SICK NAV-LOC Operating Instructions Manual
NAV-LOC
Laser positioning system
O P E R A T I N G I N S T R U C T I O NS
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Subject to change without notice
Product described
NAV-LOC
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal notes
This work is protected by copyright. The associated rights are reserved by SICK AG. Reproduction of this document
or parts of this document is only permissible within the limits of the legal provisions of copyright law. Any modification, abridgment, or translation of this document is prohibited without the express written permission of SICK AG.
The trademarks mentioned in this document are the property of their respective owners.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
1 About this document ................................................................................................................ 6
1.1 Information on the operating instructions ..................................................................................... 6
1.2 Explanation of symbols ..................................................................................................................... 6
1.3 Further information ........................................................................................................................... 7
1.4 Customer service ............................................................................................................................... 7
2 Safety information .................................................................................................................... 8
2.1 General safety notes ......................................................................................................................... 8
2.2 Hazard warnings and operational safety ....................................................................................... 8
2.3 Intended use ....................................................................................................................................... 8
2.4 Improper use ...................................................................................................................................... 8
2.5 IP technology ...................................................................................................................................... 9
2.6 Requirements for operating personnel .......................................................................................... 9
3 Product description ................................................................................................................ 10
3.1 Scope of delivery ............................................................................................................................. 10
3.2 Design and function of NAV-LOC .................................................................................................. 11
3.3 Sensor Integration Machine (SIM) ............................................................................................... 12
3.4 Measurement accuracy ................................................................................................................. 12
3.5 Telegram listing .............................................................................................................................. 12
3.6 Data interfaces................................................................................................................................ 12
3.7 Diagnosis.......................................................................................................................................... 12
3.7.1 Diagnostic via LED status indicators ................................................................................................ 13
3.7.2 Diagnostic via SOPAS AIR .................................................................................................................. 14
3.7.3 Diagnostic via telegram ..................................................................................................................... 15
3.8 Reference map ............................................................................................................................... 15
3.9 Dynamic Environment Handling ................................................................................................... 17
3.10 Initial position .................................................................................................................................. 17
3.10.1 X,Y (position uncertainty) ................................................................................................................... 17
3.10.2 Yaw (orientation uncertainty) ............................................................................................................ 17
3.10.3 Environment specific considerations ............................................................................................... 18
3.11 Output of position and additional information .......................................................................... 21
3.11.1 Pose quality .......................................................................................................................................... 21
3.11.2 Advanced options ................................................................................................................................ 22
4 System requirements of NAV-LOC........................................................................................ 24
4.1 Requirements for the environment ............................................................................................. 24
4.2 Requirements for the 2D LiDAR sensor ...................................................................................... 24
5 Operating modes of NAV-LOC ............................................................................................... 26
5.1 IDLE mode ....................................................................................................................................... 26
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5.2 READY mode ................................................................................................................................... 26
5.3 PREPARE mode .............................................................................................................................. 27
5.4 LOCALIZE mode .............................................................................................................................. 27
6 Initial commissioning and demonstration mode............................................................... 28
6.1 Initial connection setup ................................................................................................................. 28
6.2 Creating a demo map .................................................................................................................... 29
7 Full Integration and commissioning .................................................................................... 31
7.1 Notes and preparatory information ............................................................................................. 31
7.2 Required software .......................................................................................................................... 32
7.3 Power supply ................................................................................................................................... 32
