AGV装配线关键技术专项方案.doc

长安福特汽车南京企业
Changan Ford Automobile Co., Ltd. Nanjing Company
发动机、前后桥AGV系统
Engine & Axel AGV System

技 术 方 案
Technical Plan

沈阳新松机器人自动化股份
Shenyang SIASUN Robot & Automation Co., Ltd.

目 录 Contents
1. 概述Summary 5
2. 设计依据Design Gist 5
2.1 生产工艺基础要求Basic Requirement of Production Process 5
2.2 现场基础技术条件Basic Field Technical Condition 6
2.3 责任范围Responsibility Scope： 6
3. AGV装配输送系统概述AGV Assembly & Transportation System Summary 7
4. 自动导引车AGV系统技术指标Automated Guided Vehicle AGV System Technical Specification 9
5. AGV工作过程描述AGV Working Process Description 11
6. 发动机装配升降工作台Engine Assembly Lifter Worktable 14
6.1 伸缩套筒式升降工作台Extension Sleeve Lifter Worktable 14
6.2 剪式液压机构升降工作台Scissor Hydraulic Lifter Worktable 16
6.3 托盘底面距发动机最高点距离和升降平台高度关系计算Calculation on the Relation Between Distance from Pallet Bottom to Engine Zenith and Height of Lifter Table 19
7. 后悬装配举升装置Rear Suspension Assembly Lifting Equipment 22
7.1 伸缩套筒式升降工作台 22
7.2 剪式液压机构升降工作台Scissor Hydraulic Lifter Worktable 24
7.3 升降平台上平面到地面高度计算Calculation on the Height from the Plane of the Lifter Table to the Ground 26
8. 不一样轴距车体装配实现Body of Different Wheelbases Assembly Realization 28
9. AGV 动态装配处理方案AGV Dynamic Assembly Solution 29
10. AGV 关键设备AGV Main Equipment 29
10.1 AGV（LGV）车载控制器 AGV（LGV）Vehicle Controller 29
10.2 AGV（LGV）驱动系统AGV（LGV）Drive System 30
10.3 导航系统Navigation System 30
10.4在线自动充电系统Online Automatic Charge System 32
10.5无线局域网通讯系统 Wireless LAN Communication System 33
10.6驱动控制系统Drive Control System 34
10.7非接触防碰装置Non-contact Bumper Device 35
11. AGV安全系统AGV Safety System 35
11.1非接触防碰装置Non-contact Bumper Device 35
11.2接触式防碰装置 Contact Bumper Device 36
11.3离线保护系统 Offline Guarding System 36
11.4信息交互系统 Information Exchange System 36
11.5紧急停车系统Emergency Stop System 37
11.6多AGV避碰 Multi-AGV Collision Prevention 37
12. AGV控制台和调度管理系统AGV Console & Dispatching Management System 37
12.1 AGV控制台AGV Console 37
12.2调度管理系统Dispatching Management System 38
13. AGV车载控制系统和数据采集AGV Vehicle Control System & Data Collection 40
14. 导航线铺设Navigation Line Paving 41
15. AGV系统特点AGV System Characteristics 42
15.1 高速无线局域网建立和应用 Setup and Application of High-speed Wireless LAN 42
15.2 AGV运行灵活性Flexibility of AGV Running 43
15.3 高精度导航系统High Accuracy Navigation System 43
15.4 友好人机界面User Friendly Human Machine Interface 44
15.5 完善自诊疗系统Perfect Self-diagnosis System 44
15.6 AGV可靠性方法Measures on AGV Reliability 44
15.7 在线快速自动充电方法和快速充电电池应用Online Automatic Instant Charge Method and Application of Instant Rechargeable Battery 46
15.8 故障修复时间（MTR）Mean Time of Repair（MTR） 47
AGV系统故障修复时间有两类： There’re two kinds of MTR for AGV system: 47
15.9 平均无故障时间（MTBF）Mean Time To Failures（MTTF） 48
16. AGV运行路线图 AGV Running Route Graph 48
16.1 装配线AGV运行布局图 Assembly AGV Running Layout 48
16.2 样机车间AGV运行布局图 Sample Workshop AGV Running Layout 48
18. 环行装配线AGV系统设备清单Circular Assembly AGV System Equipment List 51
19. 项目进度Project Schedule 53
20. 培训Training 53
20.1 培训人员范围、数量立即间Scope, amount and time for training people 54
20.2 培训内容Training content 54
21. 售后服务After-sale service 55

