Bosch Rexroth 3 842 560 099 Operating Manual
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Bosch Rexroth 3 842 560 099 Operating Manual

Bosch Rexroth 3 842 560 099 Operating Manual

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ACTIVE Shuttle
Transport vehicle
3 842 560 099
3 842 560 570
3 842 560 107
3 842 560 108
3 842 560 206
3 842 560 151
Operating manual
3 842 560 081/2023-07
Replaces: –
ENGLISH
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Summary of Contents for Bosch Rexroth 3 842 560 099

  • Page 1 ACTIVE Shuttle Transport vehicle 3 842 560 099 3 842 560 570 3 842 560 107 3 842 560 108 Operating manual Replaces: – 3 842 560 206 3 842 560 081/2023-07 ENGLISH 3 842 560 151...
  • Page 2 Our products are subject to natural wear and aging. © All rights reserved by Bosch Rexroth AG, also for the registration of industrial property rights. This document may not be reproduced or distributed to third parties without our consent.
  • Page 3 ACTIVE Shuttle Transportno vozilo Hrvatski MTNO 560 080 media ACTIVE Shuttle Transportkjøretøy Norsk media MTSL 560 080 ACTIVE Shuttle Transportno vozilo Slovenščina MTSK 560 080 media ACTIVE Shuttle Prepravné vozidlo Slovenčina 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 4: Table Of Contents

    Unpacking the charging station Positioning/preassembling the charging station 7.5.1 Connecting the charging station electrically Unpacking the ACTIVE Shuttle Commissioning Emergency measure pressing emergency stop device Emergency measure removing lithium-ion battery Initial commissioning Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 5 Load distribution on the loading area 16.8 Scanning levels of the personal protection systems (laser scanner) 16.9 Protective fields 16.9.1 Front protective fields 16.9.2 Rear protective fields 16.10 Stereo camera fields for 3D obstacle detection 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 6: About This Documentation

    ) If not included in the scope of delivery, download from the manufacturer's website: [email protected] AMR RB02831888 manual This manual explains the AMR (Autonomous Mobile Robot) and its functionalities. This manual provides information on configuration and operation of the ACTIVE Shuttle. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 7: Presentation Of Information

    Indicates a hazardous situation that may result in minor to CAUTION moderate injury if not avoided. NOTICE Property damage: The product or the surrounding area could get damaged. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 8: Symbols

    Designation Meaning Autonomous Mobile Robots Rexroth ACTIVE Shuttle Management System Automated Guided Vehicle system Small load carrier according to VDA 4500 Source Loading point Unloading point German Association of the Automotive Industry Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 9: Safety Instructions

    89. • Technical data see page 85. • For ambient conditions, see page 87. Handheld controller The handheld controller is used in the "Manual" operating mode exclusively for controlling the ACTIVE Shuttle. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 10: Improper Use

    Any use other than that described in the section "Intended use" is considered improper and is not permitted. Bosch Rexroth AG is not liable for any damage resulting from improper use. The user alone bears any risks associated with improper use. The following foreseeable misuses also constitute improper use: •...

  • Page 11: Product-Specific Safety Instructions

    Secure the system against being switched back on. • Dispose of the product in accordance with the regulations in your country. During disposal 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 12: Active Shuttle

    Risk of serious injury due to a speed not adapted to the situation. The speed of the ACTIVE Shuttle must be reduced in narrow corridors, curves, „ intersections and areas with passenger traffic. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 13 Danger of collision with obstacles outside the protective area! The ACTIVE Shuttle can be damaged by obstacles outside the protective area. Keep the driving range free of obstacles, especially flat objects or objects „ protruding into the driving range. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 14 (see chapter 10.5). NOTICE Risk of damage through unauthorized use! Unauthorized opening of the ACTIVE Shuttle housing can damage the vehicle. Always keep the square key secured against unauthorized use. „ Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 15: Lithium-Ion Batteries

