Original instructions iGo neo Supplement to the standard operating instructions for the OPX OPX 20 OPX 25 OPX-L 12 OPX-L 20 OPX-L 20 S 1089 1090 1091 1092 1093 50108046112 - 07/2020 (03)
Preface Address of manufacturer and contact details STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de OEM of the iGo Neo’s Ultrawideband radio frequency sensor system Comnovo GmbH Emil-Figge-Str. 76 44227 Dortmund, Germany Tel.
Preface Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code.
Table of contents 1 Foreword Your iGo neo ................................................................................................................... 2 Intelligent order picking - your iGo neo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Using the iGo neo ........................................................................................................... 5 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of contents Residual dangers, residual risks ..................................................................................... 27 Overview of hazards and countermeasures .................................................................... 28 Danger to employees when "Assistance" mode is used .................................................. 30 Safety tests ...................................................................................................................
Table of contents Safety regulations in "Assistance" mode ............................................................................ 60 Instructions for the safe operation of the iGo neo .............................................................. 60 Priority rules in mixed "Manual/Assistance" traffic ............................................................. 68 Keeping roadways clear of obstacles ...............................................................................
Table of contents DimensionsiGo neo OPX-L 12 ..................................................................................... 113 DimensionsiGo neo OPX-L 20 ..................................................................................... 114 DimensionsiGo neo OPX-L 20 S .................................................................................. 115 VDI datasheetiGo neo OPX 20, 25 ...............................................................................
1 Foreword
1 Foreword Your iGo neo Your iGo neo Intelligent order picking - your iGo neo The iGo neo works with its operator as an autonomous team-mate. It accompanies the operator at every stage of the order-picking process and is always within reach. It intuitively adapts to the working rhythm of its human companion. This autonomous team function is made possible by the motion tracking system developed by STILL. Two high-performance sensors with a 360° circumferential view monitor the entire surrounding area.
1 Foreword Your iGo neo and people in the vicinity are completely protected. The iGo neo autonomously detects the entire warehouse layout using its laser environment recognition system. As well as racks and obstacles, the system identifies its operator and all other people in the area. The safety laser scanner on the front guarantees driving safety through early identification and intelligent assessment of obstacles.
1 Foreword Your iGo neo 4 50108046112 EN - 07/2020 (03)
1 Foreword Using the iGo neo Using the iGo neo Intended use The iGo neo is based on a manually operated STILL series-production truck that is equipped with additional navigation and safety components. The truck can be used in two different modes of operation: Manual mode and Assistance mode.
1 Foreword Using the iGo neo Improper use The operating company or operator, and not the manufacturer, is liable for any hazards caused by improper use. It is prohibited to use the truck for purposes other than those described in these operating instructions.
1 Foreword Using the iGo neo Alternating operation between different temperature ranges CAUTION Danger from the optical safety systems fogging up when moving between warm areas and cold areas When the truck is in Assistance mode, ensure that the optics covers (inspection windows) on the movement tracking sensors, on the foot protection sensors and on the safety laser scanner do not fog up. If the optics cover of the safety laser scanner fogs up, the truck may respond by initiating an emergency stop.
1 Foreword Using the iGo neo CAUTION Danger from the optical safety systems fogging up when moving between warm areas and cold areas During use, ensure that the optics covers (inspection windows) on the movement tracking sensors, on the foot protection sensors and on the safety laser scanner do not fog up. If the optics cover of the safety laser scanner fogs up, the truck may respond by initiating an emergency stop.
1 Foreword Using the iGo neo manufacturer. Adjustments of this type must be performed only by qualified personnel at the manufacturer who have been trained to complete this work.
1 Foreword Using the iGo neo Required safety distances in the aisle Before using the iGo neo, the operating company must ensure that nobody could be put at risk as a result of operating the truck in Assistance mode. The aisle widths must allow for the required safety distance between the truck and the racks or any obstacles on the roadway. Y2 Y1 The shaded area shows the minimum safety distances (X1, Y1, Z1) that the iGo neo must maintain.
1 Foreword Using the iGo neo Suitable protective measures may include: ● Floor markings ● Warning signs Customer-specific configuration by the authorised service centre The authorised service centre can configure Assistance mode to suit the specific application conditions.
1 Foreword Using the iGo neo Copyright clause for open-source programs STILL uses open source software to operate the iGo neo as licensed by the owners of the respective rights. The used open source software can be made available for general use, however excluding any liability. This exclusion of liability includes implicit warranty of marketability or suitability of the software for a particular use. For more details, please refer to the individual license documents.
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1 Foreword Roadways Roadways Requirements for the ground conditions of roadways The truck is equipped with running wheels and drive wheels made from Vulkollan. The ground conditions of roadways affect the length of the braking distance (e.g. when performing an emergency stop) and therefore also have implications for the safety of persons and equipment.
1 Foreword Roadways DANGER Risk of accident from sloping edges and gradients on or in the roadway In Assistance mode, the truck does not check the roadway for height differences, e.g. on sloping edges, steps, platforms, ramps and gradients. The truck will tip or fall over. – Maintain a safe distance away from height differences on or in the roadway when the truck is in Assistance mode. – Always use Manual mode to drive along difficult roadways. The roadways must meet the requirements as per EN 1525 A.9.
