沈陽新松-長安南京AGV裝配線技術(shù)方案

1、.長安福特汽車有限公司南京公司Changan Ford Automobile Co., Ltd. Nanjing Company發(fā)動機、前后橋AGV系統(tǒng)Engine & Axel AGV System技 術(shù) 方 案Technical Plan沈陽新松機器人自動化股份有限公司Shenyang SIASUN Robot & Automation Co., Ltd.目 錄 Contents1. 概述Summary52. 設(shè)計依據(jù)Design Gist52.1 生產(chǎn)工藝基本要求Basic Requirement of Production Process52.2 現(xiàn)場基本技術(shù)條件Basic Field

2、 Technical Condition62.3 責任范圍Responsibility Scope：63. AGV裝配輸送系統(tǒng)概述AGV Assembly & Transportation System Summary74. 自動導引車AGV系統(tǒng)技術(shù)指標Automated Guided Vehicle AGV System Technical Specification95. AGV工作過程描述AGV Working Process Description116. 發(fā)動機裝配升降工作臺Engine Assembly Lifter Worktable146.1 伸縮套筒式升降工作臺Extensi

3、on Sleeve Lifter Worktable146.2 剪式液壓機構(gòu)升降工作臺Scissor Hydraulic Lifter Worktable166.3 托盤底面距發(fā)動機最高點距離與升降平臺高度關(guān)系計算Calculation on the Relation Between Distance from Pallet Bottom to Engine Zenith and Height of Lifter Table197. 后懸裝配舉升裝置Rear Suspension Assembly Lifting Equipment227.1 伸縮套筒式升降工作臺227.2 剪式液壓機構(gòu)升降工

4、作臺Scissor Hydraulic Lifter Worktable247.3 升降平臺上平面到地面的高度計算Calculation on the Height from the Plane of the Lifter Table to the Ground268. 不同軸距車體裝配實現(xiàn)Body of Different Wheelbases Assembly Realization289. AGV 動態(tài)裝配解決方案AGV Dynamic Assembly Solution2910. AGV 主要設(shè)備AGV Main Equipment2910.1 AGV（LGV）車載控制器 AGV（LG

5、V）Vehicle Controller2910.2 AGV（LGV）驅(qū)動系統(tǒng)AGV（LGV）Drive System3010.3 導航系統(tǒng)Navigation System3010.4在線自動充電系統(tǒng)Online Automatic Charge System3210.5無線局域網(wǎng)通訊系統(tǒng) Wireless LAN Communication System3310.6驅(qū)動控制系統(tǒng)Drive Control System3410.7非接觸防碰裝置Non-contact Bumper Device3511. AGV安全系統(tǒng)AGV Safety System3511.1非接觸防碰裝置Non-con

6、tact Bumper Device3511.2接觸式防碰裝置 Contact Bumper Device3611.3離線保護系統(tǒng) Offline Guarding System3611.4信息交互系統(tǒng) Information Exchange System3611.5緊急停車系統(tǒng)Emergency Stop System3711.6多AGV避碰 Multi-AGV Collision Prevention3712. AGV控制臺和調(diào)度管理系統(tǒng)AGV Console & Dispatching Management System3712.1 AGV控制臺AGV Console3712.2調(diào)度管

7、理系統(tǒng)Dispatching Management System3813. AGV車載控制系統(tǒng)和數(shù)據(jù)采集AGV Vehicle Control System & Data Collection4014. 導航線的鋪設(shè)Navigation Line Paving4115. AGV系統(tǒng)特點AGV System Characteristics4215.1 高速無線局域網(wǎng)的建立和應用 Setup and Application of High-speed Wireless LAN4215.2 AGV運行的靈活性Flexibility of AGV Running4315.3 高精度導航系統(tǒng)High A

8、ccuracy Navigation System4315.4 友好的人機界面User Friendly Human Machine Interface4415.5 完善的自診斷系統(tǒng)Perfect Self-diagnosis System4415.6 AGV可靠性措施Measures on AGV Reliability4415.7 在線快速自動充電方法和快速充電電池的應用Online Automatic Instant Charge Method and Application of Instant Rechargeable Battery4615.8 故障修復時間（MTR）Mean Ti

