE, CHECK BATTERY WITH A BATTERY LOAD

TESTER TO SEE IF THE BATTERY IS HOLDING A PROPER CHARGE. (CHECKS INTERNAL

RESISTANCE OF THE BATTERY).

• IF BATTERY IS NOT HOLDING A CHARGE, REPLACE ONE OR MORE OF THE BATTERIES.

• WHEN REPLACING BATTERIES, REVIEW WIRING DIAGRAM ON THE CART.

• CHECK BATTERY ORIENTATION IN THE BATTERY TRAY.

• ENSURE LATCHING MECHANISM IS PROPERLY ATTACHED AND THAT IS IN WORKING

FUNCTION INCLUDING THE PROX TO DETECT THAT LATCH IS LOCKED

5. BATTERY CHARGER:

• CHECK CABLES FOR TIGHT CONNECTIONS.

• CHECK CABLE CONNECTION TO CHARGER FOR BROKEN WIRE STRANDS AND

REPLACE IF BROKEN.

• CHECK THE “SMART CONTROLLER ~ IQ4” ACCESSORY PLUG TO SEE IF LED IS

WORKING PROPERLY.

• CHECK “SMART CONTROLLER” FUNCTION:

o UPON INITIAL CONNECTION TO THE BATTERY, THE LED WILL FLASH 12 TIMES

FOR A 24 VOLT BATTERY SYSTEM.

o BULK CHARGE – GREEN LED FLASHES RAPIDLY.

o ABSORPTION CHARGE – GREEN LED FLASHES AT A SLOWER RATE.

o FLOAT CHARGE – GREEN LED WILL REMAIN LIT AND NO LONGER FLASH.

o WHEN FIRST CONNECTED AND THE BATTERY IS NOT IN NEED OF CHARGING,

FLOAT CHARGE WILL BEGIN IMMEDIATELY AND THE LED WILL REMAIN LIT

AFTER IT HAS COUNTED THE 12 BATTERY CELLS.

• CHECK FAN. FAN ONLY OPERATES WHEN THE CHARGER IS WORKING PROPERLY. IT

MAY TAKE SEVERAL MINUTES FOR THE FAN TO START AS THE CHARGER HEATS UP.

• THERE ARE 2 FUSES PER CHARGER. INSPECT CHARGER FOR LOOSE FUSES. IF FUSES

ARE LOOSE, RE SEAT LOOSE FUSE(S).

“SMART CONTROLLER” IS OPTIONAL FEATURE NOT INCLUDED IN ALL AGC’S

AUTO-CART

Section 07-00



6. WIRING:

• INSPECT ALL WIRES, PLUGS, AND ELECTRICAL CONNECTIONS FOR LOOSE

CONNECTIONS, BREAKS AND/OR DAMAGE.

• CHECK WIRING FOR CHAFFING.

AUTO-CART

Section 07-00



7. GUIDEPATH Care & Condition:

• FLOOR TAPE WILL SHOW WEAR AND TEAR AND SHOULD BE REPLACED OR CLEANED

AS NEEDED TO PREVENT LOSS OF GUIDANCE AND MINIMIZE THE TIME SPENT

FOLLOWING IRREGULAR TAPE EDGES. IRREGULAR TAPE EDGES CAUSE THE

STEERING TO CYCLE MORE OFTEN AND WILL INCREASE THE WEAR ON THE STEERING

COMPONENTS.

• MORE DAMAGE AND WEAR WILL OCCUR NEAR AND INTO THE HORIZONTAL TURNS

BECAUSE THE WHEEL PATHS MAY CROSS THE GUIDEPATH.

• DEBRIS SUCH AS SCREWS, BOLTS OR CLIPS COULD BECOME WEDGED UNDER THE

WHEELS CAUSING DAMAGE TO THE TAPE AS THEY ARE PUSHED ALONG THE FLOOR.

