Gotting HG G-73650-A Installation guide

Basics + Software HG G-73650-A
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Track Guidance Controller
Basics, Commissioning and Software
HG G-73650-A
English, Revision 07 Dev. by: M.L.
Date: 07.03.2018 Author(s).: RAD / A.F.
Götting KG, Celler Str. 5, D-31275 Lehrte - Röddensen (Germany), Tel.: [phone] / 80 96 -0,
Fax: [phone] / 80 96 -80, eMail: [email protected], Internet: www.goetting.de

Contents HG G-73650-A
English, Revision 07, Date: 07.03.2018 1
Contents
1 Introduction.......................................................................4
1.1 Virtual tracks .......................................................................... 4
1.2 Suitable and unsuitable vehicle types ...................................... 5
1.3 How it works ........................................................................... 6
1.3.1 System Structure ........................................................................... 6
1.3.2 Steering Controller ........................................................................ 6
1.3.3 Sensor Fusion ...............................................................................7
1.3.4 Track Controller............................................................................. 7
1.3.5 Parameterization ........................................................................... 8
1.4 Preconditions / Options........................................................... 9
2 Guidance Control in Detail...............................................10
2.1 Steering controller ................................................................ 10
2.1.1 Segments .................................................................................... 10
2.1.1.1 The segment file ..................................................................... 11
2.1.1.2 Segment search...................................................................... 13
2.1.1.3 Specifiying the segments ........................................................ 13
2.1.1.4 Transmission of the segments................................................. 15
2.1.2 Attributes..................................................................................... 15
2.1.3 Offset driving............................................................................... 15
2.1.4 Calculation of the Steering Angle ................................................. 16
2.1.4.1 Feed Forward Control ............................................................. 17
2.1.4.2 Feed Back Control .................................................................. 17
2.1.5 Velocity Calculation ..................................................................... 18
2.1.6 Driving Modes ............................................................................. 18
2.1.6.1 Idle Mode ............................................................................... 18
2.1.6.2 Modus Parameter Test............................................................ 19
2.1.6.3 Automatic Mode ...................................................................... 19
2.1.7 Vehicle Options: Fork Lift Vehicle ................................................ 19
2.2 The Internal Sensor Fusion ................................................... 19
2.2.1 Odometric System ....................................................................... 20
2.3 Sensors for navigation .......................................................... 21
2.3.1 The Transponder Antenna ........................................................... 21
2.3.1.1 Transponder System for Positioning Calculation ...................... 21
2.3.1.2 Initialization of the Transponder Sensor Fusion ....................... 22
2.3.1.3 Transponder List..................................................................... 22
2.3.2 Sky-Trax ..................................................................................... 23
2.4 Vehicle Control Unit .............................................................. 23
3 Interfaces........................................................................25
3.1 CAN Bus .............................................................................. 25

Contents HG G-73650-A
English, Revision 07, Date: 07.03.2018 2
3.1.1 CAN 1 ......................................................................................... 25
3.1.2 CAN 2 ......................................................................................... 25
3.2 Profibus................................................................................ 26
3.3 Ethernet ............................................................................... 26
3.4 Serial Interfaces ................................................................... 26
3.4.1 SIO 1 .......................................................................................... 26
3.4.2 SIO 2 .......................................................................................... 26
3.4.3 SIO 3 .......................................................................................... 26
3.4.4 SIO 4 .......................................................................................... 27
3.5 Terminal ............................................................................... 27
3.6 IO 1 to 4 ............................................................................... 27
4 Commissioning................................................................28
4.1 Commissioning of Communication......................................... 28
4.2 Commissioning Terminal Program......................................... 29
4.2.1 Finding Hyper Terminal / Adding Hyper Terminal to the system .... 29
4.2.2 Parameter Settings ...................................................................... 30
4.3 Using the Terminal Program.................................................. 30
4.4 Main Menu ........................................................................... 31
4.5 (A) Main Monitor Navigation.................................................. 32
4.5.1 Monitor Outputs........................................................................... 32
4.5.2 Input Options............................................................................... 35
4.6 (B) Main Monitor Sensorfusion .............................................. 35
4.7 (C) Vehicle Monitor ............................................................... 39
4.8 (D) Datalogging .................................................................... 39
4.9 (E) Test Monitor.................................................................... 40
4.9.1 Display outputs............................................................................ 40
4.9.2 Input Options............................................................................... 41
4.10 (F) Error Logger.................................................................... 42
4.11 (G) Parameters Navigation.................................................... 49
4.11.1 (A) Main ...................................................................................... 50
4.11.2 (B) Geometric.............................................................................. 52
4.11.3 (C) Accuracy ............................................................................... 54
4.11.4 (D) Steering................................................................................. 55
4.11.4.1 Parameters ............................................................................. 55
4.11.4.2 Steering correction.................................................................. 56
4.11.5 (E) Stering Controller................................................................... 57
4.11.6 (F) Speed Controller .................................................................... 60
4.11.7 (G) Sensor Fusion ...................................................................... 61
4.11.8 (H) Vehicle Specials .................................................................... 63

