F3-Design NIPPER User manual
INSTALLATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS NIPPER - JULY 2020
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All rights reserved. No part of this documentation may be duplicated in any form without authorisation, or
processed or recorded using electronic systems. Subject to changes without notice. F3-Design BV is NOT liable
for technical or printing errors in this manual and assumes no liability for any damage caused by the use of the
manual.
INSTALLATION INSTRUCTIONS NIPPER - JULY 2020
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Content
1 Basic safety advice............................................................................................................7
2 Definitions..........................................................................................................................8
3 Dimensions
9
4 Technical DatA................................................................................................................10
Performance ......................................................................................................10
Environments.....................................................................................................10
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Floor conditions..................................................................................................10
Load intake ........................................................................................................10
5 Accessories.....................................................................................................................11
6 Start-Up...........................................................................................................................11
Manual transport................................................................................................11
Tank venting ......................................................................................................12
Initial commissioning..........................................................................................13
Important.....................................................................................13
Switching ON...............................................................................13
Movements..................................................................................14
7 Device description...........................................................................................................15
General description............................................................................................15
Mechanical equipment.................................................................15
Rotating circle..............................................................................20
Electrical equipment....................................................................21
Control of the vehicle...................................................................23
Light indication...................................................................................................23
8 Safety features................................................................................................................25
Construction of protective devices......................................................................25
Safety button...............................................................................27
Safety laser scanner....................................................................28
Safety.................................................................................................................28
Straight ahead with curves:................................................................................30
Rotate/reverse: ..................................................................................................30
Protective field selection by the safe CPU...................................31
9 Handling..........................................................................................................................33
Forward movements with laser scanner protective field monitoring:...................33
Reversing movement or forward movement with Muting (protective field
evaluation deactivated)...........................................................................................................34
Standard turning (VLeft = –VRight ) ..................................................................34
Limitation:...........................................................................................................34
Acceleration values:...........................................................................................34
10 Functions.........................................................................................................................35
Pallet recording..............................................................................................35
Charging station.............................................................................................35
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11 Environmental requirements............................................................................................36
Required floor................................................................................................36
Properties................................................................................36
Cleaning..................................................................................36
Operator staff..........................................................................36
Operation................................................................................36
Mixed operation with people....................................................36
12 Safety.............................................................................................................................37
Safety tests before commissioning.................................................................40
Operator staff..........................................................................41
Operation................................................................................41
Mixed operation with people....................................................41
13 Alarm codes ....................................................................................................................42
14 Maintenance....................................................................................................................46
Daily...............................................................................................................46
Monthly..........................................................................................................46
Checking the emergency stop elements..................................46
Checking the safety switchgear...............................................47
At intervals of three (3) months......................................................................47
Battery removal..............................................................................................47
15 Delivery ...........................................................................................................................48
16 Storage............................................................................................................................48
17 Figures............................................................................................................................48
18 Table...............................................................................................................................50
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1 BASIC SAFETY ADVICE
If safety warnings are not observed, people may be exposed to hazards that can result in minor to severe injuries
or, in serious cases, even death. In less serious cases, plants and equipment may be damaged.
The following symbols indicate the individual risks and the degree of hazard and are briefly explained in terms of
their respective meaning. Please therefore familiarise yourself with the safety signs and their meanings in order
to prevent hazards and risks at an early stage.
Indicates a low-risk hazard that could result in minor bodily harm or property
damage if not avoided.
Indicates a possible medium-risk hazard that will result in death or (severe) bodily
harm if not avoided.
Indicates an immediate high-risk hazard that will result in immediate death or
severe injury if not avoided.
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2 DEFINITIONS
FTS Driverless transport system (AGV)
BWS Security device (laser scanner)
Bumper Safety button
TTO Time to obsolescence
The authority Instructed by the manufacturer or representative
SLS Safely limited speed
STO Safe torque off
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3 DIMENSIONS
Figure 1: Dimensions
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4 TECHNICAL DATA
Performance
- Supply voltage 24 V
- Performance LiFePO4 24 V/2 x 420 W/h
- Duration of use 4 h (according to the standard cycle for comparability)
- Charging time (standard charger) 30 min at full charge
- Lifting 130 mm
- Maximum speed 1 m/s in main direction
- Tare weight 191 kg
- TTO 15000h
Environments
- Max. ambient temperature 30°C
- Min. ambient temperature 0°C
- Humidity 95%
Floor conditions
- Unevenness maximum 5 mm
- Maximum inclination 3%
Load intake
- Euro pallet Standard pallet size
(Other pallets after approval by the manufacturer)
- Max. payload 1000 kg
- Max. load balancing front/rear 60/40%
- Max. load distribution left/right 55/45%
- Max. load height 1.6m
Tipping safety of the load at maximum deceleration must be given by the customer.
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5 ACCESSORIES
Only use original accessories, which are approved by the manufacturer, otherwise fault-free functioning cannot
be guaranteed.
