AGILE1500 per la logistica · 2019. 7. 16. · Propertyof Comau -Duplicationprohibited Made in...

Made in Comau

"AGILE1500 per la logistica

dell’industria 4.0"

Giulio Scifo

Sales Account – Comau RoboticsMilano, 26 of June 2019

Made in ComauProperty of Comau - Duplication prohibited

▪ Introduction

▪ Vehicle HW architecture

▪ Vehicle SW architecture

▪ Implements

Index

2


Introduction

33

Made in Comau

Industry 4.0 is an increasingly popular term identifying a platform that unifiesinformation among participants in the entire value chain, from productinception to design, manufacturing, services and refurbishment. The endresult is a system in which all processes are integrated and information isexchanged in real time. In this ‘smart factory,’ machines and productscommunicate in real time with each other cooperatively driving production.Raw materials and machines are interconnected within an industrial ‘Internetof Things’ to support highly individualized, efficient mass production.

Autonomous vehicles as part of the platform, will provide adaptiveinterlogistic model ensuring flows optimization, just in time and just insequence production, safety improvements, warehouse management.

Abstract– Welcome Industry 4.0

4

Future challenges

• Volatile markets

• Increasing customization of products

• Built-to-order production

• Complexity of products and production processes

• short life-cycle of products

Future Needs

• Growing demands for flexibilityand reconfigurability

• Minimal use of resources

• Adaptive production system


Source: Roland Berger, 2014

Industry 4.0 is a platform that

unifies information among

participants in the entire value

chain, from product inception to

design, manufacturing, services

and refurbishment. The end result

is a system in which all processes

are integrated and information is

exchanged in real time.

5

Abstract– Welcome Industry4.0


AGV - Market forecast

* Estimated values, Source IFR

US

$ 1

,53B

US

$ 1

,61B

US

$ 1

,71B

US

$ 1

,88B

US

$

2,1

7B

US

$ 2

,33B

CAGR 40%

CAGR 13%

3410 4250 4800 5500 6100 680015515

2172130409

42573

59602

83443

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

2015 2016* 2017* 2018* 2019* 2020*

AG

V u

nit

s

AGV in NON mfgenvironment

YEARS 2015 2016* 2017* 2018* 2019* 2020*

AGV in MFG 3410 4250 4800 5500 6100 6800

AGV in NON-MFG 15515 21721 30409 42573 59602 83443

TOT 18925 25971 35209 48073 65702 90243

Market demand


1. To replace conveyors in continuously moving

and stop-and-go assembly lines

▪ Tesla uses tape-guided AGCs (Daifuku Webb) in a continuously moving assembly line in place of traditional

conveyors. Low-profile AGCs carrying the main chassis are sequenced so they move at a particular distance

apart. Seats, consoles and bumpers are installed as AGCs transport this work-in-process car down the

assembly line.Carts like these are also being used to assemble riding

lawn mowers at John Deere.

▪ AGCs in assembly lines offer flexibility. If production

needs to increase by 30%, it can simply increase the number of carts by 30%.

2. For lineside delivery of parts

▪ Many operations are creating kits and pre-assembling

components in another part of the plant and delivering these kits and components directly to the assembly line,

also known as “lineside delivery”.

3. As a personal assistant to the assembler

▪ As the worker is assembling Part A at Location 1, the

robot is already moving Part 2 to Location 2

4. To connect islands of automation

▪ Tape-free, target-free AGVs are especially suited for automatically moving

material through high-traffic main aisles notorious for wearing down magnetic tape.

5. For storage and retrieval applications

6. Use for picking

7. For automatic truck loading (and unloading)

7 ways AGV are being deployed today


Top 5 ways AGVS improve manufacturing

1. Reduce Costs

▪ Labor costs

▪ Product and building damage

▪ Quick, easy and cost-effective installation versus

conveyors

2. Ultimate Flexibility

▪ Easy modification of guide-path

▪ Change carriers to accommodate future product changes

▪ Scalable – add or subtract vehicles to change capacity

▪ Fast opportunity charging allows vehicles charge in process

3. Improve Safety and Ergonomics

▪ Less accidents versus fork trucks

4. Reduce Floor Space

▪ Less floor space required than conveyors

▪ No fixed assets required by conveyors

▪ Guide-path does not impede other traffic

▪ Customize guide-path

5. Increase Productivity and Efficiency and

Reliability

▪ AGVs operate as independent carriers versus conveyors

▪ Reduces cycle time

▪ Integrates easily with other equipment and management

systems

▪ Lean manufacturing goals are easier to achieve

▪ If an AGV broke, it can be simply substitute


Index

9

▪ Introduction

▪ AGILE1500 HW architecture

▪ AGILE1500 SW architecture

▪ Implements


AGILE1500 Rel 1

10


Vehicle architecture

11

Main characteristics of vehicle:

▪ Max payload 1500 kg

▪ Max speed forward 1700 mm/s

▪ Max backward speed 1000 mm/s

▪ Multinavigation

▪ Double laser scanner

▪ Automatic charging station

▪ Differential vehicle: 2 driving wheel on back and

1 caster wheel in front of vehicle

▪ Multipurpose with implement concept


Agile1500 rel.1 - Specifications

33

0

mm


Agile 1500 rel.1 – vehicle architecture

DRIVING

WHEELDRIVING

WHEEL

CASTER

WHEEL

Layout

• 1 caster wheel on the front of the vehicle

• 2 driving motor wheels on the rear of the vehicle

Motion capability

• Forward: dependent from navigation

natural / reflector : up to 1700 mm/s

magnetic spot: up to 1200 mm/s

• Backward: up to 1000 mm/s

• Rotation on the spot: possible, respect to the point given by the intersection of motor wheels

rotation axis and longitudinal vehicle axis

• Crabbing functionality: not possible


Laser scanner – S300 expert (S30B-3011GB)

14

The laser scanner is a S300 expert model.

