Devices and media for AGV fault diagnosis system at automated docks

Abstract

This invention discloses an apparatus and medium for an automated terminal AGV fault diagnosis system, including an AGV control unit, an AGV network connection unit, a vehicle selection unit, a task selection unit, a driving file selection unit, a task execution unit, an automatic report generation unit, a dispatch building module, a remote monitoring unit, and a remote fault diagnosis system. This invention optimizes the AGV network connection unit by establishing a 5G vehicle-mounted base station within the unit, increasing the bandwidth to 1000 Mbps to support the data flow of subsequent remote fault diagnosis tools. It also incorporates a driving process parameter recording unit and a self-developed remote fault diagnosis software tool, enabling real-time acquisition and processing of AGV driving data and remote, intelligent, and automated identification and processing of abnormal states. This lowers the technical threshold for maintenance personnel, improves the operational efficiency and accuracy of fault diagnosis, and reduces the frequency of on-site fault handling by maintenance personnel.

Description

Technical Field

[0001] This invention relates to the field of AGV fault diagnosis technology, specifically to the device and medium for AGV fault diagnosis systems in automated docks. Background Technology

[0002] AGV is an abbreviation for Automated Guided Vehicle, referring to a transport vehicle equipped with electromagnetic or optical automatic guidance devices. It can travel along a predetermined guidance path and has safety protection and various transfer functions. The control of the AGV system is achieved through the cooperation of the logistics upper-level scheduling system, the AGV ground control system, and the AGV on-board control system. In the existing fault handling mode, AGV duty room personnel can only view the fault name reported after the AGV stops abnormally, and cannot obtain the operating status information of each mechanism of the AGV in the period before the fault. This inevitably leads to disadvantages such as blindness and long processing time in fault handling. Furthermore, it is impossible to remotely monitor, modify, and download the stand-alone electrical control PLC program online, resulting in the inability to remotely obtain the real-time status information of the "walking mechanism and safety mechanism that only communicate with the electrical control PLC" when the AGV malfunctions. Summary of the Invention

[0003] The purpose of this invention is to provide a device, medium, and equipment for AGV fault diagnosis system in automated terminal, so as to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: an apparatus for AGV fault diagnosis system at an automated terminal, comprising an AGV control unit, an AGV network connection unit, a vehicle selection unit, a task selection unit, a vehicle travel document selection unit, a task execution unit, an automatic report generation unit, a dispatch building module, a remote monitoring unit, and a remote fault diagnosis system. The AGV control unit is bidirectionally connected to the AGV network connection unit. The output of the vehicle selection unit is communicatively connected to the input of the task selection unit. The output of the task selection unit is communicatively connected to the input of the vehicle travel document selection unit. The output of the vehicle travel document selection unit is communicatively connected to the input of the task execution unit. The output of the task execution unit is communicatively connected to the input of the automatic report generation unit.

[0005] The AGV control unit is used to control and process the operating status of the traveling AGV.

[0006] The AGV vehicle network connection unit is used to connect with the base station network between AGV vehicles;

[0007] The vehicle selection unit is used to confirm AGV vehicles that require fault diagnosis.

[0008] The task selection unit is used to select the fault diagnosis mode for the AGV vehicle.

[0009] The driving file selection unit is used to extract and retrieve the content file of driving data;

[0010] The task execution unit is used to parse all the information contained in the extracted driving data file and perform intelligent fault diagnosis operations.

[0011] The automatic report generation unit is used to summarize the relevant information of all the previously analyzed institutions into a txt document for archiving;

[0012] The dispatch building module is used for dispatching and allocating the received data information;

[0013] The remote monitoring unit is used to remotely monitor the navigation PLC program, the electronic control PLC program, and the real-time image of the laser anti-collision unit inside the AGV vehicle.

[0014] The remote fault diagnosis system is used to remotely and automatically diagnose and process faults by extracting the driving data of the AGV.

[0015] Preferably, the AGV control unit includes an onboard 5G wireless module, a laser anti-collision module, a ModBus gateway module, a navigation PLC controller, an electronic control PLC controller, and a driving process parameter recording unit. The onboard 5G wireless module is bidirectionally connected to the laser anti-collision module, the onboard 5G wireless module is bidirectionally connected to the ModBus gateway module, the onboard 5G wireless module is bidirectionally connected to the navigation PLC controller, the ModBus gateway module is bidirectionally connected to the electronic control PLC controller, the navigation PLC controller is bidirectionally connected to the driving process parameter recording unit, the onboard 5G wireless module is bidirectionally connected to the remote monitoring unit, and the onboard 5G wireless module is bidirectionally connected to the remote fault diagnosis system.

[0016] The vehicle-mounted 5G wireless module is used to establish a 5G vehicle-mounted base station and to perform wireless connection processing for the vehicle-mounted 5G.

[0017] The laser anti-collision module is used to sense the distance to surrounding obstacles and the current load of the vehicle;

[0018] The ModBus gateway module is used to convert the RS232 serial port of the electronic control PLC into an RJ45 network port, connect it to the image switch through a network cable, and then remotely connect to the dispatch building module through the 5G wireless network.

