1.0       Purpose:

 

The purpose of this document is to provide a User Document for  the functionality specified in the System Design Specification Document.

 

2.0       Scope:

 

State the Board Number(s) to which this specification is applicable.

 

IND-7710        AGV Guidance Board

IND-7720        Communications Board

IND-7730        Power Supply/Power Monitor/Safety Board

IND-7740        4 Slot Controller Backplane

IND-7750        Sleep/Wake Board

SLC-5/04        Allen-Bradley PLC

 

 

3.0       Design Engineer(s):

 

David Barr - Engineer

 

 

 

4.0       Introduction:

 

The AGV Truck Control Retrofit is an electronic control package upgrade for the Portec AGV trucks. The retrofit package will replace the Portec on-board computer, communications system, guidepath controller and vehicle electronics power supply. The new control package provides an Allen-Bradley SLC-500 PLC and five custom printed circuit boards. The new control will replace the current Portec electronics rack and connect to the vehicle using the existing power, control and antenna connectors. The new control package will maintain the same functions and truck operations as the original Portec electronics.

 

4.1       Definitions, Acronyms, and Abbreviations:

 

AGV - Automatic Guided Vehicle

Portec. - Original manufacture of the ‘86 Chassis Portec AGV System.

PATC - Portec Administrative Controller.

DCS - Discrete Communications System

PDG - Portec Data Gathers

PVC - Portec Vehicle Controller

PIT - Position Identification Transmitter

Burr-Brown -

 

5. General description

 

5.1       Perspective

 

The following is a general description of the current Portec control electronics.

 

5.2       Functional

 

The PORTEC ULC-340 automated  guided vehicles act as mobile assembly platforms, drive through the assembly areas on a 2500 feet guide path.

 

The PORTEC. Administrative Controller (PATC) directs the AGV movements  working independently of Buicks's main host computer. The Buick host computer generates the production sequence listing that are used to load production parts on the AGV's in sequential order.

 

 

 

 

The ULC-300 is a Unit Load Carrier Vehicle designed for assembly applications The vehicle is battery powered with electric drive, steering and two lift decks.

 

5.2.1 Operation Modes

 

1. Automatic Mode: AGV system is controlled by the on-board PLC. The PLC processes commands from the host. The PLC and steering control will command the steering motor to follow the AGV guidepath.

 

2. Manual Mode: AGV is controlled by a operator pendant.

 

5.2.2 Safety Bumpers

 

The front Safety Bumper is a simple  plastic bumper with a photocell monitor and reflector target on the bumper.

 

For Emergency Stops - The bumper only operates during automatic forward travel.

 

 

5.2.3 Visual Warning Devices

 

1. Warning Light - Flashing Yellow lights  mounted on the front and rear of the AGV warn personnel of approaching vehicle. Light will be turned on 3 seconds before vehicle starts to move and will be on while vehicle is moving.

 

2. Beeper - An electronic beeper will sound when the vehicle crosses  fork truck or pedestrian aisles. The Beeper will also sound for 3 seconds before the vehicle starts to move.

 

5.2.4 Vehicle Communications

 

1. Switch Element - is used to recognize floor embedded permanent magnets.

 

2. Front Guidance Antenna - Mounted on the drive wheel. The antenna tracks the center line of the AGV guidepath in a straight, forward or backward travel.

 

3. Communications Transmit Antenna: This antenna transmits information to the PTC.

 

4. Communications Receive Antenna: This antenna receives information from the PTC.

 

5. Blocking Sensor - Part of the steering control. The blocking sensor monitors the guidepath frequencies for a truck blocking signal. When this signal is sensed,   the vehicle will stop its movement and turn on the Blocking light indicator until the blocking signal is removed.

 

5.2.5 Vehicle Control

 

The vehicle is controlled by an Allen-Bradley PLC and a custom electronic control package. The PLC controls the vehicle movement and communicates to the PTC. The custom electronics control package provides the steering, power, safety and communications circuits.

5.2.6 Vehicle Consoles

 

The vehicle consoles are located at the front and rear of the AGV. The consoles are used to operate the vehicle in both manual and automatic modes. The vehicle may be started, stopped and various other operations carried out using these consoles.

 

Console Components

 

 

 

 

1. Vehicle ON/OFF Keyswitch: Used to turn the vehicle ON or OFF.

 

2. Manual/Automatic Keyswitch: Used to select operational mode. Manual Mode - All vehicle control is switched to pendent control. Automatic Mode - Vehicle is controlled by the PLC.

