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About this product

Bosch Rexroth AG, ActiveShuttle: ActiveShuttle 1.0, 3 842 560 593/2020-07

Fig. 3: 

560 592-03

E

C

D

B

A

Handheld controller 1.0

A:

Emergency stop 
device, rotary release

B:

Color display

C:

Joystick for 
controlling the 
ActiveShuttle in the 
"Manual" operating 
mode

D:

Membrane keypad:

E:

Enabling switch 
3-stage
-  Stage 1: Not 

actuated, OFF

-  Stage 2: Approval, 

ON

-  Stage 3: Panic 

function, OFF 
(ActiveShuttle is 
shut down)

+/–

Speed ±

Lifting the loading 
area

Lowering the loading 
area

Source position

Dip position

Charging station 
position

Parking position

Summary of Contents for 3 842 560 101

Page 1: ...Operating manual 3 842 560 593 2020 07 Replaces 2020 02 ENGLISH ActiveShuttle 1 0 Transport vehicle 3 842 560 431 3 842 560 106 3 842 560 422 3 842 560 101 ENGLISH ...

Page 2: ...ador en la parte superior derecha en Search introduzca 3 842 560 596 a continuación haga clic en Search PT O presente manual de montagem está disponível nos idiomas aqui indicados Demais idiomas sob consulta Como versão impressa ou o arquivo PDF para download no diretório de mídias www boschrexroth com mediadirectory Insira a máscara de pesquisa parte superior direita em Search 3 842 560 597 e cli...

Page 3: ...l operation 17 2 9 2 Logistics employees 17 2 9 3 Logistics planner 17 3 General notes on property and product damage 18 4 Scope of delivery 19 4 1 Condition on delivery 19 5 About this product 19 5 1 Specifications 19 5 1 1 Use 19 5 2 Product description 20 5 3 Safety and warning devices 25 5 3 1 Signaling 26 5 3 2 Protective fields 27 5 3 3 Reference to limits of the personal protection system 27 ...

Page 4: ...o reduce wear 51 9 1 7 Environmental factors 51 10 Maintenance and repair 52 10 1 Cleaning and care 52 10 2 Regular safety inspections 52 10 2 1 Periodic inspection minimum requirements 53 10 3 Procedure for testing the personal protection systems laser scanner 54 10 3 1 Checking the basic function of the personal protection systems laser scanner 54 10 3 2 Checking the areas to be protected 54 10 ...

Page 5: ... Required and supplementary documentation Title Document number Document type General safety instructions for the electrical installation of MPS components 1 3 842 358 820 Employee safety training 1 3 842 527 147 Handheld Controller 1 0 2 Manufacturer documentation Manual Battery Safety Instructions 3 Manufacturer documentation 1 If not included in the scope of delivery download from the media dir...

Page 6: ...rd Meaning DANGER Indicates a hazardous situation that will result in severe injury or death if not avoided WARNING Indicates a hazardous situation that may result in severe injury or death if not avoided CAUTION Indicates a hazardous situation that may result in minor to moderate injury if not avoided NOTICE Property damage The product or the surrounding area could get damaged 1 3 2 Symbols The f...

Page 7: ...lude them when giving the product to a third party 2 2 Intended use ActiveShuttle 1 0 The product is a complete machine You may use the product as follows For automated material transport in production with operator defined driving ranges Loading sources and unloading points dips Speeds in areas used jointly with passenger traffic For the transport of KLTs stacked on approved dollies see chapter 8 5...

Page 8: ...the relevant regulations pertaining to the work being performed Qualified personnel must comply with the relevant technical regulations and have the necessary expertise Bosch Rexroth offers training support for specialized fields You can find an overview of the training content online at http www boschrexroth de didactic 2 5 General safety instructions As owner please note the following before the in...

Page 9: ...following tasks within the scope of the product s intended use Starting or operating the system or interfering with its normal operation Operating component or part adjusters Only allow people to be in the immediate vicinity of the product when it is operating if they are authorized by the owner to be there This also applies when the product is idle Do not use EMERGENCY STOP controls for routine s...

