California AHMCT Research Center University of California at Davis California Department of Transportation DEPLOYMENT SUPPORT OF AHMCT MACHINES 1999-2002 Aaron E. Raley Steven A.
Copyright 2011, AHMCT Research Center, UC Davis
Technical Documentation Page 1. Report No. 2. Government Accession No. 4. Title and Subtitle Deployment Support For AHMCT Research Center Prototype Machines 3. Recipient’s Catalog No. 5. Report Date July 24, 2002 6. Performing Organization Code 7. Author(s): 8. Performing Organization Report No. Aaron E. Raley, Steven A. Velinsky UCD-ARR-00-02-06-30-05 9. Performing Organization Name and Address 10. Work Unit No.
Deployment Support Copyright 2011, AHMCT Research Center, UC Davis iv
Deployment Support Abstract The purpose of work was to provide support to machines developed by the AHMCT Center and deployed into the Caltrans work place. The scope of deployment support work included working with Caltrans maintenance and equipment operators for field testing of the various equipment developed at AHMCT and serving as a liaison to AHMCT engineering staff thus expediting the development and commercialization process.
Deployment Support Copyright 2011, AHMCT Research Center, UC Davis vi
Deployment Support Executive Summary The AHMCT Research Center has been developing and field testing demonstrable prototypes for many years including machines to paint aerial survey marks, apply herbicide selectively to actively growing vegetation, remove litter and debris from the roadside, etc. The AHMCT Research Center has been involved with Caltrans staff in initial prototype testing.
Deployment Support Copyright 2011, AHMCT Research Center, UC Davis viii
Deployment Support Table of Contents Abstract .................................................................................................................. v Executive Summary ............................................................................................ vii Table of Contents ................................................................................................. ix Disclaimer / Disclosure ........................................................................................
Deployment Support Copyright 2011, AHMCT Research Center, UC Davis x
Deployment Support Disclaimer / Disclosure The research reported herein was performed as part of the Advanced Highway Maintenance and Construction Technology (AHMCT) Program, within the Department of Mechanical and Aeronautical Engineering at the University of California, Davis and the New Technology and Research Program of the California Department of Transportation. It is evolutionary and voluntary. It is a cooperative venture of local, state and federal governments and universities.
Deployment Support Copyright 2011, AHMCT Research Center, UC Davis xii
Chapter1 Introduction The Deployment Support Task Order has allowed for a wide range of support to numerous AHMCT projects from July 01, 1999 to June 30, 2002. The primary goal has been to provide field support for all AHMCT projects undergoing field-testing and evaluation. In addition to training operators in safe machine operation, field support has included reverse engineering and design modification work.
Copyright 2011, AHMCT Research Center, UC Davis 2
Chapter 2 Supported Projects 2.1 Introduction The support of machines is extensive during the field deployment phase of the project. However, additional support is provided during the development phase. Information gathered during the field testing is often important during development of other projects. Current highway maintenance equipment, practices, and operator interface issues are a few items of great value. 2.
actual roadway for the purpose of retrieving debris. The following plan of action was devised.
develop the anti-collision radar system. When traveling around corners, trees can appear as a possible collision; however, these are merely false warnings. Hence a false warning suppression algorithm was developed and tested, in these areas, to eliminate false warnings being indicated to operators. 2.
Therefore, a battery charging isolation system was added including two additional heavy density batteries. The additional batteries allowed more energy to be stored, while driving to and from the work zone, and used during the short time use of the ACM equipment. The system was tested repeatedly and found to be a sound solution. The cone stowage assembly on the ACM was an area that required frequent inspection and maintenance.
With each field test, complete training in the safe operation of the machine was provided. Additionally, operators and their supervisors were provided a copy of the Automated Cone Machine Safe Operation documentation (Appendix D). Training continued on an as needed basis during field testing. Technical support was a priority in order to facilitate a successful testing period. Caltrans’ interest in the ACM has grown strong; therefore, they have decided to acquire the machine from the AHMCT Center.
