AGV 46 Slides

Somnath ChattopadhyayaAssistant Professor/ Workshop Superintendent

Indian School of Mines University, DhanbadDhanbad 826004

1Slides of AGV S. Chattopadhyaya,ISMU

What is AGV?Automated Guided Vehicles (AGVs) are driverless industrial trucks, usually powered by electric motors and batteries.

Applications of AGV-systems, with loads ranging from (cardboard) boxes to pallets and (steel) coils, can typically be found in and between production- and storage environments.

Slides of AGV S. Chattopadhyaya,ISMU 2

Introduction to AGVAutomated Guided Vehicles, termed

AGV's, carry the containers from the marine quay to the adjacent storage area.

There, smaller vehicles take care of the temporary storage.

In order to attain optimum road behaviour and efficient traffic control modern computer simulation techniques are used during the design process.


Introduction to AGVThe AGV must position itself not only quickly, but also accurately under the hoisting equipment.

That ensures the safe coupling of the spreader, the hoisting gear of the equipment.


What is AGV?What is AGV?The Automatic Guided Vehicle (AGV) is a safe,

reliable, and efficient material transport system that can be used instead of forklifts to move loads of all sizes.

AGVs are available in tape, wire, and laser guidance configurations for maximum layout flexibility, and their crabbing capability saves floor space.

AGV models are available to transport weights from 220 to 550 lbs., as well as pallets up to 6,600 lbs.


What is AGV?What is AGV?Automated Guided Vehicles (or Automatic Guided Vehicles) have been moving materials and products over 50 years.

The first AGV system, a modified towing tractor with trailer following an overhead wire, was built and introduced in 1953 in a grocery warehouse.


What is AGV?What is AGV?By the late 50's and early 60's towing

AGVs were in operation in many types of factories and warehouses.

This type of AGV, a tugger, is still applied today.

In 2003 Frog AGV Systems supplied four automated 7tons Tuggers for a chassis marriage process within an automotive

factory.


Components of AGVVehicle.

Guidance system.

Input/output/transfer mechanism.


Classification criteria of AGVsTote/box or pallet handling. Guidance system

Tape. Wire. Laser.

Input/output/transfer mechanism Roller conveyor. Chain conveyor. Fork top. Rear fork.

Battery charge/recharge option. Number of vehicles.


Technological features of AGVPermanent 10-year battery eliminates need for battery changing.

Opportunity charging allows automatic battery charging without removing vehicle from service.

Quiet operation (<65 db). Slides of AGV S. Chattopadhyaya,ISMU 10

Technological features of AGVMulti-directional wheels allow travel

forward, backward and sideways, with 90Âº crabbing, minimizing space requirements.

Microprocessor control with Radio Frequency (RF) communications.

Laser guidance option allows maximum layout flexibility.


History of AGVsIn 1973, Volvo in Kalmar, Sweden set

out to develop non-synchronous assembly equipment as an alternative to the conventional conveyor assembly line.

The result was 280 computer-controlled assembly AGVs.

In the mid 1970s the unit load AGV was introduced - a big development for the AGV industry.


History of AGVSThe unit load Automated Guided Vehicle gained

widespread acceptance in the material handling marketplace because of its' ability to serve multiple functions: assembly platform, transportation device and linking the control and information systems within a production facility.

Nowadays AGVs are applied in all types of markets for the transportation of material: warehouse environments, factories, hospitals and other industrial and commercial settings. Frog also supplies AGVs for outdoor applications in harbors and for the transportation of people - in a public transportation setting, but also for rides in the entertainment industry.


History of AGVSThe unit load Automated Guided

Vehicle gained widespread acceptance in the material handling marketplace because of its' ability to serve multiple functions: assembly platform, transportation device and linking the control and information systems within a production facility.

Nowadays AGVs are applied in all types of markets for the


History of AGVWire guidance was the principal AGV guidance

technology in the 1970's. An electronic frequency is induced in a wire

that is buried in the floor. A device called a 'floor controller' turned the

frequency on the wires on and off and directed the AGV through its intended route.

As the intelligence of the system was in the floor controllers, these systems were typified as 'smart floors, dumb vehicles'.


