Zalpha User Manual Release 1.1.0 DF Automation and Robotics (M) Sdn. Bhd.
CONTENTS: 1 2 3 Preface 1.1 Introduction . . . . . . . . . . . . . . . . . 1.2 Manual Instructions . . . . . . . . . . . . . 1.3 Warning Symbols and Notes in This Manual 1.4 Definition . . . . . . . . . . . . . . . . . . . 1.5 More Information . . . . . . . . . . . . . . Safety 2.1 Introduction . . . . . . . . 2.2 Validity and Responsibility . 2.3 Intended Use . . . . . . . . 2.4 Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Technical Specifications 7.1 Dimension of Zalpha . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Dimension of Zalpha with Extension Module . . . . . . . . . . . . . . . . . . 7.3 Dimension of Charging Station . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 Charging Station Mounting Drilling Dimension . . . . . . . . . . . . . . . . . 7.5 Payload Handling Module Mounting Holes for Zalpha . . . . . . . . . . . . . 7.
Zalpha User Manual, Release 1.1.0 Copyright Notice: The information contained herein is the property of DF Automation & Robotics (M) Sdn. Bhd., and shall not be reproduced in whole or in part without prior written approval of DF Automation & Robotics (M) Sdn. Bhd. The information herein is subject to change without notice and should not be construed as a commitment by DF Automation & Robotics (M) Sdn. Bhd. The documentation is periodically reviewed and revised. DF Automation & Robotics (M) Sdn. Bhd.
CHAPTER ONE PREFACE 1.1 Introduction Congratulations on the purchase of your Zalpha AGV by DF Automation & Robotics (M) Sdn. Bhd. Fig. 1.1: Zalpha_AGV. The DF Zalpha AGV (Automated Guided Vehicle) is a mobile robot that can be used to transport many different types of material including pallets, rolls, racks, carts, trolleys and containers. DF Zalpha AGV is configurable to use different navigation methods - magnetic track guided, colour track guided or even trackless laser guided.
Zalpha User Manual, Release 1.1.0 1.2 Manual Instructions The manual contains instructions for installing and using the Zalpha AGV. It consists of Zalpha AGV specification. This manual is intended for the integrator who is expected to have a basic level of mechanical and electrical knowledge. It is also helpful, though not necessary, to be familiar with elementary concepts of programing. No special knowledge about AGV in general or DF Automation & Robotics is required. 1.
Zalpha User Manual, Release 1.1.0 AVG AGV is the abbreviation of Automated Guided Vehicle or Automatic Guided Vehicle, which refer to a mobile robot that follows markers or wires in the floor, or uses vision, magnets, or lasers for Version 2.0 10 Zalpha navigation. They are most often used in industrial applications to move materials around a manufacturing facility or warehouse. Payload Handling Module It refers to anything that attached to the robot to handle your material.
CHAPTER TWO SAFETY 2.1 Introduction This chapter contains important safety information, which must be read and understood by the integrator of AGV. It is essential that all instructions and guidance provided in other chapters and parts of this manual are observed and followed. 2.2 Validity and Responsibility The information does not cover how to design, install and operate a complete AGV application, nor does it cover all peripheral equipment that can influence the safety of the complete system.
Zalpha User Manual, Release 1.1.0 2.3 Intended Use AGVs are industrial robot which intended for transporting materials such as pallets, rolls, racks, carts, trolleys and containers in a workspace. Industries currently utilizing AGVs including (but are not limited to): Manufacturing, Pharmaceutical, Chemical, Automotive, Warehousing, Food & Beverage and Hospital. Any use of application deviating from the intended use is deemed to be impermissible misuse.
CHAPTER THREE ZALPHA AGV 3.1 Introduction This chapter briefly describes the basics of the mechanical implemented on Zalpha. The panel info, safety features, recommended magnetic track setup, charging station, optionals and peripherals. 3.
