Automated Guided Vehicles

Topics
     

History What is AGVs /AGVSs Components of AGVS Types of AGVS Important issues for the AGVS System design of AGVS

Automated Guided Vehicle System

Transport material from loading to unloading stations Highly flexible, intelligent and versatile material-handling systems. A very flexible solution for the problem of integrating a new automated transportation line into an existing transportation environment by using automatic guided vehicle.

HISTORY


First AGV developed in 1954 by A.M.Barrett,Jr. Using a overhead wire to guide a modified towing truck pulling a trailer in a grocery warehouse. Subsequently, commercial AGV were introduced by Barrett. 1973, Volvo developed automated guided vehicles to serve assembly platforms for moving car bodies through its final assembly plants. Later, Volvo marketed their unit load AGVs to other car companies.

What is AGV?
  

Driverless Vehicle Electric motors, battery powered Programming capabilities  Destination  Path selection  Positioning  Collision avoidance System Discipline

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.

Types of AGVSs
     

AGVS towing vehicle AGVS unit load carriers AGVS pallet trucks AGVS forklift trucks AGVS light-load transporters AGVS assembly-line vehicles

AGVS Towing Vehicles

First type of AGV introduced. Towing vehicle is called an automated guided tractor Flatbed trailers, pallet trucks, custom trailers can be used. Generally, used for large volumes (>1000 lb) and long moving distances (>1000 feet).

Load Capacity:1,500 lbs Vehicle Type:Laser Guided Tugger AGV Products, Inc

AGVS Unit load Carriers

To transport individual unit load onboard the vehicle. Equipped with powered or non-powered roller, chain or belt deck, or custom deck. Loads can be moved by Pallet truck, forklift truck, automatic loading/unloading equipment, etc.
Load Capacity3,000 lbs Vehicle Type: Unit Load with variable Height Conveyor

AGVS Pallet Trucks

No special device is needed for loading except the loads should be on pallet Limited to floor level loading and unloading with palletized load Widely used in distribution functions Capacity 1000-2000 lb Speed > 200ft/min Pallet truck can be loaded either manually or automatically

AGVS Forklift Trucks  Ability to pickup and drop palletized load both at floor level and on stands.  Pickup and drop off heights can be different  Vehicle can position its fork according to load stands with different heights  Very expensive  Selected where complete automation is necessary/required.

Load Capacity: 1,500 lbs Vehicle Type: Laser Guided Fork Lift AGV Products, Inc

AGVS Light Load Transporters

Capacity < 500lb To handle light and small loads/parts over moderate distances Distribute between storage and number of workstations Speed 100ft/min, turning radius 2ft For areas with restricted space

AGVS Assembly-Line Vehicles  Variation of an light load transporter  For serial assembly processes  As the vehicle moves from one station to another, succeeding assembly operations are performed  This kind provides flexibility for the manufacturing processes  Lower expenses and ease of installation  Complex computer control and extensive planning is required to integrate the system.

Important issues for AGVS

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  Teaching type

Wire-guided:  An energized wire is rooted along the guide path.  The antenna of the AGV follows the rooted wire. Optical:  Colorless florescent particles are painted on the concrete/tiled floor.  Photosensors are used to track these particles. Inertial:  The guide path is programmed on a microprocessor which is fixed on the AGV  Sonar system is incorporated for finding obstacles.

Infrared:  Infrared light transmitters are used to detect the position of the vehicle.  Reflectors are affixed on the top of vehicle to reflect the light. Laser:  Laser beam is used to scan wall-mounted bar-coded reflectors.  Accurate positioning can be obtained. Teaching type:  AGV learns the guide path by moving the required route.  Sends the information to the host computer.

AGVS Routing

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.

PathPath-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

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.
AGV

Guided path AGVS process controller Display terminal

Controller for guided path

Display terminal

Host 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 System Design

Many issues must be considered before designing system for an AGVS:  Selection of guidepath and vehicle  Guidepath layout / Flow path design  Number of vehicles 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.

Attributes for selection of guidance & AGVS Vehicle Related attributes:  Cost of the vehicle system  Cost of guidance system  Vehicle dimensions  Load capacity
Maximum weight  Maximum Volume (depending on AGV inner dimensions) Maximum speed at loaded/unloaded condition Maintenance facilities: Modular components for maintenance, self diagnosis, etc. Charging related attributes such as charging time, on-line charging. Turning Radius Position sensors Loading system i.e. unit load, pallet, or other attachments required.


     

Flow path design

Type of flowpath within the layout i.e. unidirectional, bidirectional or combination Type of guidepath layout Position of load transfer or loading /unloading stations Number of stoppage stations Storage space of the stations. 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.

Number of vehicles
General notations:  Dd = total average loaded travel distance  De = total average empty travel distance  Ndr = Number of deliveries required per hour  Nd = Number of deliveries per vehicle per hour  Th = loading and unloading time  Tdv = total time per delivery per vehicle  Tf = traffic factor that accounts for blocking and waiting of vehicles and at intersections. if only 1 vehicle than Tf =1 if Number of vehicles > 1 than Tf <1  v = vehicle speed Tdv = (Dd / v) + Th + (De / v) = loaded travel time + loading/unloading time + empty travel time Nd = ( 60*Tf ) / Tdv Number of automated guided vehicles = Ndr / Nd

Advantages of AGVs
 

 

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