7.4 Network setup ................................................................................................................................. 33
7.4.1 SIM configuration ................................................................................................................................ 33
7.4.2 Connection setup ................................................................................................................................ 35
7.4.3 Switch usage ........................................................................................................................................ 36
7.4.4 Result port output ............................................................................................................................... 37
7.5 Transfering the reference map ..................................................................................................... 37
7.6 Configuration of the the embedded application ........................................................................ 38
7.6.1 Invoking SOPAS AIR via web browser .............................................................................................. 38
7.6.2 IDLE: Data source settings ................................................................................................................. 39
7.6.3 IDLE: Mounting Position (optional) ................................................................................................... 40
7.6.4 IDLE: Scan filter (optional) ................................................................................................................. 41
7.6.5 READY: Settings for localization ....................................................................................................... 43
7.6.6 LOCALIZE: Indication of contour and position ................................................................................ 45
7.6.7 LOCALIZE: Settings for the result port (data output) ..................................................................... 46
8 Synchronization ....................................................................................................................... 49
8.1 Synchronization options ................................................................................................................ 49
8.1.1 Synchronization via telegram request (polling) .............................................................................. 49
8.1.2 Synchronization via telegram request (polling) and HW port ...................................................... 50
8.1.3 Synchronization via a cyclical pulse provided on HW port ........................................................... 51
8.2 Setting of the hardware outputs .................................................................................................. 52
9 Troubleshooting ...................................................................................................................... 54
9.1 Hints to the network connection .................................................................................................. 54
9.2 Hints to initialization ...................................................................................................................... 54
9.3 Localization hints ............................................................................................................................ 55
9.3.1 Localization does not start ................................................................................................................ 55
9.3.2 No localization data is output ........................................................................................................... 55
9.3.3 Characters ............................................................................................................................................ 55
10 Transport and storage ............................................................................................................ 56
10.1 Transport .......................................................................................................................................... 56
10.2 Transport inspection ....................................................................................................................... 56
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10.3 Storage ............................................................................................................................................. 56
11 Service and maintenance ...................................................................................................... 57
12 NAV-LOC data sheet ............................................................................................................... 58
12.1 NAV-LOC features ........................................................................................................................... 58
12.2 System latencies............................................................................................................................. 59
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1 About this document
1.1 Information on the operating instructions
These operating instructions are intended to allow the technical personnel to perform safe mounting,
electrical installation work, configuration, commissioning, and maintenance on the 2D LiDAR sensor
and the “Sensor Integration Machine” (SIM) for localization based on contour data. The SIM20000A20A00 and a 2D LiDAR sensor are used together and referred to as NAV-LOC in the following description. The system components are referred to as 2D LiDAR sensor and SIM (Sensor Integration
Machine) for short, unless a clear distinction needs to be made.
This document describes solely how to operate NAV-LOC in a general sense. The instructions stated
below are supplementary device-specific documents for 2D LiDAR sensors, which can be combined
with the SIM2000-0A20A00 as a data source. These are required in addition as they describe the
specific connection options and configuration for each sensor:
NAV-LOC: SIM2000, NAV310 operating instructions (German 8023449, English 8023450)
NAV-LOC: SIM2000, NAV245 operating instructions (German 8023451, English 8023452)
NAV-LOC: Telegram Listing (English 8021387)
1.2 Explanation of symbols
All symbols used in this document and their meaning, warnings, and important information are marked
with symbols in this document and are compiled below. The warnings are introduced by signal words
that indicate the extent of the danger. These warnings must be observed at all times and care must be
taken to avoid accidents, personal injury, and material damage.
DANGER
… indicates a situation of imminent danger, which will lead to a fatality or serious
injuries if not prevented.
WARNING
… indicates a situation of possible danger, which can lead to a fatality or serious
injuries if not prevented.
CAUTON
… indicates a situation of possible danger, which can lead to minor or moderate
injuries if not prevented.
IMPORTANT
… indicates a situation, which can lead to property damage
if not prevented.
NOTE
… highlights useful tips and recommendations as well as information for efficient
and trouble-free operation.
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1.3 Further information
NOTE
All the documentation available for the device can be found on the online product page at:
www.sick.com
Solely type the specific document or device number in the search field.
