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Alert Alphabot User Manual

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Alphabot
User Manual
1000004-MN-01 - Rev C
Manual Template PN: 1000020-FM-01 Rev A

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  • Page 1 Alphabot User Manual 1000004-MN-01 - Rev C Manual Template PN: 1000020-FM-01 Rev A...
  • Page 2 This manual must always be placed in an operator accessible location near the Alphabot® System. This manual is intended to provide generic information related to all models of Alphabot® System. Due to specific design changes, contents of this manual may not entirely apply to the purchased model of the system.

  • Page 3: Table Of Contents

    Hazard Description ..................... 16 2.1.2 Personal Protective Equipment (PPE) ................ 17 2.1.3 Environmental Safety ....................18 2.1.4 Inherent Safety Hazards of the Alphabot ..............19 2.1.5 Persons with Pacemakers ................... 22 2.1.6 Fire Safety ........................22 2.1.7 Seismic ........................22 2.1.8...
  • Page 4 2.2.4 Decommissioning of Equipment ................37 2.2.5 Radiation Exposure Statement .................. 37 2.2.6 Description of the Alphabot System E-Stop Circuitry ..........38 2.2.6.1 Bot: Emergency Stop and Safe Torque Off (STO) ................40 Hardware General Description ......................41 Alphabot Components ...................... 41 Bot LEDs ..........................
  • Page 5 Table of Contents Alphabot User Manual Scope of Troubleshooting ....................69 Regulatory Compliance Information Standards Compliance ....................... 70 FCC Compliance ......................... 72 ISED Regulatory Information ..................... 74 Revision History 1000004-MN-01 - Rev C Page 5 of 77...

  • Page 6: Introduction

    Note: The term Alphabot is interchangeable with "Bot". This manual uses both terms to refer to the Alphabot. 1000004-MN-01 - Rev C...

  • Page 7: Reference Documents

    Introduction Alphabot User Manual Reference Documents Document Part Number / Link Alert Academy https://academy.alertinnovation.com/ Alphabot System 1010755-01 Reference Guide Alphabot Pre and 1000067-SR-01 Post Procedures Alphabot APSD 1000035-SF-01 System LOTO Manual Acronyms and 1000030-OP-01 Alert-Specific Terms Alphabot system 1000016-MN-01 Master Control...

  • Page 8: Product Overview

    Alphabots have their own vertical-drive mechanism, which engages with vertical tracks in the Alphabot System structure to allow each bot to move from one elevation to another. A wheel retraction/extension mechanism enables the Alphabot to transition between vertical and horizontal modes at any point, and travel horizontally to any storage or workstation level.

  • Page 9: Supporting Products

    Alphabot User Manual Supporting Products The Alphabot is one part of the larger Alphabot System, working in concert with a number of other Alert products to fulfill customer orders. Individual Alphabots are inducted into the Alphabot System and commanded by the Master Control System to arrive at workstations upon command.

  • Page 10: Totes And Sub-Totes

    Introduction Alphabot User Manual Totes and Sub-Totes The Alphabot interacts with two kinds of totes, distinguished by their purpose: Product Totes and Order Totes. Product Totes are stored in racks within the Structure’s storage module aisles. These totes contain “eaches” (individual items) that are made available to Pickers as stock to fulfill orders for sale.

  • Page 11: Transit Planes

    Introduction Alphabot User Manual Transit Planes Transit planes are uniform platforms that allow the Alphabots to move two- dimensionally to access aisles and workstations. To reduce the amount of time a product remains out of its desired environmental zone, each Transit Plane can be vertically split into two zones: chilled and ambient.

  • Page 12: Static Workstation

    Static Workstation Static workstations are fixed workstations that provide an interface to introduce product totes or sub-totes into the storage module of the Alphabot system. These workstations are also meant for collecting the completed/dispensed orders and for exception handling, a.k.a. “Hospital” functionality.

