SEW-Eurodrive MAXOLUTION MAXO-MS User manual

*26868113_0321*
Drive Technology \ Drive Automation \ System Integration \ Services
Assembly and Operating
Instructions
MAXOLUTION® System Solution
MAXO-MS/M/SM-GIOP Sensor Module
Edition 03/2021 26868113/EN

SEW-EURODRIVE—Driving the world

Table of contents
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module 3
Table of contents
1 General information.................................................................................................................. 5
1.1 About this documentation ...............................................................................................5
1.2 Other applicable documentation .....................................................................................5
1.3 Structure of the safety notes ...........................................................................................5
1.4 Decimal separator in numerical values ...........................................................................6
1.5 Rights to claim under limited warranty ............................................................................6
1.6 Product names and trademarks......................................................................................6
1.7 Copyright notice ..............................................................................................................6
2 Safety notes .............................................................................................................................. 7
2.1 Preliminary information ...................................................................................................7
2.2 Duties of the user............................................................................................................7
2.3 Target group ...................................................................................................................7
2.4 Designated use ...............................................................................................................8
2.5 Network security and access protection .........................................................................9
2.6 Transport.........................................................................................................................9
2.7 Installation/assembly.......................................................................................................9
2.8 Electrical installation .....................................................................................................10
2.9 Startup and operation ...................................................................................................10
2.10 Inspection/maintenance ................................................................................................10
3 Device structure ..................................................................................................................... 11
3.1 Type designation...........................................................................................................11
3.2 Overview of designs......................................................................................................11
3.3 Short designation ..........................................................................................................11
3.4 Nameplate.....................................................................................................................12
3.5 Device overview............................................................................................................13
3.6 Operating principle........................................................................................................14
4 Mechanical installation .......................................................................................................... 15
4.1 Track and vehicle geometry..........................................................................................15
4.2 Minimum clearances .....................................................................................................17
4.3 Travel direction .............................................................................................................17
4.4 Project planning notes on inductive track guidance......................................................19
4.5 Project planning notes, RFID system............................................................................21
4.6 Mounting the device......................................................................................................23
5 Electrical installation.............................................................................................................. 24
5.1 Electrical connections ...................................................................................................24
6 Service..................................................................................................................................... 27
6.1 Waste disposal..............................................................................................................27
6.2 Return Information ........................................................................................................28
7 Technical data......................................................................................................................... 29
7.1 General .........................................................................................................................29
7.2 Track guidance .............................................................................................................29
7.3 Rotation rate and acceleration sensors ........................................................................29
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Table of contents
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module
4
7.4 Read head for RFID transponder..................................................................................30
7.5 Dimension Sheet...........................................................................................................31
8 Approvals ................................................................................................................................ 32
8.1 USA/Canada .................................................................................................................32
8.2 Europe ..........................................................................................................................32
9 MAXOLUTION® Competence Center ..................................................................................... 34
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1
General information
About this documentation
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module 5
1 General information
1.1 About this documentation
The documentation at hand is the original.
This documentation is an integral part of the product. The documentation is intended
for all employees who perform work on the product.
Make sure this documentation is accessible and legible. Ensure that persons respon-
sible for the systems and their operation as well as persons who work on the product
independently have read through the documentation carefully and understood it. If you
are unclear about any of the information in this documentation or if you require further
information, contact SEW‑EURODRIVE.
1.2 Other applicable documentation
Observe the corresponding documentation for all additional components.
1.3 Structure of the safety notes
1.3.1 Meaning of signal words
The following table shows the grading and meaning of the signal words for safety
notes.
Signal word Meaning Consequences if disregarded
DANGER Imminent hazard Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the product or its envi-
ronment
INFORMATION Useful information or tip: Simplifies
handling of the product.
1.3.2 Structure of section-related safety notes
Section-related safety notes do not apply to a specific action but to several actions
pertaining to one subject. The hazard symbols used either indicate a general hazard
or a specific hazard.
This is the formal structure of a safety note for a specific section:
SIGNAL WORD
Type and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the hazard.
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1General information
Decimal separator in numerical values
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module
6
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
1.3.3 Structure of embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous action.
This is the formal structure of an embedded safety note:
SIGNAL WORD! Type and source of hazard. Possible consequence(s) if disregar-
ded. Measure(s) to prevent the hazard.
1.4 Decimal separator in numerical values
In this document, a period is used to indicate the decimal separator.
Example: 30.5kg
1.5 Rights to claim under limited warranty
Read the information in this documentation. This is essential for fault-free operation
and fulfillment of any rights to claim under limited warranty. Read the documentation
before you start working with the product.
1.6 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.6.1 Trademark of Beckhoff Automation GmbH
EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany.
