AGC Manual

AUTO-CART AGC
MODEL #
E500-TUG-CAM-S-CSB-BC25-FB-LS-A6-A8-B1
TECHNICAL MANUAL 3D Sales for
JCI RAMOS
IDC SALES CONTACT Ginger Smigelski (517) 646-0358
AUTO CRAFT SALES CONTACT Marianna Walters (810) 765-1333 Job # J9642 Rev. 1.0 Released 10/2010
3-D SALES, INC.* 604 SMITH STREET * ALGONAC, MI 48001-1441 (810) 794-8160 PHONE (810) 794-8165 FAX sales@threedsales.com 3-D SALES INC. is a CERTIFIED MINORITY BUSINESS
AUTO-CART SUPPORT HOT LINE for JCI

LAYOUT AND MECHANICAL SUPPORT CONTACTS: Office 7:00am 4:30pm (810) 765-1333 (586) 615-2552 (810) 650-6988 (586) 615-2580
Dave Benke Tom Dudek Michael DuVernay
CONTROLS SUPPORT CONTACTS Office 7:00 3:30 pm. (517) 646-0358 (517) 648-2724 (517) 648-2719 (517) 648-2725
Jim Black Pete Walacavage Matt Robel
AFTER HOURS PHONE SUPPORT
TECHNICAL TECHNICAL TECHNICAL MANUAL MANUAL MANUAL
AGC AGC AGC
JCI - SOUTHVIEW
E3500-TUG-CAM-SR-AGM-BC40-FB-US-A6-A8-SP
JCI - SOUTHVIEW
JCI - SOUTHVIEW
J9642
Auto Craft Tool & Die
J9642
J9642
AUTO-CART Section 00-01 Overview TABLE OF CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
VEHICLE SIZE AND TYPE GUIDANCE CONTROLS BATTERIES OBSTACLE AVOIDANCE MISCELLANEOUS OPTIONS PREVENTATIVE MAINTENANCE SPARE PARTS MECHANICAL ASSEMBLIES ELECTRICAL TROUBLE SHOOTING WARRANTY
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AUTO-CART Section 00-02 Overview AUTO-CART GENERAL OVERVIEW

The Auto-Cart is a battery operated automated delivery cart guided by a color camera. The cart is designed to follow colored floor tape or a painted stripe path. The base cart is loaded with user-friendly features that can provide a delivery route with just a few basic rules in path design. Step Control models are step controlled, where each step in the path can have a host of parameters to set operating speed, travel distance, guidance by left or right edge or center of the stripe, use various laser sensing patterns, and control peripherals devices on the cart such as lifts and actuators. Each step also has a communication interface to other carts to provide traffic control, allowing carts to share common paths while avoiding collisions. This is all accomplished without having a master control. Web interface allows any Laptop computer with Internet Explorer to view and change cart speed, step values, camera settings and drive configurations. Carts are factory programmed to follow safety orange color tape or paint. User may choose a new color that provides the best color contrast against their floor using a color selection routine. The cart is provided with an automatic speed control, based on tape width, or a particular speed can be selected for each step. When selected to use tape width to control speed, widening the tape will reduce cart speed. Placing wider tapelines in front of stopping areas such as load/unload stations and corners will automatically slow down the cart to provide optimum guidance and to prevent spilling payloads. The speed may also be selected in each step control. During that setting, the tape width is ignored for speed control. The cart is provided with a floor proximity sensor. Each time the cart senses a steel plate it will initiate a slow down and stop. It is advisable to place 4-6 ft of widened tape in front of the stopping plate to slow the cart speed before stopping. This will provide a more precise stopping location. Cart can be programmed to recognize different length floor plates to be associated to a particular step in the program. This will positively re-synchronize the cart to the correct step in its programmed path. Anytime during operation the obstacle avoidance laser will stop the cart when an obstacle is detected. The cart will resume operation when the obstacle is removed or cleared from its path. If an obstacle was encountered suddenly very close, such as a person stepping directly in front, the brake will be applied immediately to provide an emergency stop. At that time the cart must be re-initiated manually by pressing the green button. During normal operation the cart may be stopped anytime by pressing the Green start/stop button. Pressing the green button again will initiate the cart to go, resuming the current step. Pressing the red button will remove power from the motor drives and immediately apply the brake.
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AUTO-CART Section 00-02 Overview AUTO-CART GENERAL OVERVIEW
Touch screen for information and Program Settings Operating Lamp with flash annunciating Flash sequence Cart Emergency Stop Button Push to stop Pull to Resume Audible warning Module (Optional Melody Module also available)
Main Power On/Off Electronic Laser Bumper Start/Stop Initiate
The cart is provided with an alarm sounding alert horn and yellow alert light. The sound module is usually set to play a melody when the cart is in motion. However each step has a choice of continuous, pulsed on/off, or muted sound. The module will also ring to indicate when the cart is blocked by an obstacle and sound a bell when the batteries are low. The yellow beacon will change its flash sequence to alert the operator the following conditions. Slow flash is normal operation when the cart is moving. Fast flash indicates that the cart is off the color path or the color is not properly selected. The cart will not move in this condition. A double fast flash followed by a pause indicates that the brake is not selected in the run position. The brake release handle is located on cart back and must be in the operating position run (handle down).
Brake Handle located in the Down (run) position for operation
Back of Cart
The cart guidance servo system is provided with steering gain proportional to speed. This gives the cart its ability to make tight turns at slow speeds and to smoothly follow a straight line at faster speeds. There is a gain vs. speed table in the web page for tuning the cart. This table is factory set and usually requires no additional changes. The cart is provided with anti-runaway protection that will shut down the cart immediately upon detection. Cart must be reset and restarted by powering with the power on/off selector switch. If problem persists see troubleshooting.
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AUTO-CART Section 01-00 AUTO-CART SIZE AND TYPE AUTO-CART SIZE 1. Model E500
The Model E500 AUTO-CART can be used in Tugger, Tunnel or Unit Load applications. It has a distributed deck capacity of 500 lbs., a towing capacity of up to 1,000 lbs. depending on traction capabilities and towed cart wheel friction. Paint color is Battleship Gray.
AUTO-CART STYLE 2. TUG (TUGGER) STYLE

A TUGGER style AUTO-CART will tow carts using a wide variety of hitches, receivers, pins or customer supplied hitch designs. The cart, being towed, must have a tongue length to allow the towed cart to turn and not create a pinch point between it and the Auto-Cart or another towed cart. The total combined weight of the cart(s) being towed cannot exceed the allowed towing capacity of the AutoCart. A flexible bumper is provided in most application. CAUTION: The owner of a towed cart or a load which is wider than the Auto-Cart deck is responsible for providing or advising this Auto-Cart manufacturer which collision avoidance methods are to be used based on local requirements.
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AUTO-CART Section 01-00 AUTO-CART SIZE AND TYPE AUTO-CART SIZE 1. Model E500
The Model E500 AUTO-CART can be used in Tugger, Tunnel or Unit Load applications. It has a distributed deck capacity of 500 lbs., a towing capacity of up to 1,000 lbs. depending on traction capabilities and towed cart wheel friction. Paint color is Battleship Gray.
2.
Model E3500
The Model E3500 AUTO-CART can be used in Tugger, Tunnel or Unit Load applications. It has a distributed deck capacity of 1,000 lbs., a towing capacity of up to 3,500 lbs. depending on traction capabilities and towed cart wheel friction. Paint color is Battleship Gray.
AUTO-CART STYLE 3. TUG (TUGGER) STYLE

A TUGGER style AUTO-CART will tow carts using a wide variety of hitches, receivers, pins or customer supplied hitch designs. The cart, being towed, must have a tongue length to allow the towed cart to turn and not create a pinch point between it and the Auto-Cart or another towed cart. The total combined weight of the cart(s) being towed cannot exceed the allowed towing capacity of the AutoCart. A flexible bumper is provided in most application. CAUTION: The owner of a towed cart or a load which is wider than the Auto-Cart deck is responsible for providing or advising this Auto-Cart manufacturer which collision avoidance methods are to be used based on local requirements.
4.
TUN (TUNNEL) STYLE

A TUNNEL style AUTO-CART will tow carts using an electric actuator to attach the towed cart to the Auto-Cart. The cart, being towed, must have a counter-weighted attachment to receive the AutoCart actuator pin. The towed carts can be released, on command from the Auto-Cart controls. Normally, only one (1) cart is towed. This style cart is used to perform cart exchanges (dropping off a full cart and exchanging it for an empty cart). The total combined weight of the cart being towed cannot exceed the allowed towing capacity of the Auto-Cart. A flexible bumper is provided. CAUTION: The owner of a towed cart or a load which is wider than the Auto-Cart deck is responsible for providing or advising this Auto-Cart manufacturer which collision avoidance methods are to be used based on local requirements.
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AUTO-CART Section 01-01 AUTO-CART SIZE AND TYPE
AUTO-CART SIZE 1. Model E500

The Model E500 AGC can be used in Tugger, Tunnel or Unit Load applications. It has a distributed deck capacity of 500 lbs., a towing capacity of up to 1,000 lbs. depending on traction capabilities and towed cart wheel friction. Paint color is Battleship Gray.
AUTO-CART STANDARD FEATURES: Drive and Steering:

o o o o o o 24 VDC differential transaxle w/ motor and an electrically released, spring set, fail-safe brake; 8/208.4mm diameter Urethane drive wheels; Linear position feed-back sensor; High torque steering actuator; 4 dia. spur gear driven Urethane steering wheel; Steering position feed-back module;
AUTO-CART STANDARD FEATURES:

Speed Control: o Pulse Width Modulated (PWM) o High bred Closed loop o Automatic deceleration in curves and selected straight sections without programming; o Programmable speeds o Automatic speed selection with the STEP programming module; Battery and Charger: o (2) 12 VDC GEL @ 71 Amp Hour; o 24 VDC, motor operating voltage; o 25 amp smart charger, (3) auto charge levels; o Removable battery tray for easy recharging; o Quick connectors for faster battery exchange;
Guidance: o Digital video camera with custom algorithms; o Modulated, uniform, self-contained light source; o Guidepath tape re-teach or program new color; o Dead reckoning capable; o Loss of guidance sensing; Cart Controls: o A dedicated micro-processor core module controls: speed, steering, guidepath imaging and the linear STEP program; o Operator controls; o Obstacle detection and bumper control; o Diagnostics o Battery and charger management; o Web page control and interface; o Communication interfaces, when necessary; o Part present and Stop floor marker detection; Visible Diagnostics: o Battery condition, low; o Loss of guidepath; o Obstacle detected;
SPECIFICATIONS:
Live load capacity (on deck)......500 lbs Tugger Capacity....Up To 1000 lbs Mule wt w/batteries and charger.......250 lbs Max. Speed ..225 FPM Drive Voltage......24 VDC Stopping Accuracy ......25 Inch Ground Clearance.....1 inch Min. Turn Radius (90 )...25 inches @ 90 FPM Deck Dimensions................36 L x 24 W x 9 H Deck MaterialPre-Punched, Formed and Welded Steel
NOTES:
Please consult the factory for a list of options, price, delivery and AGC application assistance. Demo and proto-type vehicles may be
This document is Uncontrolled when printed. Rev.: 11172007
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AUTO-CART Section 01-02 AUTO AUTO-CART SIZE AND TYPE
AUTO-CART STYLE TUG (TUGGER) STYLE

A TUGGER style AUTO-CART will tow carts using a wide variety of hitches, receivers, pins CART or customer supplied hitch designs. The cart, being towed, must have a tongue length to allow the towed cart to turn and not create a pinch point between it and the A Auto-Cart or another towed cart. The total combined weight of the cart(s) being towed cannot exceed the allowed towing capacity of the A Auto-Cart. A flexible bumper is provided in most application. exible CAUTION: The owner of a towed cart or a load which is wider than the Auto-Cart deck is Auto responsible for providing or advising this A Auto-Cart manufacturer which collision avoidance methods are to be used based on local requirements.
Examples:
E3500
E500
E3500
E500
E500
E3500
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AUTO-CART Section 02-01 Guidance COLOR CAMERA
CAM COLOR CAMERA w/ TAPE GUIDANCE

The vehicles are guided by a commercially available color camera. They follow a colored vinyl aisle marking tape. Inputs from the camera are processed and the resulting signals cause the drive steering motor to steer. The baseline steering heading is pre-programmed into the AGC controls. The camera system can be adjusted, by the end user, to follow other tape colors besides the standard orange color. Gaps in the tape can be bridged by dead reconning across the gap. The length of travel across a dead reconning space is an end user defined variable. Tape can be laid on top of other tape, including magnetic guidepath. Damaged tape can be repaired easily witout any special tools. It is difficult to lift the tape from the floor but it can be cut by fork truck forks or racks/pallets and other dunnage being pushed across the tape. This technology allows camera system to provide other benefits such as: automatic slow-down in turns, a wider guidepath with regard to a loss of guidance stoppage.
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AUTO-CART Section 02-02 Guidance CAMERA SETUP Ver 2.xx, 3.xx, 4.xx and 5.xx This program allows the user to select the color of the guidance stripe with background color to optimize tracking. This process must be done for each cart to optimize the cart guidance due to slight variations in camera exposures. Cart camera must be positioned on center of guidance stripe. Connect serial cable to Guidance processor 9-pin plug. Position the first toggle switch located next to serial plug for the camera to the PC position.
(2) Click on CMUcam2GUI Icon on your desktop (3) Click OK if you are using the No. 1 serial port or type in your port number and click OK. Once connected the screem shown on the next page will open up.
Connect PC to this serial port with a standard serial cable. (1)To view camera via software position the toggle switch to the PC position. This disconnects the camera from the processor and connects it to the computer.
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AUTO-CART Section 02-02 Guidance CAMERA SETUP
This message indicates that the computer recognizes the camera.
CMUcam type 2 Version 6
(4) Click the Config button and the next screen will pop up.
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(5) Select all of the following: Color Space-YCrCb White Balance-Off Auto Gain-Off Camera Resolution-High
10
174
110
(6) Type 10 to crop upper window edge.
(7) Type 110 to crop lower window edge.
(8) Click on Set Window.
(9) Click Camera View to view the image stripe.
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(10) Type in CR 0 8 (Camera Gain range 4 thru 63) and click the send box to the right. Then type CR 6 128 (Camera brightness range 1 thru 255) and click the send box again. Keep one space between each number. Note these values may need to be adjusted depending on color and floor background.
(11) Click the Send button to transmit each "CR" command (see item 10) to the camera. Repeat for the CR 6 128 command.
(12) Type 25 for typical tolerance. The wider the value the more color range the camera will track.
(13) Select Grab Frame This will initiate a snapshot of the Camera view. (Next page)
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(14) Place the curser over the desired area (usually in the center of the bright spot) and Click. A light blue highlighted area will be automatically selected. You may select different areas to achieve as much solid highlight area over the stripe as you can, as shown. If any blue highlighted areas are visible outside the stripe, or if you can't achieve solid highlighting, you may need to change camera brightness and gain setting (step 10/11), then repeat steps 12-14 to test your changes.
A color strip will be visible after the "Grab Frame" button is clicked. In YcrCb mode the colors may not appear normal, but you should be able to clearly distinguish the stripe.
(15) After Light Blue highlighted area is satisfactorily selected, Click on the Color tab and the next screen will appear.
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After clicking on the color track button below, (See step 16), this blue highlighted area will appear. This is the tracking window that will produce the position error signal to the guidance processor.
(17) These 6 groups of numbers are the color values selected by the camera. They must be documented and entered in the WEB page for Color Stripe Setup Note: Min and Max values are entered in the Min and Max values on the WEB page. Dont transpose entry.
Red
Green Min
Blue
Red
Green Max
Blue
(16) Click on the Track Color button and a dark blue window will appear. Moving the cart from left to right of the stripe will show the tracking. The dark blue stripe should be steady and visible across the whole window when the cart is moved from left to right of stripe. With the blue stripe visible you may test run the cart by simply switching the toggle switch on the guidance processor to RUN. These values are not saved so dont kill the cart during the test. You should copy the six min and max numbers, along with the brightness and camera gain values which you set up in step 10. Once satisfied with values enter the Min and Max colors values, camera brightness and gain via the WEB interface under the Color Setup. Note: the CMU camera viewer program may not resume operation if you switch the camera back to the PC port with the toggle switch; it may be necessary to use Task Manager to quit the program and start over. If so, you will need to reenter all of your settings and parameters as the viewer program initializes the camera to a default condition upon startup. Rev 1_02 02-02 Camera Set-Up Rev1_02.doc Page 6 of 6
AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL

Table of Content Page Section 1 - Step Description.. 3 Section 2 - Basic Step Components.............. 3 2.1 Step Initiation. 3 2.1.1Go Mode 3 2.2 Step Action........................ 4 2.2.1 Function 4 2.2.2 Speed & Speed Mode... 4 2.2.3 Direction and Navigation..... 3 2.2.4 Size.. 4 2.2.5 Obstacle Avoidance (Scanner)..... 4 2.2.6 Loss of Guidance..... 5 2.3 End of Step... 5 2.3.1 End Mode..... 5 2.3.2 Next Step.............. 5 2.3.3 End Action 5 2.4 Examples of Basic Steps... 6 2.4.1 Basic Steps........... 6 2.4.2 90 deg. Intersection.............. 8 2.4.3 Intersection (Y) .... 9 2.4.4 Basic Loop 10 Section 3 - Advanced Step Controls. 12 3.1 Delay for Warning. 12 3.2 Sound 12 3.3 Next Step... 13 3.4 Initiation Triggers.. 14 3.5 Hardwired Outputs 15 3.6 Plate Recognition... 19 3.7 Occupied Step... 20 3.8 Routes.... 21 Appendix A - Important Terms 22 Table of Figures Page Figure 1-1 Basic Step Layout...... 2 Figure 2-1 Basic Step Example 1............ 6 Figure 2-2 Basic Step Example 2............ 6 Figure 2-3 Basic Step Example 3.............7 Figure 2-4 Example of 90 deg. Intersection............ 8 Figure 2-5 Example of an Intersection.............9 Figure 2-6 Basic Loop Example............. 10
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Table of Figures (contd) Page Figure 3-1 Next Step Example................ 12 Figure 3-2 Initiation Triggers using Hardwired Inputs........... 14 Figure 3-3 Initiation Triggers using Radio Inputs............... 15 Figure 3-4 Outputs Example 1............ 16 Figure 3-5 Outputs Example 2............ 18 Figure 3-6 Occupied Step List Example.................. 20
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AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL 1 Step Description
The Auto-Cart is programmed to navigate a path using a Step Program. This program allows the path to be broke down into smaller sections. Each section allows the AGC to be setup to carry out a different function that can range from navigating corners and intersections to raising and lowering lifts. Each section contains the need information for the AGC to complete a portion of the path. As these sections, or steps, are put together in sequence, the AGC uses the supplied information to navigate the entire path A step contains three main components; initiation, action, and end. The initiation portion of the step informs the cart how to determine when to start the step. The AGC will wait until the initiation conditions are satisfied prior to starting the step. Once the step has been initiated, the cart will use the data stored in the action portion of the step to determine which functions to perform. This data contains information ranging from the steps speed and size to how to perform obstacle avoidance. As the cart approaches the end of the step, the end portion of the step tells the cart how to determine that it is at the end of the step and what actions to take. To achieve a seamless transition between two steps, the end action of one step has to be set to work with the initiation of the next. Initiate Action End
Figure 1-1 Basic STEP Layout
2 Basic Step Components

