INSTRUCTION MANUAL

AGV'S
PRESENTS:
Eduardo Rodríguez Salinas

CK CIVAC, MORELOS AUGUST 2017

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Table of contents
Chapter 1 Precautions
1-1. Security alert.................................3

1-2. Precaución de seguridad4

Chapter 2 General Overview of the AGV

2. Visualization........................................5

Chapter 3 Overview of AGV

3-1. Basic performance ................................. 6

3-2. The operating environment..........................7

Chapter 4 Issues to be verified before the operation

4-1. Matters to be verified before the operation...........................7

4-2. Precautions ................................. 7

4-3. Other causes of anomalies...........................................8

Chapter 5 Description of AGV Operations

5-1. Description of the operation panel...............................9

5-2. Description of the LB operation panel ............................ 11

5-3. AGV switched on (Start)........................12

5-4. AGV off (Stop) .......................... 14

Chapter 6 Description of the commands

6-1. Description of commands..............................16

6-2 Precautions and installation description of commands..........................18

Chapter 7 Security Systems

7-1. Obstacle sensor.................................19

Emergency stop.................................20

7-4. The warning systems............................20

7-5. Control Section.................................21

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1. PRECAUTIONS
1-1. Security Alert
Make sure to follow the instructions below to operate safely
AGVs.
Attention
(Conditions that can cause serious accidents, such as fatal accidents and
serious injuries, when the devices are used in the wrong way)
① This device is for indoor use only. Do not use outdoors. (This is not the
waterproofing, protection against dust.)
② This device is not designed to be resistant to explosives. Do not use it in
an environment with gases or fuels.
③ Do not use this device while standing on the platform. This may
to cause injuries from falls or crushing between machines.
④ Do not stay on the battery cover or place anything on it. This can
to deform the battery cover and damage the internal battery.
⑤ Unit in motion, do not touch the controls for the unit while it is in
Malfunctioning can cause injuries from having the hand crushed.
⑥ Place signs or warning devices on the AGV operating routes to
avoid the routes of people. And the objects from entering the routes.
⑦ Do not put or place objects on the operation routes, as it may cause
serious consequences due to unexpected collisions.
⑧ Do not touch the parts inside the control panel or the terminals of the cables.
electricals, except the circuit breaker while the battery is connected. This can
cause a short circuit, an electrical shock, or an electricity leak that can
damage devices or cause injuries or fires.
⑨ Do not operate the AGV while it is standing in the direction of the AGV's forward movement.
accidents can occur when the AGV starts unexpectedly.

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1-2. Safety precaution
(Conditions under which the incorrect handling of devices can lead to
injuries or damages to properties and conditions that can have consequences
serious in some cases.
① Before starting work, make sure that the safety devices (sensor
of obstacles, Switch, stop switch, etc.) function correctly.
② Do not use this device when the ambient temperature exceeds 0 ~ 50 ° C.
Electrical devices may not function properly in such environments. Do not use it.
in the environment more than 80% of (Do not condense the dew)

③ The drive unit is suspended in the air and disables the driving of the AGV when the
The unevenness on the road surface is more than ± 7 mm
④ The AGV cannot generate the designed drive, force on the steps or
Inclined surfaces Remove the steps and inclines of the driving routes.
⑤ The drive wheels slip and the AGVs cannot drive correctly on
Flooded or oily surfaces clean the surfaces of the roads to remove the oil.
or the water.

⑥ When using AGVs near areas where welding work is in progress,

Take precautions so that the AGV do not get crushed directly. The spraying
can stick to magnetic tapes for conduction and magnetic tapes of
commands and negatively affect AGV operations.
⑦ Small pieces such as screws and solid waste on the roads can
get trapped between wheels and tires and cause derailments. Keep the
clean routes.
⑧ Rough surfaces, such as concrete and asphalt, accelerate the wear of the
tires. Keep driving routes as smooth as possible.
⑨ Read the instruction manuals and follow the instructions to use correctly.
⑩ Do not pull the electrical wires when removing the battery connectors, as it causes the
disconnection of the lines or short circuits.
⑪ Read the instruction manuals for the automatic fast charger and follow the
instructions for correctly using the chargers.
⑫ People with specialized knowledge must carry out the maintenance of
this machine following the procedures.