• ANY DEBRIS OR MARKS ON OR NEAR THE GUIDANCEPATH WHICH ARE OF SIMILAR

COLOR MAY CAUSE THE CART TO STRAY OFF COURSE.

• SWEEP/DUST AND/OR MOP OR USE A FLOOR WASHER TO CLEAN THE GUIDEPATH.

MILD DETERGENTS MAY BE USED BUT THEY MUST BE RINSED TO REMOVE ALL

DETERGENT RESIDUE.

• EXCESSIVE DUST WILL ADVERSELY AFFECT THE CAMERA AND LASER OPERATING

CHARACTERISTICS.

NOTE:

THE GUIDEPATH MUST BE KEPT IN GOOD CONDITION FOR SMOOTH OPERATIONS.

TRACK-CLEANING SCHEDULE RECOMMENDATIONS

• HIGH TRAFFIC AREAS AND CORNERS SHOULD BE CLEANED AND INSPECTED WEEKLY

• LOW TRAFFIC AREAS AND STRAIGHT SECTIONS SHOULD BE CLEANED AND INSPECTED

TWICE A MONTH

• AREAS WHERE THERE IS EXCESSIVE DEBRIS SHOULD BE CLEANED AND INSPECTED

DAILY

AUTO-CART

Section 07-00



8. OBSTACLE SENSING LASER:

• CHECK FOR LOOSE MOUNTING BOLTS. RE-TIGHTEN.

• DO NOT USE FINGERS TO REMOVE DUST FROM LENSE.

• CLEAN LENSE WITH A SOFT, DRY CLOTH.

• DO NOT USE ANY CLEANING AGENTS OR CHEMICAL CLEANERS.

• INSPECT ALL WIRING AND CONNECTORS FOR WEAR AND DAMAGE. REPLACE IF

NECESSARY.

9. FRAME:

• CHECK FOR LOOSE BOLTS AND RE-TORQUE TO TORQUE SCHEDULE.

• ADJUST DECK PER THE SETUP DIMENSIONS IF DECK DOES NOT SIT LEVEL TO THE

FLOOR.

10. FLOOR PROXIMITY SENSOR:

• CHECK FOR LOOSE LOCK NUTS AND RE-TORQUE ACCODINGLY.

• CHECK HEIGHT POSITION TO VERIFY PROXIMITY TO FLOOR PLATES.

• VERIFY WIRING.

AUTO-CART

Section 10-01 Electrical

Auto-Cart Boards

Rev 1 01 10-01 AGC Boards Whirlpool Rev1 01.docx Page 1 of 10

Guidance Board

GUI Input

Radio Input

T1 Terminal Block Diagnostic Port

Selector

T4 Terminal Block

T3 Terminal Block

Analog Connection

Motor Connection Rabbit Core

Prog. Port

T2 Terminal Block

Dead Reckon Test

Camera Input

Diagnostic Input

AUTO-CART


Auto-Cart Boards


Guidance Board

(Continued)

Drive Overload

Range Frequency

Battery Frequency

Drives Enable Camera Override

Pendant Guide Right

Pendant Guide Left

Pendant Enable

High Speed

Low Speed

Floor Marker Input

Dynamic Brake Enabled

Reverse Enabled

Main Drive Enabled

Steering Drive Enabled

Guidance

Brake Module

AUTO-CART


Auto-Cart Boards


Power and Safety Board

(Weidmuller Terminal Blocks (Orange) may be present, Phoenix Terminal Blocks (Green) Shown)

P1 Terminal Block P3 Terminal Block

P4 Terminal Block

P2 Terminal Block

LED#1 LED#2

38) LED#3

LED#4 & LED#5

Jumpers

LED#6

J6 Jumper

J3 Connection

Relays

AUTO-CART


Auto-Cart Boards


Steering and Drive Board

J2 Terminal Block

PLD Software Version

J5 Connection

J4 Connection

PLD Prog. Port

J6 Terminal Block

Serial Number

Steering Position Feedback

Feedback Adjust

Oscillator Bias Adjust

Oscillator Amplitude Adjust

J1 Terminal Block

Speed Control

AUTO-CART


Auto-Cart Boards


Expander Board

Keyence Scanner Interface Board

Laser Scanner Connection

PC Connection

NPN/PNP

Config.