2.1 Step Initiation
2.1.1 Go Mode The Go Mode is used by the AGC to determine when to initiate a step. The cart will wait for the initiation condition to be true prior to placing the cart into cycle for the step. The options available for this parameter are: Operator Release The AGC will initiate cycle when the Master Start pushbutton is pressed. Automatic If the AGC is already in cycle upon transition into the step, the AGC will continue to run. Otherwise the Master Start pushbutton will have to be pressed to release the cart. Input Triggers The AGC will wait until the entire input trigger conditions are true prior to initiating the step. This option will be discussed in Section 3.4.
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2.2 Step Action
2.2.1 Function The step Function is used by the AGC to determine what actions to carry out during the step. The options available for this parameter are: Set Outputs, Forward The AGC will set the hardwired and radio outputs to the step's programmed settings and travel the distance set in Step Size. Set Outputs Only -The AGC will set the hardwired and radio outputs to the step's programmed settings and then go to the next step. Set Outputs, Delay -The AGC will set the hardwired and radio outputs to the step's programmed settings and delay the time set in Step Size.
2.2.2 Speed & Speed Mode The Speed and Speed Mode parameters are used by the AGC to set the speed that it will travel during the step. The speed uses units of inches per second. In Single Speed mode the cart will maintain the programmed speed. In Proportional Speed mode, the programmed Speed will be achieved on standard width tape and straight steering, but the AGC will automatically slow down if it sees wider tape or enters a turn. The AGC will determine which state to use based on the setting in the Speed Mode. The options available for this parameter are: Speed Mode Proportional to Line Width The maximum speed that the AGC will run will be the speed set in the Speed parameter. It will slow from this speed as the tapes width increases or when a turn is entered. Single Fixed Speed The AGC will run the speed set in the Speed parameter. Speed Speed Units Inches/Second Speed Limits 0 to 33
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2.2.3 Direction and Navigation The AGC uses the Direction and Navigation to decide how it will steer through the step. In most cases the cart should be set to follow the tape; in this mode the cart will use the Direction parameter to determine what portion of the tape to follow -Left edge, Right edge, or Center. The other option allows the cart to run without tape; it will move straight, or execute a maximum turn left or right depending on the Direction parameter. The options available for the parameters are: Navigation Normal Guidance The AGC will follow the tape based on the setting set in Direction. Dead Reckon The AGC will not follow the tape and will head in the direction set in Direction.
Direction Direction when Normal Guidance is used: o Left The AGC will follow the left side of the tape. o Center The AGC will follow the center of the tape. o Right The AGC will follow the right side of the tape. Direction when Dead Reckon is used: o Left The AGC will turn to the left. o Center The AGC will travel straight. o Right The AGC will turn to the right. * Direction Programming Recommendations: Follow the center of the tape when able. When transitioning from one side of the tape to the other, pass through a short step that uses the center of the tape. This will reduce the appearance of the cart jumping from one side to the other. If any paths must cross, have the tape cross at ninety degrees when able.
2.2.4 Size The AGC uses the Size parameter to determine the length of the step. The way that this is used is based on the setting in the Function parameter. Bellow is how this parameter affects the units of the parameter. Set Outputs, Forward When this function setting is used, the Size parameter will use the unit of inches.
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Set Outputs Only When this function setting is used, the Size parameter is ignored. Set Outputs, Delay -When this function setting is used, the Size parameter will use the unit of seconds. Size Limits 0 to 9999
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2.2.5 Obstacle Avoidance (Scanner) The Obstacle Avoidance parameter, also referred to as Scanner, is used by the AGC for selecting the obstacle detection modes. The value set in this parameter will correspond to the areas setup in the scanners software. Refer to the area settings in this software to determine the appropriate area to use. Limits STI limits: 1 & 2 Hokuyo limits: 1 15
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2.2.6 Loss of Guidance The AGC will use the value set in Loss of Guidance to determine how far it is allowed to travel after the guidance tape is lost. This feature is used to help accommodate missing portions of the tape. This value will be ignored when using Navigation Setting of Dead Reckon. Loss of Guidance Units inches Loss of Guidance Limits 6 to 24
2.3 End of Step

2.3.1 End Mode The End Mode is used by the AGC to trigger the end of the step. When the End Mode setting is satisfied, the cart will load the step set in Next Step and perform the End Action. The options available for this parameter are: Distance The AGC has reached the end of the step after it has traveled the distance that is set in the Size parameter. Marker The AGC has reached the end of the step after it has traveled over a marker, or exhausted the Distance parameter. Time -The AGC has reached the end of the step after it has delayed for the time period that is set in the Size parameter.
2.3.2 Next Step The AGC uses the Next Step parameter to sequence the steps. Once the End Mode is satisfied, the cart will load the step set in this parameter. If this is set to zero, the steps will be loaded consecutively. Refer to Section 3.3 for more details on how this parameter is used. Next Step Limits 0 to 99
2.3.3 End Action The End Action is used by the AGC to determine whether to remain in cycle for the next step. This parameter, along with the Go Mode of the next step, will determine how the AGC will respond during the transition to the next step. The options available for this parameter are: Stop The AGC will load the step set in Next Step and then wait for a signal to continue. This is usually used in conjunction with the next steps Go Mode setting of Operator Release or Input Triggers. Merge -The AGC will load the step set in Next Step and then continue to run that step. This is usually used in conjunction with the next steps Go Mode setting of Automatic.
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2.4 Examples of Basic Steps
2.4.1 Basic Steps Example 1 In this example, the cart will be programmed to run a straight path of 310 inches. It will require an operator to release the cart, and once it has reached the end, it will stop. The carts speed is not critical so it will be set to a lower speed of ten inches per second. The step will be programmed as follows. 310
Figure 2-1 Basic STEP Example 1
Step Initiation Go Mode Operator Release Step Action Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 10 Navigation Normal Guidance Direction Center Size 310 Loss of Guidance 12 End of Step End Mode Distance End Action -Stop Example 2 In this example, the cart will be programmed to run a straight path of 100 inches maximum, but instructed to stop when it encounters a floor marker plate any time within the 100 inch move, to provide precision alignment with some external fixture. It will require an operator to release the cart, and once it has found a floor marker, it will stop. The cart's speed is not critical so it will be set to a low speed of ten inches per second. The step will be programmed as follows. 100
Figure 2-2 Basic Step Example 2
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Step Initiation Go Mode Operator Release Step Action Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 10 Navigation Normal Guidance Direction Center Size 120 Loss of Guidance 12 End of Step End Mode Marker End Action Stop
!
The Step size was set twenty inches longer than the actual step size to allow the cart to have the distance to travel over the marker.
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Example 3 In this example, the two steps from the first two examples will be put together. Example one will become step one and example two will become step two. The cart will travel at a moderate speed of twenty inches per second through step one and then slow to eight inches per second in step two to prepare for a stop at an operator station marked by a floor marker. It will be assumed that the scanner has area 1 set for high speed travel and area 2 programmed to be narrow for slower speed steps near operator stations. The step program for these two steps will appear as follows. STEP 2: 100 STEP 1: 310
Figure 2-3 Basic Step Example 3
Step 1 Step Initiation Go Mode Operator Release Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 20 Navigation Normal Guidance Direction Center Size 310 Obstacle Avoidance -1 Loss of Guidance 12 End Mode Distance End Action -Merge Step Action Step Initiation
Step 2 Go Mode Automatic Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 8 Navigation Normal Guidance Direction Center Size 120 Obstacle Avoidance - 2 Loss of Guidance 12 End Mode Marker End Action - Stop
Step Action
End of Step End of Step
End of Step End of Step
In step two, the Speed Mode parameter was set to Proportional to Line Width to have the ability to add a second width of tape to help slow down for the plate if needed. The step would have cycled properly if it was left at Single Fixed Speed. To have the two steps run as one step, the End Mode of step one was set to Merge and the Step Initiation of step two was set to Automatic. By setting the steps this way, the cart will transition between the two steps without stopping.
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2.4.2 90 deg. Intersection This example will be the same as example one of section 2.4.1 except that another path crosses it at ninety degrees. In this example, the step will be programmed exactly the same way. In order for the cart to travel through the intersection properly, the AGCs direction must be set to center.
310
Figure 2-4 Example of 90 deg. Intersection
Step Initiation Go Mode Operator Release
Step Action Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 10 Navigation Normal Guidance Direction Center (Must be set to Center) Size 310 Loss of Guidance 12
End of Step End Mode Distance End Action Stop
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2.4.3 Intersection This example will be the same as example one of section 2.4.1 except that another path turns off of this path to the left. The cart will travel straight past the intersection. In this example, the steps will be programmed similarly. The only change that will need to be made is to have the navigation Direction follow the right side of the tape.
310
Figure 2-5 Example of an. Intersection
Step Initiation Go Mode Operator Release
Step Action Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 10 Navigation Normal Guidance Direction Right (Must be set to Right) Size 310 Loss of Guidance 12
End of Step * End Mode Distance End Action Stop
To have the cart follow the path to the left, the carts direction would need to be set to the left.
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2.4.4 Basic Loop In this example, the cart will be programmed to navigate the loop shown in Figure 2-6. The cart will leave operator station one in step one traveling at fifteen inches per second and head toward the operator station two. Along the way, it will come to an intersection where the AGC will have to choose between three directions. The cart will travel straight through the intersection and on to step two where the cart will slow to eight inches per second to prepare to stop on the floor marker. After operator is complete with the cart at the second station, the operator will release the cart to travel back toward the first station. The cart will then need to navigate though two intersections. The first one will require the cart to navigate to the left. The second intersection will require the cart to navigate to the center of the tape. The cart will travel at fifteen inches per second through these two sections. As the cart approaches the first station, it will use double width tape to slow from twelve inches per second to prepare for the stop at another marker. Operator Station 1 Step 5: 200 Step 4: 100 Step 3: 450
Step 1: 650
Figure 2-6 Basic Loop Example
Step 2: 100 Operator Station 2
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Step 1 Step Initiation
Go Mode Operator Release Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 15 Navigation Normal Guidance Direction Center Size 650 Obstacle Avoidance - 1 Loss of Guidance 12 End Mode Distance End Action Merge

Go Mode Automatic Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 8 Navigation Normal Guidance Direction Center Size 120 Obstacle Avoidance -2 Loss of Guidance 12 End Mode Marker End Action - Stop
Step Action
Step Action
End of Step
End of Step

Go Mode Operator Release Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 15 Navigation Normal Guidance Direction Left Size 450 Obstacle Avoidance -1 Loss of Guidance 12 End Mode Distance End Action -Merge

Go Mode Automatic Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 15 Navigation Normal Guidance Direction Center Size 100 Obstacle Avoidance -1 Loss of Guidance 12 End Mode Distance End Action -Merge
Step Action
Step Action
End of Step
End of Step

Go Mode Automatic Function Set Outputs, Forward Speed Mode Proportional to Line Width Speed 12 Navigation Normal Guidance Direction Left Size 230 Obstacle Avoidance -1 Loss of Guidance 12
!
Step Action
The direction in step five is set to follow the left side of the tape so that it wont appear to run toward the right on the double wide tape.
End of Step End Mode Marker End Action -Stop

AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL 3 Advanced Step Controls
3.1 Delay for Warning
The Delay for Warning is used by the AGC to determine how long to wait between the step initiation and the start of motion. At any point when motion has been stopped during this step, the cart will execute this delay prior to restarting. During the delay, the cart will activate the sound module. If the cart is already in cycle due to transitioning from another step, then this parameter will be bypassed and the cart will continue to run the step. Delay for Warning Units Seconds Delay for Warning Limits 0 to 5
3.2 Sound
The Sound parameter is used by the AGC to determine how the sound module is used during the step. The options available for this parameter are: Silent The sound module is not used while the AGC is in motion. This is not recommended where personnel may be present. Continuous The sound module is held on continuously while the AGC is in motion. Pulsed The sound module will be turned on and off while the AGC is in motion.
3.3 Next Step

The Next Step is used by the cart to sequence the steps. This allows the step numbers to be nonconsecutive. For example, this allows steps to be added into a preexisting path without affecting other steps. -Example: Using the example in section 2.4.4 Basic Loop, the steps could have been programmed in the following sequence. Step 1 : 200 Step 3: 100 Step 5: 450
Step 4: 650 Figure 3-1 Next Step Example
Step 2: 100
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Go Mode Automatic Function Set Outputs, Forward Speed Mode Proportional to Line Width Speed 12 Navigation Normal Guidance Direction Left Size 230 Loss of Guidance 12 End Mode Marker End Action Stop Next Step 4

Go Mode Automatic Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 8 Navigation Normal Guidance Direction Center Size 120 Loss of Guidance 12 End Mode Marker End Action Stop Next Step 5
Step Action
Step Action
End of Step
End of Step

Go Mode Automatic Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 15 Navigation Normal Guidance Direction Center Size 100 Loss of Guidance 12 End Mode Distance End Action Merge Next Step 1

Go Mode Operator Release Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 15 Navigation Normal Guidance Direction Center Size 650 Loss of Guidance 12 End Mode Distance End Action Merge Next Step 2
Step Action
Step Action
End of Step
End of Step

Go Mode Operator Release Function Set Outputs, Forward Speed Mode Proportional to Line Width Speed 15 Navigation Normal Guidance Direction Left Size 450 Loss of Guidance 12
Step Action
End of Step End Mode Distance End Action Merge Next Step 3

3.4 Initiation Triggers
If Initiation Triggers are selected for the Go Mode, the AGC will use its hardwired and radio inputs to place the cart into cycle for the step. This allows the cart to initiate off of signals sent by a remote device. In order for this function to operate properly, all of the hardwired and radio inputs have to be set correctly. Any unused input must be set to N/A to inform the cart that the state of this input is not critical for a release. Otherwise, the input must be set as On or Off. It is recommended that the steps that use input triggers as their Go Mode are set to use a short distance or to be set as a delay step.
!
When radio input triggers are used, the ID number for the remote station must be set in the Target Radio for the step. -Example 1: The AGC is to be released from an operator station when an operator steps on a pedal that reveals a reflector that will activate a photoeye mounted on the AGC. The photoeye will be wired into input one. Step one will be set to delay three seconds and then transition into step two where the AGC will travel one hundred inches at fifteen inches per second and then stop. Step 2 100
Step 1 Delay
Figure 3-2 Initiation Triggers using Hardwired Inputs

Go Mode Input Triggers

Go Mode Automatic
Hardwired Input 1 = On Hardwired Input 2-10 = N/A Radio Input 1-16 = N/A
Step Action Function Set Outputs, Delay Speed Mode Single Fixed Speed Speed 0 Navigation Normal Guidance Direction Center Size 3 Obstacle Avoidance 1 Loss of Guidance 12 End of Step End Mode Time End Action Merge All non-motion steps are shown as a red line. Speed Mode, Navigation, Direction, Obstacle Avoidance, and Loss of Guidance settings are not critical for step one.
Step Action Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 15 Navigation Normal Guidance Direction Center Size 100 Obstacle Avoidance -1 Loss of Guidance 12 End of Step End Mode Distance End Action Stop

-Example 2: The AGC is to be released from a remote operator station that will communicate to the carts over the radio communications. The remote operator station is setup to transmit using the ID of fifty. When an operator presses the release button on the station, then the station turns on the carts third Radio Input. Once Radio Input three turns on, the AGC will initiate step one where the cart will travel five inches and then transition into step two. The AGC will travel sixty inches at twenty-eight inches per second in step two and then stop. Step 1 : 5 2 : 60
Figure 3-3 Initiation Triggers using Radio Inputs


Go Mode Automatic
Hardwired Input 1-10 = N/A Radio Input 1 & 2 = N/A Radio Input 3 = On Radio Input 4-16 = N/A
Target ID 50
Step Action Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 28 Navigation Normal Guidance Direction Center Size 5 Obstacle Avoidance 1 Loss of Guidance 12 End of Step End Mode Distance End Action Merge
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-Example 3: In this example, the cart will execute the same as in Example 2 except that the AGC also must see the pallet present prox that is wired into the hardwired input five Off prior to releasing in step one. The cart will now release only when both hardwired input five is off and radio input three is on at the same time. Step 1 Step Initiation

Go Mode Automatic
Hardwired Input 1-4 = N/A Hardwired Input 5 = Off Hardwired Input 6-10 = N/A Radio Input 1 & 2 = N/A Radio Input 3 = On Radio Input 4-16 = N/A
Target ID 50
Step Action Function Set Outputs, Forward Speed Mode Single Fixed Speed Speed 28 Navigation Normal Guidance Direction Center Size 5 Obstacle Avoidance 1 Loss of Guidance 12 End of Step End Mode Distance End Action Merge
3.5 Hardwired Outputs

Each step has the ability to turn on or off the hardwired outputs. This gives the cart the ability to control lifts, photoeye senders, additional lights and sound modules, and so on. The available options for the outputs are: On Turns the output on when the step is initiated. Off Turns the output off when the step is initiated. N/A Leaves the output in its current state. -Example 1: The AGC has an additional warning light to be used when crossing isle ways. This light is wired into output six and is used in step two which crosses an aisle way.

