MIR MiR1000 Commissioning Manual

MiR500 and MiR1000
Commissioning Guide
Commissioning documentation package
Release date: yyyy.mm.dd
MiR500 and MiR1000 Commissioning Guide
Table of contents
1
Introduction ......................................................................................................................................................3
2
Terminology ......................................................................................................................................................3
3
Commissioning .................................................................................................................................................4
3.1
Products in the system .............................................................................................................................4
3.2
Illustration of the final setup ....................................................................................................................4
3.3
Detailed description of the hazard areas and zones ................................................................................5
3.4
Examples ...................................................................................................................................................5
3.4.1
Example 1. Charging station .............................................................................................................5
3.4.2
Example 2: Pallet rack ......................................................................................................................6
3.4.3
Example 3: Narrow corridor..............................................................................................................6
3.5
Brake test..................................................................................................................................................7
3.6
Inclines / Declines: are they within specifications? .................................................................................7
3.7
Evaluation of the environment and recommendations ...........................................................................7
3.8
Detailed description of user groups and permissions ..............................................................................8
3.9
Training .....................................................................................................................................................8
3.9.1
Interacting ........................................................................................................................................9
3.9.2
Warnings and signals ........................................................................................................................9
3.9.3
Zones and markings on the floor ................................................................................................... 10
3.9.4
Maintenance .................................................................................................................................. 10
3.9.5
Ratings ........................................................................................................................................... 10
3.9.6
Sensor system ................................................................................................................................ 10
3.9.7
How to create and change zones. ................................................................................................. 10
4
User manual................................................................................................................................................... 11
5
Declaration of conformity ............................................................................................................................. 12
6
Appendix A: Resources .................................................................................................................................. 13
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MiR500 and MiR1000 Commissioning Guide
1 Introduction
This commissioning document contains a series of sections describing tasks to complete before the robot can
be considered safely commissioned. It is the integrator’s responsibility to make sure that all relevant data is
assigned to the customer.
2 Terminology
•
•
•
•
•
•
•
Awareness indicator: Light and/or acoustic signals.
Charging station: Unit connected to a factory power outlet, which enables a robot to autonomously
charge its batteries.
Relative marker: Object with specific physical dimensions and shape used for precision positioning of
the robot. Examples are pallet rack, charging station, V-, VL- and L-markers.
Operating hazard zone: Marked area according to standard EN 1525:1997 clause A.3.2. No obstacles
other than those specified by each scenario can be placed inside this zone.
Pallet lift: Top module that enables MiR500 and MiR1000 robots to carry pallets on the load surface.
Pallet rack: Delivery station for pallets. Dimensions L1300 x W1182 x H352 mm.
Protective field: Area in which a protective stop is automatically triggered if a person or object enters
the area.
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MiR500 and MiR1000 Commissioning Guide
3 Commissioning
3.1 Products in the system
List all products sold that are relevant to this system. Use serial number.
•
•
•
•
•
Robots
Top modules
Charging stations
Racks
Markers
Example:
Products sold:
Product name
MiR500
MiR500
MiR500 EU Pallet Lift
MiR500 EU Pallet Lift
MiR EU Pallet Rack
MiRCharge 48V
Serial number
XXXXXXX01
XXXXXXX02
XXXXXXX01
XXXXXXX02
XXXXXXX01
XXXXXXX01
Other relevant products sold prior to the integration:
Product name
Serial number
Mirror
N/A
Product name
Serial number
Product name
Serial number
3.2 Illustration of the final setup
Make a detailed illustration of the final setup, including but not limited to the following:
•
•
•
•
Area marked for:
o Robots
o Staff and visiting guests
o Other traffic
o Charging stations
o Pallet rack
o Elevators
o Other
Zones on the map
Positions and markers on the map
Mirrors and other helping aids that improve safety
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MiR500 and MiR1000 Commissioning Guide
It is recommended to use pictures and screen shots of maps to illustrate the setup. To identify the hazard
areas, use the ID numbers from the table in clause 2.2.
3.3 Detailed description of the hazard areas and zones
List all hazard areas and make a detailed description of each area, at a minimum all relevant risks from the risk
analysis must be included.
•
•
Name all racks/stations/markers/etc.
Needed safety precautions for the specific areas.
o Fence.
o Markings on the floor etc.
o Other types of marking (stickers, etc.)
o Top modules (Pallet lifts, etc.)
o Muted protective fields
o Awareness indicators (light or acoustic)
o List of the residual risks in case of any
Notice! Be aware of stairways, the robot is not able see them.
Add screens shots of the map.
3.4 Examples
The following sections give examples of how to take precautions in hazardous areas and zones in different
situations.
3.4.1 Example 1. Charging station
Description of charging station area
The charging station area consists of one MiRCharge 48V (A) placed against a wall. Two meters to the left of
MiRCharge 48V is the door to the canteen, which makes the area highly concentrated with traffic.
