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1、AGV故障诊断手册1.AGV故障诊断概述41.1编写本手册的目的The purpose of the manual41.2AGV故障诊断手段41.3常见故障的分类52.AGV控制系统回顾72.1AGV控制系统结构回顾72.2AGV控制系统的自动保护功能72.3在动态合装段中停车的处理72.3.1合装段的操作者暂停停车82.3.2合装段的E-stop停车82.3.3合装段的故障停车82.3.4合装段的合装超时停车83.AGV启动故障93.1AGV启动过程93.2启动引导代理程序介绍93.3AGV主控制软件Carryboy的启动过程103.3.1参数文件装入错误103.3.2CAN设备初始化失败1
2、13.3.3AGV车体伺服轴初始化失败113.3.4舵角校正失败124. AGV一般设备故障的诊断134.1车体供电系统故障诊断134.2车体主控制器VCU100故障诊断154.3基本数字I/O故障的诊断164.4CAN通讯系统故障诊断184.5手控盒设备故障诊断194.6液晶显示器故障诊断204.7保险杠及非接触防碰设备故障诊断214.8磁导航传感器及其接口模块的故障诊断214.9磁地标传感器的故障诊断224.10车轮电机抱闸的故障诊断234.11车轮电机增量式编码器故障诊断244.12车轮转舵机构电机伺服放大器故障诊断254.13车轮电机的故障诊断 Wheel motor fault di
3、agnosis264.14驱动轮测速机的故障诊断 Drive wheel tachometer fault diagnosis264.15AGV车轮舵角异常的诊断274.16无线接入点（Wireless Access Point）的故障诊断274.17车载无线通讯设备的故障诊断 On-board wireless communication fault diagnosis294.18同步跟踪传感器的故障诊断304.19提升机的故障诊断314.19.1提升机编码器的故障诊断314.19.2提升机电机驱动器的故障诊断314.19.3提升机限位开关的故障诊断324.20地面辅助导航设备的故障诊断32
4、4.20.1导航带失效324.20.2地标带失效324.20.3 RF-ID失效 Invalidation335. AGV运行典型故障诊断流程345.1自动运行中导航失败345.2自动运行中地标校正失败 Landmark proofread failure during automatic running355.3自动运行无法登录到控制台365.4自动运行中无线通讯中断 Wireless Communication loss during automatic running365.5失去ALLOK信号375.5.1失速保护机制原理375.5.2超差保护机制原理375.6车轮驱动故障375.7电
5、池电量过低 Battery Power Low386. AGV动态合装故障的诊断396.1动态目标捕捉失败 Dynamic target catch failure396.2在没有同步目标的情况下误报开始同步396.3动态跟踪目标丢失406.4动态合装中提升机故障401. AGV故障诊断概述1.1 编写本手册的目的The purpose of the manual编写本手册的目的是介绍和描述AGV使用过程中可能出现的故障，并对这些故障的排查、诊断提供一套快速的诊断流程，以便于AGV维修人员能够快速、准确地查明故障的原因，并在最短时间内将故障排除。The purpose of this manu
6、al is to describe the possible errors that may be encountered during the usage of the AGV, and to provide a quick diagnostic procedure for these errors. With the help of this manual, maintenance engineers will be able to pin-point most of the common troubles within short time. 1.2 AGV故障诊断手段同其它的控制系统故
7、障诊断一样，AGV的故障诊断必须借助于硬件诊断工具如万用表等。除此之外，SIASUN的AGV控制系统的软件也提供了一些故障诊断功能。这些功能包括：Just like in other control systems, to debug an AGV error an maintenance engineer has to use certain diagnosis tools like digital multi-meter. However, besides these commonly used diagnostic tools, the maintenance engineers can
8、 also make use of some other software/hardware tools that are provided by SIASUN. These include: 一个专门用于对低层数字I/O、模拟量输入及以太网络通讯状态进行测试、诊断的工具软件CE-Tool。它可以在VCU100启动时由操作员选择运行。 CE-TOOL: A software tool dedicatedly developed to debug basic digital I/O, analog input and the Ethernet port onboard the AGV AGV运行
9、主控制软件本身具有较强的故障检测能力，能够主动发现AGV运行中发生的多种错误，并采取一定的保护措施防止事故的发生。同时，车载软件具有对多种设备的状态进行动态观察的能力，帮助维修人员查明故障位置。 The AGV control software has a lot of error detection functions, which can detect most of the common errors during the working process, and can automatically take necessary safety measures to prevent ac
10、cidents from happening. Meanwhile, the vehicle control software also provides dynamic inspection function for most of the signals onboard the vehicle, to help the maintenance engineers to check the status of the control components 对于运行过程中出现的故障，一般来说AGV会将错误状态通过无线通讯传送给控制台，并由控制台在屏幕上提示所出现的故障； If an AGV h