Example 1 (contd) Step 1 : 25 Step 2 : 95 Step 3 : 45
Figure 3-4 Outputs Example 1

Go Mode Automatic Function Set Outputs, Forward Outputs

Step Action Outputs 1-5 = N/A Output 6 = Off Outputs 7-10 = N/A
Speed Mode Single Fixed Speed Speed 20 Navigation Normal Guidance Direction Center Size 25 Obstacle Avoidance -1 Loss of Guidance 12 End Mode Distance End Action Merge
Step Action Outputs 1-5 = N/A Output 6 = On Outputs 7-10 = N/A

Speed Mode Single Fixed Speed Speed 15 Navigation Normal Guidance Direction Center Size 95 Obstacle Avoidance -1 Loss of Guidance 12 End Mode Distance End Action Merge
End of Step
End of Step

Step Action Outputs 1-5 = N/A Output 6 = Off Outputs 7-10 = N/A
Speed Mode Single Fixed Speed Speed 20 Navigation Normal Guidance Direction Center Size 45 Obstacle Avoidance -1 Loss of Guidance 12 End Mode Distance End Action Merge 03-02 Step Programming Manual Rev 1_02.docx Page 20 of 25
End of Step
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-Example 2: An AGC uses a pin lift to transport part racks to and from the operator stations. When the AGC enters the drop off station, it will push the empty rack forward until the AGC reaches the operator station. The AGC will then turn on output two to lower its lift pin so that the full rack will be left at the operator station. The cart will then start to pull under the empty rack. When it is clear of the link mechanism of the full rack, the AGC will turn on output one to raise its lift pin which will then engage the empty rack as it is passing by.
Operator Station
Step 1: 25
Step 3: 20
Step 4: 53
Loaded Cart
Empty Cart
Step 2: Outputs Only

Figure 3-5 Outputs Example 2

Go Mode Operator Release Function Set Outputs, Forward Outputs

Step Action Output 1 = On Output 2 = Off Outputs 3-10 = N/A

Speed Mode Single Fixed Speed Speed 8 Navigation Normal Guidance Direction Center Size 25 Obstacle Avoidance 2 Loss of Guidance 12 End Mode Distance End Action Merge
Step Action Output 1 = Off Output 2 = On Outputs 3-10 = N/A

Speed Mode Single Fixed Speed Speed 0 Navigation Normal Guidance Direction Center Size 5 Obstacle Avoidance 2 Loss of Guidance 12 End Mode Time End Action Merge
End of Step
End of Step
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Step 3 Step Initiation Go Mode Automatic Step Action Function Set Outputs, Forward Outputs Output 1 = Off Output 2 = On Outputs 3-10 = N/A Speed Mode Single Fixed Speed Speed 8 Navigation Normal Guidance Direction Center Size 20 Obstacle Avoidance -2 Loss of Guidance 12 End of Step End Mode Distance End Action Merge Step 4 Step Initiation Go Mode Automatic Step Action Function Set Outputs, Forward Outputs Output 1 = On Output 2 = Off Outputs 3-10 = N/A Speed Mode Single Fixed Speed Speed 8 Navigation Normal Guidance Direction Center Size 53 Obstacle Avoidance -2 Loss of Guidance 12 End of Step End Mode Distance End Action Merge
3.6 Plate Recognition

The Plate Recognition table utilizes floor marker plates of different lengths to orient the AGC to certain locations in a path. After the cart has traveled over a floor marker, the cart will compare the measured plate length to the data set in the Plate Recognition Table. If there is a step number entered for that length, the cart will load that step and then perform the action set in the associated End Action parameter (the End Action acts in the same manner as the step End Action). If the step number for that plate length is set to zero, the cart will treat that plate as a generic plate length. Each route has its own Plate Recognition Table and will only load the steps within that route. Length The length of the plate in inches. Step 0 Plate will be treated as a generic floor marker. 1-99 -After the cart has traveled over the plate, this step number will be loaded (within the current route). End Action Stop The AGC will load the step set in Next Step and the wait for a signal to continue. This is usually used with a Go Mode setting of Operator Release or Input Triggers. Merge -The AGC will load the step set in Next Step and then continue to run that step. This is usually used with a Go Mode setting of Automatic. * Plate Recognition Programming Recommendations: Allow 2 and 4 plates to be generic plate lengths. Avoid using recognition plates on corners. Set a recognition plate at the point in the path were carts will be introduced to the path.

3.7 Occupied Step
The Occupied Step List is used with Cart-to-Cart communications to set step priority amongst the carts. When another cart transmits a current step number that is in the step list, the cart will hold until the step is clear. -Example: In the path below there is an intersection where Cart-to-Cart communication is used to set the step priority. In this example, cart one (in steps 50-52) has priority over cart two (in steps 1-3). If the two carts were to come to the intersection at the same time, the cart in step fifty would continue and the cart in step one will stop and wait until the intersection is clear to continue. However, if cart two has already entered step two, cart one will hold until the intersection is clear.
Step 52
Step 1 Cart 2
Step 2 Step 51
Step 3
Cart 1
Figure 3-6 Occupied Step List Example
Step 50
Step 1 Occupied Step List 2 50 51
Step 2 Occupied Step List 2
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Avoid having two steps that would block each other. If step fifty above had step one in it Occupied Step List, then when a cart is setting in step one and fifty, neither cart would move.
3.8 Routes
Routes are used by the AGC so that it can have multiple paths of up to ninety nine steps per route. This option is best utilized when a Main Cart Control Panel (MCCP) is used to control the cart system or the carts need the ability to travel several different paths.
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AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL Appendix A -Important Terms
AGC Automated Guided Cart Companion Cart An additional structure that supports the weight of the material and is transported by a mule is referred to as a Companion Cart. HMI Human Machine Interface Marker - A floor plate used to mark the end of a step. Also refer to Stop Plate and Recognition Plate. MCCP Main Cart Control Panel Mule An AGC that transports a cart (Companion Cart) that carries the majority of the payload is referred to as a Mule. Occupied Step Each step has an occupied step list. If any AGC that is running the same path is transmitting that it is in one of the steps in the occupied step list, than that AGC is in an occupied step. While the AGC is in this step, the AGC with this occupied step list is not allowed to run. Recognition Plate A floor plate used to mark the transition point of steps and is associated to a specific step in the Plate Recognition data table is referred to as a Recognition Plate. When an AGC travels over a Recognition Plate, it will automatically load the associated step. Also refer to Marker and Stop Plate. Route A route can contain up to 99 steps and a AGC can have multiple routes. This feature allows a complicated AGC path to be broken down into multiple sections (or routes). It divides the path down into smaller, easier to manage individual paths. This also allows for easier path modifications without potentially affecting other areas of the overall path. RSSI Received Signal Strength Indication This is used as a generic term for the received signal strength for the AGCs. Step A step contains the needed information for an AGC to manipulate a small portion of an overall path. This information contains data such as speed, distance to travel, guidance direction, and much more. The number of steps needed to put a path together depends on the complication of the overall path. Stop Plate -A floor plate used to mark the end of a step which typically causes the AGC to stop. Also refer to Marker and Recognition Plate.
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AUTO-CART Section 03-03 Controls XBEE RADIO INTERFACE

AGC Communications The carts communicate with each other and/or a fixed base station using MaxStream XBee Pro Radios. The default network parameters for the AGC are: PAN ID MY ID 18301 (0x477D) Assigned by cart prompt
In normal operation each cart broadcasts its status as a block of 18 bytes as follows: Byte 0 Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Byte 9 Byte 10 Byte 11 Byte 12 Byte 13 Byte 14 Byte 15 Byte 16 Byte 17 Current Step Most Significant Byte Current Step Least Significant Byte RF Coils Most Significant Byte (Coils 9-16) RF Coils Least Significant Byte (Coils 1-8) AGC Voltage MSB AGC Voltage LSB AGC Current MSB AGC Current LSB Current Route MSB Current Route LSB Distance Traveled MSB Distance Traveled LSB AGC Inputs 9-16 AGC Inputs 0-8 AGC Outputs 9-16 AGC Outputs 0-8 Fault Code MSB Fault Code LSB
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When this is received by an XBee radio operating in API mode with the same PAN ID, the radio outputs the following packet structure: Byte 0 Start of Frame, 0x7e Byte 1 High Byte of Frame Length Byte 2 Low Byte of Frame Length Byte 3 API Command Code (0x81) Byte 4 High Byte of senders MY ID (0) Byte 5 Low Byte of senders MY ID (Cart No.) Byte 6 Received Signal Strength, abs(-dB) Byte 7 Option Byte (2 = broadcast within PAN) Byte 8 Current Step MSB Byte 9 Current Step LSB Byte 10 RF Coils 9-16 Byte 11 RF Coils 1-8 Byte 12 AGC Voltage MSB Byte 13 AGC Voltage LSB Byte 14 AGC Current MSB Byte 15 AGC Current LSB Byte 16 Current Route MSB Byte 17 Current Route LSB Byte 18 Distance Traveled MSB Byte 19 Distance Traveled LSB Byte 20 AGC Inputs 9-16 Byte 21 AGC Inputs 0-8 Byte 22 AGC Outputs 9-16 Byte 23 AGC Outputs 0-8 Byte 24 Fault Code MSB Byte 25 Fault Code LSB Byte 26 8-bit checksum RF Coils refers to the RF Output bits programmed for each step. AGC Inputs refers to the discrete inputs into the expander board. AGC Outputs refers to the outputs on the expander board programmed for each step. AGC Fault Codes: o 0 = No Fault o 1 = Illegal Step Number o 2 = Laser Scanner Blocked o 3 = Blocked By Radio o 4 = Master Off o 5 = Loss Of Guidance o 6 = Step Cycle On o 7 = Waiting For Triggers o 8 = Charging o 9 = Low Battery
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o 10 = Brake Disabled All receivers get this information for every transmitter in range. As part of the parameters for each step in the carts program, any individual cart can be instructed to listen to a particular sender (defined by the RF Target ID item in the step program), mapping that senders RF Coils to the receivers RF Input bits. This information is transmitted approximately once a second starting from the time the cart powers up and completes initialization, so they are random to start with. In addition, each transmitter implements some random delay from the last received packet, so the net effect is that the packets arrive with random timing. Each cart is equipped with a display as shown below. This allows the operator to see status of the communications and the current route, step, and relative signal strength for each cart. The cart number display is used to show the status of the corresponding watchdog timer. The communications are OK when the background is white, and communications is lost when black.
Figure 1: AGC Communications Status Display
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MCCP Communications The multi-route carts are designed to receive a one word command from the Main Cart Control Panel (MCCP). When the AGC receives a transmission from the MCCP, the cart extracts its individual command word and separates it into the five command components shown in the table below. Bits: 1-8 Step # Bits: 9-13 Route # Bit: 14 Jump to Step Bit: 15 Control Stop Bit: 16 Remote Start
Step and Route #: The Route and Step number commands are used by the AGC when the Remote Start or Jump to Step command signals are received. When the Remote Start command is received, the AGC will verify that its current Route and Step number equal that of the commanded Route and Step number before initiating the current step. For the Jump to Step command, the AGC will load the Route and Step number. Jump to Step: This bit is used to instruct the cart load the corresponding Route and Step numbers from the above commands. Control Stop: While this bit is held high, the AGC will cease all motion and display a radio block alarm. Remote Start: The AGC will initiate cycle when this bit goes high as long as its current Route and Step numbers match the above Route and Step numbers.
The packet sent to the radio should be in the form of: Byte 0 Start of Frame, 0x7e Byte 1 High Byte of Frame Length Byte 2 Low Byte of Frame Length Byte 3 API Command Code (0x01) Byte 4 Disable Response Frame (0x00) Byte 5 Broadcast MSB (0xFF) Byte 6 Broadcast LSB (0xFF) Byte 7 Disable ACK (0x01) Byte 8 AGC 1 Command MSB Byte 9 AGC 1 Command LSB Byte 10 AGC 2 Command MSB Byte 11 AGC 2 Command LSB Byte 12 AGC 3 Command MSB Byte 13 AGC 3 Command LSB
Byte [(* x 2) + 6] (*=AGC#) AGC * Command MSB (Max. * = 50) Byte [(* x 2) + 7] (*=AGC#) AGC * Command LSB (Max. * = 50) Byte [(* x 2) + 8] (*=Last AGC#) 8-bit checksum Note: This packet format can transmit up to fifty cart command words.
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Note that a transmitting device should follow the Xbee Pro API mode instructions for transmitting data, as the radio uses API mode for both transmit and receive packets. The API mode allows sending commands to set the protocol addresses, as well as many other control parameters. It is up to the designer whether to fix the PAN ID and MY ID through the modem configuration utility, in which case they dont need to be initialized by the controller, or let controller do the configuration upon startup. The advantage to the latter approach is that the MY ID, for instance, could be changed dynamically should such a need arise. The other advantage is that an off-the-shelf radio would automatically be configured when attached to the system, without need for special setup before deployment, reducing spare part inventory and simplifying replacement procedures. One thing to take note of, though, is that the units come from the factory in ASCII mode, so regular AT commands must be sent first to put it into API mode. The default network parameters for the MCCP are: PAN ID 18301 (0x477D) MY ID 150 (0x96) It is suggested that a monitoring or control system store the received information in an array, indexed by the sender IDs. A corresponding watchdog timer per cart is also recommended, so that loss of communication with any one cart can be detected. If a controller is designed to transmit to the carts, it is suggested that a 1-second transmit interval is appropriate. In the event that a large number of carts need to operate in a given area in different subsystems, groups of different carts with different PAN IDs could be configured to isolate them from each other. In this case, it is conceivable that a central control/monitoring system could either use multiple radios with different PAN IDs or dynamically switch PAN IDs to selectively monitor/control more than one subsystem. Although the Xbee radios are capable of mesh networking to extend the range beyond the reach of a single pair, this is not presently implemented for throughput reasons. If a situation should arise where carts cant talk to each other directly because of physical limitations such as plant walls, etc., then a central controller could act as a relay by operating so that carts on either side of the barrier would talk to the controller, and the controller would relay the information, preferably selectively based on some combination of cart ID and step locations. Should this situation arise, further discussion would be in order.
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AUTO-CART Section 03-04 Controls RFBASE UNIT USER GUIDE