1.7 Copyright notice
©2021SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-
tion, distribution or any other use of the whole or any part of this documentation is
strictly prohibited.
26868113/EN – 03/2021

2
Safety notes
Preliminary information
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module 7
2 Safety notes
2.1 Preliminary information
The following general safety notes serve the purpose of preventing injury to persons
and damage to property. They primarily apply to the use of products described in this
documentation. If you use additional components, also observe the relevant warning
and safety notes.
2.2 Duties of the user
As the user, you must ensure that the basic safety notes are observed and complied
with. Make sure that persons responsible for the machinery and its operation as well
as persons who work on the device independently have read through the documenta-
tion carefully and understood it.
As the user, you must ensure that all of the work listed in the following may be carried
out only by qualified specialists:
• Setup and installation
• Installation and connection
• Startup
• Maintenance and repairs
• Shutdown
• Disassembly
Ensure that the persons who work on the product pay attention to the following regula-
tions, conditions, documentation, and information:
• National and regional safety and accident prevention regulations
• Warning and safety signs on the product
• All other relevant project planning documents, installation and startup instructions,
and wiring diagrams
• Do not assemble, install or operate damaged products
• All system-specific specifications and conditions
Ensure that systems in which the product is installed are equipped with additional
monitoring and protection devices. Observe the applicable safety regulations and leg-
islation governing technical work equipment and accident prevention regulations.
2.3 Target group
Specialist for me-
chanical work
Any mechanical work may be performed only by adequately qualified specialists. Spe-
cialists in the context of this documentation are persons who are familiar with the
design, mechanical installation, troubleshooting, and maintenance of the product who
possess the following qualifications:
• Qualifications in the field of mechanics in accordance with the national regulations
• Familiarity with this documentation
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2Safety notes
Designated use
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module
8
Specialist for elec-
trotechnical work
Any electrotechnical work may be performed only by electrically skilled persons with a
suitable education. Electrically skilled persons in the context of this documentation are
persons who are familiar with electrical installation, startup, troubleshooting, and main-
tenance of the product who possess the following qualifications:
• Qualifications in the field of electrical engineering in accordance with the national
regulations
• Familiarity with this documentation
Additional qualific-
ations
In addition to that, these persons must be familiar with the valid safety regulations and
laws, as well as with the requirements of the standards, directives, and laws specified
in this documentation.
The persons must have the express authorization of the company to operate, pro-
gram, parameterize, label, and ground devices, systems, and circuits in accordance
with the standards of safety technology.
Instructed persons All work in the areas of transportation, storage, operation and waste disposal must be
carried out by persons who are trained appropriately. The purpose of the training is to
give persons the ability to perform the required tasks and work steps in a safe and cor-
rect manner.
2.4 Designated use
The product consists of a unit with the following sensors, which are used for track
guidance:
• 2 acceleration sensors for the X and Y axes
• 2 rotation rate sensors for the Z axis
• 1 inductive track guidance
• 1 read head for RFID transponders
Moreover, the product is equipped with a connection for the power supply and com-
munication interfaces:
• 2 EtherCAT® interfaces (IN and OUT)
• 2 CAN interfaces
• RS422 interface for external optical track guidance (optional)
• DC24V supply
The product is designed for installation in mobile electrical systems or machines, es-
pecially for automated guided vehicles.
In case of installation in electrical systems or machines, startup of the product is pro-
hibited until it is determined that the machine meets the requirements stipulated in the
local laws and directives. For Europe, Machinery Directive 2006/42/EC as well as the
EMC Directive 2014/30/EU apply. Observe EN60204-1 (Safety of machinery - elec-
trical equipment of machines). The product meets the requirements stipulated in the
Low Voltage Directive 2014/35/EU.
Technical data and information on the connection conditions are provided on the
nameplate and in chapter "Technical data" in the documentation. Always comply with
the data and conditions.
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2
Safety notes
Network security and access protection
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module 9
Observe the following restrictions:
• Do not open the product.
Safe and fault-free operation can no longer be ensured if you open the product. In
case of service, send your product back to SEW‑EURODRIVE. Your right to claim
under warranty no longer applies if you open the product.
• Do not make any changes to the product.
Your right to claim under warranty no longer applies if you make changes to the
product.
Unintended or improper use of the product may result in severe injury to persons and
damage to property.
2.5 Network security and access protection
A bus system makes it possible to adapt electronic drive technology components to
the particulars of the machinery within wide limits. There is a risk that a change of pa-
rameters that cannot be detected externally may result in unexpected but not uncon-
trolled system behavior and may have a negative impact on operational safety, system
availability, or data security.
Ensure that unauthorized access is prevented, especially with respect to Ethernet-
based networked systems and engineering interfaces.