1 Foreword Information about the documentation Information about the documentation Validity of this supplement to the operating instructions This supplement to the operating instructions applies in addition to the existing operating instructions for the series-production truck and both are to be considered as the original operating instructions.
1 Foreword Information about the documentation in these operating instructions cannot be asserted. If you require technical support for the truck, please contact the authorised service centre. Copyright and trademark rights These instructions must not be reproduced, translated or made accessible to third parties —including as excerpts—except with the express written approval of the manufacturer.
1 Foreword Information about the documentation operating instructions also apply to storage area situations in which the truck drives along a contour formed by other load carriers (e.g. pallets in block storage areas).
1 Foreword Environmental considerations Environmental considerations Disposing of components used for "Assistance" mode The instructions for environmentally friendly disposal of truck components that are specified in the operating instructions for the seriesproduction truck also apply to components used for Assistance mode.
2 Safety
2 Safety Definition of terms used for responsible persons Definition of terms used for responsible persons Duties of the operating company The operating company is the natural or legal person or group who uses the truck or on whose authority the truck is used. The operating company must ensure that the truck is only used for its intended purpose and in compliance with the safety regulations in these operating instructions and the operating instructions for the series-production truck.
2 Safety Definition of terms used for responsible persons ● ● ● The operating company must ensure that the set maximum speed of the truck is permissible in the work area and appropriate in terms of occupational safety The operating company must ensure that the work area of the truck is sufficiently lit.
2 Safety Definition of terms used for responsible persons When the truck is switched on, the remote control must be kept in a safe place to prevent unintentional operation. The remote control can be operated unintentionally, e.g. if it is carried in a trouser pocket / jacket pocket, or if objects are placed on top of the remote control. While operating the truck, the remote control must always be kept in the supplied holder.
2 Safety Definition of terms used for responsible persons Specialist A qualified person is defined as a service engineer or a person who fulfils the following requirements: ● A completed vocational qualification that demonstrably proves their professional expertise. This proof should consist of a vocational qualification or a similar document.
2 Safety Basic principles for safe operation Basic principles for safe operation Modifications and retrofitting If the truck needs to be converted or retrofitted for work that is not listed in these operating instructions or in the operating instructions for the series-production truck, approval from the manufacturer must be obtained in advance. Any modifications to the construction can impair the safety of the truck in Assistance mode and cause accidents.
2 Safety Basic principles for safe operation manufacturer who have been trained to complete this work! All modifications must be documented. Warning regarding non-genuine parts Genuine parts, components and accessories, including for Assistance mode, are specially designed for this truck. We specifically draw your attention to the fact that parts, components and accessories supplied by other companies have not been tested and approved by STILL.
2 Safety Basic principles for safe operation The contractually agreed set values for Assistance mode may be changed only by qualified personnel at the manufacturer who have been trained to complete this work. Work on the electrical system (e.g. additional headlights) is only permitted with the manufacturer's written approval. All work carried out on the electrical system must be documented.
2 Safety Residual risk Residual risk Residual dangers, residual risks Despite working carefully and complying with directives and standards, the possibility of other dangers occurring when operating the truck in Assistance mode cannot be entirely excluded. The system components used for Assistance mode comply with current safety requirements. Nevertheless, some residual risk cannot be excluded, even when the truck is used for its intended purpose and all instructions are observed.
2 Safety Residual risk ● ● ● ● ● ● ● ● Risk of accident at bottlenecks (e.g.
2 Safety Residual risk Hazard Load-carrying equipment incorrect; load could slip Unpredictable driving behaviour Roadways blocked or (temporarily) closed Roadways intersect in a mix of Assistance / Manual mode Limitations to the person detection function due to the environment scanner in Assistance mode Obstacles such as ladders and working platforms within the movement area of the truck, e.g.
2 Safety Residual risk Hazard Course of action Obstacles that are crosswise to the roadway or that protrude into the roadway that cannot be detected by the safety systems on the truck. Bottlenecks (e.g. narrowed aisles, obstacles on the roadway) if a small safety distance is parameterised on the opposite side of the roadway to which the truck is aligned.
2 Safety Residual risk The result must be documented (§ 6 ArbSchG). In the case of applications involving similar hazard situations, it is permitted to summarise the results. The overview in the chapter entitled "Overview of hazards and countermeasures" provides advice on complying with this regulation. The overview specifies the primary hazards that, in the event of noncompliance, are the most frequent causes of accidents.
2 Safety Safety tests Safety tests Regular safety inspection of the truck Safety inspection based on time and extraordinary incidents The operating company must ensure that the entire truck is inspected by a qualified person at least once a year or after unusual incidents. As part of this testing of the entire truck, the condition and function of the components used for Assistance mode must also be checked. The testing of these components may be performed only by the authorised service centre.