History of AGVWire guidance was the principal AGV guidance

technology in the 1970's. An electronic frequency is induced in a wire that is buried in the floor.

A device called a 'floor controller' turned the frequency on the wires on and off and directed the AGV through its intended route. As the intelligence of the system was in the floor controllers, these systems were typified as 'smart floors, dumb vehicles'.

The AGVs were equipped with an antenna that would seek out the frequency and guide the vehicle based on the strength of the signal.

For decision points and intersections, multiple (costly) wires need to be installed. The system would energize the wire that would correspond to the intended direction of travel.


Introduction to AGVAutomated Guided Vehicles, termed AGV's, carry

the containers from the marine quay to the adjacent storage area.

There, smaller vehicles take care of the temporary storage.

In order to attain optimum road behaviour and efficient traffic control modern computer simulation techniques are used during the design process.

The AGV must position itself not only quickly, but also accurately under the hoisting equipment.

That ensures the safe coupling of the spreader, the hoisting gear of the equipment.


Benefits of AGVEliminates forklift traffic.

Individual load tracking from pickup to delivery for precise inventory control.

Safe, reliable operation using ultrasonic sensors, acoustical and visual operating indicators, emergency stop button, and full-perimeter contact bumper.


Applications and ControlsWithin industrial environments, the use

of AGVs has evolved drastically: from traditional distribution-oriented applications at one end of the spectrum to complex computer-controlled automobile assembly systems with robotic interfaces at the other end.

They can be stand-alone systems, an integral part of another system, or aid in pulling together islands of automation.


Applications and ControlsAGV originally designed for horizontal

transportation of palletized material, the design and application of AGVs and controls are now as varied as those of industrial robots.

Outside industrial environments, Automated Guided Vehicles are now also being applied for transhipment at ports, as people movers and in the entertainment industry.


Applications of AGVRecommended applications by product

type: Transport raw materials, work-in-

process, and/or finished goods between storage buffers and workstations.

Transport finished goods from order-picking workstations to consolidation and shipping.


Navigation system of AGVsThese first generation navigation schemes were

expensive to install. The exact path of the AGV needed to be 'cut' in

the floor to bury the wire in. The cut for a turn had to follow the radius curve

that the vehicle would make when turning. Many systems had to embed four wires - three

for guidance and one for communications. Often, rebar or electronic signals would

interfere with the guidance signals imposed on the wires.


Navigation system of AGVsToday the wire-guided technology is

outdated. New AGV guidance systems, such as the FROG-technology, offer many advantages (installation costs, flexibility, maintainability) over the wire-guided AGV technology.

For very basic applications, this technology is sometimes still applied.


Navigation system of AGVsAs electronics and microprocessors advanced, so

did AGV applications. More intelligent Automatic Guided Vehicles were created and the need for a sophisticated path was reduced.

The first major development was 'dead reckoning'. Dead reckoning is the ability to traverse space without having to rely on the physical presence of a guidance wire. The biggest advantage was that dead reckoning eliminated the need to make the cut radius turns at intersections. The AGVs could leave the wire, turn at a programmed radius, and then pick-up the wire to continue its course of travel. The path still required multiple wires in the floor, but the installation was greatly simplified.


Navigation system of AGVsDuring the 1980s, non-wire guided AGV

systems were introduced. Laser and inertia guidance are two AGV

guidance technologies allowing for increased system flexibility and accuracy.

Changes to the path can be made without costly, time-consuming floor alterations or production interruptions.


Navigation system of AGVsModern AGVs are computer-controlled

vehicles with onboard microprocessors (such as the FrogBox and FrogBox Light).

Most AGV-systems also have a supervisory control system (e.g. SuperFROG) to optimise the AGV utilization, generate and/or distribute transport orders, tracking and tracing modules and acting as 'traffic cop' based on priorities.


IM70 an inductive modem for IM70 an inductive modem for wireless guidance of AGVwireless guidance of AGV


IM70 It is a wireless communication device

used for the intercommunication between a driverless carrier (AWG) and the central control system.

When the AWG gets an order to pick up an article from the store.

It needs to navigate its way along a wire sling which is buried in the concrete floor.