 

3. LEFT/RIGHT Keyswitch: Used to select right or left side of vehicle to operate pendent.

 

4. Vehicle ON indicator (White) - Indicates that the vehicle is in ON and not in E-STOP mode.

 

5. AUTO/ON Indicator (Green) - Indicates vehicle is in Automatic Mode and is following guidepath.

 

6. Emergency Stop Indicator (Red) - Indicates the an Emergency Stop condition is active (Stop Button, Front Bumper or Pendent)

 

7. Blocking Indicator (Yellow) - Indicates vehicle is sensing a blocking condition and has stopped movement.

 

8. Battery Level Meter - Monitors the battery charge level.

 

9. Start Buttons - These buttons are used to release the vehicle from a  work station or normal stop.  One button is on the left side of the vehicle and one button is located on the right.

 

10. Stop Buttons - These buttons are used to bring the vehicle to a normal stop condition at any time on the guidepath. Normal operation is resumed by pressing a start button.

 

11. E-STOP Button - These are used to stop the vehicle immediately in an emergency condition. These buttons are self-locking and require manual reset.

 

12. Remote Lift Connector - Used for remote lift control.

 

13. Hour Meter - Meter displays the vehicle operation hours in automatic and manual mode.

 

14. Raise Buttons - Used to Raise the front or Rear lift assembly.

 

15. Lower Buttons - Used to Lower the Front or Rear lift assembly.

 

16. Raise Button - Raise rear lift.

 

17. Lower Button - Lower rear lift.

 

18. Connector - Used for remote lift control.

 

19. E-STOP Button

 

5.2.7 Burr-Brown Pendent

 

The Burr-Brown Pendent can be plugged into the vehicle for troubleshooting and off-guidepath vehicle movement. The pendent contains an alpha-numeric keyboard, six special function keys and a numeric display. The monitor connects to one of the pendent connectors on the vehicle and allows the operator to communicate to the PLC. A maintenance operator may request status of the PLC functions and  vehicle position. Numeric codes will be displayed on the diagnostic monitor.

 

 

Function Key Table

F1	F2	F3	F4	F5	F6	F7	DISPLAY/RETURN	Function/Entry
		1					SSSSL -------  \ ---LANE #       \--------STATION #	Display Last Station  and Lane Number
1								Enter Station 22 Lane Number 1, 2, 3, 4
	1							Enter Last Station Number
			1					Trigger High Speed Manual Mode

 

 

 

5.2.8 Modes of Vehicle Operator

 

 

AUTOMATIC Mode - The vehicle is controlled by the on-board PLC and commands processed from the Portec Administrative and Traffic Controller (PATC). When the vehicle is placed over the PIT on the guidepath, operator has selected AUTOMATIC mode and the start button is depressed no further manual intervention is required.

 

 

MANUAL Mode - The vehicle is controlled by the Burr-Brown pendent. This allows an operator to manually remove or introduce the vehicle to/from the system.

 

            NOTE: When operating vehicle in Manual Mode, there are no active safety features. Care must be taken that no objects are hit when in motion.

 

SLEEP Mode - The Sleep/Wake control board monitors for a sleep/wake signal from the guidepath. When a vehicle is in Automatic Mode, senses a sleep signal and the vehicle stops the PLC can place the vehicle into a low current power consumption mode. The Sleep/Wake control continues to monitor for a wake signal to resume vehicles operation.

 

NOTE: Sleep Mode can be deactivated by removing the Sleep/Wake board from the vehicle.

 

BLOCKING Mode - The vehicle in Automatic mode can be stopped by Vehicle-to-Vehicle Blocking and Zone Blocking. In Vehicle-to-Vehicle Blocking a vehicle uses a reflective photocell mounted on its front to sense another AGV in its guidepath. Zone Blocking is controlled by the PATC that enables a Zone Blocking signal that stops the vehicle until the blocking signal is removed.

 

5.2.9 Vehicle AGV Status and Fault Messages

 

The Status and Fault Messages are displayed on the two digit LED display on the IND-7720 Communications Board. These codes are generated by the PLC for vehicle status and fault information. In the event several status and fault messages are activated the PLC will only display the highest level code.

