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113.3.3AGV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 diagnosis264.14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324.20.1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 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