P2 Terminal Block

P4 Terminal Block

To Expander Board interface for Laser Scanner

NPN/PNP Select Jumper

For front and rear laser scanners. Used for bank select, reset, warning zone protection and powering laser scanner units

AUTO-CART


Auto-Cart Boards


Brake Driver Board

Camera Lighting Board

Brake Disengaged

Master On

Power Connection Lighting LEDs

AUTO-CART


Auto-Cart Boards


Item # Description

Guidance Board IDC AGC3700 Processor Base supports the Rabbit Core processor module. The high performance processor supports analog and digital inputs along with serial and Ethernet connections. The processor base and core module is specifically designed for AGC cart operation utilizing a specialized color camera to provide guidance to a steering servo drive and motor speed control. Most cart functions are stored in the core processor. Core processor is plug-in allowing for easy field updates.

1 Radio Communication Port. Connects to AGC Radio.

2 Camera Communication Port. Connects to AGC Camera Board.

3 Graphical User Interface (GUI) communications port. Connects to GUI.

4 PC Diagnostic Port for camera, radio, or graphic user interface. This port connects to the device that is selected by the (6) Diagnostic Port Selector.

5

The Diagnostic Port Selector switches select which, if any, port that the Diagnostic Port (4) is connected to. Only one switch should be in the PC selection at a time. Run: Sets the corresponding port for normal cart operation. PC: Connects the corresponding port to the Diagnostic Port.

CAM-A: Connects the Diagnostic Port to the camera.

Comm: Connects the Diagnostic Port to the radio.

GUI: Connects the Diagnostic Port to the graphical user interface.

6 T1 Terminal Block. 24V control power, pendant control. Refer to AGC wiring diagram for more information.

7 T2 Terminal Block. 24V control power, charge relay, status outputs Refer to AGC wiring diagram for more information.

8 T3 Terminal Block. Analog inputs, Current Sensing. Refer to AGC wiring diagram for more information.

9 T4 Terminal Block. 5V control voltage, ultrasonic trigger & receivers. Refer to AGC wiring diagram for more information.

10 Motor Connection to (47) J4 Connection on Drive Board

11 Analog Connection to (45) J5 Connection on Drive Board

12 Brake Module Port

13 Rabbit Core Programming Port

14

Used to perform a Dead Reckon Test.

1: Dead Reckon to the left.

2: Dead Reckon to the right.

3: Dead Reckon enabled.

4: Not Used

AUTO-CART


Auto-Cart Boards


15

Guidance Status Indicator

Rapid Flash: Guidance Ok

0.5 Second Flash: Dead Reckon Mode Enabled

Steady On or Off: Guidance Not OK

16 Drive Overload

17 Battery Frequency

18 Range Frequency

19 Camera Override

20 Drive Enabled

21 Pendant Guide Left Light turns on when input from pendant tells cart to go left.

22 Pendant Guide Right Light turns on when input from pendant tell cart to go right.

23 Pendant Enable Light turn on when input from pendant tell cart to enable motion.

24 High Speed (Base Cart only)

25 Low Speed (Base Cart only)

26 Floor Marker Input Light turns on while the proximity sensor senses a floor marker.

27 Main Drive Enabled

28 Steering Drive Enabled

29 Dynamic Brake Enabled

30 Reverse Enabled

Power and Safety Board IDC PSB-SFTY-BRD is used to distribute power to all components. With force guided contacts monitoring a safety circuit, the power safety board has the ability to control power to devices based upon a safe condition being maintained.