 

ALL MODE FAULT MESSAGES:

FF        PLC Communications Time Out

FE        PLC Command Error

86        Bumper Pressed

85        Blocked Ahead

84        Blocking Loop Detected

83        E-Stop Pressed

82        26 Volts Detected, Voltage to High

81        20 Volts Detected, Voltage to Low

80        Manual Mode

 

AUTO MODE FAULT MESSAGES:

68        No Position

67        No Guidance Frequency, Only in Automatic Mode

66        Vehicle PIT Update Fault

65        Invalid Position Entered

64        Waiting for Destination

63        22 Volts Detected, Low Voltage Warning

62        Cannot Release - FRONT LIFT NOT DOWN

61        Cannot Release - REAR LIFT NOT DOWN

60        No Charge at Work Station

 

MARRIAGE FAULT MESSAGES:

41        Font Lift Middle and Upper Limit Switches Made at Same Time

40        Front Lift Lower and Upper Limit Switches Made at Same Time

39        Rear Lift Middle and Upper Limit Switches Made at Same Time

38        Rear Lift Lower and Middle Limit Switches Made at Same Time

37        Rear Lift Lower and Upper Limit Switches Made at Same Time

36        Foot Switch Disabling Front Lift

35        Front Lift Time-Out

34        Rear Lift Time-Out

33        6° Tilt Violated-FRONT to HIGH

32        6° Tilt Violated-REAR to HIGH

31        Waiting for FRONT Release at Marriage

30        Waiting for REAR Release at Marriage

 

ALL STATION FAULT MESSAGES:

11        Waiting for Start to be Pressed

10        Station Time-Out

1-5       PIT 1-5 Detected or At Station 22 (Split) Rec. Lane # from host

5.3       System Characteristics

 

5.3.1 Electronic Packaging

 

The retrofit package  replaces the Portec on-board computer, communications system, guidepath controller and vehicle electronics power supply. The new control package  provides an Allen-Bradley SLC-5/04 PLC and five custom printed circuit boards. The new control will replace the current Portec electronics rack and connect to the vehicle using the existing power, control and antenna connectors. The new control package will maintain the same functions and truck operations as the original Portec electronics.

 

 

 

 

 

 

 

The following is a summary list of the control board functions.

 

IND-7730 Power Supply/Safety/Battery Monitor

* Converts the vehicle +24V battery power to regulated +5V, +12V and +24V.

* Master E-Stop control monitor

* Vehicle E-STOP push button controls

* Front Bumper Monitor

* Guide Path Field OK monitor

* PLC Watchdog monitor

* Battery Voltage Monitor

 

IND-7710 Guidance Board

* Manual Steering Control

* Automatic Steering control and tracking of guide path signal

* Floor Zone Blocking Detector

 

IND-7720 Communications Board

* Process communications commands from the PLC

* Process communications to the Burr-Brown Pendent

* Provide two digit LED Status display

* Process Host Destination commands from floor communications loop

* Process PIT signal from floor communications loop

* Transmit vehicle ID number to host computer

* Transmit vehicle signal for enabling vehicle battery charge station

 

IND-7750 Sleep/Wake Board

* Monitor for host Wake signal and report to PLC and Re-activate to normal mode

* Monitor for host Sleep signal and report to PLC

* Provide Sleep mode data latch. Triggered by PLC, Reset by Wake signal

 

SLC 5/04 PLC

* Provide vehicle control functions - Lifts, Steering, Drive

* Process Burr-Brown Pendent commands

* Process Host Destinations commands

* Process PIT signals

5.3.2 Truck Electronics

 

The control retrofit will  maintain the operator controls, motor control relays and existing vehicle wiring. The new PLC/Control rack will replace the current Portec vehicle controller.

 

NOTE: All the Diode and Capacitor control function in the original Portec control logic have been replaced with direct control from the new PLC. Only the E-Stop control functions are processed through the new Power Supply/Safety Board.

 

 

5.4.5    AGV Safety Systems

 

The Indocomp Systems Portec AGV Truck Control Retrofit will maintain the original Portec Safety circuits and programmed safety functions.

 

5.4.5.1 E-STOP Circuit

 

The AGV Safety System will follow the Portec defined safety circuit.

 

*          Front Safety Bumpers - The front Safety Bumper is a simple  plastic bumper with a photocell monitor and reflector target on the bumper. On detection of an object, the bumper moves and interrupts the photocell. The bumper photocell has a true and a complement output that are processed by a hardwired relay system on the Power Supply/Power Monitor/Safety Board. In the event that either of the outputs from the photocell are not in the correct state the AGV will be placed in  an E-STOP mode. The vehicle will remain in this condition until the fault is removed.

 

NOTE: For Emergency Stops - The bumper only operates during forward automatic travel.