[0019] The navigation PLC controller is used for positioning and motion navigation control of the AGV vehicle.

[0020] The electronic control PLC controller is used to control the wheel speed and steering angle of the AGV trolley.

[0021] The driving process parameter recording unit is used to record and process component parameter data during the driving process of the AGV.

[0022] Preferably, the driving process parameter recording unit includes a dispatching system remote command process data recording module, a navigation and positioning antenna process data recording module, a gyroscope process data recording module, a wheel speed encoder process data recording module, a wheel steering encoder process data recording module, a drive process data recording module, and a hydraulic system process data recording module.

[0023] The remote instruction process data recording module of the scheduling system is used to record and process remote instruction data for scheduling.

[0024] The navigation and positioning antenna process data recording module is used to record and process the status words of the navigation antenna in the AGV vehicle and the magnetic nail number and relative coordinates of the positioning magnetic nail scanned by the antenna in real time.

[0025] The gyroscope process data recording module is used to record and process the body steering angular velocity data of the AGV trolley during its movement;

[0026] The wheel speed encoder process data recording module is used to record in real time the speed input to the four wheels and the feedback value of the wheel speed encoder during the driving of the AGV.

[0027] The wheel steering encoder process data recording module is used to record and process the steering angle given by the system to the four wheels and the steering encoder feedback value in real time during the AGV's movement.

[0028] The driver process data recording module is used to record and process the ramp speed input and feedback, voltage, current, torque, and fault code data of the AGV trolley driver in real time.

[0029] The hydraulic system process data recording module is used to record the pressure changes of the hydraulic steering pump and the hydraulic brakes of the front and rear wheels in real time during the movement of the AGV.

[0030] Preferably, the task selection unit includes a health diagnosis module and a fault analysis module, wherein the health diagnosis module and the fault analysis module operate independently;

[0031] The health diagnosis module is used to detect and process the health status of the AGV vehicle during normal operation.

[0032] The fault analysis module is used to analyze and process the fault information obtained after the AGV stops abnormally.

[0033] Preferably, the vehicle file selection unit includes a remote automatic download module and a local manual selection module, wherein the remote automatic download module and the local manual selection module operate independently;

[0034] The remote automatic download module is used to remotely and automatically download the latest 10 consecutive driving data files to a folder automatically generated on the duty room computer desktop based on the selected vehicle number and operation time;

[0035] The local manual selection module is used to manually select the folder containing the local driving data files.

[0036] Preferably, the task execution unit includes a vehicle file integration module, a parameter analysis module, a positioning antenna and bad magnetic nail drawing and intelligent diagnosis module, a gyroscope parameter drawing and intelligent diagnosis module, a wheel speed encoder parameter drawing and intelligent diagnosis module, a steering encoder parameter drawing and intelligent diagnosis module, a motor driver parameter drawing and intelligent diagnosis module, and a hydraulic system parameter drawing and intelligent diagnosis module.

[0037] The driving file integration module is used to merge and reorganize data files to obtain continuous data of all parameters during the AGV driving process;

[0038] The parameter parsing modules are used to extract each parameter from the continuous data of all parameters in sequence and perform pre-analysis processing.

[0039] The positioning antenna and faulty magnetic nail drawing and intelligent diagnosis module is used to parse the working status word of the navigation positioning antenna and to perform time-domain drawing of the magnetic nail number information scanned by the antenna and the change of the relative coordinates of the magnetic nail with respect to the navigation antenna coordinate system. It also identifies and marks unstable factors such as external magnetic field interference on the antenna in the drawing, and intelligently judges whether the magnetic nail is abnormal based on the antenna status word and the change of the relative coordinates of the magnetic nail. The abnormal magnetic nail number and the abnormal time are marked in sequence, and corresponding maintenance suggestions are given.

[0040] The gyroscope parameter plotting and intelligent diagnosis module is used to plot the actual rotational angular velocity of the AGV vehicle monitored by the gyroscope during the AGV's movement and the rotational angular velocity data calculated according to the vehicle's motion state equation in the time domain. It also performs comprehensive analysis and diagnosis based on the changes and relative deviations of the two, marks the abnormalities, and provides corresponding maintenance suggestions.

[0041] The wheel speed encoder parameter plotting and intelligent diagnosis module is used to plot the speed of the four wheels given by the AGV vehicle's control system and the feedback value of the corresponding wheel speed encoder in the time domain, and to perform a comprehensive analysis in combination with the vehicle's operating status and the wheel brake status, so as to diagnose the fault of the wheel speed encoder mechanism. At the same time, it automatically frames the data image of abnormal periods and provides corresponding maintenance suggestions.