Introduction The AutoCart RF Base unit provides a bidirectional radio link between a system of AutoCarts and a stationary control system, such as robots, automatic doors, loaders, lifters, etc. To minimize cost and spare parts requirements, it utilizes the same hardware as the AutoCarts themselves with a special program suited for the purpose. In general terms, the RFBase Unit receives the broadcast status information from all nearby AutoCarts, and using the program setups outlined below it reports 8 status bits from relevant carts to its host device via 24 V DC open-collector (a.k.a. sinking) outputs, which can be interfaced to various controllers, relays, etc. At the same time, it accepts 8 input bits from 24 V DC Sourcing devices and broadcasts these status bits to all AutoCarts in range, so that those carts can use the information to trigger various actions according to their step sequence programs. The unit has numerous configuration options that are configured using Web pages on a built-in Ethernet connection. More detail on how this actually works is found below in the description of the setup web pages. The unit is housed in an industrial enclosure, as shown in the photo below:
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Physical mounting information is shown in the drawing below:
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Terminal hookups for user use are shown in this drawing:
All configuration and setup is performed by built-in web pages via common internet browser software. For one-on-one connection with a computer a crossover cable is needed, or the user may connect the device to a standard ethernet switch to enable remote access. If the device is connected to the a customer's general network it is strongly recommended that the user should consider security issues in their environment and take appropriate steps to prevent unauthorized access to the unit. The RF Base is supplied with a standard IP address as shown in the following screen documents, although the address can be changed in the field consult the factory for help in changing the address if so desired.
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Login Screen (appearance may vary depending on your browser) This screen should appear when you type the IP address of the RF Base Unit into the address bar of your browser.
The user name is user, and the password is password Upon successful login, the Main Page will appear as shown below.
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Main Menu Page
Click any of the links to go to the corresponding page.
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Status Viewer: Note that this screen will take a few seconds to fully display the status table.
The Radio Pan ID and Radio Unit ID are readouts of the configuration entered in the Radio Setup editor, detailed later in this document.
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The Hardware Input, Hardware Output and RF Source ID items display the current state of the hardware I/O for diagnostic use. Note that hexadecimal format is used to allow determination of the state of each I/O bit. Table Column explanations are: Unit ID is the Cart ID of the transmitting cart. The table is sorted by this column, so if you want to see what Cart 10 is doing, for example, you would look at the line for Unit ID 10. Silence Timer is a count of seconds since the Cart on a particular line has been heard from. If this time exceeds a time limit indicating that the unit is out of range or off the air, then this cell will be highlighted in red, and the Route and Step information will be cleared. This allows the system to clear itself if a cart is turned off, for example. Current Route reports the latest Route information from each cart. This is part of the selection process used to choose which cart's status information is be reported on the hardware outputs. Current Step reports the latest Step information from each cart. This is part of the selection process used to choose which cart's status information is be reported on the hardware outputs. Current RF Coils is a hexadecimal readout of the Radio Coils programmed for each cart as an item in the step controls. It is reported here primarily for diagnostic purposes. Refer to the Receiver Mapping Page description for an explanation of how and when this information will be relayed to the host hardware. Current RSSI is an indicator of Radio Signal Strength for the particular cart: the higher the number, the stronger the signal.
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Receiver Mapping Page: note that this page can take a while to load because it is preparing a very large set of choices for you to select from.
This is the heart of the system for relaying status bits from one or more carts to the base unit's Output bits. The base unit is continuously listening to status broadcasts from every cart within radio range. However, it only has a fixed number of hardware outputs to report this information to its host control system. To do so, it sorts through all the received status information from all of the carts, and when it finds that a cart is in a location that is of concern to its host system, as specified by the route and step combinations in this table, it can select that cart's RF Coils to be mapped to the hardware outputs. Since there could be several steps, or several carts, in the area of the base unit that need to interlock with the local control system, two options are available to choose which cart's information is passed on.
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Priority Mode The simplest mode is Priority mode, where the first cart found in the specified list of Route & Step combinations takes full control of all available outputs to the base machine. When that Route/Step slot is vacated by the cart, the rest of the list will be searched until a lower-priority site is found to be occupied; the cart at that location will then get its coils copied to the hardware outputs. If none of the Route/Step combinations listed here are occupied, then all outputs will be turned off. In this scenario, there can be only one cart at a time controlling all outputs to the base machine. This is the only appropriate mode if an MCCP (Master Cart Control Panel) is chosen to control the outputs. Mask Mode An alternative Bit Masked mode is available that can allow the available hardware outputs to be distributed amongst carts in several locations simultaneously. In this mode, when a cart is found to be in the specified Route/Step combination for line 1, for instance, its outputs (that is, the RF Coils programmed in its step table) will be logically ANDed with the bit mask specified in column 3 and held in an accumulator. The 2nd line will then be scanned, and the outputs of any cart in that location will again be ANDed with the 2nd line's bitmask specification, then that result will be logically ORed with the previously mentioned accumulator. This continues through all lines in the table. Thus, certain bits from each line can be combined with bits from the other lines. The accumulation of all these bits will be output on the hardware. For readers less familiar with programmerese, the following explanation of the aforementioned logical AND and OR operations may be helpful. First it is necessary to understand the mapping of bits to a value in order to understand how to specify the Bit Mask. This is accomplished by place value mapping, just like ordinary decimal arithmetic except that the place values are all powers of 2 instead of 10. The first input bit has a value of 1, the 2nd has a value of 2, the third has a value of 4, etc.; each bit has double the value of the next lower bit. A summary table for the 8 input bits available can be expressed as follows: Bit NumberPlace Value when ON 11 22 34 48 516 632 764 8128 Any combination of bits can be expressed by adding up the table values for the bit. The result will be somewhere between 0 and 255. For example, if bits 3 and 4 are ON, then the resulting value is 12.
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In the AND operation, any bit that is ON in the bitmask will allow the corresponding bit of the cart's RF Coil data to be passed on the the Accumulator, while any bit that is OFF in the bitmask will be blocked from the accumulator for that particular cart. So, to allow bits 3 and 4 to be controlled by the cart in the Route/Step combination from Line 2, for instance, the bitmask value of 12 would be specified in Line 2. Keep in mind that the AND function described above is applied to each individual line. After that, the OR function is applied between lines. In the OR operation, any bit that is On in either input value will be ON the result. For example, if the cart in line 1 has bits 1 & 2 ON with a value of 3 in the Line 1 bitmask, and the cart in line 2 has bits 2 & 3 on with a value of 12 in the Line 2 bitmask, then the result will be Bits 1, 2, and 3 ON. In this example Bit 4 will be OFF; this happens because the AND operation in line 2 allowed bits 3 and 4 to be controlled by that cart, and the cart sent bit 4 OFF so that result appeared in the accumulator. This example is presented in a table format below: Row Description #1 Bit Mask #1 Cart Coils Bit 4 Bit 3 Bit 2 Bit 1 Numeric Explanation Value 0 0 1 1 3This would be entered in the Bit Mask column of the setup page, Line 1 1 0 1 1 11This value isn't displayed anywhere, but is shown just as a further example of place value calculations 0 0 1 1 Only Bits 1 & 2 pass through the AND mask 1 0 1 1 0 1 0 0 12This would be entered in the Bit Mask column of the setup page, Line 2 6This value isn't displayed anywhere, but is shown just as a further example of place value calculations 4Only Bits 3 & 4 pass through the AND Mask Only Bits 1 & 2 pass through the AND mask 4Only Bits 3 & 4 pass through the AND Mask 7 Any ON bit passes through to OR result
#1 AND Result
#2 Bit Mask #2 Cart Coils
#2 AND Result
#1 AND Result #2 AND Result #1 OR #2, output to hardware
0 0 0
0 1 1
1 0 1
1 0 1
And so on: the AND operation applies to each line in the table individually, then the OR operation combines all the individual line results into a final 8-bit output sent to the hardware outputs. In either mode, the Timeout parameter is used to decide that the given Route/Step is unoccupied. In Priority mode, this will allow lower priority lines to be searched when the specified timeout expires; if all Rev 1_02 03-04 RFBase Unit User Guide Rev 1_02.docx Page 10 of 17

rows are timed out then the outputs will be cleared. In OR mode a timed out state will clear the Cart Coil bits for that particular line. The choice between these two modes is implemented via the Multiple Received Data Selection Mode combo-box. This choice must be made first; the rest of the table can then be filled in as needed to accomplish the user's I/O objectives. Note that the RF Base unit regularly broadcasts its hardware inputs from its host machine to all carts in radio range. This means that any cart within range can be programmed with the Base Unit's Radio ID as the Target Radio in any number of steps; this will allow such steps to use Radio Trigger bits from the Base Unit to trigger actions on the cart. When the parameters are set up as you want them, then you can either Apply them without saving or Save and Apply in one step. The difference is that if you Apply them they will take effect immediately, but won't survive a power-down: if you cycle power the previously saved parameters will be restored. After an Apply action you can also revert to the previously Saved settings if you decide to do so by clicking the Reload last settings button and clicking the Submit button. You may also choose to revert to factory defaults, but that may not be practical on this page. Once you've got it set up and chosen your action, click the Submit button to actually implement your choices.
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Radio Address parameter page:
There are two critical parameters that determine how these radios operate. First, all inter-operating Carts and RF Base units must have the exact same PAN network code. This must be a number between 1 and 65535. It doesn't really matter what this code is, as long as they're all the same, but different from unrelated AutoCart systems (or other Zigbee radio networks). Second, each radio in the system must have a UNIQUE Radio ID. The system currently allows buffers for 50 radios in a given network. While it's not critical, it is slightly more efficient to use the lower numbers for Carts and the next available numbers for Base units. The Radio Sequencing Delay is a parameter that is helpful to optimize radio throughput when a Master Cart Control Panel is in use. Usually this is a PLC-based system, and depending on the brand of PLC deployed there may be speed limits in its receive buffer, and this parameter allows slowing the carts down to a rate that can be reliably received by the particular PLC. Generally, the carts and RF Base units broadcast their status information at some interval - with no MCCP the broadcasts are not synchronized, but are broadcast at interval specified in the Block Transmit delay described below. When an MCCP is Rev 1_02 03-04 RFBase Unit User Guide Rev 1_02.docx Page 12 of 17

used, however, it is most efficient to have the broadcast packet from the MCCP trigger a sequential transmission from each cart and/or base unit. This is accomplished by the use of a transmit delay that is determined by this parameter and the unit's Radio ID; each starts a timer with the preset based on this parameter times its own radio ID, and when that timer is done it transmits. This scheme eliminates packet collisions and allows controlling the transmission rate so the host PLC can't be overrun. In order for this to work, all Carts and RF Base Units associated with a particular MCCP must be set to the same delay factor as well as having unique IDs. The Block Transmit Delay is used if an MCCP is not present or fails to transmit. In this case each cart and RF Base unit will broadcast status at this interval, unsynchronized with respect to each other. When an MCCP is deployed, this value must be somewhat larger than the MCCP's transmit interval so that collisions with the MCCP pulse don't occur. If the system includes no MCCP, then this parameter should be set system-wide to some value such as the number of system radios divided by 10. Note that there is an implied decimal in the drop-down menu: the value 150 is 15.0 seconds, for example. When the parameters are set up as you want them, then you can either apply them without saving or Save and Apply in one step. The difference is that if you Apply them they will take effect immediately, but won't survive a power-down: if you cycle power the previously save parameters will be restored. You may also choose to revert to factory defaults, but if you do then you should promptly fix the Radio ID to avoid conflicts with other units. Once you've got it set up and chosen your action, click the Submit button to actually implement your parameters.
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Input-to-coil Mapping page:
This page is best understood by referring to the sample ladder diagram displayed at the top of the page, keeping in mind the notion that the ladder rung applies to each row of the table. A key concept here is that each hardware input corresponds one-to-one with a bit broadcast to all listeners as a radio coil. Input 0 maps to Radio Coil 0, etc. Each row of the setup table allows additional features to be applied to the input as follows.
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The Echo to Output option allows any particular hardware to be echoed (with or without the latch and/or flash options described below) to one of the hardware Outputs. This may be used to drive a pushbutton acknowledgement light, for example. The Output choices are selected via a drop-down menu as follows:
It is the user's responsibility to avoid assigning one output to multiple inputs. In every case the Radio Output is automatically mapped, so the choice is merely whether and which hardware output will be attached. The Latch option can be used to remember a momentary input, such as an operator pressing a pushbutton, until it is cleared by some subsequent control signal specified in the Unlatch Trigger column. The No option will keep the input from latching, which may be useful for inputs that will remain on until externally reset, such as a robot or machine cycle complete which is reset externally at the start of the next cycle. The Yes option will cause the input to be remembered: if this is chosen, then it is important to also choose the Unlatch Trigger or else the radio coil (and any hardware echo) will remain on until power is reset. Rev 1_02 03-04 RFBase Unit User Guide Rev 1_02.docx Page 15 of 17

The Flash option applies only when an output echo is chosen. If set to Yes then the specified output will flash about once a second when the coil (latched or unlatched) is On.
The Unlatch Trigger option applies when the Latch option is On, and specifies what will unset the Latched coil. Valid choices are indicated in the drop-down menu: When the chosen trigger comes ON, the latch will be reset. The Radio Inputs, if used, are as mapped out on the Receive Data to Output Mapping page, described above. When the parameters are set up as you want them, then you can either Apply them without saving or Save and Apply in one step. The difference is that if you Apply them they will take effect immediately, but won't survive a power-down: if you cycle power the previously save parameters will be restored. You may also choose to revert to factory defaults, but if you do then you should promptly fix the Radio ID to avoid conflicts with other units. Once you've got it set up and chosen your action, click the Submit button to actually implement your parameters. Rev 1_02 03-04 RFBase Unit User Guide Rev 1_02.docx Page 16 of 17

HMI Configuration Screen The RF Base Unit supports an optional HMI panel for programming and diagnostic uses. At present two brands are supported, which can be selected here.
The previously detailed Action and Submit functions apply similarly here.
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AUTO-CART Section 03-05 Controls WEB PAGE CONFIGURATION

