SICK APS Operating instructions

OPERATING INSTRUCTIONS

EN

APS

Driver Assistance System

Operating Instructions

APS

2 Operating Instructions | SICK 8018378/2015-10-22

Subject to change without notice

This work is protected by copyright. Any rights derived from the copyright shall be reserved for SICK AG.

Reproduction of this document or parts of this document is only permissible within the limits of the legal

determination of Copyright Law. Alteration or abridgment of the document is not permitted without the explicit

written approval of SICK AG.

Operating Instructions

APS

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Contents

1 About these operating instructions ................................................................................. 6

1.1 Function of this document .................................................................................... 6

1.2 Target group .......................................................................................................... 6

1.3 Information depth ................................................................................................. 6

1.4 Abbreviations used ............................................................................................... 7

1.5 Symbols used ........................................................................................................ 7

2 Safety .................................................................................................................................. 8

2.1 Qualified safety personnel .................................................................................... 8

2.2 Applications of the system ................................................................................... 8

2.3 Intended use ......................................................................................................... 9

2.4 General safety notes and protective measures ...................................................... 9

2.4.1 Safety notes and symbols................................................................... 9

2.4.2 General safety notes .........................................................................10

2.4.3 Potential sources of danger .............................................................11

2.5 Protection of the environment............................................................................13

2.5.1 Power consumption ..........................................................................13

2.5.2 Disposal after final decommissioning ..............................................13

3 Product description .........................................................................................................14

3.1 Scope of delivery .................................................................................................14

3.2 System components ...........................................................................................15

3.3 System functionality ............................................................................................17

3.4 Project planning ..................................................................................................18

3.5 Status indicators .................................................................................................19

4 Mounting ..........................................................................................................................21

4.1 Function test before mounting ...........................................................................21

4.2 Mounting the laser scanner ...............................................................................21

4.3 Mounting the bracket for the operator display ..................................................23

4.4 Mounting the tone buzzer ...................................................................................24

4.5 Mount the Ethernet switch .................................................................................24

5 Electrical installation ......................................................................................................25

5.1 Wiring plan ...........................................................................................................25

5.2 Connecting the laser scanner ............................................................................26

5.3 Connecting the Ethernet switch .........................................................................28

5.4 Connecting the operator display ........................................................................29

5.5 Connecting the tone buzzer ................................................................................32

6 Commissioning ................................................................................................................33

6.1 Launching the system .........................................................................................33

6.2 The operator display in configuration mode ......................................................34

6.3 Making system settings ......................................................................................35

6.4 Configuring the laser scanner ............................................................................37

6.4.1 Starting sensor setup ........................................................................37

6.4.2 Specifying mounting position of the laser scanner .........................37

6.4.3 Align laser scanner in the yaw axis ..................................................38

6.4.4 Align the laser scanner in the pitch and roll axis ............................42

6.4.5 Restrict angle range ..........................................................................45

6.4.6 Completing the configuration of the laser scanner .........................46

6.5 Expanding the warning zone ..............................................................................46

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Contents

6.6 Switch to the operating mode ............................................................................ 47

6.6.1 Quit configuration mode ................................................................... 47

6.6.2 Operating mode for person carrying out commissioning ............... 47

6.6.3 Enable operating mode for tug drivers ............................................ 49

7 Operation ......................................................................................................................... 50

7.1 Start the tug ........................................................................................................ 50

7.2 The operator display in the operating mode for tug drivers ............................. 51

7.3 Lifting the nose wheel ........................................................................................ 52

7.3.1 Determination of the aircraft type ................................................... 52

7.3.2 Confirm aircraft type ......................................................................... 53

7.4 Tug the aircraft ................................................................................................... 54

7.4.1 Display of the direction of travel ...................................................... 54

7.4.2 Switching between day/night mode ................................................ 55

7.4.3 Detecting objects outside of the warning zone ............................... 55

7.4.4 Collision warning in the event of obstacles in the warning

zone ................................................................................................... 56

7.4.5 React to collision awareness ........................................................... 57

7.5 Release nose wheel drive unit again ................................................................. 58

8 Maintenance ................................................................................................................... 59

