AGV装配线技术方案
长安福特汽车有限公司南京公司
Changan Ford Automobile Co., Ltd. Nanjing Company
发动机、前后桥AGV系统
Engine & Axel AGV System
技术方案
Technical Plan
沈阳新松机器人自动化股份有限公司
Shenyang SIASUN Robot & Automation Co., Ltd.
目录Contents
1. 概述Summary (5)
2. 设计依据Design Gist (5)
2.1 生产工艺基本要求Basic Requirement of Production Process (5)
2.2 现场基本技术条件Basic Field Technical Condition (6)
2.3 责任范围Responsibility Scope： (6)
3. AGV装配输送系统概述AGV Assembly & Transportation System
Summary (7)
4. 自动导引车AGV系统技术指标Automated Guided Vehicle AGV System
Technical Specification (9)
5. AGV工作过程描述AGV Working Process Description (11)
6. 发动机装配升降工作台Engine Assembly Lifter Worktable (14)
6.1 伸缩套筒式升降工作台Extension Sleeve Lifter Worktable (14)
6.2 剪式液压机构升降工作台Scissor Hydraulic Lifter Worktable (16)
6.3 托盘底面距发动机最高点距离与升降平台高度关系计算Calculation on
the Relation Between Distance from Pallet Bottom to Engine Zenith and Height of Lifter Table (19)
7. 后悬装配举升装置Rear Suspension Assembly Lifting Equipment (22)
7.1 伸缩套筒式升降工作台 (22)
7.2 剪式液压机构升降工作台Scissor Hydraulic Lifter Worktable (24)
7.3 升降平台上平面到地面的高度计算Calculation on the Height from the
Plane of the Lifter Table to the Ground (26)
8. 不同轴距车体装配实现Body of Different Wheelbases Assembly
Realization (28)
9. AGV 动态装配解决方案AGV Dynamic Assembly Solution.. 29
10. AGV 主要设备AGV Main Equipment (29)
10.1 AGV（LGV）车载控制器 AGV（LGV）Vehicle Controller (29)
10.2 AGV（LGV）驱动系统AGV（LGV）Drive System (30)
10.3 导航系统Navigation System (30)
10.4在线自动充电系统Online Automatic Charge System (32)
10.5无线局域网通讯系统 Wireless LAN Communication System (33)
10.6驱动控制系统Drive Control System (34)
10.7非接触防碰装置Non-contact Bumper Device (35)
11. AGV安全系统AGV Safety System (35)
11.1非接触防碰装置Non-contact Bumper Device (35)
11.2接触式防碰装置 Contact Bumper Device (36)
11.3离线保护系统 Offline Guarding System (36)
11.4信息交互系统 Information Exchange System (36)
11.5紧急停车系统Emergency Stop System (37)
11.6多AGV避碰 Multi-AGV Collision Prevention (37)
12. AGV控制台和调度管理系统AGV Console & Dispatching Management System (37)
12.1 AGV控制台AGV Console (37)
12.2调度管理系统Dispatching Management System (38)
13. AGV车载控制系统和数据采集AGV Vehicle Control System & Data Collection (40)
14. 导航线的铺设Navigation Line Paving (41)
15. AGV系统特点AGV System Characteristics (42)
15.1 高速无线局域网的建立和应用 Setup and Application of High-speed Wireless LAN (42)
15.2 AGV运行的灵活性Flexibility of AGV Running (43)
15.3 高精度导航系统High Accuracy Navigation System (43)
15.4 友好的人机界面User Friendly Human Machine Interface (44)
15.5 完善的自诊断系统Perfect Self-diagnosis System (44)
15.6 AGV可靠性措施Measures on AGV Reliability (44)
15.7 在线快速自动充电方法和快速充电电池的应用Online Automatic Instant Charge Method and Application of Instant Rechargeable Battery
(46)
15.8 故障修复时间（MTR）Mean Time of Repair（MTR） (47)
AGV系统的故障修复时间有两类：There’re two kinds of MTR for AGV system: (47)
15.9 平均无故障时间（MTBF）Mean Time To Failures（MTTF） (48)
16. AGV运行路线图AGV Running Route Graph (48)
16.1 装配线AGV运行布局图 Assembly AGV Running Layout (48)
16.2 样机车间AGV运行布局图 Sample Workshop AGV Running Layout . 48 18. 环行装配线AGV系统设备清单Circular Assembly AGV System Equipment List (51)
19. 项目进度Project Schedule (53)
20. 培训Training (53)
20.1 培训人员的范围、数量及时间Scope, amount and time for training people (54)
20.2 培训的内容Training content (54)
21. 售后服务After-sale service (55)
1. 概述Summary
