AGV装配线技术方案

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1、长安福特汽车有限公司南京公司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有限公司Shenyang SIASUN Robot & Automation Co., Ltd.目录 Contents1.概述Summary.错误 ! 未指定书签。2.设计依据 Design Gist .错误 ! 未指定书签。2.1生产工艺基本要求 Basic Requirement of Production Process错误!未指定书

2、签。2.2现场基本技术条件 Basic Field Technical Condition错误 ! 未指定书签。2.3责任范围 Responsibility Scope： .错误! 未指定书签。3. AGV 装配输送系统概述 AGV Assembly & Transportation SystemSummary.错误! 未指定书签。4. 自动导引车 AGV系统技术指标 Automated Guided Vehicle AGVSystemTechnical Specification.错误! 未指定书签。5. AGV工作过程描述 AGV Working Process Description错误

3、 ! 未指定书签。6.发动机装配升降工作台 Engine Assembly Lifter Worktable错 误 !未 指 定书签。6.1伸缩套筒式升降工作台 Extension Sleeve Lifter Worktable错误! 未指定书签。6.2剪式液压机构升降工作台 Scissor Hydraulic Lifter Worktable错误!未指定书签。6.3托盘底面距发动机最高点距离与升降平台高度关系计算Calculation onthe Relation Between Distance from Pallet Bottom to Engine Zenith andHeight o

4、f Lifter Table.错误! 未指定书签。7.后悬装配举升装置 Rear Suspension Assembly Lifting Equipment错误 !未指定书签。7.1伸缩套筒式升降工作台 .错误! 未指定书签。7.2剪式液压机构升降工作台 Scissor Hydraulic Lifter Worktable错误!未指定书签。7.3 升降平台上平面到地面的高度计算Calculation on the Height from thePlane of the Lifter Table to the Ground.错误! 未指定书签。8. 不同轴距车体装配实现 Body of Diff

5、erent Wheelbases AssemblyRealization.错误! 未指定书签。9. AGV 动态装配解决方案 AGV Dynamic Assembly Solution错 误 !未指定书签。10. AGV 主要设备 AGV Main Equipment .错误! 未指定书签。10.1AGV（LGV）车载控制器 AGV（LGV）Vehicle Controller错误 ! 未指定书签。10.2AGV（LGV）驱动系统 AGV（LGV）Drive System .错误! 未指定书签。10.3导航系统 Navigation System .错误! 未指定书签。10.4在线自动充电系统

6、 Online Automatic Charge System错误 ! 未指定书签。10.5无线局域网通讯系统 Wireless LAN Communication System错误 ! 未指定书签。10.6驱动控制系统 Drive Control System .错误! 未指定书签。10.7非接触防碰装置 Non-contact Bumper Device .错误! 未指定书签。11. AGV安全系统 AGV Safety System . .错误! 未指定书签。11.1非接触防碰装置 Non-contact Bumper Device .错误! 未指定书签。11.2接触式防碰装置 Cont

7、act Bumper Device .错误! 未指定书签。11.3离线保护系统 Offline Guarding System.错误! 未指定书签。11.4信息交互系统 Information Exchange System .错误! 未指定书签。11.5紧急停车系统 Emergency Stop System .错误! 未指定书签。11.6多 AGV避碰 Multi-AGV Collision Prevention.错误! 未指定书签。12. AGV控制台和调度管理系统 AGVConsole & Dispatching ManagementSystem .错误! 未指定书签。12.1 AGV

8、控制台 AGV Console .错误! 未指定书签。12.2 调度管理系统 Dispatching Management System. 错误! 未指定书签。13. AGV车载控制 系统 和数据采 集 AGV VehicleControl System & DataCollection .错误! 未指定书签。14.导航线的铺设 Navigation Line Paving.错误! 未指定书签。15. AGV系统特点 AGV System Characteristics. . 错误! 未指定书签。15.1高速无线局域网的建立和应用 Setup and Application of High-s