Contents HG G-73650-A
English, Revision 07, Date: 07.03.2018 3
4.11.9 (I) Datalogging (Parameterization of the output) ........................... 63
4.12 Display and key pad of the control unit .................................. 65
4.12.1 Status output on the Display ........................................................ 65
4.12.2 Direct input options at the control unit .......................................... 67
5 Trouble Shooting.............................................................69
6 List of Images .................................................................71
7 List of Tables ..................................................................72
8 Essential Information for Reading this Manual..................74
9 Copyright and Terms of Liability ......................................75
9.1 Copyright.............................................................................. 75
9.2 Exclusion of Liability ............................................................. 75
9.3 Trade Marks and Company Names........................................ 75

Introduction HG G-73650-A
English, Revision 07, Date: 07.03.2018 4
1 Introduction
The subject of this manual is the track guidance controller for AGV (Automated Guided
Vehicles) used for following virtual tracks (see below). This manual describes the fol-
lowing components of the track guidance controller:
1. Track control with steering controller, sensor fusion and vehicle control (see
chapter 2 on page 10)
2. Overview of interfaces (see chapter 3 on page 25)
3. Commissioning (see chapter 4 on page 28)
4. The description of the hardware and the telegram listing of the interfaces can
be found in two separate documents
The following sections of the introduction will provide an overview of these areas.
1.1 Virtual tracks
A virtual track describes a route that does not have physical tracks or marks (e.g. op-
tical lines or inductive guide wires). It is usually defined in a CAD program (below we
will refer to Malz++Kassner CAD 6 for which Götting KG provides a plug-in for the track
guidance controller) where the required track is directly drawn into a layout. The vehi-
cle will follow this virtual track like on a real track or rails. The CAD software has to re-
flect the features of the vehicle used (see below) in order to make tracking as accurate
as possible.
Figure 1 Example: Virtual track with support points
The virtual track consists of several segments that define the sections between
branches and end points. Each of the segments must consist of at least four support
points which are positioned at equal distance over the whole route. These support
points are not actual points on the route (for example transponders in the ground). The
distance between them depends on the type of the route and the vehicle used. The
closer the support points lie next to one another the more precisely the tracking will
correlate with the virtual track. However, very close distances between the points are
unnecessary for large vehicles because the vehicle itself cannot drive that accurately.
Should the distances between the points be too long, the CAD software would display
them as polygonal curves because no rounded curve can be calculated from points
which are wide apart from one another.

Introduction HG G-73650-A
English, Revision 07, Date: 07.03.2018 5
1.2 Suitable and unsuitable vehicle types
The range of particularly suitable vehicle types covers all vehicles that either have a
fixed axle or symmetrical steering. Vehicles such as trucks, forklift trucks, electric tow
tractors and some heavy-duty transporters fulfill these requirements. A fixed axle can
be applied to the axis of symmetry without the problem of dragging wheels in curves.
Figure 2 Example: A selection of vehicle types
The sketch below shows simplified versions of all vehicles as three-wheelers, because
this is the base vehicle model used by the track guidance controller. For example also
a car is only steered from one point, so the computer can consider it a three-wheeler.
Both wheels on the front axle follow a specified steering angle. The track guidance
controller can also be used for vehicles where the steered wheel is not in the middle
(e.g. some fork-lift trucks).
Figure 3 Sketch: Suitable vehicle types
The further the actual vehicle diverges from the typical three-wheeler model (e.g. cen-
ter-pivot steered vehicles such as front loaders where the distance between the axles
varies when turning), the less precise the tracking will be. Omnidirectional vehicles are
also suitable, but require a different firmware than the three-wheeler models.
Fixed axle
particularly suitable
e.g. fork lift trucks
Symmetrical axle
particularly suitable
e.g. some types of
heavy-load vehicles
Two fixed axles
reduced accuracy and
partially slipping wheels
e.g. large tractors
Articulated steering with
center pivot point
less accuracy
e.g. loader
Omnidirectional
drive / Mecanum
drive
requires different
firmware