Copyright 2011, AHMCT Research Center, UC Davis
DRV Final Evaluation Report Appendix A Copyright 2011, AHMCT Research Center, UC Davis 1
DRV Final Evaluation Report Copyright 2011, AHMCT Research Center, UC Davis 2
DRV Final Evaluation Report Debris Removal Vehicle (DRV) AHMCT Evaluation Report Aaron Raley Deployment Support October, 2001 University Of California, Davis Advanced Highway Maintenance and Construction Technology Research Center Davis, CA 95616 Technical Support: 530.752.
DRV Final Evaluation Report Introduction The field operational testing and evaluation phase of the Debris Removal Vehicle (DRV) project has produced valuable feedback regarding the interface of the operator with the machine and the machine with the environment. Equally important is the infrastructure in place and its role in the removal of roadside debris. The information gathered should facilitate the formulation of efficient solutions to the remaining problems.
DRV Final Evaluation Report Plan of Action • • • Install and implement a new hydraulic and electronic control system that exhibits reliable and controllable motion. Make reasonable structural repairs to the azimuth joint and short arm sections. Perform the repair with a goal of one year of usable service for the purpose of evaluating the machine concept. Work on the rebuild of the DRV was conducted at the AHMCT Research Center and the Caltrans Equipment Service Center.
DRV Final Evaluation Report operator constrained in a standard vehicle cab and presents ergonomic design issues. Important areas to investigate are the interface of the operator with the controls and the interface of the operator with the task. The relation of a joystick axis to its associated joint and joystick motion to joint directional motion is very intuitive. An equipment operator can accomplish the joystick operation quickly from either side of the vehicle.
DRV Final Evaluation Report reported complaints by any operators regarding the use of a joystick relating to comfort or effort. The efficiency of the DRV is related to the experience of the operator and its integration into the debris removal program plan. The more frequently that an operator used the machine the more efficient the operation became. There were several techniques operators employed as their exposure to the machine increased that sped up the operation.
DRV Final Evaluation Report arises when the work zone is close to the vehicle as found when retrieving debris next to a sound wall or on a narrow shoulder. In both of these cases the garbage can be dumped but it takes more tedious manipulation of the arm by the operator, hence, decreasing the efficiency of the machine. With further investigation, modes could be implemented where different code sections are executed based on the environment selected by an operator.
DRV Final Evaluation Report handled with anticipation of the DRV being used to retrieve it, that the machine could be more efficient than a manual operation and considerably safer. Obviously, improvements in the design of the machine would greatly increase the efficiency providing for a debris removal process more efficient and safer than the current operation. Key Points • • • • • • • Debris removal plan must be in place and complete.
DRV Final Evaluation Report looking out the side window. This was accomplished with the combination joystick pushbutton control. There were no reported complaints about the ergonomics of the joystick. In fact, operators were enthused about the use of the joystick pushbutton combination. Deploying the arm from the folded up position to the roadside is a complex process because of the pre-existing design of the arm. Likewise, folding the arm up to dump the garbage is also a tedious task.
DRV Final Evaluation Report implement with a standardized interface allows for the adaptation to debris localized to a single region not considered at initial development. In addition, the ideal design for 70 percent of the work should not be compromised by accommodating the other 30 percent. Payload capacity is always a concern. Field testing found that retrieving large piles of green ice plant were the heaviest task encountered in the Southern California region.
AHMCT Release for Field Operational Testing and Evaluation We, the undersigned, have observed a demonstration of the Debris Removal Vehicle and we have also visually inspected the machine. Based upon our signatures below, this machine meets our minimum standards for initial testing in actual highway operations. This machine is a first generation prototype, and accordingly, it is intended for limited operation for qualification purposes only.
The AHMCT Research Center, in conjunction with the Caltrans Equipment Service Center, has rebuilt the Debris Removal Vehicle (DRV). The following was the scope of the project and plan of action as determined by both of the above groups. Project Scope • • Evaluate the existing mechanical, hydraulic, and electronic control structure. Devise a plan of action to repair the existing project with the goal of redeployment for the purposes of field operational testing and evaluation.
tanks were having problems equalizing due to plumbing complications. A single tank was used in place of the dual tanks and new plumbing installed. Concerns • • • The spherical bearings on the end joints of the wrist actuator are showing signs of excessive wear. Despite the structural work done to the azimuth joint and short arm section, there is significant flexure present in the robotic arm. Inspections of the arm should be conducted on a regular basis to identify any cracks.