9、peedWireless LAN .错误! 未指定书签。15.2 AGV运行的灵活性 Flexibility of AGV Running. 错误! 未指定书签。15.3高精度导航系统 High Accuracy Navigation System错误 ! 未指定书签。15.4友好的人机界面 User Friendly Human Machine Interface错误 ! 未指定书签。15.5完善的自诊断系统 Perfect Self-diagnosis System错误 ! 未指定书签。15.6 AGV可靠性措施 Measures on AGV Reliability. 错误! 未指定书签

10、。15.7在 线快 速自动充电 方法 和快 速充 电 电池的应用 Online AutomaticInstant Charge Method and Application of Instant Rechargeable Battery.错误! 未指定书签。15.8故障修复时间（ MTR）Mean Time of Repair（MTR）错误 ! 未指定书签。AGV系统的故障修复时间有两类：Therere two kinds of MTRfor AGVsystem:.错误! 未指定书签。15.9 平均无故障时间（ MTBF）Mean Time To Failures （MTTF）错误 ! 未指定

11、书签。16. AGV运行路线图 AGV Running Route Graph . 错误! 未指定书签。16.1 装配线 AGV运行布局图 Assembly AGV Running Layout错误 ! 未 指 定书签。16.2 样机车间 AGV运行布局图 Sample Workshop AGV Running Layout 错 误 !未指定书签。18.环 行装 配 线 AGV系 统设 备 清单 CircularAssembly AGV SystemEquipment List . .错误! 未指定书签。19.项目进度 Project Schedule .错误! 未指定书签。20.培训 Tra

12、ining . .错误! 未指定书签。20.1培训人员的范围、数量及时间 Scope, amount and time for trainingpeople .错误! 未指定书签。20.2培训的内容 Training content .错误! 未指定书签。21.售后服务 After-sale service.错误! 未指定书签。1. 概述 Summary根据长安福特汽车有限公司南京公司发动机、前后桥AGV系统的设计要求，新松公司采用的装配型AGV系统进行发动机、前后桥与车身合装，具有同步动态跟踪功能的AGV可实现发动机、前后桥在装配段任何工位同时装配。导航方式采用磁导航，地面施工量小，只要根据

13、工艺要求变更磁条的粘贴路径，在对控制程序稍加改动，就可以改变装配路线的长短，适应不同的装配工艺要求。 AGV系统由一条近似梯形的环线组成，在装配段进行前悬挂/ 发动机、后桥与车身合装，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的组装。根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. onengine and axle AGV system, SIASUN uses assembly AGV system for engin

14、e,axleand body decking,and AGVwith thefunctionofsynchronizationdynamictrackingcan realizesimultaneousassemblyofengine and axleatanyassemblyzone orstations.Byusing magneticnavigation,groundconstruction is small and by changing the path of magnetic strip upontechnicalrequirementsand modifyingslightlyc

15、ontrolprogram,thelengthofassembly pathcanbe alteredtomeetdifferentassemblyprocessrequirements. AGV system is formed by a loop line, which is close to atrapezium.The assembly zone isused forfrontsuspension/engine,rearaxleand body decking and the non-assembly zone is used for engine and axlesuspending

16、 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.整个系统包括 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,AGVconsole, chargesystem, navigationsystem, c

17、ommunication system, data collectionsystem and assembly jig,etc.2. 设计依据 Design Gist2.1生产工艺基本要求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/vehicle2.2现场基本技术条件Basic Field Technical Condition动

18、力电源：交流 380 10%50HZ 2%3 相5线Power supply:AC 38010%50HZ 2%3 phases 5 lines温度：-5 45Temperature:-5 45湿度：6095%Humidity:60 95%防护等级：IP54Protection grade:IP54绝缘等级：B级Insulation level:Level B2.3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 des

19、ign and manufacturing.3）AGV装配系统发运前调试、考机实验。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。AGVcontrolsystemdesignand manufacturing,vehiclecontrolsoftware, scheduler software design.6）AGV工