  • Page 13: Dynamic Workstation / Picking Workstation

    The Alphabot enters the picking workstation from a lower transit plane, ascends into the transfer position in front of the picker, and then exits to an upper transit plane. To ensure product accuracy, the workstation controller uses an overhead projector to illuminate both the pick and put locations (pick-to-light and put-to-light).

  • Page 14: Master Control System (Mcs)

    1.10 Master Control System (MCS) MCS is an advanced software system responsible for processing all orders, scheduling all Alphabot tasks, managing all bot moves to optimize flow and throughput while preventing collisions between bots, and interfacing to the external systems. An MCS dashboard provides information regarding the general system health, current asset utilizations and system notifications.

  • Page 15: Safety

    Alphabots require manual startup and shutdown by trained and qualified operators. Never enter the Alphabot System if you have not been trained to do so. Only maintenance personnel trained to enter the Alphabot System may enter the locked entry gate.

  • Page 16: Personnel Safety

    Alphabot User Manual Personnel Safety 2.1.1 Hazard Description The Alphabot System shall be operated, maintained and serviced by trained personnel only. Safety pictograms and labels are located on the equipment and used within this manual to make the user aware of potential hazards and to indicate lockout/tagout (LOTO) locations.

  • Page 17: Personal Protective Equipment (Ppe)

    Some procedures in this manual require you to use personal protective equipment (PPE). The necessary PPE is detailed at the start of each procedure. However, you should always remain alert to the need to protect yourself while working in any capacity, on or near this equipment.

  • Page 18: Environmental Safety

    Alphabot User Manual 2.1.3 Environm ental Safety Alert Innovation, Inc. is committed to designing and manufacturing products in an environmentally responsible manner. Alert recognizes that eliminating certain hazardous substances from our products is beneficial to the environment and to AI customers.

  • Page 19: Inherent Safety Hazards Of The Alphabot

    Alphabot User Manual 2.1.4 Inherent Safety Hazards of the Alphabot UNEXPECTED BOT MOTION Ensure that the Alphabot's main board breaker switch is in the OFF position, and that bot LOTO procedures have been performed. This will prevent the bot from executing any move commands.
  • Page 20 Safety Alphabot User Manual ELECTRICAL SHOCK HAZARD Verify that the bot is fully discharged before beginning this procedure. Contact with the internal capacitor board prior to discharging the bot will result in serious injury or death. BODY CRUSH HAZARD Do not stand under a Bot/object stuck in a tower at any level or under any condition.
  • Page 21 Failure to do so may result in minor or moderate injury. Operators / Authorized employees who perform operation activities on the Alphabot System shall be qualified and trained on proper handling of the equipment and safe entry procedures into the system.

  • Page 22: Persons With Pacemakers

    Bots upon an early smoke detection alarm. The Alphabot System is not designed for the storage of flammables or organic products. 2.1.7 Seism ic All Alphabot systems and subsystems are bolted to the floor. Seismic designs, engineering and anchoring is provided depending on the end user’s location following the IBC code...

  • Page 23: Ergonomics

    Safety Alphabot User Manual 2.1.8 Ergonom ics HEAVY OBJECT May cause strain or back injury. Do not attempt to lift a bot. Bots weigh up to 95 kg (210lbs.) when loaded. Do not lift the driving wheels to push or pull a disabled Bot.

  • Page 24: Safety Equipment Rules

    Padlocks are used when servicing an Alphabot, and any time an access door must be opened to enter the structure. On an Alphabot, a padlock, or lockout hasp, is applied to the main switch to prevent the Alphabot form being turned on during service. When entering the structure, a padlock is applied to the access door to prevent the door from being closed when personnel is inside the system.

  • Page 25: Corrective Action Records

    Safety Alphabot User Manual If an Authorized Employee becomes disabled inside the Alphabot Structure during access or is physically incapable of removing their padlock, the Supervisor is allowed to remove the Authorized Employee’s padlock device from the interlock device under the following...