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2. GENERAL VISUALIZATION OF AGV
2-0. Visualization
Operating system
The operating system consists of the Dolly platform, the transport platform of
product, the towing mechanism and other necessary control functions.
The AGV is a system that transports the wagons using tape detection.
magnetic and the conduction in the strips, while the reading of commands
previously established by parameters with polarity sensors and the control of
various movements and functions that it conducts on magnetic tapes.

Traction pin system

Main AGV Unit

Command
Sensor conductor
Magnetic tape drive

KIT transporter Producto transportador

Battery box

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3. GENERAL DESCRIPTION OF THE AGV
Basic performance

Model of the main unit: Type of sliding trailer

Guidance method: Magnetic guiding method
Driving method: Forward movement
Driving method: Driving based on speed differences
on two wheels

(NE1) (NE2)
Driving motor: DC 24V 100W * 2 (200W) DC 24V 200W * 2
(400W)
Traction capacity:≦ 500KG ≦ 800KG
Driving speed:≦ 45m / min Adjustable mental speed ≦ 30m /min

Driving functions: Start / stop, restart after a stop

automatic, separation
Stopping precision: ± 10MM
Turning radius:≧ 600MM
Emergency braking distance:≦ 20MM
Continuous operations: Specification of LB (with the use of the battery charger)
fast)
Charging method: Manual operation or automatic fast battery charger
Battery: LIBATTERY
Safety guiding range: Laser sensor type ≤ 4 m adjustable
Adjustable infrared type ≤ 3 m
Alarm method: Sound and light

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3-2. The operational environment

Temperatura: 0 ℃ a 50℃
Humedad: Humedad relativa ≦ 80% (without condensation)
The room must be free of corrosive gases, explosive gases, harmful gases, or liquids.
The operating environment must be free from direct sunlight, dust, oil mist, dust of
steel or rainwater.

4. SUBJECTS TO VERIFY BEFORE THE OPERATION AND

PRECAUTIONS

4-1. Matters to be verified before the operation.

Please check the items below before operating
① There should be no anomaly in the AGV segment.
② Check the screens on the operation panels, LB BOX and make sure to
that there are no anomalies.

③ Check the operational status of the processes and press the Start button.
Stop to start the system operation.
④ Inspect the sensors and security systems to ensure that
each part works correctly every day and refrains from malfunctioning
when there is any abnormality.
Always carry out inspections at the beginning of work every time before
start an operation.)
The inspection table is attached as a reference.

4-2. Precautions
① The conduction mechanisms, the control system, and the sensors are
connected to the AGVs. The control system receives signals from the sensors and
determine the movements. Do not touch the sensors during operation to
avoid risks.
②Do not enter the AGV's movement area during operation.
Also, do not touch the control parts and moving parts of the AGV to avoid
risks.

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③Untrained people will not repair AGVs. Please contact
trained personnel when AGVs need to be repaired. (Please take
the necessary precautions during the repair.)
④If an abnormal noise is detected during the operation of the AGV, stop.
immediately the AGV. Inspect the AGV and resolve the issues before
resume operation.
⑤If an anomaly occurs during operation, stop
immediately the AGV. Eliminate the anomaly according to the instructions of the
manual before resuming operation.
⑥Do not repair the AGV without stopping it.
⑦Disable the power when the AGV is not used for a long time
to save battery

4-3. Other causes of abnormalities

Anomalies can occur during driving due to the following
factors. Thoroughly inspect the driving routes.
① Damage to the magnetic tape drive causes malfunctioning
unstable, which causes derailment.
② Damage to the tape drive command causes abnormal movement
due to errors in reading.
③The conditions (foreign objects such as water, oil, and dust) in the
the surfaces of the roads cause the driven wheels to slip, resulting in
result variations in unemployment positions..
To avoid previous anomalies, regular monitoring is recommended, as it
recommend the inspection of the initial operation (every day). Precautions
For battery use, please read the instructions attached to the battery beforehand.
to use.
Precautions
①When charging the battery to 70%, use the timer to avoid overcharging.
allows using the battery for a long lifespan.
②Do not drop or impact the battery while transporting it to avoid the
heat and fire.

