Automated Guided Vehicles

JEEVAN REDDY
Rollno:ME15B011
 Automated Guided Vehicles

 Topics to be covered in this lecture:

 Components of AGVS
 Important issues for the AGVS
 System design of AGVS
 Vehicle Management
 No of AGVs required
Components of
AGVS:

 The Vehicle – No operator

 The guide path – The path for the AGV

 The control Unit – Monitors and Directs system operations including

feedback on moves, inventory, and vehicle status.

 The computer interface – Interfaces with other mainframe host

computer, the automated storage and retrieval system (AS/RS), and
the flexible manufacturing system.
Factors determining the functioning of AGV’S:

 Guidance system
 Routing
 AGVS control systems
 Load transfer
 Interfacing with other subsystems
 AGVS Guidance system

 The goal of an AGVS guidance system keep the AGV on

track/predefined path.

 One of the major advantage of AGV is ease in modification given by

the guidance system for changing the guide path at low cost compare
to conveyors, chains, etc.

 Another benefit is: guide path is flexible which means intersection of

path is possible.

 Generally, guide path does not obstruct another systems.

 The guidance systems can be selected based on the type of AGV

selected, its application, requirement and environmental limitation.
 Wire-guided
 Optical
 Inertial
 Infrared
 Laser
 AGVS Routing

 AGVS routing means determining how the vehicle conforms the path
and takes a shortest path between the two points

 A routing system is used to select the vehicle which is positioned with

the optimum path.

 A network controller gives the destination, while the on-board

controller navigates the vehicle.

 Commonly used methods:

 Frequency select method

 Path-switch select method

 Frequency select Method

 At the bifurcation of path (decision point), the vehicle reads a code in

the floor in the form of metal plate, or coded device.

 The vehicle selects one of the frequencies as per the direction

required.

 A continuous wire is used to loop the frequencies.

Path-switch select Method

 Path is divided into segments.

 One frequency is used, Segments are switched On/Off by separate

floor controls according to the path to be followed.

 Less preferred over Frequency select method.

AGVS Control Systems
AGVS Control Systems
1)Computer Controlled System

2)Remote Dispatch Control System

3)Manual Control System

 AGVS Control Systems
Computer controlled system:

 The path controller controls the guide path of AGVS.

Sends information to AGVS process controller.

 Process controller directs movement of vehicles.

 Interchanges information with the host computer.

 Most Expensive and complex type of control.

Guided
AGV
path

Controller for AGVS process Display

guided path controller terminal

Display Host
terminal computer
Remote dispatch control system:

•Instructions are issued to vehicle from a remote control station

via a human operator.
•Control system sends instruction directly to vehicle.
•The human operator does have the direct control over the
vehicles.
•This type of system generally have automatic loading and
unloading capability.

Manual control system:

•The destination is fed on the onboard control on the vehicle via a

human operator after loading.
•The vehicles moves through the guide path for the destination by
itself.
•Reaching destination, it stops for the human operator to direct
unloading.
•Least expensive control system.
•Efficiency depends on operators performance and varies.
AGVS Load Transfer

 Load Transfer of the vehicle means loading/unloading. The two

types of load transfer operations are:
 Manual Load Transfer

 Manually loading and unloading the Vehicle.

 Use of forklift trucks, pallet trucks, roller, etc.

 Manually coupling/uncoupling towed vehicles
 Automatic Loading and unloading

 Efficient system

 Use of Powered roller, belt, and chain

 Powered lift/lower devices, push/pull devices

 Automatic couple/uncouple
Interfacing with other subsystems

 AGVS system can be interfaced with other subsystems through the

distributed processing network or using Host computer. Such
subsystems are:
 Automated storage and retrieval system

 Flexible Manufacturing systems

 Computer Numerical control (CNC)

 Process Control Equipment

 Shop Floor control system

AGVS Design Features
 Some special features unique to the AGVS, such as stopping
accuracy, facilities, safety, and maintenance.

 A very important attribute of the AGVS system is “Stopping

Accuracy”.

 In an AGVS, the stopping accuracy is provided by the feedback of

Computer Control Systems.

 Stopping accuracy depends on the applications, for example, ±0.001

inch for machine tool interfaces, ±1 inch or more for towing and
light-load vehicles, and ± 3 inch for a manual system.