2.6 Transport
Inspect the shipment for damage as soon as you receive the delivery. Inform the ship-
ping company immediately about any damage. If the product is damaged, it must not
be assembled, installed or started up.
When you return the product, pack it into a suitable box.
Observe the information on climatic conditions in chapter "Technical data" of the docu-
mentation.
2.7 Installation/assembly
When installed in an automated guided vehicle system, adjacent or attached compo-
nents must not result in exceeding the permitted operating temperature of the device.
Protect the product from strong mechanical strain. The product and its mounting parts
must never protrude into the path of persons or vehicles. Electrical components must
not be mechanically damaged or destroyed.
2.7.1 Restrictions of use
The following applications are prohibited unless the device is explicitly designed for
such use:
• Use in potentially explosive atmospheres
• Use in areas exposed to harmful oils, acids, gases, vapors, dust, and radiation
• Operation in applications with impermissibly high mechanical vibration and shock
loads in excess of the regulations stipulated in EN61800-5-1
• Use at an elevation greater than 2000m above sea level
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2Safety notes
Electrical installation
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module
10
2.8 Electrical installation
The preventive measures and protection devices must comply with the applicable reg-
ulations (e.g. EN60204-1 or EN61800-5-1).
2.9 Startup and operation
Damaged products Never install damaged products. Submit any complaint to the shipping company im-
mediately in the event of transportation damage. Do not start up damaged products.
2.10 Inspection/maintenance
Never open the device. Only SEW‑EURODRIVE may repair the device.
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3
Device structure
Type designation
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module 11
3 Device structure
3.1 Type designation
MAXO MAXOLUTION® system solution
–
MS Mobile system
/
MModule
/
SM Sensor module
–
Design with the following combination options:
G Acceleration and rotation rate sensor
I Inductive
O Optical (connection available for external optical track guidance)
P RFID
3.2 Overview of designs
Designation Part number
MAXO-MS/M/SM-GIP
(without RS422 connection for external optical
track guidance)
28279883
MAXO-MS/M/SM-GIOP
(with RS422 connection for external optical track
guidance)
28272528
3.3 Short designation
The following short designations are used in this documentation:
Designation Short designation
MAXO-MS/M/SM-GIOP Sensor Module Device
Automated guided vehicle Vehicle
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3Device structure
Nameplate
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module
12
3.4 Nameplate
[1]
D-76646 Bruchsal
Made in Germany
Type:
P#: FCC ID: IC:
U
I
T
S#:
=
=
=IP =
[2]
33552897163
[1] Product designation
[2] Version
Depending on the device design, the following information is listed on the main name-
plate:
Value Specification
Type Type designation
P# Part number (for customer-specific products)
S# Production number
FCC ID
IC
Radio approval for USA/Canada
U Voltage
I Current
T Ambient temperature
IP Degree of protection
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3
Device structure
Device overview
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module 13
3.5 Device overview
X4251_11 X4251_12 X4111 X4101 X1512
[1] [2]
X4030
[3] [4] [5] [6]
33692952587
[1] X4251_11 EtherCAT® interface (IN)
[2] X4251_12 EtherCAT® interface (OUT)
[3] X4030 RS422 interface for connecting an external optical
track guidance (optional)
[4] X4111 CAN interface
[5] X4101 CAN interface (diagnostics)
[6] X1512 Interface for power supply
For further information, refer to chapter "Electrical installation"(→224).
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3Device structure
Operating principle
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module
14
3.6 Operating principle
The following figure shows the block diagram of the sensor module:
[B] X4251_11
X4251_12 X4030
X4101
X4111 X1512
C
[2]
[1]
[2]
[2]
[3]
[5]
[6]
RFID chip
ind. track sensor
RFID antenna
GA GA
[2]
[4]
DC-24-V
CAN
CAN
EtherCAT® RS422 CAN
33985535883
The sensor module is used in a mobile assistant. It consists mainly of the following
components:
[1] Communication interfaces
[2] Rotation rate and acceleration sensors
[3] Microcontroller
[4] Power supply
[5] Read head and antenna for detection of RFID transponders
[6] Inductive track guidance
Inductive track guidance [6] detects the deviation of the vehicle from the specified
track on the MOVITRANS® line cable. At the same time, odometry data is collected by
the rotation rate sensor and acceleration sensors.
The data of the inductive track guidance is transmitted to the microcontroller [3] via
CAN for evaluation. The data is also available to other devices via the CAN female
plug connector X4111. Another CAN female plug connector X4101 is connected to the
microcontroller and can be used for diagnostics or programming of the device.
The data of the RFID transponders is collected and read [5] and transmitted serially to
the microcontroller for referencing.
For traveling along an optical track, the sensor module can be equipped with an
RS422 interface for connecting an external optical track guidance.