9、me of Repair（MTR）47AGV系統(tǒng)的故障修復時間有兩類： Therere two kinds of MTR for AGV system:4715.9 平均無故障時間（MTBF）Mean Time To Failures（MTTF）4816. AGV運行路線圖 AGV Running Route Graph4816.1 裝配線AGV運行布局圖 Assembly AGV Running Layout4816.2 樣機車間AGV運行布局圖 Sample Workshop AGV Running Layout4818. 環(huán)行裝配線AGV系統(tǒng)設(shè)備清單Circular Assembly A

10、GV System Equipment List5119. 項目進度Project Schedule5320. 培訓Training5320.1 培訓人員的范圍、數(shù)量及時間Scope, amount and time for training people5420.2 培訓的內(nèi)容Training content5421. 售后服務After-sale service551. 概述Summary根據(jù)長安福特汽車有限公司南京公司發(fā)動機、前后橋AGV系統(tǒng)的設(shè)計要求，新松公司采用的裝配型AGV系統(tǒng)進行發(fā)動機、前后橋與車身合裝，具有同步動態(tài)跟蹤功能的AGV可實現(xiàn)發(fā)動機、前后橋在裝配段任何工位同時裝配。導

11、航方式采用磁導航，地面施工量小，只要根據(jù)工藝要求變更磁條的粘貼路徑，在對控制程序稍加改動，就可以改變裝配路線的長短，適應不同的裝配工藝要求。AGV系統(tǒng)由一條近似梯形的環(huán)線組成，在裝配段進行前懸掛/發(fā)動機、后橋與車身合裝，在非裝配段進行發(fā)動機、前后橋由分裝線往AGV裝配托盤上吊裝，并可在非裝配段進行部分零部件的組裝。根據(jù)產(chǎn)量及裝配時間確定環(huán)線上AGV數(shù)量。According to design requirement of Changan Ford Automobile Co., Ltd. on engine and axle AGV system, SIASUN uses assembly A

12、GV system for engine, axle and body decking, and AGV with the function of synchronization dynamic tracking can realize simultaneous assembly of engine and axle at any assembly zone or stations. By using magnetic navigation, ground construction is small and by changing the path of magnetic strip upon

13、 technical requirements and modifying slightly control program, the length of assembly path can be altered to meet different assembly process requirements. AGV system is formed by a loop line, which is close to a trapezium. The assembly zone is used for front suspension/engine, rear axle and body de

14、cking and the non-assembly zone is used for engine and axle suspending on AGV assembly pallet through subassembly line and also for assembly of part of components. The number of AGV on the loop line is set according to output and assembly time.整個系統(tǒng)包括AGV、AGV控制臺、充電系統(tǒng)、導航系統(tǒng)、通訊系統(tǒng)、數(shù)據(jù)采集系統(tǒng)和裝配夾具等幾部分組成。The wh

15、ole system includes AGV, AGV console, charge system, navigation system, communication system, data collection system and assembly jig, etc. 2. 設(shè)計依據(jù)Design Gist2.1 生產(chǎn)工藝基本要求Basic Requirement of Production Process工位間距Distance between stations： 5，800mm生產(chǎn)節(jié)拍Production rate： 最大：1分鐘/輛 Max.: 1minute/vehicle 最

16、?。?分鐘/輛Min.: 5minutes/vehicle2.2 現(xiàn)場基本技術(shù)條件Basic Field Technical Condition 動力電源： 交流38010% 50HZ2% 3相5線Power supply: AC 38010% 50HZ2% 3 phases 5 lines溫度： -545Temperature: -545濕度： 6095%Humidity: 6095%防護等級： IP54Protection grade: IP54絕緣等級： B級Insulation level: Level B2.3 責任范圍Responsibility Scope：1） AGV裝配系統(tǒng)總

17、體設(shè)計、制造。AGV assembly system design and manufacturing.2）AGV車體設(shè)計、制造。AGV vehicle design and manufacturing.3）AGV裝配系統(tǒng)發(fā)運前調(diào)試、考機實驗。 AGV assembly system debugging and trial running before delivery.4）AGV裝配系統(tǒng)運輸、接收、搬運。 AGV assembly system transport, reception, carriage.5）AGV控制系統(tǒng)設(shè)計、制造，車載控制軟件、調(diào)度軟件設(shè)計。 AGV control s

