Gotting HG G-73650ZD Manual

Documentation HG G-73650ZD
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Navigation Controller
Basics, Setup and Software
HG G-73650ZD
English, Revision 04 Dev. by: ML / LM
Date: 28.10.2016 Author(s): RAD / AF / Ext.
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-73650ZD
English, Revision 04, Date: 28.10.2016 1
Contents
1 Introduction.......................................................................7
1.1 Tasks of the Navigation Controller........................................... 7
1.2 Intended Use .......................................................................... 7
1.3 Requirements / Options .......................................................... 8
2 Basic Principles of Track Guidance....................................9
2.1 Suitable and Unsuitable Vehicle Types.................................... 9
2.2 System Composition ............................................................. 10
2.3 Position Determination with Sensor Fusion............................ 10
2.3.1 The Odometry ............................................................................. 11
2.3.2 Sensors for Navigation ................................................................ 11
2.3.2.1 Transponder Antenna ............................................................. 11
2.3.2.1.1 Single Antenna Evaluation — Calculation of the Position
with one Antenna ......................................................13
2.3.2.1.2 Double Antenna Evaluation ...................................... 15
2.3.2.1.3 The Triple Antenna Evaluation.................................. 16
2.3.2.1.4 Initialising the Transponder Sensor Fusion (Placing the
Vehicle on the Track) ................................................16
2.3.2.1.5 The Transponder List ............................................... 17
2.3.2.2 GPS ....................................................................................... 17
2.4 Coordinate Systems.............................................................. 18
2.4.1 The Vehicle Coordinate System ................................................... 18
2.4.2 The Local Coordinate System ...................................................... 18
2.4.3 Characteristics of the Coordinate Systems ................................... 19
2.5 Reconstruction of the Route (Segments) ............................... 20
2.5.1 Virtual Tracks .............................................................................. 20
2.5.2 The Segment File ........................................................................ 21
2.5.2.1 Structure of the Segment File.................................................. 21
2.5.2.2 The Segment Search .............................................................. 23
2.5.2.3 Selection of Segments ............................................................ 23
2.5.2.4 Transmission of Segmente ...................................................... 25
2.5.3 Attributes..................................................................................... 26
2.5.3.1 Offset Driving.......................................................................... 26
2.5.3.2 Inverted Steering .................................................................... 27
2.5.3.3 Stop Distance ......................................................................... 28
2.5.3.4 Spot Turn ............................................................................... 29
2.5.4 Creating / Editing of a Segment File ............................................. 29
2.6 Track Guidance .................................................................... 30
2.6.1 Speed Calculation ....................................................................... 32
2.6.2 Steering Angle Calculation........................................................... 32
2.6.3 Guidance of an omnidirectional Vehicle........................................ 32

Contents HG G-73650ZD
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2.6.4 Guidance of a non-omnidirectional Vehicle................................... 34
2.6.5 Driving Modes ............................................................................. 35
2.6.5.1 Idle Mode ............................................................................... 35
2.6.5.2 Parameter Test Mode ............................................................. 35
2.6.5.3 Automatic Mode...................................................................... 35
2.6.5.4 Remote Control Mode ............................................................. 36
2.6.5.5 Vector Steering Mode ............................................................. 36
2.7 Communication with the Vehicle Control (e.g. PLC) ............... 37
3 Hardware ........................................................................38
3.1 Mounting .............................................................................. 39
3.2 Front Panel........................................................................... 40
3.3 Control Elements on Front Panel........................................... 40
3.4 Display Elements on Front Panel .......................................... 40
3.5 Connectors ........................................................................... 41
3.5.1 ETH ............................................................................................ 41
3.5.2 USB ............................................................................................ 41
3.5.3 SIO 1 (GPS Receiver).................................................................. 42
3.5.4 SIO 2 .......................................................................................... 42
3.5.5 CAN 1 ......................................................................................... 43
3.5.6 CAN 2 ......................................................................................... 43
3.5.7 SIO 3 .......................................................................................... 43
3.5.8 POWER....................................................................................... 44
3.5.9 IO ............................................................................................... 44
3.5.10 ENCODER 1 / ENCODER 2 ......................................................... 44
3.5.11 PROG ......................................................................................... 45
3.5.12 ANT1 / ANT2 ............................................................................... 45
3.6 Extension module Feldbus .................................................... 45
4 Software .........................................................................46
4.1 Main menu ........................................................................... 47
4.2 Status menu ......................................................................... 48
4.2.1 Navigation menu.......................................................................... 48
4.2.1.1 Status..................................................................................... 48
4.2.1.2 Deviation ................................................................................ 49
4.2.1.3 Seg. Table .............................................................................. 49
4.2.1.4 Segment ................................................................................. 50
4.2.1.5 PLC ........................................................................................ 51
4.2.2 Transponder menu ...................................................................... 51
4.2.2.1 Antenna.................................................................................. 52
4.2.2.2 Result..................................................................................... 52
4.2.2.3 Odometry................................................................................ 53
4.2.3 GPS ............................................................................................ 53