 

*          Manual E-STOP controls - The vehicle operator has a number of E-STOP push buttons on the vehicle and remote pendants to activate an E-STOP condition. The vehicle will remain in this condition until the fault is removed.

 

Manual E-STOP Locations

 

* Front Left

* Front Right

* Rear Left

* Rear Right

* Front Pendent

* Rear Pendent

 

*          E-STOP Automatic Mode - These are vehicle operating conditions that will place the AGV into an active E-STOP condition.

 

* Motor Thermal Protection

* Loss Guide Path Field

* Bumper

* PLC Watchdog timer

 

5.4.5.2 Visual/Audio Warning Devices

 

1. Warning Light - Flashing Yellow light mounted on the front and rear of the AGV warns personnel of approaching vehicle. Light will be turned on 3 seconds before vehicle starts to move and will be on while vehicle is moving.

 

2. Beeper - An electronic  beeper will sound when the vehicle crosses  fork truck or pedestrian aisles. The Beeper will also sound for 3 seconds before the vehicle starts to move.

 

 

 

6. Specific Requirements

 

The Indocomp Systems AGV Truck Control Retrofit  replaces the Portec Electronic control package.

 

6.1       Functional Description

 

The  retrofit package replaces the Portec on-board computer, communications system, guidepath controller and vehicle electronics power supply. The new control package provides an Allen-Bradley SLC-5/04 PLC and five custom printed circuit boards. The new control will replace the current Portec electronics rack and connect to the vehicle using the existing power, control and antenna connectors.

 

 

 

6.1.1    PLC Control

 

The Allen-Bradley SLC 5/04 PLC Controller provides the AGV truck control. The PLC will process commands from the PATC and control the basic AGV functions.

 

 

  Allen-Bradley SLC-500 small programmable controller.

 

1          1747-L542      5/04 with 12K program memory, 4K data memory

RS-232 and DH+ Communication Ports

1          1746-A10        10 Slot Chassis

3          1746-IB16       16 Bit Digital Input Module, 24VDC

3          1746-OB16     16 Bit Digital Output Module, 24VDC

 

 

 

 

PLC Key Switch

 

POSITION      FUNCTION

RUN                Run Mode (Normal Position)

REM                Remote Program Mode selection. Used with PLC programming panel.

PROG              Program Mode. Used with PLC programming panel

 

Allen-Bradley SLC 5/04 PLC CPU  Processing Errors
PLC LED :LIGHTS
RUN	FLT	BATT	FORCE	DH+	RS232	FAULT
OFF	OFF	OFF	OFF	OFF	OFF	No Power to PLC
OFF	ON	OFF	OFF			Power Problem
ON	OFF	OFF	OFF			PLC Running OK
OFF	ON	OFF	OFF			PLC Fault - Replace PLC CPU 1. CPU Memory Error 2. Faulty Memory Module 3. Faulty CPU 4. PLC Firmware wrong
OFF	FLASH	OFF	OFF			PLC Fault - Replace PLC CPU 1. Initial Factory Power-up, needs program 2. Hardware/Software Major Fault.
			ON			PLC set with Forced I/O
ON	FLASH	ON				PLC Battery Problem
				FLASH		PLC Communications to Programming Panel OK
					FLASH	PLC Communications to Communications Board. OK

 

NOTE: The PLC has an EPROM program backup module. In the event of a PLC processor or Memory fault the PLC will load the EPROM program into the PLC RAM program memory. If PLC RAM is reloaded from the EPROM the vehicle track position and mode will be reset. The vehicle operator must restor the track and position.

For more information on SLC500 Hardware refer to Allen-Bradley “Installations and Operation Manual”

 

 

 

NOTE: An automatic tilt control is provided to limit the amount of assembly tilt between the front and rear lift assemblies. If the amount of assembly tilt is greater than 6 Deg. between the front and rear lifts the PLC will stop the active lift until the assembly is within the 6 Deg. Pitch. The automatic tilt control can be disabled by disconnecting the cable to the front or rear part-in-place sensor for the engine cradle or muffler .

 

Following lists the SLC-500 I/O Board connections.

 

Input Card 1

 

I:1/0                     Auto Mode

I:1/1                     Floor Magnet

I:1/2                     NOT E‑STOP SAFETY

I:1/3                     Rear Lift Upper  Limit

I:1/4                     Rear Lift Lower  Limit

I:1/5                     REAR LIFT MIDDLE L.S.

