Cart Tool User Manual

SmartCart® Automatic Guided Cart (AGC)
And
Cart Management System (CMS)
Configuration Software
User Manual
Jervis B. Webb Company

8212 M-119 Highway
Harbor Springs, MI 49740 USA
Date: April 13, 2004
Page 1
Users Manual Document Revisions
Document Revisions
Date Version Description
7/21/2003 ........... 1.0...................... Initial release of User Manual
12/17/2003 ........1.01..................... Added Automatic Charging Command
1/26/2004 ..........1.02..................... Added PLC Do Command. Added CMS and Blocking Database Tabs.
2/26/2004 ..........1.03..................... Added checkbox to disable Automatic Restart Bumper.
4/13/04 ..............1.04..................... Added route naming cautions in “Using Alternate Routing”. Added reference to VSMINFO.LIS file
in FAQ section.
4/21/04 .............1.04A ................... Document reformatting
5/12/04 .............1.04B ................... Added warning paragraph to Terms of Use.
1/6/05................1.04C ................... Various edits for format, style, and spelling.
6/29/05 ..............1.07..................... Updated battery level voltages on Cart Configuration Tab. Added Negative Block Numbers to the
Powerful Commands section. Largest block number was 300 now 1000.
Page 2
Users Manual Table of Contents
Table of Contents
1 Terms of Use........................................................................................................................................................................................ 4
2 Introduction........................................................................................................................................................................................... 4
®
3 CartTools Software............................................................................................................................................................................. 4
3.1 Overview ..........................................................................................................................................................................................................4
3.2 Initial Startup Screen........................................................................................................................................................................................5
Cart Functions Tab........................................................................................................................................................................................................6
3.3.1 Overview.........................................................................................................................................................................................6
Location Box ....................................................................................................................................................................................................6
3.3.3 Available Commands.....................................................................................................................................................................7
3.3.4 Arrival Functions.............................................................................................................................................................................8
Destination Functions ......................................................................................................................................................................................8
Release Functions...........................................................................................................................................................................................9
3.3.7 Cart Connected ............................................................................................................................................................................10
Cart Configuration Tab ................................................................................................................................................................................................ 11
3.4.1 Guidance ...................................................................................................................................................................................... 11
3.4.2 Horn Time..................................................................................................................................................................................... 11
3.4.3 Battery Reporting ......................................................................................................................................................................... 11
3.4.4 Cart Model.................................................................................................................................................................................... 11
3.4.5 Speed Outputs.............................................................................................................................................................................. 11
3.4.6 Installed Options........................................................................................................................................................................... 11
3.5 Cart I/O Tab....................................................................................................................................................................................................12
3.6 CMS and Blocking Database Tabs ...............................................................................................................................................................12
3.6.1 CMS Tab.......................................................................................................................................................................................13
Blocking Database Tab..................................................................................................................................................................................13
3.6.3 Block Numbers.............................................................................................................................................................................13
4 System Design...................................................................................................................................................................................16
4.1 Using Destination Numbers...........................................................................................................................................................................16
4.2 Using Release Numbers ...............................................................................................................................................................................16
4.3 Using Alternate Routing.................................................................................................................................................................................16
4.4 Simple System...............................................................................................................................................................................................17
4.4.1 Simple System - Single Cart........................................................................................................................................................17
4.4.2 Simple System - Multiple Carts....................................................................................................................................................17
4.5 Designing a Traffic Controlled System..........................................................................................................................................................17
4.5.1 Traffic Control Concepts ..............................................................................................................................................................17
4.5.2 Designing Your Traffic Controlled System..................................................................................................................................18
5 SmartCart Removal From System ...................................................................................................................................................26
6 Reading Transponders......................................................................................................................................................................27
7 Other Features and Tips....................................................................................................................................................................28
7.1 Frequently Asked Questions .........................................................................................................................................................................28
7.2 The Powerful Commands..............................................................................................................................................................................28
7.2.1 Set Destination and Destination Functions. ................................................................................................................................28
7.2.2 Wait Until Input. ............................................................................................................................................................................28
7.2.3 Delay – While Still Traveling.........................................................................................................................................................28
7.2.4 Negative Block Numbers .............................................................................................................................................................29
7.3 CCU Board – I/O Location List......................................................................................................................................................................29
7.3.1 Inputs ............................................................................................................................................................................................29
7.3.2 Outputs .........................................................................................................................................................................................29
8 PLC Do – Onboard PLC Interface....................................................................................................................................................30
8.1 Definition of Handshaking Signals ................................................................................................................................................................30
8.1.1 From the CCU to the PLC............................................................................................................................................................30
8.1.2 From the PLC to CCU..................................................................................................................................................................30
8.2 Power supply for Onboard PLC ....................................................................................................................................................................30
8.3 Application Considerations............................................................................................................................................................................30
8.3.1 Bumper Trips ................................................................................................................................................................................30
8.3.2 General Wiring Considerations....................................................................................................................................................30
8.3.3 PLC Initiation Timing ....................................................................................................................................................................31
8.3.4 AGC “Settling” Once Stopped......................................................................................................................................................31
8.3.5 Cart Release – During PLC Do ...................................................................................................................................................31
8.3.6 PLC Idle Timing............................................................................................................................................................................31
Page 3
Users Manual CartTools Software - Overview
1 Terms of Use
The use of this software program is subject to the SMARTCART® END-USER SUBLICENSE TERMS agreed to during the
installation process. See Help About to view these terms. Copyright © 2003-2004 Jervis B. Webb Company (JBW). All rights
reserved.
This software is designed specifically for use with SmartCart AGCs and related products. Operation of this software for any other
purpose than with a SmartCart AGC is prohibited.
Any such use is not the responsibility of JBW.
It is the User's responsibility to ensure that the final

cart configuration and system are designed and
installed in compliance with all applicable Federal,
State and Local laws, regulations, and codes and any
other applicable safety requirements governing AGC
equipment and systems, including but not limited to
ASME b56.5.
Safe operation of a SmartCart AGC in conjunction
with CartTools Software is the sole responsibility of the
User. Complete and thorough functional testing of the
SmartCart AGC is required upon any configuration
change or download to a SmartCart AGC.
It is the User’s responsibility to ensure that all
appropriate guarding, warning or other safety devices
are installed, functional, and properly maintained at all
times. Failure to do so is not the responsibility of
JBW.
2 Introduction
JBW has developed CartTools in conjunction with the SmartCart AGC product. This program allows the user to configure the
operating parameters of carts based on transponder locations. In addition, when a Cart Management System (CMS) is employed,
this program allows the configuration of a Blocking Database, which the CMS uses to facilitate traffic control on a multi-cart system,
and allows the declaration of interface for carts with the CMS.
Be sure that the computer running this software meets the “minimum system requirements” listed on the supplied
installation disk.
®
It is assumed that the user of this software tool is proficient in Windows PC navigation and spreadsheet applications. CartTools does
not provide a graphical interface to assist in the logical configuration of a cart system; therefore much of this documentation will
discuss methods pictorially representing the configuration of a system.
®
3 CartTools Software
3.1 Overview
Setting up your SmartCart AGC system and the functions of each cart is simple with our CartTools software. The tools are
®
incorporated in one simple Windows PC based software package.
Cart configuration tools or CartTools Software allows you to specify the functions of the discrete I/O available on each cart. The tools
also allow you to set up your entire system path including the functions to be performed at specified locations along the path.
Locations along the magnetic guidepath are identified with small transponders affixed to the floor. The AGC reads these unique
codes and performs one or more of the standard functions available to the Cart Control Unit (CCU).
The cart and path configuration can be downloaded to each cart via a serial cable (P/N C1074181). If the optional spread spectrum
radio system is purchased the configuration can be broadcast from the CMS to all carts in the system automatically.
Page 4
Users Manual CartTools Software - Overview
3.2 Initial Startup Screen
When opening CartTools you will be presented with a blank screen. Selecting File will present you with a list of standard file options.
 New – creates a new cart configuration file (CCT).
 Open – allows you to load a previously saved CCT file for modification or re-download.
 Save – saves the existing named CCT file overwriting the previously saved version.
 Save As – prompts you for a new CCT file name to save the current file.
 Exit – closes CartTools.
Page 5
Users Manual CartTools Software - Cart Functions Tab
3.3 Cart Functions Tab

