Analysis of hawker traditional AGV and contactless power supply system



Traditional AGV

The traditional AGV is battery powered, equipped with non-contact guiding device and independent addressing system. Due to the battery power supply, the power and driving distance of traditional AGV are greatly limited, and the utilization rate of AGV is not high. In order to improve the utilization of AGV, the battery of AGV must be charged regularly. In order to ensure that AGV can be charged in the production line without moving out of the production process, battery charging station must be set and installed in the place where AGV is allowed to pause (such as sectional transportation area, steering area and loading stop area) when the whole production process system is installed, so as to charge AGV regularly and at fixed points. AGV vehicle power supply generally uses the traditional "high rate open nickel cadmium battery" to meet the requirements of fast charging and large current discharge. However, due to the memory effect of Ni Cd battery, it is difficult to use and maintain. At the same time, the pollution of cadmium in nickel cadmium battery is not conducive to environmental protection. In addition, the increasing number of charging stations also increases the total construction cost of AGV transportation system. HAWKER





Contactless power supply system

With the development of IPT (inductive power transfer) contactless power supply technology, IPT contactless power supply technology is applied to AGV logistics transportation system, which greatly improves the defects of the current AGV power supply system. The new power supply system can provide driving power and control power for AGV without battery, and can also charge AGV battery continuously or regularly without charging station. However, the non-contact power supply is limited by the underground power supply cable, which is not conducive to the on-site transformation and reduces the flexibility of the route. HAWKER HUADA



The power supply cabinet of contact power supply system can produce high frequency continuous circulating AC power supply. The power supply cable is laid in two ways, one is the output current, the other is the return current, and the current is in reverse flow. This creates a double strong magnetic field between the two cables, while there is no magnetic field outside the two cables. The magnetic field is converted into electric energy by the power taking device (similar to the transformer principle) on the AGV car body, and then converted into DC for AGV.



Field AGV console and main power supply cabinet



Field AGV console and main power supply cabinet



Application cases

Based on strong technical advantages and innovation ability, and years of AGV technology accumulation and application experience, hawker has successfully implemented the AGV assembly system of non-contact power supply for Haishi No.2 general assembly plant of Shenyang Huachen Jinbei Automobile Co., Ltd. In the first phase of the project, a set of power supply device is designed for two loop lines, and four AGVs are used for the assembly of engine assembly and rear axle assembly respectively to meet the 296s production rhythm of the first phase. On the premise of meeting the existing models, the system considers the needs of new models in the future.



1. System structure and functions

The system consists of four scissor type single lift AGVs, one set of AGV ground power supply and guidance system, one set of AGV console, one set of data acquisition system, AGV dispatching management system and communication system.



(1) AGV AGV completes the assembly positioning, conveying and auxiliary assembly of engine assembly and rear axle.



(2) AGV ground power supply and guidance system ground guidance system is the route and track of AGV operation, and realizes electromagnetic guidance through power supply cable.



(3) AGV console and dispatching management system AGV console and dispatching management system are responsible for data processing of data acquisition system, exchanging information with upper computer, generating AGV operation tasks, and solving collision avoidance problems among multiple AGVs.



(4) The communication system consists of wireless local area network. The communication protocol between AGV and console is TCP / IP. Ethernet is used to transmit data between PC and console.



2. Hawkerpzs of AGV working process

After the AGV console detects the position signal of the car body on the conveyor chain through the counter firing switch, it dispatches the AGV with the engine assembly (rear axle) on the waiting station to enter the lower part of the conveyor chain according to the predetermined time and speed, captures the cooperative target fixed on the car body in the predetermined area, maintains the stable tracking state, manually controls the lifting, and the AGV automatically opens the sliding platform lock pin . The fixing bolts are installed by the assembler, and the installation end signal is sent manually after the assembly. According to the end signal, AGV automatically falls down the lifting mechanism and resets, the sliding platform automatically locks, and AGV accelerates to leave the assembly station. After the engine assembly (rear axle) is installed at the loading station, AGV sends the loading completion message to the console, and AGV drives to the waiting place according to the command of the console and enters the next cycle.



According to the arrival signal of the main assembly suspension car body, the AGV console sends a driving signal to the assembly car at the waiting point. If the main assembly line is empty, the AGV car is still waiting. When the engine assembly (rear axle) cannot be supplied in time, the conveyor chain operation can be stopped manually by the conveyor chain emergency stop switch set beside the assembly station. When the AGV enters the alarm station for special reasons and fails to complete the assembly, the AGV system and the conveyor chain give an alarm, and the conveyor chain stops at the same time to complete the assembly.



