AGC Manual

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<p>AUTO-CART AGCMODEL #</p> <p>E500-TUG-CAM-S-CSB-BC25-FB-LS-A6-A8-B1TECHNICAL MANUAL 3D Sales for</p> <p>JCI RAMOS</p> <p>IDC SALES CONTACT Ginger Smigelski (517) 646-0358</p> <p>AUTO CRAFT SALES CONTACT Marianna Walters (810) 765-1333 Job # J9642 Rev. 1.0 Released 10/2010</p> <p>3-D SALES, INC.* 604 SMITH STREET * ALGONAC, MI 48001-1441 (810) 794-8160 PHONE (810) 794-8165 FAX sales@threedsales.com 3-D SALES INC. is a CERTIFIED MINORITY BUSINESS</p> <p>AUTO-CART SUPPORT HOT LINE for JCILAYOUT AND MECHANICAL SUPPORT CONTACTS: Office 7:00am 4:30pm (810) 765-1333 (586) 615-2552 (810) 650-6988 (586) 615-2580</p> <p>Dave Benke Tom Dudek Michael DuVernay</p> <p>CONTROLS SUPPORT CONTACTS Office 7:00 3:30 pm. (517) 646-0358 (517) 648-2724 (517) 648-2719 (517) 648-2725</p> <p>Jim Black Pete Walacavage Matt Robel</p> <p>AFTER HOURS PHONE SUPPORT</p> <p>TECHNICAL TECHNICAL TECHNICAL MANUAL MANUAL MANUAL</p> <p>AGC AGC AGC</p> <p>JCI - SOUTHVIEWE3500-TUG-CAM-SR-AGM-BC40-FB-US-A6-A8-SP</p> <p>JCI - SOUTHVIEWE3500-TUG-CAM-SR-AGM-BC40-FB-US-A6-A8-SP</p> <p>JCI - SOUTHVIEWE3500-TUG-CAM-SR-AGM-BC40-FB-US-A6-A8-SP</p> <p>J9642Auto Craft Tool &amp; Die</p> <p>J9642Auto Craft Tool &amp; Die</p> <p>J9642</p> <p>Auto Craft Tool &amp; Die</p> <p>AUTO-CART Section 00-01 Overview TABLE OF CONTENTS</p> <p>1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.</p> <p>VEHICLE SIZE AND TYPE GUIDANCE CONTROLS BATTERIES OBSTACLE AVOIDANCE MISCELLANEOUS OPTIONS PREVENTATIVE MAINTENANCE SPARE PARTS MECHANICAL ASSEMBLIES ELECTRICAL TROUBLE SHOOTING WARRANTY</p> <p>Rev 0</p> <p>00-01 Auto-Cart Manual Table of Contents.docx</p> <p>Page 1 of 1</p> <p>AUTO-CART Section 00-02 Overview AUTO-CART GENERAL OVERVIEWThe 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.</p> <p>Rev 1</p> <p>00-02 Auto-Cart General Overview Rev 1-01.docx</p> <p>Page 1 of 2</p> <p>AUTO-CART Section 00-02 Overview AUTO-CART GENERAL OVERVIEW</p> <p>Touch screen for information and Program Settings Operating Lamp with flash annunciating Flash sequence Cart Emergency Stop Button Push to stop Pull to Resume Audible warning Module (Optional Melody Module also available)</p> <p>Main Power On/Off Electronic Laser Bumper Start/Stop Initiate</p> <p>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).</p> <p>Brake Handle located in the Down (run) position for operation</p> <p>Back of Cart</p> <p>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.</p> <p>Rev 1</p> <p>00-02 Auto-Cart General Overview Rev 1-01.docx</p> <p>Page 2 of 2</p> <p>AUTO-CART Section 01-00 AUTO-CART SIZE AND TYPE AUTO-CART SIZE 1. Model E500The 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.</p> <p>AUTO-CART STYLE 2. TUG (TUGGER) STYLEA 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 AutoCart. 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.</p> <p>Rev 0</p> <p>01-00 Vehicle Size-Type E500 TUG.docx</p> <p>Page 1 of 1</p> <p>AUTO-CART Section 01-00 AUTO-CART SIZE AND TYPE AUTO-CART SIZE 1. Model E500The 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.</p> <p>2.</p> <p>Model E3500The Model E3500 AUTO-CART can be used in Tugger, Tunnel or Unit Load applications. It has a distributed deck capacity of 1,000 lbs., a towing capacity of up to 3,500 lbs. depending on traction capabilities and towed cart wheel friction. Paint color is Battleship Gray.</p> <p>AUTO-CART STYLE 3. TUG (TUGGER) STYLEA 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 AutoCart. 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.</p> <p>4.</p> <p>TUN (TUNNEL) STYLEA 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 AutoCart 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.</p> <p>Rev 0</p> <p>01-00 Vehicle Size-Type.docx</p> <p>Page 1 of 1</p> <p>AUTO-CART Section 01-01 AUTO-CART SIZE AND TYPE</p> <p>AUTO-CART SIZE 1. Model E500The 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.</p> <p>AUTO-CART STANDARD FEATURES: Drive and Steering:o o o o o o 24 VDC differential transaxle w/ motor and an electrically released, spring set, fail-safe brake; 8/208.4mm diameter Urethane drive wheels; Linear position feed-back sensor; High torque steering actuator; 4 dia. spur gear driven Urethane steering wheel; Steering position feed-back module;</p> <p>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;</p> <p>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;</p> <p>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 MaterialPre-Punched, Formed and Welded Steel</p> <p>NOTES:Please consult the factory for a list of options, price, delivery and AGC application assistance. Demo and proto-type vehicles may be</p> <p>This document is Uncontrolled when printed. Rev.: 11172007</p> <p>Rev 0</p> <p>01-01 Vehicle Size E500.docx</p> <p>Page 1 of 1</p> <p>AUTO-CART Section 01-02 AUTO AUTO-CART SIZE AND TYPE</p> <p>AUTO-CART STYLE TUG (TUGGER) STYLEA TUGGER style AUTO-CART will tow carts using a wide variety of hitches, receivers, pins CART 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 A Auto-Cart or another towed cart. The total combined weight of the cart(s) being towed cannot exceed the allowed towing capacity of the A Auto-Cart. A flexible bumper is provided in most application. exible CAUTION: The owner of a towed cart or a load which is wider than the Auto-Cart deck is Auto responsible for providing or advising this A Auto-Cart manufacturer which collision avoidance methods are to be used based on local requirements.</p> <p>Examples:</p> <p>E3500</p> <p>E500</p> <p>E3500</p> <p>E500</p> <p>E500</p> <p>E3500</p> <p>Rev 0</p> <p>01-02 Vehicle Type TUG.docx</p> <p>Page 1 of 1</p> <p>AUTO-CART Section 02-01 Guidance COLOR CAMERA</p> <p>CAM COLOR CAMERA w/ TAPE GUIDANCEThe 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.</p> <p>Rev 1_02</p> <p>02-01 Guidance Cam.doc</p> <p>Page 1 of 1</p> <p>AUTO-CART Section 02-02 Guidance CAMERA SETUP 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 CMU...</p>