8.1 Overview of maintenance tasks ......................................................................... 59

8.2 Maintenance during operation .......................................................................... 59

8.2.1 Cleaning the laser scanners ............................................................ 59

8.2.2 Visual inspection of the cables ........................................................ 60

8.3 Replacing components ....................................................................................... 61

8.3.1 Replacing a laser scanner ................................................................ 61

8.3.2 Replacing the operator display ........................................................ 62

8.3.3 Replacing the Ethernet switch ......................................................... 62

8.4 Activities on the web interface ........................................................................... 63

8.4.1 Calling up the web interface ............................................................ 63

8.4.2 Enable configuration mode on the display ...................................... 64

8.4.3 Activating operating mode for tug drivers via the web

interface ............................................................................................ 65

8.4.4 Updating aircraft database .............................................................. 66

9 Fault diagnosis ................................................................................................................ 67

9.1 Response to faults .............................................................................................. 67

9.2 Fault indicators of the LMS511 ......................................................................... 67

9.3 Typical fault situations during commissioning .................................................. 68

9.3.1 Configuration incomplete or incorrect ............................................. 68

9.3.2 Laser scanner not available ............................................................. 68

9.4 Typical fault situations during operation ........................................................... 70

9.4.1 Aircraft type not detected ................................................................. 70

9.4.2 Aircraft type lost during the tugging process .................................. 71

9.4.3 Viewing window of the laser scanner contaminated ...................... 73

9.4.4 Laser scanner not available ............................................................. 74

9.4.5 Display of the direction of travel suddenly switches ...................... 75

9.4.6 No image on display ......................................................................... 76

9.5 SICK support ....................................................................................................... 76

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Contents

10 Annex ................................................................................................................................77

10.1 Technical data .....................................................................................................77

10.2 Dimensional drawings ........................................................................................78

10.2.1 Dimensional drawing of the LMS511 laser scanner .......................78

10.2.2 Display dimensional drawing ............................................................79

10.2.3 Ethernet switch dimensional drawing ..............................................80

10.2.4 Tone buzzer dimensional drawing....................................................80

10.3 Using a connection box (optional) ......................................................................81

10.4 Tone selection for tone buzzer ...........................................................................82

10.5 Overview of operating processes .......................................................................83

11 Figures and tables ...........................................................................................................84

11.1 List of tables ........................................................................................................84

11.2 List of figures .......................................................................................................85

11.3 Keywords index ...................................................................................................87

Chapter 1 Operating Instructions

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About these operating instructions

1 About these operating instructions

Please read through this chapter carefully before you use the documentation and work

with the APS driver assistance system.

1.1 Function of this document

These operating instructions are designed to give technical personnel instructions on

the safe mounting, configuration, electrical installation, commissioning, operation and

maintenance of the Aircraft Protection System APS.

These operating instructions do not provide information on operating the vehicle into

which the APS is or will be integrated. For information about this, refer to the vehicle's

operating instructions.

1.2 Target group

These operating instructions are intended for people who install, connect, commission,

operate, and maintain APS.

Activities Target group

Mounting, electrical installation,

maintenance, and replacement

of system components

Qualified personnel, such as service technicians

or industrial electricians

Commissioning and

configuration

Qualified personnel, such as technicians or

engineers

Operating the system Personnel qualified in running and operating the

system (tug drivers)

Tab. 1 Target group

1.3 Information depth

These operating instructions contain information about the APS driver assistance system

on the following topics:

• Product description

• Mounting

• Electrical installation

• Commissioning and configuration

• Operation

• Maintenance and repairs

• Fault diagnosis and troubleshooting

• Technical data and dimensioned drawings

When planning and using the APS driver assistance system, technical skills are required

that are not covered by this document.

The official and legal regulations for operating the APS must always be complied with.

Further information on laser measurement technology can be obtained from the

department for automatic detection and position determination at SICK AG or is available

online at www.sick.com.