Page 10: ...ndividual components inside the housing may heat up Wait a reasonable time before opening the housing Personal injury when staying in the driving range especially in curve areas Risk of serious injury from collision with the ActiveShuttle If possible do not stay within the driving range of the ActiveShuttle Restrict passenger traffic within the ActiveShuttle s driving range as much as possible Alwa...

Page 11: ... incorrect loading condition Risk of serious injury due to incorrect loading condition when changing to the Automatic operating mode After manual loading no change to the Automatic operating mode is permitted Danger due to limited safety functions in the Manual operating mode Risk of serious injury from incorrect operation In the Manual operating mode the ActiveShuttle may only be operated by spec...

Page 12: ...able solvent Never use dropped or damaged batteries Do not use defective or damaged lithium ion batteries Do not use lithium ion batteries with a defective connection cable or defective contacts To charge the lithium ion battery in the ActiveShuttle use only the charging station supplied by Bosch Rexroth or the charger supplied by Bosch Rexroth Only operate lithium ion batteries and accessories in...

Page 13: ...he operating manual of the manufacturer BMZ Battery Assembly Centre GmbH Am Sportplatz 28 63791 Karlstein Germany www bmz group com NOTICE Recommendations for best possible battery life Store lithium ion batteries with a charge level of about 50 After three months check the charge level and recharge to approx 50 if necessary 2 6 3 Handheld controller 1 0 CAUTION Possible hazard through unauthorize...

Page 14: ...jury by bridging the charging contacts of the charging station By bridging the charging contacts there is a risk of damage sparks overheating and fire Do not place any objects especially electrically conductive or flammable objects in the area in front of the charging contacts of the charging station CAUTION Risk of injury due to incorrect positioning of the charging station If the charging station ...

Page 15: ...easures after evaluation of the user to prevent stepping into the protective field from the side e g Installing mirrors at narrow junctions Using the Bluespot of the AGV Giving warning tones for narrow junctions Providing doors at junctions etc Driving routes must be planned in such a way that gradients are only used in the direction of travel forwards or backwards Driveways must not be inclined si...

Page 16: ...nstricted or even blocked by AGVs Due to the danger of tripping do not plan any waiting positions in walkways When employees are in hazardous areas or in sources or dips e g between crate stacks in a supermarket e g in the case of maintenance work in supermarkets the affected areas must be secured To do this a barrier must be used that can be recognized by the AGV in combination with a definition o...

Page 17: ...der must first be tested in the presence of a qualified person Route planning Distance of the route from permanent or expected obstacles The installer must plan a sufficient distance to permanent or expected obstacles on the driveway also bypassing zones with regard to free cornering also taking into account vehicle rotation and vehicle parts moving out Expected obstacles are for example pallets at a...

Page 18: ... gradients are only used in the direction of travel forwards or backwards Driveways must not be inclined sideways Do not plan curves turns on slopes gradients If necessary define slow speed zones for slopes gradients depending on the actual load 3 General notes on property and product damage The warranty only applies to the delivered configuration The warranty is void in the event of incorrect assem...

Page 19: ...tion on delivery Transport vehicle ActiveShuttle 1 0 ready for use incl lithium ion battery and installed lift aid Handheld controller 1 0 ready for connection Charging station ActiveShuttle 1 0 ready for connection Lithium ion battery ready for connection 5 About this product 5 1 Specifications 5 1 1 Use ActiveShuttle 1 0 Automated material transport in production with operator defined driving rang...

Page 20: ...1 Personal protection system laser scanner E2 Personal protection system laser scanner and laser navigation F Warning signal lamps G Bluespot H Drive rollers I Cam rollers J Ventilation slots K Battery charging contacts L Detection of dolly charging station T Lift aid with Velcro strap mounted to ActiveShuttle in condition on delivery Battery charge indicator B2 display by pressing the ON OFF key ...

Page 21: ... ActiveShuttle 1 0 M WLAN antenna N ON OFF button O Activation button P Connection of the handheld controller Q Emergency stop device rotary release R Battery charge indicator S Release brake buttons Battery charge indicator R during operation Display Color State of charge Red 0 15 Green 16 33 Green 34 50 Green 51 67 Green 68 83 Green 84 100 ENGLISH ...