31 P1 Terminal Block Battery Power, Charger Power, Drive Board, Motor Power

32 P2 Terminal Block. safety inputs, switched power Refer to AGC wiring diagram for more information.

33 P3 Terminal Block Cart Power On/Off, E-Stop, Unswitched Power

34 P4 Terminal Block. brake power, light motor power/control, switched power Refer to AGC wiring diagram for more information.

35 J3 Connection Connection used for current sensing.

36 LED#1 Safety Circuit 1 Satisfied

37 LED#2 Safety Circuit 2 Satisfied

AUTO-CART


Auto-Cart Boards


38 LED#3 Safety Circuit cross-check Satisfied

39 LED#4 & LED#5 Safety override mode enabled when BOTH are on.

40 LED#6 Master Relay On

41 J6 Jumper Safety Mode Select Holding.

42 Jumpers Safety Bypass Enable (when drive not moving)

43 Relays Pin Lift Control. Based upon cart options, relays may be present.

Steering and Drive Board IDC Model DD-2060 servo drive board is dual channel MOSFET pulse width driver capable of operating two servomotors, one for steering and one for motor drive. The servo inputs are capable of being commanded by an external pulse width signal for steering position and drive speed. Motor drive is speed regulated with a pulse tachometer sensor that also provides position (distance) counting to the processor board. Dynamic braking and reversing can be selected by command from the host controller. Drive provides filtered & buffered speed & current signals to the host controller for diagnostics.

44 J1 Terminal Block Steering Motor Power

45 J2 Terminal Block Drive Motor power

46 J4 Connection Digital Signals from Guidance Board

47 J5 Connection Analog Signals from Guidance Board

48 J6 Terminal Block Position Sensing, Tachometer, and Drive Enable

49 PLD Software Version

50 PLD Programming Port

52 Oscillator Bias Adjust

52 Oscillator Amplitude Adjust

53 Steering Position Feedback Adjust

Expansion Board IDC AGC-3700B EXP provides access to the use of a laser scanner, in addition the user gains the use of more I/O to assist in other AGC applications such as part in place proximity sensors, status indicators, or whatever needs may exist for 24V control sensors or actuators.

54 P2 Terminal Block

AUTO-CART


Auto-Cart Boards


Expanded Inputs, User Configurable based upon application.

55 P4 Terminal Block Expanded Outputs, User Configurable based upon application.

56 Laser Scanner Connection

57 PC Connection Plug a serial cable into this slot to interface with the Laser Scanner (Hokuyo).

58 NPN/PNP Configures the Laser Scanner Inputs/Outputs to work with NPN or PNP devices.

Brake Adapter Board IDC Model AGC 3700-BD is used to assist with the normally closed electrically guided brake. This is a high current brake driver to create better stopping ability and safer running carts. The brake will only be disengaged when told to release; if power were to fail the brake would be applied, providing a fail-safe function.

59 Brake Disengaged LED On when brake is disengaged

60 Master On LED On when both safety circuits have been satisfied

Light Board IDC Model LAMP-18 provides a uniform band of light to aid in providing a constant image color for the camera to follow.

61 Power Connection Provides power to light board.

62 Lighting LEDs Provides light for illuminating stripe

AUTO-CART


Parts List

Rev 1 01 10-02 Part List Rev1 01.docx Page 1 of 9

1) Indicator Light

2) H.M.I.