Note

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About these operating instructions

1.4 Abbreviations used

Aircraft Protection System = driver assistance system for aircraft tugs

Laser measurement sensor = laser scanner from SICK AG

1.5 Symbols used

Recommendations are designed to assist you in the decision-making process with respect

to the use of a certain function or technical measure.

Notes provide information about the features of a device, application tips, or other

information that may come in useful.

Instructions that must be carried out in the described order are referred to as step-by-step

instructions and are indicated by numbered lists. Carefully read and follow the instructions

for action.

Instructions for taking action are indicated by an arrow. Carefully read and follow the

instructions for action.

LED symbols describe the status of a diagnostics LED. Examples:

 The LED is illuminated continuously.

 The LED is flashing.

 The LED is off.

Display symbols show the status of the 7-segment display:

 Constant display of characters, e.g., U

 Flashing display of characters, e.g., 8

 Alternating display of characters, e.g., L and 2

APS

LMS

Recommendation

Note

1. / 2. ...







,





,



Chapter 2 Operating Instructions

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Safety

2 Safety

This chapter concerns your own safety and the safety of the system operator.

 Please read this chapter carefully before you begin working with APS.

2.1 Qualified safety personnel

The APS must only be mounted, commissioned, and maintained by adequately qualified

personnel.

A qualified person

• has sufficient skills in the field of the respective equipment based on their technical

training and experience and

• has been instructed by the manufacturer in system operation and all applicable safety

guidelines and

• is familiar with all relevant country-specific occupational safety regulations, work safety

regulations, guidelines, and generally accepted technical rules and standards (e.g.,

DIN standards, VDE regulations, country-specific rules) to such an extent that he/she

is able to evaluate the safe condition of the power-operated equipment and if he/she

• has access to and has read the operating instructions.

2.2 Applications of the system

APS is a driver assistance system for towbarless aircraft tugs at airports. The system gives

the driver visual and acoustic warnings of possible obstacles during the tugging process.

The tugging processes tug/maneuver, push-back and enter/exit hanger are supported.

Laser scanners mounted on the tail of the tug detect the aircraft type to be monitored

during the lifting process of the nose landing gear. APS uses this to determine the size and

shape of the monitored area for the hazardous points of the wing and tail.

During the tugging process, APS constantly monitors the surroundings of the aircraft/tug

combination. If an obstacle is detected in the monitored area, the assistance system

promptly gives an acoustic and visual warning.

APS only detects objects which are visible in the measurement plane for the laser

scanner. Therefore, the laser scanner must have a free view of the area to be

monitored.

Using APS means that hazardous situations, such as parked vehicles, ground equipment,

staircases, landing gear blocks, insufficiently opened hanger doors or incorrectly

positioned aircraft, are detected in good time and that accidents during the tugging

process are avoided.

APS is a driver assistance system. This means that at all times the driver bears the full

responsibility for safe operation, in particular for people who are in the hazardous zones of

the vehicle.

Note

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Safety

2.3 Intended use

APS may only be used as described in section 2.2 Applications of the system. It may only

be used by qualified personnel in the environment in which it was mounted and initially

commissioned by qualified safety personnel in accordance with these operating

instructions.

APS is not a safety device for human protection and it therefore does not comply with

any safety standards. For safety applications, please contact SICK AG.

In the event of any other usage or of modification to the system – including in the context

of mounting and installation – any claims against SICK AG under the warranty will be

rendered void.

2.4 General safety notes and protective measures

2.4.1 Safety notes and symbols

The following safety and hazard symbols are used for your own safety, for the safety of

third parties, and for the safety of the machine. You must therefore observe these symbols

at all times.

HAZARD

Denotes an immediate hazard that may result in severe to fatal injuries.

The symbol shown on the left-hand side of the note refers to the type of hazard in question

(the example here shows a risk of injury resulting from electrical current).

WARNING

Denotes a potentially dangerous situation that may result in severe to fatal injuries.

The symbol shown on the left-hand side of the note refers to the type of hazard in question

(the example here shows a risk of damage to the eye by laser beams).

CAUTION

Denotes a potentially dangerous situation that may result in minor personal injury or

possible material damage.

NOTE

Denotes a potential risk of damage or functional impairment to the device or the devices

connected to it.