A
Potential hazards
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MiR500 and MiR1000 Commissioning Guide
•
•
A person standing next to the charging station and the robot while the robot is docking → Risk of
getting crushed
A person standing between the charging station and the robot while the robot is docking → Risk of
getting crushed
Measures needed to be taken
Markings around the operating hazard zone on the floor
Awareness indicators implemented
Training of staff and visiting guests
The speed limitations of MiR500/MiR1000
The area in front of the door is a restricted zone for MiR500/MiR1000
Implemented
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Residual risk: extremely low.
3.4.2 Example 2: Pallet rack
Description of the area
A pallet rack placed in the end of a conveyor belt. MiR500/MiR1000 must always enter and exit from the same
site.
Potential hazards
•
•
•
Pallet is lowered onto the robot’s top surface during docking procedure while a person is touching the
surface → Risk of getting crushed.
The robot is maneuvering towards the pallet rack while a person is standing near → Risk of getting
crushed.
Person standing next to or between the charging station and the robot while the robot is docking →
Risk of getting crushed.
Needed measures to be taken
Markings around the operating hazard zone on the floor.
Awareness indicators implemented.
Training of staff and visiting guests.
Restricted area for MiR500/MiR1000 at one side of the pallet rack.
Implemented
Yes/no
Yes/no
Yes/no
Yes/no
Residual risks: extremely low.
3.4.3 Example 3: Narrow corridor
Description of the area
The area is a narrow corridor with two doors and there are often many pallets in the corridor.
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Potential hazards
•
MiR500/MiR1000 cannot detect a person entering the corridor from one of the doors → risk of getting
crushed
Measures needed to be taken
Awareness indicators implemented when MiR500/MiR1000 is approaching a door.
Training of staff and visiting guests.
Markings around the area where pallets are placed. Pallets may not be placed close to a
door.
Speed limitations of MiR500/MiR1000 in the corridor.
Restricted area for MiR500/MiR1000 in the doorway.
Mirrors placed in the corridor opposite the doors.
Implemented
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
Residual risks: extremely low
3.5 Brake test
A brake test should be performed to ensure, that the field of view is satisfactory according to the following:
1.
2.
3.
4.
Add maximum load the robot will be driving with.
Find the worst-case area for making the brake test (e.g. on a decline).
Drive full speed with the joystick toward an object (cardboard box or similar).
Measure the distance from the front of the robot to the object it was driving toward.
If the distance between the object and the robot is 20 cm or above, the brake test is completed and safe.
3.6 Inclines / Declines: are they within specifications?
Check all inclines and declines to ensure they are within the specifications for robots listed in section 3.1. The
specifications can be found under Specifications on MiR’s website.
3.7 Evaluation of the environment and recommendations
Evaluate the environment that the robots are going to operate in, and if any recommendations are given,
document them here. Pay special attention to the floor conditions.
Example:
There is a leak in a water pipe or there is an area with tools lying on the floor: it needs to be handled before the
robot can drive properly.
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MiR500 and MiR1000 Commissioning Guide
3.8 Detailed description of user groups and permissions
Make a detailed description of the different user groups and what they can do. Consider a few questions
before deciding the user groups:
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•
•
Who should have permission to do what?
Which zones/positions/etc. will be owned by which users/user groups?
How should the user permissions be set up (user groups)?
Assigning mission
Zone 1
Zone 2
X
X
Creating missions
X
Joystick
X
Positions
Zones
Integrator
System
administrator
Maintenance
Operator 1
Operator 2
Other
Map
User
groups
Warnings
Permissions
Markers,
charging stations,
pallet racks etc.
Example:
The table below gives an example of user group permissions:
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
3.9 Training
This section covers the subjects the training at a minimum must cover. Different systems might need added
training subjects, these must be added by the integrator.
All training material must be available to persons in the system, and each user group must know who to ask in
case of questions, errors etc.
Example:
The following table indicates the minimum level of training required for the different user groups, including
visiting guests:
Level of Integrator
training
Training subject
Interacting
Awareness indicators
Zones and markings
X
X
X
Local
system
administra
tor
X
X
X
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Maintainer
Operator
Visiting
guests
Others
X
X
X
X
X
X
X
X
X
X
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MiR500 and MiR1000 Commissioning Guide
Ratings
Sensor system
Assigning missions
Maintenance
Environmental
conditions
Create and change
zones
Other
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
The following sections describe the mentioned training subjects.
3.9.1 Interacting
Persons interacting with or passing the system must know how to interact with the robots.
This training session must include the following, but not be limited to:
• Don’t walk or drive directly toward MiR500/MiR1000.
• Don’t step directly into the path of MiR500/MiR1000.
• Don’t walk though or stop in hazard zones (permissions can be given to experienced personnel).
