AGV装配线技术方案.docx

1、AGV装配线技术方案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 52. 设计依据Design Gist 52.1 生产工艺基本要求Basic Requirement of Production Process 52.2 现场基本技术条

2、件Basic Field Technical Condition 62.3 责任范围Responsibility Scope： 63. AGV装配输送系统概述AGV Assembly & Transportation System Summary 74. 自动导引车AGV系统技术指标Automated Guided Vehicle AGV System Technical Specification 95. AGV工作过程描述AGV Working Process Description 116. 发动机装配升降工作台Engine Assembly Lifter Worktable 146.1

3、 伸缩套筒式升降工作台Extension Sleeve Lifter Worktable 146.2 剪式液压机构升降工作台Scissor Hydraulic Lifter Worktable 166.3 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 on the Relation Between Distance from Pallet Bottom to Engine Zenith and Height of Lifter Table 197. 后悬装配举升装置Rear Suspension Assembly Lifting Equipment 227.1 伸缩套

4、筒式升降工作台 227.2 剪式液压机构升降工作台Scissor Hydraulic Lifter Worktable 247.3 升降平台上平面到地面的高度计算Calculation on the Height from the Plane of the Lifter Table to the Ground 268. 不同轴距车体装配实现Body of Different Wheelbases Assembly Realization 289. AGV 动态装配解决方案AGV Dynamic Assembly Solution 2910. AGV 主要设备AGV Main Equipment

5、 2910.1 AGV（LGV）车载控制器 AGV（LGV）Vehicle Controller 2910.2 AGV（LGV）驱动系统AGV（LGV）Drive System 3010.3 导航系统Navigation System 3010.4在线自动充电系统Online Automatic Charge System 3210.5无线局域网通讯系统 Wireless LAN Communication System 3310.6驱动控制系统Drive Control System 3410.7非接触防碰装置Non-contact Bumper Device 3511. AGV安全系统AG

6、V Safety System 3511.1非接触防碰装置Non-contact Bumper Device 3511.2接触式防碰装置 Contact Bumper Device 3611.3离线保护系统 Offline Guarding System 3611.4信息交互系统 Information Exchange System 3611.5紧急停车系统Emergency Stop System 3711.6多AGV避碰 Multi-AGV Collision Prevention 3712. AGV控制台和调度管理系统AGV Console & Dispatching Manageme

7、nt System 3712.1 AGV控制台AGV Console 3712.2调度管理系统Dispatching Management System 3813. AGV车载控制系统和数据采集AGV Vehicle Control System & Data Collection 4014. 导航线的铺设Navigation Line Paving 4115. AGV系统特点AGV System Characteristics 4215.1 高速无线局域网的建立和应用 Setup and Application of High-speed Wireless LAN 4215.2 AGV运行的

8、灵活性Flexibility of AGV Running 4315.3 高精度导航系统High Accuracy Navigation System 4315.4 友好的人机界面User Friendly Human Machine Interface 4415.5 完善的自诊断系统Perfect Self-diagnosis System 4415.6 AGV可靠性措施Measures on AGV Reliability 4415.7 在线快速自动充电方法和快速充电电池的应用Online Automatic Instant Charge Method and Application of

9、 Instant Rechargeable Battery 4615.8 故障修复时间（MTR）Mean Time of Repair（MTR） 47AGV系统的故障修复时间有两类： Therere two kinds of MTR for AGV system: 4715.9 平均无故障时间（MTBF）Mean Time To Failures（MTTF） 4816. AGV运行路线图 AGV Running Route Graph 4816.1 装配线AGV运行布局图 Assembly AGV Running Layout 4816.2 样机车间AGV运行布局图 Sample Worksh

10、op AGV Running Layout 4818. 环行装配线AGV系统设备清单Circular Assembly AGV System Equipment List 5119. 项目进度Project Schedule 5320. 培训Training 5320.1 培训人员的范围、数量及时间Scope, amount and time for training people 5420.2 培训的内容Training content 5421. 售后服务After-sale service 551. 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，

11、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 Automo

12、bile Co., Ltd. on engine and axle AGV system, SIASUN uses assembly AGV system for engine, axle and body decking, and AGV with the function of synchronization dynamic tracking can realize simultaneous assembly of engine and axle at any assembly zone or stations. By using magnetic navigation, ground c

13、onstruction is small and by changing the path of magnetic strip upon technical requirements and modifying slightly control program, the length of assembly path can be altered to meet different assembly process requirements. AGV system is formed by a loop line, which is close to a trapezium. The asse

14、mbly zone is used for front suspension/engine, rear axle and body decking and the non-assembly zone is used for engine and axle suspending 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 as

15、sembly 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, AGV console, charge system, navigation system, communication system, data collection system 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 st

16、ations： 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 动力电源： 交流38010% 50HZ2% 3相5线Power supply: AC 38010% 50HZ2% 3 phases 5 lines温度： -545Temperature: -545湿度： 6095%Humidity: 6095%防护等级： IP54Protection grade: IP54绝缘等级：

17、 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 design 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 transp

18、ort, reception, carriage.5）AGV控制系统设计、制造，车载控制软件、调度软件设计。 AGV control system design and manufacturing, vehicle control software, scheduler software design.6）AGV工作环线设计、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。 Fie

19、ld installation, unit machine debugging and complete line linkage 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AGV Assembly & Transportation System Summary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 & transpo

20、rtation system includes AGV, AGV ground guided system, online automatic charge system, AGV console, data collection system, AGV dispatching management system and communication system, etc. AGV：AGV完成发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AGV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 r

21、ear suspension and assistant assembly jobs. Assembly operator can stand and work on AGV pedal, which is made of aluminum board with decorative figures and safe 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 syste

22、m 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 magnetic strips have been embedded underground, the ground will be smooth and wont influence people or vehicle to pass. 在线自动充电系统Online Automatic

23、Charge System：为了保证AGV 24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 AGV to run 24 hours continuously, charge system uses the method of large electrical current and instant electrification to charge AGV. AGV charge process is conducted automatically under the supervision and cont

24、rol 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之间的避碰问题。Console and AGV dispatching management system is the dispatching management center of AGV system, responsible for data processing in data co

25、llection system and information exchange with upper computer to create AGV running tasks and solve the problems of multi AGV collision. 通讯系统Communication System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 wireless local network. Wireless tr

26、ansmitter-receiver is adopted between AGV and console to exchange information and the communication protocol is TCP/IP protocol. Ethernet is used between console and the upper computer for 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

27、，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 on the suspending tools of the main transmission line has run to the position, where signal will be sent to inform AGV at the waiting station to move sideways to realize

28、sequence assembly. If the body hasnt passed, AGV at the waiting station will stay all along in the status of waiting. If passed, but theres no AGV waiting at the station, AGV console 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

29、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 technical specifications of AGV with synchronization tracking and lifting framework include:AGVS控制方式： 控制站集中调度、监控、管理AGV系统的运行状态AGVS control mode: control station makes centralized dispatch, monitoring & control and management on the ru

30、nning 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 desi

31、gn)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 occupied running space)最大速度： 直线60mmin，侧移30mminMaximum speed: straight 60mmin，sideways moving 30mmin导航精度：

32、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 around 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。Lifting equipment: dual li