The main characteristics of this laser scanner are:

- 16 field set;

- Field set dinamic change according to speed (see Tips&Tricks

section for more details);

- Safety area (red area), the vehicle stops with slowdown slope 1500

mm/s 2̂ (CAT1);

- Warning area (yellow area), the vehicle slowdowns to 300 mm/s

speed with slowdown slope 400 mm/s 2̂;


Laser scanner speed routing → SW_2.0.0

15

The laser scanner field sets are changed

dinamically according to speed.

In table aside there is an example of monitoring

cases, but speed and Input are freely

configurable.

Pay attention the measuring unit is cm/s and

NOT mm/s.

If SegmentTriggerBit0 and/or

SegmentTriggerBit6 are flagged on segment

where vehicle is driving, the Input A and/or B are

enabled (set them to 0 if not used in layout).

Set all the cases till the max speed the vehicle

will drive.

Max backward speed is 1000mm/s.

Put an additional 100mm/s to maximum speed to

compensate speed oscillation.

Inputs Velocity [cm/s]

Name A B from to Field set

CaseNegative 0 0 -110 -11Negative

Case300mm/s 0 0 -10 30 300

Case500mm/s 0 0 31 50 500

Case1000mm/s 0 0 51 100 1000

Case1250mm/s 0 0 101 125 1250

Case1500mm/s 0 0 126 150 1500

Case1700mm/s 0 0 150 180 1700

Same laser scanner configuration method for

additional implement laser scanner if signal routing is

done on implement safe.

AGV v2 – same rear laser scanner configuration

method (remember the speed should be negative).


Agile1500 rel.1 – Free path , no obstacleV

[m

/s]

t [s]

Max_Acc := 400 m/s^2Dec := 400 m/s^2

Max_Speed

Product Development working on

possibility to change Deceleration

in normal working environment


Agile1500 rel.1 – Warning fieldV

[m

/s]

t [s]

Max_Acc := 400 m/s^2

Dec := 400 m/s^2

Max_Speed

SlowDown_Speed := 250 m/s

Deceleration due to laser scanner warning field

is fixed and the AGV slows down to a fixed

speed until area is engagedObstacle


Power supply and battery pack - Lithium

18

1

1. Manual charging: the Anderson connector on

the vehicle allows to manually connect the

battery charger;

2

2. Automatic charging: lateral

charging contacts allow

automatic recharge and

opportunity charging;

Standard cable 3m


Index

19

▪ Introduction



▪ Implements


Kollmorgen suite

There are different SW categories

• Application Engineer Toolkit – the package “Application Engineering Toolkit” includes all the tools necessary to design, build, survey, diagnose, and maintain an application - A single license has an annual fee.

• Systems SW – these SW packages are needed to make the application run: 1 AGV system = 1 license (up to 100 vehicles)

For System Integrator

Annual fee license

Every AGV system needs these 2

licenses - One shot fee


Index

21

▪ Introduction



▪ Implements


The CAN software module is a CANopen master that

performs guarding of all slave CAN nodes and

supervision of some vital internal resources, typically

output values for steer and drive.

If the CAN software module encounters an error it will

enter safe state and communicate to the Supervisor

module to open the vehicle controller AllOK relay (the

Safe plc will CAT0 the vehicle).

In the CANopen network, CVC600 is the master node 1

and the SDIO module in CVC600 is node 2. The

OPT100 is node 3 and the two drives are node 5 and 7.

The SAFE plc is node 20. BMS node is 23.

Implement: CANopen

22

CPUCVC 600

HMIOPT100

SAFE

PLC

BMSTerminal resistor

OR

Node #: Implement

Drive Drive

Node 1: Master

Node 2: SDIO

Node 3: OPT100

Node 5: ACS Node 7: ACS

Node 20: Safe plc

Node 23: Lithium BMS


Implement examples

23

Lifter

Power Roller BedPower Roller Bed

Tow

MASS

Cart


Agile1500 & Implements

24

Lifter400 + ConveyorLifting/roller payload: 400 kg

Lifting positions: from 0 to 400mm

Max lifting time:10 sec

Dimensions (LxWxH): 1500x800x200 mm

Conveyor platedimensions (LxW): 600x600 mm

Made in ComauProperty of Comau - Duplication prohibited 25

Lifter1200Lifting payload: 1200kg

Lifting positions (low / high): 0 / 80mm

Lifting time: 8sec

Dimensions (LxWxH): 1300x800x150mm

Universal upper plate height: 510mm from the floor

Agile1500 & Implements

Made in ComauProperty of Comau - Duplication prohibited 26

Features

• Compact design

• Fully electric (low maintenance required)

• Easy to use

• IoT ready

• High performance (speed, payload and stroke)

• Best in class performance (high payload)

Benefits

• Fully integrated with base vehicle

• Applicable inmanual andautomaticassembly lines, stop & go and continuous movement

• Suitable for pallet exchange logistics application (with conveyor systems)

Made in Comau

Via Rivalta, 30 - 10095 Grugliasco - Torino ITALY - www.comau.com

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