3.3.1 Overview
The primary function of this screen is to allow for the
configuration of locations and associated transponder.
The locations are the "way points" or "events" in your
system that signal the cart to perform different commands.
For each location there are three types of functions that

can be executed.
1. Arrival Functions are the commands that are
executed every time any cart reads a transponder.
2. Destination Functions are the commands executed
by a cart based on the "destination" of a cart or where
the cart is going. These are also the last commands
the cart executes before it comes to a stop, if a stop
command is executed in any of the command lists.
3. Release Functions are commands that are executed
as the cart resumes travel. If the cart did not stop at
the location, these functions are performed
immediately after the Destination Functions.
Functions are added or removed from the list of Available Commands. After selecting the command you wish to use from the
Available Commands list the arrow buttons are used to enter/pass the command to one of the three functions lists. The functions of
these arrows are described below:
[] – Highlight a command in the Available Commands list and select the [] and this will add the command to the corresponding
functions list for the current Location.
[] – Highlight a command in the Arrival Functions list and select the [] and this will remove the command from the corresponding
functions list for the current Location.
[ All] – Selecting this button will remove all of the commands entered on the function list for the current Location.
The "Cart Connected" check box on the Cart Functions tab is used to indicate that the user wants a serial connection established
between the configuring computer and the CCU board using a download cable.
Once a connection is established and the cart is started, the view will change to show each transponder as it is read by the AGC.
This same connection is also used to perform the introduction of new transponders to the system.
3.3.2 Location Box
To view how an existing location is configured you can
select the pull down window and scroll through the list of
locations and click on the location you would like to view.
Once a location number appears in the Location Box its
configuration will show in all of the panes to the left
(Arrival, Destination, and Release Functions).
Due to hardware limitations a cart can only store 383
Transponder Numbers, while Location Numbers are
limited to 999.
The transponder and its factory assigned hexadecimal
number will appear below “Transponder:” as shown
above. In most cases you will configure a location with a
transponder associated with it. Although, as we will
describe later under Reading Transponders, you can
configure locations without transponders associated to
them. And when you’re ready to install your path you can
associate/assign each transponder to a location.
Add – This button allows you to create a new location.
You are prompted to input the new location number and
you have the option to copy the configuration settings of
the location currently on your screen into this new location.
Delete – This button will delete the current location.
Page 6
3.3.3 Available Commands

After selecting each of the Available Commands from the list you must click on the appropriate left arrow [] button to add the
command to one of the three function lists.
Unless otherwise indicated, commands take milliseconds

to process and do not stop command list processing.
● Set Output – Turns on the identified output.
Immediately after adding this command to a function
list, a pull down menu of available outputs is activated
and you must assign the desired output from the list.
The list of available outputs contains all
predefined/programmed outputs and any additional
outputs you may have added. See the Cart I/O
section for more details.
● Clear Output – Turns off the identified output. After
this command is added to one of the three function
lists you are prompted to select the output to clear.
● Follow Left Tape Edge – Instructs the cart to follow
the left edge of the magnetic guidepath. In this
fashion, a cart can choose which ‘fork’ in the path it
will follow.
● Follow Right Tape Edge – Instructs the cart to follow
the right edge of the magnetic guidepath. In this
fashion, a cart can choose which ‘fork’ in the path it
will follow.
● Follow Tape Center – Instructs the cart to follow the
center (or both edges) of the magnetic guide path.
This is the ‘normal’ fashion of following the magnetic tape.
● Change Speed – Allows the cart’s speed to be changed to fast, medium, slow, or creep. Immediately after adding this command
to a function list, a pull down menu of available speeds is activated and you must assign the desired speed from the list. The list
of available speeds contains four settings. These speeds are independently configurable, reference the Cart Configuration
section for more details.
● Timed Hold Stop – Stops the cart after waiting 2 seconds or if a CMS is configured, the 2 seconds are used to wait for a
“release” from the CMS. If the release is received within the 2-second window the cart will not stop.
● Immediate Hold Stop – Stops the cart immediately upon executing. Power is removed from the drive wheel immediately. If the
AGC is travelling in Creep or Slow speed there is a 0 ms delay before the brake is activated. For Medium speed the delay is
400 ms and for Fast speed there is a 500 ms delay.
If a CMS is configured, as soon as the release is granted, the cart will start travel at the previously set speed.
● Wait Until Input xx On – Halts processing of commands until the identified Input is On. Immediately after adding this command
to a function list, a pull down menu of available inputs is activated and you must assign the desired input. The list of available
inputs contains all predefined/programmed inputs and any additional input(s) you may have added. See the Cart I/O section for
more details.
● Wait Until Input xx Off – Halts processing of commands until the identified Input is Off. After this command is added to a
function list you are prompted to select which input you are waiting for.
● Delay Time (seconds) – Halts processing of commands for a specified amount of time. Immediately after adding this command
to a function list, a "Time:" field is activated and you are required to enter the number of seconds to delay, from 1 to 3600 (one
hour).
● Report Location – When included in a Function List the cart will report its current location to a CMS, when a CMS is
implemented. This allows the CMS to determine which blocks are assigned to which carts and when carts need to be held. In
most cases this command should precede all others.
● Issue Release – Releases the cart from a stop command. Immediately after adding this command to a function list, a pull down
menu of release number choices is activated. The release number choices include "Current Destination", "Previous Release",
or any configured Release Command Numbers (reference Release Functions). If Current Destination is chosen, the cart is
automatically assigned a release number the same as the current destination number. If you chose Previous Release, the
release number will be left what it was prior to entering the station. More detail on the assignment of functions based on release
number is covered later in the manual under Release Functions. When this command is issued processing jumps immediately
to the Release Functions, this means that any functions that might have followed this command or any Destination Functions will
NOT be executed.
● Set Destination – Sets the destination number of the cart. Immediately after adding this command to a function list, a pull down
menu of available Destinations is activated and you must assign the desired destination from the list.
Page 7
● Inhibit Optic Blocking – Tells the cart to ignore the input from the optic blocking sensor until the next Report Location command
is executed. This means that if the Report Location is contained in the current location, this will turn the optic blocking sensor
back on.
● Automatic Charge – Notifies the cart that it can take on a charge from an on floor charge plate, the cart engages the charger
only if the “Can charge” level of the battery pack is breached. The cart will continue to take on a charge until the cart is released.
● PLC Do – Halts processing of commands and allows a PLC processor to perform routines. When the PLC is finished it can
notify the CCU to resume processing. Reference the PLC Do section later in this document.
If an option is not turned on in the Cart Configuration Tab, commands associated with that option are not removed from the screen.
For example, if the Inhibit Optic Blocking command is used and the Optic Blocking sensor is not installed but enabled in error, there is
no effect to the operation of the cart.
3.3.4 Arrival Functions
The Arrival Functions list is the sequence of commands
that a cart always executes, every time the transponder
associated with the location is read.
All functions in this list are executed in the order that they
are shown in the list. The hand symbols can be used to
move commands up or down the list. Select the command
you want to move and select the hand that is pointing in the
direction you want to move the command (up or down).
3.3.5 Destination Functions