3) Pendant Control Receptacle

4) Programming Port

5) Laser Scanner

6) Sound Module

7) Cart Power Switch

8) Radio System

6) Laser Scanner

9) Bumper Photoeye

10) Reflector

AUTO-CART


Parts List


12) Control Power Circuit Breaker

13) Motor Drives Circuit Breaker

14) Prox. Cable

15) Proximity Sensor

16) Brake Mechanism

17) Transaxle

18) Light Board

19) Charger

11) Lift Control Circuit Breaker

AUTO-CART


Parts List


20) Steering Position Sensor

21) Steering Drive

22) Camera Package

23) Battery

24) Fuse Holder

2) H.M.I. 6) Sound Module

1) Indicator Light

25) E-Stop

26) Master Start/Reset Button

27) Cart Power Switch

AUTO-CART


Parts List


29) Expansion Board

30) Brake Adapter

32) Core Module

31) Guidance Board

33) Drive Board

34) Power Safety Board

35) Keyence Scanner Interface Board

28) Status Indicator

AUTO-CART


Parts List


36) Rack Detect PhotoEye

AUTO-CART


Parts List


Part Description Part Number/ Manufacturer

E500 Tugger

E500 Tunnel

E3500 Tugger

E3500 Tunnel

1 Indicator Light

HW2P-IFQD-Y-24V / IDEC

N/A STD N/A STD

BLR-24-Y / MARAYASU

OPT OPT OPT OPT

2 HMI AGP3200-T1-D24 /

PROFACE STD STD STD STD

3 Pendant

Receptacle FK 4.5-0.5 / TURCK STD STD STD STD

4 Programming Port ENSP1F5C305 /

BRAD CONNECTIVITY STD STD STD STD

5 Laser Scanner

SZ-16V / KEYENCE

OPT OPT OPT OPT PBS-03JN-CE / HOKYO

PX-24ES / SUNX

OS3101 / STI

6 Sound Module BD-24AK / PATLITE STD STD STD STD

7 Cart Power Switch XB4BD21 /

TELEMECANIQUE STD STD STD STD

8 Radio System XBP24-PKI-001-RA /

XBEE OPT. OPT. OPT. OPT.

9 Bumper Photoeye HP100-P1-CN03 /

YAMATAKE STD STD STD STD

10 Reflector FE-RR8 / YAMATAKE STD STD STD STD

11 Lift Control

Circuit Breaker CLB-033-11B3A-B-A /

CARLING OPT. OPT. OPT. OPT.

12 Control Power Circuit Breaker

CLB-033-11B3A-B-A / CARLING

STD STD STD STD

13 Reg. Duty Motor

Drives Circuit Breaker

691-CLB15311B3ABA / MOUSER

STD STD N/A N/A

13 Heavy Duty Motor

Drives Circuit Breaker

691-CLB15311B3ABA / MOUSER

N/A N/A STD STD

14 Proximity Sensor

Cable V1-G-YE5M-PVC / P & F STD STD STD STD

15 Proximity Sensor MGS-S-24-10V-PX /

IDC CORP STD STD STD STD

16 Brake Mechanism BRAKE MECHANISM STD STD STD STD

17 Reg. Duty Transaxle

TRANSAXLE STD STD N/A N/A

17 Heavy Duty TRANSAXLE N/A N/A STD STD

AUTO-CART


Parts List


Transaxle

18 Light Board LAMP-18 / IDC CORP. STD STD STD STD

19 Battery Charger CHARGER STD STD STD STD

20 Steering Position

Sensor IDC-CMU-F-8796 /

IDC CORP. STD STD STD STD

21 Steering Motor STEERING MOTOR STD STD STD STD

22 Camera Package 3-09-00089 / 3-D SALES STD STD STD STD

23

Battery (Varies based upon customer

request)

M34 SLD G / MK POWERED

STD STD STD STD 8012-021 / OPTIMA

24 Fuse Holder MET FBW801MANL /

TSUNAMI STD STD STD STD

25 E-Stop Button XB4BT42 /

TELEMECANIQUE STD STD STD STD

26

Master Start/Reset Button

ZB4BC3 / TELEMECANIQUE

STD STD STD STD

27 Cart Power Switch XB5AD33 /

TELEMECANIQUE OPT. OPT. OPT. OPT.