18、ystem design and manufacturing, vehicle control software, scheduler software design.6）AGV工作環(huán)線設(shè)計、制造，地面導航線布局設(shè)計、敷設(shè)。 AGV working loop line design and manufacturing, ground navigation line layout design and laying.7）現(xiàn)場安裝、單機調(diào)試、全線聯(lián)動調(diào)試。 Field installation, unit machine debugging and complete line linkage de

19、bugging.8）技術(shù)培訓和售后服務。 Technical training and after-sales service.控制臺Console充電器Charger3. AGV裝配輸送系統(tǒng)概述AGV Assembly & Transportation System Summary發(fā)動機/后橋AGV裝配輸送系統(tǒng)由AGV、AGV地面導引系統(tǒng)、在線自動充電系統(tǒng)、AGV控制臺、數(shù)據(jù)采集系統(tǒng)、AGV調(diào)度管理系統(tǒng)和通訊系統(tǒng)等構(gòu)成。Engine/rear axle AGV assembly & transportation system includes AGV, AGV ground guided s

20、ystem, online automatic charge system, AGV console, data collection system, AGV dispatching management system and communication system, etc.l AGV：AGV完成發(fā)動機或后懸掛系的輸送和輔助裝配工作。裝配人員可以站在AGV車的腳踏板上進行裝配作業(yè)，腳踏板采用花紋鋁板制造，操作安全。AGV conducts transportation of engine or rear suspension and assistant assembly jobs. Ass

21、embly operator can stand and work on AGV pedal, which is made of aluminum board with decorative figures and safe to operate. l AGV地面導引系統(tǒng)AGV Ground Guided System：地面導引系統(tǒng)是AGV運行的路線和軌跡，AGV的導引系統(tǒng)采用基于地圖的磁帶導航方法。當工藝確定磁條埋入地下后，地面將保持平整狀態(tài)，完全不影響人、車通行。Ground guided system is AGV running path and track. AGV guided s

22、ystem adopts the method of magnetic tape navigation based on the map. When the process has confirmed that the magnetic strips have been embedded underground, the ground will be smooth and wont influence people or vehicle to pass.l 在線自動充電系統(tǒng)Online Automatic Charge System：為了保證AGV 24小時連續(xù)運行，充電系統(tǒng)采用大電流快速充電

23、的方法為AGV補充電量。AGV的充電過程是在控制臺的監(jiān)控下自動進行的。To ensure AGV to run 24 hours continuously, charge system uses the method of large electrical current and instant electrification to charge AGV. AGV charge process is conducted automatically under the supervision and control of the console. l AGV控制臺和AGV調(diào)度管理系統(tǒng)AGV Co

24、nsole and AGV Dispatching Management System控制臺和AGV調(diào)度管理系統(tǒng)是AGV系統(tǒng)的調(diào)度管理中心，負責數(shù)據(jù)采集系統(tǒng)的數(shù)據(jù)處理，與上位機交換信息，生成AGV的運行任務，解決多AGV之間的避碰問題。Console and AGV dispatching management system is the dispatching management center of AGV system, responsible for data processing in data collection system and information exchange w

25、ith upper computer to create AGV running tasks and solve the problems of multi AGV collision. l 通訊系統(tǒng)Communication System通訊系統(tǒng)由無線局域網(wǎng)組成。AGV與控制臺之間采用無線電臺進行信息交換，通訊協(xié)議為TCP/IP協(xié)議?？刂婆_可與上位機之間采用以太網(wǎng)進行數(shù)據(jù)傳輸。Communication system is formed by wireless local network. Wireless transmitter-receiver is adopted between AG

26、V and console to exchange information and the communication protocol is TCP/IP protocol. Ethernet is used between console and the upper computer for data transmission.l 光電檢測系統(tǒng)Photoelectricity Testing System 光電檢測系統(tǒng)是用于檢測主輸送線吊具上車身是否運行到位，運行到位將發(fā)出信號通知處在等待站點的AGV可以側(cè)移運行，實現(xiàn)順序裝配。如果沒有車身通過，等待站點的AGV始終處于等待狀態(tài)。如果有車身

