沈陽新松-長安南京AGV裝配線技術(shù)方案

1、長安福特汽車有限公司南京公司 ChanganFord Automobile Co., Ltd. Nanjing Company 發(fā)動機、前后橋AGV系統(tǒng) Engine Test ing for body into positi on, which is to test the positi on of the vehicle to be assembled on the chassis assembly line in order to provide running con trol data for AGV tran sportati on system. 2、 工藝鏈運行檢測和控制，主要

2、檢測工藝鏈運行狀態(tài)，同時根據(jù)工藝鏈運行 狀態(tài)控制AGV的運行狀態(tài)確保 AGV系統(tǒng)在運行過程中的安全性，根據(jù) AGV的 運行狀態(tài)，一旦AGV發(fā)生故障或其他原因造成 AGV停車，控制工藝鏈的停止運 行，防止對設(shè)備或工件的損壞； Testi ng and con trolli ng the running of the process cha in, which is mai nly to test the running state of the process chain and at the same time control AGV running state to ensure the s

3、afety of AGV system in its running course. According to AGV running state, once AGV malfunction happens or AGV stops running due to other reasons,it shall con trol the process cha in to stop running in order to preve nt damage to equipme nt or workpiece. 3、 充電器工作狀態(tài)的檢測，檢測充電器的工作狀態(tài)，保證AGV正常充電。 Testi ng

4、the worki ng state of the charger, which is to test charger worki ng state to en sure AGV no rmal charge. 14. 導(dǎo)航線的鋪設(shè) Navigation Line Paving AGV地面導(dǎo)航線有兩種鋪設(shè)方式，一種為鋪設(shè)在地面上的，導(dǎo)航線由長 500mm寬50mm厚度為1mm的磁性橡膠鋪設(shè)而成，由于該方式更改性較好，此鋪 設(shè)方式一般采用在裝配工藝路線未完全確定時；另外一種方式為埋于地下，導(dǎo)航 磁條由長1000mm寬10mm厚度為15mm的磁性橡膠組成，此種方法一般在裝配 工藝確定后實施。 Th

5、ere are two methods for AGV ground navigation line paving. One is to pave on the ground. The navigation line is made of magnetic rubber of 500mm length, 50mm width and 1mm thick ness. This method is easy to cha nge and gen erally used whe n the assembly process path cant be con firmed completely. Th

6、e other method is to pave under the ground. The navigation magnetic strip is made of magnetic rubber of 1000mm length, 10mm width and 1mm thickness. This method is used when the assembly process has bee n con firmed. 埋于地下的導(dǎo)航線剖面圖 15. AGV 系統(tǒng)特點 AGV System Characteristics 15.1 高速無線局域網(wǎng)的建立和應(yīng)用 Setup and Ap

7、plication of High-speed Wireless LAN AGV系統(tǒng)采用工業(yè)級的無線通信模塊，建立高速無線局域網(wǎng)，通信速率可以達 到3-54Mbps,明顯優(yōu)于無線串行通訊的 K級通訊速率。在高速無線局域網(wǎng)通信系 統(tǒng)支持下，AGV系統(tǒng)可以很好的實現(xiàn)多臺 AGV多種任務(wù)、復(fù)雜地圖避碰調(diào)度和任 務(wù)調(diào)度，極大地提高了 AGV系統(tǒng)的監(jiān)控能力。 AGV system adopts in dustrial wireless com muni cati on module and set up high-speed wireless LAN with the com muni cati on

8、speed reachi ng 3-54Mbps, surpass ing largely the K level com muni cati on speed of the wireless serial commun icatio n. With the support of high-speed wireless LAN com muni cati on system, AGV system can realize the running of multi-AGVs and many kinds of tasks as well as collisi on preve nti on di

9、spatchi ng and tasks dispatch ing with complex map, which has largely improved AGV system mon itori ng and con trol. AGV系統(tǒng)的通信能力的提高，為系統(tǒng)帶來的好處是明顯的。 The improveme nt of AGV system com muni cati on has appare nt adva ntages for the system. 1）提高了控制臺對AGV的控制效率。 Improvi ng con sole con trol efficie ncy on AG