Zalpha User Manual, Release 1.1.0 With purchase of Zalpha Extension Module, the module will be assembled to Zalpha, unless otherwise stated. • Hooking Module With purchase of Zalpha Hooking Module, the module will be assembled to Zalpha, unless otherwise stated. Note Hooking Module will be bundled together with Extension Module. • Towing Module With purchase of Zalpha Towing Module, the module will be assembled to Zalpha, unless otherwise stated.
Zalpha User Manual, Release 1.1.0 3.3 Modules of Zalpha Fig. 3.1: Basic Module Of Zalpha. Fig. 3.2: Zalpha With Extension Module 3.4 Panel of Zalpha Panel consists of Reset Key, Emergency Stop, Low Battery Indicator, ON/OFF Button, LCD Touchscreen, Start Button, Brake Release Button, Stop Button and Antenna. The function of each component is as below: 3.3.
Zalpha User Manual, Release 1.1.0 Fig. 3.3: Panel Zalpha • Emergency Stop: Emergency Stop button let user to trigger an immediate stop on the AGV Movement. Button is needed to be manually released before resuming AGV Operation. • Low Battery Indicator: Low Battery Indicator will light up when the battery level is lower than 20%. Operations are not recommended if the Low Battery Indicator lit up. • ON/OFF Button: To power on Zalpha AGV, press and hold the ON/OFF Button for 1s.
Zalpha User Manual, Release 1.1.0 Start Button served as an alternative for the “OK” option in Wait Acknowledge and “Yes” option in Confirm Action’s popup. • Brake Release Button: To release the braking mechanism of the AGV to manually move AGV with external force. For detailed brake release operation please see Brake Release. • Stop Button: Stop Button served as an alternative for the “No” option in Confirm Action’s popup. • Antenna: Zalpha AGV’s WiFi transmitter and receiver.
Zalpha User Manual, Release 1.1.0 Fig. 3.4: Zalpha Charging Contact The Charging Contact of Zalpha is located at the side of the AGV. The Charging Contact is configurable to either left or right side of the AGV. Changing side for the Charging Contact will involve some rewiring work. Please contact authorised personnel to perform the changes. Fig. 3.5 shows the Charging Station of Zalpha. The Charging Station consists of two guide wheels at the side, and a spring loaded Charging Contact at the middle.
Zalpha User Manual, Release 1.1.0 Fig. 3.5: Charging Station Of Zalpha Fig. 3.6: Power Inlet and Manual Charging Port Fig. 3.7: Power Cord of Charging Station 3.5.
Zalpha User Manual, Release 1.1.0 Fig. 3.8: Manual Charging Cable Fig. 3.9: Zalpha is docked to the Charging Station. 3.6 Getting Started Step 1 After unpacking Zalpha, check for any damage on the AGV. If damage on the AGV is found, please contact the authorised personnel immediately. The examples of damage are cracked LCD Touchscreen, dented AGV body, broken bumper cushion etc. If everything is fine, press the ON/OFF button on the Panel for 2s to power on the AGV.
Zalpha User Manual, Release 1.1.0 Step 2 Setting up the Automatic Charging Station. You can skip this step if you are using the manual charging port to charge Zalpha. After the location of the Automatic Charging Station is confirmed, drill the floor according to the recommended specification and insert wall plug into the hole. Mount the Charging Station and secure the nuts. For the drilling template of the Charging Station, please refer to Appendix.
Zalpha User Manual, Release 1.1.0 3.7.1 Front and Rear Laser Obstacle Sensor Fig. 3.11: Front Laser Scanning Obstacle Sensor Zalpha front laser scanning Obstacle Sensor is located underneath the Panel Module as shown in Fig. 3.11. While Zalpha AGV is moving, the laser scanning Obstacle Sensor will scan and locate obstacle in front of Zalpha.
