SEW-Eurodrive MAXOLUTION MAXO-MTS-T005-P-00-B04 User manual

*23507268_1217*
Drive Technology \ Drive Automation \ System Integration \ Services
Operating Instructions
MAXOLUTION® System Solution
Automated Guided Vehicle
MAXO-MTS-T005-P-00-B04-04-C-VR0-A-00
Edition 12/2017 23507268/EN

SEW-EURODRIVE—Driving the world

Table of contents
Operating Instructions – Automated Guided Vehicle 3
Table of contents
1 General information.................................................................................................................. 5
1.1 About this documentation ...............................................................................................5
1.2 Structure of the safety notes ...........................................................................................5
1.3 Rights to claim under limited warranty ............................................................................6
1.4 Exclusion of liability.........................................................................................................7
1.5 Other applicable documentation .....................................................................................7
1.6 Product names and trademarks......................................................................................7
1.7 Copyright notice ..............................................................................................................7
2 Safety notes .............................................................................................................................. 8
2.1 Preliminary information ...................................................................................................8
2.2 Working on the system solution ......................................................................................8
2.3 Target group ...................................................................................................................8
2.4 Designated use ...............................................................................................................9
2.5 Functional safety...........................................................................................................10
2.6 Bus systems..................................................................................................................10
2.7 Transport.......................................................................................................................11
2.8 Electrical installation .....................................................................................................11
2.9 Startup and operation ...................................................................................................11
2.10 Inspection and maintenance .........................................................................................12
2.11 Storage .........................................................................................................................12
3 Vehicle ..................................................................................................................................... 13
3.1 Type designation...........................................................................................................13
3.2 Short designations ........................................................................................................13
3.3 Nameplates...................................................................................................................14
3.4 Structure .......................................................................................................................15
3.5 Detailed drawings .........................................................................................................19
3.6 Functional principle .......................................................................................................20
3.7 Caution signs on the vehicle .........................................................................................21
3.8 Load handling device interfaces ...................................................................................21
4 Warning and safety devices .................................................................................................. 23
4.1 Safety concept ..............................................................................................................23
4.2 Safety functions ............................................................................................................23
4.3 Safety laser scanner .....................................................................................................24
4.4 Emergency stop button .................................................................................................25
4.5 Optical and acoustic warning signals............................................................................26
4.6 Key switch.....................................................................................................................27
5 Operation................................................................................................................................. 28
5.1 Notes on safe operation................................................................................................28
5.2 Operating modes of the vehicle ....................................................................................29
5.3 Control elements on the vehicle....................................................................................30
5.4 Switching on the vehicle ...............................................................................................30
5.5 Switching off the vehicle ...............................................................................................30
5.6 DOP operator panel ......................................................................................................30
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Table of contents
Operating Instructions – Automated Guided Vehicle
4
6 Maintenance............................................................................................................................ 40
6.1 Inspection and maintenance work ................................................................................40
6.2 Failures .........................................................................................................................43
6.3 Status and error messages...........................................................................................44
6.4 Replacing the battery ....................................................................................................46
6.5 Transport.......................................................................................................................48
6.6 Spare parts ...................................................................................................................49
6.7 Electronics Service .......................................................................................................49
7 Technical data......................................................................................................................... 51
7.1 Ambient conditions........................................................................................................51
7.2 Vehicle ..........................................................................................................................51
7.3 Startup parameters .......................................................................................................52
7.4 Dimension sheets .........................................................................................................55
8 MAXOLUTION® Competence Center ..................................................................................... 56
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1
General information
About this documentation
Operating Instructions – Automated Guided Vehicle 5
1 General information
1.1 About this documentation
The current version of the documentation is the original.
This documentation is an integral part of the product. The documentation is written for
all employees who assemble, install, start up, and service this product.
Make sure this documentation is accessible and legible. Ensure that persons respons-
ible for the machinery and its 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 require further in-
formation, contact SEW‑EURODRIVE.
1.2 Structure of the safety notes
1.2.1 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 envir-
onment
INFORMATION Useful information or tip: Simplifies
handling of the product.
1.2.2 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.
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
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1General information
Rights to claim under limited warranty
Operating Instructions – Automated Guided Vehicle
6
Hazard symbol Meaning
Warning of dangerous electrical voltage
Warning of hot surfaces
Warning of risk of crushing
Warning of suspended load
Warning of automatic start-up
No access to persons with pacemakers
Do not ride on vehicle
1.2.3 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 disreg-
arded. Measure(s) to prevent the hazard.
1.3 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.