Page 22: ...tary release B Color display C Joystick for controlling the ActiveShuttle in the Manual operating mode D Membrane keypad E Enabling switch 3 stage Stage 1 Not actuated OFF Stage 2 Approval ON Stage 3 Panic function OFF ActiveShuttle is shut down Speed Lifting the loading area Lowering the loading area Source position Dip position Charging station position Parking position ...

Page 23: ...eld controller has been pressed ActiveShuttle is stopped because ActiveShuttle is not activated ActiveShuttle is activated the software has not yet switched to Manual mode The software has switched to Manual mode but localization information is not yet available red ActiveShuttle is unlocalized yellow ActiveShuttle is unlocalized but is only in odometry mode red ActiveShuttle can be moved and is l...

Page 24: ...roth AG ActiveShuttle ActiveShuttle 1 0 3 842 560 593 2020 07 Fig 4 560 592 04 C A B D Charging station ActiveShuttle 1 0 A Charging contacts B Charging compartment C Detection sensor for ActiveShuttle D Connection for operating voltage ...

Page 25: ...AG 5 3 Safety and warning devices Fig 5 560 592 09 Q F E F E S Q F S E F G Safety devices and warning signs Q Emergency stop device rotary release S Release brake buttons G Bluespot F Warning signal lamps E Personal protection system laser scanner Not visible Acoustic signal transmitter ENGLISH ...

Page 26: ...active Battery is fully charged Light green Dark green flashing 1 Hz Battery charging active Battery is charging Light green Light red flashing 1 Hz Battery charging active Charging voltage interrupted Reconnect charging voltage Light red flashing 1 Hz Hardware error 1 Press the activation key Q 2 Restart the ActiveShuttle 3 Check the hardware Light red Emergency stop Unlock the emergency stop device...

Page 27: ...dentify persons and obstacles and thus prevent accidents The dimensions of the protective fields can be found in chapter 16 8 5 3 3 Reference to limits of the personal protection system The personal protection system is designed for the detection of standing and lying adult persons Persons or obstacles that are not recognizable with the thickness of a human calf at the level of the scanning planes ...

Page 28: ...ng over Always maintain ambient conditions during loading and transport see page 59 6 1 Transporting the product WARNING Suspended loads may fall Falling objects can result in severe injury or even death Only use the lift aid included in the scope of delivery to lift the ActiveShuttle Before lifting check the correct seat of the lift aid see chapter 6 1 1 Mounting removing lift aid Use only slings...

Page 29: ...59 When storing lithium ion batteries observe the safety instructions on Page 12 and the recommendations of the VdS data sheet 3103 Association of Property Insurers Please note Only use the lift aid included in the scope of delivery to lift the ActiveShuttle Keep the lift aid for further use Make sure that the parts of the lift aid touching metal are protected by foam material stickers 1 Unfold th...

Page 30: ...h size mm MD required tightening torque Nm MD 8Nm SW5 Hex socket wrench SW wrench size mm MD required tightening torque Nm 2 1 3 Graphical depiction of the assembly steps The numbers correspond to the sequence of assembly steps in accordance with the instructions in the accompanying text A B C X Graphical depiction of the designation of components The letters denote the components mentioned in the...

Page 31: ...id malfunctioning and associated risks Route the connection cable according to the country specific specifications for avoiding risks Risk of injury and possible damage due to incorrect use When climbing or stepping onto the charging station there is a risk of injury from falling and of damage to the housing of the charging station Do not use the charging station 1 0 as a stepladder or climbing aid ...

Page 32: ... 5 MD 1 3 Nm 20 2 2 Mounting the charging station 1 0 Please note The protective conductor X must not be disassembled Otherwise a new test in accordance with DIN EN 60204 1 Section 18 is required 1 Remove both lateral housing parts 2 Set the dimension D with the leveling feet and align the charging station horizontally 3 Screw the charging station to the base 4 Mount the lateral housing parts ...