Copyright 2011, AHMCT Research Center, UC Davis
Summary of Repairs Conducted on the Debris Removal Vehicle (DRV) During Field Testing for the Period 1/01/01 – 5/31/02 January 2001 Report Auto dump function will not work. Problem The position sensor on the short arm joint drifted out of calibration due to mechanical forces causing loosening. This prevented the arm from reaching the targeted coordinates required due to travel limitations on the joint. Therefore, the motion sequencing could not be completed.
imposing an excessive force on the position sensor. The force is great enough to loosen the lock nut on the position sensor and allow the sensor to rotate. Fix The peak-peak displacement of the axle bolt was measured, throughout the joints range of motion, and compared to the flexible range of the coupling. It was decided that the potentiometer may be able to physically withstand the increased frictional force if it was restrained.
The long arm axle bolt rotated on the set screw. In addition, there was a problem with the backup battery in the controller. All motion profiles and control law coefficients that remain constant are burned to the EEPROM along with the rest of the compiled source code. However, constants that can be changed, such as positions for the presets modified by operators, are stored in RAM. The RAM is preserved through system power and the internal battery during power outages.
Appendix B Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
The Debris Removal Vehicle Operator’s Manual and Technical Reference version 1.0 June 30, 2000 University Of California, Davis Advanced Highway Maintenance and Construction Technology Center Davis, CA 95616 Technical Support: 530.752.
Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Machine Operation 23 TABLE OF CONTENTS 1 INTRODUCTION Theory of Operation .......................................................................... 3 2 MACHINE OPERATION Pre-operational System Checks......................................................... 3 Hydraulic Oil Level............... 2.1.1 Arm Restraint Pins ................ 2.1.2 Machine Clearances .............. 2.1.3 Emergency Stop .................... 2.1.4 System Power On .................. 2.1.5 Joystick Calibration............... 2.1.
Machine Operation 24 1: Theory Of Operation The Caltrans/AHMCT Debris Removal Vehicle (DRV) is an operator controlled garbage collecting manipulator with limited automatic modes to assist in the most tedious tasks. In normal operation, the operator would program preset manipulator locations into the machine. These preset locations are accessible from joystick buttons P1 through P4. In the field, the operator would deploy the manipulator to a preset location by depressing the appropriate button.
Machine Operation 25 2.1.5 System Pow er O n Place the power switch on the operator’s console in the "ON" position. After the controller diagnostic checks have completed, the power light will begin to blink. 2.1.6 Joystick C alibration The operator joysticks should be calibrated at the beginning of each shift. With the "emergency stop" placed in the "IN" position, place both the "left guard" and "right guard" toggle switches in the down position simultaneously.
Machine Operation 26 2.2 System Operation 2.2.1 Joystick The majority of motion commands for the arm is accomplished through the use of joysticks. The active joystick is determined via the position of the "joystick power" selector switch on the operator’s console. Mounted on the joystick (Figure 1) are a trigger button and four (4) push buttons. These five (5) buttons allow the operator to perform preprogrammed, complicated operations.
Machine Operation 27 compactor cycle, the compactor indicator light will blink and the joystick commands will be disregarded by the machine controller. The button combination "trigger + P3" moves the machine from its current position to the stowed position. In the stowed position, the boom and azimuth restraint pins can be reinstalled and the machine secured for transport or shutdown. Figure 1: Joystick 2.2.2 Toggle Sw itches On the operator’s console are a large number of toggle switches (Figure 2).
Machine Operation 28 Boom Up/Down Turntable CW/CCW Raises or lower the boom Rotates the machine turntable clockwise (CW) or counterclockwise (CCW) Figure 2: Cab console 2.2.3 C onsole Lights On the operator’s console are a number of indicator lights (Figure 2). Their meaning is listed in the table below. Note that a flashing light has a different indication than a solidly illuminating light.
Machine Operation 29 (blinking) Gate Up Compactor (blinking) Compactor System is executing an automatic motion profile. The compactor is not in the home position. The compactor is in use. 2.3 System Shutdown To shut the system down, press "trigger + P3" to stow the machine. Depress one of the emergency stop buttons on the side of the operator’s console and then reinstall the boom and azimuth restraint pin. Then turn off the system power by placing the "power" switch in the "OFF" position.