• Only walk or drive in zones allocated for those purposes.
3.9.2 Warnings and signals
This training session must include the following, but not be limited to:
• Identification of the signal for driving.
• How to stop MiR500/MiR1000 in case of an emergency.
• Identification of the signal for emergency stop.
• Awareness indicators.
In addition to the above, the user groups interacting with the robots daily must be trained to know the
following:
• All warnings and signals listed in the User Guide:
o Waiting for job
o Goal/path blocked
o Planning /Calculating
o Mission paused
o Startup signal before PC is active
o Shutting down robot
o General error, e.g. hardware, localization
o Charging
o Prompt user/Waiting for user’s response
• Signal for low battery
• Signal for personnel detection mode switched off
• Other signals
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3.9.3 Zones and markings on the floor
Pedestrians must be aware of which zones they are allowed to walk in and how the zones are marked.
Truck drivers must be aware of which zones they are allowed to drive in and how the zones are marked.
User groups interacting in the setup daily must have knowledge of all zones and markings and how to behave
in the zones.
3.9.4 Maintenance
Personnel responsible for maintenance of the setup must receive training of how to keep the robot(s) and the
environment maintained. Including but not limited to the following:
• Cleaning the sensors, cameras, wheels etc.
• Cleaning the environment where the robot is operating.
• Keeping the paths of MIR500/MiR1000 clear of objects.
• Maintain the floor.
• Maintain the markings.
• How to troubleshoot for the most common errors.
• Who to contact in case of an error that cannot be solved internally or if spare parts are needed.
3.9.5 Ratings
This training session must contain the knowledge of relevant ratings:
• Payload specifications: payload diagrams and dimensions.
• Max lift height
• Other
3.9.6 Sensor system
This training session must contain knowledge of the sensor system and the 3D camera, including the limits of
the system:
• Objects on the floor
• Light beams
• Glass
• Field of view
3.9.7 How to create and change zones.
This training session must contain information about hazard zones, including the following but not limited to:
• The requirements of safety zones, including:
o Braking distance and speed
o Warning signals (audial and/or visual).
o Markings.
o Other.
• How to change the safety zones.
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MiR500 and MiR1000 Commissioning Guide
4 User manual
A user manual must be created by the integrator and contain at least the following subjects:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
How to turn the robot(s) on and off (copy from the existing user guide).
Awareness indicators of the robot (copy from the existing user guide).
How to operate the robot (run missions, clear missions from queue, see status of missions, etc.).
How to charge the robot.
How to maintain the robot.
a. Cleaning (copy from the user guide).
b. Warning signs on the robot (stickers, light, audial warnings, etc.).
c. Change of wear parts (make a table to update when changing a component).
d. Change of safety components with an expiration day (lifetime) (make a table to update when
changing a component).
Maintenance of the environment.
a. Markings on the floor.
b. Cleaning of floor, mirrors etc.
Error handling from the end customers’ point of view.
a. Common errors and who to handle them.
b. Who to contact in case of an error.
Are there any top modules or other special cases?
MiRFleet.
What is the customer allowed/not allowed to change in order to maintain the declaration of
conformity of the setup (which changes will need the integrator’s approval)?
Residual risks.
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MiR500 and MiR1000 Commissioning Guide
5 Declaration of conformity
A declaration of conformity of the whole system must be created by the integrator. It must comply with EN
1525.
The declaration of conformity should as a minimum constrain the following (according to the Blue Guide
https://eur-lex.europa.eu/legal-content/EN/TXT/PDF/?uri=CELEX:52016XC0726(02)&from=EN):
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•
•
•
•
•
•
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A number identifying the product (the number does not have to be unique for each product, it could be
an item number).
Name and address of the integrator (which in this case will become the manufacturer).
Statement that the setup is the responsibility of the integrator.
Description of the product.
All relevant harmonization legislation of the European Union and harmonized standards the setup is
compliant with. Other relevant technical information may be added.
Name and address of the notified body if a notified body was involved in the conformity assessment.
Other relevant information, if applicable.
Date of the issued declaration along with the signature and title of an authorized person.
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MiR500 and MiR1000 Commissioning Guide
6 Appendix A: Resources
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MiR500 /MiR1000: MiR500 and MiR1000 Risk Analysis Guide v. 1.0
MiR500: MiR500 User Guide rev. 1.1
MiR1000: MiR1000 User Guide rev. 1.0
MiRCharge 48V: MiRCharge 500 Operating Guide v1.0
MiR500 EU Pallet Lift: MiR500 EU Pallet Lift Operating Guide v1.0
MiR EU Pallet Rack: MiR EU Pallet Lift Operating Guide v1.0
MiR500 lift: MiR500 Lift Operating Guide v1.0
MiR Lift Pallet Rack: MiR500 Lift Operating Guide v1.0
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