IM70 IM70 is a little box under the vehicle capable of using this wire sling as a bi-directional data link.

Our task was to design the electronics inside this IM70-box.

All digital electronics was built around a Xilinx. FPGA. There were also some analogue filters and tuned power amplifiers.


Navigation system of AGVsIt is a wireless communication device used for

the intercommunication between a driverless carrier (AWG) and the central control system.

When the AGW gets an order to pick up an article from the store.

It needs to navigate its way along a wire sling which is buried in the concrete floor.


Navigation system of AGVsIM70 is a little box under the vehicle capable of using this wire sling as a bi-directional data link.

Our task was to design the electronics inside this IM70-box. All digital electronics was built around a Xilinx. FPGA. There were also some analogue filters and tuned power amplifiers.


Replacement Applications of AGVConveyors

Forklift trucks.

Hand carts.


Advances of AGVS over previous technology

Reduced load damage. Less facility wear and tear. Requires less operating space. System capacity increased by adding

vehicles. Elimination of single-point failure;

system can continue operating if a vehicle fails.


Problems addressed by AGV

Floor space Provides more space for production.

Productivity Supplements limited capacity in storage

and production areas. Inventory

Solves the problem of poor product accessibility


Problems addressed by AGV

Ergonomics Workers in hostile environments. Workers walking long distancesExcessive noise levels from material

handling equipment Safety hazardsLabor-intensive processes


Problems addressed by AGV Disjointed Operations (Lack of

Integration)Multiple staging areas Product is often moved from one staging area

to anotherLabor

High employee turnoverHigh labor costsSmall labor poolLow job satisfaction


Exemplary specifications of AGVMaximum load weight: 220-6,600 lbs. (100-

3000 kg).

Maximum load size:Length: 30-51 in. (0.76-1.30 m).Width: 20-47 in. (0.50-1.19 m).

Maximum speed: 164-196 ft./min. (50-60 m/min.).

Crabbing speed: 49 ft./min. (15 m/min.). Turning radius: 24-56 in. (.60-1.42 m).


Exemplary specifications of AGVExemplary specifications of AGVTransfer height: 16-21 in. (.41-.53 m). Traveling direction: multi-directional. Battery voltage: 48 V. Battery capacity: 40-80 Amp. hrs. Battery charging/discharging ratio:

1:10. Communication: spread spectrum

radio frequency. Steering system: direct drive power

wheel steering. Slides of AGV S. Chattopadhyaya,ISMU 38

Photographic view of a forklift type AGV with wireless guiding system


AGV accessing materials from different racksAGV accessing materials from different racks


Applications of AGV in Automobile Applications of AGV in Automobile IndustryIndustryTypical AGV applications in the automotive

industry include automated raw material delivery, automated work in process movements between manufacturing cells, and finished goods transport.

AGVs link shipping/receiving, warehousing, and production with just-in-time part deliveries that minimize line side storage requirements.

AGV systems help to create the fork-free manufacturing environment which many plants in the automotive industry are seeking.


Photographic view of an AGV


Software related to AGVsAGV Manager is the name of a

software which is basically dealing with the flow management.

This is based on a modular core which allows it not only to manage AGVs fleet but also operators, palletisation cells, stretch-wrapping or pallet covering machines, automatic or manual warehousing, dispatching.


Software related to AGVsIts flexibility allows it to easily

integrate with any industrial process — production and logistics — and to communicate with all management systems (ERP, WMS, GPAO, etc).

With its Focus functionalities, it can manage a simple automatic point-to-point transfer, ends of lines, storing missions, or a whole warehouse.


Operations of an AGVFor an easy operation of the installation

and an effective gain in productivity, AGV Manager (a branded software) pilots and coordinates all the flows.

Automated Guided Vehicles (AGVs) Movements and missions of forklift

operators Conveying networks Peripheral devices


Traceability and Adaptation by AGVAGV Manager also integrates the

identification and traceability of all loads transported.

It provides a complete tracking of the products, from production to dispatching and warehousing.

• Whether installations are existing or not, manual or automatic, computerized or not, AGV Manager adapts to all your constraints in order to manage your production logistics and meet all your needs.


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AGV 46 Slides