28 Status Indicator

Light (Mast Mounted)

BLR-24-Y / MARAYUSU OPT N/A OPT N/A

29 Expansion Board 3700B EXP / IDC CORP. OPT. OPT. OPT. OPT.

30 Brake Adapter

Board AGC-3700-BD /


31 Guidance Board AGC-3700-BASE /


32 Core Module RCM 3700 / IDC CORP. STD STD STD STD

33 Drive Board DD-2060 / IDC CORP. (HEAT SINK VARIES)

STD STD STD STD

34 Power Safety

Board PWR-SFTY-BRD /


35 Keyence Scanner Interface Board

IDC-KEYENCE-INTERFACE/ IDC CORP.

OPT. OPT. OPT. OPT.

36 Rack Detect PhotoEye

GLV18-55/115/120/ Pepperl+Fuchs

OPT OPT OPT OPT

NOT PICTURED

37 Right Angle Bracket for Reflector

HP100-BP01 / YAMATAKE

STD STD STD STD

38 HMI AIGT003B /

PANASONIC (OBSOLETE)

N/A N/A N/A N/A

AUTO-CART


Parts List


39 1/2 “ Hole Plug AS050 / HOFFMAN STD STD STD STD

40 Rubber Grommet 9703K85 /

MCMASTER CARR STD STD STD STD

41 Rubber Grommet 9600K63 /

MCMASTER CARR STD STD STD STD

42 Ultrasonic Unit

(QTY#1) US-2M-TTL / IDC CORP.

STD STD STD STD

43 Crank Shaft

Position Sensor SU147 / WELLS STD STD STD STD

44 Plug for Crank Shaft Position

Sensor

ECC57-4502 / CARQUEST

STD STD STD STD

45 Chime SC628ND / MALLORY

(OBSOLETE) N/A N/A N/A N/A

46 Cable Assembly BCB-73 / IDC CORP. STD STD STD STD

47 Cable Assembly BCC-62 / IDC CORP. STD STD STD STD

48 Part in Place

Proximity Sensor BES 516325GE5YS4 /

BALLUF OPT OPT OPT OPT

49 Cable For P.I.P. Proximity Sensor

V1-G-TE5M-PVC / P&F OPT OPT OPT OPT

50 Housing For

Female Brake Plug

538-03-06-1023 / MOLEX

STD STD STD STD

51 House Male Brake

Plug 538-03-06-2023 /

MOLEX STD STD STD STD

52 Female Sockets For Brake Plug

538-02-06-1103 / MOLEX

STD STD STD STD

53 Male Pins For

Brake Plug 538-02-06-2103 /

MOLEX STD STD STD STD

54 Female Housing For Motor Drive

35143-0201 / MOLEX STD STD STD STD

55 Male Housing For

Motor Drive 35141-0201 / MOLEX STD STD STD STD

56 Female Sockets For Motor Drive

Housing 35728-0201 / MOLEX STD STD STD STD

57 Male Pins For Motor Drive

Housing 357-0201 / MOLEX STD STD STD STD

58 Battery

Connectors 8026K65 / STD STD STD STD

59 Pins For Battery

Connectors 8026K92 / STD STD STD STD

60 Power Supply For SD-25B-24 / OPT OPT OPT OPT

AUTO-CART


Parts List


STI Laser Scanner

MEANWELL

61 Cable For STI Laser Scanner

OS3101-CBL-XXPT / STI OPT OPT OPT OPT

62 Proximity Switch for Lift (Customer

Dependant)

516-325-G-ES-Y-S-4 / BALLUFF

OPT OPT OPT OPT

SECTION 11-00

11-01 Troubleshooting Rev1_01 PAGE 1 of 8

Troubleshooting

Steering Position Feedback Sensor The steering position sensor provides angular feedback of the wheel position to the servo drive and core processor. This provides a closed loop position along with a camera command that provides high precision following. The position sensor utilizes a non-contacting magnetic sensor. An embedded magnet attached to the gear drive provides the angular measurement and is detected by a proprietary sensor similar to a compass. This measurement method is superior to other transducers that have mechanical connections such as a pot or resolver.