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4.2.3.1 GPS ....................................................................................... 54
4.2.3.2 ONS ....................................................................................... 54
4.2.3.3 Controller Deviation ................................................................ 55
4.2.3.4 Controller Correction............................................................... 55
4.2.3.5 Status..................................................................................... 55
4.2.4 GPS Receiver.............................................................................. 56
4.2.4.1 UTC........................................................................................ 56
4.2.4.2 Status..................................................................................... 56
4.2.4.3 Position .................................................................................. 56
4.2.4.4 Diff. Data Age ......................................................................... 57
4.2.4.5 Satellites ................................................................................ 57
4.2.4.6 Accuracy ................................................................................ 57
4.2.4.7 Base Vector ............................................................................ 57
4.2.4.8 Heading.................................................................................. 57
4.2.5 Error ........................................................................................... 58
4.2.6 TCP ............................................................................................ 59
4.3 Configuration menu .............................................................. 59
4.3.1 Configuration —> Main ................................................................. 60
4.3.2 Configuration —> Guidance .......................................................... 62
4.3.3 Wheels........................................................................................ 63
4.3.3.1 What type of vehicle is involved?............................................. 63
4.3.3.2 The non-omnidirectional vehicle .............................................. 63
4.3.3.3 The omnidirectional vehicle..................................................... 64
4.3.3.4 Which wheels should be used for the odometry? ..................... 64
4.3.3.5 How are the positions specified on the vehicle?....................... 64
4.3.3.6 Configuration —> Wheels ......................................................... 65
4.3.4 Configuration —> Antennas........................................................... 67
4.3.5 Configuration —> Accuracy ........................................................... 68
4.3.6 Configuration —> Steer Controller................................................. 69
4.3.7 Configuration —> Speed Controller ............................................... 72
4.3.8 Configuration —> Sensor Fusion Transponder............................... 73
4.3.9 Configuration —> Sensor Fusion GPS ........................................... 74
4.3.10 Configuration —> Gyro.................................................................. 77
4.3.11 Configuration —> Servo ................................................................ 78
4.4 Network menu ...................................................................... 80
4.5 Config File menu .................................................................. 81
4.5.1 Upload Configuration —> Load parameters from a file on the PC into
the navigation controller .............................................................. 81
4.5.2 Download —> Transfer parameters from the navigation controller into
a file on the PC ........................................................................... 82
4.6 Segment File menu............................................................... 82
4.6.1 Upload Segment File —> Transfer a segment file from the PC into the
navigation controller .................................................................... 83
4.6.2 Download Segment File —> Transfer segment file from the navigation
controller into a file on the PC...................................................... 83