3. Technical index of AGV system Huada hawker

The AGVS control mode is centralized dispatching, monitoring and management control of the console. AGV control mode has full-automatic, offline mode and manual function. The communication mode is WLAN, the navigation mode is electromagnetic navigation, and the driving mode is dual wheel differential. The maximum load capacity of AGV system is 1000kg, the movement direction is forward, backward and turning, the maximum linear speed is 60m / min, the turning radius is 1.5m, the navigation accuracy is ± 10mm, and the parking accuracy is ± 10mm. The anti-collision device of AGV system is laser anti-collision + contact bumper. The lifting device is electric scissor lifting, the lifting stroke is 1000mm, the lifting force is 1t, and the lifting speed is 4.5m/min. AGV system activity platform: length of X (vehicle length direction) is ± 120mm; length of Y (vehicle width direction) is ± 50mm; horizontal rotation is ± 2 °. The AGV system adopts non-contact power supply mode, the size of the car body before lifting is 2500 mm & times; 1200 mm × 800 mm, and the size of the car body after lifting is 2500 mm × 1200 mm × 1800 mm.



4. AGV vehicle controller hawker battery

According to the latest development situation of AGV technology, combined with many years of design and application experience, Xinsong company has designed a new embedded can bus main controller. The main controller is an industrial embedded host computer, which integrates the main computer, electronic disk, network card, can communication port, serial port and other components and communication channels needed by high-speed computing host It can be packaged independently. The most basic unit for AGV control is integrated in the controller. The controller itself has no expansion slot and uses simple power supply. There is a display output port, a RJ45 network port, a PS / 2 keyboard and mouse universal interface, two RS232 serial ports and two can communication ports on the panel. There is a mounting bracket with shock absorber at the bottom of the controller.



The motion control module muc50 is a distributed motion controller based on CAN bus communication, which can achieve accurate control of AGV body motion by adjusting the servo driver. Each motion controller can not only control two axis servo drivers, but also has 16 I / O input ports, 8 I / O output ports, 4 ad input ports and two Da output ports. The motion control module muc50 communicates with the main controller vcu300 through CAN bus.



The mcu50 motion control module of distributed design is easy to install, and various states can be observed directly through the status indicator on its upper part, which makes the maintenance easier. Mcu50 motion control module adopts centralized plug with lock in the wiring mode, which makes the wiring more reliable and not easy to loosen, and improves the overall stability of the system.



5. AGV car body software hawker power

AGV vehicle controller uses Windows CE operating system, including AGV vehicle body control embedded software, vehicle body parameter file, vehicle body tool software, vehicle body operation map file and black box file recording vehicle body operation status.



(1) AGV car body control embedded software is based on Windows environment. It can perform multi task operation, dynamic observation in multi windows and has strong recovery function. In the process of AGV movement, the working state of AGV equipment and the feedback information of position loop can be dynamically observed through the display terminal. In case of emergency stop, communication interruption or optical target loss, there is no need to go online again, and the operation can be resumed immediately after the fault is solved. AGV car body control embedded software improves the maintainability of AGV and shortens the stopping time.



(2) Car body tool software is the tool software for AGV debugging and troubleshooting. Through AGV tool software, it is convenient to observe the status of AGV input and output, and then the communication status.



(3) The car body parameter file records the parameter information of AGV equipment. This parameter file can be changed by wireless transmission through AGV console or directly on AGV.



(4) The car body operation map file is the path information of AGV operation planning. With the change of AGV operation route, AGV system only needs to adjust the car body operation map file to change the AGV operation loop.



(5) The black box file records the information of AGV operation. When AGV fails, the black box file can quickly find out the cause of the failure.



6. AGV dynamic assembly solution

At present, the automobile assembly basically adopts the continuous operation assembly mode, and the assembly (on-line assembly) under the continuous operation of process chain and body is the key of dynamic assembly. The dynamic tracking sensor developed by Xinsong company is a special position sensor. When AGV enters under the body, it detects the cooperation target. AGV detects the cooperation target placed under the body, calculates the position between AGV and the body, adjusts the running speed of AGV, and makes AGV keep running synchronously with the body, so as to realize dynamic assembly.



In this way, AGV directly synchronizes with the position of the car body, which avoids the position error caused by sling installation, process chain pitch matching and other reasons, and can make timely response to the problems such as the climbing of the catenary. It is the most effective synchronous tracking method at present. Because the tracking synchronization is completed by AGV body independent sampling, even in the AGV manual offline state, it can still complete the dynamic synchronous assembly work, so it has more overall flexibility. HAWKER HUADA



7. Conclusion

At present, the battery powered AGV is widely used in the field of vehicle assembly, and the contactless power supply AGV is just in its infancy. Under the premise of full consideration of the scheme, the initial one-time layout is in place. Even if the future output increases, the number of AGVs can be directly increased without secondary construction on the ground, and the flexibility is comparable to that of battery powered AGVs. Through a period of operation in Jinbei, the adaptability and stability of the AGV can meet the demand. At the same time, the battery is free of maintenance. In the long run, the maintenance cost of contactless power supply AGV is relatively low. However, if the cost of relevant power supply and power taking devices can be reduced, and then the initial investment can be reduced, the development and application prospect of contactless power supply AGV is optimistic. HAWKER


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