Bottom view of steering Wheel and Position Sensor

Steering Wheel

Motor Power Connections

Magnetic Position Module

Sensor Plug See wiring diagram for connections.

SECTION 11-00


Steering position sensor Measurement It is important to time the steering position feedback sensor to the servo drive. This insures that the absolute encoder will indicate left, straight and right when commanded by the processor. The first step is to make sure that the output from the position feedback is close to zero when the steering wheel is straight. Insure that the wheel is square to the cart. With power turned on, measure with a digital voltage meter (DVM) between terminals 3 & 4 to make sure the position output is with in range of zero (0) +/- .650V DC. See Fig.6 below. If measurement is out of range check to make sure that the position of the magnet is perpendicular to the wheel when the wheel is straight. Failure to make this adjustment may result in erratic steering. Check magnet under sensor cover Fig.5. There is a Transtork nut assembly above the motor drive that may be loosened and the sensor re-positioned by hand. Once you have aligned the magnet assembly, be sure to tighten the Transtorque nut assembly to 19.8nm. Install cover assembly and make sure magnet is not touching or scraping circuit board or cover.

Magnet Check

Fig. 5

Magnet must be perpendicular to wheel when wheel is straight. Compensation adjustment (P4) in servo module can correct for slight misalignment.

Sensor cover removed to expose magnet on gear assembly.

Steering wheel

Transtorque nut assembly on motor shaft: Torque to 19.8nm.

SECTION 11-00


Measurement of transducer position

Measure between terminals 3 and 4 with a DVM Fig.6. Voltage should be between -.650 to +. 650 If measurement is out of this range see magnet check procedure above.

Fig.6

Steering Sensor Compensation adjustment0

With the steering wheel perfectly straight, turn power on but do not initiate cart to cycle. Measure on Pin 1 of IC U1 for 0.0VDC with DVM (Fig.7). Adjust P4 to achieve this value. P4 is a 25 turn pot and can be rotated indefinitely with out damage. If 0.0V cannot be achieved re-check position sensor reading above to be sure that the voltage is below .65 volts.

Fig.7

Dead Reckon Steering

Pin 1 on U1

Terminal 3 Common

SECTION 11-00


Command Check and Adjustment

A steering command must be calibrated to associate true straight command from the

processor to the servo drive. This is accomplished after the steering position check performed above has been accomplished. The cart may be put in “Dead Reckon” mode to perform this test. Test may be checked with the cart on its back or on the floor to check for straight movement.

To put the cart in Dead Reckon mode plug in the pendant control. This will automatically set the cart to move without a color path. Press the green run button and the cart will move forward providing there are no obstacles in front blocking the laser scanner. The cart should move in a straight line. If a noticeable left of right turn is detected the servo board must be adjusted If the wheel is not straight, adjust the steering centering Pot P1 on Servo Drive board to correct any misalignments. See Fig.9

Servo Drives Fig.8

After the dead reckoning test and adjustment, you may test the left and right commands by pressing and holding the left and right button on the pendant control.

P1 Adjusts Dead Reckoning for straight wheel operation when the pendant control in plugged in and operated.

SECTION 11-00


Guidance Camera

IDC –CMU-500

Fig.10

Fig.11

Camera

Connection Plug

Cooling Fan

Camera With

Close focus Lens

Secure Lens with anti-rattle

cement

LED Lamp assembly

LED power connection

SECTION 11-00


AutoCraft Cart Troubleshooting Guide Electrical

Cart will not turn on

Check circuit breaker in control panel to insure they are all on.

Check Battery plug connection to control panel. Battery connection is located inside battery box. This is a blue inline plug. Check to be sure cable plug is fully seated.

Check Battery voltage to insure 24 Volts. Measure with DVM on power terminals on lower left side of control panel. Terminals will have a #6 red and black wire coming from battery.

