DESIGN AND DEVELOPMENT OF AUTONOMOUS GUIDED VEHICLE

(AGV)

ABDUL HAFIZ BIN MOHAMAD

A dissertation submitted in fulfillment of the

requirements for the award of the degree of

Mechanical Engineering

Faculty of Mechanical Engineering TT__ T'.-I---- ---=

EI^PU f̂WXW

UNIVERS!TI MALAYSIA PAHANG No. Peroehan 037933

No. P&ggUc-n

\43Lf. 1006

Tarkh

jrs

NOVEMBER 2007

ABSTRACT

The technologies running fast we ever imagined before. The implementation

of computer chip can be seen anywhere in every parts of this world. Humans are

looking for automatic system that will make their life easier. This paper describes a

project of design and development of autonomous guided vehicle (AGV). An AGV

is a vehicle that uses no operator to drive that often used in material transportation in

an automated production line or in automatic storage and retrieval system. This AGV

running through the electronic programmed to drive the material or parts product to

the specific destination. Sometimes this vehicle programmed to move to follow the

line on the floor. This project required the student to build a prototype of an AGV in

smaller scale but have the basic function as the real AGV where this prototype of

AGV are able to move to the specific workstations and waiting for the task to

accomplished. This project requested to complete the process of technical study,

design, analysis, parts machining, assembly as well as testing and refinement of an

AGV in the two-semester course. The four-wheeled AGY is driven by a stepper

motor, move and steered by a different rotation of the motor. This AGV controlled

by PlC microcontroller and TJLN2803AG integrated circuit. Through this project,

students are able to learn how to innovate the technological product through the

small scopes of project.

V

AIBSTRAK

• Teknologi han im bergerak sangat pantas tanpa kita sedan. Penggunaan cip

komputer boleh dilihat di mana-mana sahaja di setiap pelosok dunia. Manusia

mencan sistem automatik yang boleh memudahkan kehidupan mereka. Thesis im

menerangkan projek mereka dan membangunkan kenderaan pacuan automatic

(AGV). Kenderaan mi bergerak tanpa pemandu yang kerap digunakan untuk

pangangkutan bahan dalam bans pengeluaran automatik atau dalam bahagian

peyimpanan dan pengagihan barang-barang. AGV mi akan bergerak mengikut

program elektronik untuk membawa barang-barang kepada destinasi yang spesifik.

Kadangkala kenderaan im telah diprogramkan untuk bergerak mengikut garis

panduan yang dilukis pada lantai. Projek mi mengkehendaki pelajar untuk membina

prototaip AGV yang boleh bergerek ke hentian kerja and menunggu sehingga selesai

kerja. Projek mi meminta pelajar untuk menyelesaikan kajian teknikal, mereka,

analisis, proses pembuatan juga pemasangan termasuk pencubaan dan

penambahbaikan dalam dua semester ini. Kenderaan automatik empat roda im di

jana oleh motor stepper yang mana belokan ke kiri dan ke kanan dikawal dengan

perbezaan putaran rodanya. AGV mi dikawal dengan mikro kawalan PlC dan litar

sepadu IJLN2803AG. Melalui projek mi, pelajar dapat mempelajan bagaimana untuk

menginovasikan produk teknikal melalui projek yang kecil skopnya.