10、V. 2）控制臺可以更快的獲得各臺 AGV的運行狀態(tài)，提高了對 AGV故障處理的及 時性。 The con sole can get the running state of each AGV quickly, thus improve timeli ness of AGV malf unction disposal. 3）可以由控制臺對AGV進行避碰調(diào)度，任務(wù)調(diào)度。 Can use the con sole to make dispatch for collisio n preve ntio n and task dispatch to AGV 4) 控制臺顯示AGV勺位置更準(zhǔn)確。 The

11、con sole displays AGV positi on more accurately. 5) 大大增加了 AGV系統(tǒng)運行的可靠性。 Increasing largely the reliability of AGV system running 15.2 AGV 運行的靈活性 Flexibility of AGV Running 1) AGV勺導(dǎo)航方式為磁導(dǎo)航，運行的軌跡可通過軟件和更改磁條的粘貼位 置來修改，使裝配的路線更為柔性。 AGV uses magn etic n avigatio n method. Its running track can be ame nded th

12、rough software and by changing the paste position of the magnetic strip in order to make the assembly path more flexible. 2) AG訕控制臺集中調(diào)度管理，線上 AGV數(shù)量可根據(jù)使用情況自由增減， agvB現(xiàn)故障可撤離裝配線維護縮短停線時間。 AGV is dispatched and man aged by the con sole. The nu mber of AGV on the line can be added or reduced freely accord i

13、ng to usage. Whe n AGV has malfunction, it can leave the assembly line for maintenance and save break time of the producti on line. 15.3 高精度導(dǎo)航系統(tǒng) High Accuracy Navigation System AGV系統(tǒng)采用磁導(dǎo)航傳感器可以獲得位置控制精度：10mm AGV system adopts magn etic n avigati on sen sor to reach positi on con trol accuracy: 10mm. A

14、GV系統(tǒng)采用磁地標(biāo)傳感器控制停車，可以獲得停車位置控制精度：10mm AGV system uses magnetic land mark sensor to control vehicle to stop and get the stop positi on con trol accuracy: 10mm. AGV系統(tǒng)采用基于PSD原理的跟蹤傳感器，可以同步跟蹤車身運行跟蹤精度可 達到10mm AGV system adopts tracking sensor based on PSD principle to realize synchroni zati on track ing of t

15、he body moving and get track ing accuracy: 10mm. 15.4 友好的人機界面 User Frie ndly Human Machi ne In terface 1. 方便的全中文菜單，提供豐富的操作內(nèi)容； Provid ing convenient Chin ese menu, and abundant operatio n contents 2. 顯示器和操作面板可以提示操作步驟，AGV工作狀態(tài)，故障信息。 Display and operation panel can give clue on operation steps, AGV work

16、ing state and malf unction in formati on. 3. 可以通過顯示和操作面板設(shè)定系統(tǒng)參數(shù)，修改系統(tǒng)參數(shù)。 Sett ing and ame nding system parameters through display and operatio n panel 4. 可以通過顯示和操作面板設(shè)定工作參數(shù)，修改工作參數(shù)。 Sett ing and ame nding work ing parameters through display and operati on pan el. 15.5 完善的自診斷系統(tǒng) Perfect Self-diagnosis Sys

17、tem AGV車載控制器軟件和硬件的設(shè)計提供了完善的AGV系統(tǒng)自檢測、自診斷、自 保護能力。 The desig n of AGV vehicle con troller software and hardware has provided it with perfect fun cti ons of AGV system self-test ing, self-diag no sis and self-protecti on. 15.6 AGV 可靠性措施 Measures on AGV Reliability 新松公司從八十年代初就開始進行移動機器人和自動導(dǎo)引車AGV的研究和軟 件開發(fā)，在

18、系統(tǒng)設(shè)計和軟件開發(fā)方面積累了豐富的經(jīng)驗。九十年代新松公司首次 將AGV用于汽車裝配行業(yè)-沈陽華晨金杯汽車公司，在此基礎(chǔ)上新松公司不斷完善 裝配型AGV的功能及應(yīng)用，到目前為止新松公司與國內(nèi)大多數(shù)汽車廠簽訂了裝配 型AGV的合同，至2005年底新松公司共生產(chǎn)用于汽車裝配的AGV近 100臺。 From the early 1980s, SIASUN has begu n research and software developme nt on moving robot and automated guided vehicle (AGV) and has accumulated abundant