2 Safety Labelling points Labelling points 2 2 1 1 2 45904391300 1 Warning sign: Lifting of persons with the forks is prohibited 2 Warning sign: Risk of feet being crushed by the pantograph lift (OPX-L 20 S) 50108046112 EN - 07/2020 (03) 33
2 Safety Labelling points 34 50108046112 EN - 07/2020 (03)
3 Components of the iGo neo
3 Components of the iGo neo Overview of components used for "Assistance" mode Overview of components used for "Assistance" mode 1 1 1 9 8 2 7 3 6 4 5 1 2 3 4 5 6 7 36 LED signalling units Movement tracking sensors (left-hand and right-hand side of the truck) Collision avoidance camera (variant) Safety laser scanner Foot protection sensors (variant) Driver platform Additional emergency off switches (left and right-hand side of the truck) 8 9 Keypad (on the left-hand side and right-hand side
3 Components of the iGo neo LED signalling units LED signalling units Information signals and warning signals on the LED signalling units 1 2 3 4 The LED signalling units provide information on: ● The current mode of operation (Assistance / Manual) ● The truck alignment ● The status of the connection between the remote control and the truck ● Emergency stop Signal 1 2 3 4 Truck function signalled Truck in Assistance mode Lighting zone indicates the truck align● The truck aligns itself with the
3 Components of the iGo neo LED signalling units Truck alignment display on the LED signalling units 1 2 3 The truck alignment is the side of the aisle to which the truck is oriented in Assistance mode. The operator can use the remote control to set the RIGHT, LEFT and MIDDLE truck alignment settings. A moving light spot on the LED signalling units indicates the selected truck alignment.
3 Components of the iGo neo Operator detection Operator detection Operator detection system 1 2 1 2 34 For movement tracking of the operator to be able to function, the truck has to identify the operator and track the operator's current position.
3 Components of the iGo neo Operator detection Movement tracking sensors The truck uses the two movement tracking sensors (1) to track the position of the operator. In combination with the position tracking of the remote control, reliable detection of the operator is guaranteed. 1 The sensors capture the area around the truck within a visible radius of max. 15 m. The light from the sensors is not dangerous to the human eye.
3 Components of the iGo neo Operator detection Symbol / meaning 3 Operator not identified. ("Eye" symbol/contour) 4 Operator not identified. ("Pause" symbol/contour) Information The truck follows the operator ● No exact approach to the selected stop position next to the operator.
3 Components of the iGo neo Laser scanner Laser scanner Function of the safety laser scanner The safety laser scanner detects the rack contour and the surrounding environment. Using the spatial data, the truck can automatically follow the operator along the rack contour. The safety laser scanner (1) checks the roadway for obstacles while the truck is in motion.
3 Components of the iGo neo Laser scanner ● ● In the drive direction, the size of the monitored range depends on the current speed.
3 Components of the iGo neo Laser scanner the truck. The scanning height is approx. 9 cm. The safety laser scanner detects stationary objects on the ground that have the following minimum dimensions ( on the illustration): ● Diameter: at least 70 mm in scanning height (on the side facing the safety laser scanner) ● Height: at least 200 mm If the safety laser scanner does not detect an obstacle because these required dimensions do not apply, the truck could ram the obstacle.
3 Components of the iGo neo Foot protection sensors Foot protection sensors Function of the foot protection sensors (OPX-L 20 S) The foot protection sensors (1) are only installed on truck variants with a pantograph lift. They are located on both sides next to the lower fixing point of the pantograph lift on the truck. In Assistance mode, the operator can lower the forks with the remote control. When the fork carriage is raised, the foot protection sensors check the area under the forks.
3 Components of the iGo neo Keypad on the side of the truck Keypad on the side of the truck Functions of the keypad on the side of the truck 1 NOTE 4 3 The functions performed using the keypad on the side of the truck can also be carried out via the appropriate buttons or the remote control.
3 Components of the iGo neo iGo neo buttons iGo neo buttons Functions of the iGo neo buttons 1 1234 2 1 iGo neo button (left and right side of the truck) 2 iGo neo button (remote control) Using the iGo neo buttons, the operator can switch between the ACTIVE and PAUSED states for Assistance mode. When an iGo neo button is pressed, the operator is identified. iGo neo buttons 1 , 2 Push 1 x briefly 1 x long press (min. ½ sec.
3 Components of the iGo neo Emergency off switch Emergency off switch Additional emergency off switches The truck is equipped with additional emergency off switches (1) (left and right-hand side of the truck). – In the event of imminent danger to people, the load or the truck, press one of the emergency off switches immediately. This is the fastest way to bring the truck to a standstill.
3 Components of the iGo neo Remote control Remote control Functions of the remote control Switching the remote control on and off – To switch the remote control on, push the iGo neo button (1). – To switch off the remote control, simultaneously press the "lift" and "lower" buttons for several seconds. 3 4 2 The remote control switches off automatically: ● When the truck is switched off and the set run-on time of the robotics system has expired (can be set by the authorised service centre).
3 Components of the iGo neo Remote control Operating the buttons on the remote control Button 1 - Assistance mode ACTIVE / PAUSED (iGo neo button) Operation Assistance mode When the truck is stationary: PAUSED Push 1 x briefly When the truck is in motion: ACTIVE When the truck is stationary: 1 x long press (min. ½ sec.
3 Components of the iGo neo Remote control Charging the remote control NOTE A new remote control must be fully charged after it is delivered to ensure that its battery charge is correctly displayed. Checking the battery charge of the remote control If the remote control is not connected to the truck, the display LEDs on the remote control indicate the battery charge level.