11、as some error in the automatic working mode, usually the AGV controller can report the error to the traffic controller, and the traffic controller will display the corresponding error message on the screen so that operators can know what is wrong with the AGV AGV所使用的一些主要部件，如VCU100主控制器、MCU50运动控制器等均具有
12、LED指示灯，可以显示当前的工作状态，方便维修人员迅速对故障原因作出判断 The major AGV control components (such as VCU100 main controller, MCU50 motion controller, etc.) have LED indicators on them to show their current working status, which is very convenient and helpful for maintenance VCU100主控制器的软件具有自动运行记录(黑匣子)，在实际运行中，可以通过一定方式将自动运行
13、记录导出到控制台计算机或其它计算机机中。必要时，现场维修人员可将导出的黑匣子文件通过互联网发送到SIASUN公司技术支持部门，SIASUN的技术人员就可以根据黑匣子的内容分析判断故障的原因； The software in the VCU100 vehicle controller has a built-in “working process auto-recording function” (the so-called AGV “Black Box”), which can automatically record the last period of the working proces
14、s of the AGV. When necessary, the maintenance engineers can upload the black-box files from the VCU100 controller to the traffic controller or some other computer through wireless communication, and then send these files to SIASUN through Internet. The support engineers of SIASUN will then be able t
15、o know the last working status before the error, and will help the plant maintenance engineers to find out the cause of the error.1.3 常见故障的分类从故障产生的原因来看，AGV的故障可分为机械故障、电气故障、软件故障等。本手册主要分析AGV电气、软件等方面的故障，有关机械方面的故障分析请参见机械维护手册。All the errors in an AGV fall into the following 3 categories: mechanical error,
16、 electric hardware error and software error. In this manual, only the electric hardware & software error will be addressed. For the trouble shooting of mechanical errors, please refer to AGV maintenance manual-mechanical part在AGV运行中，有以下几种原因可能导航AGV工作发生故障：The followings are the possible reasons for AG
17、V errors:n AGV控制系统部件如电机、传感器等失效或损坏n AGV (such as motors, sensors) Components failuren AGV电缆或接头等由于接触不良、线路磨损等造成的故障n In-proper connection in connectors and cable error caused by wearingn 由于工作环境不正常引起的干扰，如地面有油污杂物造成车体运行打滑，无线通讯受到干扰而引起通讯中断等n Disturbance caused by environmental factors (such as slippage in th
18、e floor, wireless communication disturbance, etc)在本文中，将按照故障可能发生的阶段，将AGV故障分为以下几类：In this manual, we classify all the AGV errors into the following types:n AGV启动故障n Booting errorn AGV手动运行故障n Errors in manual controln AGV在自动运行中的一般故障n Errors in normal workingn AGV在自动合装过程中的故障n Errors in marriage process2
19、. AGV控制系统回顾2.1 AGV控制系统结构回顾AGV控制系统主要由VCU100，MCU50这两种控制器作为主要的控制器。结构简图见图2.1。Fig2.1 the structure of control systemVCU100（Vehicle Control Unit）作为AGV的主控制器，外设有VGA接口，LAN接口，COM串口和PS/2接口，分别满足显示屏，网络，手控盒，RFID读码器以及键盘等外设对接口的需要。在VCU100内部还有使用104总线CAN通讯卡PCM3680，以实现中心处理单元与各信号采集单元间的数据交换。MCU50（Motion Control Unit）作为下层