Utilizing an Ethernet connection with a crossover cable and Internet Explorer allows you to access operating data, enter colors from the camera viewer program and set the cart operating speeds. The following pages are available for setups. Note that most of this information is also available on the touchscreen, as detailed in a following section.
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Main Page:
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Status Viewer:
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Steering & Speed Setup Page:
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Color Stripe Setup Page:
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Radio Setup Page:
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Step Editor: Step selection
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Step Initiation Edit Page: Go Mode Choices:
Input Trigger Mask Choices:
Target Radio Choices:
Radio Trigger Mask Choices
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Alternate Step Hardware Input Mask:
Alternate Step Radio Input Mask:
Alternate Step Number Entry Field (0-99):
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Step Action Editor Overview: Step Function Choices:
Speed Mode Choices:
Navigation Mode Choices:
Navigation Directions Choices:
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Audible Warning Delay Choices
Loss of Guidance Choices:
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Cart-to-cart Zone Blocking setup:
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Laser Scanner Area Choices:
Set Hardware Output Choices:
MCCP selection allows Master Cart Control Panel to take over control of an output bit for the duration of this step. Can be used, for example, to control an audio signaling device from a master timer.
Set Radio Output Choices:
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NOTE: with Version 3.44, there exists a choice between the Hokuyo Laser scanner and an infrared Optical Scanner made by Sunx. With this version the menu choices are renamed Optical Scan, instead of Laser Scan. When used with the Laser, the patterns are completely selectable via separate scanner software. When used with the Sunx sensor, the area choices are fixed according to the following table. NOTE: according Codes 0 & 8 must not be used: Short Range Code: 0 Full Range Code: 8
10
11
12
13
6 7
14 15
Here, "Full Range Code" uses the set pattern for the range configured with the adjusters within the Sunx sensor. "Short Range Code" refers to the scaled back settings where the scale factor is set by a scaled-back potentiometer on the IDC Scanner Interface Board inside the panel. When adjusting the Sunx sensor, inside make sure you have loaded a step with code 15 so that you are testing the sensor itself at full range. You can then switch to code 7 to adjust the IDC potentiometer. Codes 0 & 8 must not be used NOTE: these patterns apply only to the E Stop zone. The "Zone 2" setting described in the Sunx manual E-Stop is used for a Controlled Stop, and seems only to apply to the center beam. Zone 2 is attenuated proportionately when using the Short Range codes. For more details on the basic Sunx sensor, visit http://www.sunx-ramco.com/SunxPDFFiles/PX_2.pdf ramco.com/SunxPDFFiles/PX_2.pdf End Of Step Parameter Editor Overview
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End Trigger Mode Choices:
End Action Choices:
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Auto-Cart Section 03-06 Controls ProFace HMI
The green callouts are used to explain the screen navigation pushbuttons. The orange callouts are used to explain the screen indicators. They include the numeric displays and discrete indicators. The blue callouts are used to explain the interactive screen controls. They include the pushbuttons and numeric entries. Main Screen (Not Logged In) Battery The Battery display shows the AGCs battery Voltage. Current Step This is a numeric input that displays the step that the AGC is currently running. This value should be set after the Current Route has been set. (Input Range: 1-99)
Current Route The Current Route is a numeric input that displays the route that the AGC is running. This value should be entered prior to entering the Current Step. (Input Range: 1-15)
Distance to Go This numeric display shows the distance (inches) or time (seconds) that the AGC has remaining in the current step.
My ID This is the numeric display for the AGCs identification number. This should be a unique number for all carts that utilize cart to cart communications. Input Status Go to the cart input status screen. Log In This allows the operator to log into the AGC. Once logged in, the operator will be able to access the screens to edit the steps. Information Go to the AGC information screen. Manual Go to the cart manual control screens.
Cart Communications Go to the cart communications screen.
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Main Screen (Logged In) Current Route The Current Route is a numeric input that displays the route that the AGC is running. This value should be entered prier to entering the Current Step. (Input Range: 1-15) Current Step This is a numeric input that displays the step that the AGC is currently running. This value should be set after the Current Route has been set. (Input Range: 1-99)
Battery The Battery display shows the AGCs battery Voltage.
Distance to Go This numeric display shows the distance (inches) or time (seconds) that the AGC has remaining in the current step. Logout Logout of AGC. Cart Communications Go to the cart communications screen. Edit Step Go to the carts edit step screens. Input Status Go to the carts input status screen.
My ID This is the numeric display for the AGCs identification number. This should be a unique number for all carts that utilize cart to cart communications. Information Go to the AGC information screen. Manual Go to the cart manual control screen.
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Edit Step
Main Go to the main AGC screen. Set Outputs Go to the AGCs output settings screen. Step Action Go to the carts step action screen. Plate Recognition Go to the carts plate recognition screen.
Initiation Triggers Go to the cart initiation triggers screen. Alternate Triggers Go to the carts alternate step triggers screen. Occupied Steps Go to the carts occupied step list screen. Route This numeric display shows the route number that contains the steps that are being edited. Step to Edit This is used to load the step that will be edited. Only steps contained in the route displayed above can be edited. Target Radio This input is used to set the ID number of the radio that will be used for the initiation triggers. Next Step Next Step is a numeric input used to instruct the carts which step to run after this step is complete.
Save Apply and save the changes made to the current step being edited to the AGC memory. These values will remain until the step is edited again. Apply Apply the changes made to the current step being edited. These values will not be saved to memory and the values will be lost when the carts power is cycled.
Alt. Step- is a numeric input used to instruct the carts which step to run after current step is complete and input condition is satisfied for a jump step sequence.
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Edit Step (Cont.)
Go Mode The Go Mode is used by the AGC to determine when to start the step. When the AGC is running this step and the conditions in this parameter are satisfied, the AGC will start the step. Operator Release-The step is initiated when the Master Start button is pressed. Automatic-When the step is entered from a previous step, the cart will execute this step without stopping. Input Triggers-The cart will initiate the step when the hardwired and radio input conditions are satisfied. Op Release w/ Alt Steps-Upon Operator Release, the cart will choose the current step or an alternative step based upon specific input states Auto w/ Alt Steps- Upon entering this step from a previous step, or upon Operator Release if this step was just selected from the Main Screen, the cart will choose either the current step or an alternative step based upon specific input states. Trigger w. Alt Steps- When Step Cycle is ON (by entry from a previous step or Operator Release) the cart will wait for the Trigger Conditions to be met before continuing: if the primary Trigger Condition are met this step will be executed, but if the Alternate Trigger conditions are met first then it will run the specified Alternate Step.
End Action The End Action, along with the Go Mode, is used by the AGC to determine how to handle the transition to the next step. Stop-The AGC will stop and wait to be reinitiated by the Master Start or Input Triggers. Merge-The AGC will stay in cycle for the start of the next step. End Mode End Mode is used by the AGC to determine when to transition to the next step. When the conditions set in this parameter are satisfied, the AGC will load the step set in Next Step. Distance-The AGC travels the preset distance set in the Size parameter. Marker-The AGC searches for a floor marker. Time-The AGC delays the preset time set in the Size parameter.
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Step Actions
Speed The speed the AGC will travel during the step. (Range: 0-33 inches/second) Edit Step Go to the cart's main edit step screen. Scanner This will select the scanner area that the AGC will use during the step. Refer to the settings in the scanner to determine the appropriate scanner area. (Input Range: STI: 1or 2, Hokuyo: 1-15)
Size The distance (inches) the AGC will travel or the time (seconds) that the AGC will delay during the step. (09999)
Route This numeric display shows the route number for the steps that are being edited. Step This numeric display shows the step number for the step that is being edited. Loss of Guidance The distance (inches) the AGC will travel without guidance tape. This is used to accommodate damaged tape. (Input Range: 6-24)
Delay for Warning The number of seconds the AGC will delay and sound a warning before the initiation of cycle. If the AGC transitions from another step and does not stop, this setting will be bypassed. (Range: 05)
Direction The guidance direction is used by the cart to determine which side of the tape the AGC will follow. Left-The AGC will follow the left side of the tape. Center- The AGC will follow the center of the tape. Right- The AGC will follow the right side of the tape.
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Step Action (cont.) Beginning with Version 8.01, there are additional screens to accommodate various Obstacle Avoidance sensors, including the Laser Scanners and the Ultrasonic Modules. The screens are as follows: Displays current Obstacle Avoidance Setting
Go To Obstacle Avoidance Main Selection Screen Illustration 1: Version 8.01 Step Action Screen, with Obstacle Avoidance readout and screen button This current setting display is a text display; typical readouts are, for example: Text Explanation Unrecognized!!! Scanner Mode 5 Scanner Disabled Sonic Left = 44 Sonic Left <= 44 Sonic Both = 44 Sonic Disabled An invalid selection (never set for this step) Laser Scanner selected, Pattern # 5 Laser Selected, but disabled (cart may not move) Left Ultrasonic sensor, brake at 44 inches for any speed Left Ultrasonic sensor, brake at 44 inches, less for low speed Alternate left & right sonic sensors, fixed 44 Inch range Disable Ultrasonic sensors (not recommended)
See the Obstacle Avoidance section of the manual for more information about the Laser Scanner area patterns and ultrasonic capabilities. The green Obstacle Avoidance button takes the user to the next screen:
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Obstacle Avoidance Primary Selection Screen
Go to Ultrasonic Setup screen
Go to Scanner Setup Screen Displays current Obstacle Avoidance Setting
Return to Step Action Screen
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Scanner Set Up Screen
Current Setting text, described above; updates when one of the numbered pattern buttons is pressed. Return to Obstacle Avoidance Primary Selection Screen Press a numbered button to select a laser pattern for the step being edited
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Ultrasonic Setup Screen Displays current Obstacle Avoidance Setting; updates when buttons pressed or new range entered.
Fixed column: Range number is stop threshold in inches, for any cart speed. Left button selects left sensor, Right button selects right sensor, Both selects alternating sensors
Variable column: Range number is stop threshold at full speed; range is reduced as cart slows or stops, down to 20 inches at 0 speed. Left button selects left sensor, Right button selects right sensor, Both selects alternating sensors Touch here to enter the distance (in inches) at which an obstacle stop should begin.
Disables Ultrasonic sensor: use only in restricted areas!
Return to Obstacle Avoidance Primary Selection Screen
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Step Actions (Cont.)
Function The Function parameter is used by the AGC to determine the actions to perform during the step. The AGC hard wired and radio outputs will be set for all options. Set Output, ForwardThe AGC will travel the speed set in the Speed parameter until it satisfies the End Mode. Set Outputs Only-The AGC will set the outputs and then transition to the next step. Set Outputs, Delay-The AGC will delay for the time set in the Size parameter. Sound The Sound parameter sets how the audible alarm sounds during the step. This will take affect after the Delay for Warning is complete. Silent-No audible alarm will be used. Not recommended where personnel may be present. Continuous-The audible alarm will be held on continuously while the AGC is in motion. Pulsed-The audible alarm will be turned on and off while the AGC is in motion.
Navigate The Navigate parameter is used by the AGC to determine how to navigate through the step. Normal Guidance-The AGC will follow the guidance tape. Dead Reckon-The AGC will not use the guidance tape to navigate through the step. The AGC will travel according to the setting in the Direction parameter. Left-Turns to the Left Center-Travels Straight Right-Turns to the Right Speed The Speed parameter sets how the AGC speed is determined. Proportional to Line Width-The AGC will adjust its speed based on the width of the tape. The AGC speed will increase as the tapes width decreases until it reaches the speed set in the other Speed parameter. Single Fixed Speed-The AGC will run the speed set in the other Speed parameter.
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Occupied Step
Route This numeric display shows the route number for the steps that are being edited.
Step This numeric display shows the step number for the step that is being edited.
Edit Step Go to the cart edit step screens.
Occupied Steps While the AGC is in this step (the step that is being edited) and any AGC is transmitting that it is in a step that is in this list, the cart will stop and hold until the step is clear. The step numbers on this screen are set as four digit words (XXYY). The first two digits (XX) represent the route number and the second two (YY) are the step number. Below are some examples on how to enter the route and step numbers into the Occupied Step list. Example: Route 2, Step 50 Enter 250 Route 11, Step 22 Enter 1122 Route 1, Step 1 Enter 101 Route 15, Step 8 Enter 1508
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Plate Recognition
Step After an AGC travels over a floor plate in the Length column, it will load the corresponding step set in the Step parameter and perform the End Action associated to it. If the Step parameter is set to 0, the plate will be treated as a general floor marker. Each route has its own Plate Recognition Table.
Route This numeric display shows the route number for the plates that are being edited. Edit Step Go to the remainder of the Plate Recognition Table. Save Apply and save the changes made to the Recognition Plate Table to AGC memory. These values will remain until the Recognition Plate Table is edited again. Apply Apply the changes made to the Recognition Plate table. These values will not be saved to memory and the values will be lost when the carts power is cycled.
End Action This is similar to the End Action that was described earlier. This informs the AGC what action to take after it travels over the corresponding plate size. Merge-The AGC will load the appropriate step and run the step. Stop-The AGC will load the appropriate step and stop.
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Plate Recognition (Cont.)
Step After an AGC travels over a floor plate in the Length column, it will load the corresponding step set in the Step parameter and perform the End Action associated to it. If the Step parameter is set to 0, the plate will be treated as a general floor marker. Each route has its own Plate Recognition Table.
Route This numeric display shows the route number for the plates that are being edited. Edit Step Go to the remainder of the Plate Recognition Table. Save Apply and save the changes made to the Recognition Plate Table to AGC memory. These values will remain until the Recognition Plate Table is edited again. Apply Apply the changes made to the Recognition Plate table. These values will not be saved to memory and the values will be lost when the carts power is cycled. Edit Step Go to the cart edit step screens.
End Action This is similar to the End Action that was described earlier. This informs the AGC what action to take after it travels over the corresponding plate size. Merge-The AGC will load the appropriate step and run the step. Stop-The AGC will load the appropriate step and stop.
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Initiation Hardwired Input Triggers
Radio Trigger Go to the radio initiation trigger edit screens.
Initiation Hardwired Input Triggers Input triggers are used when the Go Mode parameter is set to Input Triggers. The hardwired input triggers allow the cart to be initiated by discrete switches such as photoeyes, prox switches and similar. The input triggers can be setup to initiate the cart based on several different signals at the same time. N/A-The input can be in either the On or Off state. On-The input has to be On. Off-The input has to be Off.
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Initiation Radio Input Triggers
Initiation Trigger Go to the hardwired initiation trigger edit
Radio Trigger Go to the remainder of the radio initiation
Initiation Radio Input Triggers Input triggers are used when the Go Mode parameter is set to Input Triggers. The radio input triggers allow the cart to be initiated by discrete radio signals from a remote station. The AGC will only look at the signals sent by the radio identified by the Target Radio parameter specified on the main Step Edit screen.. The input triggers can be setup to initiate the cart based on several different signals at the same time. N/A-The input can be in either the On or Off state. On-The input has to be On. Off-The input has to be Off.
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Initiation Radio Input Triggers (Cont.)
Initiation Trigger Go to the hardwired initiation trigger edit screens.
Radio Trigger Go to the remainder of the radio initiation trigger edit screens.
Initiation Radio Input Triggers Input triggers are used when the Go Mode parameter is set to Input Triggers. The radio input triggers allow the cart to be initiated by discrete radio signals from a remote station. The AGC will only look at the signals sent by the radio identified by the Target Radio parameter specified on the main Step Edit screen.. The input triggers can be setup to initiate the cart based on several different signals at the same time. N/A-The input can be in either the On or Off state. On-The input has to be On. Off-The input has to be Off.
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Alternate Step Input Triggers Route This numeric display shows the route number for the steps that are being edited. Step This numeric display shows the step number for the step that is being edited. Alternate Step This numeric display shows the Alternate step number that will be initiated if the input combination specified here occurs. Edit Step Go to the cart edit step screens.
Alternate Radio Triggers Go to the radio initiation trigger edit screens. Alternate Step Radio Triggers
Route This numeric display shows the route number G for the steps that are being edited.
Alternate Step This numeric display shows the Alternate step number that will be initiated if the input combination specified here occurs Edit Step Go to the cart edit step screens. Rev 1_04
Alternate Step Triggers Go to initiation trigger edit screens.

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Set Hardware Output
Step This numeric display shows the step number for the step that is being edited. Radio Outputs Go to the radio output edit screens. Charger Sets the charger contactor (if present) to be on or off for the given step.
Set Hardwired Outputs The hardwired outputs on the I/O Expander can be turned on and off for each step. The output state will be set as soon as the step is loaded, without waiting for Cycle Start to begin executing the step. N/A-Leaves the output in its current state. On-Turns the output on. Off-Turns the output off. MCCP- The Master Cart Control Panel is allowed to control the output by radio command.
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Set Radio Output
Route This numeric display shows the route number for the steps that are being edited. Edit Step Go to the cart edit step screens. Radio Outputs Go to the remainder of the radio output edit screens.
Hardwired Outputs Go to the hardwired output edit screens.
Set Radio Outputs

The radio outputs can be turned on and off for each step. The outputs are broadcast to all listening carts and base stations, and may be used to pass trigger conditions to base units or carts.
N/A-Leaves the output in its current state. On-Turns the output on. Off-Turns the output off.
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Set Radio Output (Cont.)
Route This numeric display shows the route number for the steps that are being edited. Edit Step Go to the cart edit step screens.
Radio Outputs Go to the remainder of the radio output edit screens.
Hardwired Outputs Go to the hardwired output edit screens.
Set Radio Outputs The radio outputs can be turned on and off for each step. The outputs are broadcast to all listening carts and base stations, and may be used to pass trigger conditions to base units or carts. N/A-Leaves the output in its current state. On-Turns the output on. Off-Turns the output off.
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Apply Step Data Confirmation
Yes The data for the step that is currently being edited will be temporarily activated, but not saved. If editing the current operating step, then the current step counter position will be retained. Unless later saved, the new data will be lost if a new Route is selected or the AGC power is cycled.
No The data for the step that is currently being edited will not be implemented (or saved).
Save Step Data Confirmation
Yes The data for the step that is currently being edited will be saved. This data will be retained through a power cycle. Rev 1_04
No The data for the step that is currently being edited will not be saved.
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Apply Plate Data Confirmation
Yes The plate recognition table will be temporarily applied, but not saved. This data will be lost if the AGC power is cycled or a different Route is selected..
No The plate recognition table will not be updated.
Save Plate Data Confirmation
Yes The plate recognition table will be saved. This data will be retained through a power cycle.
No The plate recognition table will not be saved.
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Manual Control for Outputs
Charger The charger buttons are used to control the charger contactor (if present). The master circuit has to be enabled for the contactor to operate.
Output Name Display The string displays are used by the AGC to display the name of the output. The cart controller will send an ASCII string to the HMI to name the output. Manual Go to the remainder of the carts manual control screen. Main Go to the main AGC screen.
Manual Control Pushbuttons The manual control pushbuttons are used to control the corresponding outputs. The master circuit has to be enabled for the outputs to operate.
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Manual Control for Outputs (Continued)
Manual Control Pushbuttons The manual control pushbuttons are used to control the corresponding outputs. The master circuit has to be enabled for the outputs to operate.
Output Name Display The string displays are used by the AGC to display the name of the output. The cart controller will send an ASCII string to the HMI to name the output.
Manual Go to the remainder of the carts manual control.
Main Go to the main AGC screen.
Rev 1_04
Page 24 of 28

Input Status
Input Status Indicators The input indicators show the status of the carts hared wired inputs.
Input Name Display The string displays are used by the AGC to display the name of the input. The cart controller will send an ASCII string to the HMI to name the input.
Input Status Go to the remainder of the carts input status.
Rev 1_04
Page 25 of 28

Input Status (Continued)
Input Status Indicators The input indicators show the status of the carts hared wired inputs. Input Name Display The string displays are used by the AGC to display the name of the input. The cart controller will send an ASCII string to the HMI to name the input.
Input Status Go to the remainder of the carts input status.
Rev 1_04
Page 26 of 28

Cart Communications
Target ID This indicator shows the radio ID number that this AGC is watching for Trigger info, if used.
My ID This is the numeric entry for the AGCs identification number. This should be a unique number for all carts that utilize cart to cart communications. This can only be changed while the operator is logged in.
Radio Input Status Go to the carts radio input status screen. Information Go to the AGC information screen. Main Go to the main AGC screen. RSSI (Received Signal Strength Indicator) This indicator is used to display the relative signal strength for the corresponding AGC. The larger the RSSI number the stronger the signal strength. Step The step indicator displays the step number that the corresponding AGC is reporting that it is in.
Cart This column is a row header for the Radio ID data to in the other columns. If the indicator has a white background than that radio has been heard from recently. A black background means that radio has not been heard recently. Route The route indicator displays the route number that the corresponding AGC is reporting that it is in.
Rev 1_04
Page 27 of 28

Radio Input Status
Radio Input Status Indicators The input indicators show the status of the carts radio inputs. A white background indicates the input is on and the input is off when the background is black. Information
Firmware Version This will display the controller software version number. IP Address This will display the controller IP address.
Screen Version This will display the screen software version number.
Subnet Mask This will display the controller subnet mask for the IP address. Main Go to the main AGC screen.
Rev 1_04
Page 28 of 28
AUTO-CART Section 04-00 CSB
CSB
Customer Supplied Battery
Rev 1
04-00 CSB_Customer_Supplied_Battery.docx
Page 1 of 1
05_02 Laser Scanner with Flexible Bumper

The laser scanner has fifteen programmable areas to be used for obstacle avoidance and cart stacking. The areas are selected by the AGC based on the settings in the step program. When an object is detected within the detection area, the AGC will perform a controlled stop and will resume motion when the object is clear of the detection area. The flexible bumper is used by the AGC to perform an emergency stop. A dual photoswitch and a reflector are used to sense a collapse in the bumper and will turn off the master circuit when the bumper is deformed.
Illustration 1: Typical Scanner & Bumper Arrangement
Add DP to the end of the selection to receive (2) photoeyes with the flexible bumper (LSDP).
05_02_Laser Scanner with Flexible Bumper_1.01
Illustration 2: Typical Dual Photo-switch and reflector arrangment
Basic Concepts
There are several models of laser scanners available from different manufacturers. The most popular is the Hokuyo brand, which allows the cart to select one of 15 preset patterns in any given step. This scanner is the lowest cost, however it is doesn't have redundant safety features so some users are unwilling to accept it. In that case, other models with redundancy features may be considered at higher cost. All of the laser scanners use the same basic principal: an infrared laser beam is swept in a horizontal circular plane. Objects that the beam encounters reflect some of the light back to the scanner's receiver, which can measure the distance to the object by the time between transmitting the beam and receiving the reflection. This develops an image of items in the scanner's view that can be visualized on a computer screen. While the details vary between different models, the illustration below is typical:
Illustration 3: Sample Scanner View with 3 object detection zones In this particular view, the gray area is unoccupied, while the white areas are occupied by some obstacle. Notice that a nearby obstacle obscures the view of anything beyond it in a radial direction, however this is generally not a concern since the distance to the nearest object is the important measurement in an obstacle avoidance application. Notice also that the measurements are centered around the sensor itself, which is typically located at the center of the front of the cart. The colored zones in this display illustrate boundaries that have been set up for this particular protection pattern, designated in this scanner model by the label Area 1. The outer 2 boundaries are used by the cart for path blockage detection, causing the cart to execute a controlled deceleration and stop when these areas are occupied by any obstacle. The innermost red area can be configured to cause an Emergency stop, where power 05_02_Laser Scanner with Flexible Bumper_1.01
is removed from the drives and the brake sets immediately whenever an object is detected in this zone. In many instances, however, users opt to rely on the bumper for E-Stop function and use the laser for cycle stops, at least when a non-redundant scanner is used. This usage must be discussed and agreed upon when ordering Carts, as it determines certain hardware configurations. The sections that follow will illustrate features and usage for specific laser scanner models. For specifications and literature for these models the user is encouraged to consult the particular manufacturer for more information: this manual will specifically address the AutoCart use of the scanners
Hokuyo UBG series Laser Scanner

This scanner features 31 active protection patterns, of which one of the first 15 may be selected by the AutoCart in any given Step. Hokuyo provides a software utility to configure the units, save the configuration to a computer and upload/download configurations to copy from one unit to another. Unfortunately they have not, as of this writing, provided good documentation on how to use it, so this manual will attempt to cover the basics, with specific application to the AutoCart system.
Connecting to the scanner

The software connects to the scanner with an RS-232 serial port. It supports either a real hardware serial port or a USB to Serial adapter. A connector is provided inside the cart control panel to let the PC talk to the scanner while in operation, as shown in this photograph:
Illustration 4: Serial Cable connection for Hokuyo scanner, in cart's control enclosure Note that it is necessary to have the cart power on and the red E-Stop PB raised to provide power to the scanner for programming purposes.
The Hokuyo utility shortcut is similar to the following, where the actual disk path may be different:
Illustration 5: Hokuyo UBG series Software Utility Shortcut, illustrating Icon and Application File Name Of particular note are the desktop icon and the application file name; the user may edit the displayed name of the shortcut to something more easily recognized. When the Hokuyo software starts, it will search the available serial ports for an active scanner and automatically connect (if if doesn't you'll see a message and have an option to work off-line). When the scanner is connected you'll see a screen something like this:
Illustration 6: Typical UBG scanner view upon initial connection, before loading scanner Area setups This is a live image of the scanner's view of the world. By default the gray area is open; white areas indicate an area that is obscured from view by some object. In this particular case a briefcase is parked at the back left edge of the field of view, approximately in line with the left edge of the cart assembly to provide an on-screen reference for setting up the protection zones in the following steps.
Reading Area Patterns from the scanner