3 Components of the iGo neo Remote control Charging the remote control The remote control is inductively charged with the charger supplied. – Connect the charger. R – Place the remote control on the designated surface of the charger with the keypad facing down. The display LEDs on the remote control (1) and on the charger (2) indicate the progress of the charging process.
3 Components of the iGo neo Remote control Each receiving unit can save a maximum of 20 pairing codes. If there are already 20 pairing codes present and more codes need to be saved, all existing pairing codes must first be deleted. Individual pairing codes cannot be deleted from the memory of the receiving unit. If multiple remote controls that are registered to a truck attempt to access the truck simultaneously, the remote control that first made contact with the truck retains control.
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4 Operating the iGo neo
4 Operating the iGo neo Checks and tasks to be carried out when commencing "Assistance" mode Checks and tasks to be carried out when commencing "Assistance" mode Safety information for carrying out the tests WARNING Damage or other defects to the components used for Assistance mode can result in accidents. If damage or other defects are identified on the components during the following inspections, the truck must not be used until it has been properly repaired.
4 Operating the iGo neo Checks and tasks to be carried out when commencing "Assistance" mode – Report defects to the supervisory personnel. Do not use the truck until it has been properly repaired Checks after switching on "Assistance" mode Safety brake test after switching on "Assistance" mode After switching on Assistance mode, the operator must perform a check to ascertain whether the truck automatically stops in front of an obstacle.
4 Operating the iGo neo Checks and tasks to be carried out when commencing "Assistance" mode After releasing the emergency off switches and restarting the system, the movement tracking sensors must show "Assistance mode PAUSED". Function checking of the foot protection sensors after switching on "Assistance" mode (OPX-L 20 S) After switching on Assistance mode, the operator must check that the two side foot protection sensors are working.
4 Operating the iGo neo Checks and tasks to be carried out when commencing "Assistance" mode Visual inspections when Assistance mode is active Check that the set minimum distances to the rack and to obstacles in the roadway are ob● served Only after a change to the crosswise roadway settings by the authorised service centre: ● Make sure that the truck detects the crosswise roadways and stops automatically (1) Information signals and warning signals are part of the safety concept.
4 Operating the iGo neo Safety regulations in "Assistance" mode Safety regulations in "Assistance" mode Instructions for the safe operation of the iGo neo Wear safety shoes In the interest of safety, the operator and people in close proximity to the truck must wear work safety shoes in the correct size while the truck is being operated.
4 Operating the iGo neo Safety regulations in "Assistance" mode Observe the limitations of the foot protection sensors in the event of impermissible or poor application conditions (OPX-L 20 S) 1 DANGER Risk of feet being crushed in the event of impermissible or poor application conditions In the event of impermissible or poor application conditions, the foot protection sensors may not reliably detect objects in certain situations.
4 Operating the iGo neo Safety regulations in "Assistance" mode Observe the risk of accident from crossing the roadway immediately in front of the truck 1 DANGER Danger for people or objects that quickly cross the roadway immediately in front of the truck. The safety laser scanner detects obstacles in the roadway in front of the truck.
4 Operating the iGo neo Safety regulations in "Assistance" mode Maintain a safe distance from sloping edges and gradients DANGER Risk of accident from sloping edges and gradients on or in the roadway In Assistance mode, the truck does not check the roadway for height differences, e.g. on sloping edges, steps, platforms, ramps and gradients. The truck will tip or fall over. – Maintain a safe distance away from height differences on or in the roadway when the truck is in Assistance mode.
4 Operating the iGo neo Safety regulations in "Assistance" mode Load individual pallets onto trucks with long forks from the side WARNING Risk of injury in the unladen area of the fork In the unladen area of the fork, the operator is able to get closer to the fork: In the area behind the pallet (1) there is a risk of feet being crushed when the forks are lowered. In the area in front of the pallet (2) there is a risk of collision with the pallet when the truck drives off.
4 Operating the iGo neo Safety regulations in "Assistance" mode Observe information and warning signals in "Assistance" mode DANGER Risk of accident due to failure to observe warning signals When operating in Assistance mode, the truck emits audible and optical information signals and warning signals. The LED signalling unit provides information about Assistance mode. The warning buzzer emits an acoustic signal when the truck starts to move.
4 Operating the iGo neo Safety regulations in "Assistance" mode Lifting of persons with the forks (not permitted) DANGER Risk of injury when lifting persons with the forks – Do not use the forks to lift people. – Never use the truck's remote control or side keypad to lift the operator or other persons with the forks.
4 Operating the iGo neo Safety regulations in "Assistance" mode DANGER Risk of accident if the remote control is actuated by anyone other than the operator If anyone else actuates the remote control, the truck may move unexpectedly and injure people. – Never give the remote control to anyone else while you are working. The remote control may only be operated by the operator. – Never leave the remote control unattended while you are working.
4 Operating the iGo neo Safety regulations in "Assistance" mode Priority rules in mixed "Manual/ Assistance" traffic DANGER Risk of collision in areas with mixed Manual/ Assistance traffic A truck in Assistance mode may not detect a second truck or may detect it too late, for example if the forks of the second truck are above or below the 9 cm scanning height of the safety laser scanner. A truck in Assistance mode may start moving or stop moving unexpectedly.
