1、 Printed copies are uncontrolled. 1 of 8 AUTOMATED GUIDED VEHICLES 1.0 PURPOSE: The purpose of this Standard is to promote safety through design, construction, application, operation and maintenance of Automated Guided Vehicles and Automated Guided Vehicle Systems. This Standard may be used by gover
2、nmental authorities desiring to formulate safety rules and regulations. 2.0 SCOPE: This standard applies to all Automated Guided Vehicles (AGVs) and Automated Guided Vehicle Systems purchased by Ford Motor Company. 3.0 REFERENCES: American National Standards Institute (ANSI): B56.1 Low Lift and High
3、 Lift Trucks B56.5 Guided Industrial Vehicles B56.9 Operator Controlled Industrial Tow Tractors B56.11.3 Load Handling Symbols for Powered Industrial Trucks B56.11.4 Hook-Type Forks and Fork Carriers NFPA-505 Fire Safety Standard for Powered Industrial Trucks UL 583 Standard for Safety for Electric
4、Powered Industrial Trucks Canadian Safety Association Standards (CSA) Code of Federal Regulations (CFR) - Title 29, Part 1910, Occupational Safety and Health Administration Standards (OSHA) Ford Manufacturing Standards EL3X Programmable Controller Application EX1 General Electrical for Mass Producti
5、on Equipment HX1 Hydraulic Systems LX1 General Lubrication w-ZA1 Basic Industrial Vehicles w-ZA2 Batteries and Compartments, Battery Connectors, Battery Chargers Industrial Truck Association Standards (ITA) National Electric Manufacturers Association Standard (NEMA) Tire and Rim Association Standard
6、s (TRA) European Standards DIN EN 1525 Safety of Industrial Trucks Driverless Trucks and Their Systems VDI 2513 Checklist for AGVs DIN EN 1726 Self Propelled Trucks up to incl. 10,000 kg DIN EN 1175 1-3 Electrical Requirements DIN EN 1755 Safety of Machinery Operation in Potentially Explosive Atmosp
7、heres Use in Flammable Gas, Vapor Mist and Dust DIN EN 1050 Error however, the universal application of strobe lights on all systems is not recommended. Locations electing to install strobe lights on automated guided vehicles should consider the following criteria: Blue lens or color not subject to
8、color detection confusion 80-90 flashes per minute 85 candela or different luminance from the immediate background Assure visibility in outdoor applications Mount at top of vehicle Printed copies are uncontrolled. 3 of 8 Standard Number w-ZA65 Issue Date: 20000524 Global Manufacturing Standards Rev:
9、 5.6 EMERGENCY CONTROLS AND DEVICES: Vehicle Emergency Controls and Devices shall be in accordance with ANSI B56.5 and with the following: 5.6.1 EMERGENCY CONTROLS: Emergency controls shall be directly connected to the responsive component and shall not require other processing components. 5.6.2 BUM
10、PERS: Bumpers (in the normal direction(s) of travel) shall be used as the primary emergency stopping device. The front bumper and rear bumper (required if the vehicle travels in the reverse direction) shall be a minimum of 6 inches (152 mm) in height and have an under-clearance of 2 inches (51 mm),
11、minimum, and 4 inches (102 mm) maximum. When determining bumper height, potential obstacles in the vehicle path (i.e. outrigger style racks) shall be considered. Bumpers may be mechanical or laser; however, they shall provide the coverage area as defined in the previous paragraph. 5.7 VEHICLE NON-EM
12、ERGENCY CONTROLS AND DEVICES: Non-emergency controls and devices shall be in accordance with ANSI B56.5 and with the following: A non-contact collision avoidance system (i.e. optics) may be supplied which will detect objects within the maximum moving width of the vehicle and its intended load. The c
13、ollision avoidance system may cause the vehicle to reduce travel speed and stop the vehicle until the detected obstacle is removed. Specific sizes, shapes and reflectivity of the detected objects and area of effective coverage shall be defined and agreed upon between the supplier and by persons desi
14、gnated by AME-PE. The collision avoidance system may be turned off in designated areas. The vehicles shall be equipped with a visual indication of the operation / non-operation of the collision avoidance system. 5.8 OPERATIONAL MODES: Operational modes shall be in accordance with ANSI B56.5 and with
15、 the following: 5.8.1 MODES - GENERAL: The vehicle shall be equipped with a pushbutton and/or key switch to permit selection of either manual or automatic mode of operation. The mode selection and initiation shall not be possible from the pendant control. 5.8.2 MODES - AUTOMATIC: In the automatic mo
16、de, the vehicle shall be under full control of the central computer system or on-board computer system. After selecting automatic mode, vehicle restart shall require manual initiation with a separate pushbutton and/or key switch. 5.8.3 MODES - MANUAL: In the manual mode, controls shall be provided f
17、or performance of all vehicle functions and/or motions. 5.9 MANUAL OPERATION: Manual operation shall be in accordance with ANSI B56.5 and with the following: 5.9.1 CONTROLS - GENERAL: Activation of manual controls shall deactivate all automatic controls, except automatic brakes; however, automatic b