[0042] The steering encoder parameter plotting and intelligent diagnosis module is used to plot the steering angle given to the four wheels by the AGV vehicle driving control system and the feedback value of the corresponding wheel-side steering encoder in the time domain. It also performs a comprehensive analysis in combination with the vehicle operating status, hydraulic steering main pressure and wheel brake status to diagnose the fault of the wheel-side steering encoder mechanism. At the same time, it automatically frames the data image of abnormal periods and gives corresponding maintenance suggestions.

[0043] The motor driver parameter plotting and intelligent diagnosis module is used to plot the ramp given speed and speed feedback, output voltage, current, torque and driver fault codes of the AGV trolley's traveling motor driver in the time domain, and to perform comprehensive analysis in combination with the vehicle's operating status and wheel brake status, thereby diagnosing faults in the wheel speed encoder mechanism. At the same time, it automatically frames the data images of abnormal periods and provides corresponding maintenance suggestions.

[0044] The hydraulic system parameter plotting and intelligent diagnostic module is used to plot the main pressure value, brake pressure value, and steering proportional valve current value of the hydraulic oil pump system during AGV operation in the time domain. It also performs a comprehensive analysis in conjunction with the vehicle's operating status, the steering setpoint of the control system, and the wheel brake status, thereby diagnosing faults in the hydraulic oil pump mechanism. At the same time, it automatically frames the data images during abnormal periods and provides corresponding maintenance suggestions.

[0045] Preferably, the remote monitoring unit includes a navigation PLC monitoring module, an electrical control PLC monitoring module, and a laser monitoring module;

[0046] The navigation PLC monitoring module is used to monitor and process the navigation PLC program in the AGV in real time.

[0047] The PLC monitoring module is used to monitor and process the AGV trolley's PLC program in real time.

[0048] The laser monitoring module is used to monitor and process the scanned images of the laser in real time.

[0049] The medium of the automated terminal AGV fault diagnosis system stores a computer program, which, when executed by a processor, implements the storage management of data in the apparatus of the automated terminal AGV fault diagnosis system according to any one of claims 1 to 7.

[0050] The equipment of the AGV fault diagnosis system for automated docks includes an AGV monitoring unit, a fault data identification unit, a fault confirmation unit, and an AGV fault repair unit. The output of the AGV monitoring unit is communicatively connected to the input of the fault data identification unit, the output of the fault data identification unit is communicatively connected to the input of the fault confirmation unit, and the output of the fault confirmation unit is communicatively connected to the input of the AGV fault repair unit.

[0051] The AGV monitoring unit is used to monitor and process the working status of the AGV vehicle in real time.

[0052] The fault data identification unit is used to identify and process component data when the AGV is working.

[0053] The fault confirmation unit is used to identify anomalies by recognizing component data when the AGV is working, and to confirm and process the faults of the AGV.

[0054] The AGV fault diagnosis and repair unit is used to perform inspection and maintenance on the identified locations when abnormal AGV component data is detected.

[0055] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure.

[0056] Compared with existing technologies, the beneficial effects of this invention are as follows: By optimizing the AGV vehicle network connection unit, the on-board base station within the AGV vehicle network connection unit is established using a 5G on-board base station, increasing the bandwidth to 1000 Mbps, providing strong support for the data flow of subsequent remote fault diagnosis tools; by adding a vehicle process parameter recording unit, real-time acquisition and processing of AGV vehicle driving data is achieved; through a self-developed remote fault diagnosis software tool, remote, automated, and intelligent identification and processing of abnormal states during AGV vehicle operation are achieved, thereby greatly reducing the technical threshold for AGV maintenance personnel, improving the operational efficiency and accuracy of fault diagnosis, and reducing the frequency of maintenance personnel entering the site to handle faults. This is of great significance for the continuity of AGV cluster operations in automated yards and the personal safety of on-site maintenance personnel; by adding an automatic report generation unit, the recording of each fault analysis is realized, facilitating maintenance personnel to classify and summarize maintenance experience, and playing an important reference role in future software optimization. Attached Figure Description

[0057] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0058] Figure 1 This is a system block diagram of the present invention;

[0059] Figure 2 This is a block diagram of the fault diagnosis system of the present invention;

[0060] Figure 3 This is a system block diagram of the vehicle driving process parameter recording unit of the present invention;

[0061] Figure 4 This is a network topology diagram of the present invention;

[0062] Figure 5 This is a system diagram of the main operation interface during the initialization phase of this invention;

[0063] Figure 6 The system diagram for the main operation interface of this invention is complete;

[0064] Figure 7 The system diagram for the interface of this invention is complete;

[0065] Figure 8 This is a diagram showing the abnormal magnetic nail readings from the navigation and positioning antenna of this invention.

[0066] Figure 9 This is a diagram indicating an abnormal feedback value from the speed encoder of the rear left wheel of the AGV of the present invention.

[0067] Figure 10 This is a diagram illustrating an abnormality in the rear axle hydraulic steering system of the present invention.

[0068] Figure 11 This is a network topology diagram prior to the present invention;

[0069] Figure 12 This is the remote monitoring unit of the present invention. Detailed Implementation

[0070] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this disclosure. Rather, they are merely examples of apparatuses consistent with some aspects of this disclosure as detailed in the appended claims.