根据长安福特汽车有限公司南京公司发动机、前后桥AGV系统的设计要求，新松公司采用的装配型AGV系统进行发动机、前后桥与车身合装，具有同步动态跟踪功能的AGV可实现发动机、前后桥在装配段任何工位同时装配。导航方式采用磁导航，地面施工量小，只要根据工艺要求变更磁条的粘贴路径，在对控制程序稍加改动，就可以改变装配路线的长短，适应不同的装配工艺要求。AGV系统由一条近似梯形的环线组成，在装配段进行前悬挂/发动机、后桥与车身合装，在非装配段进行发动机、前后桥由分装线往AGV装配托盘上吊装，并可在非装配段进行部分零部件的组装。根据产量及装配时间确定环线上AGV数量。
According to design requirement of Changan Ford Automobile Co., Ltd. on engine and axle AGV system, SIASUN uses assembly AGV system for engine, axle and body decking, and AGV with the function of synchronization dynamic tracking can realize simultaneous assembly of engine and axle at any assembly zone or stations. By using magnetic navigation, ground construction is small and by changing the path of magnetic strip upon technical requirements and modifying slightly control program, the length of assembly path can be altered to meet different assembly process requirements. AGV system is formed by a loop line, which is close to a trapezium. The assembly zone is used for front suspension/engine, rear axle and body decking and the non-assembly zone is used for engine and axle suspending on AGV assembly pallet through subassembly line and also for assembly of part of components. The number of AGV on the loop line is set according to output and assembly time.
整个系统包括AGV、AGV控制台、充电系统、导航系统、通讯系统、数据采集系统和装配夹具等几部分组成。
The whole system includes AGV, AGV console, charge system, navigation system, communication system, data collection system and assembly jig, etc.
2. 设计依据Design Gist
2.1 生产工艺基本要求Basic Requirement of Production Process
工位间距Distance between stations：5，800mm
生产节拍Production rate：最大：1分钟/辆
Max.: 1minute/vehicle
最小：5分钟/辆
Min.: 5minutes/vehicle
2.2 现场基本技术条件Basic Field Technical Condition
动力电源：交流380±10% 50HZ±2% 3相5线
Power supply: AC 380±10% 50HZ±2% 3 phases 5 lines
温度：-5℃～45℃
Temperature: -5℃～45℃
湿度：60—95%
Humidity: 60—95%
防护等级：IP54
Protection grade: IP54
绝缘等级：B级
Insulation level: Level B
2.3 责任范围Responsibility Scope：
1）AGV装配系统总体设计、制造。
AGV assembly system design and manufacturing.
2）AGV车体设计、制造。
AGV vehicle design and manufacturing.
3）AGV装配系统发运前调试、考机实验。
AGV assembly system debugging and trial running before delivery.
4）AGV装配系统运输、接收、搬运。
AGV assembly system transport, reception, carriage.
5）AGV控制系统设计、制造，车载控制软件、调度软件设计。
AGV control system design and manufacturing, vehicle control software, scheduler software design.
6）AGV工作环线设计、制造，地面导航线布局设计、敷设。
AGV working loop line design and manufacturing, ground navigation line
layout design and laying.
7）现场安装、单机调试、全线联动调试。
Field installation, unit machine debugging and complete line linkage
debugging.
8）技术培训和售后服务。
Technical training and after-sales service.
3. AGV 装配输送系统概述AGV Assembly & Transportation System Summary
发动机/
后桥AGV 装配输送系统由AGV 、AGV 地面导引系统、在线自动充电系统、AGV 控制台、数据采集系统、AGV 调度管理系统和通讯系统等构成。
Engine/rear axle AGV assembly & transportation system includes AGV, AGV ground guided system, online automatic charge system, AGV console, data collection system, AGV dispatching management system and communication system, etc.
● AGV ：
AGV 完成发动机或后悬挂系的输送和辅助装配工作。装配人员可以站在AGV
车的脚踏板上进行装配作业，脚踏板采用花纹铝板制造，操作安全。
AGV conducts transportation of engine or rear suspension and assistant assembly jobs. Assembly operator can stand and work on AGV pedal, which is made of aluminum board with decorative figures and safe to operate.
● AGV 地面导引系统AGV Ground Guided System ：
地面导引系统是AGV 运行的路线和轨迹，AGV 的导引系统采用基于地图的