Automated Guided Vehicle System

Automated guided vehicle
CHAPTER 1
INTRODUCTION
An automated guided vehicle system is a material handling system that uses independently operated , self propelled vehicle that are guided along defined pathways on the floor. The vehicles are powered by means of on board batteries that allow operation for several hours (8-16 hrs.) between recharging. Guidance is achieved by using sensors on the vehicles that follow the guide wires. The vehicle is controlled by an off board controller or a microprocessor. This controller sends commands to the vehicle such as identification of load, its destination and other special instructions. An AGV system provides a material handling system i.e. both flexible and readily adaptable to either production or production changes.
AGV systems are originally developed for the distribution of material in warehouse environments although this is an imp. use, two major growth areas have been evolved the movement of material to and from production areas in manufacturing facilities, reflecting manufacturing work lifts and use of carriers of work in progress in assembly plants, replacing serial type asynchronous or fixed index assembly conveyor system and small packages, in hospitals to deliver meals, and for material handling.
Automated guided vehicles increase efficiency and reduce costs by helping to automate a manufacturing facility or warehouse. The AGV can tow objects behind them in trailers to which they can autonomously attach. The trailers can be used to move raw materials or finished product. The AGV can also store objects on a bed. The objects can be placed on a set of conveyor and then pushed off by reversing them. Some AGVs use fork lifts to lift objects for storage. AGVs are employed in nearly every industry, including, pulp, paper, metals, newspaper, and general manufacturing. Transporting materials such as food, linen or medicine in hospitals is also done. .
D Y Patil COE, Pune.
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CHAPTER 2 TYPES OF VEHICLES

2.1 Towing Vehicles: These vehicles consist of an AGV with no load carrying facility but with a hitch or tow bar that can pull trailers, carts pallets jacks and wheeled racks. They are used where large volume of product to be moved or in retro fit applications where product in historically been moved by trailers. These vehicles can move loads up to 50,000 pounds.
2.2 Unit load Transporters: These vehicles are designed to carry individual loads. Unit load transporter can have an extremely versatile deck design, which permits them to be equipped with rollers, belt conveyors, power lifts, special fixtures, or on board robot arm, These AGV can be either bidirectional or unidirectional and are used in house as well as on factory flowers. Unit load transporter scan lift loads ranging between 12,000 to 60,000 pounds.
2.3 Standard Automatic Guided pallet Trucks: These vehicles are designed to service palletized loads to and from floor level positions. The shadow fork region has limited fork travel and is designed to move pallets to and from floor positions exclusively. The fork truck version has travel up to 20 feet and can move pallets both at floor level and on stands or racks.
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2.1 Types of AGVs 2.4 Assembly Line Vehicles: These vehicles have a fixture on board that accept the frame initial parts of the product that is to be assembled. The vehicle is routed through the various manufacturing stations of the factory where parts and assembly are added to the product. these AVG can provide total automatic transfer of material these are known as material handling system on automated assembly line. They can skip assembly section if required in particular section breaks down.
2.5 Light Load Transporters: These vehicles are design to carry boxes, baskets, small parts, etc. with any other unitized container. It generally has a footprint allowing its use in tight spaces and narrow aisles. These vehicles are used for a wide range of functions from mailrooms to clean rooms in every type of manufacturing and office environments.
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2.6 Advantages and Disadvantages 2.6.1 Advantages of AGV Following are the advantages of AGV 1. 2. 3. 4. 5. 6. 7. 8. 9. Reduction in labor force. Improved productivity and quality. Job enrichment and worker satisfaction. Reduction in space requirement Reduction in product damage. Improvement in house keeping. Ease of removal and relocation. Integration with other type of automations. System adaptability and flexibility.