20、的运动控制单元，是基于CAN总线通讯方式的分布式运动控制器，具有2路增量式编码器信号的反馈输入，通过对伺服驱动器的调节，来达到对AGV车体运动的精确控制。另外MCU50还集成了4路模拟信号输入、2路模拟信号输出、16路数字信号输入和8路数字信号输出，可满足多种传感器及外设信号的输入输出需要。GIU10通过CAN通信将车体导航传感器的采集的导航信号传送给VCU100进行导航偏差的矫正，GIU10在导航传感器检测到导航带时，会有红灯亮起。VCU100，MCU50，GIU10通过工业控制总线CAN总线通信，保证车体内部各控制器的协调关系，已完成VCU100对AGV的精准控制。MCU50通过PWM输出
21、控制相应伺服放大器，以编码器反馈信号完成对轮系电机的闭环控制。同时，对应I/O输入输出完成对车体信号的采集，以及继电器的输出控制。2.2 AGV控制系统的自动保护功能MCU50的ALLOK信号保护功能ALL-OK signal protectionMCU50是一个由新松公司自行研制开发的基于CAN的专用模块，它集闭环运动控制、数字输入、数字输出、模拟输入等功能于一身，具有很高的性能。The MCU50 is a high performance motion control modular based on CAN, which incorporates the functions of po
22、sition feedback motion control, digital input, digital output, and analogue input.在运动控制方面，MCU50不仅提供了两个增量式编码器接口，两个PWM控制输出，以及内同嵌的PID调节器，同时对伺服轴位置超差、伺服轴速度失控、CAN通讯心跳异常等故障提供了保护。当发生以上这些故障时，MCU50会自动将其ALLOK信号置为OFF。由于在AGV的控制系统中，车体主控制器VCU100、各个MCU50模块的ALLOK信号以及控制系统的ESTOP均串接在一起，最终控制各个电机及抱闸的供电，所以，一但本MCU50的ALLOK信
23、号为OFF，整个车体的动力电源就会失去，从而实现对车体的保护。请参见“MCU50技术资料”中的相关介绍。On the motion control aspect, MCU50 not only provides two incremental encoder interfaces, two PWM outputs and two built-in PID regulators, but also provides automatic error protections on position error over limit, abnormal axis velocity and CAN he
24、artbeat lost. In the presence of any of the above errors, the MCU50 modular will set the ALL-OK output to off, to indicate that an error has occurred. Since the ALL-OK signal in each MCU50 and VCU100 modules are connected in a series manner, whenever anyone of the modules in the AGV lost its ALL-OK
25、signal, the output of the ALL-OK chain will be off, which will lead to motors power off and motor brakes locking, to realize vehicle protection for these errors. For the detail of AGV ALL-OK off protection, please refer to MCU50 Technical Description.2.3 在动态合装段中停车的处理在AGV动态合装过程中，整个AGV系统与车身吊链之间具有安全的互锁
26、信号。互锁信号可以保证在动态合装过程中吊链与AGV之间的运行同步，顺利完成整个合装过程。2.3.1合装段的操作者暂停停车在合装过程中，如果操作者人为按下Run-stop按钮，AGV系统软件将通过控制台互锁信号通知吊链停止运行，这样，正在跟踪的AGV也将同时停止运行，等待吊链重新运转。这种停车方式停车是在发出停车要求后通过停掉吊链系统后，AGV作为被动方停车，停车过程缓慢安全，避免急速停车造成不必要的危险和危害。2.3.2合装段的E-stop停车在合装过程中，当出现紧急以外的情况时，操作者可以通过按下急停按钮停车，此时AGV的轮系供电立即被切断。同时，AGV将上报给控制台急停信号，控制台通过互锁
27、信号停止正在运行的吊链。这种停车方式快速，可以满足紧急情况时停车的快速性要求，由于AGV停车后，控制台的互锁信号才起作用，吊链的停止会有1秒左右的延时，但是提升机顶部的滑台活动余量可以满足延时所造成的距离要求，因而这种停车方式可以满足紧急情况下的AGV合装停止。2.3.3合装段的故障停车在合装过程中，当AGV出现故障，如导航丢失，跟踪信号丢失，通信失败等等时，AGV将进行停车保护处理，与此同时，控制台将通过互锁信号停止正在运行的吊链，同时发出报警，通知维护人员进行处理，以恢复AGV合装的正常运行。2.3.4合装段的合装超时停车在合装过程中，如果操作者由于某种情况未能及时的完成合装操作，AGV即
28、将到达合装结束节点时，AGV会发出警告通知操作者合装超时，同时上报控制台合装超时信号，并通过互锁信号停止吊链运行，直到合装完成，操作人员进行复位操作之后，继续运行。3. AGV启动故障3.1 AGV启动过程AGV启动过程如下：The booting process of an AGV is as follows:n VCU100控制器上电n Power on the AGV, the VCU100 start bootingn VCU100启动Windows CE操作系统n VCU100 starts the Windows CE operation systemn VCU100启动引导代理程
29、序(BootLoad)n The booting agent program (BootLoad) start runningn 引导代理程序BootLoad运行AGV控制软件(Carryboy)n BootLoad loads the main control software Carryboy and run it 3.2 启动引导代理程序介绍启动引导代理程序是Windows CE系统启动后运行的第一个程序，它具有三个功能：The Bootload software is the first running software after the Windows CE is started.