19、 experie nee on system desig n and software developme nt. In the 1990s, SIASUN applies AGV in automobile assembly industry for Shenyang Brilliance Jinbei Automobile Co., Ltd. for the first time. Based on this, SIASUN makes continuous efforts to perfect the fun cti on and applicati on of the assembly

20、 AGV. By now, SIASUN has sig ned con tract of assembly AGV with most of domestic automotive manu facturers and by the end of 2005, SIASUN has produced about 100 AGVs used for automotive assemble. 考慮到當(dāng)前國內(nèi)的實際情況，為提高AGV系統(tǒng)的可靠性，AGVt使用的主要零、 部件全部是從國外著名公司購買的。例如，磁導(dǎo)航傳感器，帶有直流伺服電機、 抱閘、編碼器、測速機的驅(qū)動輪總成，充電連接器，伺服電機放大器

21、，開關(guān)，繼 電器，無線通訊模塊，控制計算機等。 Considering the current situation in China and for the purpose of improving AGV system reliability, the main comp onents used on AGV are purchased from intern ati onal famous company. For example, the magnetic navigation sensor, DC servo motor, holding brake, coder, driving w

22、heel assembly of the tachometer, charge linker, servo motor amplifier, switch, relay, wireless com muni cati on module and con trol computer, etc. 新松公司的AGV具有多種工作模式，提供自動運行方式、離線運行方式及手 動運行方式，可在各種情況下滿足生產(chǎn)的需要，提高整個系統(tǒng)的可用性。其中離 線運行方式是讓AGV兌離AGV空制臺的調(diào)度，AGV按地圖及內(nèi)部預(yù)定程序進行半自 動運行的方式，可用于系統(tǒng)調(diào)試及 AGV控制臺停電時的緊急生產(chǎn)。 SIASUN AGV

23、 has man ifold worki ng modes and provides automatic, offli ne and manual running methods to meet product ion n eeds un der differe nt circumsta nces in order to improve the usability of the whole system. Among them, offline running method is to let AGV break away from the dispatch of the con sole a

24、nd move semi-automatically according to the map and internal preset program. This can be used for system debuggi ng and emerge ncy producti on whe n AGV con sole is in the situati on of power cut. AGV使用的是48V電池組，正常情況下 AGV每個工作循環(huán)只消耗4鳩下的電 量，因而即使主電源停電，AGV仍能以其剩余電容量繼續(xù)運行一段時間，另在AGV 控制臺中用戶可安裝相應(yīng)容量的 UPS使AGV控制臺在

25、主電源停電的情況下也可以 繼續(xù)運行一段時間，且 AGV控制臺中的UPS我們選擇的是在線式的產(chǎn)品，也可有 效地濾除外網(wǎng)電源的波動，保證整個系統(tǒng)的穩(wěn)定運行。 AGV uses 48V battery charger. In normal circumstanee, AGV only consumes electricity of less tha n 4% in every work ing cycle, so eve n the main power supply is cut off, AGV can continue to run with the rest of electricity f

26、or a period of time. Besides, user can in stall UPS of releva nt capacity in the AGV con sole to en able AGV to run continuously for a period of time when the main power supply is cut off. Moreover, we choose on li ne products for the UPS of the AGV con sole and can filter out effectively the fluctu

27、ation of electrical source in the external network to ensure stable running of the whole system. 15.7在線快速自動充電方法和快速充電電池的應(yīng)用Online Automatic Instant Charge Method and Applicati on of In sta nt Rechargeable Battery 采用可以快速充電的堿性電池，充電電流可以大于放電電流的數(shù)十倍，這樣 在系統(tǒng)設(shè)計時就可以采用大電流充電，以很短的充電時間補充電池容量，獲得相 對長的工作時間?，F(xiàn)在系統(tǒng)設(shè)計的充電時間

28、和放電時間之比為1: 6，即電池工作 時間為充電時間的6倍。AGV能夠自動檢測電池容量的狀態(tài)，在需要的時候，通過 控制臺的管理，完成電池容量的補充，實現(xiàn)了在線快速自動充電技術(shù)。 We use in sta nt rechargeablealkali ne battery. The charge curre nt can be several tens of the current used, thus when designing the system, we can adopt large electricity for charge so that we can make up batte