27、通過，但等待站點沒有AGV等待，AGV控制臺將通知總控室。 Photoelectricity testing system is used to check if the body on the suspending tools of the main transmission line has run to the position, where signal will be sent to inform AGV at the waiting station to move sideways to realize sequence assembly. If the body hasnt pa

28、ssed, AGV at the waiting station will stay all along in the status of waiting. If passed, but theres no AGV waiting at the station, AGV console will notify the general control room.4. 自動導引車AGV系統(tǒng)技術(shù)指標Automated Guided Vehicle AGV System Technical Specification此圖片僅供參考 This picture is for reference only帶

29、有同步跟蹤和舉升機構(gòu)的AGV，其主要技術(shù)指標：Main technical specifications of AGV with synchronization tracking and lifting framework include:AGVS控制方式：控制站集中調(diào)度、監(jiān)控、管理AGV系統(tǒng)的運行狀態(tài)AGVS control mode: control station makes centralized dispatch, monitoring & control and management on the running state of AGV systemAGV控制方式具備功能：全自動

30、半自動手動AGV control function: automatic/semi-automatic/manual通訊方式：無線局域網(wǎng)Communication: wireless LANAGV導航方式：磁導航AGV navigation method: magnetic navigationAGV驅(qū)動方式：雙舵輪驅(qū)動。AGV steering: powered wheel steering負載能力：2000KG（以最終設(shè)計為準）Payload: 2000KG (subject to final design)AGV自重：2000KG（以最終設(shè)計為準）AGV weight: 2000KG (

31、subject to final design)同步跟蹤精度：10mmSynchronization tracking accuracy: 10mm運動方向：全方位（所占用運行空間最小化）Moving direction: Omni-directional moving(to minimize occupied running space)最大速度：直線60mmin，側(cè)移30mminMaximum speed: straight 60mmin，sideways moving 30mmin導航精度：10mmNavigation accuracy: 10mm停車精度：10mmParking acc

32、uracy: 10mm工作時間： 24小時連續(xù)（三班）Working time: 24 hours continuously (3 shifts)防碰裝置： 四周安裝接觸式保險杠，前后另安裝激光防碰裝置。Collision prevention device: contact bumper installed around and laser collision prevention device installed in the front & back side舉升裝置：雙舉升機構(gòu)，可以同步舉升或單獨舉升。Lifting equipment: dual lift framework, fo

33、r synchronization lifting or separate lifting托盤夾具： 按照實際需要設(shè)計（本方案中不含該部分內(nèi)容）Pallet fixture: design according to demands (not included in this solution)電池組：48V100AH，正常使用，壽命大于3年Battery charger: 48V100AH, in normal usage and its longevity is over 3 years.充電方式：全自動充電器實現(xiàn)在線自動充電，保證連續(xù)24小時工作Charging: automatic ch

34、arger realizes online quick charge to ensure 24 hours continuous working 操作高度： 裝配人員站在AGV提供的腳踏板上相對靜止進行零部件裝配，腳踏板到地面高度200mm。Operation height: Operator stands on AGV foot pedal to assembly parts in relative still condition and the height from the foot pedal to the ground is 200mm.車體尺寸：4800 mm1800 mm900

35、mm長寬高(舉升前)Body dimension: 4800 mm1800 mm900 mm (lengthwidthheight (before /after lifting)5. AGV工作過程描述AGV Working Process Description （1） AGV小車按控制臺計算機的指令行駛到后橋總成上裝點，由操作人員根據(jù)生產(chǎn)計劃完成后橋總成的吊裝，當將后橋總成從后橋分裝線吊到AGV后橋舉升裝置上的后橋夾具上并放穩(wěn)后，操作人員通過車體上的操作按鈕向AGV小車發(fā)出完成上件確認信號，允許AGV向下一個站點運行；AGV will run upon console computer o

36、rders to loading point of rear axle final assembly and operator will complete this based on production plan. After the rear axle final assembly is moved from the rear axle subassembly line and placed well on the rear axle fixture of AGV rear axle lifting device, operator presses the button on the ve