The Destination Functions list is the sequence of
commands that a cart always executes based on a
destination number.
If you require the cart to perform a function or series of
functions based on the carts assigned destination, (see Set
Destination command) you must create a destination for
one or more of the locations in the system. To create
destination based functions you must do the following:
1. Select the appropriate location from the location drop
down list.
2. Click on the [+] button shown adjacent to the
destination list box.
3. The dialog box shown above appears and requires

you to enter a destination number from 1 to 999. If you
already have destination numbers assigned you can
copy the functions of a previously defined destination by selecting the ‘Copy From Current’ check box.
Page 8
4. Click on the ‘OK’ button.
5. The destination number will show up in the Destination Pull Down Menu as an available choice.
Clicking on the [–] minus button will delete the currently displayed Destination.
To view how an existing destination is configured you can select the pull down window and scroll through the list of destinations and
click on the destination you would like to view. Once a destination number appears in the Destination Box its configuration will show
in the Destination Functions list.
All functions in this list are executed in the order that they are shown in the list. The hand symbols can be used to move commands
up or down the list. Select the command you want to move and select the hand that is pointing in the direction you want to move the
command (up or down).
You can Add or Remove commands in this list by using the arrow buttons.
[] – Highlight a command in the Available Functions list and select the [] and this will add the command to the Destination
Functions list for the current Location.
[] – Highlight a command in the Destination Functions list and select the [] and this will remove the command from the
Destination Functions list for the current Location.
[ All] – Selecting this button will remove all of the Destination Functions from the current Location.
After the Destination Functions are processed and the cart has stopped motion due to either a Timed Hold Stop or a Hold Stop,
processing of commands stops until a Release is issued from the CMS (if implemented) or the operator presses and holds the start
button.
3.3.6 Release Functions

The Release Functions list is the sequence of commands
that a cart always executes as it is leaving a location,
based on the release number.
If you require the cart to perform a function or series of
functions based on the carts assigned release number,
(reference Issue Release command) you must create
release functions for one or more of the locations in the
system. To create release-based functions you must do
the following:
1. Select the appropriate location from the location
drop down list.
2. Click on the [+] button shown adjacent to the
Release Functions list box.
3. The dialog box shown below appears and requires
you to enter a release number from 1 to 999. If you
already have release numbers assigned you can
copy the functions of a previously defined release by
selecting the Copy From Current check box.
4. Click on the ‘OK’ button.

5. The release number will show up in the Release Pull Down Menu as an available choice.
Page 9
Clicking on the [–] minus button will delete the currently displayed Release number and its corresponding Release Function list.
To view how an existing release is configured you can select the pull down window and scroll through the list of releases and click on
the release you would like to view. Once a release number appears in the Release Box its configuration will show in the Release
Functions list.
You can Add or Remove commands in this list by using the arrow buttons between the Release Functions and the Available
Functions.
[] – Highlight a command in the Available Functions list and select the [] and this will add the command to the Release Functions
list for the current Location.
[] – Highlight a command in the Release Functions list and select the [] and this will remove the command from the Release
Functions list for the current Location.
[ All] – Selecting this button will remove all of the Release Functions from the current Location.
Release Functions usually are only needed in a system with a CMS installed. If you are implementing a Simple System, only
Destination Functions should be used.
3.3.7 Cart Connected
Connect the download cable (C1074181) to the serial port
on your computer and the other end to the SER3
connector on the CCU board. You are ready to download
your CCT file to the cart. ‘Save’ your last changes to your
CCT file, select the correct COM port from the pull down
list, and check the Cart Connected box. If a message
appears on the screen that says “Did not receive
Date/Time from Cart”, try another COM port.
When successful communication commences the cart’s
Green light will flash twice indicating the download is being
accepted and verified.
Page 10
Users Manual CartTools Software – CMS & Blocking Database Tabs
3.4 Cart Configuration Tab

This tab allows you to configure all of the default settings
of a cart.
3.4.1 Guidance
The only valid option is to select Magnetic. Optical and
Wire guidance are not supported at this time.
3.4.2 Horn Time
Start Time – Is the number of milliseconds the cart will
sound its horn prior to initiating travel. This number can
be from 1 to 5000. Note: 1000 milliseconds equals one
second.
Loss of Auto – Is the number of milliseconds the cart
will sound its horn each time a cart loses guidance and
drops from automatic mode. This number can be from 1
to 5000.
Travel Duration – Is the number of milliseconds the
horn sounds out of every second as it is traveling. This
number can be from 1 to 1000.
3.4.3 Battery Reporting
Do not modify these settings unless you are VERY familiar with the voltage levels of a 24-volt DC battery pack.
Can Charge – The voltage at which the cart will attempt to take on a charge if automatic charging is implemented. The intent of this
parameter is to prevent the cart from attempting to continually charge when its batteries are over 80% of capacity, since doing so can
result in a reduction in the life of the battery. This field is user-programmable in order to accommodate a variety of batteries/chargers.
Low – The voltage at which a cart flags a CMS system that the battery is very low. The intent of notifying the CMS of this situation is
so action can be taken to investigate the reason for such a deep battery depletion. Typically a battery reaching this level is indicative
of a level which, if repeatedly reached, will reduce the affective life of the batteries. This field is configurable so that different batteries
can be accommodated or so that the meaning of this parameter can be altered.
Lockout – Once this level is reached, proper cart operation cannot be guaranteed, so the cart will not respond to release commands
from any source. Frequently allowing batteries to be depleted to this level will reduce the life of the battery.
Averaging Time – The number of seconds that the cart uses to maintain a rolling average of the voltage level. Voltage is averaged
ONLY while the cart is stationary. This means that during Automatic Charging and operations like a conveyor transfer using a PLC
operate during this averaging time.
3.4.4 Cart Model
Select which model SmartCart AGC you are configuring. The model number should be displayed on the vehicle data label.
Warning – Selecting the wrong Model will cause the cart to malfunction.
3.4.5 Speed Outputs
Slide the slider bars for each of the speeds by clicking and holding the arrow indicator then sliding to the speed that you desire. If you
are using Closed Loop Speed Control (Model 100HD or Model 200) you can enter the speeds by clicking the number next to the
FPM (feet per minute), entering it, then selecting another item.
3.4.6 Installed Options
Check the boxes associated with these options if they are installed on the cart. Each one of these options may have reserved
required Inputs or Outputs associated with them in the Cart I/O Tab.
Automatic Charge – If this option is installed the cart can be configured to automatically charge at a properly equipped charge
station.
Charge times of less than a minute do not add any significant power back to the battery.
You cannot over charge the battery. The automatic charger is configured to take proper care of your batteries.
Every 2 to 4 weeks the battery pack should be plugged into a charger and allowed to charge for 12 hours. This “equalization charge”
will maximize battery life.
Consult factory for recommended automatic charge times in your specific system application.
Page 11
Closed Loop Speed – It is only necessary to check this option if you have purchased the HD option on the Model 100 SmartCart
AGC. This option includes an encoder installed on the drive unit and an external motor controller installed in the CCU board
compartment.
Warning – Selecting the closed loop speed control option when the option is not installed will cause the cart to
malfunction.
Onboard PLC – For applications that require additional logic, the cart can be equipped with a Programmable Logic Controller.
Optic Blocking – When installed this option allows carts to see a reflective surface with the blocking optic and stop without tripping
the bumper. When the reflective surface moves away the cart will reinitiate travel.
Side Swipe Switches – Checking this option tells the cart to monitor the inputs indicated on the Cart I/O Tab. These switches allow
the cart to detect objects next to it and prevent them from colliding with a trailer that it is pulling.
Automatic Bumper Restart – This box defaults to checked and allows a cart to automatically restart after a bumper trip, in slow
speed. The cart will attempt to restart twice after the initial bumper trip. Unchecking this box will cause the cart to stop and error
without retrying to start
3.5 Cart I/O Tab

This tab allows you to view all of the inputs and outputs
(I/O) of the cart.
All fields that are not dark gray can be clicked on and
their text can be modified. Names that are entered in the
I/O chart appear as selections in the Cart Functions Tab
for the Wait until Input…, Set Output, and Clear Output
commands. All dark gray fields can not be referenced by
these same commands.
Once the name is entered in this tab the I/O number
indicated on the left of the screen must be wired to match
the name of the I/O. Reference the CCU Board – I/O
Location List section.
Any field that says “Required for…” means that when the
option is turned on associated with this I/O, the I/O will
immediately be turned dark gray and flagged as
reserved. These I/O can be used for non reserved
features but will immediately be reserved by CartTools
when an option is enabled.
As an example: When the Optic Blocking check box on the Cart Configuration Tab is checked Input #15 will turn dark gray and read
“RESERVED-Optic Blocking”.
3.6 CMS and Blocking Database Tabs
These tabs are used to set up Traffic Control using Wireless Ethernet Radio Communication.
Until this point in the documentation, all editing has affected only one file, the current .CCT file.
To edit any of the information in the following CMS and Blocking Database Tabs, the following files must be located in the same
system directory as the .CCT file:
Concom.ini (Connection and Communications Initialization) Holds the IP address information for the carts in the system and
initialization values.
Sysdef.dat (System Definition Data) Defines most of the pertinent system variables.
Vsminfo.dat (Vehicle System Manager Information Data) Holds the Blocking Database information.
If the above files are missing in the directory that you save your .CCT file in, they are created by CartTools.
Warning – Selecting the ‘File – New’ menu option in a directory that has an existing Blocking Database, It will be ERRASED and
replaced with an empty Blocking Database.
Page 12
3.6.1 CMS Tab