I:1/6                     Front  Raise Limit

I:1/7                     Front Lower  Limit

I:1/8                     FRONT MIDDLE LIMIT

I:1/9                     Man. Mode Steer  Left

I:1/10                   Man. Steer Right

I:1/11                   Vehicle  Blocking Sensor

I:1/12                    FRONT READY PB

I:1/13                    REAR READY PB

I:1/14                    STOP PB

I:1/15                    START PB

Input Card 2

 

I:2/0                      Front Lift Raise Push Button

I:2/1                      Front Lift Lower Push Button

I:2/2                      Rear Lift Raise Push Button

I:2/3                      Rear Lift Lower Push Button

I:2/7                      BRAKE TOOL DETECT PROX.

I:2/11                    Safety Front Lift Foot Switch

I:2/12                    REAR LIFT PART PRES

I:2/13                    FRONT LIFT PART PRES

I:2/14                    Forward Push Button

I:2/15                    Reverse Push Button

 

 

Input Card 3

 

I:3/1                      Steering Field  Detect

I:3/3                      Zone   Blocking

I:3/4                      Wake Freq. Detect

I:3/5                      Sleep Freq. Detect

I:3/7                      BATTERY  HIGH

I:3/8                      BATTERY 22V

I:3/9                      BATTERY 20V

I:3/10                    Bumper OK

 

Output Card 4

            O:4/0                     Drive Relay K2

O:4/1                     High Speed Relay K6

O:4/2                     Drive Brake K1

O:4/6                     Warning Horn

O:4/7                     RED Light E‑STOP

O:4/8                     GRN Light Field Sense

O:4/9                     YEL Light Blocking

O:4/10                    Vehicle ON RELAY K7

O:4/12                    Front lift K11

O:4/13                    Rear Lift Raise K14

O:4/15                    Warning Running Light

Output Card 5

 

O:5/0                     Front Lift Safety  Light

O:5/1                     Steering  Relay K13

O:5/2                     Drive  Reverse Relay K3

O:5/3                     Rear Lift K15

O:5/4                     Front Lift Raise  K10

 

Output Card 6

 

O:6/0                     Steering CH A

O:6/1                     Steering CH B

O:6/2                     Steering CH C

O:6/3                     Guidance  BD Enable

O:6/4                     MAN.  STEERING RIGHT

O:6/5                     MAN  STEERING  LEFT

O:6/6                     STEERING CONTROL AUTO MODE

O:6/7                     Sleep Mode Trigger

O:6/8                     Guidance BD Aux‑In

O:6/9                     Guidance  BD PLC‑IRQ

O:6/10                   Guidance BD MODE

O:6/11                   Guidance BD WDOG

6.2       Custom Control Electronics

 

The Custom Control Electronics replace the Portec Power Supply, CPU, Communications, Guidance, Sleep and Safety Boards. The new electronics combined several of the Portec boards into single control boards. The functions of the Portec I/O and CPU are controlled by the SLC 5/04 PLC.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTE: DO NOT INSTALL OR REMOVE ANY CONTROL BOARD OR PLC MODULE WITH VEHICLE POWER ON.

 

NOTE: All boards have been pre-calibrated. No vehicle calibration is required.

6.2.1    AGV Guidance Board            IND-7710

 

The AGV guidepath board enables the AVG vehicles to navigate around the Buick assembly. The AGV guidepath is a Low Frequency RF Antenna embedded into the floor of the plant. The AGV vehicle follows the RF antenna by a remote pickup antenna mounted on the AGV vehicles steering wheel.

 

The AGV system uses four (4) guidance frequencies for the four (4) lanes.

 

 

Freq. 1             Channel 1         05.5 kHZ Guidepath

Freq. 2             Channel 2         07.0 kHZ Guidepath

Freq. 3             Channel 3         10.1 kHZ Guidepath

Freq. 4             Channel 4         12.2 kHZ Guidepath

 

Blocking Freq.                          32.0 kHZ "blocking"

 

 

The Guidance Board operates in one of two modes.

 

1. Manual Mode - The vehicle steering is controlled from the Burr-Brown pendent. The operator can control the right and left steering. The command for the steering is sent from the pendent to PLC and to the guidance board which drives the steering amplifier board and the steering motor.

 

2. Automatic Mode - The vehicle steering is controlled by the PLC selecting one of four guidance frequencies and the guidance board tracks the guidance path in the plane floor. A guidance antenna mounted on the front steering driver motor monitoring the selected frequency and controlling the steering amplifier and steering motor to maintain the steering antenna to follows the center of the guide path. .

