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F3-Design NIPPER, Installation Instructions Manual

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F3-Design NIPPER Installation Instructions Manual Download Page 21

 

 

 

INSTALLATION INSTRUCTIONS NIPPER - JULY 2020 

21 

 

  Electrical equipment 

The Nipper V2 is powered by two (2) independent LiFePO4-Batteries with 420 W/h and a nominal voltage of 24 
V,  for  service  life  reasons  the  batteries  are  never  discharged  in  normal  operation  below  20%  of  their  nominal 
capacity. The charging process takes place with the charging contacts attached to the bottom (fork side), which 
are disconnected by an electronic circuit.  

 

 

 Wiring 

The individual modules are connected to the bus and power supply by means of system cabling.  

 

Summary of Contents for NIPPER

Page 1: ...INSTALLATION INSTRUCTIONS ...

Page 2: ...INSTALLATION INSTRUCTIONS NIPPER JULY 2020 2 Publisher F3 Design B V Meerheide 282 NL 5521 DW Eersel Holland www f3design nl info f3design nl ...

Page 3: ...tation may be duplicated in any form without authorisation or processed or recorded using electronic systems Subject to changes without notice F3 Design BV is NOT liable for technical or printing errors in this manual and assumes no liability for any damage caused by the use of the manual ...

Page 4: ...INSTALLATION INSTRUCTIONS NIPPER JULY 2020 4 Content 1 Basic safety advice 7 2 Definitions 8 3 Dimensions 9 4 Technical DatA 10 Performance 10 Environments 10 ...

Page 5: ...the vehicle 23 Light indication 23 8 Safety features 25 Construction of protective devices 25 Safety button 27 Safety laser scanner 28 Safety 28 Straight ahead with curves 30 Rotate reverse 30 Protective field selection by the safe CPU 31 9 Handling 33 Forward movements with laser scanner protective field monitoring 33 Reversing movement or forward movement with Muting protective field evaluation ...

Page 6: ...on with people 36 12 Safety 37 Safety tests before commissioning 40 Operator staff 41 Operation 41 Mixed operation with people 41 13 Alarm codes 42 14 Maintenance 46 Daily 46 Monthly 46 Checking the emergency stop elements 46 Checking the safety switchgear 47 At intervals of three 3 months 47 Battery removal 47 15 Delivery 48 16 Storage 48 17 Figures 48 18 Table 50 ...

Page 7: ...e degree of hazard and are briefly explained in terms of their respective meaning Please therefore familiarise yourself with the safety signs and their meanings in order to prevent hazards and risks at an early stage Indicates a low risk hazard that could result in minor bodily harm or property damage if not avoided Indicates a possible medium risk hazard that will result in death or severe bodily...

Page 8: ...20 8 2 DEFINITIONS FTS Driverless transport system AGV BWS Security device laser scanner Bumper Safety button TTO Time to obsolescence The authority Instructed by the manufacturer or representative SLS Safely limited speed STO Safe torque off ...

Page 9: ...INSTALLATION INSTRUCTIONS NIPPER JULY 2020 9 3 DIMENSIONS Figure 1 Dimensions ...

Page 10: ...m s in main direction Tare weight 191 kg TTO 15000h Environments Max ambient temperature 30 C Min ambient temperature 0 C Humidity 95 Floor conditions Unevenness maximum 5 mm Maximum inclination 3 Load intake Euro pallet Standard pallet size Other pallets after approval by the manufacturer Max payload 1000 kg Max load balancing front rear 60 40 Max load distribution left right 55 45 Max load heigh...

Page 11: ...port For transport belts can be pulled under the device at the indicated points Ensure that a 2 angle is not exceeded when lifting and lowering Figure 2 Transport Note The original packaging must be used for transportation or storage Attention Pull two belts underneath the vehicle on the points which are marked with arrows to lift Then the vehicle can be raised and placed on the bottom of the orig...

Page 12: ...STRUCTIONS NIPPER JULY 2020 12 Tank venting The unit has two tank openings Figure 3 Tank ventilation The device must not be turned over Figure 3 Tank ventilation Note Upon delivery the air ventilation screws are open ...