29、ry capacity in a very short charging time and get relative long working time. The current rate of charging time versus using time in system design is 1:6, i.e. battery working time is 6 times of charging time. AGV can test automatically the state of battery capacity, and finish the suppleme nt of ba

30、ttery capacity through the man ageme nt of the con sole whe n n eeded to realize on li ne automatic in sta nt charge tech no logy. 在每個循環(huán)中，AGV勺耗電量是電池容量的10% AGVt池基本是工作在浮充 狀態(tài)或淺度放電狀態(tài)，所以保證電池的使用壽命3年以上。（長馬這次要5年） In each cycle, AGV consumption of power supply is only 10% of the battery capacity. The AGV bat

31、tery is in the basic working state of floating charge or light discharge, thus en suri ng the battery Ion gevity to be over 3 years. 如果在節(jié)假日放假時間較長的情況下，AGV電池有少量的自放電，正常情況 下AGV運行幾個循環(huán)就可以將自放電的能量補充上來。保險起見可以在放假前將 AGV的供電保險絲拔掉。 During the holidays, AGV battery will have small amount of self-discharge. Normall

32、y, AGV will make up for these energies after running for several cycles. To en sure the safety, the power supply fuze can be pulled out before holiday. 這種設(shè)計的優(yōu)點是明顯的，AGV系統(tǒng)可以連續(xù)三班生產(chǎn)。在連續(xù)三班生產(chǎn)的 情況下，不用增加AGV充電機和電池的數(shù)量。 The adva ntage of the desig n is appare nt. AGV system can work con ti nu ously for 3 shift

33、s without in crease the nu mber of AGV, charger or battery. 在電池的使用過程中，會有一定的記憶效應(yīng)，可以通過電池活化裝置定期（正 常6個月）活化，消除記憶效應(yīng)。在該項目中，新松公司贈送一套電池活化裝置。 In the course of battery usage, there will be certain memory effect, which can be activated periodically （no rmally 6 mon ths） through battery activati on fixture for e

34、limination. In this project, SIASUN will present one set of battery activation fixture for free. 15.8 故障修復(fù)時間（MTR Mean Time of Repair （MTR） AGV 系統(tǒng)的故障修復(fù)時間有兩類：There e two ki nds of MTR for AGV system: 系統(tǒng)的修復(fù)時間System MTR 部件的修復(fù)時間 Compo nent MTR 系統(tǒng)的修復(fù)時間：System MTR 系統(tǒng)的修復(fù)時間是指在整個系統(tǒng)中一臺 AGV出現(xiàn)故障，AGVF線修復(fù)，系統(tǒng)恢 復(fù)正常運

35、行的停頓時間，這個時間通常為 35分鐘。實際上通過多AGV勺組合提 高了系統(tǒng)運行的可靠性，出現(xiàn)故障也不影響整條生產(chǎn)線的運行。 System MTR means the pause time for the system to recover no rmal running whe n in the whole system there is one AGV has malfunction and must be removed from the line for repair. Usually the time is 3-5 minu tes. In fact, by comb in ati

36、on of multi-AGVs, system-running reliability is improved and the whole production line will not be in flue need due to malf unction. 部件的修復(fù)時間：Compo nent MTR 主要有以下兩點 Ma in ly in cludi ng the followi ng two aspects: 1）對于局限于各類功能單元內(nèi)的故障 （指可以快速插拔的功能單元），在確 認故障后應(yīng)能在530分鐘內(nèi)更換功能模塊并恢復(fù)運行。 此次長馬：故障重大故 障（故障時間超過20分鐘），

37、每6月小于一次 In terms of the malfunction localized in each function cell （means the fast plug in and out fun cti on cell）, the function module can be replaced and recovered for running within 5-30 minutes after confirmation of malfunction. 2）對于拆裝重大部件，如驅(qū)動電機、車輪等應(yīng)能在12小時內(nèi)完成。 In terms of removing and installi