At this point the PC software does not yet know how the protection zones are configured in the scanner. To view the settings configured in the scanner, use the Communication menu and select the Area Read function - confirm the operation to read the areas from the scanner. This will result in a view something like the following:
Illustration 7: Typical UBG scanner view after reading Area Patterns This operation loads all 32 areas from the scanner into the PC memory. Using the dropdown menu box at the top of the screen, the user can overlay any of these existing patterns on the current scan. Notable features of this display and edit screen include: On-screen measurement grid Mouse position readout (in mm) at the bottom of the screen Grab handles to graphically adjust outermost pattern area Grab Bars to adjust interior patterns relative to the outer pattern, discussed below. Area Number drop-down menu box at the top of the screen Sub-area shape selection drop-down menu box near the top of the screen, discussed below.
Note that all measurements are relative to the center of the scanner, which is usually located at the center of the front of the cart.
Viewing and editing protection patterns

A variety of typical patterns are illustrated below, with further discussion to follow:
Illustration 8: Typical scanner setup for straight, low speed moves In this case, the pattern is quite wide (almost 2 meters, or nearly 6 feet) because the application being illustrated includes a wide companion cart attached to the base cart, so it is important to have the pattern protect the full width of the payload. This remains true for the rest of the illustrations in this section, although some users without a wide payload will want to use a narrower pattern. This low-speed pattern looks forward far enough to allow the cart to decelerate nicely and stop without collision when an obstacle is encountered. Note that this is Area 1, identified on the screen by the drop-down menu at the top and the message in the bottom status bar. This will be used by the cart when executing any step with the Scanner parameter set to 1, which would be most straight, low-speed moves. For example, Route 1 Step 1 would be set up on a cart like this (note this illustration is for AutoCart firmware Version 5.xx - see also V8.xx firmware update at the end of this document):
Next is a slightly different pattern:
Illustration 9: Typical scanner setup for straight, high speed moves This pattern is appropriate for a heavy payload traveling at higher speeds: in this situation the stopping distance is increased, so it is necessary to detect obstacles at longer range. Note that this is Area 3, identified on the screen by the drop-down menu at the top and the message in the bottom status bar. This will be used by the cart when executing any step with the Scanner parameter set to 3, which would be most straight, high-speed moves.
The following pattern, Area 6, is typical for use where the cart will be making a left turn, and would be specified only for a step that is actually executing such a turn. In this scenario, because the cart is actually turning away from objects near its front right corner, this corner of the pattern can be pulled back. On the other hand, since the cart is turning toward any obstacles that might be off to its left, the pattern is extended in that direction to provide advance notice of obstacles in time to stop for them. Notice also the additional corner points established by the square grab handles around the perimeter. Up to seven such handles are available; in the simpler patterns above, the unused handles are stacked at location 0,0 - they can be deployed by grabbing the handle at the center and dragging it out the periphery. Such peripheral vertices can, if desired, be removed by dragging one vertex handle onto another, whereupon they will merge together and one will disappear (or be relocated to 0,0). Notice also the selection of the Ratio menu at the top of the screen: this is used to make the interior detection patterns follow the general outline of the outermost pattern, which is most useful for asymmetrical patterns like this. The ratio between the internal and outermost patterns is adjusted by grabbing the color bars on the central axis of the scanner and moving them up or down. .
Illustration 10: Typical scanner setup for low speed left turns, using Ratio option for zones 2 & 3 The actual actual contour of the right corner is a function of the sharpness and speed of the turn; this means it may be appropriate to have several left turn patterns for various ranges of turning radius in the path. They are deployed in the cart by specifying the appropriate scanner pattern number in each individual step.
The following pattern, Area 8, is typical for use where the cart will be making a right turn, and would be specified only for a step that is actually executing such a turn. In this scenario, because the cart is actually turning away from objects near its left corner, this corner of the pattern can be pulled back. On the other hand, since the cart is turning toward any obstacles that might be off to its right, the pattern is extended in that direction to provide advance notice of obstacles in time to stop for them. Notice also the additional corner points established by the square grab handles around the perimeter. Up to seven such handles are available; in the simpler patterns above, the unused handles are stacked at location 0,0 - they can be deployed by grabbing the handle at the center and dragging it out the periphery. Such peripheral vertices can, if desired, be removed by dragging one vertex handle onto another, whereupon it they will merge together and one will disappear. Notice also the selection of the Ratio menu at the top of the screen: this is used to make the interior detection patterns follow the general outline of the outermost pattern, which is most useful for asymmetrical patterns like this. The ration between the internal and outermost patterns is adjusted by grabbing the color bars on the central axis of the scanner and moving them up or down.
Illustration 11: Typical scanner setup for low speed, moderate right turns, using Ratio option for zones 2 & 3 Shown below is a special case that was used to allow the cart to maneuver into close quarters with a stationary machine, approaching from a tight right turn and continuing into a work cell. In this particular instance the
work cell had equipment that was below the companion cart, so both sides of the pattern were pulled inward to allow the cart core to enter between the cell machinery. In addition, because of the right-turn approach, the left front corner was trimmed back to just clear the equipment while entering the cell. In cases like this, the scanner should be considered as protecting the cart from physical crashes: in this particular instance personnel must take responsibility to keep clear of the outer portions of the payload. Alternatively, external protection devices could be used to prevent the cart from entering the area with personnel present.
Illustration 12: Example setup for tight right turn into close quarters with machinery Another special case is shown below: this illustrates the adjustment made to allow the cart to drive into an online charging station which sits close enough to the path that it can make contact with the right side of the cart. Hence, the right side is trimmed to allow passing the charger shoes. Like the pattern above, this limits operator protection for the right side of the cart, so other precautions must be observed to protect personnel.
Illustration 13: Special setup for approaching an on-line charger on the right side of the cart, at low speed
Saving the Detection Area:

The above represent typical scenarios that can be created for an application. At this point in the process, the patterns exist on the PC, but if any editing has been done, then they may not match what is actually in use in the scanner. It is highly recommended that the user should use the file menu to save the setup, as shown here:
Chose an appropriate location and file name. Note that the program will not over-write an existing file name; if you try, it will report an error and not save anything. Therefore you must either create a new name or delete an existing name before trying to use it again. It is suggested that sequential file names be use, to maintain a backup path in case of error. Once an area has been saved, the file menu's Open Area File can be used to read it back into the system from the PC's storage, as an alternative to loading it directly from a scanner. This can allow a user to initialize a new scanner, for instance, with a saved setup. This procedure is described below.
Writing the area setup to the scanner to make it effective

When the PC has an appropriate set of patterns established, whether by direct editing or by opening a stored Area file, the areas must be written to the Scanner to take effect. The patterns may have been uploaded from an existing scanner, edited on-line, or read back from a file that was previously saved. In any case, the operation to write update the scanner to use these patterns is the same, as shown here:
It doesn't matter which area pattern is in view when writing: the operation will write all Area patterns to the scanner. Immediately after the write, the scanner will utilize the patterns that were written.
Specifying the Area Pattern for a step (AutoCart Firmware Version 5.xx)
As briefly mentioned above, the patterns reside in the scanner itself. Which pattern it uses at any particular moment is controlled by a numeric code sent from the carts step control system. Part of the definition process for each step in the cart program is to decide which Area Pattern is appropriate for the operation. Once the Area Number has been defined in the scanner and selected for a particular application step, then it must be entered as one of the parameters for that step. This is accomplished through the HMI edit screens, which are detailed elsewhere. For purposes of this discussion, however, it is appropriate to show how a particular area number gets entered into the system for a given step. Observe the Scanner data entry field in the display below:
The number entered into the Scanner field will be the Area number used for the step. This must be set up for each step, of course. It is suggested that users should establish some pattern to the area numbers so that they are not difficult to remember. For example, Area 1 could be used for slow, straight moves, with areas 2 & 3 also straight but at progressively higher speeds. In the same vein, Areas 4 - 6 could be a sequence of left turn patterns in some progression such as speed of motion or increasing turn radius; a similar sequence could establish a progression of right-turn patterns in Areas 7-9. Areas 10 & up could be used for relatively rare special cases such as illustrated above.
Specifying the Area Pattern for a step (AutoCart Firmware Version 8.xx)
As briefly mentioned above, the patterns reside in the scanner itself. Which pattern it uses at any particular moment is controlled by a numeric code sent from the carts step control system. Part of the definition process for each step in the cart program is to decide which Area Pattern is appropriate for the operation. Once the Area Number has been defined in the scanner and selected for a particular application step, then it must be entered as one of the parameters for that step. This is accomplished through the HMI edit screens, which are detailed elsewhere. For purposes of this discussion, however, it is appropriate to show how a particular area number gets entered into the system for a given step. Version 8.xx supports either Ultrasonic or Laser sensors as a user selection for each step. To accommodate these options the HMI screens have been redesigned as shown here:
The textbox above the OBSTACLE AVOIDANCE button displays the currently selected obstacle avoidance mode for the step being edited. To change this parameter, press the green Obstacle Avoidance button to advance to the screen below:
This screen (above) again displays the current setting, and allows further selection between Ultrasonic sensors or Laser Scanner, with subsequent setup screens for those two types - obviously the appropriate hardware must be installed for the mode selected. As we are addressing the laser scanner usage in this document, press the Optical Scanner Setup to advance to the following screen:
On this screen you can choose the scanner pattern number by pressing the appropriate button. The textbox at the top of the screen will update to confirm the selection. Note that option 0 technically exists to turn the scanner off, though the cart will not move in that state. This could theoretically be used to save a small amount of battery power in a step that is merely waiting for something to happen externally. There is a startup delay before the scanner will resume operation, which would have to be allowed for in the subsequent step. This concept is hypothetical and unproven as of this writing. Once the appropriate pattern is chosen, use the yellow Previous buttons (on this screen and the previous one) to get back to the Step Function screen, where the Obstacle Avoidance textbox will now display your selected pattern which will be the Area number used for the step. This must be set up for each step, of course. It is suggested that users should establish some pattern to the area numbers so that they are not difficult to remember. For example, Area 1 could be used for slow, straight moves, with areas 2 & 3 also straight but at progressively higher speeds. In the same vein, Areas 4 - 6 could be a sequence of left turn patterns in some progression such as speed of motion or increasing turn radius; a similar sequence could establish a progression of right-turn patterns in Areas 7-9. Areas 10 & up could be used for relatively rare special cases such as illustrated above.
Documenting the Scanner Setup

The edit utility can print the patterns as displayed on the screen. It only prints the currently selected pattern, however. A useful method of documenting the patterns it to paste screen grabs of the patterns into a document or spreadsheet, which can then be printed in a single step.
NEW PRODUCTS
LASER RANGE-FINDER TYPE OBSTACLE DETECTION SENSOR
UBG-05LN
WIDE SCANNING ANGLE ! SUPER-SMALL SIZE !
* Long range detection(5m) * High accuracy with semi-conductor laser(+/- 20mm at 1m) * 31 kinds of detecting area can be made
General/Feature
Structure(Light scanning image)
Power/input/ AGVs control output device UBG
Max. 4m
AGV Scanning angle : 180 Max. step : 500 Resolution : 0.36
Application
Max. 5m
Obstacle detection sensor on AGV
UBG-05LN
Specifications
Model No. Power source Current consumption Light source Detection distance Accuracy Hysteresis Output Scanning angle Scanning time Response time Indicators Connection method Ambient light resistance Ambient temperature/ humidity Vibration resistance Impact resistance Protective structure Weight Life Material UBG-05LN 24VDC10%(Startup voltage range 18 to 30VDC) 150mA or less(Rush current 300mA) Semiconductor laser diode(wavelength 785nm), Laser safety class 1(FDA) 0.01 to 5m(White sheet with 125125mm) 20mm at 1m or less, 2% of measurement, Repeatability 10mm Values specified while setting area patterns(Default 6.25%) 6.25% of detecting distance(not less than 60mm) 3.17% of detecting distance(not less than 30mm) Output 1 to 3, trouble output, Photo-coupler/NPN open-collector output(30VDC 50mA Max) 180(Resolution 0.36) 100msec/scan Less than 210msec(Scanning time 100msec/1 rev.) Output lamp 1 to 3(orange), Power lamp(green) Lead wire 1m long Halogen/mercury lamp : 10000lux or less, Fluorescent lamp : 6000lux(Max.) -10 to +50, 85%RH or less(Not condensing) 10 to 55Hz, double amplitude 1.5mm Each 2 hour in X, Y and Z directions 196m/s2(10G) Each 10 time in X, Y and Z directions IP64 Approx. 185(260 with cable) 5 years during normal condition(motor life) Front case : polycarbonate, rear case : ABS
External dimension
PHOTO SENSOR, LASER SENSOR, MICROWAVE SENSOR, COUNTER,AUTOMATIC DOOR

HOKUYO AUTOMATIC CO.,LTD. 1-10-9 Niitaka, Yodogawa-ku, Osaka 532-0033,Japan Tel(06)6394-2102 Fax(06)6394-2339 http://www.hokuyo-aut.jp E-mail:info@hokuyo-aut.jp No.RS-1
Date2006.05.18
DISTANCE MEASURING TYPE Obstacle Detection Sensor UBG-05LN Specifications
Symbol
Amended Reason
Page
Date
Corrector
Approved
MORI
Checked
SUEKUNI
Drawn
SANTOSH
Designed
MORI
Title
Obstacle Detection Sensor UBG-05LN Specifications

17
No.
C 42 3404
1. Outline 1. Operating Principle UBG-05LN is an obstacle detection sensor with 785nm wavelength laser light source. It detect objects in the predefined area by scanning 180 semicircle and calculates the coordinates of the detected object by measuring its distance and angle. The product is laser class 1 safe. 2. Area Setting 31 different area patterns and their coordinate points can be set using application software and serial communication RS232C. 3-step outputs can be selected for each area. 3. Area Switching Bit input at terminal points switches the predefined area patterns. 4. Malfunction Output Self-diagnostic functions continuously check laser radiation and motor rotation and supplies malfunction output upon error detection.
2. Structure (Scan Image)
Non-radiated area: 180
Scan Angle: 180 Max. Step: 500 Resolution: 0.36
Power Supply Input/Output Connections
AGV Control
Max. 10m
AGV
Max. 5m Max 8m with special reflector.
UBG-05LN
Specifications
C 42 3404
27
Specifications Model Light source UBG-05LN Semiconductor laser diode (=785nm) Laser safety Class 1 (FDA) Laser power:0.8mW or less(Scanning satishfies the laser Class 1 safety.) 24V DC 10% (Startup voltage range 18~30V) 150mA or less (Rush current 300mA) 100mm ~ 5000mm* (White sheet 125125 mm or more) 100mm ~ 8000mm* (Specific reflector 250250 mm or more) Distance 100 ~ 1000mm 20mm* Distance 1000 ~ 4000mm 2% of measurement* Repeatability 10mm* Values specified while setting area patterns (Default: 6.25%) 6.25% of detection distance (not less than 60 mm) 3.17% of detection distance (not less than 30 mm) Photo coupler open collector output (DC 30V, 50mA max.) Output 1: Turns OFF during object detection inside area. Output 2: Turns OFF during object detection inside area. Output 3: Turns OFF during object detection inside area. Malfunction Output: Always ON during normal operation. (Note: All the outputs turn OFF during malfunction) 180(Resolution 0.36) 100msec/scan Less than 210 msec (Note: Additional delay of max. 100 msec (1 scan time) will occur during area switching) Within 10 sec after power supply. (Varies with startup conditions) Power supply (Green): Flashes during startup or sensor malfunction Output 1 (Orange): Switches on during object detection inside area Output 2 (Orange): Switches on during object detection inside area. Output 3 (Orange): Switches on during object detection inside area. Flying lead cable (1m) Halogen/Mercury light: 10000Lx or less Fluorescent Light: 6000 Lx (max.) (Note: Direct sunlight or strong light source may cause misdetections)
Power source Current consumption Detection distance Accuracy
Hyteresis Outputs
Scan Angle Scan Time Output Response Time Start up Time Light Display
Connection Ambient Light Resistance Ambient Conditions Temperature: Humidity: Storage temperature Vibration Resistance
-10 ~ 50C 85% or less (non-condensing) -25 ~ 75C Double amplitude 1.5mm 10 ~ 55Hz, 2 hours XYZ direction, and 98m/s2 55Hz ~ 200Hz in 2 minutes sweep, 1 hours in XYZ directions Impact Resistance 196 m/s2 (10G), 10 times in XYZ directions Weight Approx. 185g (260g with cable) Protection Class IP64 Case Front: Polycarbonate / Back: ABS External dimension 60 W60 H75 D mm *Under standard test conditions.
UBG-05LN
Specifications
C 42 3404
37
3. Specifications (continue) Area Setting Output1 setting: Area with maximum 7 points form 0 to 5000mm Output2 setting: Straight : Fan Shape : Percentage of Output1 area points Output3 setting: Same as Output2 Inputs and Area Photo coupler input (Anode common, supply current to switch on the Selection inputs = 4mA) Area Switching: Set area numbers with [Input1][Input2] [Input3][Input4][Input5] Laser radiation stops with all inputs ON. High: OFF Low: ON
[Input1] ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF [Input2] ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF [Input3] ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF [Input4] ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF [Input5] ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF Area Patterns Laser OFF Area 1 Area 2 Area 3 Area 4 Area 5 Area 6 Area 7 Area 8 Area 9 Area 10 Area 11 Area 12 Area 13 Area 14 Area 15 Area 16 Area 17 Area 18 Area 19 Area 20 Area 21 Area 22 Area 23 Area 24 Area 25 Area 26 Area 27 Area 28 Area 29 Area 30 Area 31
Input Response Time Input reading frequency: 1 scan time (100msec) (Note: Input reading frequency is 1msec when Laser is switched off externally)
UBG-05LN
Specifications
C 42 3404
47
4. Lead cable color and signals Color Black White White (Blue) Orange Gray Red Green Yellow Purple White (Yellow) White (Purple) Brown Blue Yellow (Red) Yellow (Green) Yellow (Black) Note: Signal Output1 Output2 Output3 Malfunction Output Output common minus Input common plus Input1 Input2 Input3 Input4 Input5 +V IN -V IN Serial Input (RXD) Serial Output (TXD) Serial Ground (GND)
1. Leave the unused input terminals open or connect to input common plus (red). 2. Leave the unused output terminals open or connect to input common minus (gray). 3. Colors inside ( ) suggest wires with colored lines on either sides.
5. Installation Notice When mounting the device make sure to provide sufficient space for light window. Sensor will not operate normally if its view is blocked leading to serious injuries or property damage. Note For Long Term Use: It is necessary to readjust/reset sensors operating for more than one year to maintain the absolute accuracy.
UBG-05LN
Specifications
C 42 3404
57
6. Light Display Position
UBG
Output3
Output2
Output1
Power Supply (Flashes on malfunction)
7. Area Setting Range and Shape