37、hicle to sent signal, informing AGV that loading has been finished and allow AGV to move towards next station. （2） AGV小車行駛到發(fā)動機總成上裝點，由操作人員根據(jù)生產(chǎn)計劃完成發(fā)動機總成的吊裝，當將發(fā)動機總成從發(fā)動機分裝線吊到AGV發(fā)動機舉升裝置上的發(fā)動機夾具上并放穩(wěn)后，操作人員通過車體上的操作按鈕向AGV小車發(fā)出完成上件確認信號，允許AGV向下一個站點運行AGV runs to loading point of engine final assembly and operator

38、 will complete engine final assembly suspending. When the engine final assembly is moved and placed well on the engine fixture of AGV engine lifting device from engine subassembly line, operator then sends confirmation signal of the completion of loading by pressing operation button on the body to i

39、nform AGV vehicle to move towards next station.（3） AGV小車按控制計算機的指令行駛到等待地點； AGV moves to waiting place according to the order from control computer.（4） AGV小車在某一停留時間相對長的站點（動力總成上裝點或其它點）進行自動充電；AGV will charge itself automatically at one station (power train assembly loading point or other point) for rele

40、vant long waiting time.（5） AGV控制臺檢測工藝鏈上車體的位置信號，當被裝車體到位后調(diào)度已載有發(fā)動機前后懸掛總成AGV按預定時間、速度進入懸鏈下方（時間、速度根據(jù)生產(chǎn)線要求可通過車載顯示器進行更改），在裝配段快速向前運行，在預定區(qū)域捕獲預先固定在被裝車身上的合作目標。保持穩(wěn)定跟蹤狀態(tài)后，人工操作舉升手控盒或腳踏開關(guān)，進行舉升裝置上升操作，操作人員可以同時或單獨發(fā)動機舉升裝置和后橋舉升裝置。在舉升裝置上升同時，打開平臺鎖定裝置，使舉升裝置上平臺處于浮動狀態(tài)，操作人員一邊按上升按鈕一邊夾具上車身定位銷插入車身的工藝定位孔。當舉升到安裝位置，所有的螺栓安裝孔均已定位。由裝配

41、人員安裝固定螺栓，完成裝配后裝配人員按一下舉升裝置上的裝配結(jié)束按鈕，AGV將自動落下舉升裝置到零點。當前后舉升裝置全部復位到零點以后，AGV將加速離開裝配工位，在非裝配段加載站備好發(fā)動機及后橋，完成一次工作循環(huán)。AGV console will test the signal of body position on the process chain. When loaded body has gotten to the position, AGV with engine and front & rear suspension assembly is dispatched according

42、to set time and speed to the underneath of the suspending chain (time & speed can be changed through vehicle displayer according to requirements of the production line). Then AGV moves forward quickly in the assembly zone and captures in the prearranged area the cooperative target set in advance on

43、the body. After tracking state is stable, manual control box or foot pedal switch is done by manual operation to raise the lifter. Operator can run simultaneously or separately the engine lifting device and rear axel lifting device. When the lifting device is raised, the lock fixture is opened to ma

44、ke the table floating. Operator presses the button for lifting and at the same time puts the body locating pins on the fixture into the process locating hole of the body. When getting to the installation position, all bolt installation holes are located. Then assembly workers will install the set bo

45、lts and press the button on the lifting fixture after completion of assembly. AGV will lower the lifting fixture to zero automatically. When all lifting fixtures reach zero, AGV will accelerate to leave assembly station. After equipped with engine and rear axle at loading station, AGV finishes one w

46、orking cycle. 當發(fā)動機前后懸掛總成不能及時供應時，可通過設(shè)置在裝配工位的懸鏈急停開關(guān)，由人工控制，停止懸鏈運行。即使不按懸鏈急停，AGV系統(tǒng)也會通過控制臺申請停止懸鏈運行。When engine and front & rear suspension assembly cant be supplied in time, make manual control by using emergency stop switch on the assembly station to stop suspending chain to run. Even without pressing th