[0071] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0072] Example 1:

[0073] See Figures 1 to 12 As shown, the device for the automated terminal AGV fault diagnosis system of this invention includes an AGV vehicle control unit, an AGV vehicle network connection unit, a vehicle selection unit, a task selection unit, a vehicle travel document selection unit, a task execution unit, an automatic report generation unit, a dispatch building module, a remote monitoring unit, and a remote fault diagnosis system. The AGV vehicle control unit and the AGV vehicle network connection unit are bidirectionally connected. The output end of the vehicle selection unit is communicatively connected to the input end of the task selection unit. The output end of the task selection unit is communicatively connected to the input end of the vehicle travel document selection unit. The output end of the vehicle travel document selection unit is communicatively connected to the input end of the task execution unit. The output end of the task execution unit is communicatively connected to the input end of the automatic report generation unit.

[0074] The AGV control unit is used to control and process the operating status of the traveling AGV.

[0075] The AGV vehicle network connection unit is used to connect with the base station network between AGV vehicles, increasing the bandwidth to 1000 Mbps. The gateways of the two base stations are the same as the original networks, that is, base station 1 is still in the 172.16.158 network segment, and base station 2 is still in the 172.16.160 network segment.

[0076] The vehicle selection unit is used to confirm the AGV trolleys that require fault diagnosis.

[0077] The task selection unit is used to select the fault diagnosis mode for the AGV vehicle.

[0078] The vehicle data file selection unit is used to extract and retrieve the content files of vehicle data;

[0079] The task execution unit is used to parse all the information contained in the extracted driving data file and perform intelligent fault diagnosis operations;

[0080] The automatic report generation unit is used to summarize the relevant information of all the previously analyzed institutions into a txt document for archiving;

[0081] The dispatch building module is used for dispatching and allocating received data.

[0082] The remote monitoring unit is used to remotely monitor the navigation PLC program, the electronic control PLC program, and the real-time image of the laser anti-collision unit inside the AGV vehicle.

[0083] The remote fault diagnosis system is used to remotely and automatically diagnose and process faults by extracting the driving data of the AGV.

[0084] Example 2:

[0085] The AGV control unit includes an onboard 5G wireless module, a laser anti-collision module, a ModBus gateway module, a navigation PLC controller, an electronic control PLC controller, and a driving process parameter recording unit. The onboard 5G wireless module is bidirectionally connected to the laser anti-collision module, the onboard 5G wireless module is bidirectionally connected to the ModBus gateway module, the onboard 5G wireless module is bidirectionally connected to the navigation PLC controller, the ModBus gateway module is bidirectionally connected to the electronic control PLC controller, the navigation PLC controller is bidirectionally connected to the driving process parameter recording unit, the onboard 5G wireless module is bidirectionally connected to the remote monitoring unit, and the onboard 5G wireless module is bidirectionally connected to the remote fault diagnosis system.

[0086] The vehicle-mounted 5G wireless module is used to establish 5G vehicle-mounted base stations and to perform wireless connection processing for vehicle-mounted 5G, increasing the bandwidth to 1000 Mbps. The gateways of the two base stations are the same as the original networks, that is, base station 1 is still in the 172.16.158 network segment and base station 2 is still in the 172.16.160 network segment.

[0087] The laser collision avoidance module is used to sense the distance to surrounding obstacles and the vehicle's current load status;

[0088] The ModBus gateway module converts the RS232 serial port of the PLC to an RJ45 network port, connects it to the image switch via a network cable, and then remotely connects to the dispatch building module via 5G wireless network. The online program monitoring module is used for online monitoring and modification of the PLC program. With the addition of an industrial-grade Modbus gateway module and a laser scanner, the PLC's RS232 serial port is converted to an RJ45 network port, and then connected to the image switch via a network cable. The image switch is then connected to the vehicle-mounted 5G base station 2 via a network cable, and directly connected to the VMS system in the dispatch building 2 kilometers away via 5G wireless network. The dispatch building is then connected to the remote duty room via fiber optic cable, allowing duty personnel to monitor and modify the PLC program online, thus realizing the networking of the PLC.

[0089] The navigation PLC controller is used for positioning and navigation control of AGV vehicles;

[0090] The PLC controller is used to control the wheel speed and steering angle of the AGV trolley.

[0091] The vehicle driving process parameter recording unit is used to record and process component parameter data during the AGV vehicle's driving process.

[0092] The driving process parameter recording unit includes a dispatch system remote command process data recording module, a navigation and positioning antenna process data recording module, a gyroscope process data recording module, a wheel speed encoder process data recording module, a wheel steering encoder process data recording module, a drive process data recording module, and a hydraulic system process data recording module.

[0093] The remote instruction process data recording module of the scheduling system is used to record and process remote instruction data for scheduling.

[0094] The navigation and positioning antenna process data recording module is used to record and process the status words of the navigation antenna in the AGV vehicle and the magnetic nail number and relative coordinates of the positioning magnetic nail scanned by the antenna in real time.