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5. DESCRIPTION OF AVG OPERATIONS
5-1. Description of the operations panel.
Description of the main operation panel
The main operation of AGV takes place in this control panel.
main. The following is the description of each segment.

Figure 1. Operation panel

NO NAME FUNCTION
1 Power switch Provides power to move and control the AGV.

2 Error Display monitor Show error code in case of anomaly

Detection control monitor AGV.

3 Home button System startup stop (AGV start).

When the system is turned on (in AGV), if
press this button, the system stops (AGV
STOP).

4 Error reset button In the system error, after it is

delete the error, press this button then, the
The system error is raised.

5 Emergency stop button Stop the AGV in case of emergency

6 Warning system When an AGV stamp is issued, in case of

an error is heard as a bell.

7 Indicator lamp Show the driving status of AGV by

colors and blinks.

Precautions the buttons 'START / STOP', 'ERROR RESET' are different

according to the specifications.

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 ERROR CODE LIST Error code

1. ERROR OF E / STOP 1, Emergency stop ERROR

2. BUMPER ERROR 2, Bumper ERROR
3. TRACTION WHEEL ERROR 3, Traction bar ERROR
4. OBSTACLE ERROR 4, OBSTACLE ERROR
5. LOW VOLTAGE ALARM 5, low voltage ALARM
6. LH DRIVING ERROR 6, Left unit ERROR
7. RH DRIVING ERROR 7, Right unit ERROR
8. PLC ERROR 8, ERROR PLC
9. DERIVATION OF AGV 9, ERROR AGV.
Black

Show the command number read by AGV for 5 seconds. When it is

use the keyence SZ-16V sensor in Obstacle Sensor, mark 2 is displayed
with protected area detection.
Caution: The screen flashes to indicate the anomaly.
The vertical operation of the traction pin alternates when it
simultaneously press [Reset Button] and [Start / Stop] when pressing the button of
emergency stop.

Figure 2. Description of the traction pin manually

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5-2. Description of the LB-BOX battery operation panel
48V lithium battery (hereinafter LB = BOX) is used for the source of
AGV feeding. As the main unit of AGV and the control system LB-
BOX are independent of each other, a unique LB-BOX operation is necessary.
This chapter describes the function of each button on LB-BOX.
Please refer to the attached sheet for the detailed explanation of the body.
principal of LB-BOX.

Figure 3. Button description

Function of the buttons

The green light turns on when the battery is in a normal state.
It blinks green when the battery is charging.
3. Visualization of a battery's charge status
The capacity is shown using a light that is on, blinking or
turned off.
Off: Almost fully charged.
Blinking (1 second interval): Battery capacity is below 50%.
Intermittent (2-second interval): Battery balance is disabled.
The light is on. The battery capacity is below 20%.

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2. GENERAL VISUALIZATION OF AGV
2-0. Visualization
Operating system
The operating system consists of the Dolly platform, the transport platform of
product, the towing mechanism and other necessary control functions.
The AGV is a system that transports the wagons using tape detection.
magnetic and the conduction in the strips, while the reading of commands
previously established by parameters with polarity sensors and the control of
various movements and functions that it conducts on magnetic tapes.

Traction pin system

Main AGV Unit

Command
Sensor conductor
Magnetic tape drive

KIT transporter Producto transportador

Battery box

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When the yellow LED of the [BAT] light is on, the capacity of the battery
is less than 20%. Charge the battery as soon as possible because there is the
risk of stopping the function while driving. (The blinking indicates that the
the battery capacity is below 50%.
① Start of LB-BOX
Pulse [POW ON_SW] until the green LED on the normal screen lights up.
[RUN]. (Approximately 2 seconds)
When LB-BOX starts normally, both [PWR ON] and [RUN] are
they light up.

② AGV start-up
Press 'Power ON' on the main AGV unit.

★ The touch panel screen lights up. The lamp

the warning also turns red.

