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Summary of Contents for F3-Design NIPPER
- Page 1 INSTALLATION INSTRUCTIONS...
- Page 2 Publisher: F3-Design B.V. Meerheide 282 NL-5521 DW Eersel Holland www.f3design.nl info@f3design.nl INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
- Page 3 All rights reserved. No part of this documentation may be duplicated in any form without authorisation, or processed or recorded using electronic systems. Subject to changes without notice. F3-Design BV is NOT liable for technical or printing errors in this manual and assumes no liability for any damage caused by the use of the manual.
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Page 4: Table Of Contents
Content Basic safety advice ......................7 Definitions .......................... 8 Dimensions Technical DatA ........................ 10 Performance ...................... 10 Environments ..................... 10 INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... - Page 5 Reversing movement or forward movement with Muting (protective field evaluation deactivated) ......................34 Standard turning (VLeft = – VRight ) ..............34 Limitation:......................34 Acceleration values: ................... 34 10 Functions ......................... 35 Pallet recording ....................35 Charging station ..................... 35 INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
- Page 6 Checking the safety switchgear ..........47 At intervals of three (3) months ..............47 Battery removal ....................47 15 Delivery ........................... 48 16 Storage ..........................48 17 Figures ..........................48 18 Table ..........................50 INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
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Page 7: Basic Safety Advice
Indicates a possible medium-risk hazard that will result in death or (severe) bodily harm if not avoided. Indicates an immediate high-risk hazard that will result in immediate death or severe injury if not avoided. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 8: Definitions
DEFINITIONS Driverless transport system (AGV) Security device (laser scanner) Bumper Safety button Time to obsolescence The authority Instructed by the manufacturer or representative Safely limited speed Safe torque off INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 9: Dimensions
DIMENSIONS Figure 1: Dimensions INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 10: Technical Data
(Other pallets after approval by the manufacturer) Max. payload 1000 kg Max. load balancing front/rear 60/40% Max. load distribution left/right 55/45% Max. load height 1.6m Tipping safety of the load at maximum deceleration must be given by the customer. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 11: Accessories
As this is a special pallet, the vehicle must be transported with a suitable means of transport. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 12: Tank Venting
Tank venting The unit has two tank openings (Figure 3: Tank ventilation). The device must not be turned over. Figure 3: Tank ventilation Note: Upon delivery, the air ventilation screws are open. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 13: Initial Commissioning
Figure 4: Main switch Note: By pressing the switch briefly, the device switches on automatically (<1 second), by pressing it for longer, it switches off (>3 seconds). INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 14: Movements
For this reason, the speed is limited to a maximum of 300 mm/s (here the speed is limited to a maximum of 300 mm/s (The outer edge v = <300 mm/s). Note: Secondary directions may only be used if there is no other possibility to arrive at the desired position. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 15: Device Description
DEVICE DESCRIPTION General description Mechanical equipment Figure 6: Explosion drawing INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... - Page 16 [1] Lower chassis The sub-chassis contains the lifting mechanism and two (2) turntables and the evaluation sensors with the safety edges. This represents a chassis unit and ensures an optimum balance of uneven floors. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
- Page 17 Wi-Fi communication, charging contacts attached at the bottom and at the front, safety button so the device can be shut down immediately from any location. Figure 7: Front module with safety button INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
- Page 18 This is the safety control for evaluation of the safety laser scanner. [8] Safety laser scanner Figure 8: Safety laser For mixed operations, a safety laser scanner with eight (8) field sets has been installed, which guarantees the highest possible level of safety. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
- Page 19 Two (2) battery packs for the supply of the independent chassis units are attached to the device. [12] Front control Responsible for the control and evaluation of the laser scanner. [13] Light pole To improve the visibility of vehicles in mixed operation with people or forklift traffic. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
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Page 20: Rotating Circle
Rotating circle The rotating circle is 1700 mm excl. the safety field. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 21: Electrical Equipment
Electrical equipment The Nipper V2 is powered by two (2) independent LiFePO4-Batteries with 420 W/h and a nominal voltage of 24 V, for service life reasons the batteries are never discharged in normal operation below 20% of their nominal capacity. The charging process takes place with the charging contacts attached to the bottom (fork side), which are disconnected by an electronic circuit. - Page 22 LiFePO4 battery pack The Nipper V2 is attached with two (2) separate -LiFePO4- battery packs with a nominal power of 420 W/h. Figure 9: W420AH battery pack Note: The battery must be stored with 30% charge. If the battery has been stored for more than six months, it must be fully discharged and then recharged to 30%.
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Page 23: Control Of The Vehicle
Forks (2) Red / yellow at the same time 9. Protective field active a. Forks (2) Alarm flashing red quickly b. Beacon (13) Alarm flashing red quickly 10. Display vehicle has stopped - has order, but is waiting INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... - Page 24 Forks (2) Front red steady b. Forks (2) Rear green steady c. Beacon (13) Orange also steady 11. Safety light Only when driven by the safety light in the direction of travel INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
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Page 25: Safety Features
SAFETY FEATURES Construction of protective devices Figure 10: Construction of protective devices INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... - Page 26 The Nipper has seven (7) independent protective devices. This guarantees maximum safety in every situation and in every work situation. The safety laser scanner makes it possible to detect people and obstacles in the main driving direction and to stop the vehicle, if necessary.