Page 13: ...are available The operator is familiar with the documents Switching ON The switch is pressed briefly to turn it on Then the device is automatically switched on After the start time of 60 seconds the vehicle is ready to use Figure 4 Main switch Note By pressing the switch briefly the device switches on automatically 1 second by pressing it for longer it switches off 3 seconds ...

Page 14: ...pment In the main direction the black arrow the guided route is checked by the personal safety laser scanner for obstacles and people The secondary directions all others directions can only be partially monitored or not at all by the safety laser scanner For this reason the speed is limited to a maximum of 300 mm s here the speed is limited to a maximum of 300 mm s The outer edge v 300 mm s Note S...

Page 15: ...INSTALLATION INSTRUCTIONS NIPPER JULY 2020 15 7 DEVICE DESCRIPTION General description Mechanical equipment Figure 6 Explosion drawing ...

Page 16: ...7 Bus Communication Cable A1 VK 015 18 Bumper Unit 19 Bumper Cover 20 LED Bridge Unit 20 1 Wifi Module WLAN 1100 21 Sigmatek HMI 3 5 22 Emergency Stop Button 23 Connector Joystick 24 Protection Cover Front 24 1 Protection Cover Back 25 LED Bridge Vertical Tube side BlueSpot 25 LED Bridge Vertical Tube 26 Start Button 27 Front Bumper Cover Black 28 Blue Spot 29 Pepperl Fuchs 2D LiDAR Sensor HD incl...

Page 17: ...ors for lane guidance automatic pallet detection height measurement indicators secure radio transmission for manual control Wi Fi communication charging contacts attached at the bottom and at the front safety button so the device can be shut down immediately from any location Figure 7 Front module with safety button ...

Page 18: ...rvo engine 4 Lifting mechanism For even weight distribution on complex loads 5 Hydraulic unit The load is absorbed hydraulically 6 Load handling forks The load handling device connects the two independent chassis units 7 Assembly sheet This is the safety control for evaluation of the safety laser scanner 8 Safety laser scanner Figure 8 Safety laser For mixed operations a safety laser scanner with ...

Page 19: ...l components are also supplied with power 11 Battery pack Two 2 battery packs for the supply of the independent chassis units are attached to the device 12 Front control Responsible for the control and evaluation of the laser scanner 13 Light pole To improve the visibility of vehicles in mixed operation with people or forklift traffic ...

Page 20: ...INSTALLATION INSTRUCTIONS NIPPER JULY 2020 20 Rotating circle The rotating circle is 1700 mm excl the safety field ...

Page 21: ...ge of 24 V for service life reasons the batteries are never discharged in normal operation below 20 of their nominal capacity The charging process takes place with the charging contacts attached to the bottom fork side which are disconnected by an electronic circuit Wiring The individual modules are connected to the bus and power supply by means of system cabling ...

Page 22: ...ry packs with a nominal power of 420 W h Figure 9 W420AH battery pack Note The battery must be stored with 30 charge If the battery has been stored for more than six months it must be fully discharged and then recharged to 30 Attention Attention is paid to the GDV brochure about loss prevention of the German Insurance Industry ...

Page 23: ...breaks b Beacon 13 Short flash Long breaks 2 Driving a Forks 2 In the direction of travel red LED in time with the safety light no continuous light b Forks 2 Back side green 1 sec flash 3 Turn left right a Forks 2 LED flash in the direction of turning a little faster than 0 7 sec 4 Crossing a Forks 2 Red LED on side of the direction of travel flashing light cycle b Forks 2 The others are green 5 T...

Page 24: ...LATION INSTRUCTIONS NIPPER JULY 2020 24 a Forks 2 Front red steady b Forks 2 Rear green steady c Beacon 13 Orange also steady 11 Safety light a Only when driven by the safety light in the direction of travel ...

Page 25: ...INSTALLATION INSTRUCTIONS NIPPER JULY 2020 25 8 SAFETY FEATURES Construction of protective devices Figure 10 Construction of protective devices ...

Page 26: ... detect people and obstacles in the main driving direction and to stop the vehicle if necessary For secondary directions and in such situations where it is not possible to secure it with the laser scanner e g pallet feed it is protected by four 4 safety edges and two 2 emergency stop switches which can be operated from any direction on foot In addition the speed is limited to a maximum of 300 mm s...