Zalpha User Manual, Release 1.1.0 Fig. 3.13: Front Movement Laser Scanning Profile • Laser scanning profile for Reverse Movement: Fig. 3.14: Reverse Movement Laser Scanning Profile Note Rear Obstacle Sensor is not included in standard package of Zalpha AGV. It is available as an optional purchase. • Laser scanning profile for Rotate Left Movement: Fig. 3.15: Rotate Left Movement Laser Scanning Profile 3.7.
Zalpha User Manual, Release 1.1.0 Note Rear Obstacle Sensor is not included in standard package of Zalpha AGV. It is available as an optional purchase. • Laser scanning profile for Rotate Right Movement: Fig. 3.16: Rotate Right Movement Laser Scanning Profile Note Rear Obstacle Sensor is not included in standard package of Zalpha AGV. It is available as an optional purchase. 3.7.3 Laser Scanning Obstacle Sensor Limitation Fig. 3.
Zalpha User Manual, Release 1.1.0 using the laser scanning Obstacle Sensor. To counter this limitation, Zalpha AGV is equipped with another important safety component Bumper . For more information about Bumper , see Front and Rear Bumper. 3.7.4 Front and Rear Bumper Fig. 3.18: Front and Rear Bumper When the Bumper of Zalpha contacted with obstacle, Zalpha will stop its movement and the braking mechanism will be engaged immediately.
Zalpha User Manual, Release 1.1.0 3.7.5 Emergency Stop Button Fig. 3.19: Emergency Stop Button Emergency Stop button is a manual control device. It is a method of initiating the emergency stop function for Zalpha movement. Upon the activation of this button, the movement of Zalpha will stop immediately. User confirmation are required to resume the operation after the Emergency Stop button is released.
Zalpha User Manual, Release 1.1.0 3.7.7 Brake Fig. 3.20: Brake Release Button The brake of Zalpha will always be engaged even after power off. Brake Release button is a function to allow user to push/move Zalpha freely. In order to release the brake, it require user to press and hold on the button.
Zalpha User Manual, Release 1.1.0 Fig. 3.21: Steps To Select Manual Line Follow App 3. In Manual Line Follow app window, toggle the Free Motor option. Push the Brake Release button to push Zalpha AGV freely Fig. 3.22: Free Motor Option In Manual Line Follow App 3.7.
Zalpha User Manual, Release 1.1.0 3.7.8 Safety Measure of Manual Charging Fig. 3.23: Manual Charging Port Charger Connected Safety Trigger is a safety feature that prevent Zalpha AGV from moving if the Manual Charging Port is connected with Charger. On the event that Zalpha AGV is being instructed to operate and the Manual Charging Port is connected, a Safety Trigger will be activated and a Safety Triggered message will be shown on the LCD Touchscreen.
Zalpha User Manual, Release 1.1.0 Fig. 3.24: Obstacle Blocked Safety Triggered Message ii. Clear any obstacle that blocked the movement of the AGV (see Laser Scanning Area) iii. A Resuming a message as shown in Fig. 3.25 will be shown on the LCD Touchscreen. Fig. 3.25: Resuming Message 4. AGV will automatically resume its operation after 2 seconds Front and Rear Bumper Safety Trigger i.
Zalpha User Manual, Release 1.1.0 Fig. 3.26: Bumper Blocked Safety Triggerd Message ii. Clear the obstacle at the Bumper sensor. A Safety Resume message as in Fig. 3.27 will be shown Fig. 3.27: Safety Resume Message iii. Press the Resume button on display panel or Start Button to resume the operation iv. A Resuming a message as shown below will be shown on the LCD Touchscreen 3.7.
Zalpha User Manual, Release 1.1.0 Fig. 3.28: Resuming Message v. AGV will automatically resume its operation after 2 seconds Emergency Stop Safety Trigger i. Upon manual activation of the Emergency Stop button , Zalpha AGV will stop its current operation immediately and a Safety Trigger message with Emergency button pressed will be shown on the LCD Touchscreen . See Fig. 3.29. Fig. 3.29: Emergency Button Pressed Safety Triggered Message. ii.