47、e suspension chain emergency switch, AGV system can also apply to stop running through the console.當AGV進入報警工位（裝配工位末端）而未完成合裝時，AGV將自動停止運行，AGV控制臺報警并控制工藝鏈停線，直到完成裝配后自動恢復運行。When AGV enters into alarming station (at the end of assembly station) and hasnt finished assembly, AGV will stop automatically and A

48、GV console will alarm and control the process chain to stop. After assembly, it will recover automatically. （5）AGV在分裝工位的運行速度可根據(jù)現(xiàn)場實際設(shè)置。 AGV running speed in subassembly station can be setup according to actual situation. 6. 發(fā)動機裝配升降工作臺Engine Assembly Lifter WorktableAGV發(fā)動機裝配升降工作臺是將發(fā)動機前懸總成舉升到裝配位置高度的設(shè)備，

49、目前我公司應客戶要求普遍采用純機械傳動的伸縮套筒式升降工作臺。為適應各使用現(xiàn)場的不同要求，我公司將剪式液壓機構(gòu)升降工作臺列為備選設(shè)備供用戶選擇。兩者主要區(qū)別為前者采用直流伺服電機驅(qū)動升降，執(zhí)行元件為滾珠絲杠。后者采用液壓泵站驅(qū)動升降，執(zhí)行元件為液壓缸。AGV engine assembly lifter worktable is the equipment that lifts engine front suspension final assembly to the assembly position. Now, based on customer requirements, our com

50、pany mainly adopts pure mechanical driving extension sleeve lifter worktable. To meet different demands in various application fields, our company makes the scissor hydraulic lifter worktable to be an optional device for customer to choose. The main difference between these two lies in the fact that

51、 the previous one uses DC servo motor to drive lifter and the executive component is ballscrew, while the latter adopts hydraulic pumping station to drive lifter and the executive component is hydraulic cylinder. 6.1 伸縮套筒式升降工作臺Extension Sleeve Lifter Worktable該裝置主要由滑動工作平臺、舉升裝置、手控盒等組成（如圖升降工作臺簡圖），其中滑動

52、工作平臺在使用過程中可通過直線軸承組合的機構(gòu)進行兩個方向的水平移動，另外滑動工作臺通過組合軸承結(jié)構(gòu)可旋轉(zhuǎn)一定的角度。舉升裝置是完成升降動作的主要裝置，其主要由滾珠絲杠機構(gòu)、一層起重鏈輪組合、二層起重鏈輪組合、電機減速機、齒輪傳動及各伸縮套筒組成。該電機采用進口的直流電機、減速器一體機，滾珠絲杠及螺母等零件采用德國進口零件，性能可靠，傳動穩(wěn)定。This equipment is formed by the sliding worktable, lifting device and manual control box, etc (See the lifter worktable sketch).

53、 Among them, the sliding worktable can move horizontally in two directions through straight bearing combination in the course of application. Besides, it can also rotate in certain angle by this structure. The lifting fixture is the main device to finish the action of lifting and lowering. It is com

54、posed of ballscrew, one layer lift chain wheel combination, two layers lift chain wheel combination, motor reducer, gear driving and each extension sleeve. The motor adopts the imported DC motor and reducer of one machine. Parts, such as the ballscrew and nut are imported from Germany. They are reli

55、able in performance and stable in driving. AGV舉升裝置可由手動操縱上升下降，操作人員可以通過操作配套在舉升裝置兩側(cè)的手控操作盒或腳踏開關(guān)實現(xiàn)舉升裝置的上升或下降。待AGV進入裝配路段并跟蹤上車身后，操作者松開滑動平臺鎖定裝置，利用舉升手控盒手動操縱舉升裝置升降。裝配結(jié)束后，按動裝配結(jié)束按鈕舉升裝置自動復位至初始位置后人工鎖定滑動平臺。每個舉升裝置安裝有編碼器，可時時反饋提升的位置，舉升的高度也可通過軟件設(shè)定，設(shè)定需要舉升的高度及極限高度。在發(fā)動機合裝托盤上安裝托盤位置傳感器，用于監(jiān)測發(fā)動機合裝托盤在下降過程中是否與升降臺分離，確保操作安全。AGV lifting equipment can be operated manually to ascend and descend. Operator can run it through manual operation box or footswitch at the two sides of the lifting equipment. After AGV enters into assembly path