20、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。Fieldinstallation,unitmachine debuggingand completelinelinkage debugging.8）技术培训和售后服务。Technical training and after-sales service.3. AGV装配输送系统概述AGVAssembly &Transpor

21、tationSystemSummary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构成。Engine/rear axle AGV assembly & transportation system includes AGV, AGVground guided system, online automatic charge system, AGVconsole, data collection system, AGV dispatching management system and communi

22、cation system, etc.AGV：控制台AGV完充成电发器动机或后悬挂系的输送和辅助装配工作。装配人员可以站在ConsoleChargerAGV车的脚踏板上进行装配作业，脚踏板采用花纹铝板制造， 操作安全。AGV conducts transportation of engine or rear suspension andassistantassembly jobs. Assembly operator canstand and workonAGVpedal,which is madeof aluminum board with decorativefiguresand safe

23、 to operate.AGV地面导引系统 AGV Ground Guided System：地面导引系统是AGV运行的路线和轨迹， AGV的导引系统采用基于地图的磁带导航方法。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 mag

24、netic strips havebeen embedded underground, the ground will be smooth and won t influence people or vehicle to pass.在线自动充电系统Online Automatic Charge System：为了保证 AGV24 小时连续运行，充电系统采用大电流快速充电的方法为AGV补充电量。 AGV的充电过程是在控制台的监控下自动进行的。To ensure AGVto run 24 hours continuously,charge system uses themethod of larg

25、e electrical current and instant electrification to charge AGV. AGV charge process is conducted automatically under the supervision and control of the console.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系统的调度管理中心，负责数据采集系统的数据处理，与上位机交换信息，生成 AGV的运行任务，解决多 AGV 之间的

26、避碰问题。Console and AGV dispatching management system is the dispatchingmanagement center of AGV system, responsible for data processingin data collection system and information exchange with uppercomputer to create AGVrunning tasks and solve the problems of multiAGV collision.通讯系统 Communication System

27、通讯系统由无线局域网组成。 AGV与控制台之间采用无线电台进行信息交换，通讯协议为TCP/IP 协议。控制台可与上位机之间采用以太网进行数据传输。Communication system is formed by wirelesslocalnetwork.Wirelesstransmitter-receiverisadopted between AGV and console toexchange informationandthe communicationprotocolis TCP/IPprotocol. Ethernet isused between consoleand the up

28、percomputerfor data transmission.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在等待站点的 AGV可以侧移运行，实现顺序装配。如果没有车身通过，等待站点的 AGV始终处于等待状态。如果有车身通过，但等待站点没有 AGV等待， AGV控制台将通知总控室。Photoelectricity testing system is used to check if the body onthe suspending tools of the main transmi

29、ssion line has run to the position, where signal will be sent to inform AGV at the waitingstationto move sideways to realizesequence assembly. Ifthe bodyhasnt passed, AGV at the waiting station will stay all along inthe status of waiting. If passed, but theres no AGV waiting atthe station, AGV conso

30、le 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带有同步跟踪和举升机构的AGV，其主要技术指标：Main technicalspecificationsof AGVwith synchronizationtrackingandlifting framework include:AGVS控制方式：控制站集中调度、监控、管理AGV系

31、统的运行状态AGVS control mode:control station makes centralized dispatch,monitoring& controland management ontherunning state of AGV systemAGV控制方式具备功能：全自动半自动手动AGV control function: automatic/semi-automatic/manual通讯方式：无线局域网Communication:wireless LANAGV导航方式：磁导航AGV navigation method: magnetic navigationAGV驱动

32、方式：双舵轮驱动。AGV steering:powered wheel steering负载能力：2000KG（以最终设计为准）Payload:2000KG (subject to final design)AGV自重：2000KG（以最终设计为准）AGV weight:2000KG (subject to final design)同步跟踪精度：10mmSynchronization 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 occupiedr