This document describes solely how to operate NAV-LOC in a general sense. The instructions stated
below are supplementary device-specific documents for 2D LiDAR sensors, which can be combined
with the SIM2000-0A20A00 as a data source. These are required in addition as they describe the
specific connection options and configuration for each sensor. The following information is available
for download from this page:
• NAV-LOC variants:
o NAV-LOC: SIM2000, NAV310 operating instructions (German 8023449, English
8023450)
o NAV-LOC: SIM2000, NAV245 operating instructions (German 8023451, English
8023452)
• Model-specific online data sheets for device variants, containing technical data, dimensional draw-
ings and diagrams e.g.:
o Operating instructions of the SIM2000 (German 8020763, English 8020764)
o Operating instructions of the NAV310 (German 8016534, English 8016535)
o Operating instructions of the NAV245 (German 8018477, English 8018478)
• NAV-LOC: Telegram Listing (English 8021387)
• EU declaration of conformity for the product family
• Dimensional drawings and 3D CAD dimension models in various electronic formats
• These operating instructions, available in English and German, and in other languages if necessary
• Other publications related to the devices described here
• SOPAS ET configuration software for SIM and NAV 2D LiDAR sensors configuration (SOPAS Engi-
neering Tool)
• Support is also available from your sales partner: www.sick.com/worldwide.
• Publications dealing with accessories.
1.4 Customer service
NAV-LOC requires a valid map of its surroundings in order to operate.
The map will be created by SICK customer service. Contour data from the intended area of operation
are needed for this purpose. Please contact the responsible agency for the exact process of recording
measurement data and creating a map. See the last page of this document.
NOTE
Before calling, make a note of all type label data such as type code, serial number, etc., to ensure
faster processing.
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2 Safety information
2.1 General safety notes
The following safety notes must always be observed regardless of specific application conditions:
• The device must only be mounted, commissioned, operated, and maintained by professionally
qualified personnel.
• Electrical connections with peripheral devices must only be made when the voltage supply is dis-
connected.
• The device is only to be operated when mounted in a fixed position on a vehicle.
• The device voltage supply must be protected in accordance with the specifications.
• The specified ambient conditions must be observed at all times.
• The electrical connections to peripheral devices must be screwed on or clamped correctly.
• The cooling fins must not be covered or restricted in their functionality.
• The pin assignment of pre-assembled cables must be checked and adjusted if necessary.
• These operating instructions must be made available to the operating personnel and kept ready to
hand.
2.2 Hazard warnings and operational safety
NAV-LOC uses a 2D LiDAR sensor that contains a laser light source as data source. LEDs are used for
indication in the SIM. Please note the respective warning information in the respective operating instructions.
2.3 Intended use
NAV-LOC is used for detecting the position of manned or automated guided vehicles (AGVs) on the
programmed route and is used to localize the AGV. The 2D LiDAR sensor is attached to the AGV and
continuously measures the surrounding contour. NAV-LOC determines its own position from the contour
data and a previously created map related to the optical axis of the 2D LiDAR sensor used and the
orientation. The vehicle computer can use this to correct deviations from the course of the AGV in order
to keep it on the planned route.
NAV-LOC is intended for localizing indoors (halls and rooms) and is not suitable for use outdoors.
Ethernet is used to connect the system to the AGV vehicle control.
Setup and parameterization require various technical skills, depending on how the device is used.
IMPORTANT
In the event of any other usage or modification to the components such as the 2D LiDAR sensor or the
SIM, e.g., due to opening the housing during mounting and electrical installation, or to the SICK software, any claims against SICK AG under the warranty will be rendered void.
Depending on the vehicle and surroundings, the local safety requirements must be complied and protected with safety laser scanners or other measures may be necessary. The laser positioning system is
not used for collision avoidance with other objects.
2.4 Improper use
Use of the device is generally only permitted in the ambient conditions specified in the technical data.
NAV-LOC is not suitable for certain application conditions, including:
Use in areas with explosive atmosphere (hazardous area)
Use in safety-related applications, particularly the use of the localization system for collision avoid-
ance, e.g., the positions detected by NAV-LOC are not to be viewed as safe in terms of the Machinery Directive
Use in extreme ambient conditions (see technical data)
Use under water or in a corrosive atmosphere
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2.5 IP technology
NOTE
SICK uses standard IP technology in its products for network communication. The focus is on availabil-
ity of products and services. SICK always assumes that the integrity and confidentiality of the data and
rights affected by the use of the aforementioned products will be ensured by the customer. In all cases,
appropriate security measures, such as network separation, firewalls, virus protection, and patch management, must be taken by the customer on the basis of the situation in question.