2.6.2 Disadvantages of AGV Following are the disadvantages of AGV 1. 2. 3. 4. 5. 6. 7. 8. 9. Expensive External use is limited. Requirement of specially designed floor space. Performance is affected if guide path bed is not stable. Sufficient support from management is required. Equal support from worker is required. Obstructions are created. Maintenance is required. Other considerations are :
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CHAPTER 3 AGV SYSTEM COMPONENT
3.1 AGV COMPONENTS

MECHANICAL The Mechanical components include chassis and the steering system. Functions of chassis Act as a frame for attaching other components Carry the load of other components and the payload. Act as sacrificial component to prevent damage of expensive payload in case of accidents
Steering system is for steering the AGV ELECTRICAL Electrical components include the motor and the power supply for the motor itself. ELECTRONIC Electronic components provide sensing, logical decision and control of the vehicle. It includes microprocessor for the decision logic, the motor driver as both sensing and control of motor. COMPUTER The Computer acts as a viable substitute for a central computer that provide the AGVs with the path to proceed.
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3.2 MECHANICAL DESIGN

CHASSIS The chassis is fabricated from Aluminum alloy sheet metal. This is done for ease of fabrication. It was designed in ProE, part of fabrication was outsourced due to unavailability of precision cutting tools. The Bending was done in then college workshop. The chassis was designed to take a static load of 10kg minimum. The Top part of chassis has lots of drilled holes which serves as holes for bolting other parts and reduce the weight of the chassis. The Holes are arranged in a zigzag linear arrangement so that the decrease in strength of chassis is not considerable. The flange which holds the motor was designed in a way that there is at least 10mm so that it can safely accommodate any bending due to loading above the designed value. The chassis incorporates mounting holes for both Ackermann steering and Differential steering system Technical Data for Chassis (Table 3.2.1) Feature Data Length: 194mm Breadth: 105mm Height: 42mm Material: Al Alloy Aesthetics: Power Coating Maximum static load: 12.6Kg Maximum dynamic load: 6.3Kg Maximum impact load: 1.2Kg from 1000mm Mounting Holes: 413mm Holes for motor 118mm Hole for castor >505mm Holes for general mounts
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3.3 STEERING SYSTEM The steering system used in the model is of differential type. A differential wheeled vehicle is a vehicle whose movement is based on two separately driven wheels placed on either side of the body. It can thus change its direction by varying the relative rate of rotation of its wheels and hence does not require an additional steering motion. It allows the turning center to be on the vehicle body thus the ability to rotate on the point
Fig 3.1: Differential Steering If both wheels rotate at the same speed and in the same direction, the robot will move in a straight line.
Fig: 3.2 Spinning by differential steering If the wheels rotate at equal speed, but in opposite directions, both wheels will traverse a circular path around a point centered half way between the two wheels. Therefore the robot will pivot, or spin in place. (Figure 3.2) D Y Patil COE, Pune. Page 7
Fig 3.3 Small radius turning If one of the wheels is stopped, while the other continues to rotate, the robot will pivot around a point centered approximately at the mid-point of the stopped wheel. (Figure 3.3)
Fig: 3.4 Large radius turning If one wheel rotates faster than the other, the robot will follow a curved path, turning inward toward the slower wheel. (Figure 3.4)
Steering Specifications: Table 3.3.1 Feature Wheel Base Wheel Diameter Turning Radius range Point of Zero Radius Turn
Data 142mm 70mm 0- Halfway along Breadth,
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3.4 AGV SYSTEM COMPONENTS
Although all AGV system are different, in general they consist of following components:
3.4.1 Vehicles: The component of an AGV system that is most readily identified is vehicle itself. The vehicle consists of a frame, batteries on board charging unit, electrical system drive unit, steering, precision stop unit, on board controller, communication unit, safety system and work platform.
a.
Frame : The frame is usually constructed of welded steel member with aluminum cover
Plate.
b.
Batteries and charging : AGV systems are typically powered by 24 or 48v D.C. industrial batteries. Battery
charging is accomplished by one of two techniques viz. Opportunity charging or full cycle charging.
c.
Drive unit : The main components of motor speed controller and drive mechanism. The driver speed
controller mechanism is usually a pulse width modulated four-quadrant servo drive unit. The carrier drive commands are generated either through the microprocessor or at the hand control unit.
d.
Steering:
Vehicles are designed to maneuver in three different ways forward only, forward and reverse, four directional. The major components of power steering system are the steering antenna, the steering motors and their controllers, steering linkage and steering limit switches.