  • Page 26: Product Safety

    In USA, the OSHA standard The Control of Hazardous Energy (Lockout/Tagout), Title 29 Code of Federal Regulations (CFR) Part 1910.147. Note: Alert Innovation, Inc. is responsible for providing the appropriate program(s) and lockout/tagout devices to ensure the safety of personnel operating and maintaining this equipment.
  • Page 27 Safety Alphabot User Manual 1000004-MN-01 - Rev C Page 27 of 77...

  • Page 28: Local E-Stop Button & Function

    This E-stop function applies to the specific Bot with the pressed E-stop button and the rest of the system is still operating. 2.2.1.3 Bot Lockout/Tagout Procedure See the "Bot Lockout Tagout" section of 1000035-SF-01: Alphabot Lockout Tagout Procedures for this procedure. 1000004-MN-01 - Rev C...

  • Page 29: Discharge Bot

    Safety Alphabot User Manual 2.2.1.4 Discharge Bot See the "Bot Discharge" section of 1000035-SF-01: Alphabot Lockout Tagout Procedures for this procedure. 2.2.1.5 Safety Controller The safety controller is NRTL listed using approved safety software. The hardware was developed by the controller manufacturer based on a proven safety platform to fit the size and needs for the Bot.

  • Page 30: Bot Switch And Connector

    Safety Alphabot User Manual 2.2.1.9 Bot Switch and Connector International standard symbols are located on the Bot to designate specific functions. Multipurpose connector: Capacitor charge, Capacitor discharge & Brake release MAINT 3 Way switch: Manual Mode (local commands only with Yellow flashing...

  • Page 31: Mode Switch

    Safety Alphabot User Manual 2.2.1.10 Mode Switch The Bot is provided with a 3-way selector forced guided switch connected to the safe SPLC inputs. Automatic: The default mode is the Automatic mode. The Bot is operational within the system. Off: The Bot is immobilized with brakes on.

  • Page 32: Manual Brake Release

    Charge a bot when found discharged in the system Release the motion brakes to permit the bot to move in a lane, or wrangle a stuck bot in a tower after securing it with Alert Innovation, Inc.’s special maintenance tools. 1000004-MN-01 - Rev C...

  • Page 33: Description And Location Of Safety Labels

    Safety Alphabot User Manual 2.2.2 Description and Location of Safety Labels Descriptions and locations of safety labels in the Alphabot are listed below: Label Hazard Text in Label Location DANGER Risk of electrical Front-Left side of Alphabot. shock. Under the main board disconnect Disconnect all breaker.
  • Page 34 Safety Alphabot User Manual Label Hazard Text in Label Location WARNING Magnetic Field. Front-Right side of Alphabot, to the right of the charge toe. Can be harmful to pacemakers wearers. Pacemaker wearers stay back 30 cm (12 in). 1001573-00- 1000004-MN-01 - Rev C...
  • Page 35 Safety Alphabot User Manual Label Hazard Text in Label Location WARNING Moving parts Top-right corner of backside of front can crush and section of Alphabot. cut. Rear-middle, beside rear Wifi Keep hands Antenna. clear. 1001576-00- 1000004-MN-01 - Rev C Page 35 of 77...
  • Page 36 Safety Alphabot User Manual Label Hazard Text in Label Location Shock No text. Inside Bot (2) Hazard Icon 1001574-00- 1000004-MN-01 - Rev C Page 36 of 77...

  • Page 37: Repair And Maintenance Of Safety-Relevant Modules

    Innovation, Inc. No self-repair is allowed. 2.2.4 Decom m issioning of Equipm ent The decommissioning and dismantling of the Alphabot or the Alphabot System shall be performed by authorized personnel. Dispose of waste equipment and material in accordance with local regulations.

  • Page 38: Description Of The Alphabot System E-Stop Circuitry

    Alphabot User Manual 2.2.6 Description of the Alphabot System E-Stop Circuitry The Alphabot System uses a certified safety-programmable logic controller (“Master SPLC”) located in the main electrical enclosure. The main architecture includes conventional Safety I/O modules, and the Actuator Sensor interface (ASi) technology for safe &...
  • Page 39 Safety Alphabot User Manual 1000004-MN-01 - Rev C Page 39 of 77...