Contents HG G-73650ZD
English, Revision 04, Date: 28.10.2016 4
4.7 Segment Table menu............................................................ 84
4.8 Transponder File menu ......................................................... 85
4.8.1 Upload Transponder File —> Transfer a transponder file from the PC
into the navigation controller ........................................................ 85
4.8.2 Download Segment File —> Transfer transponder file from the naviga-
tion controller into a file on the PC ............................................... 86
4.9 Transponder Table menu ...................................................... 86
4.10 'Parameter Test' menu.......................................................... 87
4.10.1 Requirements for switching into the different modes..................... 88
4.10.2 Possibilities in the 'Idle' mode ...................................................... 88
4.10.3 Possibilities in the 'Test' mode ..................................................... 88
4.10.4 Possibilities in the 'Auto' mode..................................................... 89
4.10.5 Specification of segments ............................................................ 89
4.10.6 Setting a starting position ............................................................ 89
5 Commissioning................................................................90
5.1 Interfaces usually connected................................................. 90
5.2 Test / real operation.............................................................. 90
5.3 Commissioning the communication ....................................... 91
5.4 Setting the parameters.......................................................... 91
5.4.1 Configuration -> Main .................................................................. 92
5.4.2 Configuration —> Guidance .......................................................... 93
5.4.3 Configuration —> Wheels.............................................................. 93
5.4.4 Configuration —> Antenna ............................................................ 95
5.4.5 Configuration —> Accuracy ........................................................... 96
5.4.6 Configuration —> Steer Controller................................................. 96
5.4.7 Configuration —> Speed Controller ............................................... 97
5.4.8 Configuration —> Sensor Fusion ................................................... 97
5.4.9 Configuration —> Gyro.................................................................. 98
5.4.10 Configuration —> GPS .................................................................. 99
5.5 Creating the segments .......................................................... 99
5.6 Simulation without vehicle and vehicle controller ..................100
5.7 Simulation without vehicle and with vehicle controller ...........101
5.8 Commissioning a vehicle......................................................101
5.8.1 Testing and optimizing the parameters ....................................... 101
5.8.2 Other optimisations.................................................................... 105
5.8.3 Optimising the steering controller............................................... 106
5.8.4 Optimising the speed ramps....................................................... 107
6 CAN Bus Protocol .........................................................108

Contents HG G-73650ZD
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6.1 Transmission Telegrams from Control Unit to PLC, the Wheels
and the Gyro .......................................................................109
6.1.1 Path Data Box ........................................................................... 109
6.1.2 Segment Search Box ................................................................. 110
6.1.3 Status Box................................................................................. 111
6.1.4 Error Box................................................................................... 112
6.1.5 Wheel Boxes ............................................................................. 116
6.1.6 Gyro Box ................................................................................... 118
6.2 Reception Telegrams from PLC, Wheels, Antennas, Gyro and
Sensor Fusion to the Control Unit ........................................119
6.2.1 Path data (target) Box ............................................................... 119
6.2.2 SPS Control Box........................................................................ 120
6.2.3 Remote Control Box .................................................................. 121
6.2.4 Wheel Box................................................................................. 122
6.2.5 Antenna Boxes .......................................................................... 123
6.2.6 Gyro Box ................................................................................... 124
6.2.7 Sensorfusion Boxes................................................................... 125
7 Feldbus Protocol ........................................................... 128
7.1 Tx Transmission Telegram Control Unit —> PLC ...................128
7.2 Rx Reception Telegram PLC —> Control Unit ........................132
8 USB Data Logging: Scope of the Data ........................... 136
8.1 Opening logged Data in Excel®............................................136
8.2 List of logged Parameters ....................................................137
9 Trouble Shooting........................................................... 148
10 Technical Data ..............................................................150
11 Appendix.......................................................................151
A Attributes........................................................................................ 151
B Radius Calculation with 16 Bit Resolution...................................... 152
C Configuration of the Ethernet Interface Parameters via SIO 2 ....... 153
D Firmware-Update via the USB Interface ........................................ 154
12 List of Figures ...............................................................158
13 List of Tables ................................................................161
14 Handbook Conventions..................................................163
15 Copyright and Terms of Liability .................................... 164
15.1 Copyright.............................................................................164
15.2 Exclusion of Liability ............................................................164

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15.3 Trade Marks and Company Names.......................................164