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1
General information
Exclusion of liability
Operating Instructions – Automated Guided Vehicle 7
1.4 Exclusion of liability
Read the information in this documentation, otherwise safe operation is impossible.
You must comply with the information contained in this documentation to achieve the
specified product characteristics and performance features. SEW‑EURODRIVE as-
sumes no liability for injury to persons or damage to equipment or property resulting
from non-observance of these operating instructions. In such cases,
SEW‑EURODRIVE assumes no liability for defects.
1.5 Other applicable documentation
Observe the corresponding documentation for all further components.
1.6 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.7 Copyright notice
©2017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.
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2Safety notes
Preliminary information
Operating Instructions – Automated Guided Vehicle
8
2 Safety notes
2.1 Preliminary information
The following basic safety notes must be read carefully to prevent injury to persons
and damage to property.
The safety notes refer to the use of the system solution described in this document.
This document does not replace the detailed documentation of the products and soft-
ware used. You therefore have to observe the documentation of the products and soft-
ware used.
Ensure that all safety notes are observed.
2.2 Working on the system solution
Make sure that all work steps described in this documentation are only performed by
qualified specialists.
Observe the following:
• National and regional safety and accident prevention regulations
• Personal protective equipment, e.g. safety shoes
• Caution signs on the products
• All system-specific specifications and conditions
The system solution may only be operated in systems equipped with the required
monitoring and protection devices.
2.3 Target group
Operation The product must only be operated by qualified personnel. Qualified personnel in this
context are persons who have the following qualifications:
• Appropriate instruction
• Knowledge of this documentation and all other referenced documentation
• Participation in a product training for the system solution
Specialist for
mechanical work
Any mechanical work may only be performed by adequately qualified specialists. Spe-
cialists in the context of this documentation are persons familiar with the design,
mechanical installation, troubleshooting, and maintenance of the product who possess
the following qualifications:
• Qualification in the mechanical area in accordance with the national regulations
• Familiarity with this documentation
Specialist for elec-
trotechnical work
Any electrotechnical work may only be performed by electrically skilled persons with a
suitable education. Electrically skilled persons in the context of this documentation are
persons familiar with electrical installation, startup, troubleshooting, and maintenance
of the product who possess the following qualifications:
• Qualification in the electrotechnical area in accordance with the national regula-
tions
• Familiarity with this documentation
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2
Safety notes
Designated use
Operating Instructions – Automated Guided Vehicle 9
Software specialist Any work with the software may only be performed by adequately qualified personnel.
Qualified personnel in this context are persons who have the following qualifications:
• Appropriate instruction
• Knowledge of this documentation and other applicable documentation
• Participation in a product training for the software and the products operated with
it.
Additional qualifi-
cation
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 com-
pany to operate, program, parameterize, label, and ground units, 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 instruction is
that the persons are capable of performing the required tasks and work steps in a safe
and correct manner.
2.4 Designated use
The system solution consists of one or several vehicles. The vehicle is designed for
material transport within industrial and commercial systems using an active or passive
load handling device.
The system solution is intended for integration in electrical systems and machines in
covered industrial use.
In case of installation in electrical systems or machines, startup of the system solution
is prohibited until it is determined that the system or machine meets the requirements
stipulated in the valid laws and directives.
The standards included in the declaration of conformity are applied for the system
solution.
Persons in the sys-
tem
Observe the following notes regarding the protection of persons:
• Instruct employees and visitors on how to act when accessing the system.
• The vehicle always takes priority to forklifts or other industrial trucks.
• Entering the hazardous areas is not permitted.
• Access to the closed off areas is only permitted to trained personnel.
Restrictions Adhere to the following restrictions:
• The system solution must only be used indoors and outside of potentially explosive
areas.
• Do not operate the system solution in environments containing harmful substances
(e.g. oils, acids, gases, vapors, dusts, radiation).
• Operate the system solution in a dry environment. Remove liquids from the floor.
• Do not operate the system solution in environments with conductive dirt.
• The vehicles are only suitable for transporting materials using the designated carri-
ers.
• Transporting persons or animals is not permitted.
• Make sure that there are no obstacles on the track and that no objects protrude in
the track.
• Obstacles on the floor must have a minimum height of 200mm to be detected by
the safety laser scanner (risk of collision).
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2Safety notes
Functional safety
Operating Instructions – Automated Guided Vehicle
10
• Moving obstacles are detected. However, it is possible that the vehicle may not
come to a stop in due time. The braking distance is dimensioned for standing
obstacles.
• Do not step into the travel range of the vehicle.
• Keep a distance to the vehicle during load transfer (risk of crushing).