  • Page 40: Bot: Emergency Stop And Safe Torque Off (Sto)

    Safety Alphabot User Manual 2.2.6.1 Bot: Emergency Stop and Safe Torque Off (STO) Each Bot is provided with an on-board certified SPLC and a main CPU. While the main CPU gives start, stop and operational commands over Wi-Fi communication with the MCS...

  • Page 41: Hardware

    Alphabots move inventory within an Alphabot System MCS. They are autonomous vehicles capable of lifting inventory totes and moving them as required to different locations within the confines of the Alphabot System. Alphabots operate on tracks within an assembled Structure, providing various pathways down which the bot may travel.
  • Page 42 Guide wheels and Provides movement along the channels of the towers. V wheels (two sets) Magnetic detection Used by the Alphabot to sense the magnetic strip that runs strip (“Line along the transit plane. By following this magnetic strip, the Follower”) Alphabot is able to navigate when outside the channels of the tower.
  • Page 43 Tote Fingers to pick up and release chains. Tote fingers (front Used by the Alphabot to grasp, hold, and ultimately push out a and rear) tote container by actuating the Tote Chains onto which they are attached. There are two types of Tote Fingers: Tote Grabber Fingers, which grab and hold the tote container, and Tote Pusher Fingers, which push the tote out at a workstation.

  • Page 44: Bot Leds

    Hardware Alphabot User Manual Bot LEDs Each Bot is supplied with a set of 3 LEDs on the front and the back of the vehicle. Each LED is marked with an international pictogram and the color meanings comply with EN 60204-1.

  • Page 45: Master Safety Plc Operation

    The Main Control System (MCS) works with the Master Safety PLC (“Safety Controller”) to indicate if it is safe for the Alphabot to continue running. If the bot is unable to detect a response from the MSC, the local Bot SPLC will request a controlled stop shortly before disabling motor actuation.

  • Page 46: Safety Controller Safe States And User Interaction

    When the structure is entered, either through the standard process (see the "RtE" procedure in 1000035-SF-01: Safety Manual, Lockout Tagout Procedures, APSD System, Alphabot), or by using an emergency access key, all bots in the structure will stop and be safely disabled.

  • Page 47: Alphabot Architecture

    Alphabot User Manual Alphabot Architecture The Alphabot architecture consists of a main board, where all bot interconnect comes together. The main board provides the interconnect of the 4 motors, capacitor bank, maintenance debug connector, and all core components of the Alphabot.