1. 概述Summary
依据长安福特汽车南京企业发动机、前后桥AGV系统设计要求，新松企业采取装配型AGV系统进行发动机、前后桥和车身合装，含有同时动态跟踪功效AGV可实现发动机、前后桥在装配段任何工位同时装配。导航方法采取磁导航，地面施工量小，只要依据工艺要求变更磁条粘贴路径，在对控制程序稍加改动，就能够改变装配路线长短，适应不一样装配工艺要求。AGV系统由一条近似梯形环线组成，在装配段进行前悬挂/发动机、后桥和车身合装，在非装配段进行发动机、前后桥由分装线往AGV装配托盘上吊装，并可在非装配段进行部分零部件组装。依据产量及装配时间确定环线上AGV数量。
According to design requirement of Changan Ford Automobile Co., Ltd. on engine and axle AGV system, SIASUN uses assembly AGV system for engine, axle and body decking, and AGV with the function of synchronization dynamic tracking can realize simultaneous assembly of engine and axle at any assembly zone or stations. By using magnetic navigation, ground construction is small and by changing the path of magnetic strip upon technical requirements and modifying slightly control program, the length of assembly path can be altered to meet different assembly process requirements. AGV system is formed by a loop line, which is close to a trapezium. The assembly zone is used for front suspension/engine, rear axle and body decking and the non-assembly zone is used for engine and axle suspending on AGV assembly pallet through subassembly line and also for assembly of part of components. The number of AGV on the loop line is set according to output and assembly time.
整个系统包含AGV、AGV控制台、充电系统、导航系统、通讯系统、数据采集系统和装配夹具等几部分组成。
The whole system includes AGV, AGV console, charge system, navigation system, communication system, data collection system and assembly jig, etc.
2. 设计依据Design Gist
2.1 生产工艺基础要求Basic Requirement of Production Process
工位间距Distance between stations： 5，800mm
生产节拍Production rate： 最大：1分钟/辆
Max.: 1minute/vehicle
最小：5分钟/辆
Min.: 5minutes/vehicle
2.2 现场基础技术条件Basic Field Technical Condition
动力电源： 交流380±10% 50HZ±2% 3相5线
Power supply: AC 380±10% 50HZ±2% 3 phases 5 lines
温度： -5℃～45℃
Temperature: -5℃～45℃
湿度： 60—95%
Humidity: 60—95%
防护等级： IP54
Protection grade: IP54
绝缘等级： B级
Insulation level: Level B
2.3 责任范围Responsibility Scope：
1） AGV装配系统总体设计、制造。
AGV assembly system design and manufacturing.
2）AGV车体设计、制造。
AGV vehicle design and manufacturing.
3）AGV装配系统发运前调试、考机试验。
AGV assembly system debugging and trial running before delivery.
4）AGV装配系统运输、接收、搬运。
AGV assembly system transport, reception, carriage.
5）AGV控制系统设计、制造，车载控制软件、调度软件设计。
AGV control system design and manufacturing, vehicle control software, scheduler software design.
6）AGV工作环线设计、制造，地面导航线布局设计、敷设。
AGV working loop line design and manufacturing, ground navigation line layout design and laying.
7）现场安装、单机调试、全线联动调试。
Field installation, unit machine debugging and complete line linkage debugging.
8）技术培训和售后服务。
Technical training and after-sales service.
控制台
Console
充电器
Charger
3. AGV装配输送系统概述AGV Assembly & Transportation System Summary