Zalpha User Manual, Release 1.1.0 Fig. 3.30: Safety Resume Message iv. Press the Resume button on the LCD Touchscreen or Start Button to resume the operation. v. A Resuming a message as shown below will be shown on the LCD Touchscreen Fig. 3.31: Resuming Message vi. AGV will automatically resume its operation after 2 seconds Manual Charging Safety Trigger i.
Zalpha User Manual, Release 1.1.0 Fig. 3.32: Charger Connected Safety Triggeres Message ii. Remove the manual charging cable that is connected to the Manual Charging Port iii. After disconnecting the manual charging cable, a Safety Resume message as below will be shown Fig. 3.33: Safety Resume Message iv. Press the resume button on the display panel or Start Button to resume the operation. v. A Resuming a message as shown below will be shown on the LCD Touchscreen 3.7.
Zalpha User Manual, Release 1.1.0 Fig. 3.34: Resuming Message 6. AGV will automatically resume its operation after 2 seconds 3.8 Track The basic navigation method of Zalpha is by tracing the magnetic field of the Track that lie on the floor. The Track of Zalpha is constructed using 50mm width magnetic adhesive tape. The magnetic field of the Track is in north pole face up order. The thickness of the magnetic tape is 2mm. Fig. 3.35: Magnetic Tape With Adhesive 3.8.1 Specification of the Track • Junction 3.8.
Zalpha User Manual, Release 1.1.0 Junction is defined as the whisker in between a straight path. Junction is functioned as a checkpoint for the actions of Zalpha. Zalpha locate itself by counting the amount of junctions it passed through along the Track. A junction can serve as a checkpoint for travel speed adjustment, changing navigation profile, stop station etc. Fig. 3.36: Junction Fig. 3.37 shows the recommended dimension of the Junction. Fig. 3.
Zalpha User Manual, Release 1.1.0 Fig. 3.38: Intersection Of Track Fig. 3.39 shows the recommended dimension of Intersection. Fig. 3.39: Dimension Of Intersection • Comparison between Junction and Intersection 3.8.
Zalpha User Manual, Release 1.1.0 Fig. 3.40: Comparison Between Junction And Intersection • Minimum Turning Radius Fig. 3.41: Minimum Curning Radius Of Track 3.9 Charging Station Each Zalpha AGV will have its dedicated charging station. In the ConfigPanel, the Station where the Charging Station is placed normally will be configured as the Home Station. Defining the Charging Station as the Home Station is to restrict all rotating actions of Zalpha at the Charging Station.
Zalpha User Manual, Release 1.1.0 Note Charger of Zalpha must be mounted on the same side of the Charging Contact of the AGV. 3.9.1 Charging Station Setup of Zalpha Fig. 3.42: Illustration Of Charging Station Setup Of Zalpha 3.9.
Zalpha User Manual, Release 1.1.0 3.9.2 Charging Station Setup of Zalpha with Extension Module Fig. 3.43: Illustration Of Charging Station Setup Of Zalpha With Extension Module 3.9.3 Charging Station Mounting Fig. 3.44: Charging Station Mounting Drilling Dimension 3.9.
Zalpha User Manual, Release 1.1.0 After drilling the holes, install the M6 wall plug to each of the hole. Fig. 3.45: M6 Wall Plug 3.10 ExpansionIO Zalpha comes with expansion IO port for the expansion of feature on Zalpha (payload handle). Main feature under Expansion IO port. Fig. 3.46: Expansion IO Recommended replacement connector type for these ports. By default, all the required connector will be provided on the Zalpha. • Input port and Output Port Connector: – Model: Phoenix Contact BCP-350-8 GN.
Zalpha User Manual, Release 1.1.0 – Model: Phoenix Contact BCP-508F-8 GN – Pitch: 5mm – Number of Contact: 8 3.10.1 24V Output 24V output for additional actuator on Zalpha. This 24V output is protected by 10A Power Fuse and this supply will be cut off during any safety trigger on Zalpha (Bumper, Emergency Button, Obstacle sensor or External Safety In). 10A protection fuse are accessible from the panel and the recommended replacement part are 0312010.MXP from Littelfuse. Fig. 3.