③ Start of AGV
Press 'ON' on the main power supply on the control panel②
make the AGV ready to start (takes 20 to 30 seconds) Check the
flickering of the screens on the power supply and the error code.
An error code may appear and an anomaly buzzing sound is heard when you
press enter, even if there is no anomaly, therefore reset the button once
to lift it up)

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④ Start of AGV
The anomaly rises above③, then make sure there is no
Obstacle in and around the transmission line, press the "Start / Stop" button.
AGVs drive with the flashing pilot lamp (yellow) and the
Conductor whistle. (For the speed of movement, wants to run at
the speed established at the time of the shipment inspection.

5-4. AGV Shutdown

This chapter explains how to finish AGV.
The flow of the AGV is shown below.

① Stop AGV
Pressing the 'RUN / STOP' button while the AGV is in operation, the AGV
It stops immediately.

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 ★ AGV stops in case of driving.

② AGV Off
Turn off the main power of the control panel.

③ Turn off the power of 'LB-BOX'.

Pulse [POW OFF_SW] until the green LED on the normal display [RUN] turns on.
turn off. (Approximately 2 seconds)
With the previous operation, AGV and LB-BOX are deactivated.

Figure 5. Press power off for 2 seconds

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④ AGV Completion

Methods of stopping for AGV shutdown are as follows:

Automatic stop by command.
Mandatory stop by pressing the 'Start / Stop' button.
Emergency stop with the "Emergency stop" button.
Emergency stop by bumper sensor.
Temporary stop and emergency stop due to obstacle sensor detection.

6. DESCRIPTION OF THE COMMANDS

6-1. Description of the commands
What is a marker?: A magnetic tape with N and S polarities (the tapes
cuts should be 100 mm * 50 mm * 3 mm are available on the market.
What is a command?
An expression of the signals created by the coating of various markers.
so that the AGV can detect. The AGV detects the signals by reading the South Pole
as "1" and the North Pole as "0".
The AGVs read the signals in binary digits, and four markers are expressed
in hexadecimal numbers as a whole.
Command means moving the AGV using a previously given movement command.
established.
What is a polarity switch?
The polarity switches are placed on each side of the AGV and read the
commands during the progress and reading of the AGV commands and the
reading commands during the progress and the reading of the commands of departure and
return.
The polarity switch is used to distinguish the polarities of the
markers (distinguish them as markers).
Possible number of markers used: 2, 3, and 4 Number of markers and
possible number of signals used: 15 types of signals.
15 types of commands for AGV executes the designated movements by reading the
pre-established commands while driving.

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Command marker detection sequence:
Command markers are set from the address side of
movement. (SNSS) = When making the AGV detect 1011 → B

Figure 6. Reading direction for commands

The commands are entered in a hexadecimal number in the section of

Parameter configuration.) 0 cannot be used.
Table 1. Commands in hexadecimal number.

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Table 2. Examples of driving commands

6-2. Precautions and description of the command installation

Installation and adjustment of the switch The switches fit 25 mm.
of polarity: after the shipment. However, the adjustment
it may be necessary depending on the
Adjust the switches of
site conditions.
polarity within the range of
25MM ± 5MM from the ground.

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Installation and placement of command tapes.

Commercially available command tapes

Caution: When the edges of the command tape peel from the ground, the polarity sensor
it can detect a pole different from the real pole, resulting in erroneous readings of the
commands.

7. SECURITY SYSTEMS
7-1. Obstacle sensor
Obstacle sensor has 2 types of specifications such as laser type and the
type of infrared. Laser type sensors allow for 3 detection steps like
deceleration, temporary stop and emergency stop, and infrared type allow 2
detection steps such as temporary stop and emergency stop. (NE1 has
type with SIDE obstacle sensor.

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7.2 Emergency stop
Installed at the front of the AGV as an emergency stop system.

7.3 Warning systems.

A warning system to report the operational status of AGV is installed at

front.

7.4 Control section.

Open the cover of the control panel and the PLC (sequencer) is inside the panel.
of operation. The PLC operates AGV recognizing the information and the state sent
from each sensor and determining their movements.

Figure 6. Control Panel

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7.5 Conduction mechanisms.

The drive mechanisms of AGV include units

driving motors, drive wheels, control mechanisms and
drive actuation guiding mechanisms (actuation sensor).
The drive motor design includes protection functions.
overload or overvoltage.

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