MACHT STROM MOBIL

Battery Charging Systems

10a/en 2015
2
Battery Charging Systems

Content ...........................................................................................................................................................................Seite
General ..................................................................................................................................................................................3
Models...................................................................................................................................................................................4
General installation instructions.............................................................................................................................................7

The operation of Automatic Guided Vehicles (AGVs) requires
high utilization of these vehicles in order to achieve an
optimum of profitability. Often, recharge of the batteries
which are required for the drive of the AGVs, presents a
problem.
The development of powerful batteries, which allow for quick
recharge within seconds, enables the integration of charging
contacts into the production cycle without removing the
AGVs from the production process.
Battery charging stations may be installed anywhere within
the system where the production process allows the AGV
to stop (staging areas, turn arounds, loading stops etc.).
Attention should be paid to attain best possible integration
into a given layout.
VAHLE has developed special battery charging contacts
which fully meet any requirement.
A battery charger supplies current to the base plate. Once
the AGV is in charging position and the collector has made
contact with the base plate, the AGV computer turns on the
current.
The base plate has chamfered entry/exit ramps to facilitate
smooth drive-on/drive-off of the spring loaded collector.
Bristle brushes installed on the collector remove debris from
the base plate.
VAHLE battery operating charging contacts are designed for
an voltage of 12 - 80 V. Nominal voltages > 25 V AC or 60 V DC
require a protection gainst accidental touch.
AGVs serve as transportation vehicles and mobile assembly
platforms. They connect assembly areas with assembly
lines, service AS/AR installations etc. The great variety of
possible applications often requires custom designed AGVs
with very specific demands for battery charging contacts.

A battery charging contact consists of a base plate, which is A selection of our wide range of battery charging contacts is
installed on the floor or laterally at a bracket adjacent of the shown on the following pages.
AGV runway, and a current collector which is installed on the
vehicle.

AGV: 12 units
Charging stations: 4 units 4
Central-
Batteries: 12 units 3 V A computer
3-Shift-Operation 5 Main supply AC
2 Charging station
1 = Loading stop 1 6
2 = Assembly Place on board
computer Battery
3 = Hand-over area
1
4 = AGV staging area
5 = Charging stations AGV-Collector
6 = Buffer store and floor mounted AGV-Base Plate
charging contacts

Schematic layout of power supply for Automatic Guided Vehicles (AGVs)

3
Models

AGV-Collector
2-phase, charging current 200 A
Insulated collector for vehicle installation,

68(1)
(76)
20
with two contact brushes and a bristle
cleaning brush.

160
130
90

ø11
190
220

Type Weight kg Order-No.

SA-BLS200-2-01 2,600 590 000

AGV-Base Plate
2-phase, charging current 200 A

20
contact plate 40x300

190
90

240
400

Type Weight kg Order-No.

BLK 200-2-01 2,200 590 001

AGV-Collector
2-phase, charging current 200 A
Insulated collector for vehicle installation,
with two contact brushes, surrounding
65(1)
(75)

bristle cleaning brushes and two-direc-

20

tional drive-on capability. 90

90
180
150
90
ø11

220
250

Type Weight kg Order-No.

SA-BLS200-2QU-01 3,025 590 013

(1) Height at contact position

4
Models

AGV-Collector AGV-Base Plate

2-phase, charging current 200 A 2-phase, charging current 200 A
Insulated collector for vehicle installation, with two contact Insulated Floor contact plate with two copper contact plates
brushes each for charging, two pilot contacts and a bristle for charging and two pilot copper contact plates.
cleaning brush.

20
20
68(1)
(76)

contact plate 40x190

contact plate 30x70

230
120
120

190
160

250
ø11

190
400
220

Type Weight kg Order-No. Type Weight kg Order-No.

SA-BLS 200-2B/20-2-01 3,000 590 198 BLK200-2/25-2-01 2,700 590 062

AGV-Collector AGV-Base Plate

2-phase, charging current 20 A 2-phase, charging current 25 A
15

(58)
52(1)

15

ø6

contact plate 20x150

10

M8
105
ø11

40
70

40
100
130
250

Type Weight kg Order-No. Type Weight kg Order-No.