发动机/后桥AGV装配输送系统由AGV、AGV地面导引系统、在线自动充电系统、AGV控制台、数据采集系统、AGV调度管理系统和通讯系统等组成。
Engine/rear axle AGV assembly & transportation system includes AGV, AGV ground guided system, online automatic charge system, AGV console, data collection system, AGV dispatching management system and communication system, etc.
l AGV：
AGV完成发动机或后悬挂系输送和辅助装配工作。装配人员能够站在AGV车脚踏板上进行装配作业，脚踏板采取花纹铝板制造，操作安全。
AGV conducts transportation of engine or rear suspension and assistant assembly jobs. Assembly operator can stand and work on AGV pedal, which is made of aluminum board with decorative figures and safe to operate.
l AGV地面导引系统AGV Ground Guided System：
地面导引系统是AGV运行路线和轨迹，AGV导引系统采取基于地图磁带导航方法。当工艺确定磁条埋入地下后，地面将保持平整状态，完全不影响人、车通行。
Ground guided system is AGV running path and track. AGV guided system adopts the method of magnetic tape navigation based on the map. When the process has confirmed that the magnetic strips have been embedded underground, the ground will be smooth and won’t influence people or vehicle to pass.
l 在线自动充电系统Online Automatic Charge System：
为了确保AGV 二十四小时连续运行，充电系统采取大电流快速充电方法为AGV补充电量。AGV充电过程是在控制台监控下自动进行。
To ensure AGV to run 24 hours continuously, charge system uses the method of large electrical current and instant electrification to charge AGV. AGV charge process is conducted automatically under the supervision and control of the console.
l AGV控制台和AGV调度管理系统AGV Console and AGV Dispatching Management System
控制台和AGV调度管理系统是AGV系统调度管理中心，负责数据采集系统数据处理，和上位机交换信息，生成AGV运行任务，处理多AGV之间避碰问题。
Console and AGV dispatching management system is the dispatching management center of AGV system, responsible for data processing in data collection system and information exchange with upper computer to create AGV running tasks and solve the problems of multi AGV collision.
l 通讯系统Communication System
通讯系统由无线局域网组成。AGV和控制台之间采取无线电台进行信息交换，通讯协议为TCP/IP协议。控制台可和上位机之间采取以太网进行数据传输。
Communication system is formed by wireless local network. Wireless transmitter-receiver is adopted between AGV and console to exchange information and the communication protocol is TCP/IP protocol. Ethernet is used between console and the upper computer for data transmission.
l 光电检测系统Photoelectricity Testing System
光电检测系统是用于检测主输送线吊具上车身是否运行到位，运行到位将发出信号通知处于等候站点AGV能够侧移运行，实现次序装配。假如没有车身经过，等候站点AGV一直处于等候状态。假如有车身经过，但等候站点没有AGV等候，AGV控制台将通知总控室。
Photoelectricity testing system is used to check if the body on the suspending tools of the main transmission line has run to the position, where signal will be sent to inform AGV at the waiting station to move sideways to realize sequence assembly. If the body hasn’t passed, AGV at the waiting station will stay all along in the status of waiting. If passed, but there’s no AGV waiting at the station, AGV console will notify the general control room.
4. 自动导引车AGV系统技术指标Automated Guided Vehicle AGV System Technical Specification