Page 27: ...7 Safety button The safety button immediately switches the vehicle to a safe state after operation The switching devices must be checked at least once a month The power of the activity must not exceed 100 N typically 10 N Figure 12 Safety button ...

Page 28: ...e The function may only be activated in areas where there are no persons or which are unmistakably marked as danger areas on the ground Safety The vehicle consists of two 2 completely separate chassis units each with an independent power supply circuit Figure 13 Chassis unit If an error or multiple errors occur during operation the vehicle immediately begins to decelerate until it reaches a safe s...

Page 29: ...for protective fields consists of at least one data entry which in turn consists of a maximum speed and the corresponding protective field number For different items these are sorted based on the increasing speed Standard settings The specified protective field length already takes into the offset of the scanner backwards to the front of the vehicle 68 mm the specified values are setting values Al...

Page 30: ...400 580 5 425 1400 495 6 300 outer edge 900 168 Table 2 Protective fields during cornering These protective fields are only used in active route guidance and may only be used in blockage magazines Compliance with legal safety regulations must be ensured Rotate reverse Protective field number V mm s Width mm Length mm 6 300 outside edge 900 168 Table 3 Protective fields turning and reversing ...

Page 31: ...se process will be carried out This consists of the switching time and the time out of the transmission For this reason the protective field must be switched before reaching the associated maximum speed The actual switching speed 𝑣𝑠𝑐ℎ𝑎𝑙𝑡 is the result of the maximum acceleration 𝑎𝑚𝑎𝑥 minus the maximum speed 𝑣𝑚𝑎𝑥 and the maximum transmission time 𝑡𝑚𝑎𝑥 𝑣𝑠𝑐ℎ𝑎𝑙𝑡 𝑣𝑚𝑎𝑥 𝑎𝑚𝑎𝑥 𝑡𝑚𝑎𝑥 a _ max 1000 mm s 2 t _ ...

Page 32: ...ER JULY 2020 32 Protective field switching Figure 15 illustrates the protective field switching Figure 14 Protective field switching 0 200 400 600 800 1000 1200 0 500 1000 1500 2000 2500 v mm s s mm Protective field switching v Kufe ...

Page 33: ...and VRight is performed as follows 𝑣𝐿𝑒𝑓𝑡 𝑣𝑅𝑖𝑔ℎ𝑡 𝑟 183 75 𝑚𝑚 𝑟 183 75 𝑚𝑚 Forward movements with laser scanner protective field monitoring Speed range maximum value of VLeft and VRight Minimum permitted curve radius 0 193 mm s Any 193 700 mm s 2060 mm 700 1000 mm s 3390 mm Table 3 Speed ranges To With a radius smaller than 2060 mm monitoring of the protective field cannot be guaranteed It is driven ...

Page 34: ...mum possible rotation speed of the outer edges of the vehicle must not exceed the reduced speed of 300 mm s Limitation If values are given to the vehicle that exceed fall below the maximum minimum permitted values the vehicle brakes at a maximum permissible speed so the required curve radius can be safely covered Acceleration values Delay 0 300 mm s Jerk 2000 mm s Delay 0 VL VR 0 800 mm s Jerk 400...

Page 35: ...he pallet At a distance 35 cm the values decrease accordingly Figure 155 Pallet recording Charging station Activation of the charging station detection is 40 cm 10 cm for the barcode of the charging station Figure 16 Charging station Attention In the area of the charging station the vehicle must be in a lowered state Attention When driving out the vehicle must extend at least 30 cm straight out of...

Page 36: ... lose grip After the test the load must remain stable and stop without slipping on the vehicle Cleaning The roadway must be kept clean and free of objects If necessary carry out cleaning with a brush several times a day Under no circumstances may the track be cleaned wet during operation Operator staff The operator staff must be familiar with the operation of the device Operation The distributor m...

Page 37: ...nto the device A minimum safety distance of 500 mm must not be exceeded It may only be lifted higher than 50 mm at transfer stations where a higher lift is required After lifting it you must immediately lower it to maximum 30 mm In places where it is absolutely necessary to raise it above 30 mm an acoustic signal must be given in advance These places must be unmistakably marked on the ground Addit...