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Page 27: Safety Button
The safety button immediately switches the vehicle to a "safe" state after operation. The switching devices must be checked at least once a month. The power of the activity must not exceed 100 N (typically 10 N). Figure 12: Safety button INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 28: Safety Laser Scanner
For example, in the case of battery failure on one side of the vehicle: the safety controller intervenes, the vehicle brakes immediately, the load is lowered and the engines are switched of. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... - Page 29 (68 mm), the specified values are setting values! All data must be checked for commissioning, each system must comply with the safety regulations! There are two different situations: 1. Straight ahead with curves. 2. Rotate / reverse. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
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Page 30: Straight Ahead With Curves
These protective fields are only used in active route guidance and may only be used in blockage magazines. Compliance with legal safety regulations must be ensured. Rotate/reverse: Protective field number V [mm/s] Width [mm] Length [mm] < = 300 (outside edge) Table 3: Protective fields turning and reversing INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 31: Protective Field Selection By The Safe Cpu
_ max = 1000 [mm/s^2] t _ max = 30 [Ms] Duration: The response time must be considered in the calculation of the protective fields, which is calculated as follows: s = Vmax* 200ms INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... - Page 32 Protective field switching Figure 15 illustrates the protective field switching. Protective field switching 1200 1000 1000 1500 2000 2500 s [mm] v Kufe Figure 14: Protective field switching INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
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Page 33: Handling
To (*): With a radius smaller than 2060 mm, monitoring of the protective field cannot be guaranteed. It is driven at a lower speed. Each point on the vehicle must move at a speed of less than 300 mm/s. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 34: Reversing Movement Or Forward Movement With Muting (Protective Field Evaluation Deactivated)
Acceleration values: Delay <> 0 300[mm/s²] Jerk 2000[mm/s³] Delay 0 (VL+VR=0) 800[mm/s²] Jerk 4000[mm/s³] Acceleration 300[mm/s²] Jerk 2000[mm/s³] Emergency stop 1000[mm/s²] Jerk 10000[mm/s³] Table 5: Acceleration value INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 35: Functions
Attention: In the area of the charging station, the vehicle must be in a lowered state. Attention: When driving out, the vehicle must extend at least 30 cm straight out of the charging station. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 36: Environmental Requirements
Required floor Properties The Nipper V2 can bridge inequalities up to 5 mm and a maximum gradient of 3%. It is important to reduce the expansion rate of the connections accordingly, depending on their condition. Brake test: The maximum load of the vehicle is determined for this purpose. The vehicle must be accelerated at full speed and then activate the rear bumper, while the vehicle must not lose grip. -
Page 37: Safety
In places where it is absolutely necessary to raise it above 30 mm, an acoustic signal must be given in advance. These places must be unmistakably marked on the ground. Additional precautions, such as protective grids must be taken. There must be no persons present in this area. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... - Page 38 Every load carrier that has to be transported has to be tested in advance. The parts on it must be secured in such a way that they never come loose or fall off. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
- Page 39 When the device is operated, a safety distance of at least 2 m must be maintained. The operator must have visual contact with the vehicle. The system may only be operated by authorised staff. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
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Page 40: Safety Tests Before Commissioning
Load tests can cause the pallet or parts of the load to lose their grip. These tests may only be carried out in rooms with sufficient space and in places where there are no persons under any circumstances. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 41: Operator Staff
The distributor must ensure that facilities that prevent unauthorised use are available for maintenance and manual operation. Mixed operation with people People who are in the vicinity of the system or who can enter the system must be informed about this and the safety guidelines. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 42: Alarm Codes
- Battery hardware defect - Contact the manufacturer batt. BMS charging mode - Battery hardware defect - Contact the manufacturer error - Vehicle lost the pallet while pallet lost - Check the pallet driving INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... - Page 43 - Clean the laser scanner timeout closing valve - Hydraulic valve not closed - Contact the manufacturer - Dirty - Clean device lift timeout - Oil level too low - Check oil level - Wrong oil INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
- Page 44 - Barcode distance outside the - Check layout specification Error transfer station - Transfer station failed - Check transfer station settings Too big load - Load bigger than 1000 kg - Check the weight of the load INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
- Page 45 - No protective field prot. field disabled - Contact the manufacturer specification available invalid prot. field number - Wrong field set - Contact the manufacturer comm. fault obstacle - Communication - Contact the manufacturer detection INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
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Page 46: Maintenance
If appliances are heavily contaminated, they should be cleaned with a damp cloth. Visual inspection for damage Monthly Checking the emergency stop elements On the front there are two (2) emergency stop elements, which must be checked on a monthly basis for correct operation. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 47: Checking The Safety Switchgear
To remove the battery, the front service cover must be opened. The battery can be removed evenly from the device after opening the three (3) fastening screws. Defective or damaged batteries must be replaced. For more information, please contact the manufacturer. INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... -
Page 48: Delivery
Maximum storage period 6 months Standing on the wheels Without surcharge Note: After storage, the vehicle must be checked for damage before startup. It must be charged continuously for at least 12 hours before startup. FIGURES INSTALLATION INSTRUCTIONS NIPPER - JULY 2020... - Page 49 Figure 10: Construction of protective devices ....................... 25 Figure 11: Emergency stop ........................... 26 Figure 12: Safety button ............................27 Figure 13: Chassis unit ............................28 Figure 14: Protective field switching ........................32 Figure 15: Pallet recording ............................ 35 INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...
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Page 50: Table
TABLE Table 1: System description ....................... 16 Table 2: Protective fields during cornering ..................30 Table 3: Speed ranges ........................33 Table 4: Speed ranges ........................34 Table 5: Acceleration value........................ 34 INSTALLATION INSTRUCTIONS NIPPER - JULY 2020...