18、rakes shall be capable of being released manually. Printed copies are uncontrolled. 4 of 8 Standard Number w-ZA65 Issue Date: 20000524 Global Manufacturing Standards Rev: 5.9.2 CONTROLS - PENDANT TYPE: If manual controls are of the pendant type, the pendant shall be provided with a cord of sufficien
19、t length to allow operation from all sides of the vehicle. Minimum cord length shall be 10 ft. Pendant controls shall be equipped with an emergency stop device. 5.9.3 OPERATOR COMPARTMENT: The operator compartment, if applicable, shall be ergonomically designed and shall remain stable under normal c
20、onditions. An emergency stop device shall be provided within easy reach of the operator while in his normal operating position. Platform surfaces shall be slip resistant (i.e. rubber mat). Control pedals shall have a rubber or slip resistant surface. 5.10 GUARDING: Protection from moving parts shall
21、 be in accordance with ANSI B56.5 and with the following: 5.10.1 GUARDING FOR MOVING COMPONENTS: All moving parts that represent a hazard to personnel shall be suitably guarded in conformance with the Code of Federal Regulations (CFR) - Title 29, Part 1910, Occupational Safety and Health Administrat
22、ion (OSHA) standards. 5.10.2 WHEEL AND TOE GUARDS: Wheel and toe guards shall be provided: To reduce foreseeable risk of personnel injury. Shall minimize ground clearance while remaining sufficiently flexible to allow the vehicle to operate on uneven floors. Shall not interfere with normal vehicle m
23、aintenance. 5.10.3 OTHER: Guards shall be installed on the vehicle to prevent foreign material (screws, etc.) from becoming engaged in the undercarriage of the vehicle. 5.11 LOAD HANDLING DEVICES: Load handling devices shall be in accordance with ANSI B56.5 and with the following: 5.11.1 POSITIONING
24、: Load positioning for automatic load/unload shall be within a tolerance that allows for safe transfer of the load. This accuracy shall be maintained during the complete battery cycle operating range. 5.11.2 FORKS: Forks shall not contact the floor during normal operation. Vehicle shall have sensors
25、 capable of detecting the presence of interferences or obstructions in the path of the forks traveling in either forward or reverse direction (end of fork sensors, outriggers or other methods agreed upon between supplier and by persons designated by AME-PE). Printed copies are uncontrolled. 5 of 8 S
26、tandard Number w-ZA65 Issue Date: 20000524 Global Manufacturing Standards Rev: 5.12 SIGNS: Signs shall be in accordance with ANSI B56.5 and with the following: 5.12.1 LABELING: Vehicles designed for unit loads shall have a label or stencil in letters at least 1.5“ (40 mm) high stating: “MAXIMUM PERM
27、ISSIBLE LOAD: WEIGHT = POUNDS (kg)“ Vehicles designed for load towing shall have a label or stencil in letters at least 1.5“ (40 mm) high stating: “MAXIMUM PERMISSIBLE TOWING LOAD: TOTAL WEIGHT = POUNDS (kg) NUMBER OF TRAILERS = TRAILERS“. 5.13 BATTERIES: Changing and charging of batteries shall be
28、in accordance with ANSI B56.5 and with the following: 5.13.1 GENERAL: Batteries, connectors and chargers shall conform to provisions of Ford Global Manufacturing Standards w-ZA2 where applicable. 5.13.2 RETAINING DEVICES: All vehicles shall be equipped with battery retaining devices designed to prev
29、ent shifting of the battery under all conditions of operation, without damage to the battery or retaining devices. 5.13.3 OPPORTUNITY CHARGING: Opportunity charging shall meet the battery manufacturers recommendations. 5.14 ELECTRIC/ELECTRONIC SYSTEM AND COMPONENTS: 5.14.1 SYSTEM REQUIREMENTS: All e
30、lectrical components shall be able to operate at 95 percent non-condensing relative humidity; and, shall be designed to operate outdoors, if applicable. Printed circuit boards shall have diagnostic fault lights. Vehicle shall have a minimum of 25% I/O expansion capacity. Solid-state devices and/or c
31、ontrollers shall have a minimum of 40 hours of “burn in“ at normal operating temperature prior to installation to minimize the incidence of “infant mortality“ failures. Printed copies are uncontrolled. 6 of 8 Standard Number w-ZA65 Issue Date: 20000524 Global Manufacturing Standards Rev: 5.14.2 SYST
32、EM IDENTIFICATION: All wires shall be identified at each termination by marking with a number or color coded to correspond with wiring diagram. A connection diagram shall be affixed to the inner surface of the control housing or placed in a suitable pocket. This diagram, showing part numbers, shall
33、be included in the Parts and Service Manual. 5.14.3 HOUR METER: An hour meter mounted on the control panel shall have its circuit arranged such that the actual working hours of the main drive and the accessory motors are recorded. 5.14.4 MOTORS: All drive motors shall have overload (over-current and