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Automated guided vehicle e. Precision stop controller :
A precision stop controller is used to stop AGV with close location accuracy at workstation and charge station. At some point before an up coming precision stop location, the vehicle will receive a precision stop command from off board controller or by code bar on board on the floor. AS it approaches stop point the vehicles metal detector is activated and AGV slows to the end of the plate.
f.
On board controller : The vehicle controller is used to monitor vehicle performance through encoder data to
determine position and velocity discrete digital input, monitor functions as controls, activation of safety devices, battery conditions, steering limit, break release, status. running light drive controller
g.
Communication Unit : Instructions to the vehicle microprocessor are usually generated by the Area
controller and then relayed to the vehicle. The communication System may be either continuous or discrete.
h.
Safety : Safety systems may be divided in to three specific categories, vehicle to Vehicle,
vehicle to object, and vehicle to people. The first system uses
photo cells mounted on AGVs
leading edge and reflecting material on trailing edge to avoid collision of vehicles. Vehicle to object system uses bumpers , toe born limit switches, proximity sensors to protect both vehicle and any object in AGV path generally vehicle have warning light buzzers or toner which flashes or sounds to indicate automatic mode.
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CHAPTER 4 AGV GUIDENCE & CONTROLES
INTRODUCTION Some AGV system use vehicles, which have sophisticated microprocessor on board and are known as smart or intelligent vehicles. Other systems have minimal vehicle computing ability and use a central computer for all process. In such systems central computer decides location, direction, proper rout and path of the vehicle. This is accomplished by turning on and off the path at decision points or by commanding vehicle to follow a particular frequency. All decision is making is made by central computer in smart vehicles. The central computer dispatches the vehicle to next location, though its on board microprocessor, the vehicle it self makes decision as to which path it takes.
4.1 method of Programming

the smallest system uses manual programming to direct the vehicle to specific destination and to dispatch the vehicle. These system ranges from basic toggle switches, thumbwheel switches or push button numeric pad for programming the vehicle to go to specific station. The advantage of manual system is that it is the least expensive and simplest system. The disadvantages of manual system are that its efficiency depends upon operators. Finally these types of systems controller cannot determine vehicle location while it is in transits. The second level of sophistication in control system is referred to as remote dispatch. In such systems operator intersects with the local controller who in turn transmit information such as destination , rout and automatic load/ unload commands to the vehicle this control system allows the vehicle to circulate on guide path looking for work. this system does not allowed tracking capabilities. The third level is more complex and expensive and is referred to as the central computer controlled system.
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4.2 Guide Path Techniques: Navigation

4.2.1 Wired The wired sensor is placed on the bottom of the robot and is placed facing the ground. A slot is cut in the ground and a wire is placed approximately 1 inch below the ground. The sensor detects the radio frequency being transmitted from the wire and follows it. 4.2.2 Guide Tape Many light duty AGVs (some known as automated guided carts or AGCs) use tape for the guide path. The tapes can be one of two styles: magnetic or colored. The AGC is fitted with the appropriate guide sensor to follow the path of the tape. One major advantage of tape over wired guidance is that it can be easily removed and relocated if the course needs to change. It also does not involve the expense of cutting the factory or warehouse floor for the entire travel route. Additionally, it is considered a "passive" system since it does not require the guide medium to be energized as wire does. Colored tape is initially less expensive, but lacks the advantage of being embedded in high traffic areas where the tape may become damaged or dirty. A flexible magnetic bar can also be embedded in the floor like wire but works under the same provision as magnetic tape and so remains unpowered or passive. 4.2.3 Laser Target Navigation The wireless navigation is done by mounting retroreflective tape on walls, poles or machines. The AGV carrys a laser transmitter and receiver on a rotating turret. The laser is sent off then received again the angle and (sometimes) distance are automatically calculated and stored into the AGVs memory. The AGV has reflector map stored in memory and can correct its position based on errors between the expected and received measurements.[4] It can then navigate to a destination target using the constantly updating position
. 4.2.1 laser navigation
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Modulated Lasers The use of modulated laser light gives greater range and accuracy over pulsed laser systems. By emitting a continuous fan of modulated laser light a system can obtain an uninterrupted reflection as soon as the scanner achieves line of sight with a reflector. The reflection ceases at the trailing edge of the reflector which ensures an accurate and consistent measurement from every reflector on every scan. The LS9 Scanner is manufactured by Guidance Navigation Ltd and, by using a modulated laser; this system achieves an angular resolution of ~ 0.1 mrad (0.006) at 8 scanner revolutions per second. Pulsed Lasers A typical pulsed laser scanner emits pulsed laser light at a rate of 14,400 Hz which gives a maximum possible resolution of ~ 3.5 mrad (0.2) at 8 scanner revolutions per second. To achieve a workable navigation, the readings must be interpolated based on the intensity of the reflected laser light, to identify the centre of the reflector.