Original accessories Nipper V2:
- Nipper V2 docking station
The charging station enables optimum and battery-conserving loading.
6 START-UP
Manual transport
For transport, belts can be pulled under the device at the indicated points. Ensure that a 2° angle is not exceeded
when lifting and lowering.
Figure 2: Transport
Note: The original packaging must be used for transportation or storage.
Attention: Pull two belts underneath the vehicle on the points which are marked with arrows to lift. Then the
vehicle can be raised and placed on the bottom of the original packaging by a crane, for example. As this is a
special pallet, the vehicle must be transported with a suitable means of transport.
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Tank venting
The unit has two tank openings (Figure 3: Tank ventilation). The device must not be turned over.
Figure 3: Tank ventilation
Note: Upon delivery, the air ventilation screws are open.
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Initial commissioning
Important
Before commissioning, observe the following:
- The device must not be damaged.
- All delivered documents are available.
- The operator is familiar with the documents.
Switching ON
The switch is pressed briefly to turn it on. Then the device is automatically switched on. After the start time of 60
seconds, the vehicle is ready to use.
Figure 4: Main switch
Note: By pressing the switch briefly, the device switches on automatically (<1 second), by pressing it for longer,
it switches off (>3 seconds).
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Movements
Different standard movements can be performed, as well as automatic and manual with the manual operation.
Figure 5: Directions of movement
There is a difference between the main and secondary direction. There is therefore a difference in safety
equipment:
In the main direction (the black arrow), the guided route is checked by the personal safety laser scanner for
obstacles and people.
The secondary directions (all others directions) can only be partially monitored or not at all by the safety laser
scanner. For this reason, the speed is limited to a maximum of 300 mm/s (here the speed is limited to a maximum
of 300 mm/s (The outer edge v = <300 mm/s).
Note: Secondary directions may only be used if there is no other possibility to arrive at the desired position.
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7 DEVICE DESCRIPTION
General description
Mechanical equipment
Figure 6: Explosion drawing
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No.
Description
1
Nose Module Safety Edge and Scanner (N2S)
2
Nose Module Safety Edge and Scanner (N4S)
3
Nose Module Safety Edge (N3)
4
Nose Module Safety Edge (N1)
5 + 8
Wheelset (0/1)
6 + 7
Wheelset (2/3)
9
Hydraulic Power Unit (WA12-4)
10
Battery Adapter (WA 082)
11
Sick Safety Scanner (S300)
12
Battery Pack (WA 061)
15
BlueBotics ANT Lite+ Software Box
14
Brainbox Bus Converter (ES-522)
16
Bus Communication Module (EBS-S2)
17
Bus Communication Cable (A1-VK-015)
18
Bumper Unit
19
Bumper Cover
20
LED Bridge Unit
20.1
Wifi Module (WLAN 1100)
21
Sigmatek HMI 3.5’’
22
Emergency Stop Button
23
Connector Joystick
24
Protection Cover Front
24.1
Protection Cover Back
25
LED Bridge Vertical Tube (side BlueSpot)
25
LED Bridge Vertical Tube
26
Start Button
27
Front Bumper Cover Black
28
Blue Spot
29
Pepperl & Fuchs 2D LiDAR Sensor (HD) incl. accessories
Table 1: System description
[1] Lower chassis
The sub-chassis contains the lifting mechanism and two (2) turntables and the evaluation sensors with the safety
edges. This represents a chassis unit and ensures an optimum balance of uneven floors.
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[2] Front module with safety button
This module contains: evaluation sensors for lane guidance, automatic pallet detection, height measurement
indicators, secure radio transmission for manual control, Wi-Fi communication, charging contacts attached at the
bottom and at the front, safety button so the device can be shut down immediately from any location.
Figure 7: Front module with safety button
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[3] Rotating drive units
In order to optimally protect the floor, the vehicle has two turntables per chassis unit. This allows the vehicle to be
manoeuvred from a standing position in all directions. The 80 mm wheels are driven independently by a servo
engine.
[4] Lifting mechanism
For even weight distribution on complex loads.
[5] Hydraulic unit
The load is absorbed hydraulically.
[6] Load-handling forks
The load handling device connects the two independent chassis units.
[7] Assembly sheet
This is the safety control for evaluation of the safety laser scanner.
[8] Safety laser scanner
Figure 8: Safety laser
For mixed operations, a safety laser scanner with eight (8) field sets has been installed, which guarantees the
highest possible level of safety.
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[10] Battery adapter
For quick assembly and disassembly of the battery packs. The individual components are also supplied with
power.
[11] Battery pack
Two (2) battery packs for the supply of the independent chassis units are attached to the device.
[12] Front control
Responsible for the control and evaluation of the laser scanner.
[13] Light pole
To improve the visibility of vehicles in mixed operation with people or forklift traffic.
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Rotating circle
The rotating circle is 1700 mm excl. the safety field.
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