38、ng important parts, such as driving motor andwheels, etc, can be fini shed with in 1-2 hours. 15.9 平均無故障時間(MTBF Mean Time To Failures (MTTF ) 除了正常的維護和保養(yǎng)以外，AGV勺平均無故障時間是4000小時。 Besides no rmal maintenance and care, AGV MTTF is 4000 hours. 16. AGV 運行路線圖 AGV Running Route Graph 雙舉升裝配型AGV為全方位移動輪系結(jié)構(gòu)設(shè)計，實現(xiàn)了

39、所占運行空間最小化。 Dual lift assembly AGV is designed with the structure of omni-directional moving wheels to realize mini mizatio n of occupied running space. 16.1 裝配線 AGV運行布局圖 Assembly AGV Running Layout LES ii. a 0 ffTtm tltfM,股血觀曲CH斛乩機劌說女 UCh ton 16.2 樣機車間 AGV運行布局圖 Sample Workshop AGV Running Layout 本圖為

40、樣機車間用AGV勺運行路線圖(假想情況)。具體情況可以根據(jù)用戶的 實際情況進行具體設(shè)計。 The picture shows the running route (in hypothesis) of the sample workshop AGV. It can be desig ned specifically upon custome requireme nt and actual situati on. 本方案設(shè)計配備AGV一臺、一臺充電器，不需要控制臺。 This plan design has included one AGV and one charger and has no n

41、eed for con sole. AGV運行采用離線自動運行方式(在 AGV操作面板上菜單選擇方式操作)。 AGV running adopts the method of offline automatic moving (operation through maki ng choice on the menu of AGV operatio n pan el). wcaaaasi J 話1邛咖仙性科徑耐整lam、. a k嗨師刖 齦irnet稅湖嶄 n n i i 1.i- o * t J XL R前 f.: l-j T tfb tlii 11 N 9 15 # tl * M In申 1

42、( 17.雙舉升 AGV 應(yīng)用實例 Dual Lift AGV Application Case 新松公司自開發(fā)裝配型雙舉升 AGV以來，深受廣大用戶的青睞，新松公司 在廣大用戶的熱心幫助下不斷完善自己的產(chǎn)品，現(xiàn)在裝配型雙舉升AGV各方面技 術(shù)更成熟，功能更全面。 Since SIASUN develops by itself the assembly dual lift AGV, the product is welcome among customers. With the help of its vast customers, SIASUN has made continuous eff

43、orts to perfect their products and now each technical aspects of the assembly dual lift AGV is more mature and the fun cti on is much more complete. 裝配型雙舉升AGV應(yīng)用廠家舉例： Examples of assembly dual lift AGV applicati on users: 長春一汽轎車股份有限：9臺 Cha ngchun FAW Car Co., Ltd.: 9 sets 上汽奇瑞汽車股份有限公司：一總裝 5臺，二總裝12臺 S

44、AIC Chery Automobile Co., Ltd.: 1st phase: 5 sets for final assembly 2nd phase: 12 sets for final assembly 海南馬自達汽車有限公司：一期 3臺，二期4臺 Hainan Mazda Automobile Co., Ltd.: st 1 phase: 3 sets for final assembly 2nd phase: 4 sets for final assembly 上海通用北盛公司：6臺 Shan ghai GE Beishe ng Compa ny: 6 sets 中順汽車股份有限

45、公司：3臺 Zhon gsh un Automobile Co., Ltd.: 3 sets 長豐獵豹汽車股份有限公司：3臺 Changfeng Leopard Automobile Co., Ltd.: 3 sets 長安福特汽車有限公司：一期5臺，二期6臺 ChanganFord Automobile Co., Ltd.: 1st phase: 5 sets 2nd phase: 6 sets 安徽江淮汽車有限公司：7臺 An hui Jia nghuai Automobile Co., Ltd.: 7 sets 長春一汽 AGVS Cha ngchun FAW AGVS 奇瑞 B11 生

46、產(chǎn)線 AGVS Cherry B11 Production Line AGVS 18.環(huán)行裝配線AGV系統(tǒng)設(shè)備清單Circular Assembly AGV System Equipme nt List 設(shè)備清單 Equipment List 序號 Serial No. 名稱及型號 Name & Type 數(shù)量 Qua ntity 單位 Un it 備注 Remark 1 AGV 8 臺 Un it 驅(qū)動輪、傳感器、電臺為 原裝進口 Driving wheel, sensor & tran smitter-receiver are imported 2 控制臺 Con sole 1 臺 Un