4.2.4 Gyroscopic Navigation Another form of an AGV guidance is inertial navigation. With inertial guidance, a computer control system directs and assigns tasks to the vehicles. Transponders are embedded in the floor of the work place. The AGV uses these transponders to verify that the vehicle is on course. A gyroscope is able to detect the slightest change in the direction of the vehicle and corrects it in order to keep the AGV on its path. The margin of error for the inertial method is 1 inch.[5] Inertial can operate in nearly any environment including tight aisles or extreme temperatures.[6] 4.2.5 Steering control To help an AGV navigate it can use two different steer control systems. The differential speed control is the most common. In this method there are two sets of wheels being driven. Each set is connected to a common drive train. These drive trains are driven at different speeds in order to turn or the same speed to allow the AGV to go forwards and/or backwards. The AGV turns in a similar fashion to a tank. This method of steering is good in the sense that it is easy to maneuver in small spaces. More often than not, this is seen on an AGV that is used to transport and turn in tight spaces or when the AGV is working near machines. This setup for the wheels is not used in towing applications because the AGV would cause the trailer to jackknife when it turned. The other type of steering used is steered wheel control AGV. This type of steering is similar to a cars steering. It is more precise in following the wire program than the differential speed controlled method. This type of AGV has smoother turning but cannot make sharp turns in tight spots. Steered wheel control AGV can be used in all applications; unlike the differential controlled.[5] Steered wheel control is used for towing and can also at times have an operator control it. D Y Patil COE, Pune. Page 13
Automated guided vehicle 4.2.6 Path Decision AGVs have to make decisions on path selection. This is done through different methods: frequency select mode (wired navigation only), and path select mode (wireless navigation only) or via a magnetic tape on the floor not only to guide the AGV but also to issue steering commands and speed commands. 4.2.7 Frequency select mode Frequency select mode bases its decision on the frequencies being emitted from the floor. When an AGV approaches a point on the wire which splits the AGV detects the two frequencies and through a table stored in its memory decides on the best path. The different frequencies are required only at the decision point for the AGV. The frequencies can change back to one set signal after this point. This method is not easily expandable and requires extra guide cutting meaning more money. 4.2.8 Path select mode An AGV using the path select mode chooses a path based on preprogrammed paths. It uses the measurements taken from the sensors and compares them to values given to them by programmers. When an AGV approaches a decision point it only has to decide whether to follow path 1, 2, 3, etc. This decision is rather simple since it already knows its path from its programming. This method can increase the cost of an AGV because it is required to have a team of programmers to program the AGV with the correct paths and change the paths when necessary. This method is easy to change and set up. 4.2.9 Magnetic Tape mode The magnetic tape is laid on the surface of the floor or buried in a 10 mm channel, not only does it provide the path for the AGV to follow but also sort strips of the tape in different combos of the strip tell the AGV to change lane and also speed up slow down and stop with north and south magnetic combos, this is used by TOYOTA USA and TOYOTA JAPAN.