Introduction HG G-73650-A
English, Revision 07, Date: 07.03.2018 6
1.3 How it works
1.3.1 System Structure
Figure 4 System Structure
Due to the strict separation of steering controller, sensor fusion and navigation system
as well as the smart interaction with vehicle controller the track guidance controller of-
fers a high degree of flexibility and is suitable for monitoring safety-critical vehicle
components.
1.3.2 Steering Controller
The track guidance controller includes the steering controller which calculates how to
guide the vehicle from the current position to follow the track. The steering controller's
outputs are
-nominal steering angle
-nominal vehicle velocity
-various additional parameters / information

Introduction HG G-73650-A
English, Revision 07, Date: 07.03.2018 7
Some steering servos and motor controller can be directly controlled by the steering
controller so that a vehicle control unit is not required in every application. Related to
monitoring, redundancy and customized modifications to the vehicle, a vehicle
control unit (e.g. PLC) is recommended for large vehicles.
If emergency stop devices are to be used, a vehicle control unit must be used in com-
bination with the track guidance controller to ensure maximal safety.
1.3.3 Sensor Fusion
The steering controller receives information from the sensor fusion about the position.
The sensor fusion can be connected internally (preferably when navigating with tran-
sponders or Sky Trax Tags) or externally (e.g. in the case of a laser scanner). The sen-
sor fusion provides the steering controller the following data (called pose):
-position on X coordinate
-position on Y coordinate
-velocity
-angle
The sensor fusion establishes these values based on the data of the connected sen-
sors (e.g. transponder antennas, laser scanners, GPS system). If required, systems
with physical guidance tracks can be integrated (e.g. inductive guide wire, optical
guidance).
There is a selection of different odometric sensors available, such as incremental / ro-
tary encoders. Optionally the accuracy and load-dependence of the odometry can be
enhanced by using the Götting Gyro HG 84300. It is also possible to calculate the
odometry from two sources and compare their results. This way, the sensor failures
can be identified.
1.3.4 Track Controller
The task of the track guidance controller is to move the vehicle from the current posi-
tion (given by the sensor fusion) to the next support point. The controller also calcu-
lates the rest of the track along several support points (it forms what are known as
regressions) and delivers the virtual track that the vehicle can drive on.
The tracks between the support points are reconstructed with smooth functions (re-
gressions over several support points) so that a continuously controlled movement of
the vehicle is possible. The values of position, accuracy, 16 free and 16 defined bits
are stored at each support point.

Introduction HG G-73650-A
English, Revision 07, Date: 07.03.2018 8
Figure 5 Exemplary layout with travel commands as a combination of segments
The vehicle can be placed between the support points. The track controller uses the
incoming position data to identify what segment it is on and which support point fol-
lows next. The tracks to be driven on are defined from a combination of segments that
for example state where the vehicle has to turn. A travel command can be entered at
the central control unit, the vehicle control unit or directly at the steering controller.
1.3.5 Parameterization
An RS 232 interface is provided to set the parameters and to commission the vehicle.
It can be connected to a PC/ laptop with a serial interface and a terminal program.
This interface can be used to monitor and record driving conditions (e.g. for debug-
ging purposes) and to set, import or export driving parameters. Transponder and,
marker lists as well as segments can be exported, imported and displayed. This inter-
face can also be used to update the internal operating software on the track guidance
controller.
A display with a foil keyboard is integrated into the steering controller in order to enter
the segments and show status information.
Travel command:
Segments 1, 2, 3, 7

Introduction HG G-73650-A
English, Revision 07, Date: 07.03.2018 9
1.4 Preconditions / Options
-If the internal sensor fusion is to be used, at least one incremental / rotary encoder
must be used. Please ensure that this is a push/pull type with output voltage of 5
to 25 V and two tracks perpendicular to each other.
Depending on the odometry, the Gyro HG 84300 can also be used to improve
accuracy and for redundancy.
-If a transponder system is to be used, the HG S71720 system can be connected
via the CAN bus. ID 250 transponders can be used at a reading height of up to
10 cm. The Sky Trax System can be used as an alternative or in combination with
the transponder system.
-When using the HG 43600 laser scanner at least one incremental encoder must
be directly connected to the track guidance controller. If the HG S57652 GPS sys-
tem is to be used, the rotary encoders must be connected to the GPS controller.
-To extend the input and output capabilities, the IFM module CR 2033 can be con-
nected via the CAN Bus.