Number of Carts In System – Enter the number of carts
that will be controlled with your CMS system.
If this number exceeds the valid number of carts that your
software is validated for, no error is generated at this time.
When the CMS software is initiated only the maximum
number of valid carts will show on the screen and be
controlled by the CMS computer.
IP Address Edit Window – Once you enter the number of
carts in your system, default values for IP addresses for
your carts will appear in this window. You can edit the IP
address of each cart individually or edit the first one and
use the “Fill Down” button.
Warning: This screen does not “set” the IP addresses of
the carts in your system. This screen is used to record the
addresses as you have configured them, so the CMS
computer can communicate with them. To set the IP
addresses on the radio cards of your carts, it is necessary
to use a software configuration tool provided by the
manufacturer of the Ethernet Radio.
3.6.2 Blocking Database Tab

When first viewed the screen looks like the above.
All records in the blocking database are referred to as

releases. Each new release is assigned a release
number. Reference the Release Functions section for
more information.
The Current Location pull down window will contain all
locations defined in the system. After selecting a location
from the pull down, you can select any of the following
commands:
New – Creates a new database record.
Edit – Allows you to edit an existing database record.
Delete – Deletes the selected database record.
Expand All - Expands all existing release database
records for the selected location. When selected, all
release records expand to display detail information for
each release database entry. The detail includes Release
Type, Destinations, Required Blocks, and Claimed Blocks
for each release number.
Collapse All - Collapses all existing release database records for the selected location. When selected, all release records collapse
to display release database entries as a single line without detail.
3.6.3 Block Numbers
At this point it is appropriate to identify the term “Block Numbers” or “Blocks”. Blocks are logical areas on a system layout that are
required or claimed by carts as the cart travels through a CMS controlled system.
A block can only be assigned to one cart at a time.
Any one cart can be assigned more than one block at any given time.
Logical block numbers cannot exceed 1000, exceeding this number will cause a compilation error.
Page 13
3.6.3.1 Entering New Blocking Database Record (New Release Number)

By clicking the New button the New Release Information
dialog box is displayed.
The functions of the New Release Information dialog box
are as follows:
Location Number – The location that the blocking record
is being declared for.
Release Number – Is the Release Number assigned to
the cart IF this record is successfully executed. Reference
the Release Functions section for more information. ONLY
one number should appear in this field.
Destinations – This field should contain the list of
destinations that this record will be valid for. One or more
numbers can appear in this field. All numbers shall be
separated by spaces. Ranges of destinations are specified
using a negative number: “1 -50” means “1 through 50”.
One record must include a “Default Record”.
By entering nothing in this field CartTools assumes that you want this record to be the Default Record.
Required Blocks – List of blocks that must be successfully claimed before a Release Number is issued and blocks are reserved for
the cart. Any number of blocks can appear in this field. All numbers shall be separated by spaces.
Claimed Blocks – The blocks that the cart claims immediately upon arriving at the location, according to the destination. These
blocks are continued to be claimed after the cart is released. These blocks are further claimed once the Required Blocks are
successfully claimed. Any number of Block Numbers can appear in this field. All numbers shall be separated by spaces.
If you are familiar with programming methodology, the way to read this screen logically is:
Whenever the location OR the destination of a cart changes, for any reason, perform the following:
IF (the cart reports it’s location to the CMS) THEN
IF (current cart location is declared in database) THEN
LOOKUP Destination number in database records for Current Location. If not found ‘Default Record’ is assumed to be the
Destination.
ASSIGN claimed blocks to cart
WAIT UNTIL (all required blocks in list are available)
ASSIGN required blocks to cart
Issue Release and Release Number to cart
ELSE
Cart is NEVER released
ELSE
Cart continues with current blocks claimed
Release Types declare to the CMS how a database record is evaluated.
● Normal – means that the Blocking Database has complete control over when the cart is released (when all required blocks are
available the cart is released).
● PLC Release – means that first the “Host” (PLC or Ethernet Interface) must release the cart, then the CMS evaluates the record
as if it were a normal release (all required blocks are available).
● PLC Destination – means that the CMS will sit and wait for the PLC to change the destination. “Host” (PLC or Ethernet
Interface) MUST change the destination of the cart. This type of Blocking Record can not be used to release the cart.
● It is possible for the PLC to change the destination before this time. But until this record is processed the CMS will not ‘see’ the
change take place.
● Alternate Route – means that you are declaring a list of alternates routes for carts to take leaving a location. The first record
processed that all Blocks are available to be claimed in the Required Block list is the Release record and Number that the CMS
uses to issue the release to the cart.
Notes:
During configuration of your Blocking Database records, you will be issued warnings if the records are invalid. These messages will
appear next to the “Current Location” box in red text. You should make these corrections as necessary.
When you save your .CCT file this saves the Blocking Database files and triggers a compilation program (CRTVSM) that compiles
the actual Blocking Database used by the CMS. This DOS program also validates your Blocking Database. Any errors found with
the file will be repeated in the DOS window. A new Blocking Database file is not saved until all the errors are fixed.
Page 14
The MakeDB command (found inside the CMS/MakeDB directory) must be run to complete the compilation process prior to
restarting SmartServer and SmartView.
3.6.3.2 Editing a Blocking Database Record
In the following example we have selected location 1 and clicked the Expand All button.
To edit a release record, simply click your mouse anywhere in release record you wish to edit and click on the Edit button.
The Edit button opens the Edit Release Information dialog box (shown below) to allow release record editing.
The functions of the Edit Release Information dialog box are the same as those described for the New Release Information dialog
box described previously.
Page 15
Users Manual System Design
4 System Design
For ALL Systems the first steps are:
● START with a Description of Operation. This should include a description of how every station works including what criteria the
cart uses to affect all of its behavior.
● Draw the entire path, using any means, including a hand sketch.
● Include all planned features including turns, merges, and diverges.
● Consider the tracking of the SmartCart around corners. The cart is a tricycle steer device that means the rear of the cart will cord
in on a turn. The path must be located away from posts and other floor objects to prevent the cart from hitting them while making
a turn.
● Note on the drawing the positions where you want the cart to stop, change speed, or perform any specific function (like turn on a
light).
● For each position, write a unique transponder number. You can use any number from 1 to 999.
● If you are using Optic Blocking determine what locations you may need to turn it off. A transponder will be required each time
you want to turn it off and reading the next transponder will turn it back on.
4.1 Using Destination Numbers
While examining your layout it should be considered what places to go are “Destinations”. Logical locations like stations are
destinations and they can be assigned unique Destination Numbers. These numbers need not be declared anywhere but pictorially
on your layout drawing. The logical meaning given to these destination numbers at locations in your system actually define what the
Destination Number means.
Destination numbers allow you to declare where a cart is “on its way to”. Once you do this you can define “Destination Functions”
which are processes based on where a cart is “on its way to”.
All carts default to Destination Number 200 when powered on for the first time or after a Cart Control Unit (CCU) reset.
When a cart is powered off, it retains its current Destination Number. When the cart is powered on again it will have the same
Destination Number it did when it was powered off.
Destination numbers can get changed two ways:
● Carts can set their own destination by including the “Set Destination” command in the Arrival Functions, Destination Functions,
or Release Functions lists described earlier in this manual.
● A correctly configured PLC or Ethernet host interface also allows external processes to change the destination on a cart.
4.2 Using Release Numbers
In the simplest of uses the cart will perform the functions on the Release Functions list after it performs all functions on the Arrival
Functions and Destination Functions lists.
The real power behind the use of release numbers is employed when you want to route the cart (send it down a particular path)
based on the cart’s destination or more importantly a group of destinations.
If for example you want the cart to bypass a group of stop locations (destinations) to reach a destination further down the path. You
can use release numbers to choose the bypass route to reach the required destination more quickly. We call this functionality
alternate routing.
4.3 Using Alternate Routing
Alternate Routing allows the CMS to decide which Release Number to assign to a cart based on the carts Destination and the Blocks
available.
Alternate Routing depends heavily on the order in which the records appear for a Location. The first record in the Blocking Database
that is satisfied for the Destination and Required Blocks is the record that is executed and associated Release number is assigned.
Alternate Routing is one of the most powerful yet logically dangerous capabilities for carts. It is HIGHLY recommended that after you
configure an Alternately Routed area you execute a full test of all the Blocking combinations prior to beneficial system use.
Blocking Database records of Alternate Route type are not allowed to be defined as the Default destination. However when you are
finished defining your routes you must make sure that you include a CMS Release that includes a Default Destination.
Caution: A release number from a previous location is used as a preference for the alternate routes in an alternate route location.
This can work for or against you. If you want the route to be determined solely on the blocking with no preference, release numbers
that do not equal locations in the area should always be used. Otherwise this functionality can be used to "lock in" the alternate
route selected from the previous normal release location, and maintain the appropriate claimed blocks.
Page 16
4.4 Simple System