Straight Fan Shape Ratio
Output1 Area Output2 Area Output3 Area
UBG
UBG
UBG
4m
Area Setting Range
5m
UBG
OBJECT: White Kent sheet 300300mm placed perpendicular to the sensors vertical axis within 100~5000mm from sensor axis Or Specific Reflector 200200mm placed perpendicular to the sensors vertical axis within 100~8000mm form sensor axis
UBG-05LN
Specifications
C 42 3404
67
8. Input/Output Circuit
Output 1
Main Circuit
Load
+
I/O Power Supply
Output 4 Load Output Common Input Common + 1K 4.7K
Input 1
1K 4.7K
Input 5
Power Supply Circuit
VIN + VIN Power Supply To Sensor
FG
UBG-05LN
Specifications
C 42 3404
77
06 Warning Light With Adjustable Mast

Yellow warning light will indicate that the cart is on and running. The cart will annunciate with a different flash rates that indicate the following diagnostic functions. Steady On lamp indicates that the cart is powered up and ready to run. Slow flash is normal operation when the cart is moving. Fast flash indicates that the cart has lost guidance and will not move. Two fast flashes followed by a pause indicate that the brake is not in the run position. The optional warning light can only be added to Tugger Carts. Yellow Status Beacon
Yellow Status Beacon shown with Adjustable Mast
06_Warning_Light_With_Adjustable_Mast_Rev_1.01
AUTO-CART Section 07-00 PREVENTIVE MAINTENANCE

SCHEDULE EVERY 2 WEEKS
1.
CAMERA:
INSPECT AND CLEAN THE CAMERA LENS WITH A SOFT CLOTH. DO NOT USE ANY CLEANING AGENTS OR CHEMICAL CLEANERS. DEPENDING ON THE AMOUNT OF CONTAMINATION, INSPECTION AND CLEANING MAY BE REQUIRED MORE OFTEN. DO NOT REMOVE CAMERA OR CAMERA BOARD. IF CAMERA IS LOOSE, CONTACT THE FACTORY FOR INSTRUCTION ON REPLACEMENT AND/OR RE-ALIGNMENT. CHECK CAMERA AND BOARD CONNECTORS. IF CAMERA BOARD IS LOOSE, TIGHTEN.
2.
CASTERS:
CHECK STABILIZER BALL TRANSFERS FOR WEAR & DAMAGE. CHECK URETHANE STEERING MOTOR CASTER WHEEL FOR WEAR, DAMAGE AND BONDING SEPARATION WITH THE WHEEL HUB. CHECK DRIVE AXLE URETHANE CASTER WHEELS FOR WEAR, DAMAGE AND BONDING SEPARATION WITH THE WHEEL HUB. REPLACE DEFECTIVE WHEELS
3.
STEERING/DRIVE:
MAKE SURE THAT THE DRIVE IS SECURELY ATTACHED TO VEHICLE FRAME CHECK WIRING FOR BROKEN SOLDER JOINTS AND WEAR. INSPECT STEERING MOTOR. REPLACE IF DAMAGED.
Rev 2_00
07-00 AGC Preventative Maintenance Rev2_00.doc
Page 1 of 5

4. BATTERIES:
CHECK FOR LOOSE BATTERY CABLE TERMINAL CONNECTIONS. CHECK CABLES FOR CHAFFING. IF BATTERY IS NOT HOLDING A CHARGE, CHECK THE BATTERY CHARGER FOR PROPER OPERATION. IF BATTERY IS NOT HOLDING A CHARGE, CHECK BATTERY WITH A BATTERY LOAD TESTER TO SEE IF THE BATTERY IS HOLDING A PROPER CHARGE. (CHECKS INTERNAL RESISTANCE OF THE BATTERY). IF BATTERY IS NOT HOLDING A CHARGE, REPLACE ONE OR MORE OF THE BATTERIES. WHEN REPLACING BATTERIES, REVIEW WIRING DIAGRAM ON THE CART. CHECK BATTERY ORIENTATION IN THE BATTERY TRAY. ENSURE LATCHING MECHANISM IS PROPERLY ATTACHED AND THAT IS IN WORKING FUNCTION INCLUDING THE PROX TO DETECT THAT LATCH IS LOCKED
5.
BATTERY CHARGER:
CHECK CABLES FOR TIGHT CONNECTIONS. CHECK CABLE CONNECTION TO CHARGER FOR BROKEN WIRE STRANDS AND REPLACE IF BROKEN. CHECK THE SMART CONTROLLER ~ IQ4 ACCESSORY PLUG TO SEE IF LED IS WORKING PROPERLY. CHECK SMART CONTROLLER FUNCTION: o UPON INITIAL CONNECTION TO THE BATTERY, THE LED WILL FLASH 12 TIMES FOR A 24 VOLT BATTERY SYSTEM. o o o o BULK CHARGE GREEN LED FLASHES RAPIDLY. ABSORPTION CHARGE GREEN LED FLASHES AT A SLOWER RATE. FLOAT CHARGE GREEN LED WILL REMAIN LIT AND NO LONGER FLASH. WHEN FIRST CONNECTED AND THE BATTERY IS NOT IN NEED OF CHARGING, FLOAT CHARGE WILL BEGIN IMMEDIATELY AND THE LED WILL REMAIN LIT AFTER IT HAS COUNTED THE 12 BATTERY CELLS. CHECK FAN. FAN ONLY OPERATES WHEN THE CHARGER IS WORKING PROPERLY. IT MAY TAKE SEVERAL MINUTES FOR THE FAN TO START AS THE CHARGER HEATS UP. THERE ARE 2 FUSES PER CHARGER. INSPECT CHARGER FOR LOOSE FUSES. IF FUSES ARE LOOSE, RE SEAT LOOSE FUSE(S).
SMART CONTROLLER IS OPTIONAL FEATURE NOT INCLUDED IN ALL AGCS Rev 2_00 07-00 AGC Preventative Maintenance Rev2_00.doc Page 2 of 5
6.
WIRING:
INSPECT ALL WIRES, PLUGS, AND ELECTRICAL CONNECTIONS FOR LOOSE
CONNECTIONS, BREAKS AND/OR DAMAGE. CHECK WIRING FOR CHAFFING.
Rev 2_00
Page 3 of 5

7. GUIDEPATH Care & Condition:
FLOOR TAPE WILL SHOW WEAR AND TEAR AND SHOULD BE REPLACED OR CLEANED AS NEEDED TO PREVENT LOSS OF GUIDANCE AND MINIMIZE THE TIME SPENT FOLLOWING IRREGULAR TAPE EDGES. IRREGULAR TAPE EDGES CAUSE THE STEERING TO CYCLE MORE OFTEN AND WILL INCREASE THE WEAR ON THE STEERING COMPONENTS. MORE DAMAGE AND WEAR WILL OCCUR NEAR AND INTO THE HORIZONTAL TURNS BECAUSE THE WHEEL PATHS MAY CROSS THE GUIDEPATH. DEBRIS SUCH AS SCREWS, BOLTS OR CLIPS COULD BECOME WEDGED UNDER THE WHEELS CAUSING DAMAGE TO THE TAPE AS THEY ARE PUSHED ALONG THE FLOOR. ANY DEBRIS OR MARKS ON OR NEAR THE GUIDANCEPATH WHICH ARE OF SIMILAR COLOR MAY CAUSE THE CART TO STRAY OFF COURSE. SWEEP/DUST AND/OR MOP OR USE A FLOOR WASHER TO CLEAN THE GUIDEPATH. MILD DETERGENTS MAY BE USED BUT THEY MUST BE RINSED TO REMOVE ALL DETERGENT RESIDUE. EXCESSIVE DUST WILL ADVERSELY AFFECT THE CAMERA AND LASER OPERATING CHARACTERISTICS.
NOTE:
THE GUIDEPATH MUST BE KEPT IN GOOD CONDITION FOR SMOOTH OPERATIONS.
TRACK-CLEANING SCHEDULE RECOMMENDATIONS

HIGH TRAFFIC AREAS AND CORNERS SHOULD BE CLEANED AND INSPECTED WEEKLY LOW TRAFFIC AREAS AND STRAIGHT SECTIONS SHOULD BE CLEANED AND INSPECTED TWICE A MONTH AREAS WHERE THERE IS EXCESSIVE DEBRIS SHOULD BE CLEANED AND INSPECTED DAILY
Rev 2_00
Page 4 of 5
8.

OBSTACLE SENSING LASER:

CHECK FOR LOOSE MOUNTING BOLTS. RE-TIGHTEN. DO NOT USE FINGERS TO REMOVE DUST FROM LENSE. CLEAN LENSE WITH A SOFT, DRY CLOTH. DO NOT USE ANY CLEANING AGENTS OR CHEMICAL CLEANERS. INSPECT ALL WIRING AND CONNECTORS FOR WEAR AND DAMAGE. REPLACE IF NECESSARY.
9.
FRAME:
CHECK FOR LOOSE BOLTS AND RE-TORQUE TO TORQUE SCHEDULE. ADJUST DECK PER THE SETUP DIMENSIONS IF DECK DOES NOT SIT LEVEL TO THE FLOOR.
10. FLOOR PROXIMITY SENSOR:

CHECK FOR LOOSE LOCK NUTS AND RE-TORQUE ACCODINGLY. CHECK HEIGHT POSITION TO VERIFY PROXIMITY TO FLOOR PLATES. VERIFY WIRING.
Rev 2_00
Page 5 of 5
AUTO-CART Section 10-01 Electrical Auto-Cart Boards

Guidance Board Radio Input Camera Input GUI Input T4 Terminal Block Diagnostic Port Selector T1 Terminal Block Diagnostic Input
Rabbit Core Prog. Port
Motor Connection
Dead Reckon Test
Analog Connection
T2 Terminal Block
T3 Terminal Block
Rev 1 01
10-01 AGC Boards Whirlpool Rev1 01.docx
Page 1 of 10

Guidance Board (Continued) Drive Overload
Guidance
Battery Frequency Camera Override Pendant Guide Left Brake Module
Range Frequency Drives Enable
Pendant Guide Right Pendant Enable Low Speed
High Speed
Floor Marker Input Dynamic Brake Enabled Main Drive Enabled Reverse Enabled Steering Drive Enabled
Rev 1 01
Page 2 of 10

Power and Safety Board LED#2 LED#1
38) LED#3
P4 Terminal Block
P2 Terminal Block
LED#4 & LED#5
J6 Jumper
Relays J3 Connection
Jumpers LED#6
P3 Terminal Block
P1 Terminal Block
(Weidmuller Terminal Blocks (Orange) may be present, Phoenix Terminal Blocks (Green) Shown)
Rev 1 01
Page 3 of 10

Steering and Drive Board Serial Number J2 Terminal Block PLD Software Version
Speed Control
J5 Connection J4 Connection
J6 Terminal Block PLD Prog. Port
Steering Position Feedback
Oscillator Bias Adjust Oscillator Amplitude Adjust J1 Terminal Block
Feedback Adjust
Rev 1 01
Page 4 of 10

Expander Board Laser Scanner Connection
P2 Terminal Block
PC Connection
NPN/PNP Config.
P4 Terminal Block
Keyence Scanner Interface Board For front and rear laser scanners. Used for bank select, reset, warning zone protection and powering laser scanner units To Expander Board interface for Laser Scanner
NPN/PNP Select Jumper
Rev 1 01
Page 5 of 10
Brake Driver Board Brake Disengaged
Master On
Camera Lighting Board
Power Connection
Lighting LEDs
Rev 1 01
Page 6 of 10

Item # Description
Guidance Board
IDC AGC3700 Processor Base supports the Rabbit Core processor module. The high performance processor supports analog and digital inputs along with serial and Ethernet connections. The processor base and core module is specifically designed for AGC cart operation utilizing a specialized color camera to provide guidance to a steering servo drive and motor speed control. Most cart functions are stored in the core processor. Core processor is plug-in allowing for easy field updates. 1 Radio Communication Port. Connects to AGC Radio. 2 3 4 Camera Communication Port. Connects to AGC Camera Board. Graphical User Interface (GUI) communications port. Connects to GUI. PC Diagnostic Port for camera, radio, or graphic user interface. This port connects to the device that is selected by the (6) Diagnostic Port Selector. The Diagnostic Port Selector switches select which, if any, port that the Diagnostic Port (4) is connected to. Only one switch should be in the PC selection at a time. Run: Sets the corresponding port for normal cart operation. PC: Connects the corresponding port to the Diagnostic Port. CAM-A: Connects the Diagnostic Port to the camera. Comm: Connects the Diagnostic Port to the radio. GUI: Connects the Diagnostic Port to the graphical user interface. T1 Terminal Block. 24V control power, pendant control. Refer to AGC wiring diagram for more information. T2 Terminal Block. 24V control power, charge relay, status outputs Refer to AGC wiring diagram for more information. T3 Terminal Block. Analog inputs, Current Sensing. Refer to AGC wiring diagram for more information. T4 Terminal Block. 5V control voltage, ultrasonic trigger & receivers. Refer to AGC wiring diagram for more information. Motor Connection to (47) J4 Connection on Drive Board Analog Connection to (45) J5 Connection on Drive Board Brake Module Port Rabbit Core Programming Port Used to perform a Dead Reckon Test. 1: Dead Reckon to the left. 2: Dead Reckon to the right. 3: Dead Reckon enabled. 4: Not Used
6 7 8 9 10 11 12 13
14
Rev 1 01
Page 7 of 10

Guidance Status Indicator Rapid Flash: Guidance Ok 0.5 Second Flash: Dead Reckon Mode Enabled Steady On or Off: Guidance Not OK Drive Overload Battery Frequency Range Frequency Camera Override Drive Enabled Pendant Guide Left Light turns on when input from pendant tells cart to go left. Pendant Guide Right Light turns on when input from pendant tell cart to go right. Pendant Enable Light turn on when input from pendant tell cart to enable motion. High Speed (Base Cart only) Low Speed (Base Cart only) Floor Marker Input Light turns on while the proximity sensor senses a floor marker. Main Drive Enabled Steering Drive Enabled Dynamic Brake Enabled Reverse Enabled
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Power and Safety Board

IDC PSB-SFTY-BRD is used to distribute power to all components. With force guided contacts monitoring a safety circuit, the power safety board has the ability to control power to devices based upon a safe condition being maintained. P1 Terminal Block 31 Battery Power, Charger Power, Drive Board, Motor Power P2 Terminal Block. safety inputs, switched power 32 Refer to AGC wiring diagram for more information. P3 Terminal Block 33 Cart Power On/Off, E-Stop, Unswitched Power P4 Terminal Block. brake power, light motor power/control, switched power 34 Refer to AGC wiring diagram for more information. J3 Connection 35 Connection used for current sensing. LED#1 36 Safety Circuit 1 Satisfied LED#2 37 Safety Circuit 2 Satisfied
Rev 1 01 10-01 AGC Boards Whirlpool Rev1 01.docx Page 8 of 10

38 39 40 41 42 43 LED#3 Safety Circuit cross-check Satisfied LED#4 & LED#5 Safety override mode enabled when BOTH are on. LED#6 Master Relay On J6 Jumper Safety Mode Select Holding. Jumpers Safety Bypass Enable (when drive not moving) Relays Pin Lift Control. Based upon cart options, relays may be present.
Steering and Drive Board

IDC Model DD-2060 servo drive board is dual channel MOSFET pulse width driver capable of operating two servomotors, one for steering and one for motor drive. The servo inputs are capable of being commanded by an external pulse width signal for steering position and drive speed. Motor drive is speed regulated with a pulse tachometer sensor that also provides position (distance) counting to the processor board. Dynamic braking and reversing can be selected by command from the host controller. Drive provides filtered & buffered speed & current signals to the host controller for diagnostics. J1 Terminal Block 44 Steering Motor Power J2 Terminal Block 45 Drive Motor power J4 Connection 46 Digital Signals from Guidance Board J5 Connection 47 Analog Signals from Guidance Board J6 Terminal Block 48 Position Sensing, Tachometer, and Drive Enable 49 PLD Software Version 50 PLD Programming Port 52 Oscillator Bias Adjust 52 Oscillator Amplitude Adjust 53 Steering Position Feedback Adjust
Expansion Board
IDC AGC-3700B EXP provides access to the use of a laser scanner, in addition the user gains the use of more I/O to assist in other AGC applications such as part in place proximity sensors, status indicators, or whatever needs may exist for 24V control sensors or actuators. 54 P2 Terminal Block
Rev 1 01 10-01 AGC Boards Whirlpool Rev1 01.docx Page 9 of 10

Expanded Inputs, User Configurable based upon application. P4 Terminal Block Expanded Outputs, User Configurable based upon application. Laser Scanner Connection PC Connection Plug a serial cable into this slot to interface with the Laser Scanner (Hokuyo). NPN/PNP Configures the Laser Scanner Inputs/Outputs to work with NPN or PNP devices.
55 56 57 58
Brake Adapter Board

IDC Model AGC 3700-BD is used to assist with the normally closed electrically guided brake. This is a high current brake driver to create better stopping ability and safer running carts. The brake will only be disengaged when told to release; if power were to fail the brake would be applied, providing a fail-safe function. Brake Disengaged LED 59 On when brake is disengaged Master On LED 60 On when both safety circuits have been satisfied
Light Board
IDC Model LAMP-18 provides a uniform band of light to aid in providing a constant image color for the camera to follow. Power Connection 61 Provides power to light board. Lighting LEDs 62 Provides light for illuminating stripe
Rev 1 01
Page 10 of 10
AUTO-CART Section 10-02 Electrical Parts List

1) Indicator Light 2) H.M.I. 6) Sound Module
7) Cart Power Switch
5) Laser Scanner
8) Radio System
10) Reflector
3) Pendant Control Receptacle
4) Programming Port 6) Laser Scanner 9) Bumper Photoeye
Rev 1 01
10-02 Part List Rev1 01.docx
Page 1 of 9