 

 

A 32Khz frequency is used for the floor blocking loops. The blocking signals are used by the PATC to stop a vehicle from entering a controlled zone.

 

A 10 segment LED BAR display provides a visual indication of the steering Right and Left guidance signal. 5 segments on the left indicate the Left steering chanel and the 5 segments on the right show the Right steering chanel. This display can be used to indicate a antenna or cable problem on the steering guidance system.

The following shows the alignment of the guidance antenna and the automatic guidance control of the vehicle.

 

 

 

AGV STEERING CONTROL BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POTS

 

R141 - Left Channel Gain

R135 - Right Channel Gain

R142 - Blocking Gain

R230 - Field Sense

R145 - Blocking Freq.

 

LEDS

D301 - Auto Mode                  Steering controlled by guide path controller

D302 - Field Sense                  Sensing valid floor guide path

D303 - Steer Left                     1. Auto Mode, Control steering left

2. Manual Mode, Operator steering left

D304 - Steer Right                   1. Auto Mode, Control steering right

2. Manual Mode, Operator steering right

D310 - Blocking Sense Detecting active Floor Blocking Loop

D311 - Manual Mode              Steering controlled by manual Burr-Brown Pendent

6.2.2    Discrete Communications System    IND-7720

 

The Discrete Communications Systems (DCS) is used for the PATC to communicate with the AGV Vehicles. The communication is provide by six (6) foot RF communications loops embedded in the plant floor. An AGV vehicle entering a communication loop can communicate to the PATC controller.

 

The data exchange at these loop allow the PATC to receive the vehicle ID number and dispatch the vehicle to the proper destination.

 

The vehicle crosses three PIT communication loops during one guidepath cycle. One at the cradle load, a second at the “split” and a third before marriage.

 

The  Discrete Communications card also processes commands from the Vehicle Diagnostic Monitor which can be plugged into the vehicle for troubleshooting. These commands are processed and sent to the PLC.

 

The 80C52 Micro provides a communications multiplexer for data processed by the PLC. The micro buffers data from the Burr-Brown TM25 and the Host PIT communications modem and sends the data to the PLC. The micro processed data messages from the PLC and routs the data to the TM25, Host/PIT modem and a two digit LED display.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POTS

R204 - Trans. Freq., Adjust Center freq. 54Khz

R205 - Rec, Freq., Adjust Center freq. 76Khz

R206 - Trans. Sinwave, Adjust Sinwave Symmetry

R338 - Rec. Gain

R388 - Tran. Gain

 

LEDS

D401 - Rec. Data, Receiving data bits

D402 - Rec. Carrier, Receiving data signal from Host/PIT

D403 - Tran. Byte, Sending byte to host

D404 - Rec. Byte, Processing byte from Host/PIT

D410 - Tran. Ena., Sending data to host

D411 - PLC Command, Processing PLC Command

 

6.2.3    Power Supply/Power Monitor/Safety Board IND-7730

 

The Power Supply/ Power Monitor/Safety Board provides the power conversion from the vehicle batteries to the control logic, a battery level monitor circuit and the E-STOP control relay logic. The power converter provides a regulated +5v and +24v power to the custom control logic, PLC and vehicles control relays. The Battery Monitor continually monitors the vehicles batteries for an Excess voltage (Greater than +26V), Low voltage (Less than +22V) and Very Low voltage (Less than 20V) power conditions.

 

 

The power supply board provides the power control for normal and Sleep mode operation of the PLC and control boards. The following table shows the power control to the PLC and control boards.

 

 

Power Device	Normal Mode	Sleep Mode
SLC-5/04 PLC	+5V - ON +24V ON	+5V - OFF +24V - OFF
IND-7710 Guidance Board	+5V - ON +12V - ON	+5V - ON +12V - ON NOTE: Board operating current is reduced.
IND-7720 Communication Board	+5V - ON +12V - ON +24V - ON	+5V - OFF +12V - OFF +24V - OFF
IND-7710 Sleep/Wake Board	+5V - ON +12V - ON	+5V - ON +12V - ON
Truck Control	+12V - ON +24V - ON	+12V - OFF +24V - OFF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LED STATUS LIGHTS - PC Board user status lights

 

D105   +24V - Power to PLC (Switched)

D108   +5V - Power to Sleep and Guidance Board

D106   +5V PLC - Power to PLC and Communication Board. (Switched)

D107   +12V - Power to Communication Board. (Switched)

D301   E-STOP OK - Bumper, External E-Stop, PLC and Guidance Field OK.