[0095] The gyroscope process data recording module is used to record and process the body steering angular velocity data of the AGV trolley during its movement;

[0096] The wheel speed encoder process data recording module is used to record the speed input to the four wheels and the feedback value of the wheel speed encoder in real time during the movement of the AGV.

[0097] The wheel steering encoder process data recording module is used to record and process the steering angle given by the system to the four wheels and the feedback value of the steering encoder in real time during the driving of the AGV.

[0098] The driver process data recording module is used to record and process in real time the values ​​of the AGV driver, such as ramp speed setpoint and feedback, voltage, current, torque, and fault codes.

[0099] The hydraulic system process data recording module is used to record and process the pressure changes of the hydraulic steering pump and the hydraulic brakes of the front and rear wheels in real time during the movement of the AGV.

[0100] The task selection unit includes a health diagnosis module and a fault analysis module, which operate independently.

[0101] The health diagnosis module is used to detect and process the health status of the AGV trolley during normal operation;

[0102] The fault analysis module is used to analyze and process fault information obtained after an AGV stops abnormally. First, select an AGV and choose the task type, which is divided into two types: health diagnosis and fault analysis. It automatically calls DOS commands to ping the IP addresses of the two network segments of the AGV's controller in sequence and displays the connectivity status on the main interface.

[0103] The vehicle file selection unit includes a remote automatic download module and a local manual selection module, with the remote automatic download module and the local manual selection module operating independently.

[0104] The remote automatic download module is used to remotely and automatically download the latest 10 consecutive vehicle data files to a folder automatically generated on the duty room computer desktop based on the selected vehicle number and operation time. This includes automatically calling DOS commands to ping the IP addresses of the two network segments of the AGV controller in sequence and displaying the connection status on the main interface. During the download, the FTP service is called to automatically download the ten latest vehicle data files from the AGV controller's storage card to the folder automatically generated on the duty room computer desktop based on the selected vehicle number and operation time.

[0105] The local manual selection module is used to manually select the folder containing the local driving data files.

[0106] The task execution unit includes a vehicle file integration module, a parameter analysis module, a positioning antenna and bad magnetic nail drawing and intelligent diagnosis module, a gyroscope parameter drawing and intelligent diagnosis module, a wheel speed encoder parameter drawing and intelligent diagnosis module, a steering encoder parameter drawing and intelligent diagnosis module, a motor driver parameter drawing and intelligent diagnosis module, and a hydraulic system parameter drawing and intelligent diagnosis module.

[0107] The vehicle data integration module is used to merge and reorganize data files to obtain continuous data of all parameters during the AGV vehicle's operation.

[0108] Each parameter parsing module is used to extract each parameter from the continuous data of all parameters in sequence and perform pre-analysis processing;

[0109] The positioning antenna and faulty magnetic nail drawing and intelligent diagnosis module is used to parse the working status word of the navigation positioning antenna and to perform time-domain drawing of the magnetic nail number information scanned by the antenna and the change of the relative coordinate of the magnetic nail with respect to the navigation antenna coordinate system. It also identifies and marks unstable factors such as external magnetic field interference on the antenna in the drawing, and intelligently judges whether the magnetic nail is abnormal based on the antenna status word and the change of the relative coordinate of the magnetic nail. It marks the abnormal magnetic nail number and the time of the abnormality in sequence, and provides corresponding maintenance suggestions.

[0110] The gyroscope parameter plotting and intelligent diagnostic module is used to plot the actual rotational angular velocity of the AGV vehicle monitored by the gyroscope during its movement and the rotational angular velocity data calculated according to the vehicle motion state equation. It also performs comprehensive analysis and diagnosis based on the changes and relative deviations of the two data, marks any abnormalities, and provides corresponding maintenance suggestions.

[0111] The wheel speed encoder parameter plotting and intelligent diagnosis module is used to plot the speed of the four wheels and the corresponding feedback value of the wheel speed encoder in the time domain of the AGV vehicle's control system during driving. It also performs a comprehensive analysis in combination with the vehicle's operating status and the wheel brake status to diagnose faults in the wheel speed encoder mechanism. At the same time, it automatically frames the data image during abnormal periods and provides corresponding maintenance suggestions.

[0112] The steering encoder parameter plotting and intelligent diagnostic module is used to plot the steering angle given to the four wheels by the AGV vehicle's control system during driving and the feedback value of the corresponding wheel-side steering encoder in the time domain. It also performs a comprehensive analysis in combination with the vehicle's operating status, hydraulic steering main pressure and wheel brake status to diagnose faults in the wheel-side steering encoder mechanism. At the same time, it automatically frames the data images during abnormal periods and provides corresponding maintenance suggestions.