This symbol includes a reference to supplementary technical documentation.

Note

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Safety

2.4.2 General safety notes

APS has been designed in a way that allows for safe operation. However, a certain level of

risk will always remain.

Awareness of potential sources of danger in the system will help you to work in a safer

manner and thus prevent accidents.

To avoid risks, please also observe the special warnings in each of the individual chapters.

WARNING

Safety notes

Observe the following to ensure the safe use of the system as intended.

• The notes in these operating instructions must be complied with.

• All official and statutory regulations governing the operation of the system must be

complied with.

• The national and international legal specifications apply to the installation and use of

the system, to its commissioning, and to recurring technical inspections, in particular:

– The accident prevention regulations and work safety regulations

– Any other relevant safety regulations

• The checks must be carried out by qualified safety personnel or specially qualified and

authorized personnel, and must be recorded and documented to ensure that the tests

can be reconstructed and retraced at any time.

• These operating instructions must be made available to the operator of the system.

The system operator must be instructed by qualified safety personnel and must read

the operating instructions.

• The driver must follow relevant instructions and conduct inspections in order to ensure

that the screens of all laser scanners are clean and undamaged

• The laser scanners must have a free field of vision. The sensor head must not be

covered by other objects, for example.

• SICK AG recommends carrying out a system check before commissioning the system.

WARNING

Risk resulting from improper operation

Improper installation and commissioning, damaged components, and unsuitable ambient

conditions such as excessively cold or warm temperatures and high levels of dust, fog or

spray, may cause faults and faulty alarms and may result in a complete system crash.

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Safety

WARNING

System does not comply with safety standards

APS is not suitable for the protection of humans within the meaning of the applicable

safety standards for machines. The system therefore does not comply with safety

standards.

APS is a driver assistance system. It provides the driver with visual and acoustic

warnings

about objects outside of the tug. At all times the driver bears the full responsibility

for safe

operation, in particular for people who are in the hazardous zones of the tug.

WARNING

Location of use

The system is intended exclusively for use in industrial environments.

2.4.3 Potential sources of danger

Laser protection

WARNING

Damage to the eye by laser beams

The LMS511 laser scanner used by APS conforms to laser class 1 (eye-safe) as per

EN 60 825-1 (see laser warning label on the device for publication date). This ensures

compliance with 21 CFR 1040.10 except for the tolerances according to Laser Notice

No. 50 of July 26, 2001.

The laser operates at a wavelength γ = 905 nm (invisible infrared light). The laser beam is

not visible to the human eye.

The radiation emitted in normal operation is harmless to human skin and eyes.

Improper use (e.g., opening the housing and stopping the motor) can result in dangerous

exposure to radiation.

 Never open the laser scanner housing. Opening the housing does not interrupt the

operation of the laser beam.

 Observe the laser safety regulations as per IEC 60 825Q1 (latest version).

• No maintenance is required to ensure compliance with laser class 1.

• The laser output aperture is the front screen on the LMS511 laser scanner.

• The laser warning is located on the right side of the laser scanner.

CAUTION

Important

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Safety

Electrical current

HAZARD

Risk of injury and damage caused by electrical current

Improper handling of live devices may lead to severe personal injury or death by electric

shock.

 Electrical installation and maintenance work must always be carried out by personnel

authorized to do so.

 The power supply must be disconnected when attaching and detaching electrical

connections.

 Select and implement wire cross-sections and their correct fuse protection in

accordance with the applicable standards.

 Do not touch any live components.

 In the event of danger, immediately disconnect the system from the power supply.

 Always use original fuses with the specified current rating.

 Report any damaged cables to the maintenance team without delay.

 Observe the current safety regulations when working on electrical systems.

Commissioning/Operation/Maintenance

WARNING

Risk resulting from incorrect commissioning and configuration

Do not commission without testing by qualified safety personnel!

Before you operate the system or a device for the first time, you must have it checked and

approved by qualified safety personnel.

NOTE

Claims under the warranty rendered void

Do not open the device housing. The devices are sealed.

If the device is opened, any warranty claims against SICK AG will be void.