  • Page 48: Alphabot Hardware Overview

    Hardware Alphabot User Manual Alphabot Hardware Overview The Alphabot and its external components are outlined in the diagrams that follow: General View of the Alphabot® 1. Status Lights 2. WiFi Antenna (Front) 3. Front Cover 4. E-stop Button 5. Camera (Top) 6.
  • Page 49 Hardware Alphabot User Manual Front View With Cover On 1. Guide Wheel 2. Drive Wheel 3. Charge Toe 4. Vee Wheel 5. Cover 6. Status Lights 7. WiFi Antenna 8. Service Switch 9. Maintenance Port 10. Camera 11. Magnetic Detection Strip Front View Top-Down No Cover 1.
  • Page 50 Hardware Alphabot User Manual Front View No Cover 1. Tote Motor 2. Worm Gearbox Rear View With Cover 1. Guide Wheel 2. Drive Wheel 3. Camera (Left) 4. Pusher Finger (Rear) 5. Status Lights (Rear) 6. Camera (Rear) 7. WiFi Antenna (Rear) 8.
  • Page 51 Hardware Alphabot User Manual Rear View No Cover 1. Linkage 2. 30 Chain Left Side View With Cover 1. Guide Wheel (Left) 2. Maintenance Port 3. WiFi Antenna (Front) 4. Main Board Cutoff Switch 5. Vee Wheel 6. Camera (Left) 7.
  • Page 52 Hardware Alphabot User Manual Right Side View With Cover 1. Guide Wheel (Right) 2. Tote Sensor (Right) 3. Positioning Sensor (Right) 4. RFID Reader (Right) 5. Tote Sensor (Right) 6. Camera (Right) 7. Vee Wheel (Right) 8. Charge Toe 9. Drive Wheel (Right) 10.
  • Page 53 Hardware Alphabot User Manual Top-Down View With Cover 1. Guide Wheel (Left) 2. RFID Reader (Left) 3. Drive Wheel (Left) 4. Guide Wheel (Left) 5. Maintenance Port 6. Status Lights (Front) 7. WiFi Antenna (Front) 8. E-stop Button 9. Camera (Up) 10.
  • Page 54 Hardware Alphabot User Manual Top-Down View No Cover (Diagram) Top-Down View No Cover (Photo) 1000004-MN-01 - Rev C Page 54 of 77...
  • Page 55 Hardware Alphabot User Manual Bottom View With Cover (Diagram) Bottom View No Cover (Photo) 1. Guide Wheel (Left) 2. RFID Reader (Left) 3. Drive Wheel (Left) 4. Guide Wheel (Left) 5. Guide Wheel (Right) 6. Caster Wheel 7. Tote Transfer Shaft 8.
  • Page 56 Hardware Alphabot User Manual Status Lights, WiFi Antennae, and Service Switch Maintenance Port Connector Maintenance Port Connector and Maintenance Port 1000004-MN-01 - Rev C Page 56 of 77...
  • Page 57 Hardware Alphabot User Manual Breaker (Disconnect) Switch 1000004-MN-01 - Rev C Page 57 of 77...

  • Page 58: Physical Specifications

    Hardware Alphabot User Manual Physical Specifications 1000004-MN-01 - Rev C Page 58 of 77...

  • Page 59: Power Requirements

    Hardware Alphabot User Manual Power Requirements Power Storage Capacitor Board Required Charging Equipment Structure Charge Rail Standard State w/ Fully-Active Capacitor 3.5W-5W Bank (W) Power-Save/Sleepy Bear Mode Usage (W) <200mW 3.10 Technical Specifications, Capacity, Velocity Max Alphabot Loads lbs. Alphabot Mass 63.95...
  • Page 60 Hardware Alphabot User Manual Max Alphabot Loads lbs. Rear Wheel Contact Area 0.27 Caster Load 33.11 Max Load on Caster 74.8 Caster Contact Area 0.18 Alphabot Velocity Maximum Velocity (Horizontal) 4 mps Maximum Velocity (Vertical) 1 mps Stopping Time 2.5 s Stopping Distance 4.6 m...

  • Page 61: Environmental Specifications

    3.12 Lifecycle Alphabots are designed for 10 years of active service. Active service is defined as the time the Alphabot is either in motion, or otherwise in the process of executing a mission but temporarily idle. 1000004-MN-01 - Rev C...

  • Page 62: Operation

    Alphabots are started up or shut down. Alphabots are started up when initially being inducted into the larger Alphabot System (when the MCS first becomes aware of their existence), and when recovering from a disabling condition within the Alphabot System that requires human intervention.

  • Page 63: Theory Of Operation

    Operation Alphabot User Manual Theory of Operation The Alphabot constitutes one part of the larger Alphabot System, whose overall operation entails the fulfillment of customer product orders, or “eaches”. The Alphabot System consists of four major systems: 1. Bot Subsystem: Comprised of a fleet of mobile vehicles called “Alphabots” (or simply "bots"), which perform all storage/retrieval and transport tasks required to assemble...

  • Page 64: Unpacking An Alphabot

    Operation Alphabot User Manual Unpacking an Alphabot Alphabots are shipped fully assembled; therefore no material setup is required. Simply unpack the drive unit and move to a location where the drive unit is safe until it is ready for induction/installation onto the floor.