vi

TABLES OF CONTENTS

CHAPTER TITTLE PAGE

STUDENT DECLERATION ii

DEDICATION iii

ACKNOWLEDMENT iv

ABSTRACT V

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF SYMBOLS 0 xv

LIST OF APPENDICES xvi

INTRODUCTION 1

1.1 Prologue 1

1.2 History of AGV 3

1.3 Project Problem Statement 5

1.4 Project Objectives 6

1.5 Project Scopes 6

2 LITERATURE REVIEW 7

2.1 Definition of AGV 7

2.2 Type of AGVs 8

2.3 Basic of AGV 12

2.4 Sensor 13

2.5 Actuator 18

V11

viii

2.5.1 Motor for Actuator 20

3 METHODOLOGY 28

3.1 Introduction 28

3.2 Concept Design 29

3.3 Vehicle Design 29

3.4 Concept Design 1 30

3.4.1 Process for the Wheels Fabrication 30

3.4.2 Problem with the Concept Design 1 31

3.4.3 Wheel Design 32

3.5 Concept Design 2 33

3.5.1 Problem with the Concept Design 2 33

3.6 Modification on Selected Design 35

3.6.1 Stabilizing Caster 35

3.7 Flow of Methodology Process 36

3.8 Flow of Fabrication Process 38

3.9 CAM 39

3.10 Motor 41

3.10.1 Motor Selection 41

3.10.2 Motor Control 43

3.10.3 Stepper Motor Sequence 44

3.11 Hardware 45

3.12 Software 48

3.13 Diagram of Downloading Programming to the 51

PlC 16F877A

3.14 Parts List and Cost 52

4 RESULTS & DISCUSSIONS 53

4.1 Introduction 53

4.2 Static Analysis 53

4.2.1 Wheel Shaft Analysis 54

4.2.2 Torque Analysis on Wheel 57

4.3 Controlling the stepper motor 59

lx

4.4 Fabrication Analysis 63

4.5 Fabrication Result 65

5 CONCLUSION 67

5.1 Introduction 67

5.2 Project Objectives Achievement 67

5.3 Recommendation for Future Work 67

5.4 Conclusion 69

REFERENCES 70

Appendices A-B 72-83

LIST OF TABLE

x

PAGE TABLE NO. TITTLE

3.1 Two Phase Sequence

3.2 Wave Sequence

3.3 Half step Sequence

3.4 Combination of LED Segments (Bates, 2000)

3.5 Determination of port in PlC Microcontroller

3.6 Component List and Cost

44

44

45

ER

48

52

4.1 Set-up Schedule General Data of Operation 63

LIST OF FIGURE

FIGURE NO. TITTLE PAGE

1.1 Architecture for intelligent control. Source: Advance 2

Robotics & Intelligent Machines

1.2 Vennootschap Mechelse Veilingen(VMV) Unit Load 3

type of AGV Source: Egemin Automation Global

2.1 Towing type of AGV. Source: Egemin Automation 9

Global

2.2 Vennootschap Mechelse Veilingen(VMV) Unit Load 9

type of AGV. Source: Egemin Automation Global

2.3 Pallet truck type of AGV. Source: Egemin 10

Automation Global

2.4 Leen Menken AGV fork truck type. Source: Egemin 10

Automation Global

2.5 Light load type of AGV. Source: Egemin 11

Automation Global

2.6 AGV Assembly Line type used by Pharmacia & 11

Upjohn. Source: Egemin Automation Global

xi

xii

2.7 3D Range Cameras Source: Bostelman SPIE Paper 16

2.8 Gyro Sensor Source: 17

http://www.agve.se/frameset.htm

2.9 DC motor structures Source: 21

http://www.idcmotion.com

2.10 Stepper motor structures Source: 23

http://www.idcmotion.com

2.11 Variable reluctance motor structures Source: 24

ams2000.com

2.12 Permanent stepper motor structures Source: 25

arns2000.com

2.13 Typical dc servo motor system with either encoder or 26

resolves feedback. Some older servo motor systems

use a tachometer and encoder for feedback. Source:

http://www.electricmotors.machinedesign.com

3.1 Flow Diagram of wheel processing 30

3.2 Concept Designs 1 31

3.3 Black Box 32

3.4 Wheel Design 32

3.5 Concept Design 2 34

3.64

Parts Design for Laser Cutting 34

3.7 Modification on selected design 35

3.8 Flow chart for the overall process 37

3.9 Flow process in development of an autonomous 38

guided vehicle in manufacturing process

3.10 Example of CAM Model 39

3.11 Example of G-Code 40

3.12 Laser Cutting Machine 40

3.13 Laser Cutting Process 41

3.14 12VDC Unipolar Stepper Motor 42

3.15 Side View and Front View of Stepper Motor 42

3.16 Plc 16F877A Microcontroller 42

3.17 Model of interface between PlC and stepper motor 43

drivers

3.18 Plc 16F877A Microcontroller 47

3.19 Port of PlC Microcontrollers 47

3.20 Plc c Compilers 49

3.21 CD2M Bootloader 50

xiii

xlv

3.22 RED serial RS 232 cable 50

3.23 Downloading programming into PlC Microcontroller 51

4.1 Placement of main parts in AGV 54

4.2 Weight Distribution 55

4.3 Free body diagram of vehicle 57

4.4 Free body diagram of vehicle wheel 59

4.5 Dimension of the Wheel and the separation distance 60

4.6 The degree of rotation 61

4.7 Show the example of G —code. 64

4.8 Top View of fabricated AGV 65

4.9 Side View of fabricated AGV 65

4.10 Front View of fabricated AGV 66

4.11 Isometric View of fabricated AGV 66

LIST OF SYMBOLS

cm - centimeter

DC - direct current

PM - permanent magnet

pWM - Pulse Width Modulation

- positive current flow

- negative current flow

V - Voltage

CAD - Computer Aided Drawing

CAM - Computer Aided Manufacturing

mm - millimeter

h - hour

mm - minute

s - second

% - percentage

X - vertical axis

Y - horizontal axis

x - multiple

/ - divide

kg - kilogram

RM - Ringgit Malaysia

xv

LIST OF APPENDICES

APPENDIX TITTLE PAGE

A Programming for overall movement of autonomous 72

guided vehicle

B Microchip LTLN 2803 Datasheet 75

xvi

CHAPTER 1

INTRODUCTION

1.1 Prologue

The creations of a truly autonomous and intelligent system - one that can

sense and interact with its environment, one that can integrate much more into lives

of human from day to day - has ever been the motivating factor behind the work on

artificial intelligent, control theory and robotics, autonomous vehicle.(Shuzhi Sam

Ge, 2006) The technology involve is highly complex. Autonomous systems are little

by little becoming a part of our way of life. There are huge improvements of

intelligent of robotic systems in current indoor and outdoor application ranging from

factory transport systems, public transport systems, security systems to military

application.

This project is focusing mainly on development of autonomous guided

vehicle for manufactunng especially for factory transport systems generally called an

AGV. The benefits are that we can learn the fundamental of sensing, control,

decision-making and application. Sensing is supplementary to how AGVs can

perceive the environment such as destination, obstacle detection and its own current

state. Control of AGVs is about how AGVs can react to the environment, tracking

maneuvers - forward tracking, backward tracking, driving and steering - and actuator

for higher level decision-making mechanism. Intelligent control is all about the

autonomous, thus the most important part is how AGV's ability to manipulate the

information. This is more to the automatic control which require feedback control.

2

This information is used to execute tasks through the actuation and feedback control.

(E. Grant) The application of AGVs can be seen in big factory such as

DaimlerChrySler, Procter & Gamble, Mactac Europe and others big company.

BASE.... 4

Figure 1.1 Architecture for intelligent control. Source: Advance Robotics &

Intelligent Machines

3

Figure 1.2 Vennootschap Mechelse Veilingen(VMV) Unit Load type of AGV Source:

Egemin Automation Global

1.2 History of AGV

Automated Guided Vehicles (AGVs) are driverless industrial trucks, usually

powered by electric motors and batteries (Amerdeen, 2006).

The first AGV system, a modified towing tractor with trailer following an

overhead wire, was built and introduced in 1953 in a grocery warehouse. (Frog,

1984) 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. (Frog,

1984)

Modem AGV technology began back in 1962 when Goran Netzler and

Anders Dahlgren founded NDC Sweden, a Swedish company focuses on the new

technology on designing and standardized the modular industrial electronic solutions

and control components to satisfy the need for efficient maintenance and ease of

interface between operator and machine (Transbotics, 2006). The birth of modem-

4

day technology of Automatic Guided Vehicle Systems (AGVS) can be accredited to

the pioneering efforts of the two men brought to the material handling industry.