47、it 3 充電器 Charger 3 臺 Un it 新松公司 SIASUN 4 地面充電連接器 Ground charge lin ker 3 塊 Block 進口 Import 5 地面磁導(dǎo)航系統(tǒng) Groundmagn etic n avigati on system 1 套 Set 新松公司 SIASUN 資料清單Material List 序號 Serial No. 名稱及型號 Name & Type 數(shù)量 Qua ntity 單位 Un it 備注 Remark 1 AGV使用說明書 AGV operatio n in structi on 3 本 Book 2 AGV維護說明書 A

48、GVmaintenance in structi on 3 本 Book 3 控制臺使用說明書 Con soleoperati on in structi on 3 本 Book 4 充電器使用說明書 Chargeroperati on in structi on 3 本 Book 5 AGV電器接線圖 AGV electrical applianee wiri ng diagram 3 本 Book 6 控制臺電器接線圖 Con sole electrical applia nee wiri ng diagram 3 本 Book 7 AGV軟件備份光盤 AGV software copy

49、disk 1 張 Disk 8 控制臺軟件備份光盤 Con sole software copy disk 1 張 Disk 9 易損件備件清單 Spare part list for easily 1 套 Set damaged comp onents 19.項目進度 Project Schedule 工期：合同啟動后6.0個月，具體時間計劃如下表所示： Time limit: 6.0 mon ths after con tract startup. Detailed time pla ns are show n in the following table: 序號 Serial No. 項

50、目內(nèi)容 Project Content 時間計劃 Time Pla n 地點 Place 備注 Remark 1 機械、電控設(shè)計、圖紙 會簽 Meet ing for sig nature on mecha ni cal and electrical con trol desig n and draw ings 合同啟動1.5月之內(nèi) 1. 5 mon ths within con tract startup 沈陽 Shenyang 2 機械、電氣加工、外購 件采購 Mach in ery,electric process ing & comp onent purchas ing 合同啟動4.5

51、月之內(nèi) 4.5 mon ths within con tract startup 沈陽 Shenyang 3 安裝調(diào)試 Installation and Debugg ing 合同啟動5.5月之內(nèi) 5.5 mon ths within con tract startup 沈陽 Shenyang 4 考機、預(yù)驗收、發(fā)運場 調(diào)試 Trial running, pre-check ing and field debuggi ng 合同啟動6.0月之內(nèi) 6.0 mon ths within con tract startup 沈陽 Shenyang 預(yù)驗收 Pre-check ing 20.培訓(xùn) Tr

52、aining 鑒于甲方發(fā)動機及后橋裝配生產(chǎn)線是 AG的系統(tǒng)應(yīng)用工程，乙方將在系統(tǒng)調(diào) 試、設(shè)備運行和現(xiàn)場維護等方面對甲方的人員進行詳細的培訓(xùn) As engine and rear axle assembly production line of Party A is AGV system application engineering, Party B will provide detailed training on Party A persons in the aspects of system debugg ing, equipme nt running and field mainten

53、an ce, etc. 20.1 培訓(xùn)人員的范圍、數(shù)量及時間 Scope, amou nt and time for trai ning people 1） 設(shè)備管理人員：12人，時間2天 Equipme nt man ager:2 pers ons, 2 days 2） 電器維修工程師：12人，時間57天 Electricia n: 1 2 pers ons,7 days 3） 機械維修工程師：12人，時間57天 Mach ini st: 1 2 pers ons, 5- 7 days 4）現(xiàn)場操作人員：23人，時間35天 Field operator: 2 3 persons, 35 days 20.2 培訓(xùn)的內(nèi)容 Training content 1）經(jīng)過培訓(xùn)的維修工程是應(yīng)具備正確使用各類檢查設(shè)備，準(zhǔn)確判斷故障部 位的能力，對于局限在各功能模塊的故障應(yīng)能在規(guī)定的時間內(nèi)排除。因此，維修 工程是應(yīng)在培訓(xùn)后掌握 AGV控制系統(tǒng)的結(jié)構(gòu)，各功能單元的關(guān)系，主要測試點的 測量方法、技術(shù)指標(biāo)。 After trai