33、unning space)最大速度：直线 60mmin，侧移 30m minMaximum speed:straight 60mmin， sideways moving 30m min导航精度：10mmNavigation accuracy:10mm停车精度：10mmParking accuracy:10mm工作时间：24小时连续（三班）Working time:24 hours continuously (3 shifts)防碰装置：四周安装接触式保险杠，前后另安装激光防碰装置。Collision prevention device: contact bumper installed aro

34、und and laser collision prevention device installed in the front & back side举升装置：双举升机构，可以同步举升或单独举升。Liftingequipment:dualliftframework, for synchronizationliftingor separate lifting托盘夹具：按照实际需要设计（本方案中不含该部分内容）Pallet fixture:design according to demands (not included inthis solution)电池组：48V100AH，正常使用，寿命大

35、于3 年Batterycharger:48V100AH, in normal usage and itslongevityis over 3 years.充电方式：全自动充电器实现在线自动充电，保证连续24 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提供的脚踏板上相对静止进行零部Operationheight:车体尺寸：件装配，脚踏板到地面高度200mm。Operatorstands on AGVfootpedal

36、to assemblypartsin relativestillconditionand the heightfrom the foot pedal to the ground is 200mm.4800 mm1800 mm 900 mm长宽高(举升前)Body dimension:(length4800 mm 1800 mm 900 mmwidthheight(before/afterlifting)5. AGV 工作过程描述 AGV Working Process Description（ 1） AGV小车按控制台计算机的指令行驶到后桥总成上装点，由操作人员根据生产计划完成后桥总成的吊装，

37、当将后桥总成从后桥分装线吊到AGV后桥举升装置上的后桥夹具上并放稳后，操作人员通过车体上的操作按钮向AGV小车发出完成上件确认信号，允许AGV向下一个站点运行；AGV will run upon console computer orders to loading point of rearaxlefinalassemblyandoperatorwillcompletethisbased onproduction plan. After the rear axle final assembly is moved from the rear axle subassembly line and p

38、laced well on the rear axlefixture of AGVrear 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， 由操作人员根据生产计划完成发动机总成的吊装，当将发动机总成从发动机分装线吊到AGV发动机举升装置上的发动机夹具上并放稳后，操作

39、人员通过车体上的操作按钮向AGV小车发出完成上件确认信号，允许AGV向下一个站点运行AGVruns to loadingpointof engine finalassembly and operatorwillcomplete engine final assembly suspending. When the engine finalassembly is movedand placed wellon the engine fixtureof AGVenginelifting device from engine subassembly line, operator then sendsco

40、nfirmationsignalofthecompletionofloadingbypressingoperation button on the body to inform AGV vehicle to move towardsnext station.（ 3） AGV小车按控制计算机的指令行驶到等待地点；AGVmoves towaitingplaceaccordingtotheorderfromcontrolcomputer.（ 4） AGV小车在某一停留时间相对长的站点 （动力总成上装点或其它点） 进行自动充电；AGV will charge itself automatically

41、at one station (power trainassembly loading point or other point) for relevant long waitingtime.（ 5） AGV控制台检测工艺链上车体的位置信号， 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、速度根据生产线要求可通过车载显示器进行更改），在装配段快速向前运行，在预定区域捕获预先固定在被装车身上的合作目标。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，操作人员可以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

42、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的工艺定位孔。当举升到安装位置，所有的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的装配结束按钮，AGV将自动落下举升装置到零点。 当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 processchain.Whenloaded body has gottentotheposition,AGVwit

43、hengineand front & rearsuspensionassembly isdispatchedaccordingtosettime and speed to the underneath of the suspending chain (time &speedcanbechanged throughvehicledisplayeraccordingtorequirementsoftheproductionline).ThenAGV moves forwardquickly in the assembly zone and captures in the prearranged a

44、reathe cooperative target set in advance on the body. After trackingstate is stable, manual control box or foot pedal switch is doneby manualoperationtoraisethelifter.Operatorcanrunsimultaneously or separately the engine lifting device and rearaxel lifting device. When the lifting device is raised,