Today AGVs expands in virtually every major industry such as in the

aerospace, apparel, automotive, beauty product, books and library systems,

communication, electronics, healthcare, mail order fulfillment, pharmaceuticals and

health care, retail, toys, warehouse, and storage facilities. (Bastian, 2006)

Most AGV-systems have system management computers in which AGV

utilization is optimize, transport orders, tracking history material in transfer and

system direct to control the AGV traffic. (Bastian, 2006) Most AGVs sold today are

however special made machines, special designed for special purposes. AGVs today

can be equipped with robot for examples arms and grippers and can perform robotic

handling functions. AGVs are also used as storage machines equipped with forks,

handling loads in storage racks. (Bastian, 2006)

Overall, the objectives of using AGV are to reduce operating cost and

requirements of the human operator in a process. AGV is a part of flexible

manufacturing system (FMS). During 1960-1970, operation cost was the primary

concern. So, a new strategy was formulated. The more customizability, mean more

flexible in their operation. The main advantage of FMS is its flexibility in managing

manufacturing resources like time and effort in order to manufacture new product.

Different FMSs levels and an example for each is stated below,

ii. Flexible Manufacturing Module (FMM): a numerical control (NC)

machine, a pallet changer and a part buffer.

iii. Flexible Manufacturing Assembly (FMA): four FMMs and an AGV.

iv. Flexible Manufacturing Group (FMG): two FMCs, a FMIvI and two

AGVs which will transport parts from a loading area through machine, to

a part unloading area.

V. Flexible Production System (FPS): a FMG and FAC, two AGVs, an

automated tool storage and automated part/assembly storage.

vi. Flexible Manufacturing Line (FML): multiple stations in a line layout and

AGVs.

5

Flexible manufacturing systems can benefit from the linkage with AGYs. AGVs are

often highlighted as saving billon in production plant and material handling. Today,

there are hundreds of instances of computer-controlled systems designed to handle

and transport materials, many of which have replaced conventional human-driven

platform trucks. The advantages of AGVs as a part of FMS are that it can reduce the

number of damages to in-process materials, simplified inventory tracking &

production scheduling, increasing safety and fewer personnel than in conventional

systems.

1.3 Project Problem Statement

In our local country, the implementation of AGVs is very rare to see in the

industry. But for the establish industry such as Toyota, BMW that mostly from big

manufacturer, they already use AGVs on their production. In order to make AGVs as

the main transportation, we must understand the existing performance without AGV

compare to the used of AGV. The general comparisons are stated below,

ii. The variety of production can be made with AGV as it flexibility can be

controlled.

iii. Manual operation are limited to hourly shift, contrast with the use of

AGV, it can be used in multi-shift environment or 24-hour operation.

iv. Rearrangement of production floor area always to be made as there is new

retrieval or when there is a change of layout. AGV make the works more

easier as AGV's system can be reconfigure quickly and easily.

V. Manual operation always making some mistake, but AGV system

operation are more precise and automatic can lead to a significant

reduction in the incident of damage to the materials.

vi. The maximum material load by manual operation are much more less

than AGV operation as it can tow or lift to thousand kilos more than

human does.

1.4 Project Objectives

The project objective is to build one model of AGV that function as a

transport. It must have control panel for programming input and work as the program

written. The case study is to be created. Then the analysis to be made based on its

performance. The specific objectives are as below:

i. To design the AGV that meet the basic requirement of the real AGV that

will follow a path as navigation and stop at the station to complete the

specific task.

ii. To analyze the performance of the AGV, the movement, and the

intelligent it has based on the structure fabricate.

iii. To fabricate the prototype AGV.

iv. Testing the AGV

1.5 Project Scopes

This AGV is built based on the following aspect:

i. This project is to make the prototype AGV. Thus the scale is much

smaller. It only can lift only the small weight approximate less than a

kilogram.

ii. Powered by using DC battery. It could be Nickel Cadmium (NiCad) or

Lithium Polymer (LiPo).

iii. The motor used is stepper motor.

iv. Flexible scheduling with different route by different programs written. It

should be less than three programs.