[0113] The motor driver parameter plotting and intelligent diagnosis module is used to plot the ramp setpoint speed and speed feedback, output voltage, current, torque and driver fault codes of the AGV trolley's traveling motor driver in the time domain, and to perform comprehensive analysis in combination with the vehicle's operating status and wheel brake status, thereby diagnosing faults in the wheel speed encoder mechanism. At the same time, it automatically frames the data images of abnormal periods and provides corresponding maintenance suggestions.

[0114] The hydraulic system parameter plotting and intelligent diagnostic module is used to plot the main pressure value, brake pressure value, and steering proportional valve current value of the hydraulic oil pump system during AGV operation in the time domain. It also performs a comprehensive analysis in combination with the vehicle operating status, the steering setpoint of the control system, and the wheel brake status to diagnose faults in the hydraulic oil pump mechanism. At the same time, it automatically frames the data images of abnormal periods and provides corresponding maintenance suggestions.

[0115] The remote monitoring unit includes a navigation PLC monitoring module, an electrical control PLC monitoring module, and a laser monitoring module.

[0116] The navigation PLC monitoring module is used to monitor and process the navigation PLC program in the AGV in real time.

[0117] The PLC monitoring module is used to monitor and process the AGV trolley's PLC program in real time.

[0118] The laser monitoring module is used to monitor and process the scanned images of the laser in real time.

[0119] Example 3:

[0120] The medium of the automated terminal AGV fault diagnosis system stores a computer program that, when executed by a processor, implements the storage management of data in the apparatus of the automated terminal AGV fault diagnosis system according to any one of claims 1 to 7.

[0121] Example 4:

[0122] The equipment of the AGV fault diagnosis system for automated terminal is characterized by comprising an AGV monitoring unit, a fault data identification unit, a fault confirmation unit, and an AGV fault repair unit. The output end of the AGV monitoring unit is communicatively connected to the input end of the fault data identification unit, the output end of the fault data identification unit is communicatively connected to the input end of the fault confirmation unit, and the output end of the fault confirmation unit is communicatively connected to the input end of the AGV fault repair unit.

[0123] The AGV monitoring unit is used to monitor and process the working status of the AGV vehicle in real time.

[0124] The fault data identification unit is used to identify and process component data during the operation of the AGV trolley;

[0125] The fault confirmation unit is used to identify anomalies by recognizing component data when the AGV is working, and to confirm and handle AGV faults.

[0126] The AGV fault diagnosis and repair unit is used to inspect and maintain the identified locations when abnormal AGV component data is detected.

[0127] Example 5:

[0128] S1. An industrial-grade Modbus gateway module and a laser scanner are added to convert the RS232 serial port of the electrical control PLC to an RJ45 network port. This RJ45 port is then connected to an image switch via a network cable. Another network cable is then plugged into the image switch and connected to the vehicle-mounted 5G base station 2. This allows direct connection to the VMS system in the dispatch building 2 kilometers away via 5G wireless network. The dispatch building is then connected to a remote control room via fiber optic cable, enabling on-duty personnel to monitor and modify the electrical control PLC program online, thus achieving network connectivity for the electrical control PLC.

[0129] S2. First, select an AGV and choose the task type, which is divided into two types: health diagnosis and fault analysis. The system will automatically call DOS commands to ping the IP addresses of the two network segments of the AGV controller in sequence and display the connection status on the main interface. When downloading, the FTP service will be called to automatically download ten of the latest driving data files from the AGV controller's storage card to a folder automatically generated on the duty room computer desktop based on the selected vehicle number and operation time.

[0130] S3. After the download progress reaches 100%, the background process automatically imports the downloaded data file, integrates and parses the data from all files, and obtains the data on the changes over time (resolution of 10 milliseconds) of the following during the AGV's operation: the given and feedback speed of the four wheels, the given and feedback wheel steering angle, the given and feedback speed of the walking motor driver on the slope, the output voltage, current, torque, the working status of the navigation and positioning antenna, the information related to the magnetic nail, the working status of the gyroscope, and the working status of the oil pump and the steering ratio solenoid valve. Then, the relevant variables of each mechanism are combined into a graph, and the relationship between the variables is analyzed. Any abnormalities are marked, and solutions are provided.

[0131] S4. Click the "Generate Report" button to summarize the relevant information of all the institutions analyzed earlier into a txt document for easy archiving;

[0132] S5. By examining the encoder wiring module, coupling module, transmission gear module, gearbox module, and lubrication oil module, it was discovered that the encoder's refresh rate was 10 milliseconds during the fault period. This indicates that the wear of the outer teeth of the nylon gear between the encoder coupling and the gearbox caused the wheel speed encoder to not fully synchronize with the gearbox shaft. When it encountered the worn teeth, it only rotated due to inertia, so the feedback speed decreased. Then it rotated to the normal teeth, that is, it meshed again, so the feedback speed increased rapidly.

[0133] S6. Through the proportional valve current value detection module, cylinder response judgment module, oil pipe detection module and oil pump detection module of the rear axle hydraulic steering system abnormality detection unit, the oil pressure of the entire oil circuit is put more demanding when the AGV is traveling diagonally than when it is traveling in a right-angle bend, and fault detection and handling are performed through oil pressure.