D202   <26V - Battery Level greater than 26V Battery Charging.

D203   >22V - Battery Level less than 22V

D204   >20V - Battery Level less than 20V

D205   PLC RUN - Signal to PLC Power level OK to run.

 

6.2.4    Backplane Board       IND-7740

 

The Backplane Board provides the interconnect wiring for the custom control boards, communications receiver and transmitter antenna, guidance antenna, Input/Output and power connections. The Backplane also provides for a DC-DC power converted that is used to stabilize the incoming vehicle battery input power.

 

 

 

 

6.2.5    Sleep/Wake Board     IND-7750

 

The AGV Sleep/Wake Board enables the AGV vehicles monitor the  guidepath for a Low Frequency Sleep and Wake signal embedded into the floor of the plant. The board monitors for the presents of Wake and Sleep frequencies and signals the PLC controller. The PLC controller determines that a vehicle can be placed into sleep mode and signals the board to trigger the sleep mode.

 

Once in Sleep Mode the board will monitor for the Wake signal and reset the Sleep Mode.

 

 

AGV SLEEP/WAKE BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POTS

 

R141 - Signal  Gain

R135 - Not Used

R142 - Not Used

R230 - Signal Threshold

R145 - Not Used

 

LEDS

D301 - Wake Freq. - Indicates Wake frequency detected

D302 - Sleep Freq. - Indicates Sleep frequency detected

D303 - Not Used

D304 - Not Used

D310 - Not Used

D311 - Sleep Mode - Indicates vehicle in Sleep mode. Guidance board,

Communications boards and PLC are not powered.

7.0       Trouble Shooting Guide

 