30、 It has the following functions:n 自动运行AGV主控制程序Carryboyn Run the main vehicle control software Carryboyn 根据用户的选择，运行AGV辅助诊断程序；n Run AGV auxiliary diagnosis tool CE-tool upon the operators choicen 接受来自AGV文件管理机(可以是控制台/笔记本电脑等)的文件上传、下载指令，对VCU100内部的软件进行管理及更新；n Accept the file upload/download command from t
31、he file management computer (may be the traffic controller or any computer/laptop that has Ethernet capacity), and do file upload/download operation当启动引导代理程序启动之后，如果在10秒之内没有接到操作者的任何输入，它将自动启动AGV运行主程序。如果操作者希望对AGV的I/O系统进行低层的诊断、或是希望对VCU100控制器软件进行更新，应在此之前在操作面板上选择相应的功能。After running, the Bootload software
32、will wait for 10 seconds for operator input, and will load and run the vehicle main control software Carryboy if no input is received from the operator. If the maintenance engineer want to perform low level diagnosis on the I/O or the network, they should inputs corresponding command before the vehi
33、cle main software is started.3.3 AGV主控制软件Carryboy的启动过程AGV主控制程序的启动主要是调入系统运行所需的各种参数及数据。在启动过程中，AGV操作面板上显示当前的启动过程。如果在启动过程中发现程序停止在某一阶段，维修人可以根据所停止的阶段推断出发生了何种故障。当Carryboy的启动过程正确完成后，AGV操作面板上即可进入主控制画面。The booting of the vehicle main control software Carryboy is a process of loading parameters and data. Infor
34、mation about the the current booting status will be displayed on AGV LCD display while the Carroboy is booting. If any error happens during the booting process of the Carryboy software, the display will halt at that step, so maintenance engineer will be able to deduce what kind of error has occurred
35、. After the booting process of the Carryboy software completes successfully, the AGV LCD will display the main menu of the vehicle software.正常情况下，Carryboy的启动可以正常完成；但如果控制系统的软件、硬件出现故障，启动过程就可能中途停止。Normally, the booting of Carryboy can be finished automatically. But if there is some error in the control
36、 system, the booting process may halt.以下具体介绍几种典型的启动故障：In the following section, we are going to introduce some of the typical errors in the booting process.3.3.1 参数文件装入错误参数装入错误主要是指系统参数文件、用户参数文件、工作地图文件等参数文件格式错误或文件读取错误。正常情况下，这种文件装入错误的情形在普通使用程中不会出现，因为在AGV提交给用户使用这前，所有这些参数文件都已由SIASUN技术人员调整完毕。仅在以下两种情况下可能出
37、现这种故障：Parameter loading errors are errors caused by wrong file format or file missing of parameter/map files. Normally, all the parameter files should have been properly downloaded into the VCU100 by SIASUN field installation engineers before the AGV system is put into work, so this kind of error sh
38、ould not be encountered by operators, except for the following two conditions: n 刚刚由用户修改了某些系统文件，如用户自行更改并下载了AGV系统工作地图文件，如果更改的文件有错误，就会出现文件装入错误的情况；n The customer has just modified and downloaded some of the system files in the AGV controller (for example, if the customer created a wrong map file and do