4 Operating the iGo neo Safety regulations in "Assistance" mode Keeping roadways clear of obstacles DANGER Risk of accident in the event of additional work being performed in the roadway that could impede Assistance mode, e.g. in the form of people on ladders and workshop hoists. – If additional work is being performed in the working area, close off the roadways using cones at a maximum distance of 1.0 m.
4 Operating the iGo neo Safety regulations in "Assistance" mode Pay particular attention to objects in the roadway that extend more than approx. 9 cm in height above the ground, e.g. long objects that protrude out of the rack. The safety laser scanner detects only the area close to the ground. On trucks with a collision avoidance camera (variant), this area is recorded and monitored as well.
4 Operating the iGo neo Operating the truck in "Assistance" mode Operating the truck in "Assistance" mode Overview of "Assistance" mode CAUTION Risk of accident as a result of differences between the Manual and Assistance modes of operation. In Manual mode, the safety devices that are available in Assistance mode do not assist the driver. The truck does not brake automatically or steer automatically. – Pay full attention when operating the truck, taking safety into account at all times.
4 Operating the iGo neo Operating the truck in "Assistance" mode In Assistance mode, the truck moves only in the drive direction, not in the load direction. During this process, the truck maintains a safety distance (1) to the rack in which the operator can move safely. This safety distance is always set to at least 50 cm. Further safety distances (e.g. from obstacles in the roadway) are set by the authorised service centre.
4 Operating the iGo neo Operating the truck in "Assistance" mode Switching the truck on and off Switching on the truck – Switch on the truck following the instructions given in the original operating instructions for the series-production truck. 30 sec. = ON The components for Assistance mode are initialised. The components are ready to operate after approximately 30 seconds. NOTE After the LED signalling units flash (after approx. 20 seconds), the truck is ready to be operated in Manual mode.
4 Operating the iGo neo Operating the truck in "Assistance" mode Switching on "Assistance" mode Before Assistance mode is available, the remote control must be connected and Assistance mode must be switched on. Connecting the remote control to the truck When commencing Assistance mode, the operator must connect the remote control to the truck once. 1 – To connect the remote control, enter the driver's platform and press the iGo neo button (1) on the remote control.
4 Operating the iGo neo Operating the truck in "Assistance" mode Switching on "Assistance" mode – If necessary, the desired truck alignment can be adjusted using the remote control (see the following chapter "Adjusting the truck alignment"). 1x – Press the iGo neo button on the remote control or on the truck. Assistance mode is ACTIVE immediately. The truck follows the operator along the rack contour.
4 Operating the iGo neo Operating the truck in "Assistance" mode Adjusting the truck alignment Before order picking starts, the operator specifies whether the truck must align to the right (1), in the middle of the aisle (2) or to the left of the aisle (3). In Assistance mode, the truck then automatically follows the selected rack contour. – Adjust the truck alignment using the remote control: A 1 Button (A) ● Push x 1 briefly: Switch the truck alignment in sequence (LEFT ► MIDDLE ► RIGHT ► LEFT ...
4 Operating the iGo neo Operating the truck in "Assistance" mode Positioning the truck in the aisle It must be possible for the truck to detect a straight rack contour. The rack contour (distance between the rack uprights) must not have any gaps larger than 2.7 m (can be parameterised). Larger gaps are detected as a crosswise roadway. It must be possible for the truck to detect the rack contour (1) over a distance of 2 to 3 m in front of the truck. The truck must be positioned parallel to the rack.
4 Operating the iGo neo Operating the truck in "Assistance" mode Correctly positioning the truck in line with the rack when the truck is aligned sideways CAUTION Risk of collision if the truck is positioned at too sharp an angle in relation to the rack contour If the truck is positioned at too sharp an angle in relation to the rack contour, the system may not correctly detect the rack under certain circumstances and will therefore collide with the rack.
4 Operating the iGo neo Operating the truck in "Assistance" mode Switching between ACTIVE and PAUSED states for "Assistance" mode 1x 1 Using the iGo neo button on the remote control or on the truck, the operator can switch between the ACTIVE and PAUSED states for Assistance mode. – Before entering the truck, always switch Assistance mode to PAUSED. Allow the truck to come to a standstill. The LED displays of the movement tracking sensors must display the symbol ( ).
4 Operating the iGo neo Operating the truck in "Assistance" mode Identifying the operator For the movement tracking to work, the truck must identify the operator. This is necessary when you start Assistance mode or if the truck has lost the position of the operator.
4 Operating the iGo neo Operating the truck in "Assistance" mode Stopping automatically at the end of the racking or in a crosswise roadway CAUTION Risk of collision at the end of the racking or when entering the crosswise roadway If an object, e.g. another truck, is stationary in an unfavourable position at the end of a rack or in a crosswise roadway, the truck may not detect the end of the rack under certain circumstances.
4 Operating the iGo neo Operating the truck in "Assistance" mode Stopping before a crosswise roadway The truck can cross a crosswise roadway in Assistance mode. The operator must first press the iGo neo button on the remote control or on the truck to enable the truck to proceed across the crosswise roadway. 2 The truck detects that the rack contour continues after the crosswise roadway. The truck stops automatically before the crosswise roadway.