 Features like incorporation of automatic door-opening devices,

elevators, object detectors, automatic warning signals etc must be of
paramount importance in the minds of the designers so as to avoid
the human injuries and damage to other equipment, materials, and
vehicle itself.
 System Design of AGVS:

Many issues must be considered before designing system for an

AGVS:
 Guide path layout / Flow path design

 Selection of guide path type and vehicle

 Number of vehicles

 Type of flow path within the layout

 Location and number of load transfer points and load transfer station
storage space.

There are several other issues regarding timing of AGVs, dispatching

rules, routes, etc. Also, there must be interaction between design
and operational issues for system design.
Decisions involved in flow path design:

 Type of guide path layout.

 Flow path within the layout i.e. unidirectional, bidirectional or

combination.

 The number and locations of load transfer points.

 Load transfer function station storage space.

For developing a flow path design simulation software can be

used. These software takes into consideration the layout, locations of
P/D stations, timings of AGV, material flow intensities between stations,
etc.
Vehicle blocking, congestion, and unloaded vehicle travel
are the issues to be taken into consideration and depend on the
number of the vehicles and the requests for vehicles from various
pickup and delivery stations.
Vehicle Management

For AGVS to operate efficiently, the vehicles must be well managed

Two aspects of vehicle management:
(1) Traffic Control
(2) Vehicle Dispatching

Methods of traffic control :

(1)On-board vehicle sensing
(2) zone control
Methods of dispatch:
(1) On-board control panels
(2) Remote call locations
(3) Central computer control
 Traffic Control
On-board vehicle sensing:
- Uses optical or ultrasonic sensors on each vehicle to detect the
presence of other vehicles and obstacles ahead on the guide path.
- When on-board sensor detects an obstacle in front of it, the vehicle
stops and when removed the vehicle proceeds.
- Effectiveness of forward sensing is limited by the capability of the
sensor to detect obstacles that are in front of it on the guide path.
- Most effective on straight pathways.
- Less effective at turns and convergence points where forward vehicles
may not be directly in front of the sensor.
zone control:
- AGVS layout is divided into separate zones, and the operating rule is
that no vehicle is permitted to enter a zone that is already occupied by
another vehicle.
- - the length of a zone is at least sufficient to hold one vehicle plus
allowances for safety and other considerations.
 zone control:
 To implement blocking system.
 Zones A,B and D are blocked.
 vehicle 2is blocked from entering zone A by vehicle1.
 Vehicle 3 is free to enter zone C
Guide path

AGV1 AGV2 AGV3

Zone A Zone B Zone C Zone D

 When one vehicle occupies a given zone, any trailing vehicle is not
allowed to enter that zone. The leading vehicle must proceed into the
next zone before the trailing vehicle can occupy the current zone.

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Dispatching
On-board control panels:
-used for manual control, vehicle programming and other functions for
dispatching AGV to a given station in AGVS layout.
-represents lowest level of sophistication, flexibility & timeliness in coping
with changes & delivery requirements.
Remote call locations:
- satisfy delivery requirements in which a simple push-button is mounted at
the load/unload station.
- it transmits a hailing signal for any available vehicle in the neighborhood to
dock at the station and either pick up or drop off a load.
- sophisticated stations permit the vehicle’s destination to be programmed at
the same time the vehicle is called
Central computer control
-used to accomplish automatic dispatching of vehicles according to
preplanned schedules of pickups and deliveries in the layout.
- issues commands to the vehicles in the system concerning their destinations
and the operations they must perform
Problem:
Q1)Jeevan Engineering is contemplating to integrate the AGVS and
AS/RS with their flexible manufacturing system. It is also in the
process of determination of number of AGVSs for its manufacturing
system. It has to deliver 67 pieces per hour. The company has decided
in favour of installing a wire guided path system and the unit load
AGVS. The following data has been collected as shown in Table
Solution
Advantages of AGV’s
 Unobstructed movement
 Flexibility
 Locations, path, P/D points can be reprogrammed
 Easy to change guide path system
 Number of vehicles can be altered depending on requirement
 Greater reliability
 Less environmental problems
 AGV can be replaced by another, in case of failure.
 Lower investment
 Higher operating savings on long run
 Minimal labor cost
 Easy maintenance
 Easy to interface with other systems
 Best choice for AS/RS, FMS