Page 38: ... strictly prohibited Ensure compliance with safety distances Otherwise other adjustments must be taken to avoid dangerous situations Before each start up compliance with the safety distance must be checked by qualified staff Attention Never carry out repairs to the safety equipment Note The safety laser scanner works largely maintenance free the cover hood should be cleared regularly of dust and d...

Page 39: ...an be switched off No baggy clothes may be worn in the area of the vehicles Note Objects lower than 145 mm are no longer detected by the vehicle When the device is operated a safety distance of at least 2 m must be maintained The operator must have visual contact with the vehicle The system may only be operated by authorised staff ...

Page 40: ...ive 90 to the right and press the bumper Drive 90 to the left and press the bumper The load can only be transported if it does not slide parts fall off or lose its stability In general only loads that meet the above criteria may be transported If it can be assumed that the test load deviates from the expected one it must not be transported without being retested Load tests can cause the pallet or ...

Page 41: ...dling the device Operation The distributor must ensure that facilities that prevent unauthorised use are available for maintenance and manual operation Mixed operation with people People who are in the vicinity of the system or who can enter the system must be informed about this and the safety guidelines ...

Page 42: ...k ground pollution overcurrent axis rear left Obstacle on the ground Foreign body in the chassis Clean device Check damage Check ground pollution overcurrent axis rear right Obstacle on the ground Foreign body in the chassis Clean device Check damage Check ground pollution overcurrent sum all axes Obstacle on the ground Foreign body in the chassis Clean device Check damage Check ground pollution r...

Page 43: ... low 20 Battery level low Charge the device batt voltage low 10 Battery level low Charge the device batt voltage low 5 Battery level very low Charge the device mover is not charging Battery ist not charging Check charging contacts Check functionality of charging station Partner mover is not charging Battery ist not charging Check charging contacts Check functionality of charging station battery ba...

Page 44: ...ton was triggered Acknowledge bumper rear pressed Safety button was triggered Acknowledge timeout layout download Connection to vehicle interrupted Check the wireless connection for sufficient signal strength if necessary additional EP layout position not known Vehicle not referenced Reference the vehicle not paired Communication Check battery level on both sides Contact the manufacturer communica...

Page 45: ...xis front left Communication Contact the manufacturer com fault axis front right Communication Contact the manufacturer com fault axis rear left Communication Contact the manufacturer com fault axis rear right Communication Contact the manufacturer com fault pump Communication Contact the manufacturer com fault partner mover Communication Contact the manufacturer invalid state bumper front Bumper ...

Page 46: ... is no danger to restart Calibration cam front left Calibration of the camera failed Check light Check calibration place Calibration cam rear left Calibration of the camera failed Check light Check calibration place Calibration laser rear left Calibration of the laser scanner failed Check calibration place Calibration cam front right Calibration of the camera failed Check light Check calibration p...

Page 47: ...hicles This includes Cleaning Checking for wear and tear Checking for damage Checking the charging contacts If the vehicle is damaged due to improper handling it must be repaired immediately A vehicle with damage must not be operated Battery removal To remove the battery the front service cover must be opened The battery can be removed evenly from the device after opening the three 3 fastening scr...

Page 48: ...ctions 16 STORAGE Storage specifications Dry and protected from moisture 50 Storage temperature 0 30 C Maximum storage period 6 months Standing on the wheels Without surcharge Note After storage the vehicle must be checked for damage before startup It must be charged continuously for at least 12 hours before startup 17 FIGURES ...

Page 49: ...Directions of movement 14 Figure 6 Explosion drawing 15 Figure 7 Frontmodule with safety button 17 Figure 8 Safety laser 18 Figure 9 Battery pack W420AH 22 Figure 10 Construction of protective devices 25 Figure 11 Emergency stop 26 Figure 12 Safety button 27 Figure 13 Chassis unit 28 Figure 14 Protective field switching 32 Figure 15 Pallet recording 35 ...

Page 50: ...TALLATION INSTRUCTIONS NIPPER JULY 2020 50 18 TABLE Table 1 System description 16 Table 2 Protective fields during cornering 30 Table 3 Speed ranges 33 Table 4 Speed ranges 34 Table 5 Acceleration value 34 ...

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