Appendix A Main Controller Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix A: Main Controller 31 A.1 Introduction The entire DRV is controlled by an embedded computer (Figure A.1) located in the driver’s side battery box. This computer has a 2-line LCD display and 10 function buttons. The complete operating characteristics of the manipulator can be altered through the use of the display and the function buttons. In normal use, the LCD display will show the current operating mode and/or any fault conditions that are detected.
Appendix A: Main Controller 32 A.1.1 Keypad On the embedded computer is located a 10 button keypad composed of 2 rows of 5 buttons each. Only the first row of 5 buttons is used. Starting from the left, the buttons are labeled "menu", "item", "next", "↑", and "↓". The "menu" key cycles through all the available top-level menus. If the "item" key is pressed, then the sub-level items are displayed. Successive "item" key presses cycles though the available sub-level items.
Appendix A: Main Controller 33 Long Parameters Short Parameters pos P gain: velo P gain: velo I gain: velo D gain: jstick scale: min limit: max limit: 0.0...100.0 0.0...300.0 0.0...100.0 0.0...100.0 0.0...35.0 0.0...180.0 0.0...180.0 0.80 2.0 1.8 0.0 30.0 20.0 100.0 pos P gain: velo P gain: velo I gain: velo D gain: jstick scale: min limit: max limit: 0.0...100.0 0.0...300.0 0.0...100.0 0.0...100.0 0.0...35.0 0.0...180.0 0.0...180.0 0.80 0.20 0.45 0.45 30.0 27.0 107.
Appendix A: Main Controller 34 velo D gain: Max CCW pos: Max CW pos: Center pos: Copyright 2011, AHMCT Research Center, UC Davis 0.0...100.0 0.0...100.0 0.0...160.0 0.0...100.0 0.150 20.0 140.0 80.
Appendix B Trouble Shooting Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
B.1 Introduction The DRV utilizes an industrial controller. The controller has two types of inputs, analog and digital. The analog inputs are accomplished via the analog to digital (A-D) expansion board. The A-D board converts a varying input voltage into a digital integer value that the controller can use to evaluate signal amplitude. As an example, +5 Volts may be represented as the integer value 2048 in software. Likewise, there are two types of outputs, digital and analog.
state the logic gate input, which is high impedance and considered infinite for this purpose, is high. The input state is changed when the logic gate input changes to low. Therefore, switching it to ground changes the input. When the external switch is closed and the input is grounded, the pull up resistor limits the current and results in a +5 VDC drop. The voltage at the logic gate input is now the same as the ground reference, 0 VDC potential difference to ground. Figure B.
Appendix B: Touble Shooting 38 Never use a test light to check an output. Unexpected motion can result causing personal injury and/or damage to the equipment. If a test light were connected between the groundside of the load and ground, the load would be in series with the light and the circuit completed. The low impedance of the test light may allow enough current to flow to drive the output device. The dump body valves are driven by the digital outputs via a set of relays.
Appendix B: Touble Shooting 39 For fuse locations on the fuse block, reference Figure B.3 below. The fuse block is located in the main controller cabinet in the battery box on the left side of the truck. Fault Power switch ON, power light OFF and no messages on LCD Power switch ON, power light OFF, and "HW Init Fail.
Appendix B: Touble Shooting 40 1: "System Ready" on LCD 2: Arm responds to joystick input 3: Dump body hydraulic components not functional. 1: "System Ready" on LCD 2: Arm responds to joystick input 3: Multiple hydraulic components on dump body not functional.
Appendix B: Touble Shooting 41 Figure B.