The sensor module transmits the sensor data to a higher-level controller where it is
compared and evaluated.
The sensor module has 2 EtherCAT® interfaces (X4251_11 and X4251_12) for integ-
ration into an EtherCAT® topology and as a prerequisite for communication with a
higher-level controller.
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4
Mechanical installation
Track and vehicle geometry
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module 15
4 Mechanical installation
4.1 Track and vehicle geometry
4.1.1 Distance designation
The following figure shows the vehicle from below (in the direction of travel) with the
designation of the distances:
R
A
M2
M1
SM
r
RAD
34148228235
SM Sensor module
R Distance R between the sensor module (SM) and the steered axis
M Motor
A Distance of the two drive wheels
rRAD Tire radius
These parameters are required for configuring the sensor module. They also apply to
slightly different vehicle designs with swivel wheel suspension.
An advantage of vehicles with swivel wheel suspension is that they run more smoothly
during operation.
4.1.2 Distance between the sensor module and the steered axis
The distance R between the sensor module and the steered drive axis must be at
least as large as the result calculated using the following formula:
R =
min max
( . )1 6 2
s
mA v× ×
2561101579
vmax Maximum travel speed in m/s
INFORMATION
This condition also applies to vehicle designs with swivel wheel suspension.
26868113/EN – 03/2021

4Mechanical installation
Track and vehicle geometry
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module
16
4.1.3 Minimum permitted curve radius
The smallest possible curve radius rKurve,min that can be traveled at vmax is calculated us-
ing the actual distance R:
r =
Kurve Rm ,min .
2
0 08
2561110795
4.1.4 Speed reduction in tight curves
For curve radii rK < rKurve,min, the travel speed in the curve must be reduced in accor-
dance with vmax:
v =
Kurve K
Kurve
r
rv
,max ,min max
×
2561235851
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4
Mechanical installation
Minimum clearances
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module 17
4.2 Minimum clearances
SEW‑EURODRIVE recommends observing the following clearances when mounting
the device:
C
A
D
A
A
B
AB
33693137803
The following table lists the minimum clearances:
Clearance Function Clearance
A Distance to metallic components. This way,
you can avoid a reduction of the range
when reading an RFID transponder.
≥ 50mm
B Distance to metallic components. Metallic
components prevent the sensor technology
from functioning correctly.
≥ 125mm
C Space for cable entry and plug connectors ≥ 60mm
D Distance to floor to avoid collisions with
obstacles and to ensure proper operation
of the sensor technology
≥ 25mm
4.3 Travel direction
It is important that you align the sensor module correctly in reference to the direction
of travel. To help you do this, an arrow is printed on the top of the housing to indicate
the direction of travel.
The sensor module must always be in front of the steered axis. This means a track
point is crossed first by the sensor module and then by the steered axis.
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4Mechanical installation
Travel direction
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module
18
INFORMATION
Reverse travel is not possible.
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4
Mechanical installation
Project planning notes on inductive track guidance
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module 19
4.4 Project planning notes on inductive track guidance
4.4.1 Distances for line cable routing
Inductive track guidance is used with line cables (round or wedge-shaped) that are
routed at a distance of 140mm.
The following figure shows the distances that must be observed when mounting the
sensor module using a round line cable as an example:
5 mm
25 mm 25 mm
140 mm
25 mm
[1]
[2]
[3]
34055863051
[1] Sensor module
[2] Line cable (round design)
[3] Hall floor
Install the sensor module [1] in such a way that the distance between hall floor [3] and
bottom of the housing is 25mm. This value applies when the line cable [2] is routed so
that the top edge of the cable is 5mm below the surface of the hall floor.
When routing the line cable, ensure that the distance between the top edge of the line
cable and the surface of the hall floor is kept constant along the entire track. Before
routing the line cable, exactly determine the thickness of the surface covering above
the line cable. Avoid lateral deviations when routing the line cable because the track-
guided vehicle follows the routed cable pair exactly.
A constant height must be observed between the sensor module and the line cable.
Deviations of ±3 mm in the height from the measuring system to the line cable pair
leads to a track deviation of ±2mm.
4.4.2 Distance to pick-ups
The following figure shows the installation of the sensor module between 2 flat
MOVITRANS® THM10E pick-ups:
[2]
[3]
[1] [1]
34064605195
[1] MOVITRANS® THM10E pick-up
[2] Sensor module
[3] Line cable
Observe the following notes for installation:
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4Mechanical installation
Project planning notes on inductive track guidance
Assembly and Operating Instructions – MAXO-MS/M/SM-GIOP Sensor Module
20
The MOVITRANS® THM10E pick-ups may be installed before and/or after the sensor
module, taking the minimum clearances into account (see "Minimum clear-
ances"(→217)).
26868113/EN – 03/2021