• Do not reach or walk into the pivoting/curved area of the vehicle.
• Adhere to the technical data, e.g. the maximum permitted total weight.
• Make sure no undetectable staircases, loading bays, or gaps in the floor are within
the range of the vehicle. Fence off areas that cannot be detected.
• Make sure the specified functional and safely test is completed before you start the
vehicle.
• Observe the travel range of adjacent systems.
• Operation is only permitted when the notes on safe operation are adhered to.
2.5 Functional safety
2.5.1 Safety-relevant conditions
To ensure that the emergency stop buttons can be used in case of danger, observe
the following notes:
• Do not block or cover the emergency stop buttons.
• Use the emergency stop buttons only in case of danger.
• Replace defective emergency stop buttons immediately.
2.5.2 Validation
The purpose of the validation is to confirm the specification and conformity of the drive
solution described in this document within the overall specification for the safety re-
quirements of the machine/plant.
The validation must confirm that every safety-related component of the different safety
functions fulfills the required safety guidelines.
The validation process comprises the analysis and tests in accordance with a valida-
tion plan. Consult the various standards (e.g. ISO 13849-1) and corresponding re-
sources.
If safety-relevant components and/or software is modified, the system/machine must
be validated again.
2.6 Bus systems
A bus system makes it possible to adapt electronic drive components to the particulars
of the machinery within wide limits. There is a risk that a change of parameters that
cannot be detected externally may result in unexpected (but not uncontrolled) system
behavior and may have a negative impact on operational safety, system availability, or
data security.
Especially in Ethernet-based networked systems and with engineering interfaces,
make sure that unauthorized access is prevented.
Use IT‑specific safety standards to increase access protection to the ports. For a port
overview, refer to the respective technical data of the device in use.
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2
Safety notes
Transport
Operating Instructions – Automated Guided Vehicle 11
2.7 Transport
Observe the following information to avoid damage to the product:
Before transport • Before you lift the product, read the safety notes on transport.
• Always use suitable, sufficiently rated handling equipment.
• Observe the ambient conditions of the components included in the product in the
SEW‑EURODRIVE documentation or in the documentation of the respective
manufacturer for third-party components.
During transport • Ensure that the product is not subject to mechanical impact during transportation.
After transport • Inspect the shipment for eventual damage as soon as you receive the delivery. In-
form the shipping company immediately about any damage. Do not startup any
device if it has been damaged during transport.
• Remove transport protection prior to startup.
2.8 Electrical installation
Ensure that all of the required covers are correctly attached after carrying out the elec-
trical installation.
Make sure that preventive measures and protection devices comply with the applic-
able regulations (e.g. EN60204-1 or EN61800-5-1).
2.9 Startup and operation
Do not deactivate monitoring and protection devices even for a test run. When in
doubt, switch off the unit whenever changes occur in relation to normal mode (e.g. in-
creased temperatures, noise, oscillation). Determine the cause. It may be necessary
to contact SEW‑EURODRIVE.
Where required, systems with these devices integrated must be equipped with addi-
tional monitoring and protection devices in accordance with the applicable safety regu-
lations, e.g. the legislation governing technical equipment, accident prevention regula-
tions, etc.
Additional preventive measures may be required for applications with increased haz-
ard potential. You must check the functionality of protection devices each time you
change the configuration.
Do not touch live components or power connections immediately after disconnecting
the device from the voltage supply because some capacitors may still be charged. Ob-
serve the corresponding minimum switch-off time on the device labels and in the com-
ponent documentation.
For further information on separating the power supply, refer to chapter Disconnecting
the power supply.
When the unit is switched on, dangerous voltages are present at all power connec-
tions as well as at any connected cables and motor terminals. This also applies even
when the unit is inhibited and the motor is at standstill.
The fact that the operation LED and other display elements are no longer illuminated
does not indicate that the device has been disconnected from the supply system and
no longer carries any voltage.
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2Safety notes
Inspection and maintenance
Operating Instructions – Automated Guided Vehicle
12
Mechanical blocking or internal safety functions of the unit can cause a motor stand-
still. Eliminating the cause of the problem or performing a reset may result in the drive
re-starting automatically. If, for safety reasons, this is not permitted for the drive-con-
trolled machine, first disconnect the device from the supply system and discharge it
completely. Only then, start troubleshooting.
Electric arcs may damage electrical components. Do not disconnect power connec-
tions during operation. Do not connect power connections during operation.
2.10 Inspection and maintenance
Carry out maintenance and repair work only on a secured and de-energized machine/
system. Ensure a de-energized state of the machine/system before you start working
on it. Ensure a de-energized state for the entire time you work on the system.
