Makes everything very simple. cyber® iTAS® system 2 – The drive system for AGV/AMR

Smart and lean safety architecture, an industrial design that emphasizes simplicity in all essential aspects and performance data optimized for vehicle masses between one and three tons – we are talking about the cyber iTAS system 2 from WITTENSTEIN. This latest generation of the compact servo drive system has been developed for automated guided vehicles (AGVs), autonomous mobile robots (AMRs) and other mobile platforms.

With its enormous power density, the cyber iTAS system 2 – consisting of a safety-certified servo drive from the cyber simco drive 2 series with a maximum current of 200 A plus a compact wheel drive in the form of the cyber TAS actuator 2 – makes it ideal for autonomous mobile vehicles of this size and performance class possible to achieve measurable improvements in performance and therefore productivity. The wheel actuator has a load capacity of 750 kg per wheel and IP54 protection and is not only very compact – two wheel actuators can be mounted back-to-back as a steerable differential drive to save space and, if necessary, rotated axially by 90°. Their cable outputs can then be optimally routed to the plug connections on the front of the servo drive.

AGV experts confirm that the small dimensions of the wheel actuator – total height 180 mm, total length 230 mm including a space-saving safety encoder – are particularly beneficial when designing and building flat and narrow vehicles. High-performance differential drives can be realized even when only very limited space is available, paving the way for maximum agility and enabling smooth running and short braking distances.

Slim security architecture

An essential – and in the future increasingly critical – aspect of using these vehicles is that in the vast majority of cases they occupy the same working space as humans. With its newly designed next-level security architecture, it delivers cyber iTAS system 2 the high safety requirements in this area and at the same time the requirements for performance and productivity during use. This is especially true for shared use scenarios involving humans and machines with autonomous behavior. It cyber iTAS system 2 is a drive system with integrated safety architecture that requires fewer cables and connectors, fewer interfaces, components and modules and reduces the risk of errors and the effort for assembly and documentation – without in any way compromising the safety of AGVs or AMRs . Maintenance is also easier.

Safety functions directly integrated into the drive system

The simplifications brought about by the next-level safety architecture are primarily reflected in the system's servo drive, which has a dual-channel STO (Safe Torque Off) function even in the basic version. Enhanced safety features are possible by installing an optional safety card. In addition to STO, the system also integrates Safe Brake Control (SBC) – both according to SIL 3 and PL e – and safe encoder emulation according to SIL 2 and PL d. The latter converts the safe current positions provided by the actuator into analog signals and transmits them to the safety control system. In addition, the actuator not only has an integrated safety encoder in accordance with SIL 2 and PL d for safe speed and position monitoring, but also - in addition to the regenerative braking function - an integrated spring-loaded brake. This combination of an integrated safety encoder for determining the safe position and the safe encoder emulation that performs this position means that the Safe Position (SP) function can be implemented in accordance with SIL 2 and PL d. The safe signals from the drive to the safety or vehicle control system are transferred directly via a safe fieldbus such as PROFIsafe, eliminating the need for additional wiring. More secure fieldbus interfaces are already in development.

Overall, the cyber iTAS system 2 meets at least the SIL 2 and PL d requirements according to IEC 61508 and EN ISO 13849-1, depending on the application – as prescribed by most vehicle manufacturers and operators. They benefit not only from the certified safety, but also from the shorter time and lower costs for commissioning, maintenance and documentation thanks to the lean safety architecture and the less complex safety and control technology in the vehicles.

Simple, easy to integrate and robust

The cyber iTAS system 2 drive system convinces with its industrial concept and its simple, well-thought-out design. To enable installation in the immediate vicinity of the actuator without much wiring and at the same time save space in the control cabinet, the drive in protection class IP65 is largely insensitive to dust and moisture. The wheel drive itself has IP54 and is suitable for indoor use. Standard industrial M12 connectors and ring cable lugs are used for the electrical connection of the cyber simco drive 2 servo drive. Power and logic are provided over a wide voltage range from 12 to 60 VDC.

Multi-Ethernet and CANopen interfaces ensure easy integration into different operating environments. Apart from the Vulkollan or Besthane tread wheel, the entire system is maintenance-free. The electronic identification plate guarantees trouble-free commissioning and supports diagnostic functions and a quick restart of the drive system. In addition, the slim system design helps to save on devices such as cables, contactors, relays or a second encoder. Fewer components mean less risk of malfunctions, so in this respect too the cyber iTAS system 2 contributes to optimal robustness – and therefore availability.

Design data and more available in CADENAS

The cyber iTAS system 2 makes it easy for designers to optimize their existing vehicle architectures and realize innovative AGV and AMR designs. The fact that the current 2D and 3D CAD models, CAE models and 3D PDF data sheets for the new drive system are already available online in the electronic CADENAS product catalog is a great asset here. Together with its advanced safety architecture, the drive system represents an innovative solution with enormous future potential – especially for vehicles that are both heavy and fast. Thanks to the cyber iTAS system 2, these can now be designed and built even flatter.

AGV manufacturer CREFORM Technik from Baunatal, Hesse, has stood for innovative vehicle concepts for many years to make material transport even more efficient, flexible and economical. Tim Mark, Sales Engineer – Development at CREFORM, is enthusiastic about the cyber iTAS system 2 technology and the collaboration with WITTENSTEIN cyber motor. “It scores points as a drive solution for AGVs cyber iTAS system 2 from WITTENSTEIN cyber motor with an extremely high pulling power. Our vehicles benefit from excellent acceleration values and short braking distances.”

Mark continues: “We design our vehicles more or less completely without a control box. In other words, the cyber simco drive 2 servo drive fits perfectly into our concept because it simplifies the vehicle design process, for example through space savings, better heat dissipation and lower costs.

Simplifies vehicle design

The sleek safety architecture of the cyber iTAS system 2 with its built-in safety features simplifies the architecture of CREFORM's vehicles. “For us, the smaller footprint and lower wiring costs are the most decisive benefits, along with the time and cost savings in the event of maintenance.”

Mark: “Implementing a new product technology generally means adding new functionality, often in combination with new tools. The product itself is only one aspect of a successful implementation; the support we receive from supplier WITTENSTEIN is just as essential to understand all these new functionalities and use them efficiently.”