4 Operating the iGo neo Operating the truck in "Assistance" mode Behaviour of the truck in response to obstacles in the roadway A B STOP DRIVE DRIVE DANGER Danger due to collisions with obstacles that the safety laser scanner cannot detect. Observe the notes about the limits to detecting obstacles given in the chapter entitled "Function of the safety laser scanner". – Make sure that the roadway is checked for obstacles that the safety laser scanner cannot detect. Remove these obstacles.
4 Operating the iGo neo Operating the truck in "Assistance" mode NOTE The authorised service centre can configure the minimum obstacle size that will cause the truck to come to a stop in front of an obstacle. Minimum distance to obstacles The authorised service centre can configure a minimum distance (1) at which the truck may pass an obstacle when in Assistance mode. – Observe the notes in the chapter entitled "Required safety distances in the aisle". 84 50108046112 EN - 07/2020 (03) 1 min.
4 Operating the iGo neo Operating the truck in "Assistance" mode Truck behaviour in the event of an emergency stop If an emergency off switch is pushed or the safety laser scanner detects a sudden hazard, the truck reacts with an emergency stop. ● ● ● The electromagnetic truck brake is applied. The truck stops at the maximum deceleration rate The LED signalling unit shows the "Emergency stop" signal. The lighting zones flash in rapid alternation (approx.
4 Operating the iGo neo Operating the truck in "Assistance" mode truck has been stationary for at least 10 seconds – Pay attention to the "Assistance mode ACTIVE" LED signal of the movement tracking sensors and to the warning sound. Emergency stop via an emergency off switch By pushing an emergency off switch, the operator brings the truck to an immediate standstill in the event of a dangerous situation.
4 Operating the iGo neo Operating the truck in "Assistance" mode Setting off after an emergency stop via the emergency brake push button in the cockpit: ● If Assistance mode is ACTIVE, the truck emits two brief warning sounds prior to setting off. The warning sound is output only if the truck has been stationary for at least 10 seconds – Pay attention to the "Assistance mode ACTIVE" LED signal of the movement tracking sensors.
4 Operating the iGo neo Operating the truck in "Assistance" mode the load side. If position "4" is reached, the selection begins again at position "1". Moving the stop position using the keypad on the side of the truck – Push button (1). The selected stop position moves along one position in the direction of the drive side. When the end position "1" is reached, the truck emits two short beeps. 1 – Push button (2). The selected truck position moves along one position in the directions of the load side.
4 Operating the iGo neo Operating the truck in "Assistance" mode Driving automatically without movement tracking The operator can allow the truck to drive a short distance along the rack contour independently of the movement tracking. > 2 Sec. – The LED displays of the movement tracking sensors must display "Assistance mode PAUSED" (1). – Press and hold the iGo neo button on the remote control for at least two seconds.
4 Operating the iGo neo Operating the truck in "Assistance" mode Lifting and lowering the fork carriage In Assistance mode, the operator controls the lifting functions via the remote control or by using the keypad on the side of the truck. 1 Lifting or lowering starts with a short delay, accompanied by a signal tone. An increase in the frequency of the signal tone warns the operator to keep his feet away from the area under the forks. 2 123 The OPX-L 20 S can approach six fixed lift heights.
4 Operating the iGo neo Operating the truck in "Assistance" mode Cancelling the lifting operation or lowering procedure – Press the button for lifting or lowering again or press it and hold it. The lifting operation or lowering procedure stops immediately.
4 Operating the iGo neo Operating the truck in "Assistance" mode "Z picking" mode "Z picking" mode assists the operator in allowing frequent changes between the right and left side of the racking. 2 If the operator pushes the right-hand or lefthand iGo neo button on the truck, the alignment of the truck changes to the corresponding side. The truck now aligns itself with the rack contour on the selected side. X The distance (X) from the rack contour cannot be changed.
4 Operating the iGo neo Operating the truck in "Assistance" mode Setting the drive programme when operating in "Assistance" mode In Assistance mode, the operator can select between two drive programmes (standard / tortoise). By selecting the drive programme, the operator can adjust the driving characteristics of the truck (driving dynamics, steering dynamics, braking dynamics) to suit the application situation. All safety-related features of the truck remain unchanged.
4 Operating the iGo neo Operating the truck in "Assistance" mode Warning sounds in "Assistance" mode The truck produces different warning sounds to alert the driver and bystanders that the truck is being operated in Assistance mode. Audible signals Type of signal Information Truck begins moving automatically (with Assistance mode ACTIVE). The warning 1 short warning sound "Setting off" warning sound sound is output only if the truck has been stationary for at least 10 seconds.
5 Storage
5 Storage Storing and shutting down the iGo neo Storing and shutting down the iGo neo Driverless transport vehicles cannot be stored in an operational state. They must therefore be taken out of operation. – To shut down the truck, contact the authorised service centre.
6 Cleaning
6 Cleaning Cleaning the components used for "Assistance" mode Cleaning the components used for "Assistance" mode CAUTION If water penetrates the electrical system, there is a risk of a short circuit occurring! – Never clean the components used for Assistance mode using devices such as high-pressure cleaners or rotating brushes. – While cleaning the rest of the truck, avoid cleaning the components used for Assistance mode and only clean these components in accordance with the instructions specified below.