45、the lockfixtureisopened tomake thetable floating.Operator pressesthebuttonforliftingand at thesame timeputsthebody locatingpinson the fixture into the process locating hole of the body. Whengetting to the installation position, all bolt installation holesare located. Then assembly workers will insta

46、ll the set bolts andpress the buttonon the liftingfixtureaftercompletion ofassembly.AGVwilllowerthe liftingfixturetozero automatically.Whenallliftingfixturesreach zero,AGVwillaccelerateto leaveassemblystation.Afterequipped withengine and rearaxleat loadingstation,AGV finishes one working cycle.当发动机前

47、后悬挂总成不能及时供应时，可通过设置在装配工位的悬链急停开关，由人工控制，停止悬链运行。即使不按悬链急停，AGV系统也会通过控制台申请停止悬链运行。When engineand front& rearsuspensionassemblycan tbesupplied in time, make manual control by using emergency stop switchon the assembly stationto stop suspending chain to run.Even withoutpressing the suspension chain emergency

48、switch, AGV system can alsoapply 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。WhenAGVentersintoalarmingstation(atthe end of assembly station)and hasn t finished assembly, AGV will stop automatically and AGVconsolewillalarmand controlthepro

49、cesschaintostop.Afterassembly, it will recover automatically.（ 5） AGV在分装工位的运行速度可根据现场实际设置。AGV running speed in subassembly station can be setup according to actual situation.6.发动机装配升降工作台Engine Assembly Lifter WorktableAGV发动机装配升降工作台是将发动机前悬总成举升到装配位置高度的设备，目前我公司应客户要求普遍采用纯机械传动的伸缩套筒式升降工作台。为适应各使用现场的不同要求，我公司

50、将剪式液压机构升降工作台列为备选设备供用户选择。两者主要区别为前者采用直流伺服电机驱动升降，执行元件为滚珠丝杠。后者采用液压泵站驱动升降，执行元件为液压缸。AGV engine assembly lifterworktableis the equipment thatlifts engine front suspensionfinal assembly to the assemblyposition.Now,basedoncustomer requirements, our company mainly adopts pure mechanical driving extension slee

51、ve lifter worktable. To meet different demands in variousapplicationfields,ourcompany makes thescissorhydrauliclifterworktabletobe anoptionaldeviceforcustomertochoose.The maindifference between these two lies in the fact that the previous one usesDC servo motor to drive lifter and the executive comp

52、onentis ballscrew,while the latter adopts hydraulic pumping station to drive lifter and theexecutive component is hydraulic cylinder.6.1伸缩套筒式升降工作台Extension Sleeve Lifter Worktable该装置主要由滑动工作平台、 举升装置、手控盒等组成（如图升降工作台简图） ，其中滑动工作平台在使用过程中可通过直线轴承组合的机构进行两个方向的水平移动，另外滑动工作台通过组合轴承结构可旋转一定的角度。举升装置是完成升降动作的主要装置，其主要由

53、滚珠丝杠机构、一层起重链轮组合、二层起重链轮组合、电机减速机、齿轮传动及各伸缩套筒组成。该电机采用进口的直流电机、减速器一体机，滚珠丝杠及螺母等零件采用德国进口零件，性能可靠，传动稳定。This equipment isformed by the sliding worktable,liftingdeviceand manualcontrolbox, etc(See thelifterworktable sketch).Amongthem,theslidingworktablecan move horizontallyin two directionsthroughstraightbearin

54、gcombination in the course of application. Besides, it can also rotate incertain angle by this structure. The lifting fixture is the main deviceto finishthe action ofliftingand lowering.Itiscomposed ofballscrew,one layerliftchainwheelcombination,twolayersliftchainwheelcombination, motor reducer, gear driving and each extension sleeve. Themotoradopts theimportedDC motor and reducer ofone machine. Parts,suchas the ballscrew and nut are importe