AGV故障诊断手册
1. AGV故障诊断概述 ................................................................................................................. 4
1.1 编写本手册的目的The purpose of the manual ........................................................... 4 1.2 AGV故障诊断手段 ..................................................................................................... 4 1.3 常见故障的分类 ........................................................................................................... 5 2. AGV控制系统回顾 ................................................................................................................. 7
2.1 AGV控制系统结构回顾 ............................................................................................. 7 2.2 AGV控制系统的自动保护功能 ................................................................................. 8 2.3 在动态合装段中停车的处理 ....................................................................................... 8
2.3.1合装段的操作者暂停停车 ...................................................................................... 8 2.3.2合装段的E-stop停车 ............................................................................................. 9 2.3.3合装段的故障停车 .................................................................................................. 9 2.3.4合装段的合装超时停车 .......................................................................................... 9
3. AGV启动故障 ....................................................................................................................... 10
3.1 AGV启动过程 ........................................................................................................... 10 3.2 启动引导代理程序介绍 ............................................................................................. 10 3.3 AGV主控制软件Carryboy的启动过程 .................................................................. 11
3.3.1 参数文件装入错误 ......................................................................................... 11 3.3.2 CAN设备初始化失败 ................................................................................... 12 3.3.3 AGV车体伺服轴初始化失败 ....................................................................... 12 3.3.4 舵角校正失败 ................................................................................................. 13
4. AGV一般设备故障的诊断 ....................................................................................................... 14
4.1 车体供电系统故障诊断 ............................................................................................. 14 4.2 车体主控制器VCU100故障诊断 ............................................................................ 16 4.3 基本数字I/O故障的诊断 ......................................................................................... 17 4.4 CAN通讯系统故障诊断 ........................................................................................... 19 4.5 手控盒设备故障诊断 ................................................................................................. 20 4.6 液晶显示器故障诊断 ................................................................................................. 21 4.7 保险杠及非接触防碰设备故障诊断 ......................................................................... 22 4.8 磁导航传感器及其接口模块的故障诊断 ................................................................. 22 4.9 磁地标传感器的故障诊断 ......................................................................................... 23 4.10 车轮电机抱闸的故障诊断 ..................................................................................... 24 4.11 车轮电机增量式编码器故障诊断 ............................................................................. 25 4.12 车轮\\转舵机构电机伺服放大器故障诊断 ............................................................ 26 4.13 车轮电机的故障诊断 Wheel motor fault diagnosis .............................................. 27 4.14 驱动轮测速机的故障诊断 Drive wheel tachometer fault diagnosis ................. 27 4.15 AGV车轮舵角异常的诊断 ....................................................................................... 28 4.16 无线接入点（Wireless Access Point）的故障诊断 .............................................. 28 4.17 车载无线通讯设备的故障诊断 On-board wireless communication fault diagnosis 30 4.18 同步跟踪传感器的故障诊断 ................................................................................. 32 4.19 提升机的故障诊断 ................................................................................................. 32
4.19.1 提升机编码器的故障诊断 ............................................................................. 32 4.19.2 提升机电机驱动器的故障诊断 ..................................................................... 32
4.19.3提升机限位开关的故障诊断 .............................................................................. 33 4.20 地面辅助导航设备的故障诊断 ............................................................................. 33
4.20.1 导航带失效 ..................................................................................................... 33 4.20.2 地标带失效 ..................................................................................................... 34 4.20.3 RF-ID失效 Invalidation ..................................................................................... 34
5. AGV运行典型故障诊断流程 ................................................................................................... 36
5.1自动运行中导航失败 ....................................................................................................... 36 5.2自动运行中地标校正失败 Landmark proofread failure during automatic running ....... 37 5.3自动运行无法登录到控制台 ........................................................................................... 38 5.4自动运行中无线通讯中断 Wireless Communication loss during automatic running .... 38 5.5失去ALLOK信号 ........................................................................................................... 39
5.5.1失速保护机制原理 ................................................................................................ 39 5.5.2超差保护机制原理 ................................................................................................ 39 5.6车轮驱动故障 ................................................................................................................... 39 5.7电池电量过低 Battery Power Low.................................................................................. 40 6. AGV动态合装故障的诊断 ....................................................................................................... 41
6.1动态目标捕捉失败 Dynamic target catch failure ........................................................... 41 6.2在没有同步目标的情况下误报开始同步 ....................................................................... 41 6.3动态跟踪目标丢失 ........................................................................................................... 42 6.4动态合装中提升机故障 ................................................................................................... 42
1. 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 manual 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 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 accidents 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 has 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 process 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 to 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, 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 AGV errors: ? AGV控制系统部件如电机、传感器等失效或损坏 ? AGV (such as motors, sensors) Components failure
? AGV电缆或接头等由于接触不良、线路磨损等造成的故障
? In-proper connection in connectors and cable error caused by wearing ? 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