SA-BLS20-2O-01 0,310 590 207 BLK25-2-01 0,590 590 042

(1) Height at contact position

5
Models

AGV-Collector AGV-Base Plate

single-phase, charging current 200 A single-phase, charging current 200 A
Insulated collector for vehicle installation, with one contact Insulated Floor contact plate,
brush and one bristle cleaning brush (to be used in pairs). complete with single copper contact.

16
68(1)
(76)
20

contact plate 40x250

70
100
80

280
150
ø9

400
170

Type Weight kg Order-No. Type Weight kg Order-No.

SA-BLS200-1-04 1,362 590 035 BLK 200-1-01 W 0,890 590 036

AGV-Collector AGV-Base Plate

single-phase, charging current 600 A single-phase, charging current 600 A
Insulated collector for vehicle installation, with three contact Insulated Floor contact plate,
brushes and one bristle cleaning brush (to be used in pairs). complete with single copper contact.
20
68(1)
(76)

20

contact plate 130x250

158
M10

130
190
90
45

280
210
182

400
45

Type Weight kg Order-No. Type Weight kg Order-No.

SA-BLS600-1AO-01 4,100 590 043 BLK600-1-01 3,000 590 044

(1) Height at contact position

6
Models

AGV-Collector AGV-Base Plate

2-phase, charging current 200 A 2-phase, charging current 200 A
Insulated collector for vehicle installation, Insulated Floor contact plate with two copper contacts,
with two contact brushes and cover pusher. spring loaded cover and 2 x 2 m connecting cables.
68(1)
(76)

35
20

contact plate 30 x 5 x 225

ø8,5

(120)(2)
109
50
120
90
50

40 300
ø11

170
350
200

Type Weight kg Order-No. Type Weight kg Order-No.

SA-BLS200-2E-01 2,260 590 065 BLK200-2EA-01 3,926 590 064

General installation instructions

Install AGV-collectors on vehicle with bristle cleaning brushes in direction of travel.

Install AGV-Base Plate on top of the floor.

The *marked height 68 (65, 45) of AGV-Collectors type BLS is the dimension at contact position. Allowable tolerance: + 2 mm.
In order to guarantee sufficient contact pressure the max. wear reduction of the contact brushes is limited to 5 mm whereby
the unevenness of the floor must be considered.

Between base plate and cutout at concrete floor a dust- and waterproof sealing has to be installed.

shown without bristle cleaning brush

direction of travel
90 M10

collector
~36
worn-off contacts)

bristle cleaning
(min. 5 mm with

20

brush

contact brushes
~48
10 mm

base plate
20,5
40

ø140 M8

ø10
240

(1) Height at contact position

(2) Dimensions incl. coverage

7
 Scope of delivery and services Catalog no.

1 Open conductor systems

Open conductor systems 1a
2 Insulated conductor systems
U10 2a
FABA 100 2b
U15, U25, U35 2c
U20, U30, U40 2d
3 Compact conductor systems
VKS 10 3a
VKS - VKL 3b
VMT 3c
4 Enclosed conductor systems
KBSL - KSL 4a
KBH 4b
MKH 4c
LSV - LSVG 4d
5 Contactless power supply
Contactless power supply (CPS®) 5a
6 Data transmission
VAHLE Powercom® 6a
Slotted Microwave Guide (SMG) 6b
7 Positioning systems
VAHLE APOS® 7a
VAHLE APOS Optic
®
7b
8 Festoon systems and cables
Festoon systems for -tracks 8a
Festoon systems for flatform cables on -tracks 8b
Festoon systems for round cables on -tracks 8c
Festoon systems for -tracks 8d
Cables 8e
9 Reels
Spring-operated cable reels 9a
Motor-powered cable reels 9b
10 Other
Battery charging systems 10a
Heavy enclosed conductor systems 10b
Tender 10c
Contact wire 10d
11 Automotive | Handling
Control systems 11a
BOK 11b
Assemblies / Commissioning
Spare parts / Maintenance service
DQS certified in accordance with DIN EN ISO 9001:2008
OHSAS 18001 (Reg.No. 003140 QM OH)

Kamen/Germany +49 2307 704-0 · info@vahle.de · www.vahle.com ELECTRIFICATION SYSTEMS