A simple system is defined as one that does not require upper level traffic control. A simple system only requires that you complete
the entries for Cart Functions, Cart Configuration, and Cart I/O tabs described previously.
There are two main categories of "simple systems": those with a single cart and those with multiple carts. In either case each cart is
manually downloaded the same configuration information based on your entries in Cart Functions, Cart Configuration, and Cart I/O
tabs.
4.4.1 Simple System - Single Cart
These systems can take on any shape including merges and diverges of path.
For a Single Cart System the next steps are:
● Examine your Description of Operation and review every station and plan the commands you need to execute at each station
and decision point.
● Mentally run your cart around the system and note everything you want the cart to do.
● Continue to Reading Transponders Section
4.4.2 Simple System - Multiple Carts
This type of system features:
● No merging path
● No upper level traffic control
Without upper level traffic control, a cart-to-cart Blocking Optic and a reflective tape affixed to the rear of each cart are required. This
optic stops a cart when it senses the reflective tape of a cart preceding it. It is best to plan your cart design and system layout to
maximize the ability of each cart to see a consistent part on rear of the cart in front of another.
To negotiate turns where the cart-to-cart Optic Blocking sensor cannot function consistently a simple delay can be incorporated prior
to each turn. To create the delay the following is required.
● Place a transponder prior to each turn and include a timed stop function in the Arrival Functions list for each transponder.
● Set the timed delay for each transponder to 5 to 10 seconds. This allows you to create a timed gap between vehicles entering a
turn and a cart that may follow close behind.
This process forces any carts following immediately behind the first cart to stop via the optic blocking sensor prior to stopping on the
stop/delay transponder, thus forcing carts to space themselves out going around corners.
4.5 Designing a Traffic Controlled System
A traffic controlled system incorporates the following additional hardware:
● Wireless Access Point Network
● Cart Management System (CMS) Computer
If your system was purchased with upper level traffic management, the CMS, and Blocking Database tabs within the CartTools
software package will be enabled and must be completed. A detailed description of the requirements for the CMS and Blocking tabs
can be found earlier in this manual.
To complete the Blocking Database tab you must have a clear understanding of the concepts involved. These are described below.
4.5.1 Traffic Control Concepts
Traffic control begins with an understanding of blocking.
Two types of blocking can be used in a SmartCart system, "zone blocking" and "accumulative blocking". If zone blocking is
required in the system, then a Cart Management System (CMS) computer is required. Accumulative blocking is performed by
each cart use of an optic blocking sensor.
Both zone and accumulative blocking can and should be considered for use in a system at the same time.
4.5.1.1 Accumulative Blocking
In systems equipped with this option, accumulative blocking is performed by each SmartCart using SmartCart mounted remote
object detection sensors. Accumulative blocking can be utilized on long, straight sections of guidepath and is performed independent
of CMS control logic. A cart will sense a stopped or slower cart on the guidepath ahead and stop behind it. When the stopped or
slower moving cart (ahead) resumes travel and is out of range of the trailing cart's optic sensor, the trailing SmartCart will resume
travel.
This means that carts can accumulate immediately behind each other and move up to the next controlled intersection area instead of
waiting up to several hundred feet away, resulting in greater throughput and faster SmartCart response.
● Minimum effective blocking distance between SmartCarts is approximately 36".
● Maximum effective blocking distance between SmartCarts is approximately 72” (estimated).
Page 17
Using Accumulative Blocking should decrease the number of transponder locations in a system, while at the same time it requires the
addition of the optic blocking sensor to each of the carts.
4.5.1.2 Zone Blocking Operation
Zone Blocking is used when traffic control is needed and accumulative blocking is not possible, usually at intersections, turns,
merges, and diverges. It is also necessary to create blocks everywhere in a system when Accumulative Blocking is not used
in straight path sections. Zones are logical areas that are assigned unique numbers. With correct configuration by the user,
the CMS only allows one cart at a time to be in a zone. The CMS will ensure, through the blocking database, that only one
cart is given a release to a zone blocked section of guidepath at any one time.
The above is accomplished by choreographing the use of Locations, Cart Functions, Blocks, and Destinations.
The Report Location function along with the Timed Hold Stop and Immediate Hold Stop are the cart functions in CartTools that
interact with the Blocking Database.
Blocking records are examined by the CMS as carts report locations.
A cart that is about to enter a Block needs to be configured to immediately stop or pause then stop with the Timed Hold Stop
function.
As a cart exits a Block it must release a Block so other carts waiting for the Block can be allowed to claim/enter it.
4.5.2 Designing Your Traffic Controlled System
The first step in designing a traffic-controlled system is to develop a clear understanding of the flow of carts through your system.
Use the following steps to design you system traffic control.
Step 1
● Draw your system path. Specific dimensions do not matter at this point.
● Put in your Function Transponders (places you want to stop, speed up, slow down, etc.).
● Review your path.
Step 2
Determine the areas that require blocking. These are areas that a cart will require permission from the CMS computer to enter/exit.
Typical areas that require blocking include:
● Turns
● Merging sections of path
● Bi-directional sections of path
● Intersections
● If you didn't purchase a blocking optic to utilize accumulative blocking, you must add blocking in areas where multiple carts can
accumulate on straight sections.
Step 3
With these boxes drawn in, number each block on your system path (1 through 999). These numbers should not repeat.
Step 4
Review your layout for Hold/Release control points.
● Each block does not have to have a transponder.
● Every block should have a location that “requires” it and a point where it is “released”.
● Requiring and releasing can be done with separate locations or combined on locations.
Step 6
Open CartTools and begin entering all locations and functions for each transponder as defined by you system layout. Define and
enter destination and release function for each location. See Defining System Destinations and Releases.
For each location (transponder you have defined a Hold /Release control point reference the above example to define which blocks
you “require” and which you “claim”.
Step 7
When all location transponders are defined, Open the Blocking Database tab.
Use the location pull down to pick the first Hold/Release location transponder for which you wish to begin entering blocking
requirements.
Click on the New button.
This will bring up the New Release Information dialog box. See 3.6.2.1 Entering New Blocking Database Record (New Release
Number for information on the functions of this dialog box).
Page 18
1. Using your system layout as a guide determine the number of the box / block you have defined that encompasses the location
transponder you are setting up.
2. Enter the box / block number in the Release Number field.
3. Review your layout to determine the possible destinations the cart could be in route to and enter them in the Destinations field
with a space between each destination.
● Note if this is a decision point where the cart will take a different route based on its current destination, you must enter the
blocking requirements for each possible destination separately. The reason for this is that cart will claim different blocks
based on the route it is required to travel.
4. Based on the carts destination, look to the next box/block ahead of the carts current location and enter its box/block number in
the Required Blocks field.
5. Under Claimed Blocks field enter the same number of the entered in the Required Blocks field (item 4 above).
6. Click on the OK button
7. The Release will show up as the first blocking record for the location chosen.
8. Continue entering Release record for each potential destination for the currently selected location.
9. Move on to the next Hold release location in your layout and repeat the procedure above until all Hold/Release locations and
corresponding destinations have been defined.
Accept the fact that, no matter what you do you will not foresee all the problems you may have. Allowing time for debugging and
System Runtime Testing are crucial.
Contact your SmartCart Distributor or JERVIS B. WEBB COMPANY Representative for assistance with your blocking scheme.
4.5.2.1 Typical Crossing Path Intersection Example