Page 33: ...e is a risk of damage sparks overheating and fire Do not place any objects especially electrically conductive or flammable objects in the area in front of the charging contacts of the charging station CAUTION Risk of injury due to improper installation of the charging station Route the connection cable according to the country specific specifications for avoiding risks Electrical work may only be carr...

Page 34: ...e the emergency measures and safety instructions for commissioning in chapter 8 Before lifting check the correct seat of the lift aid see chapter 6 1 1 Mounting removing lift aid Lift the product out of its packaging at the lift aid see Fig 10 Fig 10 562 530 16 70 kg Lift the ActiveShuttle Remove the lift aid see chapter 6 1 1 Mounting removing lift aid Keep the lift aid and the transport packagin...

Page 35: ...cy measure Pressing emergency stop device In emergency situations and in the event of unpredictable movements of the ActiveShuttle press the emergency stop device Q on the ActiveShuttle emergency stop device A on the handheld controller The ActiveShuttle is shut down The warning signal lamps light up permanently in red Unlock the emergency stop device by turning the mushroom knob ENGLISH ...

Page 36: ...ed lithium ion batteries Do not use lithium ion batteries with a defective connection cable or defective contacts To charge the lithium ion battery in the ActiveShuttle use only the charging station supplied by Bosch Rexroth or the charger supplied by Bosch Rexroth Only operate lithium ion batteries and accessories in perfect condition Protect the battery terminals from short circuiting Protect th...

Page 37: ...e vehicle Store the lithium ion battery in a fire resistant container or at a safe distance from combustible materials Do not inhale any vapors that may be generated Disposal of lithium ion batteries Dispose of lithium ion batteries properly Tape off the connection contacts for disposal Store damaged lithium ion batteries in fire resistant containers During transport observe the relevant hazardous g...

Page 38: ...attery compartment 3 Press the release button B1 at the battery and remove the battery Inserting the battery is done in the reverse order After inserting the battery check that the release button is engaged and that the battery is firmly seated in the battery compartment Battery charge indicator B2 display by pressing the ON OFF key Display State of charge 0 15 1 16 33 34 50 51 67 68 83 84 100 Batt...

Page 39: ... Do not move against the direction of travel towards the ActiveShuttle Always wear safety shoes Risk of crushing at the rear wheels of the load When a loaded vehicle starts up restarts there is a danger of crushing the rear wheels of the load Do not put your feet between the wheels Observe start up warning Always wear safety shoes Danger due to unadapted speed Risk of serious injury due to a speed...

Page 40: ...cesses such as loading and unloading positions and when moving in and out at the charging stations NOTICE Danger of collision with obstacles outside the protective area The ActiveShuttle can be damaged by obstacles outside the protective area Keep the driving range free of obstacles especially flat objects or objects protruding into the driving range Risk of overheating of the ActiveShuttle If the ...

Page 41: ... F flash in yellow The warning signal lamps F light up permanently in yellow A warning signal sounds The charge indicator R is lit The ON OFF button N lights up permanently in green The activation key O flashes green 2 Press the activation key O The activation key O lights up permanently in green The Bluespot G lights up The ActiveShuttle is in Automatic operating mode When the emergency stop device...

Page 42: ...g mode the ActiveShuttle may only be operated by specially trained staff using the handheld controller 1 0 The responsibility for vehicle control in Manual mode lies entirely with the operator Fig 14 560 592 14 N O Q P F C 1 D E Switching to Manual operating mode 1 Plug in the handheld controller observe coding The activation key O flashes green 2 Press the activation key O The activation key O lig...

Page 43: ...ndheld controller and pressing the activation key O again 8 3 4 Manually insert the ActiveShuttle into the charging station Fig 15 560 592 06 S S Drive unlocking The ActiveShuttle can be moved freely by hand without a handheld controller Press both buttons Release brake S simultaneously The ActiveShuttle can be moved freely by hand when the buttons are pressed Insert the ActiveShuttle into the cha...

Page 44: ...s when manually raising or lowering the loading area Limbs may be caught and crushed between the loading area and the dolly or between the floor and casters of the dolly during manual raising or lowering of the loading area Make sure that no limbs are in the hazard zone when raising or lowering the loading platform Press and hold the activation key O for more than 3 s Loading area in lower position...