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CHAPTER 5 APPLICATION OF AGVS

5.1 Common AGV Applications Automated Guided Vehicles can be used in a wide variety of applications to transport many different types of material including pallets, rolls, racks, carts, and containers. AGVs excel in applications with the following characteristics:

Repetitive movement of materials over a distance Regular delivery of stable loads Medium throughput/volume When on-time delivery is critical and late deliveries are causing inefficiency Operations with at least two shifts Processes where tracking material is important
5.2 Raw Material Handling AGVs are commonly used to transport raw materials such as paper, steel, rubber, metal, and plastic. This includes transporting materials from receiving to the warehouse, and delivering materials directly to production lines.[10] 5.3 Work-in-Process Movement Work-in-Process movement is one of the first applications where automated guided vehicles were used, and includes the repetitive movement of materials throughout the manufacturing process. AGVs can be used to move material from the warehouse to production/processing lines or from one process to another.[11] 5.4 Pallet Handling Pallet handling is an extremely popular application for AGVs as repetitive movement of pallets is very common in manufacturing and distribution facilities. AGVs can move pallets from the palletizer to stretch wrapping to the warehouse/storage and/or to the outbound shipping docks.[12] 5.5 Finished Product Handling Moving finished goods from manufacturing to storage or shipping is the final movement of materials before they are delivered to customers. These movements often require the gentlest material handling because the products are complete and subject to damage from rough handling. Because AGVs operate with precisely controlled navigation and acceleration and deceleration this minimizes the potential for damage making them an excellent choice for this type of application.[13] D Y Patil COE, Pune. Page 15
Automated guided vehicle 5.6 Trailer Loading Automatic loading of trailers is a relatively new application for automated guided vehicles and becoming increasingly popular. AGVs are used to transport and load pallets of finished goods directly into standard, over-the-road trailers without any special dock equipment. AGVs can pick up pallets from conveyors, racking, or staging lanes and deliver them into the trailer in the specified loading pattern.[14] 5.7 Roll Handling AGVs are used to transport rolls in many types of plants including paper mills, converters, printers, newspapers, steel producers, and plastics manufacturers. AGVs can store and stack rolls on the floor, in racking, and can even automatically load printing presses with rolls of paper.[15]. 5.8 Primary Application Industries Efficient, cost effective movement of materials is an important, and common element in improving operations in many manufacturing plants and warehouses. Because automatic guided vehicles (AGVs) can delivery efficient, cost effective movement of materials, AGVs can be applied to various industries in standard or customized designs to best suit an industrys requirements. Industrys currently utilizing AGVs include (but are not limited to):
5.1 A unitload vehicle for delivering steel plates
5.9 Pharmaceutical AGVs are a preferred method of moving materials in the pharmaceutical industry. Because an AGV system tracks all movement provided by the AGVs, it supports process validation and cGMP (current Good Manufacturing Practice).
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Automated guided vehicle 5.10 Chemical AGVs deliver raw materials, move materials to curing storage warehouses, and provide transportation to other processing cells and stations. Common industries include rubber, plastics, and specialty chemicals. 5.11 Manufacturing AGVs are often used in general manufacturing of products. AGVs can typically be found delivering raw materials, transporting work-in process, moving finished goods, removing scrap materials, and supplying packaging materials. 5.12 Automotive AGV installations are found in Stamping Plants, Power Train (Engine and Transmission) Plants, and Assembly Plants delivering raw materials, transporting work-in process, and moving finished goods. AGVs are also used to supply specialized tooling which must be changed.
5.2 A Tugger AGV pulling wheeled carts containing automotive body panels
5.3 Supplying a bin of parts for assembly onto cars
5.13 Paper and Print AGVs can move paper rolls, pallets, and waste bins to provide all routine material movement in the production and warehousing (storage/retrieval) of paper, newspaper, printing, corrugating, converting, and plastic film.
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5.14 Food and Beverage AGVs can be applied to move materials in food processing (such as the loading of food and/or trays into sterilizers) and at the end of line, linking the palletizer, stretch wrapper, and the warehouse. AGVs can load standard, over-the-road trailers with finished goods, and unload trailers to supply raw materials or packaging materials to the plant. AGVs can also store and retrieve pallets in the warehouse. 5.15 Hospital
AGVs are becoming increasingly popular in the healthcare industry for efficient transport, and are programmed to be fully integrated to automatically operate doors, elevators/lifts, cart washers, trash dumpers, etc. AGVs typically move linens, trash, regulated medical waste, patient meals, soiled food trays, and surgical case carts.