See also the manuals for the specific 2D LiDAR sensors used and the SIM2000.
2.6 Requirements for operating personnel
WARNING
Risk of injury due to insufficient training.
Improper handling of the device may result in considerable personal injury and material damage.
All work must only ever be carried out by the stipulated persons.
The operating instructions state the following qualification requirements for the various
Areas of work:
Instructed personnel have been briefed by the operating entity about the tasks assigned to them
and about potential dangers arising from improper action.
Skilled personnel have the specialist training, skills, and experience, as well as knowledge of the
relevant regulations, to be able to perform tasks assigned to them and to detect and avoid any
potential dangers independently.
Electricians have the specialist training, skills, and experience, as well as knowledge of the rele-
vant standards and provisions, to be able to carry out work on electrical systems and to detect and
avoid any potential dangers independently. In Germany, electricians must meet the specifications
of the BGV A3 Work Safety Regulations (e.g., Master Electrician). Other relevant regulations applicable in other countries must be observed.
The following qualifications are required for various activities:
Activities
Qualification
Mounting, maintenance
Basic practical technical training
Knowledge of the current safety regulations in the workplace
Electrical installation, device replacement
Practical electrical training
Knowledge of current electrical safety regulations
Knowledge of the operation and control of the devices in their
particular application
Commissioning,
configuration
Basic knowledge of the WindowsTM operating system in use
Basic knowledge of the design and setup of the described con-
nections and interfaces
Basic knowledge of data transmission protocols
In-depth programming knowledge in the area of vehicle control
Operation of the
device for the
specific application
Knowledge of the operation and control of the devices in their
particular application
Knowledge of the software and hardware environment for the
particular application concerned
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3 Product description
This chapter provides information on the special properties of NAV-LOC.
It describes the design and operating principle, in particular the various operating modes.
Read this chapter before you install and commission NAV-LOC.
3.1 Scope of delivery
NAV-LOC is available in a range of variants depending on the requirements:
The delivery of NAV-LOC includes the following components:
No. of
units
Component
1
2D LiDAR sensor
1
SIM2000-0A20A00 including embedded application for localization
Please note: Cables for the voltage supply and data lines are not included with delivery and can optionally be ordered as accessories.
No. of
units
Additional accessories1
1
Power cabling for 2D LiDAR sensor: M12 A-coded, 5-pin
1
Ethernet cabling for 2D LiDAR sensor: (RJ45 to M12, D-coded)
1
Power cabling for SIM2000-0A20A00
Ethernet for SIM2000 to vehicle controller: RJ45 to RJ45
Sources for obtaining more information
Additional information about the SIM2000-0A20A00 and the 2D LiDAR sensor and their optional accessories can be found in chapter 1.3.
1
Additional accessories like power and network cabling or mounting brackets can be ordered at the
NAV-LOC product page. Under option “recommended accessories” is the minimum setup material.
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3.2 Design and function of NAV-LOC
NAV-LOC is intended for determining the position of automated guided vehicles (AGVs). The vehicle
positions are calculated based only on contour data observed at the respective position.
Figure 1: System overview for the integration of NAV-LOC
The vehicle surroundings are measured using laser beams based on the measured data of a 2D LiDAR
Sensor. The current position is calculated based on contour data and a previously created reference
map. This is transmitted to the vehicle controller as x-/y- coordinates and a yaw angle together with a
time stamp. The vehicle computer controls the AGV along the programmed route and corrects any route
deviation with the help of NAV-LOC.
An absolute coordinate system with an origin must be defined for the use of NAV-LOC for position output. For example, the origin point of the coordinate system can be at the corner of a factory hall.
For the commissioning of NAV-LOC, a reference map of the current surroundings must have been created and installed (loaded).
Contact your SICK Service to create a reference map for your plant.
Figure 2: Example of a reference map for localizing in an industrial environment.