WARNING

Risk resulting from faults

Cease operation if the cause of the malfunction has not been clearly identified.

A defect in the system may result in fatal accidents or damage to the system.

 Take the APS out of operation if you cannot clearly identify the fault and if you cannot

safely remedy the problem.

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Safety

2.5 Protection of the environment

The system has been designed to minimize its impact on the environment. It consumes

very little power.

Always act in an environmentally responsible manner at work. For this reason, please note

the following information regarding disposal.

2.5.1 Power consumption

Including its components, the system typically consumes 27 W.

The peak power consumption when starting up or in the event of integrated sensor heating

is 82 W.

2.5.2 Disposal after final decommissioning

 Always dispose of unusable or irreparable devices in an environmentally safe manner in

accordance with the relevant national waste disposal regulations.

 Dispose of all electronic assemblies as hazardous waste. The electronic assemblies are

easy to dismantle.

SICK AG does not take back devices that are unusable or irreparable.

Note

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Product description

3 Product description

This chapter provides information on the special properties of the APS driver assistance

system. It describes the design and operating principle of the system.

Always read this chapter before you mount, install and commission the system.

3.1 Scope of delivery

APS consists of an LMS511 laser scanner, an interactive operator display, an Ethernet

switch, mounting kits and connecting cables as well as a tone buzzer. A connection box

can be optionally used.

Fig. 1: Scope of delivery for APS

Thorough check for completeness

 It is recommended that you carefully check for and report transport damage of any kind

as soon as possible after receiving the system.

 Also verify that the delivery includes all components listed on the delivery note.

Note

Important note

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Product description

Quantity Part no. Description

1069176

APS

1

1064730

Laser scanner LMS511

1

2078363

Operator display

1

6051544

Ethernet switch

1

6043994

Tone buzzer

1

2015623

Mounting kit 1 for mounting the LMS511

1

2015624

Mounting kit 2 for adjusting the LMS511 on mounting kit 1

1

5326406

Mounting system with swivel connector for mounting the

operator display, incl. adapter for operator display with screws

1 6048243 Ethernet cable for connection of the LMS511 to the

Ethernet switch, 10 m, 2 M12 male connectors, straight

1 6048251 Ethernet cable for connection of the operator display

to the Ethernet switch, 5 m, M12 male connector, straight,

M12 male connector, angled

1 6036160 Power supply cable Ethernet switch with

5-pin M12 coupling/open cable end, 10 m

1 6042564 Power supply cable LMS511 with 5-pin M12 coupling/open

cable end (electronics and heating), 20 m

1 2058813 Power supply cable for the operator display and for

connection of the tone buzzer.

Tab. 2: Scope of delivery for APS

You can optionally use a connection box if there are not enough terminals for connecting the

devices to the power supply of the tug.

1 2070552 Connection box for power (sensors, display, tone buzzer,

Ethernet switch)

3.2 System components

Laser scanner LMS511

The laser scanner mounted on the tail of the tug constantly monitors the entire

surroundings behind the tug during the tugging process, in a radius of up to 80 m around

the sensor.

The laser scanner scans its surroundings using a laser beam in a plane in the time-of-flight

process. The maximum scanning angle is 190°. If the emitted laser beam is reflected by

an object, the distance to the object is calculated.

The laser beam is emitted through the front screen. The scan plane position is indicated by

a housing marking next to the front screen.

Fig. 2: Laser output aperture of the LMS511

Optional

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Product description

The laser scanner features automatic contamination detection for the front screen and

interior heating. The contamination notification is output on the operator display.

The operator display

The interactive operator display is the central component of the system. During the tugging

process, it visualizes the outline of the aircraft/tug combination and the aircraft's towing

corridor to the driver. Obstacles in the monitored area are identified, and therefore can be

quickly localized.

The display has a touch screen, which allows the user to make entries during initial

commissioning and subsequent operation.

The operator display is attached to a mounting kit with a swivel connector in the tug cab,

within the driver's field of view.

Fig. 3: Operator display with mounting kit

Ethernet switch

An Ethernet switch connects the laser scanner with the operator display.