    „ defective contacts. To charge the lithium-ion battery in the ACTIVE Shuttle, use only the „ charging station supplied by Bosch Rexroth or the charger supplied by Bosch Rexroth. Only operate lithium-ion batteries and accessories in perfect condition. „ Protect the battery terminals from short circuiting.
  • Page 16 Recommendations for best possible battery service life Store lithium-ion batteries with a charge level of about 50%. „ After three months, check the charge level and recharge to approx. 50% „ if necessary. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 17: Handheld Controller

    Do not expose the handheld controller to high temperatures, large temperature „ variations or direct sunlight. Do not expose the handheld controller to mechanical shocks, excessive dust, „ moisture or strong magnetic fields. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 18: Charging Station

    Do not use the charging station as a stepladder or climbing aid. „ • The emergency stop function is carried out on the charging station by pulling out the mains plug. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 19: Personal Protective Equipment

    • Turns of the ACTIVE Shuttle must be planned at a sufficient distance from solid obstacles. • Driveways must be level, dry, clean and free of objects lying around. For exact requirements regarding the ground conditions of the driveways, see chapter 16.6 Floor requirements. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 20 After setting up ACTIVE Shuttle, the operator is obliged to check all driveways again for possible hazards! • Provide safety-related instructions/training to the operating personnel (see chapter 2.9 Training of the operating personnel) before the first commissioning or recommissioning and afterwards regularly. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 21: Minimum Marking

    & IEC 60825.1 .1 1 .1 0, R 10 5. 1 C 60 w ith & IE ie s m pl Make sure that these safety labels are present and legible. „ 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 22: Training Of The Operating Personnel

    • The distance to the intersecting paths must be large enough that a person will not enter the track of the ACTIVE Shuttle in the area of the protective field (protective field length max. 970 mm). Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 23: General Notes On Property And Product Damage

    During cleaning before starting the cleaning work. • Prevent cleaning agents from getting into the system. • Never use solvents or corrosive cleaning agents. • Do not use a pressure washer for cleaning. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 24: Scope Of Delivery

    • total weight incl. dolly of up to 260 kg and a – max. stacking height of 1,200 mm. Handheld controller To control the ACTIVE Shuttle in the "Manual" operating mode. Charging station ACTIVE Shuttle To charge the lithium-ion battery in the ACTIVE Shuttle. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 25: Product Description

    N1: Square lock N2: Square key .1 1 .1 0, R 10 5. 1 C 60 w ith ie s & IE m pl 560 080-02 Fig. 1: ACTIVE Shuttle, overall view 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 26 "Release brake" buttons WiFi antennas 560 080-03 Fig. 2: ACTIVE Shuttle, detailed view of control panel 1) No recordings or personal data are stored with the stereo cameras for 3D obstacle detection. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 27 (travel function is shut down) +/– Speed ± Lifting the loading area Lowering the loading area Source position Dip position Charging station position Parking position 560 592-03 Fig. 3: Handheld controller 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 28 The forward speed is set to 1.0 m/s. 1,0 m/s Connection to ACTIVE Shuttle lost. Loading area moves downwards. Loading area moves upwards. The maximum forward speed in "Manual" operating mode is set (1.0 m/s). Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 29 Detection flag for ACTIVE Shuttle Charging station assembly kit Assembly frame for charging station Cable duct Cover sheet Assembly frame assembly kit 560 080-24 Fig. 4: Charging station ACTIVE Shuttle 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 30: Safety And Warning Devices

    • Acoustic signal transmitter .1 1 .1 0, R 10 5. 1 C 60 w ith & IE ie s m pl 560 080-04 Fig. 5: Safety equipment and warning signs Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 31: Signaling

    - Further movement of the Remove the obstacle from the ACTIVE Shuttle is blocked protective field. by an obstacle. Battery charge indicator Visual indicator on the Bar chart touchscreen display (see chapter 5.4) 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 32: Protective Fields

    (laser scanner) of the ACTIVE Shuttle can recognize them. In areas with driveways of the ACTIVE Shuttle, no reflective surfaces may be „ present. Especially in the area of the supermarkets. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 33: Touchscreen Display