Introduction HG G-73650ZD
English, Revision 04, Date: 28.10.2016 7
1 Introduction
The subject of this manual is the Navigation Controller HG G-73650ZD that enables
AGV (Automated Guided Vehicles) to follow virtual tracks. The following terms are
used synonymously throughout this document:
-Control Unit (as printed onto the hardware)
-navigation controller
-Vehicle Guidance Controller (VGC)
1.1 Tasks of the Navigation Controller
The navigation controller has the following tasks:
1. Determination of the current position via transponders, GPS or external input,
see section 2.3 on page 10
2. Reconstruction of the route to be driven (by means of segment files), see section
2.5 on page 20
3. Track Guidance (controlling the vehicle on a track), see section 2.6 on page 30
As the navigation controller is a very complex technical product the following pages
will first cover the various aspects of the vehicle's track guidance that have to be con-
sidered before we explain the subject areas of commissioning and configuration. The
following points will be explained later in this manual:
Basic information on positioning, track creation and track guidance
Hardware description, including displays and interfaces
Software description, including all menus of the web configuration
Commissioning
Protocol description, structure of the CAN- telegrams, Feldbus (external imple-
mentation on profinet, profibus, etc.)
Listing of data, which can be logged on an USB stick for analysis purposes
Trouble shooting
1.2 Intended Use
WARNING! The navigation controller is not a safe device! It may only be
operated in connection with a safety system!
Due to its design the navigation controller is designated for a wide scope of applica-
tions. It can only be applied for the track guidance of vehicles if the manufacturer or
the plant operator ensure that sensors for position detection are used that are suitable
for the requirements of that specific place and thus work fully (GPS e.g. is only suitable
for outdoor environments with the restriction that the GPS signals experience no inter-
ferences due to occlusions). Furthermore it is essential that all parameters, e.g. con-
cerning the vehicle's dimensions and functions as well as the position of the axles and

Introduction HG G-73650ZD
English, Revision 04, Date: 28.10.2016 8
wheels have to be entered with utmost accuracy. Consequently for new projects a
comprehensive testing of the settings with a jacked-up vehicle within a closed down
section of the plant is always recommended.
ATTENTION! As vehicles using the steering controller usually drive fully auto-
mated during their final / last implementation step, there is always
the risk of damages to the vehicles and the environment if any
incorrect parameters or faulty input signals are entered!
The vehicle manufacturer as well as the plant operator are obliged to operate with the
greatest care and to inform all persons either on the vehicle or in the danger zone sur-
rounding the machine about the risks involved. Furthermore all persons entrusted with
carrying out work within or close to the area of automated operation have to be in-
formed that the vehicle is driving autonomously.
1.3 Requirements / Options
-If you want to use the internal sensor fusion, at least one rotary encoder or any
other velocity or distance determining sensor has to be in operation. When rotary
encoders are directly connected to the steering controller please ensure that it is a
push/pull type with an output voltage of 5 to 25 V, two tracks perpendicular to
each other and a resolution of 0.1 to 1 mm / pulse. Using data telegrams on the
bus it is also possible to work with encoders to which this limitation does not
apply. For an improved accuracy or to achieve redundancy you can also use
Gyro HG 84300 (according to odometry).
-If a transponder positioning system is to be used, its antennas can be connected
via CAN bus. Alternatively or in connection with the transponder system you can
use a GPS system.
-When using the laser scanner HG 43600 two rotary encoders and two steering
encoders have to be connected directly to the navigation controller or deliver their
data via the wheel telegrams on the bus.
-Some steering servos and motor control units can be controlled / addressed
directly by the navigation controller so that a vehicle control system for each indi-
vidual application (e.g. PLC) is not absolutely necessary for each application.
However, in terms of monitoring, redundancy and customized adaptions a vehicle
control system is always recommendable for larger vehicles.
-If emergency stop functions are to be provided, a vehicle control system is man-
datory as the highest possible safety can only be achieved when both steering
controller and vehicle control system are installed.

Basic Principles of Track Guidance HG G-73650ZD
English, Revision 04, Date: 28.10.2016 9
2 Basic Principles of Track Guidance
2.1 Suitable and Unsuitable Vehicle Types
The range of particularly suitable vehicle types covers all vehicles that operate pre-
dictably and reproducibly. Several non-steered axles, trailers or vehicles with a center
pivot steering are not suitable.The wheel slippage has to be low and the wheels should
be hard to minimize the friction.
Figure 1 Example: Suitable vehicle types (selection)
The sketch below shows simplified versions of all the vehicles as three-wheelers, be-
cause this is the base vehicle model used by the navigation controller. The navigation
controller can also be used for vehicles where the steered wheel is not in the middle
(e.g. some fork-lift truck types).
Figure 2 Sketch: Suitable vehicle types
One fixed axle
particularly suited
e.g. fork-lift truck
Symmetrical steering
particularly suited
e.g. some heavy duty ve-
hicles
Two fixed axles
less accuracy and partly
rubbing, grinding wheels
e.g. large towing tractors
coordinate chassis
/ omnidirectional
vehicles
particularly suited
e.g. special vehi-
cles