2.11 Storage
Observe the following instructions when shutting down or storing the product:
• Make sure that the product is not subject to mechanical impact during storage.
• In case of extended storage, connect the product to the relevant supply voltage for
at least 8hours every 2years.
• Observe the note of the manufacturer regarding the shelf life of the energy storage
device in the vehicle.
• To avoid damage to the wheels, move the vehicles at least 2times a year or store
the vehicle without load being applied to the wheels.
Adhere to the notes on storage temperature:
• In chapter "Technical Data".
• In the manufacturer documentation if third-party components are installed.
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3
Vehicle
Type designation
Operating Instructions – Automated Guided Vehicle 13
3 Vehicle
3.1 Type designation
The type designation of the vehicle contains the following data:
MAXO MAXOLUTION® system solution
-
MTS Mobile transport system
-
T3-wheel drive
005 Load capacity 500kg
-
PStandardized platform
-
00 No load handling device
-
B04 Lead crystal battery bundle 48V
-
04 DC link voltage DC48V
-
CEnergy supply with contact
-
VOptical navigation
RNavigation via RFID transponder
-
AVehicle software AGVbasic
-
00 Version
3.2 Short designations
The following short designations are used in this documentation:
Component Short designation
MAXO-MTS-T005-P-00-B04-04-C-VR0-A-00 Vehicle
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3Vehicle
Nameplates
Operating Instructions – Automated Guided Vehicle
14
3.3 Nameplates
3.3.1 Main nameplate
The main nameplate lists information about the product. The following figure shows an
example of a main nameplate:
D-76646 Bruchsal
Made in Germany
Ernst-Blickle-Str. 42
Typ:
S#:
Leergewicht: Max. Zuladung:
Max. Geschw.:
MAXOLUTION®-Projekt-Nr.:
Versorgungsspg.:
[1] [3] [4][2]
[5]
[6]
9007219191538955
[1] Type designation
[2] Serial number
[3] Data matrix code
[4] CE marking
[5] Technical data, such as no-load weight, max. velocity, max. payload, and sup-
ply voltage
[6] MAXOLUTION® project no.
3.3.2 Battery nameplate
The nameplate contains information on the battery. The following figure shows an ex-
ample of a nameplate:
D-76646 Bruchsal
Made in Germany
Ernst-Blickle-Str. 42
Typ:
S#:
Batterien Anzahl / Gewicht:
Spannung Batteriesatz:
Batterie Typ:
Fahrerloses Transportfahrzeug
Kapazität Batteriesatz:
[1] [2]
[3]
[4]
20099741835
[1] Type designation
[2] Serial number
[3] Technical data, such as number and weight of the batteries, battery type,
voltage of the battery set, and capacitance of the battery set.
[4] Designation of the system solution
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3
Vehicle
Structure
Operating Instructions – Automated Guided Vehicle 15
3.4 Structure
3.4.1 Vehicle structure
[2]
[1]
[3]
9007220061939595
[1] Load handling device module (project-specific)
[2] Energy module
[3] Technology module
3.4.2 Front of the vehicle
[2]
[3]
[4]
[3]
[5] [1]
[1]
18014418711452299
No. Component Function
[1] Caution signs Warning about hazards.
[2] WLAN antenna Communication with the higher-level controller.
[3] Emergency stop button Stopping the vehicle in case of emergency.
[4] Safety laser scanner Detecting persons and objects.
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3Vehicle
Structure
Operating Instructions – Automated Guided Vehicle
16
No. Component Function
[5] Attachment point for the
vehicle
Transporting the vehicle.
3.4.3 Bottom of the vehicle
[9]
[2]
[3]
[1]
[5]
[4]
[6]
[3]
[2][1] [4]
[8]
[3]
[3]
[7]
[10]
18014418711455755
No. Component Function
[1] Travel drive Driving the drive wheel
[2] Drive wheel Moving the vehicle
[3] LED lights Optical display of the vehicle status
[4] Auxiliary wheel Vehicle stability
[5] Safety laser scanner Recognition of persons in the direction of travel
[6] Read head Optical track guidance
[7] Read/write head Reading and writing the RFID transponder.
Distance read/write head (center) to the central axis of the vehicle: 175mm
Distance read/write head (center) to the front edge of the vehicle: 735mm
[8] Positive terminal char-
ging contact
Charging the battery. The positive terminal is on the left in the direction of
travel.
[9] Read head (optional) Optical track guidance
Only required for vehicles with reverse motion.
[10] Negative terminal char-
ging contact
Charging the battery. The negative terminal is on the right in the direction of
travel.