6 Cleaning Cleaning the components used for "Assistance" mode Cleaning the optics covers (movement tracking sensors, safety laser scanner, foot protection sensors) 1 CAUTION Abrasive cleaning materials can damage the surfaces of components! Using abrasive cleaning materials that are unsuitable for plastics can cause plastic parts to dissolve or become brittle. The covers of optical sensors can become cloudy. 3 2 – Do not use aggressive cleaning materials. – Do not use any abrasive cleaning materials.
6 Cleaning Cleaning the components used for "Assistance" mode Additional cleaning when alternating between different temperature ranges CAUTION Danger from the optical safety systems fogging up when moving between warm areas and cold areas During use, ensure that the optics covers (inspection windows) on the movement tracking sensors, on the safety laser scanner and on the foot protection sensors do not fog up.
7 Transport
7 Transport Transporting the truck Transporting the truck The instructions in the operating instructions for the series-production truck apply for transporting the truck. In addition, the following provisions listed in this chapter also apply. CAUTION Risk of accident when using Assistance mode for loading purposes When operating in Assistance mode, the truck can respond with involuntary steering and driving movements when used in an unsuitable environment.
7 Transport Transporting the truck CAUTION Abrasive lashing straps can rub against the surface of the truck and cause damage. – Position slip-resistant pads underneath the lifting points (such as rubber mats or foam). Safety regulations for driving on loading bridges and ramps DANGER Risk of accident from the truck falling off the loading bridge 1 Steering movements can cause the truck to fall from the loading bridge.
7 Transport Transporting the truck CAUTION Danger due to excessive transport weight on the loading bridge The load capacity of the means of transport, the ramps and the loading bridges must be greater than the actual total weight of the truck. Components can be permanently deformed or damaged due to overloading. – Determine the actual total weight from the nameplate on the truck.
8 Maintenance
8 Maintenance Maintaining the iGo neo Maintaining the iGo neo This section contains all of the information required for maintaining the iGo neo. Maintenance must be performed in accordance with the points in the maintenance checklist. This is the only way guarantee that the truck remains ready for operation; it is also a pre-condition for any warranty claims.
8 Maintenance Maintenance - 500 hours/every 6 months permitted for other persons to perform work on the components used for Assistance mode. This instruction does not apply to cleaning procedures on components that are not located inside the truck; refer to the chapter entitled "Cleaning".
8 Maintenance Maintenance - 1000 hours / yearly At operating hours 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Carried out ✓ 5500 Check the clearance of the electromagnetic brake (in accordance with the maintenance instructions for the series-production truck) General Read out and check the error numbers and clear the list Reset the maintenance interval Maintenance - 1000 hours / yearly At operating hours 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 ✓ 11000 Note Perfo
8 Maintenance Maintenance - 1000 hours / yearly At operating hours 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 Carried out ✓ 11000 converter, Digisound beeper, odometry signal transmitter, incremental transducer for revolution speed) Check the mechanical attachment of all components. Check that the screw contacts of the additional emergency off switches are securely fitted. Check that all screw contacts on the robotics computer are securely attached.
8 Maintenance Maintenance - 1000 hours / yearly 110 50108046112 EN - 07/2020 (03)
9 Technical data
9 Technical data DimensionsiGo neo OPX 20, 25 Dimensions iGo neo OPX 20, 25 112 50108046112 EN - 07/2020 (03)
9 Technical data DimensionsiGo neo OPX-L 12 Dimensions iGo neo OPX-L 12 50108046112 EN - 07/2020 (03) 113
9 Technical data DimensionsiGo neo OPX-L 20 Dimensions iGo neo OPX-L 20 114 50108046112 EN - 07/2020 (03)
9 Technical data DimensionsiGo neo OPX-L 20 S Dimensions iGo neo OPX-L 20 S 50108046112 EN - 07/2020 (03) 115
9 Technical data VDI datasheetiGo neo OPX 20, 25 VDI datasheet iGo neo OPX 20, 25 NOTE This VDI datasheet specifies only the technical values for industrial trucks with standard equipment. Different tyres, lifting systems, additional units etc. can produce different values. Key data Model 1.1 Manufacturer 1.2 Type designation of the manufacturer 1.3 Drive 1.4 Operation 1.5 Load capacity/load 1.6 Load centre of gravity distance 1.8 Load distance 1.
9 Technical data VDI datasheetiGo neo OPX 20, 25 Model 3.6 Track width, drive side 3.7 Track width, load side b10 (mm) b11 (mm) OPX 20 iGo neo OPX 25 iGo neo 474 474 348 (368 / 388 / 498) 348 (368 / 388 / 498) Basic dimensions Model OPX 20 iGo neo OPX 25 iGo neo - - 4.2 Height (lift mast retracted) h1 (mm) 4.3 Free lift h2 (mm) - - 4.4 Lift h3 (mm) 130 130 4.5 Height (lift mast extended) h4 (mm) - - 4.6 Initial lift h5 (mm) - - 4.