[0134] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

[0135] Other embodiments of this disclosure will readily occur to those skilled in the art upon consideration of the specification and practice of the disclosure herein. This application is intended to cover any variations, uses, or adaptations of this disclosure that follow the general principles of this disclosure and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope of this disclosure is indicated by the following claims.

Claims

1. A device for diagnosing faults in an automated terminal AGV system, characterized in that, The system includes an AGV (Automated Guided Vehicle) control unit, an AGV network connection unit, a vehicle selection unit, a task selection unit, a driving file selection unit, a task execution unit, an automatic report generation unit, a dispatch building module, a remote monitoring unit, and a remote fault diagnosis system. The AGV control unit and the AGV network connection unit are bidirectionally connected for controlling the operating status of the AGV. The output of the vehicle selection unit is communicatively connected to the input of the task selection unit for confirming AGVs requiring fault diagnosis. The output of the task selection unit is communicatively connected to the input of the driving file selection unit for selecting the fault diagnosis mode of the AGV. The output of the driving file selection unit is communicatively connected to the input of the task execution unit for extracting and retrieving the content file of the driving data. The output of the task execution unit is communicatively connected to the input of the automatic report generation unit for parsing all information contained in the extracted driving data file and performing intelligent fault diagnosis operations. The task execution unit includes a vehicle file integration module, a parameter analysis module, a positioning antenna and bad magnetic nail drawing and intelligent diagnosis module, a gyroscope parameter drawing and intelligent diagnosis module, a wheel speed encoder parameter drawing and intelligent diagnosis module, a steering encoder parameter drawing and intelligent diagnosis module, a motor driver parameter drawing and intelligent diagnosis module, and a hydraulic system parameter drawing and intelligent diagnosis module. The vehicle driving process parameter recording unit includes a dispatch system remote command process data recording module, a navigation and positioning antenna process data recording module, a gyroscope process data recording module, a wheel speed encoder process data recording module, a wheel steering encoder process data recording module, a drive process data recording module, and a hydraulic system process data recording module; The remote instruction process data recording module of the scheduling system is used to record and process remote instruction data for scheduling. The navigation and positioning antenna process data recording module is used to record and process the status words of the navigation antenna in the AGV vehicle and the magnetic nail number and relative coordinates of the positioning magnetic nail scanned by the antenna in real time. The gyroscope process data recording module is used to record and process the body steering angular velocity data of the AGV trolley during its movement; The wheel speed encoder process data recording module is used to record in real time the speed input to the four wheels and the feedback value of the wheel speed encoder during the AGV's movement. The automatic report generation unit is used to summarize the relevant information of all the previously analyzed institutions into a txt document for archiving; The dispatch building module is used for dispatching and allocating the received data information; The remote monitoring unit is used to remotely monitor the navigation PLC program, the electronic control PLC program, and the real-time image of the laser anti-collision unit inside the AGV vehicle. The remote fault diagnosis system is used to remotely and automatically diagnose and process faults by extracting the driving data of the AGV.

2. The apparatus for diagnosing faults in an automated terminal AGV system according to claim 1, characterized in that, The AGV control unit includes an onboard 5G wireless module, a laser anti-collision module, a ModBus gateway module, a navigation PLC controller, an electronic control PLC controller, and a driving process parameter recording unit. The onboard 5G wireless module is bidirectionally connected to the laser anti-collision module, the ModBus gateway module, the navigation PLC controller, the electronic control PLC controller, the navigation PLC controller, and the driving process parameter recording unit. The onboard 5G wireless module is bidirectionally connected to the remote monitoring unit and the remote fault diagnosis system. The AGV vehicle network connection unit is used to connect with the base station network between AGV vehicles, increasing the bandwidth to 1000 Mbps. The gateways of the two base stations are the same as the original networks, that is, base station 1 is still in the 172.16.158 network segment, and base station 2 is still in the 172.16.160 network segment.

3. The apparatus for diagnosing faults in an automated terminal AGV system according to claim 2, characterized in that, The vehicle-mounted 5G wireless module is used to establish a 5G vehicle-mounted base station and to perform wireless connection processing for the vehicle-mounted 5G. The laser anti-collision module is used to sense the distance to surrounding obstacles and the current load of the vehicle; The ModBus gateway module is used to convert the RS232 serial port of the electronic control PLC into an RJ45 network port, connect it to the image switch through a network cable, and then remotely connect to the dispatch building module through the 5G wireless network. The navigation PLC controller is used for positioning and motion navigation control of the AGV trolley. The electronic control PLC controller is used to control the wheel speed and steering angle of the AGV trolley. The driving process parameter recording unit is used to record and process component parameter data during the driving process of the AGV.