11) Lift Control Circuit Breaker 12) Control Power Circuit Breaker
13) Motor Drives Circuit Breaker
14) Prox. Cable
15) Proximity Sensor 16) Brake Mechanism
18) Light Board
19) Charger
17) Transaxle
Rev 1 01
Page 2 of 9

20) Steering Position Sensor 22) Camera Package
21) Steering Drive
23) Battery
24) Fuse Holder
2) H.M.I. 1) Indicator Light
6) Sound Module 26) Master Start/Reset Button 27) Cart Power Switch
25) E-Stop
Rev 1 01
Page 3 of 9
28) Status Indicator
29) Expansion Board
33) Drive Board 35) Keyence Scanner Interface Board
30) Brake Adapter 31) Guidance Board 32) Core Module
34) Power Safety Board
Rev 1 01
Page 4 of 9

36) Rack Detect PhotoEye
Rev 1 01
Page 5 of 9

Part Description Part Number/ Manufacturer HW2P-IFQD-Y-24V / IDEC BLR-24-Y / MARAYASU AGP3200-T1-D24 / PROFACE FK 4.5-0.5 / TURCK ENSP1F5C305 / BRAD CONNECTIVITY SZ-16V / KEYENCE PBS-03JN-CE / HOKYO PX-24ES / SUNX OS3101 / STI BD-24AK / PATLITE XB4BD21 / TELEMECANIQUE XBP24-PKI-001-RA / XBEE HP100-P1-CN03 / YAMATAKE FE-RR8 / YAMATAKE CLB-033-11B3A-B-A / CARLING CLB-033-11B3A-B-A / CARLING 691-CLB15311B3ABA / MOUSER 691-CLB15311B3ABA / MOUSER V1-G-YE5M-PVC / P & F MGS-S-24-10V-PX / IDC CORP BRAKE MECHANISM TRANSAXLE TRANSAXLE E500 Tugger N/A OPT STD STD STD E500 Tunnel STD OPT STD STD STD E3500 Tugger N/A OPT STD STD STD E3500 Tunnel STD OPT STD STD STD
Indicator Light
2 3 4
HMI Pendant Receptacle Programming Port
5 6 7 8 9 10 11 12 13
Laser Scanner Sound Module Cart Power Switch Radio System Bumper Photoeye Reflector Lift Control Circuit Breaker Control Power Circuit Breaker Reg. Duty Motor Drives Circuit Breaker Heavy Duty Motor Drives Circuit Breaker Proximity Sensor Cable Proximity Sensor Brake Mechanism Reg. Duty Transaxle Heavy Duty
OPT STD STD OPT. STD STD OPT. STD STD
OPT STD STD OPT. STD STD OPT. STD STD
OPT STD STD OPT. STD STD OPT. STD N/A
OPT STD STD OPT. STD STD OPT. STD N/A
13 14 15 16 17 17
N/A STD STD STD STD N/A
N/A STD STD STD STD N/A
STD STD STD STD N/A STD
STD STD STD STD N/A STD
Rev 1 01
Page 6 of 9

18 19 20 21 22 23 Transaxle Light Board Battery Charger Steering Position Sensor Steering Motor Camera Package Battery (Varies based upon customer request) Fuse Holder E-Stop Button Master Start/Reset Button Cart Power Switch Status Indicator Light (Mast Mounted) Expansion Board Brake Adapter Board Guidance Board Core Module Drive Board Power Safety Board Keyence Scanner Interface Board Rack Detect PhotoEye Right Angle Bracket for Reflector HMI LAMP-18 / IDC CORP. CHARGER IDC-CMU-F-8796 / IDC CORP. STEERING MOTOR 3-09-00089 / 3-D SALES M34 SLD G / MK POWERED 8012-021 / OPTIMA MET FBW801MANL / TSUNAMI XB4BT42 / TELEMECANIQUE ZB4BC3 / TELEMECANIQUE XB5AD33 / TELEMECANIQUE BLR-24-Y / MARAYUSU 3700B EXP / IDC CORP. AGC-3700-BD / IDC CORP. AGC-3700-BASE / IDC CORP. RCM 3700 / IDC CORP. DD-2060 / IDC CORP. (HEAT SINK VARIES) PWR-SFTY-BRD / IDC CORP. IDC-KEYENCE-INTERFACE/ IDC CORP. GLV18-55/115/120/ Pepperl+Fuchs NOT PICTURED HP100-BP01 / YAMATAKE AIGT003B / PANASONIC (OBSOLETE) STD STD STD OPT. OPT OPT. STD STD STD STD STD OPT. OPT STD STD STD OPT. N/A OPT. STD STD STD STD STD OPT. OPT STD STD STD OPT. OPT OPT. STD STD STD STD STD OPT. OPT STD STD STD OPT. N/A OPT. STD STD STD STD STD OPT. OPT STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD STD
24 25 26 27 28 29 30 31 32 33 34 35 36
37
STD
STD
STD
STD
38
N/A
N/A
N/A
N/A
Rev 1 01
Page 7 of 9

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1/2 Hole Plug Rubber Grommet Rubber Grommet Ultrasonic Unit (QTY#1) Crank Shaft Position Sensor Plug for Crank Shaft Position Sensor Chime Cable Assembly Cable Assembly Part in Place Proximity Sensor Cable For P.I.P. Proximity Sensor Housing For Female Brake Plug House Male Brake Plug Female Sockets For Brake Plug Male Pins For Brake Plug Female Housing For Motor Drive Male Housing For Motor Drive Female Sockets For Motor Drive Housing Male Pins For Motor Drive Housing Battery Connectors Pins For Battery Connectors Power Supply For
Rev 1 01
AS050 / HOFFMAN 9703K85 / MCMASTER CARR 9600K63 / MCMASTER CARR US-2M-TTL / IDC CORP. SU147 / WELLS ECC57-4502 / CARQUEST SC628ND / MALLORY (OBSOLETE) BCB-73 / IDC CORP. BCC-62 / IDC CORP. BES 516325GE5YS4 / BALLUF V1-G-TE5M-PVC / P&F 538-03-06-1023 / MOLEX 538-03-06-2023 / MOLEX 538-02-06-1103 / MOLEX 538-02-06-2103 / MOLEX 35143-0201 / MOLEX 35141-0201 / MOLEX 35728-0201 / MOLEX
STD STD STD STD STD STD N/A STD STD OPT OPT STD STD STD STD STD STD STD
57 58 59 60
357-0201 / MOLEX 8026K65 / 8026K92 / SD-25B-24 /
STD STD STD OPT
STD STD STD OPT
STD STD STD OPT
STD STD STD OPT
Page 8 of 9

STI Laser Scanner Cable For STI Laser Scanner Proximity Switch for Lift (Customer Dependant) MEANWELL OS3101-CBL-XXPT / STI 516-325-G-ES-Y-S-4 / BALLUFF OPT OPT OPT OPT OPT OPT OPT OPT
61 62
Rev 1 01
Page 9 of 9
SECTION 11-00
Troubleshooting
Steering Position Feedback Sensor The steering position sensor provides angular feedback of the wheel position to the servo drive and core processor. This provides a closed loop position along with a camera command that provides high precision following. The position sensor utilizes a non-contacting magnetic sensor. An embedded magnet attached to the gear drive provides the angular measurement and is detected by a proprietary sensor similar to a compass. This measurement method is superior to other transducers that have mechanical connections such as a pot or resolver. Bottom view of steering Wheel and Position Sensor
Magnetic Position Module Motor Power Connections
Sensor Plug See wiring diagram for connections.
Steering Wheel
11-01 Troubleshooting Rev1_01
PAGE 1 of 8
SECTION 11-00
Steering position sensor Measurement It is important to time the steering position feedback sensor to the servo drive. This insures that the absolute encoder will indicate left, straight and right when commanded by the processor. The first step is to make sure that the output from the position feedback is close to zero when the steering wheel is straight. Insure that the wheel is square to the cart. With power turned on, measure with a digital voltage meter (DVM) between terminals 3 & 4 to make sure the position output is with in range of zero (0) +/- .650V DC. See Fig.6 below. If measurement is out of range check to make sure that the position of the magnet is perpendicular to the wheel when the wheel is straight. Failure to make this adjustment may result in erratic steering. Check magnet under sensor cover Fig.5. There is a Transtork nut assembly above the motor drive that may be loosened and the sensor re-positioned by hand. Once you have aligned the magnet assembly, be sure to tighten the Transtorque nut assembly to 19.8nm. Install cover assembly and make sure magnet is not touching or scraping circuit board or cover. Magnet Check Fig. 5
Steering wheel
Magnet must be perpendicular to wheel when wheel is straight. Compensation adjustment (P4) in servo module can correct for slight misalignment.
Transtorque nut assembly on motor shaft: Torque to 19.8nm.
Sensor cover removed to expose magnet on gear assembly.
PAGE 2 of 8
SECTION 11-00
Measurement of transducer position Measure between terminals 3 and 4 with a DVM Fig.6. Voltage should be between -.650 to +. 650 If measurement is out of this range see magnet check procedure above. Fig.6
Steering Sensor Compensation adjustment0 With the steering wheel perfectly straight, turn power on but do not initiate cart to cycle. Measure on Pin 1 of IC U1 for 0.0VDC with DVM (Fig.7). Adjust P4 to achieve this value. P4 is a 25 turn pot and can be rotated indefinitely with out damage. If 0.0V cannot be achieved recheck position sensor reading above to be sure that the voltage is below .65 volts. Fig.7 Terminal 3 Common Pin 1 on U1
Dead
Reckon Steering
PAGE 3 of 8
SECTION 11-00
Command Check and Adjustment A steering command must be calibrated to associate true straight command from the processor to the servo drive. This is accomplished after the steering position check performed above has been accomplished. The cart may be put in Dead Reckon mode to perform this test. Test may be checked with the cart on its back or on the floor to check for straight movement. To put the cart in Dead Reckon mode plug in the pendant control. This will automatically set the cart to move without a color path. Press the green run button and the cart will move forward providing there are no obstacles in front blocking the laser scanner. The cart should move in a straight line. If a noticeable left of right turn is detected the servo board must be adjusted If the wheel is not straight, adjust the steering centering Pot P1 on Servo Drive board to correct any misalignments. See Fig.9 Servo Drives Fig.8
P1 Adjusts Dead Reckoning for straight wheel operation when the pendant control in plugged in and operated.
After the dead reckoning test and adjustment, you may test the left and right commands by pressing and holding the left and right button on the pendant control.
PAGE 4 of 8
SECTION 11-00 Guidance Camera

IDC CMU-500
Camera Connection Plug
Fig.10
Cooling Fan
Secure Lens with anti-rattle cement
Camera With Close focus Lens Fig.11
LED power connection
LED Lamp assembly
PAGE 5 of 8
SECTION 11-00 AutoCraft Cart Troubleshooting Guide Electrical

Cart will not turn on Check circuit breaker in control panel to insure they are all on. Check Battery plug connection to control panel. Battery connection is located inside battery box. This is a blue inline plug. Check to be sure cable plug is fully seated. Check Battery voltage to insure 24 Volts. Measure with DVM on power terminals on lower left side of control panel. Terminals will have a #6 red and black wire coming from battery.
Cart turns on but will not go when released
Laser Block This will prevent the cart from operating if an obstacle is detected by any one of the ultrasonic transducers. Cart may be too close to obstacle Master reset is depressed. Pull out red mushroom button and press green button. Waiting for operator release is an indication for operator input to tell the cart to move to the next step. Pressing the Green button initiates the move. Battery Low Is an indication that the battery is too low for safe operation. Battery must be charged. Battery Low is indicated by a doorbell chime from the music module. Brake set in free-wheel position will prevent cart motion. This insures that the cart will stop properly in load and unload locations. The yellow beacon will flash two fast blinks followed by a noticeable pause. Brake handle in back of cart must be set to the down position.
Car runs away and stops
Tach sensor or wiring fault Tach loss is checked anytime the motor is commanded to go and pulses are not detected. Cart will run fast briefly and stop immediately with the brake applied. Cart must be powered down to reset the fault. If problem persists check the tach sensor for continuity using an ohmmeter. Tach sensor is measured on terminals 9&10, the orange plug on the servo drive board. The reading should be 630 ohms +/- 10 %. Tach sensor is located on
PAGE 6 of 8
SECTION 11-00
drive motor top near the brake handle. Sensor is connected with an automotive type connector.
See Fig. 12
Ohm Meter 630 Ohms between terminals 9 & 10
PAGE 7 of 8
SECTION 11-00
Loss of Guidance
Loss of guidance is detected in the microprocessor (Flashing Red LED on processor board top left side.) The amber lamp on cart top will flash a fast sequence indicating that the cart is not on tape guidance or the camera is programmed to the wrong colors. Make sure cart is on stripe when initiated. Cart is dependent on a camera signal to operate. Color selection in the camera may be wrong. Check color values with the WEB browser. See WEB browser section to view colors. Check LED lamp board for illumination. IF no illumination is observed under the cart in front, check 9-pin serial cable to camera assembly for proper plug in. Fig.11 Check LED board for proper power connection. See Fig.12 Check Toggle switches on guidance processor for proper setting. Bat handle must be switched to the outside of the circuit board. Check motor drive for proper operation by implementing a dead reckoning command. This is accomplished by plugging the pendant control. This will test motor and steering drives. Check for loose connection to circuit board on the camera assembly under the cart. See Fig. 10 for cable placement. Check Camera view for proper focus. Use the camera view program starting on page 4. Cart does not run and no indication of faults Check for circuit breaker trip in control panel Check to be sure dipswitches are off on processor board Check to make sure all toggle switches are in the Left position Battery voltage too low. Check with volt meter for 24vdc Check for obstruction in front of laser sensor Check motor plug for connection
PAGE 8 of 8
1800 FRUIT RD. ALGONAC, MICHIGAN 48001 PHONE: (810) 794-4929 FAX: (810) 794-7449 E-mail: info@auto-craft.com
AUTO CRAFT TOOL & DIE CO., INC. PRODUCT WARRANTY

Equipment manufactured and sold by Auto Craft Tool and Die, Inc. is warranted as set forth below. This warranty extends only to the buyer purchasing the equipment directly from Auto Craft or through its dealers, distributors, or agents as new equipment. This equipment is warranted by Auto Craft to be free from defects of workmanship and materials for a period of 4,000 operating hours after delivery (except as stated below), provided that it is properly operated under conditions of normal use. Auto Crafts sole obligation under the foregoing warranty is limited to making replacements, repairs, or issuing credit for equipment or parts thereof (at Auto Crafts option) which are found to be defective. Auto Craft shall not be liable to buyer from consequential damages, or damages of any kind based upon a claim for breach of warranty other than as stated above. The foregoing warranty shall not apply, and Auto Craft shall be relieved of any obligation or liability, if this equipment has been repaired or altered. Including the use of components other than those manufactured or approved by Auto Craft by anyone other than Auto Craft, or if this equipment has been subject to abuse, misuse, negligence, or accident. This warranty does not cover buy items that would be covered under a separate manufacture warranty.

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AUTO-CART AGC

IDC SALES CONTACT Ginger Smigelski (517) 646-0358

AUTO-CART SUPPORT HOT LINE for JCI

Dave Benke Tom Dudek Michael DuVernay

Jim Black Pete Walacavage Matt Robel

AFTER HOURS PHONE SUPPORT

TECHNICAL TECHNICAL TECHNICAL MANUAL MANUAL MANUAL

AGC AGC AGC

Auto Craft Tool & Die

AUTO-CART Section 00-01 Overview TABLE OF CONTENTS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

00-01 Auto-Cart Manual Table of Contents.docx

AUTO-CART Section 00-02 Overview AUTO-CART GENERAL OVERVIEW

00-02 Auto-Cart General Overview Rev 1-01.docx

AUTO-CART Section 00-02 Overview AUTO-CART GENERAL OVERVIEW

Main Power On/Off Electronic Laser Bumper Start/Stop Initiate

Brake Handle located in the Down (run) position for operation

00-02 Auto-Cart General Overview Rev 1-01.docx

AUTO-CART STYLE 2. TUG (TUGGER) STYLE

01-00 Vehicle Size-Type E500 TUG.docx

AUTO-CART STYLE 3. TUG (TUGGER) STYLE

TUN (TUNNEL) STYLE

01-00 Vehicle Size-Type.docx

AUTO-CART Section 01-01 AUTO-CART SIZE AND TYPE

AUTO-CART SIZE 1. Model E500

AUTO-CART STANDARD FEATURES: Drive and Steering:

AUTO-CART STANDARD FEATURES:

This document is Uncontrolled when printed. Rev.: 11172007

01-01 Vehicle Size E500.docx

AUTO-CART Section 01-02 AUTO AUTO-CART SIZE AND TYPE

AUTO-CART STYLE TUG (TUGGER) STYLE

01-02 Vehicle Type TUG.docx

AUTO-CART Section 02-01 Guidance COLOR CAMERA

CAM COLOR CAMERA w/ TAPE GUIDANCE

02-01 Guidance Cam.doc

02-02 Camera Set-Up Rev1_02.doc

AUTO-CART Section 02-02 Guidance CAMERA SETUP

This message indicates that the computer recognizes the camera.

CMUcam type 2 Version 6

02-02 Camera Set-Up Rev1_02.doc

AUTO-CART Section 02-02 Guidance CAMERA SETUP

(6) Type 10 to crop upper window edge.

(7) Type 110 to crop lower window edge.

(8) Click on Set Window.

(9) Click Camera View to view the image stripe.

02-02 Camera Set-Up Rev1_02.doc

AUTO-CART Section 02-02 Guidance CAMERA SETUP

02-02 Camera Set-Up Rev1_02.doc

AUTO-CART Section 02-02 Guidance CAMERA SETUP

02-02 Camera Set-Up Rev1_02.doc

AUTO-CART Section 02-02 Guidance CAMERA SETUP

AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL

AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL

03-02 Step Programming Manual Rev 1_02.docx

AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL 1 Step Description

Figure 1-1 Basic STEP Layout

2 Basic Step Components

AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL

03-02 Step Programming Manual Rev 1_02.docx

AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL

AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL

03-02 Step Programming Manual Rev 1_02.docx

AUTO-CART Section 03-02 Controls STEP PROGRAMMING MANUAL