Appendix C Wiring Diagrams Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 43 Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 44 Cable Routing JO YSTIC K R O BO T VALVES C O N TR O L C O N SO LE PO SITIO N SEN SO R S R O BO T J-BO X LIG H TS 2 SW ITC H ES 1 LEFT JO YSTIC K 3 R IG H TJO YSTIC K VALVES_ 5 PO SITIO N _ 4 Z-C O N TR O LLER DUM P BO D Y J-BO X 7 PO SITIO N 6 VALVES___ DUM P BO D Y VALVES Copyright 2011, AHMCT Research Center, UC Davis PO SITIO N SEN SO R S DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 45 Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 46 Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 47 Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 48 Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 49 Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 50 Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 51 CONSOLE SWITCHES 8459 22 AWG PIN: COLOR: FUNCTION: A B C D E F G H J K L M N P Q R S T U V W X Y Z white/black black/white blue blue-black red/white green/white red/black black orange blue/white green/black black/red red/black/white green white/black/red orange/black white/red orange/red white red blue/red red/green black/white/red orange/green tailgate-close turntable-clockwise tailgate-open boom-down turntable-counter clockwise precrush door-up compactor-in power on d
Appendix C: Wiring Diagrams 52 INDICATOR LIGHTS 8624 16 AWG PIN: COLOR: FUNCTION: A B C D E F G H J K L M N P R S T blue/black orange/black red/black blue/red blue black/red green blue/white green/white red black/white white green/black black orange/red orange red/white right joystick left machine compactor motion e-stop ground turn table guard tailgate spare PTO ground power left joystick ground right machine +12VDC Lamps e-stop input restraint pin +12VDC PTO NOT CONNECTED white/red white/black Cop
Appendix C: Wiring Diagrams 53 DUMP BODY SENSORS 9457 20 AWG PIN COLOR A B C D E F H J K L M gray purple black yellow orange blue red tan pink dark brown white FUNCTION spare pressure spare compact limit right guard up tailgate open +12 for proximity switch spare precrush door open left guard up ground NOT CONNECTED green Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 54 DUMP BODY VALVES 8624 16 AWG PIN A B C D E F G H J K L M N P R S T COLOR green/white white/black black blue/red blue black/red green blue/white blue/black orange/black green/black red/black red white/red orange/red orange white FUNCTION pre-crush door up tailgate close spare right guard down tailgate open left guard up dump body up pre-crush door down spare spare compactor out compactor in spare left guard down right guard up dump body down ground NOT CONNECTED Red/white B
Appendix C: Wiring Diagrams 55 JOYSTICKS 83569 22 AWG PIN: COLOR: FUNCTION: A B C D E F G H J K L M N P R S T green/white blue/white black/red black white/red white/black+shield red white orange/black orange red/white black/white green blue red/black green/black blue/black spare spare spare ground spare common + 10VDC PB 2 Z-axis PB 3 spare spare PB 1 PB 4 X-axis Y-axis trigger Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C: Wiring Diagrams 56 ROBOT POSITION 83569 22 AWG PIN COLOR FUNCTION A B C D E F G* H J K L M N P R S T blue orange/black black/white red/white green black/red white/red red blue/red red/black white/black shield orange black blue/white white orange/red ground boom turntable spare short arm wrist poppet + 10VDC spare spare azimuth shield restraint spare spare ground long arm NOT CONNECTED: green/black green/white blue/black • • • Poppet valve added to shut off hydraulic flow to dump body.
Appendix C: Wiring Diagrams 57 ROBOT PWM VALVES 83719 16AWG PIN COLOR A B C D E F G H* J K L M* N P R S T U V blue/black orange/black red/black white/red white/black blue/red blue red/white green red black black/white blue/white green/black black/red orange/red orange white green/white FUNCTION boom down boom up azimuth counter clockwise wrist up azimuth clockwise long arm down left basket open turntable counter clockwise short arm up + 12 VDC + 12 VDC turntable clockwise right basket close left basket
Appendix D Hydraulic Schematics Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix D: Hydraulic Schematics 59 this page intentionally left blank (information to be provided by CalTrans) Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix E Cable Specifications Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix E: Cable Specifications 61 Cable Specification Belden # Cond. 1. 8459 AWG 25 Shielding 22 none 2. 83719 19 16 overall foil & braid 3. 83569 19 22 overall foil & braid 4. 8624 19 16 none 5. 9457 12 20 none Use: 1. 2. 3. a. b. c. 4. a. b. 5. console toggle switches robot PWM valves joystick1 joystick2 robot position sensors dump body valves console indicator lamps & E-stop dump body sensors Note: Belden cable was used since it is readily available and reliable.