4. The apparatus for diagnosing faults in an automated terminal AGV system according to claim 3, characterized in that, The wheel steering encoder process data recording module is used to record and process in real time the steering angle given by the system to the four wheels and the feedback value of the steering encoder during the driving of the AGV. The driver process data recording module is used to record and process the ramp speed input and feedback, voltage, current, torque, and fault code data of the AGV trolley driver in real time. The hydraulic system process data recording module is used to record the pressure changes of the hydraulic steering pump and the hydraulic brakes of the front and rear wheels in real time during the movement of the AGV.

5. The apparatus for diagnosing faults in an automated terminal AGV according to claim 4, characterized in that, The task selection unit includes a health diagnosis module and a fault analysis module, which operate independently of each other. The health diagnosis module is used to detect and process the health status of the AGV vehicle during normal operation. The fault analysis module is used to analyze and process the fault information obtained after the AGV stops abnormally.

6. The apparatus for diagnosing faults in an automated terminal AGV system according to claim 5, characterized in that, The vehicle file selection unit includes a remote automatic download module and a local manual selection module, and the remote automatic download module and the local manual selection module operate independently. The remote automatic download module is used to remotely and automatically download the latest 10 consecutive driving data files to a folder automatically generated on the duty room computer desktop based on the selected vehicle number and operation time; The local manual selection module is used to manually select the folder containing the local driving data files.

7. The apparatus for diagnosing faults in an automated terminal AGV system according to claim 6, characterized in that, The driving file integration module is used to merge and reorganize data files to obtain continuous data of all parameters during the AGV driving process; The parameter parsing modules are used to extract each parameter from the continuous data of all parameters in sequence and perform pre-analysis processing. The positioning antenna and faulty magnetic nail drawing and intelligent diagnosis module is used to parse the working status word of the navigation positioning antenna and to perform time-domain drawing of the magnetic nail number information scanned by the antenna and the change of the relative coordinates of the magnetic nail with respect to the navigation antenna coordinate system. It also identifies and marks the antenna when it is interfered with by the external magnetic field in the drawing, and intelligently judges whether the magnetic nail is abnormal based on the antenna status word and the change of the relative coordinates of the magnetic nail. The abnormal magnetic nail number and the abnormal time are marked in sequence, and corresponding maintenance suggestions are given. The gyroscope parameter plotting and intelligent diagnosis module is used to plot the actual rotational angular velocity of the AGV vehicle monitored by the gyroscope during the AGV's movement and the rotational angular velocity data calculated according to the vehicle's motion state equation in the time domain. It also performs comprehensive analysis and diagnosis based on the changes and relative deviations of the two, marks the abnormalities, and provides corresponding maintenance suggestions. The wheel speed encoder parameter plotting and intelligent diagnosis module is used to plot the speed of the four wheels given by the AGV vehicle's control system and the feedback value of the corresponding wheel speed encoder in the time domain, and to perform a comprehensive analysis in combination with the vehicle's operating status and the wheel brake status, so as to diagnose the fault of the wheel speed encoder mechanism. At the same time, it automatically frames the data image of abnormal periods and provides corresponding maintenance suggestions. The steering encoder parameter plotting and intelligent diagnosis module is used to plot the steering angle given to the four wheels by the AGV vehicle driving control system and the feedback value of the corresponding wheel-side steering encoder in the time domain. It also performs a comprehensive analysis in combination with the vehicle operating status, hydraulic steering main pressure and wheel brake status to diagnose the fault of the wheel-side steering encoder mechanism. At the same time, it automatically frames the data image of abnormal periods and gives corresponding maintenance suggestions. The motor driver parameter plotting and intelligent diagnosis module is used to plot the ramp given speed and speed feedback, output voltage, current, torque and driver fault codes of the AGV trolley's traveling motor driver in the time domain, and to perform comprehensive analysis in combination with the vehicle's operating status and wheel brake status, thereby diagnosing faults in the wheel speed encoder mechanism. At the same time, it automatically frames the data images of abnormal periods and provides corresponding maintenance suggestions. The hydraulic system parameter plotting and intelligent diagnostic module is used to plot the main pressure value, brake pressure value, and steering proportional valve current value of the hydraulic oil pump system during AGV operation in the time domain. It also performs a comprehensive analysis in conjunction with the vehicle's operating status, the steering setpoint of the control system, and the wheel brake status, thereby diagnosing faults in the hydraulic oil pump mechanism. At the same time, it automatically frames the data images during abnormal periods and provides corresponding maintenance suggestions.

8. The apparatus for diagnosing faults in an automated terminal AGV system according to claim 7, characterized in that, The remote monitoring unit includes a navigation PLC monitoring module, an electrical control PLC monitoring module, and a laser monitoring module. The navigation PLC monitoring module is used to monitor and process the navigation PLC program in the AGV in real time. The PLC monitoring module is used to monitor and process the AGV trolley's PLC program in real time. The laser monitoring module is used to monitor and process the scanned images of the laser in real time.

9. A medium for AGV fault diagnosis system at an automated terminal, wherein a computer program is stored thereon, characterized in that, When executed by the processor, the program implements the storage management of data in the apparatus of the automated terminal AGV fault diagnosis system as described in any one of claims 1 to 8.

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