Tone buzzer

A tone buzzer supports the visual warning about an obstacle on the display with an

acoustic warning.

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Product description

3.3 System functionality

APS is a driver assistance system for towbarless aircraft tugs at airfields. It supports the

following processes:

Identification of the aircraft type

After the nose wheel is lifted by the tug, the system uses the measured values from the

laser scanner to determine the track width of the main landing gear (track) and the

distance to the nose wheel (wheelbase).

Fig. 4: Typical installation position of the LMS511 and definition of track and wheelbase

APS compares the measured values with those in the aircraft database saved in the

system. Matching aircraft types are suggested. The tug driver selects the correct aircraft

and confirms the selection.

Visualization of the tugging process

On the display, the driver can now see an outline display of the aircraft/tug combination

with the warning zone. The size and shape of the warning zone are predefined when the

aircraft type is selected. The warning zone is the area with a gray border that moves with

the aircraft.

The measured points of the main landing gear and hanging engines are hidden.

Fig. 5: Visualization of the tugging process on the operator display

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Product description

Collision awareness during the tugging process

During the tugging process, the laser scanner constantly monitors the surroundings of the

aircraft. The warning zone automatically adjusts to the towing corridor of the aircraft.

As soon as the laser scanner detects an obstacle in the warning zone, the driver is warned

of a possible collision with other objects. The warning is carried out visually by showing the

obstacle on the display. In addition, the system issues an acoustic warning via the tone

buzzer installed in the tug cab.

Fig. 6: Collision awareness during the tugging process

The laser scanner must always identify the lifted aircraft type during the tugging process.

In order to do this, the wheelbase of the main landing gear and the distance to the nose

wheel are constantly measured and monitored.

3.4 Project planning

Reliable and problem-free use of APS depends on a number of different factors.

Aircraft tug requirement

APS has been designed exclusively for aircraft tugs without tow bars. In this tug type,

the nose landing gear of the aircraft is grasped and lifted.

Requirements for objects to be protected

APS protects aircraft with the following features:

Dimension Meaning Min. Max.

Track Track width = distance between the wheels

of the main landing gear

4.5 m 15 m

Wheelbase Wheelbase = distance from the nose wheel

to the main landing gear

10 m 32 m

Fuselage height Distance from the ground to the body of the

aircraft

> 80 cm

Tab. 3: Requirements for objects to be protected

Note

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Product description

Requirements for the detection of obstacles

APS provides warnings of all obstacles under the aircraft at the mounted height (scan

plane) of the laser scanner.

Objects which protrude into the field of vision above the mounted height (scan plane)

cannot be detected by the laser scanner due to its mounting position.

3.5 Status indicators

Laser scanner

The laser scanner is fully automatic in normal operation — no operator intervention

is required. The LEDs (1) signal the operational status of the laser scanner. In addition,

the 7-segment display (2) is also available for diagnostics when errors or faults occur

(see chapter 9.2 Fault indicators of the LMS511).

Fig. 7: Status indicators for the LMS511

Display Meaning

Laser scanner in operation, laser scanner running in measuring mode

without any errors

Laser scanner is either not in measuring mode (stopped by the user) or it is

running in measuring mode, but errors have occurred

Front screen dirty

Not used

Tab. 4: Status indicators of the LMS511

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Product description

Operator display

The operator display distinguishes between two operating modes. The system enters

configuration mode when it is first started or following unlocking via the web interface.

It contains assistants for the configuration of the laser scanner and for the expansion of

the side warning zone.

In the operating mode, the display helps the driver with the tugging process and warns of

possible obstacles.

Fig. 8: The operator display in configuration and operating mode

Tone buzzer

The tone buzzer does not have any status indicators.

The DIP switch on the underneath of the housing can be used to set the tone selection (1)

and the volume (2).

Recommended settings: OFF, ON, ON, OFF, ON (01101)

Fig. 9: DIP switch on the tone buzzer

Additional information on this can be found in the appendix in chapter 10.4 Tone

selection for tone buzzer.

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SICK APS Operating instructions

SICK APS Operating instructions

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