Page 45: ...earing during manual transport of dollies Maintain a minimum distance of 50 mm to protect hands If due to their weight it is foreseeable that dollies will be enclosed by more than just the hands the distances must be increased accordingly Fig 16 560 592 10 A L 700 mm 10 mm 300 mm 10 mm B C 1 mm 1 mm S 200 mm 10 mm Supermarket Please note The blue guide line must have a clear contrast to the backgr...

Page 46: ... modified or damaged dollies Protruding or sharp edged parts at the dolly can damage the ActiveShuttle Do not modify the dollies Make sure that no damaged dollies are used For use with ActiveShuttle 1 0 only the following dollies are permitted Table 11 Permissible dollies of Hartwall make Type Version Type Version Lean Dolly Type I DOS 1325D 1 Lean Dolly Type VII A DOS 1406 C 4 Lean Dolly Type II D...

Page 47: ...vice and contact the Bosch Rexroth Service Risk of burns from hot components inside the ActiveShuttle During operation individual components inside the housing may heat up Wait a reasonable time before opening the housing Personal injury when staying in the driving range especially in curve areas Risk of serious injury from collision with the ActiveShuttle If possible do not stay within the drivin...

Page 48: ...e of objects lying around Danger from dirty driveways Risk of serious injury from unpredictable movements of the ActiveShuttle due to dirty driveways The driving range of the ActiveShuttle must be free from contamination Danger due to incorrect loading condition Risk of serious injury due to incorrect loading condition when changing to the Automatic operating mode The change to the Automatic opera...

Page 49: ...rrosive liquid and thus possible skin irritations burns and chemical burns Increased fire hazard due to electrolyte leakage flammable solvent Never use dropped or damaged batteries Do not use defective or damaged lithium ion batteries Do not use lithium ion batteries with a defective connection cable or defective contacts To charge the lithium ion battery in the ActiveShuttle use only the charging s...

Page 50: ...e operating manual of the manufacturer BMZ Battery Assembly Centre GmbH Am Sportplatz 28 63791 Karlstein Germany www bmz group com NOTICE Recommendations for best possible battery life Store lithium ion batteries with a charge level of about 50 After three months check the charge level and recharge to approx 50 if necessary 9 1 3 Handheld controller 1 0 CAUTION Possible hazard through unauthorized...

Page 51: ... very nature Constructive measures and the selection of materials help ensure functional reliability over the full service life However wear is also dependent on the operating maintenance and ambient conditions at the place of use resistance contamination 9 1 6 Measures to reduce wear The following commonsense measures will reduce wear Avoid contamination caused by abrasive media reduce contaminat...

Page 52: ...Remove dirt from the casters regularly Damage to personal protection systems laser scanner Incorrect cleaning may cause damage to the glasses of the personal protection systems Particle contamination Carefully clean the glasses of the personal protection systems with a dry soft cloth Liquids contamination Carefully clean the glasses of the personal protection systems with a damp soft cloth water o...

Page 53: ...ents Safety device Inspection Notes on the execution Emergency stop devices Checking the basic function of the safety device Actuate the emergency stop command device on the vehicle on a connected handheld controller and check the correct response of the vehicle Personal protection system laser scanner front and rear Visual and mechanical inspection Check the safety device for visible damage and c...

Page 54: ...he ActiveShuttle has stopped remove the test object from the driving path and check whether the ActiveShuttle starts again 10 3 2 Checking the areas to be protected During this test the area to be protected and the detection capability of the respective personal protection system laser scanner are checked The purpose of the test is to reveal the following points Changes in detection capability che...

Page 55: ...e loading area Holding brake see chapter 10 2 1 11 Decommissioning This product is a component which does not need to be decommissioned Accordingly this section has been left blank 12 Disassembly and replacement 12 1 Preparing the product for storage later use Only set the product down on a flat surface Protect the product from mechanical stress Protect the product from environmental influences such...