Cart turns on but will not go when released

Laser Block This will prevent the cart from operating if an obstacle is detected by any one of the ultrasonic transducers. Cart may be too close to obstacle Master reset is depressed. Pull out red mushroom button and press green button. Waiting for operator release is an indication for operator input to tell the cart to move to the next step. Pressing the Green button initiates the move. Battery Low Is an indication that the battery is too low for safe operation. Battery must be charged. Battery Low is indicated by a doorbell chime from the music module. Brake set in free-wheel position will prevent cart motion. This insures that the cart will stop properly in load and unload locations. The yellow beacon will flash two fast blinks followed by a noticeable pause. Brake handle in back of cart must be set to the down position.

Car runs away and stops Tach sensor or wiring fault Tach loss is checked anytime the motor is commanded to go and pulses are not detected. Cart will run fast briefly and stop immediately with the brake applied. Cart must be powered down to reset the fault. If problem persists check the tach sensor for continuity using an ohmmeter. Tach sensor is measured on terminals 9&10, the orange plug on the servo drive board. The reading should be 630 ohms +/- 10 %. Tach sensor is located on

SECTION 11-00


drive motor top near the brake handle. Sensor is connected with an automotive type connector.

See Fig. 12

Ohm Meter 630 Ohms between terminals

9 & 10

SECTION 11-00


Loss of Guidance

Loss of guidance is detected in the microprocessor (Flashing Red LED on processor board top left side.) The amber lamp on cart top will flash a fast sequence indicating that the cart is not on tape guidance or the camera is programmed to the wrong colors. Make sure cart is on stripe when initiated. Cart is dependent on a camera signal to operate. Color selection in the camera may be wrong. Check color values with the WEB browser. See WEB browser section to view colors. Check LED lamp board for illumination. IF no illumination is observed under the cart in front, check 9-pin serial cable to camera assembly for proper plug in. Fig.11 Check LED board for proper power connection. See Fig.12 Check Toggle switches on guidance processor for proper setting. Bat handle must be switched to the outside of the circuit board. Check motor drive for proper operation by implementing a dead reckoning command. This is accomplished by plugging the pendant control. This will test motor and steering drives. Check for loose connection to circuit board on the camera assembly under the cart. See Fig. 10 for cable placement. Check Camera view for proper focus. Use the camera view program starting on page 4.

Cart does not run and no indication of faults Check for circuit breaker trip in control panel Check to be sure dipswitches are off on processor board Check to make sure all toggle switches are in the Left position Battery voltage too low. Check with volt meter for 24vdc Check for obstruction in front of laser sensor Check motor plug for connection

1800 FRUIT RD. • ALGONAC, MICHIGAN 48001PHONE: (810) 794-4929 • FAX: (810) 794-7449

E-mail: [email protected]

AUTO CRAFT TOOL & DIE CO., INC.

PRODUCT WARRANTY

Equipment manufactured and sold by Auto Craft Tool and Die, Inc. is warrantedas set forth below. This warranty extends only to the buyer purchasing theequipment directly from Auto Craft or through its dealers, distributors, or agentsas new equipment.

This equipment is warranted by Auto Craft to be free from defects ofworkmanship and materials for a period of 4,000 operating hours after delivery(except as stated below), provided that it is properly operated under conditions ofnormal use. Auto Craft’s sole obligation under the foregoing warranty is limitedto making replacements, repairs, or issuing credit for equipment or parts thereof(at Auto Craft’s option) which are found to be defective.

Auto Craft shall not be liable to buyer from consequential damages, or damagesof any kind based upon a claim for breach of warranty other than as statedabove.

The foregoing warranty shall not apply, and Auto Craft shall be relieved of anyobligation or liability, if this equipment has been repaired or altered. Including theuse of components other than those manufactured or approved by Auto Craft byanyone other than Auto Craft, or if this equipment has been subject to abuse,misuse, negligence, or accident.

This warranty does not cover buy items that would be covered under a separatemanufacture warranty.

Date post:	28-Oct-2014
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AGC Manual

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