34、 oven-temperature) protection. Diagnostics shall be provided to indicate such faults. All motors enclosures shall be drip proof and protect against splashing water. Sealed motors shall be used on drive to prevent conductive dust accumulation. 5.14.5 CONTROL SYSTEM: Control circuits shall be designed
35、 to allow tracing of all signals from the input point to the output point, including signals on all microcomputer component boards. The type and model of drive controller is to be determined by the vehicle manufacturer and approved by persons designated by AME-PE. 5.14.6 ELECTRICAL COMPONENTS: All e
36、lectrical control components shall be “shock“ mounted in a compartment that will maintain a clean dry environment under all operating conditions. PC boards shall be “shock“ mounted in a “vertical“ position to minimize accumulation of debris. The use of heat sinks or convection cooling systems is pre
37、ferred. Other types of systems must be approved by persons designated by AME-PE. Fans or other special systems are not acceptable for cooling. 5.15 SERVICEABILITY: 5.15.1 EMERGENCY TRANSPORT: Chassis design shall permit emergency transportation of the vehicle without damage to any of the vehicle com
38、ponents. Emergency transportation shall be by use of a fork truck or alternate method defined and agreed upon between the supplier and by persons designated by AME-PE. Printed copies are uncontrolled. 7 of 8 Standard Number w-ZA65 Issue Date: 20000524 Global Manufacturing Standards Rev: 5.15.2 LUBRI
39、CATION: Approved pressure gun type fittings shall be accessibly located at all points that require external lubrication. Gear housings and lubrication reservoirs shall be equipped with adequate and accessible fill, level and drain plugs and atmospheric bleed fittings. Lubrication points are to be se
40、aled and lubricated for life where possible. A schematic chart showing all lubrication points shall be included in the service manual. 5.15.3 CLEANING: Vehicle shall be designed for hand washing and for low-pressure spray washing. 5.15.4 DIAGNOSTICS: Vehicle systems diagnostic indicators shall indic
41、ate all current stop conditions and shall be visible on the vehicle without requiring hardware, cover plate, or load removal. Microcomputer diagnostics shall be provided. These diagnostic capabilities shall be provided to assist plant personnel in troubleshooting malfunctions. 5.16 DOCUMENTATION: Do
42、cumentation shall be in accordance with ANSI B56.5 and with the following: 5.16.1 GENERAL: Parts manuals and service manuals shall be supplied with the delivery of each system. The quantities of manuals and language (English and/or foreign) are to be specified by persons designated by AME-PE. Note:
43、In Europe, the metric system is the basis for all design, drawings, construction, etc. Also, in Europe, manuals must be prepared with the support of the EPLAN system. 5.16.2 PARTS MANUALS: Parts manuals shall list all components including dedicated part numbers. Parts that are not manufactured by th
44、e supplier shall indicate the manufacturers name, manufacturers part number and the suppliers part number. Parts manuals shall include detailed mechanical drawings of assemblies and sub-assemblies with item numbers to identify parts. 5.16.3 SERVICE MANUALS: Service manuals shall include the followin
45、g: Complete wiring diagrams including: component lists, floor controllers, panels, battery charging system, floor wiring and communication wiring Block diagrams of vehicle and control systems Troubleshooting flow chart, procedure detailed to board/component level, specifying specific electronic test
46、 points Wire net list Detailed mechanical assembly drawings Spare parts list consisting of: part name, part number, and manufacturer. OEM part number and recommended quantities to be stocked by Ford Printed copies are uncontrolled. 8 of 8 Standard Number w-ZA65 Issue Date: 20000524 Global Manufactur
47、ing Standards Rev: 5.17 SPARE PARTS: All parts specified in the spare parts list shall be available from the supplier, or a source guaranteed by the supplier within 24 hours of receipt of order. Parts shall be available for a minimum of 10 years after system acceptance. 6.0 EVALUATION AND APPROVAL:
48、All Automated Guided Vehicle types/models must be approved by AME-PE prior to purchase or lease; and, use within Ford Motor Company. 6.1 EVALUATION: The manufacturer shall submit all requests for approval of a vehicle by field evaluation to AME-PE prior to any sale. A vehicle of the type/model to be
49、 evaluated shall be delivered and installed at a designated Ford location for a minimum ninety (90) day field evaluation at no cost or liability to Ford. At the conclusion of the evaluation, the Ford field evaluation location shall furnish a report of the evaluation results to AME-PE staff for approval. 6.2 APPROVAL: AME-PE will review the results of the field evaluation; and, if appropriate, approve the vehicle type/model for purchase or lease; and, use within Ford Motor Company. A vehicle type/model will continue
