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
8018378/2015-10-22 Operating Instructions | SICK 3
Subject to change without notice
Contents
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
APS
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Subject to change without notice
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
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
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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