Page 56: ...e materials used are environmentally friendly They can be recycled or reused components may have to be processed and replaced Recyclability is ensured by the selection of materials and the ability to take the components apart Careless disposal may lead to environmental contamination Disposal of electrical components Electrical components tools batteries and packaging must be recycled in accordance...

Page 57: ...y the product The Bosch Rexroth warranty only applies to the configuration as delivered and to approved upgrades The manufacturer will not accept any warranty claims for systems with unapproved modifications or upgrades 15 Troubleshooting If you cannot correct a fault please contact one of the addresses you can find at www boschrexroth com ENGLISH ...

Page 58: ... Positioning and navigation via laser scanner Safety laser scanner front and rear Type 3 PL d SIL2 Laser class 1 according to DIN EN 60825 1 2015 Wavelength 905 nm Communication interface WLAN IEEE 802 11 ESD safe yes Derivative value of the loading area Rv 1 x 109 Ω 16 2 Lithium ion battery Battery voltage 48 V Battery capacity 17 Ah Battery power 800 W 16 3 Charging station 1 0 Dimensions LxWxH ...

Page 59: ... vermin Do not install or operate in the immediate vicinity of industrial equipment producing chemical emissions Do not install or operate near sources of sand or dust Do not install or operate in areas that are regularly subjected to high energy forces caused for example by presses or heavy machinery Contact with highly reactive acidic or alkaline substances must be avoided 16 5 Floor requirement...

Page 60: ...transported must be as low as possible on line M below the intersection of levels H 2 L 2 and B 2 in the middle of above the loading area of the ActiveShuttle The dimensions H 2 L 2 and B 2 arise from the actual dimensions of the load incl dolly The distance between the mass point and the loading area must always be H 2 16 7 Scanning levels of the personal protection systems laser scanner Scan lev...

Page 61: ...otective fields 16 8 1 Front protective fields Table 13 When driving forward Zone Vreg mm s Vmax mm s Protective field Protective field Width mm Length mm 1 0 50 500 270 100 100 2 300 350 700 460 100 100 100 100 100 3 650 700 900 690 100 100 100 100 100 4 1000 1050 900 970 100 100 100 200 200 100 ENGLISH ...

Page 62: ...es Zone Vreg mm s Vmax mm s Protective field Protective field Width mm Length mm 5 0 50 500 170 100 100 6 300 350 1000 460 100 100 100 100 100 7 650 700 1150 690 100 100 100 100 100 Table 15 In the danger area Zone Vreg mm s Vmax mm s Protective field Protective field Width mm Length mm 8 100 110 400 400 100 100 ...

Page 63: ... 16 8 2 Rear protective fields Table 17 When reversing Zone Vreg mm s Vmin mm s Protective field Warning field Protective field Width mm Length mm Length mm 1 100 110 600 150 250 1m 0m 0 5m Warning field Protective field Table 18 In the danger area Zone Vreg mm s Vmin mm s Protective field Warning field Protective field Width mm Length mm Length mm 2 100 110 400 150 250 1m 0m 0 5m Warning field Protective fi...

Page 64: ... mm s Protective field Warning field Protective field Width mm Length mm Width mm 3 Muted 100 110 130 150 400 1m 0m 0 5m 3 Slow 50 55 Warning field Protective field Table 20 Forward Zone Vreg mm s Vmin mm s Protective field Warning field Protective field Width mm Length mm Width mm 4 0 10 140 200 400 1m 0m 0 5m Warning field Protective field ...

Page 65: ...65 68 3 842 560 593 2020 07 ActiveShuttle ActiveShuttle 1 0 Bosch Rexroth AG ENGLISH ...

Page 66: ...66 68 Technical data Bosch Rexroth AG ActiveShuttle ActiveShuttle 1 0 3 842 560 593 2020 07 ...

Page 67: ...Technical data 67 68 3 842 560 593 2020 07 ActiveShuttle ActiveShuttle 1 0 Bosch Rexroth AG ENGLISH ...

Page 68: ...Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax 49 711 811 7777 info boschrexroth de www boschrexroth com Subject to modifications 3 842 560 593 2020 06 ...

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