    There are no errors. Gray tab screen: An error has occurred that has not been caused by the ACTIVE Shuttle system. Red tab screen: An error has occurred in the ACTIVE Shuttle system. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 34 You can switch between the various functions of the screen in the navigation bar (C). The menu items "Job overview" (H), "Localization" (I), "Move platform" (J), "Settings" (K) and "Error messages" (L). Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 35: Identification Of The Product

    Make sure the lifting gear is correctly fastened before lifting the product! „ Secure the product against tipping over when lifting! „ Make sure that no one but the operator is in the danger zone during lifting and „ lowering! 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 36: Mounting/Removing The Lift Aid

    • Protect the product from environmental influences, such as dirt and moisture. • Observe the ambient conditions, see page 87. • When storing lithium-ion batteries, observe the safety instructions on Page 15 and the national specifications. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 37: Installation

    Keep the transport packaging for further use (e.g. return shipment to the „ manufacturer). Dispose of the packaging material (film, cardboard boxes, etc.) in accordance „ with the applicable regulations in your country. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 38: Positioning/Preassembling The Charging Station

    When climbing or stepping onto the charging station, there is a risk of injury from falling and of damage to the housing of the charging station. Do not use the charging station as a stepladder or climbing aid. „ Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 39 Blue guide line, roll 25 m, 3 842 560 612 Charging station on assembly frame Blue guide line Wall/obstacle Teaching point Mount the charging „ station and attach the guide lines. 560 592-11 Fig. 9: Positioning the charging station 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 40 40/100 Installation Mount the assembly frame. Disassemble the rear-side guard plate. =7 Nm =18 Nm =18 Nm =18 Nm 560 080-23 Fig. 10: Mounting the assembly frame Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 41 M = 25 Nm housing parts. After assembly the docking station, verify that it is Ø 8 perpendicular to the vehicle axis. ≥ 20 SW13 =25 Nm 560 080-28 Fig. 11: Docking station assembly 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 42 Mount the wall box at the assembly frame. Ø 8 Carry out a test in accordance with DIN EN 60204-1 section 18. 560 080-25 Fig. 12: Assembly of the charging station on the assembly frame Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 43: Connecting The Charging Station Electrically

    Germany, or the corresponding regulations in the country of use. The charging station has a GST plug-in system. Further details on the connection can be found in the enclosed document "General safety instructions for electro-technical installation of MPS components" 3 842 358 820. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 44 560 080-26 the docking station. Fig. 13: Wall box and docking station connection (principle representation) Connect the grounding cable to the docking station. Connect the wall box to the power supply. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 45: Unpacking The Active Shuttle

    Dispose of the packaging material (film, cardboard boxes, etc.) in accordance „ with the applicable regulations in your country. Before moving the ACTIVE Shuttle, put it into proper operation (see chapter 8). „ 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 46: Commissioning

    The signal lamps light  up permanently in red. Unlock the emergency „ stop device by turning the mushroom knob. 560 080-07 Fig. 15: Emergency measure pressing emergency stop device Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 47: Emergency Measure Removing Lithium-Ion Battery

    To charge the lithium-ion battery in the ACTIVE Shuttle, use only the charging „ station supplied by Bosch Rexroth or the charger supplied by Bosch Rexroth. Only operate lithium-ion batteries and accessories in perfect condition. „ Protect the battery terminals from short circuiting.
  • Page 48 The state of charge of the lithium-ion battery should not fall below 6%. Reduce the discharge of the lithium-ion battery during extended downtimes „ by switching the lithium-ion battery off using the OFF/ON switch. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 49 Adjust the tensile force „ of the toggle latches in case of loose seat. 560 592-08 Fig. 16: Emergency measure removing lithium-ion battery 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 50: Initial Commissioning