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Device view:
Examples for a
2D LiDAR sensor
SIM2000-0A20A00 including NAVLOCs embedded application software
3.3 Sensor Integration Machine (SIM)
Additional information on the SIM2000-0A20A00 with notes on mounting, installation, and commissioning can be found online in the operating instructions2.
3.4 Measurement accuracy
The achievable measurement accuracy of NAV-LOC depends on the respective conditions during the
ride and their influence on the recording of measurement data.
The measurement accuracy in drive mode is influenced by:
The accuracy of the 2D LiDAR sensor used
Limitation of the visual range due to vehicles, persons and objects
Speed of the vehicle (particularly rotational movements)
Distance between vehicle and contour
Degradation of measurement performance due to fog, dust and like
Evenness of the route (e.g., uneven areas, ramps, and bumps)
Permanent changes to the surroundings (e.g. newly-built racks and walls/doors)
NOTE
The measurement accuracy specifications are listed in the data sheet in chapter 12.
3.5 Telegram listing
The specific CoLa A (Command Language ASCII) commands for communication between the SIM module and the vehicle controller is described in a separate document3.
3.6 Data interfaces
The SIM features 4 Ethernet interfaces for the connection to the network of the vehicle, which also
contains the 2D LiDAR sensor.
3.7 Diagnosis
The operation state of the embedded application can be monitored via three ways:
Via LED
Via SOPAS AIR web GUI
Via CoLa telegram
2
Open the page www.sick.com and enter the part number of the operating instructions of the SIM2000
(German 8020763, English 8020764) into the search field.
3
Open the page www.sick.com and enter the part number of the NAV-LOC telegram listing 8021387
(English) into the search field.
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In the CoLa communication, there are also three function blocks (NDEV, NAV and NRES) which have to
be initialized for the reception of data via the result port.
NDEV:
Handles the communication between NAV-LOC and the connected 2D LiDAR sensor
NAV:
Is responsible for the map handling and the localization.
NRES:
Handles the results (localization with pose and scan results) from NAV-LOC.
Besides the correct initialization, also following root causes may be checked:
Power supply of 2D LiDAR sensor
2D LiDAR sensor type
Interfacing of 2D LiDAR sensor as type, cable, IP address
3.7.1 Diagnostic via LED status indicators
When the device is operating, the operational status is indicated visually by status LEDs.
Using these status indicators, the operator can find out quickly and easily whether the device and the
peripherals are working properly or whether any faults or errors have occurred.
Monitoring the visual indicators is part of the routine inspection carried out on the device and the ma-
chine/plant area into which the device is incorporated.
The SIM LEDs are controlled by the embedded application and signal different states.
Meaning of display
Action
Color
Idle- / Interim state
Wait
Grey
Ok
No action required
Green
Warning
Act, if necessary
Yellow
Error
Action required
Red
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The following schematics illustrate the logical operation for the LEDs.
Figure 3: States related to the system
Figure 4: States related to the data source NDEV (2D LiDAR sensor)
Figure 5: States related to the application:
Figure 6: States related to the application:
3.7.2 Diagnostic via SOPAS AIR
A further analysis could be done via the SOPAS Air interface. The logical states are shown in the visualization. For a working condition, the simulated LEDs shall show a green light.
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States related to the data source NDEV (2D LiDAR sensor):
States related to the application:
3.7.3 Diagnostic via telegram
For the diagnostic via telegram, please refer to the telegram listing document chapter “Status com-
mands (read-only)”4.
3.8 Reference map
A reference map which shows the contour of the factory site is required for operation of the localization
system.
Contact your SICK Service to create a reference map for your plant. You will find a contact address for
your country on the last page of this document.
When mapping, the factory site is measured from the point of view of the 2D LiDAR sensor and entered
in a reference map.
Either a movable frame with a battery can be used, whereby the 2D LiDAR sensor must be aligned on
the same level as on the designated AGV, or the AGV with the mounted 2D LiDAR sensor is moved with
the manual control.
4
Open the page www.sick.com and enter the part number of the NAV-LOC telegram listing 8021387
(English) into the search field.