CHAPTER 2

LITERATURE REVIEW

2.1 Definition of AGV

Autonomous guided vehicle can be classified as a robot as the AGV

behaviors is intelligent. It is capable of performing many different tasks and

operations precisely and do not require common safety and comfort elements humans

need. There are various ways of defining AGVs.

Autonomous Guided Vehicles are used to consistently and predictably

transport loads of material to places that might otherwise be serviced by fork lift

trucks, conveyors, or manual cart transport (Bastian, 2006). They are typically used

where high volumes of repetitive movement of material is required, but where little

or no human decision making skill is required to perform the movement

(Bastian,2 006). For example, when the conveyor is undesirable, this type of transport

is useful for processing task.

AGVs as driverless, computer controlled vehicles that are programmed to

transport materials through designated pickup and delivery routines within a

particular facility usually a manufacturing, warehousing or distribution facility(Brian

Keiger, 2004). AGVs can be used throughout the entire process from starting

delivery of raw material all the way through to loading the trucks at the dock with

finished product.

8

In a flexible manufacturing system, a driverless computer-controlled vehicle

equipped with guidance and collision-avoidance systems and used to transport

workpieces and tools between work stations (www.Answer.com/FMS).

Autonomous Guided Vehicle (AGV) is an intelligent machine that has

'intelligence' to determine its motion status according to the environment conditions.

For an AGV to operate it must sense its environment, be able to plan its operations

and then act based on this plan (Ming Cao and Ernest Hall, 1998).

2.2 Type of AGVs

Based on the application, AGVs can do certain things, but not others things.

As they are designed properly for special purpose, they are useful and will continue

to be used. The application of AGVs today can be anywhere. It much related to

robots and computer system. For example they may be use in the nuclear industry, in

surgery, aerospace, food industry even as public transportation. Thus, AGVs is

classified based on their task. In this chapter, the type of AGVs is focus on handling

of flexible materials in automation. Basically there are about 3 tasks that AGV does,

towing, fork lift and unit load, but as time goes on; their performances are upgraded

to do more complicate tasks. These are the general types of AGVs used in industrial

for material handling process.

Figure 2.1 Towing type of AG-V. Source: Egemin Automation Global

i. AGVs Towing Vehicles were the first type introduced and are still a very

popular type today.(http://en.wikipedia.org/wiki!AGV) Towing vehicles

can pull a multitude of trailer types and have capacities ranging from

8,000 pounds to 60,000 pounds or approximately 28,000 kg.

Figure 2.2 Vennootschap Mechelse Veilingen(VMV) Unit Load type of AGV.

Source: Egemin Automation Global

AGVs Unit Load Vehicles are equipped with decks, which permit unit

load transportation and often automatic load transfer. The decks can either

be lift and lower type, powered or non-powered roller, chain or belt decks

or custom decks with multiple compartments.

(http://en.wikipedia.org/wiki/AGV)

Figure 2.3 Pallet truck type of AGV. Source: Egemin Automation Global

iii. AGVs Pallet Trucks are designed to transport palletized loads to and form

floor level; eliminating the need for fixed load stands.

(http://en.wikipedia.org/wiki/AGV)A seemingly good method of moving

material panels by place them in pallets, restraining them with clamps

while the pallets are moved.

Figure 2.4 Leen Men/ce,'i AGV fork truck type. Source: Egemin Automation Global

iv. AGVs Fork Truck has the ability to service loads both at floor level and

10

on stands. (http://en.wikipedia.orglwiki/AGV)In some cases these

vehicles can also stack loads in rack.

11

Figure 2.5 Light load type of AGV. Source: Egemin Automation Global

V. Light Load AGVs are vehicles which have capacities in the neighborhood

of 500 pounds or less and are used to transport small parts, baskets, or

other light loads though a light manufacturing environment

(www.egemin.com). They are designed to operate in areas with limited

space.

Figure 2.6 AGV Assembly Line type used by Pharmacia & Upjohn. Source:

Egemin Automation Global

1) AGVs Assembly Line Vehicles are an adaptation of the light load AGVs for

applications involving serial assembly processes.