The following will take you through the blocking logic and transponder functions of a typical crossing path traffic controlled
intersection. In this case we have not included functions based on destination. See Destination Based Traffic Control
Example following this section.
On the diagram below we have drawn five blocks numbered B26, B27, B11, B12, and B13. Also included are four transponder
codes numbered 55, 60, 20, and 21.
55
B26
B11 B12 B13
B27
20 60 21
To begin creating traffic controlled intersection you must add the appropriate Arrival Functions to the Arrival Functions List for
each transponder.
For transponder 20 and 55 which proceed the intersection in the direction of travel the following Arrival Functions are added:
● Report Location
● Timed Hold Stop (2 second)
Page 19
For transponders 21 and 60 which are read after the cart has driven through the intersection only the following Arrival Function
is required:
● Report Location
The Blocking Database records look like:
Location: 20 Release type: Normal
Release: 1
Destinations: Default Record
Required Blocks: 12 13
Claimed Blocks: 11
Release: 1
Required Blocks:
Claimed Blocks: 13
Release: 1
Required Blocks: 12 26
Claimed Blocks: 25
Release: 1
Required Blocks:
Claimed Blocks: 26
Let’s consider cart 1 arriving at location 20:
● Without stopping, cart 1 reports location 20 to the CMS.
● The location of cart 1 on the CMS computer changes to location 20.
● Cart 1 continues to process functions.
● Cart 1 processes the “Timed Hold Stop” function.
● Cart 1 begins to wait for 2 seconds to hear from the CMS that it is “released” to go.
● The CMS processes the Claimed Blocks section of the Blocking Database Record for location 20, releasing all blocks that are
not in the claimed block list. Block 11 is assigned to cart 1.
● The CMS checks to see if blocks 12 and 13 are assigned to any other carts. They are available so they are assigned to cart 1.
● Blocks 12 and 13 are assigned to cart 1 along with block 11.
● The CMS issues a release to cart 1 along with a Release Number of 1.
● All of this usually happens within the 2 seconds that cart 1 pauses waiting for the Release.
● Cart 1 continues through the intersection without stopping.
Now while cart 1 is on its way through the intersection, let’s consider cart 2 arriving at location 55:
● Without stopping, the cart reports location 55 to the CMS.
not in the claimed block list. Block 25 is assigned to cart 2.
● The CMS checks to see if blocks 12 and 26 are assigned to any carts.
● Block 12 is not available, so the CMS waits to release cart 2.
● Cart 2 finishes counting to 2 without receiving a Release from the CMS.
● Cart 2 stops prior to the intersection, while staying in automatic mode, continuing to wait for a Release.
Now let’s consider cart 1 arriving at location 21:
not in the claimed block list. Block 13 is assigned to cart 1. Blocks 11 and 12 are disassociated from cart 1.
● Cart 1 continues to travel through Block 13.
Page 20
Back at cart 2:
 The CMS realizes that block 12 and 26 are now available to assign to cart 2.
● Blocks 12 and 26 are assigned to cart 2 along with block 25.
● Cart 2 begins to travel again and continues through the intersection without stopping.
Notes:
● In the above example locations 20 and 55 can be classified as “Hold Points” while locations 21 and 61 can be classified as
“Release Points”. It should be understood that if the blocking zone is small enough, both classifications can exist for the same
location, that is a location can release blocks while at the same time requiring new blocks to be assigned to a cart. In general,
blocks that are two cart lengths or more need to have separate Claim and Release Locations.
● Also in the above example you should notice that block 12 does not contain any locations. This is common for block zones that
are merges or intersections.
4.5.2.2 Destination Based Traffic Control Example
50
51
B10
B11 Destination 1
B12
52 53
Destination 2
For transponder 50 which proceeds the intersection in the direction of travel the following Arrival Functions are added:
● Report Location
For transponder 50 Destination = 1 the following Destination Functions are added:
● Follow Left Tape Edge
● Timed Hold Stop (2 seconds)
For transponder 50 Destination = 2 the following Destination Functions are added:
● Follow Right Tape Edge
● Timed Hold Stop (2 seconds)
For transponder 51 the following Arrival Function is added:
● Follow Tape Center
For transponders 52 and 53 which are read after the cart has driven through the intersection only the following Arrival Function
is required:
● Report Location
Blocking Database entries include:
Release: 1
Required Blocks: 11
Claimed Blocks: 10
Page 21

Release: 1
Destinations: 1
Required Blocks: 12
Claimed Blocks: 10
Release: 1
Destinations: 2
Required Blocks: 11
Claimed Blocks: 10
Release: 1
Required Blocks:
Claimed Blocks: 11
Release: 1
Required Blocks:
Claimed Blocks: 12
Let’s consider cart 1 arriving at location 50:
● The CMS checks the carts current destination. The CMS then processes the following functions based on the cart’s current
destination:
● If cart 1 has the default destination (destination 200) then it will proceed to process the Blocking Database Record for Location =
50 and Destination = Default Record.
● In this example the CMS would release all previously assigned blocks that are not in the claimed block list and assign block
10 to cart 1.
● The CMS checks to see if block 11 is assigned to any other carts. If block 11 is available it is assigned to cart 1.
● If cart 1 has a previously assigned destination of 1 then it will proceed to process the Blocking Database Record for Location =
50 and Destination = 1.
10 to cart 1.
● If cart 1 has a previously assigned destination of 2 then it will proceed to process the Blocking Database Record for Location =
50 and Destination = 2.
10 to cart 1.
● The cart then passes over transponder 51 and begins to follow center of tape. Because it never reports this location, the CMS is
unaware of the transponder and therefore does no processing of its functions.
● Note: If you add a Report Location to the Arrival Functions List for location 51, you must enter corresponding Blocking
Database records to identify the blocks the cart has claimed based on its destination. For example the Blocking Database
Record for Location = 51 and Destination = Default Record would include:
Release: 1
Required Blocks:
Claimed Blocks: 10 11
You would also include records for Destinations 1 and 2 each claiming the two blocks required to pass through the
intersection in the direction of travel.
● When the cart reaches either transponder 52 or 53, the CMS processes the Blocking Database Record for 52 and 53. In both
record the database record releases all previously assigned blocks in this case Block 10 and claims block 11 or 12.
Page 22
● At this point another (cart 2) could claim Block 10 and proceed to transponder 50. If the cart 1 is still claiming Block 11 or Block
12, cart 2 will be held at transponder 50 until the block cart 2 requires is released.
4.5.2.3 Typical Alternate Routing Example
The following will take you through the blocking logic and transponder functions of a typical alternate routing scenario. In this
case we have not included functions based on destination, but since we are not allowed to use Default Destinations for
Alternate Route records we have used the “1 -999” nomenclature to route all carts through this area regardless of destination.
On the diagram below we have drawn six blocks B1 through B6. Also included are eight transponder codes numbered 41
through 48.
47
46
B5
44
B4
48 45 43 41
42
B6 B3 B2 B1
In this example the external PLC will be issuing the Release to the carts at Locations 45, 46, and 47. The following defines the
Arrival and Release functions for the Locations in this example:
Transponder 41, Arrival Functions:
● Report Location
● Follow Left Tape Edge (needed in case cart is forced to release without a Release Number)
● Timed Hold Stop (2 second)
Transponder 41, Release Function 45:
Transponder 42 and 44, Arrival Functions:
● Follow Tape Center
● Report Location
● Follow Left Tape Edge (needed in case cart is forced to release without a Release Number)
Transponders 45, 46, and 47, Arrival Functions:
● Report Location
● Immediate Hold Stop
Page 23