    Risk of serious injury due to the ACTIVE Shuttle tipping over. Observe the permissible load and the maximum stacking height. „ Ensure that the load is evenly distributed (see chapter 16.7). „ Only use the ACTIVE Shuttle in accordance with its intended use. „ Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 51 Risk of serious injury due to unauthorized intervention in automated processes by operating personnel. Under no circumstances may operating personnel intervene in the automated „ processes such as loading and unloading positions and when moving in and out at the charging stations. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 52 • Check that all safety and warning devices function in accordance with the following descriptions when switching on and off. For initial commissioning, proceed chronologically as described in the chapters 8.3.1 to 8.3.5: Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 53: Switching On The Active Shuttle

    If it is not possible to switch the ACTIVE Shuttle on, check the seating of the is stopped. battery connecting plug and press the battery main switch again (B2, see Fig. 1 The signal lamps (F)  on Page 25). light up permanently in red. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 54: Switching To "Manual" Operating Mode

    Stage 2 Approval, ON Stage 3 Panic function, OFF (travel function is shut down) The signal lamps (F)  light up permanently in yellow. 560 080-10 Fig. 18: Switching to "Manual" operating mode Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 55: Checking The Lower And Upper Loading Area Height And Adjusting It, If Necessary

    TOP setting screw. Re-tighten the adjustment screws. Check h by raising and „ lowering again. 560 080-22 Fig. 19: Checking the lower and upper loading area height and adjusting it, if necessary 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 56: Moving The Active Shuttle To The Charging Station With The Handheld Controller

    Reduce the discharge of the lithium-ion battery during extended downtimes by „ switching the lithium-ion battery off using the OFF/ON switch. Fully charge the ACTIVE Shuttle before further use (for battery charge indicator, „ see chapter 5.4 Touchscreen display). Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 57: Moving The Active Shuttle Manually

    „ charging contacts of the ACTIVE Shuttle and the charging station do not match, readjust the height of the charging 560 080-11 station (see chapter 7.5 Fig. 20: Drive unlocking Fig. 11). 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 58: Raising/Lowering The Loading Area Without Handheld Controller

    Switching off the ACTIVE Shuttle Press the ON/OFF button (P) for at least 5 seconds. The ON/OFF button (P) flashes green.  The acknowledgment button (Q) flashes green.  The ACTIVE Shuttle switches off.  Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 59: Mounting Safety Flags (Accessories, Not Included In The Scope Of Delivery)

    (see Table 1 on Page 6) and/or the documentation of the external fleet management system. Re-commissioning after a standstill Follow the steps for initial commissioning and the instructions displayed on the touchscreen display and in the AMS / external fleet management system. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 60: Preparing The Supermarket

    Maintain a minimum distance of 50 mm to protect hands. „ If, due to their weight, it is foreseeable that dollies will be enclosed by more „ than just the hands, the distances must be increased accordingly. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 61 Required accessories: Blue guide line, roll 25 m, 3 842 560 612 Dollies Blue guide line Supermarket Teaching point Access ramp Attach the guide lines. „ 560 592-10 Fig. 22: Supermarket (dimensions not to scale) 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 62: Permissible Dollies

    HDLL 10011 + version DOS-1334 D.2 ESD 4 castor wheels All configurations apart from "Wheel position 1 + brake" possible. For more compatible dollies, refer to the list of compatible accessories in the manual AMR RB02831888. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 63: Operation

    When a loaded vehicle starts up/restarts, there is a danger of crushing the rear wheels of the load. • Do not put your feet between the wheels. • Observe start-up warning. • Always wear safety shoes. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 64 Under no circumstances may operating personnel intervene in the automated „ processes such as loading and unloading positions and when moving in and out at the charging stations. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 65 „  Please note: To prevent the battery from discharging, switch off the ACTIVE Shuttle completely during longer standstill by pressing the battery main switch (B2, see Fig. 1 on Page 25). 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 66: Lithium-Ion Batteries

    To charge the lithium-ion battery in the ACTIVE Shuttle, use only the charging „ station supplied by Bosch Rexroth or the charger supplied by Bosch Rexroth. Only operate lithium-ion batteries and accessories in perfect condition. „ Protect the battery terminals from short circuiting.
  • Page 67 Recommendations for best possible battery service life Store lithium-ion batteries with a charge level of about 50%. „ After three months, check the charge level and recharge to approx. 50% „ if necessary. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 68: Handheld Controller