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CHAPTER 6 FUTURE TRENDS
Although it is difficult to predict the future with absolute certainty, it can be concluded from the trends that seem to indicate future status of AGV systems.
6.1 Guidance : The research is being accomplished to expand capability and even to eliminate the need for guidance using guide path on board controller. On board controller is becoming more sophisticated and at same time they are becoming smaller and less expensive the vehicle controllers are exhibiting such features as expanding diagnostics. Although vehicle cannot repair themselves, they can at least indicate their problems to maintenance and repair person. Controller sophistification will also allow the vehicle to operator more intelligently in complex handling situation and will increase the system integrity in the event of host computer failure.
6.2 Vehicle communication: The trend is towards continuous as opposed to discrete communication So that vehicle will be able to communicate and receive updated instruction at any time.
6.3 system controller: System will be designed to have capability to track material and store this information. They will be able to follow and control material flow to support just in time concepts. The system controller will also be able to be integrated with network allowing it to communicate with any other facility controller.
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Automated guided vehicle 6.4 Vehicle : Vehicle will become more standard requiring less engineering to adapt the vehicle to a particulate task, thus lowering the coast of vehicle to a particular task, thus lowering the coast of vehicle to a great extent this will make them easier to justify for many users.
6.5 Improved Graphical Display : There will be probability the increased use of color graphical display showing entire guide path, every vehicle location, the vehicle identification, the vehicle status and vehicle load.
6.6 Safety: New safety sensors for proximity detection will be developed and coupled with computing power of on board controller to produce on even vehicle that readily negotiate pedestrian clogged aisle.
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CHAPTER 7 CONCLUSION
This seminar report gives the introductory and brief information about the AGVS. These systems interfaces with automatic storage on one hand and with manufacturing operations on the other. They are coordinated through a centralized computer to provide virtually automatic flow of material through a manufacturing plant, taking row material to machine and carrying finished products in to storage or shipping. Such totally automatic systems are bound to become more prevalent in the future. Another trend ganging momentum is the great sophistification of controls that permits a vehicle to operate more intelligently and thus fit more ifficiently and thus fit more efficiently in to complex handling patterns. The guidance control system of AGVS can be used for other material handling systems such as lift trucks, which permits further reduction of human drivers and materials handling becomes more controllable.
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CHAPTER 8 REFRANCES
1. M. P. Groover Automation, Production Systems and Computer integrated Manufacturing TATA McGraw Hills Publications,Second Edition,1995. 2. J.H. Fuchs Advanced Manufacturing Methods, Tata McGraw Hills Publications, First Edition,1992. 3. WWW.Google.com 4. WWW.Howstuffworks.com 5. Automation production systems, and computer integrated manufacturing by MikellP.Groover 6. www.wikipedia.com 7. http://www.agvsystems.com/faqs/q5.htm 8. http://www.amerden.com/AmerdenWeb/agvinformation.html 9. A Guide to Robotic Logistics LGVs (AGVs). Elettric 80 S.p.A. 26 April 2008 10. "The Appropriate Application of Automated Guided Vehicles ". HK Systems, Inc. 01 October 2007 11. http://www.hksystems.com/agv/index.cfm 12. Automation rstedDTU, Technical University of Denmark, DTU-build. 326, DK-2800 Kgs. Lyngby, Denmark. 13. jca@oersted.dtu.dk naa@oersted.dtu.dk or@oersted.dtu.dk 14. http://www.sick.com/us/en-us/home/about_sick/partners/Pages/meet_our_partners.aspx 15. http://www.icart-agv.com/iCart-intelligence.html 16. http://www.cs.cmu.edu/~chuck/robotpg/robofaq/8.html 17. http://www.allbusiness.com/professional-scientific/scientific-researchdevelopment/107793-1.html
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D Y Patil COE, Pune.