● Report Location
The Blocking Database records include:
Location: 41 Release type: Alternate Route
Release: 45
Destinations: 1 -999
Required Blocks: 23
Claimed Blocks: 1
Release: 46
Required Blocks: 24
Claimed Blocks: 1
Release: 47
Required Blocks: 25
Claimed Blocks: 1
Release: 1
Required Blocks: 2345
Claimed Blocks: 1
Release: 1
Required Blocks: 45
Claimed Blocks: 2
Location: 45 Release type: PLC Release
Release: 1
Required Blocks: 6
Claimed Blocks: 3
Release: 1
Required Blocks: 6
Claimed Blocks: 4
Release: 1
Required Blocks: 6
Claimed Blocks: 5
Release: 1
Required Blocks:
Claimed Blocks: 6
Let’s consider cart 1 arriving at location 41 and no other carts are in the area of our example:
● The CMS checks to see if blocks 2 and 3 are assigned to any other carts. They are available so blocks 2 and 3 are assigned to
cart 1 along with block 1.
● Cart 1 continues and processes the Release Function for Release Number 45.
● Cart 1 is now following the left tape edge and continues on.
Page 24
Cart 1 arrives at location 42:

● Without stopping or reporting its location cart 1 begins to Follow Tape Center.
● Cart 1 reports location 45 to the CMS.
● Cart 1 stops.
● Cart 1 continues to process functions but there are none to process.
● Cart 1 now waits to be “released” to go by the CMS.
● The CMS now waits for the PLC to Release cart 1.
● The CMS checks to see if blocks 2 and 3 are assigned to any other carts. They are not available so the CMS proceeds to the
next record.
● The CMS checks to see if blocks 2 and 4 are assigned to any other carts. They are available so blocks 2 and 4 are assigned to
cart 2 along with block 1.
● Cart 1 is now following the right tape edge and continues on.
● Cart 2 is now following the left tape edge and continues on.
● Cart 2 reports location 46 to the CMS.
● Cart 2 stops.
● Cart 2 continues to process functions but there are none to process.
● Cart 2 now waits to be “released” to go by the CMS.
● The CMS now waits for the PLC to Release cart 2.
This example continues similarly for Cart 3 until all three stop stations are full and then when Cart 4 shows up at 41 it is not released
because all of the Alternate Routes are not valid to process.
Page 25
Users Manual SmartCart Removal From The System
5 SmartCart Removal From System

A SmartCart may be removed from the system at any point along the guidepath, then taken off-line at the CMS terminal. This
procedure will logically remove the SmartCart from CMS control (polling cycle). If the SmartCart was in a controlled area, the CMS
would then allow other SmartCarts to enter.
Page 26
Users Manual Reading Transponders
6 Reading Transponders
At any time during the configuration process you can connect a computer to the cart as stated in the Cart Connected section above
and commence reading transponders.
All that is necessary to successfully read in transponders is to run the cart on the path or make the cart “think” it is running on the
path. The cart can be fooled into thinking it is running down the path by lifting the drive wheel off the ground, putting a piece of
magnetic guide tape or path under the guidance sensor, and pressing the start button. The cart will run in place. You can then wave
transponders under the Transponder Reader.
A dialogue box will appear that says “New Transponder” and the hexadecimal number on the transponder is shown on the screen. At
this point you can associate the new transponder with an already configured transponder or create a new transponder.
Transponders can also be read in by placing them on the floor along the guidepath and running the cart over them to read them.
Due to hardware limitations a cart can only store 383 Transponder Numbers. While Location Numbers are limited to 999.
Page 27
Users Manual Other Features and Tips
7 Other Features and Tips

7.1 Frequently Asked Questions
Can I get hard copies of a CCT or Blocking Database?
Every time you save your CCT file, the file VPDATA.TXT is created or updated in the same directory the CCT file is saved in. This file
can be printed via standard Windows methods to obtain a hardcopy representation of your CCT file.
The blocking database file can be viewed in the VSMINFO.LIS file. This file is also updated every time you save a CCT.
When should I use Immediate Hold Stops vs. Timed Hold Stops?
In a Simple System where there is no CMS Timed Hold Stops usually have no purpose. In a CMS system Timed Hold Stops are a
luxury that can save you throughput time (by not stopping carts unnecessarily) and battery discharge (by not having to accelerate a
cart from a stop).
If the cart is processing commands from one location and reads the next location, what happens?
The function that is currently being processed is immediately aborted and the function list associated with the new location is started.
This is most likely to be caused by a “Wait Until Input” command or a “Delay” command being processed while moving.
7.2 The Powerful Commands
7.2.1 Set Destination and Destination Functions.
The cart sets destination numbers as it reads transponders that trigger a Set Destination function. The cart then remembers its
destination number until it is changed with another Set Destination function. Destination Functions are executed according to the
destination number at each location. This allows where a cart is to influence where it goes.
7.2.1.1 Uses
Every time a cart reaches one location the destination can be changed to another location. This means that a system can be set up
so a cart makes its way to a series of locations in the same order every time regardless of the layout.
Another use for this feature can be described as the “blood hound” trick. That is, that the cart is manually taken to a transponder in a
system and inserted on the track prior to a transponder, that will set its destination. Once set, the cart will use the same destination
functions to perform a route around a system. If the location that sets the destination is impossible for a cart with a different
destination to read, the other carts in the system will retain their destinations. That means multiple unique paths can exist in a system
but by manually moving a cart to read the “destination transponder” the system can be modified to handle different throughputs on
different loops day to day or hour to hour.
7.2.2 Wait Until Input.
Two commands: “Wait Until Input is On” and “Wait Until Input is Off” allow you to Hold processing of functions until the input is in a
desired state.
Adding any simple input device like a selector switch, push button, toggle switch, etc. allows the operators to create a state change.
7.2.2.1 Uses
At a diverge in the path, run over a location that says “Follow Left”, “Wait Until Input Is On”, then “Follow Right”. This means that if the
Input is Off the cart will go Left or if the Input is On the cart will go Right.
Enter a station and “Wait Until Input is On” then “Immediate Hold Stop”. This means if the input is On the cart will Stop otherwise it
keeps going.
Add a four position selector switch to the cart and wire the inputs so you create a 2 bit number, so in position 1 Input 5 & 6 are off, in
position 2 Input 5 is on but 6 is off, etc. This allows the operator to effectively create a different kind of destination. At diverges the
functions “Follow Left”, “Wait Until Input is Off”, “Wait Until Input is Off”, then “Follow Right” can tell the cart to turn right only if the two
inputs are off.
7.2.3 Delay – While Still Traveling.
Using the Delay function along with taking advantage of the fact that entering a new location can be a useful tool.
7.2.3.1 Use
If you want a system to stop a cart when it misses a location, add a “Delay” and an “Immediate Hold Stop” to the end of each
location. Make the delay time just a little bit longer than the amount of time that it takes the cart to reach the next location. Now
anytime a cart misses a transponder it will stop.
7.2.3.2 Potential Problems
If you read the next tag (B) while in the middle of processing commands on the previous tag (A), the cart immediately halts
processing of the commands associated with A and starts processing the commands in B.
Page 28
Users Manual Other Features and Tips
7.2.4 Negative Block Numbers