此图片仅供参考 This picture is for reference only

带有同时跟踪和举升机构AGV，其关键技术指标：
Main technical specifications of AGV with synchronization tracking and lifting framework include:
AGVS控制方法： 控制站集中调度、监控、管理AGV系统运行状态
AGVS control mode: control station makes centralized dispatch, monitoring & control and management on the running state of AGV system
AGV控制方法含有功效：全自动／半自动／手动
AGV control function: automatic/semi-automatic/manual
通讯方法： 无线局域网
Communication: wireless LAN
AGV导航方法： 磁导航
AGV navigation method: magnetic navigation
AGV驱动方法： 双舵轮驱动。
AGV steering: powered wheel steering
负载能力： KG（以最终设计为准）
Payload: KG (subject to final design)
AGV自重： KG（以最终设计为准）
AGV weight: KG (subject to final design)
同时跟踪精度： ±10mm
Synchronization tracking accuracy: ±10mm
运动方向： 全方位（所占用运行空间最小化）
Moving direction: Omni-directional moving(to minimize occupied running space)
最大速度： 直线60m／min，侧移30m／min
Maximum speed: straight 60m／min，sideways moving 30m／min
导航精度： ±10mm
Navigation accuracy: ±10mm
停车精度： ±10mm
Parking accuracy: ±10mm
工作时间： 二十四小时连续（三班）
Working time: 24 hours continuously (3 shifts)
防碰装置： 四面安装接触式保险杠，前后另安装激光防碰装置。
Collision prevention device: contact bumper installed around and laser collision prevention device installed in the front & back side
举升装置： 双举升机构，能够同时举升或单独举升。
Lifting equipment: dual lift framework, for synchronization lifting or separate lifting
托盘夹具： 根据实际需要设计（本方案中不含该部分内容）
Pallet fixture: design according to demands (not included in this solution)
电池组： 48V／100AH，正常使用，寿命大于3年
Battery charger: 48V／100AH, in normal usage and its longevity is over 3 years.
充电方法： 全自动充电器实现在线自动充电，确保连续二十四小时工作
Charging: automatic charger realizes online quick charge to ensure 24 hours continuous working
操作高度： 装配人员站在AGV提供脚踏板上相对静止进行零部件装配，脚踏板到地面高度200mm。
Operation height: Operator stands on AGV foot pedal to assembly parts in relative still condition and the height from the foot pedal to the ground is 200mm.
车体尺寸： 4800 mm×1800 mm×900 mm
长×宽×高(举升前)
Body dimension: 4800 mm×1800 mm×900 mm
(length×width×height (before /after lifting))
5. AGV工作过程描述AGV Working Process Description
（1） AGV小车按控制台计算机指令行驶到后桥总成上装点，由操作人员依据生产计划完成后桥总成吊装，当将后桥总成从后桥分装线吊到AGV后桥举升装置上后桥夹具上并放稳后，操作人员经过车体上操作按钮向AGV小车发出完成上件确定信号，许可AGV向下一个站点运行；
AGV will run upon console computer orders to loading point of rear axle final assembly and operator will complete this based on production plan. After the rear axle final assembly is moved from the rear axle subassembly line and placed well on the rear axle fixture of AGV rear axle lifting device, operator presses the button on the vehicle to sent signal, informing AGV that loading has been finished and allow AGV to move towards next station.
（2） AGV小车行驶到发动机总成上装点，由操作人员依据生产计划完成发动机总成吊装，当将发动机总成从发动机分装线吊到AGV发动机举升装置上发动机夹具上并放稳后，操作人员经过车体上操作按钮向AGV小车发出完成上件确定信号，许可AGV向下一个站点运行
AGV runs to loading point of engine final assembly and operator will complete engine final assembly suspending. When the engine final assembly is moved and placed well on the engine fixture of AGV engine lifting device from engine subassembly line, operator then sends confirmation signal of the completion of loading by pressing operation button on the body to inform AGV vehicle to move towards next station.
（3） AGV小车按控制计算机指令行驶到等候地点；
AGV moves to waiting place according to the order from control computer.
（4） AGV小车在某一停留时间相对长站点（动力总成上装点或其它点）进行自动充电；
AGV will charge itself automatically at one station (power train assembly loading point or other point) for relevant long waiting time.
（5） AGV控制台检测工艺链上车体位置信号，当被装车体到位后调度已载有发动机前后悬挂总成AGV按预定时间、速度进入悬链下方（时间、速度依据生产线要求可经过车载显示器进行更改），在装配段快速向前运行，在预定区域捕捉预先固定在被装车身上合作目标。保持稳定跟踪状态后，人工操作举升手控盒或脚踏开关，进行举升装置上升操作，操作人员能够同时或单独发动机举升装置和后桥举升装置。在举升装置上升同时，打开平台锁定装置，使举升装置上平台处于浮动状态，操作人员一边按上升按钮一边夹具上车身定位销插入车身工艺定位孔。当举升到安装位置，全部螺栓安装孔均已定位。由装配人员安装固定螺栓，完成装配后装配人员按一下举升装置上装配结束按钮，AGV将自动落下举升装置到零点。目前后举升装置全部复位到零点以后，AGV将加速离开装配工位，在非装配段加载站备好发动机及后桥，完成一次工作循环。
AGV console will test the signal of body position on the process chain. When loaded body has gotten to the position, AGV with engine and front & rear suspension assembly is dispatched according to set time and speed to the underneath of the suspending chain (time & speed can be changed through vehicle displayer according to requirements of the production line). Then AGV moves forward quickly in the assembly zone and captures in the prearranged area the cooperative target set in advance on the body. After tracking state is stable, manual control box or foot pedal switch is done by manual operation to raise the lifter. Operator can run simultaneously or separately the engine lifting device and rear axel lifting device. When the lifting device is raised, the lock fixture is opened to make the table floating. Operator presses the button for lifting and at the same time puts the body locating pins on the fixture into the process locating hole of the body. When getting to the installation position, all bolt installation holes are located. Then assembly workers will install the set bolts and press the button on the lifting fixture after completion of assembly. AGV will lower the lifting fixture to zero automatically. When all lifting fixtures reach zero, AGV will accelerate to leave assembly station. After equipped with engine and rear axle at loading station, AGV finishes one working cycle.
当发动机前后悬挂总成不能立即供给时，可经过设置在装配工位悬链急停开关，由人工控制，停止悬链运行。即使不按悬链急停，AGV系统也会经过控制台申请停止悬链运行。
When engine and front & rear suspension assembly can’t be supplied in time, make manual control by using emergency stop switch on the assembly station to stop suspending chain to run. Even without pressing the suspension chain emergency switch, AGV system can also apply to stop running through the console.
当AGV进入报警工位（装配工位末端）而未完成合装时，AGV将自动停止运行，AGV控制台报警并控制工艺链停线，直到完成装配后自动恢复运行。
When AGV enters into alarming station (at the end of assembly station) and hasn’t finished assembly, AGV will stop automatically and AG