Appendix F Electrical Parts List Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix F: Electrical Parts List 63 Parts List ZWorld Part # 101-0093 101-0022 101-0273 101-0181 ZWorld Industrial Controller PK2200 ZWorld Analog-Digital Converter XP8500 Zworld Digital-Analog Converter XP8900 ZWorld Digital I/O Expansion Board XP8100 ZWorld 2900 Spafford Street Davis, CA 95616-6800 (530) 757-3737 1 800 362-3387 http://www.zworld .
Appendix F: Electrical Parts List 64 Appendix G Hydraulic Parts List Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix G: Hydraulic Parts List this page intentionally left blank (information to be provided by CalTrans) Copyright 2011, AHMCT Research Center, UC Davis DRV Operator’s Manual and Technical Reference (rev 1 0 June 30, 2000)
Appendix C Copyright 2011, AHMCT Research Center, UC Davis
Changing Timer Pre-sets on the LCSM II The PLC must be turned on to change the pre-set timer values and the updated values only exist while the system is on. Once the PLC is turned off, the default timer values will be restored at next power-on. With the system turned on, press the CHG PRE button. The menu should appear as below: TIMER A 0600 TIMER B 0600 The + or – key will select between TIMER A and TIMER B. do not go beyond TIMER B. If you do, use the – key to get back.
Appendix D Copyright 2011, AHMCT Research Center, UC Davis
Automated Cone Machine Safe Operation 1.1 Overview The ACM is an automated piece of equipment that places and retrieves traffic cones. It allows an operator to perform their task without working outside the vehicle. A solid state controller is used to automate the process. Unlike a personal computer, this solid state controller initializes quickly and can be power cycled on and off at any time. The ACM uses electric and hydraulic power. All electric power is the nominal truck voltage 12 VDC.
There is a primary funnel located on each of the corners of the vehicle. Operators should verify that these areas are clear before energizing the system and deploying the primary funnels. 1.2.2 General Safety Rule The ACM control system should not be turned on or running with obstructions or personnel in any of the regions where the automated equipment is located or could be deployed. The control system can be shut down and re-started without any lag or start up time.
1.3 Equipment Checkout In order to reduce the opportunity of damage and/or malfunction, a thorough check out of the machine should be done prior to each use. 1.3.1 Pre-Operational Checkout 1. Pre-operational vehicle checkout 2. Visually inspect condition of the ACM components 3. Hydraulic tank level should be approximately 2/3 full 4. Inspect stowage system grippers for loose fittings and components 5. Photo eyes and reflectors should be clean 6.
5. Set the ‘PICK/DROP’ switch to the center position 6. Turn on the computer 7. Turn on the System Power 8. Select machine side ‘LEFT’ or ‘RIGHT’ 9. If placing cones, select distance ’25, 50, or 100’ and then choose ‘DROP’ 10. If retrieving cones, select ‘FORWARD’ or ‘REVERSE’ and the ‘PICK’ 11. When operation is complete, set ‘DROP/PICK’ switch to center position 12. Set machine side to ‘OFF’ 13. Once the drop box is fully retracted, turn off system power 14. Turn off computer 1.4.
1.4.4 Ending Operation When the operation is completed, move the ‘DROP/PICK’ switch into the center position. Set the ‘LEFT/RIGHT’ switch to the center ‘OFF’ position. Always work the switches from the bottom up when shutting the system down. Once the drop box is stowed turn the system power and computer off. Never drive above 25 MPH with the drop box down or the system power turned on. 1.5 Troubleshooting There are three general ways in which automated equipment malfunction.
Appendix E Copyright 2011, AHMCT Research Center, UC Davis
Copyright 2011, AHMCT Research Center, UC Davis
Copyright 2011, AHMCT Research Center, UC Davis
Machine Limitations 1. The ACM was designed to work with 28“ cones that have had the raised rubber feet removed. Using any other configuration cone may cause malfunction of the system or damage. 2. While in operation, there is minimal clearance from the drop-box to the ground. In addition, the drop-box extends off the side of the vehicle. Obstacles and un-even ground should be avoided. The operator must avoid impacting uneven surfaces and other obstacles. 3.