39、wnloaded it to the AGV controller)n VCU100内部发生硬件故障，导致文件系统工作异常。n There is some internal error in the VCU100 controller that caused error in the file system针对前一种情形，只要将正常的系统文件重新下载到VCU100控制器中，就可以将这种故障排除；而对于后一种情况，则必须更换VCU100控制器才能解除。For the first situation, the error condition can be eliminated automatica
40、lly after correct files are downloaded to the VCU100 controller; But for the second situation, the only way to resolve the problem is to replace the wrong VCU100 controller with a good one.3.3.2 CAN设备初始化失败在启动过程中CAN设备初始化失败，一般是由于CAN通讯失败引起的。请关于具体如何诊断引起该故障的原因，请参见“CAN通讯故障诊断”。The initialization failure of
41、 CAN device is usually caused by CAN communication error. For the detail of how to debug CAN communication error, please refer to “CAN communication error” 3.3.3 AGV车体伺服轴初始化失败在AGV启动过程中，VCU100需要向控制车体各运动轴的MCU50运动控制器发出初始化指令，并等待来自MCU50的应答信息。如果VCU100未能接到来MCU50的应答，则会报车体伺服轴初始化失败。During the boot up process
42、of AGV, the VCU100 sends initialization commands to each MCU50 motion controller, and expects echo from the MCU50 units. If due to some error, VCU100 fails to receive echo from the MCU50 units, it will report servo initialization error.正常初始化的MCU50单元，其状态指示灯应呈现1秒间隔的ON/OFF状态，而未成功初始化的MCU50单元则呈现3秒OFF后3秒快
43、速闪烁状态。因此可以根据各MCU50模块的指示灯状态来判断是哪些单元初始化失败。If an MCU50 unit is successfully initialized, its ALL-OK indication LED will flash for every 1 second. But if it is not initialized correctly, its ALL-OK indicating LED will first flash 3 seconds very rapidly, then become off for 3 seconds, and then flash 3 se
44、conds rapidly again. Based on the different flash style of the ALL-OK LED, an maintenance engineer is able to know which of the MCU50 units are not correctly initialized .车体伺服轴初始化失败可能由以下几种原因造成：These are some of the possible reasons for unsuccessful servo axes initialization:n MCU50模块的CAN地址设置错误（参见“AG
45、V系统CAN结点编址表”）及“MCU50说明书”(MCU50 Motion Controller Description)；n The CAN address of the MCU50 unit is not correctly set (please refer to the “CAN address allocation table of the AGV”, and “MCU50 motion controller Description for detail)n MCU50与VCU100的CAN通讯电缆故障，或CAN通讯终端电阻有误；n The CAN communication cab
46、le, or the CAN terminating resistor has some problem;n MCU50本身故障n MCU50 internal error请注意，车体伺服轴初始化的过程并不涉及对各运动轴的实际动作控制，所以，车体运动轴的硬件故障(如伺服放大器故障)并不会引起本伺服轴初始化失败。Please note that the initialization of the MCU50 unit doesnt involve any motion generation, so the failure of servo amplifier or motor will not
47、result in servo axis initialization failure. 3.3.4 舵角校正失败每次AGV启动时，都要重新校正各个转舵机构的舵角，以便各个车轮的初始方向正直，保证运行时车体各种运动的精度。Whenever an AGV is powered on, the VCU100 must re-calibrate the vehicles steers, to make sure all steers will be in straight directions.舵角校正过程必须在驱动系统上电的情况下进行，这要求所有急停开关处于松开的状态，并且保险杠处于未压缩状态。如
48、果有急停开关被按下（或保险杠被压缩），则舵角校正不会开始，直到所有急停开关松开，保险杠不被压缩。在舵角校正开始之后，操作者不应按下急停开关，否则舵角校正将暂停，直到所有急停开关松开。The calibration of steers can only be performed when the steer axes are workable, which requires all the E-Stop buttons (as well as the bumpers) should be released before the steer calibration. Otherwise the s