  • Page 65: System Start

    Operation Alphabot User Manual System Start The Alphabot system is set to start under the following conditions: Whenever the operator logs into any of the workstations System start-up initiated through the MCS directly (for advanced level users only) 1000004-MN-01 - Rev C...

  • Page 66: System Shutdown

    Alphabot User Manual System Shutdown An end of day system shutdown is desirable to leave the Alphabot system in a known idle state and to minimize cooler loss during non-operational hours. The following conditions will trigger the system to go into a shutdown state: System is idle as listed below: o The system is outside of defined operational hours.

  • Page 67: Alphabot Interactions With Workstations

    Alphabots deliver empty product totes to the Static Workstation. An operator pulls the empty totes onto the Static Workstation shelf, decants product into the tote, and loads it into the System where the Alphabot retrieves the tote. The bot then stores the tote in the System.

  • Page 68: Pull Order

    Operation Alphabot User Manual 4.8.7 Pull Order Alphabots deliver all order totes for the given order to the Static Workstation. The operator will then retrieve the totes from the Static Workstation and deliver them to the customer. 1000004-MN-01 - Rev C...

  • Page 69: Troubleshooting

    Alphabot User Manual Troubleshooting When an Alphabot experiences an error within the Alphabot System, there are several troubleshooting procedures that an Operator or Elevated User are allowed to perform to attempt to resolve the error. Most of these procedures can be carried out remotely, requiring no entry into the Structure.

  • Page 70: Regulatory Compliance Information

    Alphabot User Manual Regulatory Compliance Information Standards Compliance The Alphabot system is TUV-certified and in compliance with NFPA 79; CSA C22.2 No.301- 2016 and UL 2011 standards. Other referenced standards of compliance are shown in the table below. Standards Compliance...
  • Page 71 Regulatory Compliance Information Alphabot User Manual Standards Compliance Standard Title IEC 61508 Functional Safety Of Electrical/Electronic/Programmable Electronic Safety-Related Systems IEC 62061 Safety Of Machinery - Functional Safety Of Safety-Related Electrical, Electronic And Programmable Electronic Control Systems IEC/UL/EN/CSA C22.2 # 61010-1...

  • Page 72: Fcc Compliance

    2. This device must accept any interference received, Including interference that may cause undesired operation Changes and Modifications not expressly approved by Alert Innovation, Inc. Inc. can void your authority to operate this equipment under Federal Communications Commissions rules. This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment.
  • Page 73 Regulatory Compliance Information Alphabot User Manual FCC Labels Location of Labels RFID Label on PCB Board Alphabot Label Contents 1000004-MN-01 - Rev C Page 73 of 77...

  • Page 74: Ised Regulatory Information

    Le présent émetteur radio (IC: 26910-ALPHABOT) a été approuvé par ISED Canada pour fonctionner avec les types d’antenne énumérés ci-dessous et ayant un gain admissible maximal.
  • Page 75 à l'intérieur d'un autre appareil, l'appareil doit afficher l'étiquette sur le module de référence ci-joint. Dans ce cas, le produit final doit être étiqueté dans un endroit visible par le texte suivant: “Contains Transmitter Module IC: 26910-ALPHABOT” “Contains IC: 26910-ALPHABOT” 1000004-MN-01 - Rev C...

  • Page 76: Revision History

    Procedures Manual (PN1000035-SF- 01), the following sections have been updated or added: o Bot Lockout procedure updated Discharge Bot added Referenced Alphabot Pre and Post Procedures Manual (PN 1000067-SR- 01), for the following: Bot Induction Bot Removal Alphabot Components section moved into a table and alphabetized.
  • Page 77 Revision History Alphabot User Manual Alphabot Components : Line Finder corrected to Line Follower. General Safety renamed to Hazard Description System Lockout / Tagout - removed European Standard Mechanical Brakes updated. Bot LEDs table updated for red flashing lights. Remote Charging and Brake Release functions renamed.

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