Problem	Probable Cause	Recommended Action
Will not power-up	Battery Problem   Power Supply       Check PLC I/O O:4/10    Vehicle ON RELAY K7	Check Battery Voltage Level   1. Check vehicle Fuses 2. Replace Power Supply/Safety Board   Correct Vehicle or PLC problem
No Power to PLC	Battery Problem   Power Supply	Check Battery Level   1. Check vehicle Fuses 2. Replace Power Supply/Safety Board
Will not steer in Manual Mode	PLC Problem     Guidance Board Problem   Maintenance Pendent Problem   Check PLC I/O I:1/9    Man. Mode Steer  Left I:1/10  Man. Mode Steer Right O:5/1   Steering  Relay K13  O:6/3  Guidance  BD Enable O:6/4   MAN.  STEERING RIGHT O:6/5   MAN  STEERING  LEFT	1. Check PLC in RUN mode 2. Check Correct PLC program   Replace Guidance Board   Replace Maintenance Pendent   Correct Vehicle or PLC problem
Will not drive in Manual Mode	PLC Problem     Motor Controls   Maintenance Pendent Problem   Check PLC I/O I:2/14   Forward Push Button I:2/15   Reverse Push Button O:4/0   Drive Relay K2 O:4/1   High Speed Relay K6 O:4/2   Drive Brake K1 O:5/2   Drive  Reverse Relay K3	1. Check PLC in RUN mode 2. Check Correct PLC program   Check Motor Relays and Fuses   Replace Maintenance Pendent   Correct Vehicle/PLC problem
Will not operator Lifts in Manual Mode	PLC Problem     Motor Controls   Lift Pendent Problem   Check PLC I/O I:2/0       Front Lift Raise PB I:2/1       Front Lift Lower PB I:2/2       Rear Lift Raise PB I:2/3       Rear Lift Lower PB O:4/12    Front lift K11 O:4/13    Rear Lift Raise K14 O:5/3      Rear Lift K15 O:5/4      Front Lift Raise  K10	1. Check PLC in RUN mode 2. Check Correct PLC program   Check Motor Relays and Fuses   Replace Pendent   Correct Vehicle/PLC problem
Maintenance Pendent Burr-Brown Terminal will not work.	Pendent Problem   Control Problem	Replace Pendent   Replace Communications Board.
Maintenance Pendent will not take new station numbers.	Operator Error	Same Stations can not be re-entered. Verify station number <F3><ENTER>
Maintenance Pendent will not take new lane number.	Operator Error Stations number error	Lane numbers can only be entered for station 22 and only if host is not sending new lane number.
Vehicle will not leave Marriage	Check LED Display Code 86        Bumper Pressed 85        Blocked Ahead 84        Blocking Loop        Detected 83        E-Stop Pressed 68        No Position 67        No Guidance 62        Cannot Release - FRONT LIFT NOT DOWN  61       Cannot Release - REAR LIFT NOT DOWN 31        Waiting for FRONT Release at Marriage 30        Waiting for REAR Release at Marriage   Check PLC I/O I:1/4    Rear Lift Lower  Limit I:1/7    Front Lift Lower  Limit I:1/12   FRONT READY PB I:1/13   REAR READY PB I:1/14   STOP PB I:1/15  START PB	Correct reported problem.                               Correct Vehicle or I/O Problem
Vehicle will not run in Auto Mode	Check LED Display Code 86        Bumper Pressed 85        Blocked Ahead 84        Blocking Loop        Detected 83        E-Stop Pressed 68        No Position 67        No Guidance     Brake Fill Station     No Green Field Light   Check PLC I/O I:1/14   STOP PB I:1/15  START PB I:2/7    BRAKE TOOL  PROX SW O:6/0  Steering CH A O:6/1  Steering CH B O:6/2  Steering CH C O:6/3 Guidance  BD Enable	Correct reported problem                 Check Brake tool in place and Prox.  Sensor   Check Station Number   Correct Vehicle or I/O Problem
Missed Floor Blocking Loop	Host or Floor Sensor Problem   Vehicle Problem	Correct Host or Floor Sensor     1. Check Guidance Antenna 2. Replace Guidance Board
Will not go to Sleep and/or wake-up.	Track Signal       Vehicle Problem	Sleep/Wake signal only active to main track and 4 assembly lanes.   1. Check Guidance Antenna 2. Replace Sleep/Wake Board
Will go to Sleep or Wake-up at wrong times	Vehicle Problem	1. Check Guidance Antenna 2. Replace Sleep/Wake Board
Will not Auto Lift at Marriage	Track Problem     Vehicle Problem     Check PLC I/O I:1/3    Rear Lift Upper  Limit I:1/6    Front  Raise Limit I:2/11  Safety Front Lift Foot SW	PIT 15, 25, 35 or 45 not working correctly   1. Check Rec. Antenna 2. Replace Communication Board.   Correct Vehicle or PLC problem
Vehicle does not stop at correct stations.	Track Problem   Vehicle Problem	Check Floor Magnet   1. Check station number with Maintenance Pendent 2. Replace Floor Magnet Reed Switch on vehicle
Misses Floor Magnets	Track Problem   Vehicle Problem     Check PLC I/O I:1/1    Floor Magnet	Check Floor Magnet   Replace Floor Magnet Reed Switch on vehicle   Correct Vehicle or PLC problem
Vehicle Crashes into another Vehicle.	Other Vehicle   Vehicle Problem         Check PLC I/O I:1/11  Vehicle  Blocking Sensor	Check Vehicle rear reflector   1. Check Vehicle to vehicle photo sensor. 2. Check Vehicle to Vehicle photo sensor alignment.   Correct Vehicle or PLC problem
Vehicle Stops at Station 22 (Split)	Host Problem         Vehicle Problem	1. Verify Host computer operation 2. Verify Host ES1 Rec. And Trans. Boards.   1. Check vehicle antennas 2. Replace Communications Board.
Vehicle does not send Truck ID at Station 8 (Cradle Load)	Host Problem       Vehicle Problem	1. Verify Host computer operation 2. Verify Host ES2 Rec.   1. Check vehicle antennas 2. Replace Communications Board.
Horn will not sound	PLC program     Bad Horn	PLC program must enable the horn to sound.   Replace horn.
Vehicle Running Light will not light.	PLC program   Bad Light	PLC program must enable Running Lights. Enable only when vehicle is moving   Replace Bad Light
Vehicle steering wobbles will driving in Auto Mode	Steering Motor or Chain   Steering Board	Check Steering motor and Chain.   Replace Steering Board
Vehicle drives off guide path in Auto Mode. Works fine in Manual Mode	Steering Antenna   Steering Amp. Board   Steering Board	Check Steering Antenna   Replace Steering Amp. Board   Replace Steering Board
Vehicle drives with offset to center of the track.	Steering Antenna   Steering Board	Check Steering Antenna   Replace Steering Board
Vehicle will not start Auto Battery Charger	Battery Charge Station       Vehicle Problem	1. Fix Charge Plates 2. Fix Charger control 3. Fix Charger   1. Check Trans. Antenna 2. Replace Communications Board. 3. Check vehicle stations number.