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Example for measurement device Example for AGV with NAV310
The two steps for creating a reference map are shown below.
Architecture drawing Step 1: Raw data Step 2: Completed reference map
(Red: measured area)
The contour visible from the sensor is dependent on the installation height of the 2D LiDAR sensor.
That is why it is necessary to observe the configuration notes in chapter 4.2 “Requirements for the
position of the 2D LiDAR sensor” when selecting the scan height and preparing the sensor for map
creation.
A coordinate system (x, y) is defined for the reference map in which the position and orientation of the
sensor is determined numerically during localization. The orientation and the origin point of this coordinate system can only be configured when creating the map and must therefore be defined for the
respective plant before creating the reference map.
The reference map must be loaded on the SIM to operate NAV-LOC. This step is described in chapter
7.5.
The map used must cover the entire vehicle operation area.
If needed, for example when operating on different levels connected by an elevator, different reference
maps can be used. However, only one map can be active at a time.
NOTE
If modifications are made in the factory site which result in a considerable change to the contour visible
from the sensor, for example due to modified walls, racks or other large structures, the accuracy of the
localization in the affected area is reduced or the localization itself is impaired. In this case, the affected
area must be re-mapped. Contact SICK Service about this.
The reference map is in the *.smap data format. You will receive a graphic representation of the reference map documentation. An imprinted grid enables orientation.
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3.9 Dynamic Environment Handling
The Dynamic Environment Handling enables that contour navigation is stable even when small and
gradual changes are made to the surroundings.
The system detects deviations between the visible contour and the saved reference map. All detected
deviations from the saved map are written to an internal additional layer, while the original map file
remains unchanged.
The system uses the reference map and the deviations described in the working map to obtain enough
valid ambient properties to ensure stable localization.
At the same time, NAV-LOC outputs additional information, which is described in chapter 3.11. The
parameter described there, Local Map Modification, defines the extent of the adjustment performed
in the current surroundings.
3.10 Initial position
When switching on localization mode, the position in the coordinate system of the reference map must
be provided to the system one time. Required is the information about the current position (x, y) and
the orientation angle. A value for uncertainty (“uncertainty range”) for all three coordinates has to be
specified for the provided position.
3.10.1 X,Y (position uncertainty)
The {X,Y} position is defined according to the maps global coordinate system. The corresponding uncertainty value in x and y specifies the area around this specified position within which the actual position is located. The range is also specified in accordance to maps global coordinate system.
3.10.2 Yaw (orientation uncertainty)
The orientation and uncertainty of the yaw angle are to be provided accordingly. In difference to the xy-pose, the alignment of the 2D LiDAR sensor in the maps global coordinate system must be considered. The X-axis (in direction of LEDs) defines the sensor orientation and the direction the 2D LiDAR
sensor is pointing to.
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3.10.3 Environment specific considerations
The map required for localization is provided in *.smap format by SICK Service.
It is loaded onto the SIM, as described in chapter 7.5.
In addition, SICK Service provides documentation of the reference map, which features a grid, in *.pdf
format. This grid can be used to estimate the initial position.
For example, a grid image of the factory system could be displayed for operation using the touch screen
of an automated guided vehicle system. An operator could use this grid to specify the initial position.
Example of map documentation with coordinate system and grid
The specified position and orientation must correspond with the current position of the AGV in the map
coordinate system and should be within a position uncertainty of ± 5 m and ± 15°from the actual position and orientation. Depending on the environment, it may be necessary to specify an initial position
with a higher accuracy.
NOTE
The following contains descriptions of situations which require closer inspection of the uncertainty.
During initial positioning, there are different requirements for the uncertainty range depending on the
surroundings.
Some situations are described below in which increased requirements for the accuracy of the initial
position and the uncertainty range exist.
Example for an initial position:
X-coordinate: 45 m
Y-coordinate: 23 m
Orientation angle: 140°
Map dimensions:
X: 0.0 – 60.0 m
Y: 0.0 – 50.0 m
Grid size: 10.0 m
Orientation angle:
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