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3
Vehicle
Structure
Operating Instructions – Automated Guided Vehicle 17
3.4.4 Back of the vehicle
[1] [2] [4][3]
[7]
[5] [6][6]
[8]
9007219456717067
No. Component Function
[1] Multi-function button Flashing green lighted pushbutton
[2] Acknowledgment button Flashing blue lighted pushbutton
[3] Emergency stop button Stopping the vehicle in case of emergency
[4] Key switch Keyswitch mode
DANGER!Danger due to safety functions that can be bypassed via
keyswitch. Serious injuries.
Do not bypass safety functions in normal operation!
[5] WLAN antenna Communication with the higher-level controller
[6] Attachment point for the
vehicle
Transporting the vehicle
[7] DOP operator terminal Operating and display element for manual mode and diagnostics
[8] Safety switching strip
(optional)
Safety measure to avoid crushing.
Only required for vehicles with reverse motion.
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3Vehicle
Structure
Operating Instructions – Automated Guided Vehicle
18
3.4.5 Vehicle backside – drawer
[1]
[3]
[4]
[5]
[2]
20811159691
No. Component Function
[1] I/O module I/O system of the MOVI‑PLC®
[2] Safety relays Safe brake control
[3] MOVISAFE® UCS
safety controller
Processing the signals of all safety components on the vehicle.
[4] MOVI‑PLC®Vehicle controller
[5] WLAN client Communication of the vehicle with the logistics controller
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3
Vehicle
Detailed drawings
Operating Instructions – Automated Guided Vehicle 19
3.5 Detailed drawings
3.5.1 Technology module
X32
X42
X11
X21
X12
X22
X13
X31
UCS12B
X6
DI01020304
DOK1K20203 DI05060708
DI09101112
ENTER
STATUS
DI1314P1P2
X7 X8
1
6
5
1
6
5
9
XCS
XCD
/PS
RUN
SYSFault
X41
UCS23B
DI01020304
DIO03040506 DI05060708
DI09101112
STATUS
DIO1314P1P2
DIO07080910
X35
X45
X36
X46
X15
X25
X16
X26
UCS23B
DI01020304
DIO03040506 DI05060708
DI09101112
STATUS
DIO1314P1P2
DIO07080910
X35
X45
X36
X46
X15
X25
X16
X26
DHP11B
X30
2
2
2
2
0
1
2
3
2
2
2
4
5
6
[1]
[2]
[1]
[3]
[3]
[1]
[7]
[1]
[15] [14]
[26]
[25]
[5]
[6]
[10]
[5] [9]
[24]
[9]
[5]
[23]
[22]
[11]
[6]
[18]
[19]
[20]
[21]
[13]
[4]
[17]
[8]
[12]
[16]
21477269771
[1] LED strip [10] Read/write head for RFID
transponder
[19] LED switch
[2] Safety switching strip [11] MOVI‑PLC®[20] Fuse
[3] Motor CMP ELVCD [12] Safety relays [21] OCC11C bus coupler
[4] Energy module interface [13] Relay [22] Access Point
[5] Emergency off button [14] MOVISAFE® UCS23B [23] DOP operator terminal
[6] WLAN antenna [15] MOVISAFE® UCS12B/PS [24] Multi-function button
[7] Safety laser scanner [16] Relay [25] Key switch
[8] Charging contacts [17] Horn [26] Acknowledgment button
[9] Optical track guidance with
PGV data matrix positioning
system
[18] MOVI‑PLC® I/O system
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3Vehicle
Functional principle
Operating Instructions – Automated Guided Vehicle
20
3.5.2 Energy module
A
[2]
[3]
[4]
[6]
[1]
[5]
21483207051
[1] Measuring transducer [4] Technology module interface
[2] Batteries [5] DC/DC converter
[3] Load handling device module inter-
face
[6] Relay
3.6 Functional principle
3.6.1 Information
The following pages illustrate all options. Observe the information applicable to your
vehicle according to the type code.
3.6.2 Control and communication
The vehicle communicates with the higher-level controller (logistics controller) using
the WLAN infrastructure. The software transferring the travel order to the vehicle is in-
stalled on the logistics controller.
After having received a travel task, the vehicle warns persons close to it before it
starts its travel by means of warning and safety measures.
The vehicle transmits operating data of the vehicle to the logistics controller.
3.6.3 Energy supply
The vehicle is supplied with energy by batteries. The batteries are charged via char-
ging contacts.
3.6.4 Navigation
Optical
The track guidance is realized optically via a read head and via track marks glued to
the floor.
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