9 Technical data VDI datasheetiGo neo OPX 20, 25 Model Aisle width for pallet 800 x l6 lengthwise, 4.34 raised Aisle width for pallet 1000 x 1200 cross4.34.1 wise, raised Aisle width for pallet 800 x 1200 cross4.34.2 wise, raised 4.
9 Technical data VDI datasheetiGo neo OPX 20, 25 Other Model 8.1 Type of traction controller 10.
9 Technical data VDI datasheetiGo neo OPX 20, 25 Forks with tie rods l (mm) c (mm) x (a) (mm) y (a) (b) (mm) Ast (b) (c) Load at aisle width Ast (mm) 2390 (d) 1200 1845 2947 4305 2390 (e) 1200 1615 2717 4150 2390 1200 1845 2947 4171 2390 1200 1615 2717 4145 2900 1500 2125 3227 4738 3100 1600 2125 3227 5003 3 pallets 800 x 1200 crosswise * 2 pallets 800 x 1200 lengthwise 2 pallets 800 x 1200 lengthwise 2 pallets 800 x 1200 lengthwise Pallet 800 x l6 lengthwise (l6 = 2 x
9 Technical data VDI datasheetiGo neo OPX 20, 25 l (mm) c (mm) x (mm) Tray 53 3100 1600 2125 7.0% Tray 54 or lithium-ion battery with foot protection 5.
9 Technical data VDI datasheetiGo neo OPX-L 12, 20, 20 S VDI datasheet iGo neo OPX-L 12, 20, 20 S NOTE This VDI datasheet specifies only the technical values for industrial trucks with standard equipment. Different tyres, lifting systems, additional units etc. can produce different values.
9 Technical data VDI datasheetiGo neo OPX-L 12, 20, 20 S Model 3.3 3.4 3.5 Tyre size, load side Auxiliary wheels Number of wheels, drive side / load side (x = driven) 3.6 Track width, drive side 3.
9 Technical data VDI datasheetiGo neo OPX-L 12, 20, 20 S Model OPX-L 20 iGo neo OPX-L 20 S iGo neo OPX-L 12 iGo neo 4.24 Fork carriage width b3 (mm) 711 792 (5) 796 (5) 4.25 Width over forks b5 (mm) 570 540 (520) 560 m1 (mm) 13 / 100 (3) 18 (7) - m2 25 / 155 (3) 10 / 710 (3) 30 Ast (mm) Ast (mm) Ast (mm) Wa (mm) See lift mast table 4216 (4) 3045 (4) - - - - - - 3583 / 3455 (3) (4) 3019 / 2855 (3) (4) 2181 (4) 4.31 4.32 4.34 4.34. 1 4.34.
9 Technical data VDI datasheetiGo neo OPX-L 12, 20, 20 S Traction motor OPX-L 20 iGo neo Model 6.1 6.2 6.3 6.4 6.5 6.6 OPX-L 20 S iGo neo OPX-L 12 iGo neo Traction motor, power rating kW 3 3 3 S2=60 min Lift motor, power at S3 kW 2.2 / 5% 2.2 / 5% 2.2 / 5% Battery in accordance with DIN No No No 43531/35/36 A, B, C, no Battery voltage / nominal capacity V / 24 / 345 - 465 24 / 345 - 465 24 / 345 - 465 K5 Ah Battery weight (± 5%) kg 402 402 402 Energy consumption in accord- kWh/ 0.55 / 0.52 (11) 0.
9 Technical data VDI datasheetiGo neo OPX-L 12, 20, 20 S OPX-L 20 iGo neo lift masts Lift mast (type) Lift mast height, lowered Lift mast height, free lift Free lift (a) Telescopic 1276 1351 150 1580 (b) h1 h1 h2 h3 h4 Lift height Lift mast height, extended 2066 2200 2200 2200 3114 Truck height, lift mast low- Standard ered With pallet holder (b) Truck height, lift mast extended (a) With (b) With Standard With pallet holder (b) increased lift mast height h1 the specified load backrest on the access
Index OTHER CHARACTERS F "Assistance" mode of operation Overview. ............................................ 71 Foot protection sensors Cleaning .............................................. 99 function ................................................ 45 A Address of manufacturer. ............................ I Adjusting the truck alignment. ................... 76 Audible signals. ........................................ 94 H B Identifying the operator. . . . . . . . . . . . . . .
Index Operating instructions Storing. . . . . . . . . . . . . . . . . . . . . . . . . 15 Validity. . . . . . . . . . . . . . . . . . . . . . . . . 15 Operating "Assistance" mode Adjusting the truck alignment. . . . . . . . 76 Connecting the remote control. . . . . . . 74 Driving automatically without movement tracking ............................................. 89 Emergency stop. .................................. 85 Identifying the operator. .......................
Index Risk of accident from crossing the roadway immediately in front of the truck. 62 Risk of crushing feet. ........................... 60 Safe storage of the remote control ....... 66 Switch "Assistance" mode to PAUSED before entering the truck.................... 61 Transport of people and jumping onto the truck (not permitted). ................... 65 Wear safety shoes. .............................. 60 Setting the drive programme. .................... 93 Specifying the distance to the rack contour.
STILL GmbH 50108046112 EN - 07/2020 (03)