    Risk of injury due to incomplete assembly of the charging station! The charging station may only be operated if all housing parts and cover sheets are fully assembled. Install the charging station according to Fig. 11 on Page 41. „ Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 69: Wear

    – Liquids that thicken as they evaporate and become highly viscous or adhesive (sticky) can lead to malfunctions. – In such instances, special care must be taken when planning the system, and the maintenance intervals must be correspondingly shortened. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 70: Maintenance And Repair

    Servicing only by Bosch Rexroth. „ • Return shipment only in original transport packaging with mounted lift aid. • Observe DIN EN ISO 13857 when you remove or replace protective equipment and/or bypass safety equipment. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 71: Cleaning And Care

    The filter mats of the fans must be maintained regularly depending on the „ ambient/operating conditions (see chapter 10.5). Reduced drive/braking power due to contaminated drive rollers Dirty drive rollers may impair the drive/braking power. Remove dirt from the drive rollers regularly. „ 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 72: Regular Safety Inspections

    Depending on the actual operating conditions of the vehicle, it may be „ necessary to reduce the test cycle. In addition, it may be necessary to carry out a reduced daily inspection of the „ safety equipment. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 73: Periodic Inspection - Minimum Requirements

    If an inspection reveals an error, the ACTIVE Shuttle must be shut down immediately. In this case, have the vehicle and its safety equipment checked by the Bosch Rexroth Service. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 74: Procedure For Testing The Personal Protection Systems (Laser Scanner)

    Press the ON/OFF button (P) until the acoustic signal transmitter sounds. „ Release the ON/OFF button (P) immediately when the signal transmitter sounds. „ The acoustic signal transmitter sounds within a second after pressing the ON/OFF button and the signal lamps (F) briefly light up orange. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 75: Maintenance

    If these values are not met, replace the cam rollers (for replacing the rollers, see chapter 10.6.2). Replacement of the entire cam rollers incl. slewing ring only by Bosch Rexroth. Contact the Bosch Rexroth service for a noticeable play in the slewing ring of the cam rollers (see chapter 15).
  • Page 76 In a state of health of ≤ 60%, the battery is worn and should be replaced. It may be necessary to replace the battery earlier, e.g. if the transport performance/flow of the ACTIVE Shuttle is no longer sufficient for your application. For replacing the lithium-ion battery, see chapter 10.6.4. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 77: Replacement Of Wear Parts

    Required accessories: • Filter mat set (5 pieces), 3 842 560 623 , 10 R 10 s wi & IEC 560 080-13 Fig. 23: Set of filter mats and fan positions 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 78 ACTIVE Shuttle. Remove the filter cover. Replace the filter mat (A) if necessary. Assembly is „ correspondingly done in the reverse order. 560 080-14 Fig. 24: Replacing the filter mats (example illustration) Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 79: Replacing The Cam Rollers

    SW13 M = 10-15 Nm SW13 SW13 M = 10-15 Nm M = 10-15 Nm 3 842 560 832 3 842 560 833 560 080-15 Fig. 25: Replacing the cam rollers 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 80: Replacing The Anti-Slip Mat Of The Loading Area

    3 842 560 130 .1 1 .1 0, R 10 5. 1 C 60 w ith & IE ie s m pl 560 080-16 Fig. 26: Replacing the anti-slip mat of the loading area Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 81: Replacing The Lithium-Ion Battery

    Adjust the tensile force „ of the toggle latches in case of loose seat. 560 080-17 Fig. 27: Replacing the lithium-ion battery 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 82: Decommissioning

    You are legally obligated to return old batteries and batteries. „ You can do this free of charge at Bosch Rexroth or another „ collection point in your vicinity. You can obtain addresses of suitable collection points from your city or „...

  • Page 83: Upgrading And Modification

    13 Upgrading and modification • Do not modify the product. • The Bosch Rexroth warranty only applies to the configuration as delivered, and to approved upgrades. The manufacturer will not accept any warranty claims for systems with unapproved modifications or upgrades.