Zalpha User Manual, Release 1.1.0 3.10.2 Safety Input and Output Port Fig. 3.48: Expansion IO Safety Input And Output Port Safety Input port are additional safety input for the safety system of Zalpha. These +S IN and -S IN pin are NPN input type where they should shorted for normal condition and opened for safety trigger condition. They can be connected directly to additional Emergency Button.
Zalpha User Manual, Release 1.1.0 Input Port: • Input type: NPN Input (Sinking) • Short Input pin to GND to activate the input • Open Input pin to deactivate the input • Example1: Input pin can be activated using a push button or limit switch connected to the GND. Fig. 3.50: Input Port Example 1 • Example2: Input pin can be activated using a sinking NPN transistor controlled by microcontroller. Fig. 3.51: Input Port Example 2 • Example3: Input pin can be activated by a relay controlled by PLC. 3.10.
Zalpha User Manual, Release 1.1.0 Fig. 3.52: Input Port Example 3 3.10.4 Output Port Fig. 3.53: Expansion IO Output Port Output Port: • Output Type: NPN Output (Sinking), Maximum current 250mA protected by PTC • 24V Output: Protected by internal fuse (1.5A) • Example1: Output pin can be use to control small load like 24V LED. 3.10.
Zalpha User Manual, Release 1.1.0 Fig. 3.54: Output Port Example 1 • Example2: Output pin can be use to activate relay for higher current application like Motor activation Fig. 3.55: Output Port Example 2 3.10.
CHAPTER FOUR WARRANTIES AND DISCLAIMER 4.1 Warranties Zalpha AGV come with warranty as below; • Standard 1 Year Warranty except wear and tear parts • 3 months limited warranty for parts as below; – Navigation Caster and Wheel – Buttons – Limit Switches – Battery – Charger – External Connectors – Interactive Display Panel – Bumper cushion – Laser sensor – Wireless Antenna – Mechanical Structure Warranty applicable for manufacturing defect only 4.2 Disclaimer DF Automation and Robotics Sdn. Bhd.
Zalpha User Manual, Release 1.1.0 CAUTION: Changes or Modifications not expressly approved by the party responsible could void the user’s authority to operate this device. NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation.
CHAPTER FIVE TROUBLESHOOTING & FAQ Please visit (http://www.dfautomation.
CHAPTER SIX SERVICES AND MAINTENANCES Please refer to DF Zalpha Service Manual for more information about services and maintenances.
CHAPTER SEVEN TECHNICAL SPECIFICATIONS 7.1 Dimension of Zalpha Fig. 7.
Zalpha User Manual, Release 1.1.0 7.2 Dimension of Zalpha with Extension Module Fig. 7.2: Dimension Of Zalpha With Extension Module 7.3 Dimension of Charging Station Fig. 7.3: Dimension Of Charging Station 7.2.
Zalpha User Manual, Release 1.1.0 7.4 Charging Station Mounting Drilling Dimension Fig. 7.4: Charging Station Mounting Drilling Dimension 7.4.
Zalpha User Manual, Release 1.1.0 7.5 Payload Handling Module Mounting Holes for Zalpha Fig. 7.5: Payload Handling Module Mounting Holes for Zalpha 7.6 Payload Handling Module Mounting Holes for Zalpha with Extension Module Fig. 7.6: Payload Handling Module Mounting Holes for Zalpha With Extension Module 7.5.
Zalpha User Manual, Release 1.1.0 7.7 Charger and Battery Specification Charger: Power Rating: 220~240V AC Charging Voltage: 28.8V DC Charging Ampere: 12.5A AGV Battery: Type: LiFePO4 Battery Battery Voltage: 24V Battery Capacity: 65Ah 7.7.