You are allowed to list negative block numbers in the Blocking Database in the Required and Claimed block lists.
A negative required block is not claimed when a cart is released. Which means it is required to get the release but is not claimed
after it is released.
A negative claimed block is not claimed when the vehicle is held. Which means upon release the cart will claim the block.
7.2.4.1 Use - Controlling Two-way Traffic on a Bi-directional Path
If you had a section of bi-directional path that was 100’ long and throughput requirements demanded that you get as many carts as
possible through the area, you could use this functionality.
If location 1 is at one end and location 2 is at the other. You would have two logical block zones for the 100’ path “west bound” being
block 100 and “east bound” being block 200. At location 1 you would have the following record…
Release: 1
Required Blocks: -100
Claimed Blocks: -200
Release: 1
Required Blocks: -200
Claimed Blocks: -100
This translates to…Any cart at location 1 requires block 100 (west bound) to leave location 1, but the cart will not claim it if it is
available. When cart at location 1 leaves it will claim block 200 (east bound). Thus, not allowing any east bound traffic while traveling
west bound. Further, if another cart comes up from behind and wants to go west bound, it will be allowed, meaning more than one
cart at a time could occupy the bi-directional path. At the end of the bi-directional path the cart would process a location that released
block 200, allowing east bound traffic to happen.
7.3 CCU Board – I/O Location List
The following user configurable inputs and outputs are located on the CCU board as noted and have the listed properties. All I/O is
24 VDC:
7.3.1 Inputs
2 – TS2 Terminal 9 – Pull Low to activate.
3 – TS2 Terminal 10 – Pull Low to activate.
All of the following inputs accept bi-directional current flow from 10-30VDC to activate.
7 – TB1 Terminal 3 (+) – TB1 Terminal 4 (-)
7.3.2 Outputs
3 – TS2 Terminal 8 – 500mA sinking
9 – TB1 Terminal 7 – 500mA sinking
13 – TB1 Terminal 10 – 500mA sourcing
Page 29
Users Manual “PLC Do” On-Board PLC Interface
8 PLC Do – Onboard PLC Interface

This section describes a standard interface and protocol for the CCU to communicate to an onboard PLC and vice versa. Allowing
the user to command an onboard PLC to initiate a process sequence and inhibits any vehicle travel until the PLC returns a ‘job
complete’ signal. The PLC is also able to indicate an unsafe condition to which the CCU will immediately stop travel.
When the checkbox for “Onboard PLC” in the Cart Configuration Tab is checked. Outputs 9, 10 and 14 and inputs 13 and 14 are
reserved and the functionality described below are activated reference the Cart I/O Tab for more information.
Summary of process flow:
● “PLC Do” command is executed and CCU stops processing functions in list.
● Output 9 is turned on, “PLC Start Process”.
● CCU waits for input 14 to deactivate “PLC active”.
● CCU waits for input 14 to activate “PLC finished”.
● CCU continues to next function in list.
At any time, if input 13 “PLC Safe” is deactivated, the CCU will emergency stop the cart.
8.1 Definition of Handshaking Signals
8.1.1 From the CCU to the PLC
Executing a PLC Do command activates output 9 and 10.
Output 9 indicates to the PLC that the process can commence. Output 10 makes a parameter available to the PLC. The user can
select “A” or “B”, A is indicated by the absence of a signal and B is indicated by a signal present.
Output 14 indicates “CCU Idle”. Absence of this signal indicates that the steering circuit is active. The CCU activates this signal
when the cart is stopped and stable. This signal activates approximately 2 seconds after the brake is set during a normal stop.
Together, these three output signals indicate to a PLC that the vehicle is stopped, stable, and command one of two operations.
Additional commands (beyond two as indicated above) can be communicated by using other unallocated outputs. Using the “Set
Output” and “Clear Output” commands along with these other outputs prior to issuing the ”PLC Do” command will allow more than
two PLC operations to be indicated.
8.1.2 From the PLC to CCU
Input 14 indicates “PLC idle”. Once the “PLC Do” command is initiated the CCU will not allow processing of CartTools commands to
continue until this signal is deactivated and activated again. Deactivating this signal is equivalent to “processing” and activating the
signal when finished indicates “process complete, CCU may continue”.
The CCU ignores input 14 while other commands are being processed, i.e. if a PLC Do command is NOT active, it is not monitored.
Input 13 indicates “PLC safe”. The PLC should activate or continually active this input to indicate everything is safe/OK to continue
travel. The CCU responds to loss of this input by dropping automatic mode, and CRM output; requiring an operator to manually
restart the cart.
The PLC should not deactivate input 13 during the normal PLC process.
8.2 Power supply for Onboard PLC
Although not an explicit I/O signal, power for an onboard PLC must be routed through CRM (motor safety) contactor to ensure
inhibited PLC operation under the following conditions:
● Bumper tripped (beyond auto-restart capability)
● Emergency stop pushbutton pressed
● CCU board detected failure
8.3 Application Considerations
8.3.1 Bumper Trips
A bumper trip will stop PLC operation. If different behavior is desired, special CCU software should be requested, and a description
of preferred error recovery requirements provided with the request.
8.3.2 General Wiring Considerations
Proper fusing, wire sizing, and integration to the SmartCart AGC controls package must be considered for proper operation.
Wiring or circuit functions must be approved by Jervis B. Webb Company to avoid voiding of warranty. SmartCart AGC is designed
with one 24 VDC ground system. If PLC is run off an isolating DC/DC converter, proper return path must be provided with I/O
handshaking signals.
Page 30
Users Manual “PLC Do” On-Board PLC Interface
8.3.3 PLC Initiation Timing

When a “PLC Do” command is executed, output 10 is set/cleared within milliseconds of setting output 9. Therefore, it may be
desirable for the PLC to delay a brief period of time after recognizing an output 9 activation before performing the specified operation
in order to allow the state of output 10 to stabilize.
8.3.4 AGC “Settling” Once Stopped
If a “PLC Do” command is executed immediately following either type stop command, it is likely that output 9 will be set prior to the
output 14 “CCU Idle” being set. It is therefore recommended that either a “Delay” command (of at least 2 seconds) be executed prior
to executing the “PLC Do” command, or the PLC anticipate this condition (as a normal condition) and wait for the “CCU Idle” signal to
activate before proceeding with the specified operation.
8.3.5 Cart Release – During PLC Do
Pressing and holding the Start button for 5 seconds (to generate a manual release) or generating a release via CMS will discontinue
the execution of commands in the Arrival and/or Destination lists (as normal). However, if the “PLC Do” command is already being
executed, the CCU will still wait for the completion of the handshake of the “PLC Idle” signal (i.e., the CCU will still wait to see the
signal deactivate and then reactivate).
This means that unless the PLC is afforded a manual release override function, it is possible the cart will not be able to be overridden
to “force” the cart to leave a station.
8.3.6 PLC Idle Timing
From a timing perspective regarding the handshake of “PLC Idle” input 14, deactivating the signal for 50 milliseconds before
returning it to the active state should be sufficient for the CCU to recognize the deactivation/reactivation of this signal.
Page 31

Cart Tool User Manual

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Cart Tool User Manual

Încărcat de

Drepturi de autor:

Formate disponibile

SmartCart® Automatic Guided Cart (AGC)

Jervis B. Webb Company

It is the User's responsibility to ensure that the final

3.2 Initial Startup Screen

3.3 Cart Functions Tab

For each location there are three types of functions that

3.3.3 Available Commands

Unless otherwise indicated, commands take milliseconds

3.3.5 Destination Functions

3. The dialog box shown above appears and requires

4. Click on the ‘OK’ button.

3.3.6 Release Functions

4. Click on the ‘OK’ button.

3.4 Cart Configuration Tab

3.5 Cart I/O Tab

3.6.1 CMS Tab

3.6.2 Blocking Database Tab

All records in the blocking database are referred to as

3.6.3.1 Entering New Blocking Database Record (New Release Number)

4.4 Simple System

4.5.2.1 Typical Crossing Path Intersection Example

B11 B12 B13

Location: 50 Release type: Normal

Transponder 48, Arrival Functions:

Cart 1 arrives at location 42:

5 SmartCart Removal From System

7 Other Features and Tips

7.2.4 Negative Block Numbers

8 PLC Do – Onboard PLC Interface

8.3.3 PLC Initiation Timing

S-ar putea să vă placă și