  • Page 84: Service

    Additional information on service, repair and training as well as the current addresses of our sales offices can be found at: http://www.boschrexroth.com Outside of Germany, please contact our nearest contact person. Service Germany Tel.: +49 711 40049810 Email: [email protected] Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 85: Technical Data

    Driveway width >900 mm: approx. 1 m/s • Max. Speed: 1 m/s Please note: The maximum speed depends on the prevailing ambient conditions. If you have any questions, please contact your Bosch Rexroth contact person. • Noise emission: < 70 dB(A) • Positioning and navigation: via laser scanner •...

  • Page 86: Lithium-Ion Battery

    • Internal fuse: 16 A circuit breaker, triggering characteristic C Docking station • Dimensions (HxWxD): 417 x 402 x 131 mm • Weight: 11 kg Assembly frame • Dimensions (HxWxD): 1,253 x 342 x 671 mm • Weight: 12 kg Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 87: Ambient Conditions

    • Contact with highly reactive acidic or alkaline substances must be avoided. 16.5 IT infrastructure For IT infrastructure requirements, refer to the manual AMS RB02831885 or the manual AMR RB2831888. If you have any questions, please contact your Bosch Rexroth contact person. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 88: Floor Requirements

    – Joints not in sources, sinks or in the area of charging stations – Repeating joints (e.g. gutters, drains) not admissible – No starting over joints max. 15 mm 560 080-22 Fig. 29: Admissible uneven floors and joints Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 89: Load Distribution On The Loading Area

    • The dimensions H/2, L/2 and B/2 arise from the actual dimensions of the load incl. dolly. • The distance between the mass point and the loading area must always be ≤ H/2. 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 90 90/100 Technical data = 1200 mm max. 600 mm max. B / 2 = 400 mm max. 560 080-19 Fig. 30: Position of the mass point of the load Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...

  • Page 91: Scanning Levels Of The Personal Protection Systems (Laser Scanner)

    „ the laser scanner. Avoid reflective surfaces on the laser scanner plane. „ Scan levels each measured above the floor: • Front: scan level 130 mm • Rear: scan level 87 mm 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 92: Protective Fields

    Protective field Protective field [mm/s] [mm/s] Width Length [mm] [mm] 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1,000 1,050 2000 2000 1000 1000 1000 1000 1000 Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 93 1000 1000 1000 1000 1,080 1000 1000 1000 1000 1000 Table 14: In the danger area Zone Vreg Vmax Protective field Protective field [mm/s] [mm/s] Width Length [mm] [mm] 1000 1000 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 94: Rear Protective Fields

    Protective field Table 17: In the danger area Zone Vreg Vmin Protective Warning Protective field [mm/s] [mm/s] field field Width Length Length [mm] [mm] [mm] -100 -110 1000 Warning field Protective field Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 95 Muted Slow Warning field Protective field Table 19: Forward Zone Vreg Vmin Protective Warning Protective field [mm/s] [mm/s] field field Width Length Width [mm] [mm] [mm] 1000 Warning field Protective field 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...

  • Page 96: Stereo Camera Fields For 3D Obstacle Detection

    3.000 560 080-20 Fig. 31: Field distance range obstacle detection (all dimensions in mm) 1) No recordings or personal data are stored with the stereo cameras for 3D obstacle detection. Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 97 Technical data 97/100 560 080-21 Fig. 32: Field close range obstacle detection (all dimensions in mm) 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 98 98/100 Bosch Rexroth AG, ACTIVE Shuttle: ACTIVE Shuttle, 3 842 560 081/2023-07...
  • Page 99 99/100 3 842 560 081/2023-07, ACTIVE Shuttle: ACTIVE Shuttle, Bosch Rexroth AG...
  • Page 100 Bosch Rexroth AG Postfach 30 02 07 70442 Stuttgart Germany Fax +49 711 811–7777 [email protected] www.boschrexroth.com Subject to modifications 3 842 560 081/2023-07...

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