Department of Mechanical Engineering

ME18811 – Project Work

Academic Year – 2022-2023
DEVELOPMENT OF AUTOMATED GUIDED VEHICLE FOR INDUSTRIAL APPLICATIONS
(INHOUSE PROJECT)
Members (G24)
1. DINESH KUMAR. V (191001305)
2. JAYANT ARYAN SWAIN (191001312)
3. JEEVANANDHAN. S (191001313)
4. JEEVANANDHAM. H (191001314)
Project Supervisor
Dr. M. MOHANDASS
Associate Professor/Assistant HOD

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 Contents
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• Introduction
• Literature Survey
Contents
• Summary of the Literature Survey
• Literature Findings
• Scope and Objective of the Project
• Methodology
• Experimental details
• Results and Discussions
• Conclusion

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 Introduction
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• An automated guided vehicle (AGV), different from an autonomous mobile

robot (AMR), is a portable robot that follows along marked long lines or wires on

the floor, or uses radio waves, vision cameras, magnets, or lasers for navigation.
• They are most often used in industrial applications to transport heavy materials

around a large industrial building, such as a factory or warehouse.

• Application of the automatic guided vehicle broadened during the late 20th century.

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 Introduction
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WHAT IS AGV?
• The 1st AGV was brought to the market in 1950s by Barrett Electronics of Northbrook,
Illinois.
• It was for the purpose of reducing load carrying work done manually.
• An automated guided vehicle is a programmable mobile vehicle. The automated
guided vehicle is used in industrial application to move material around a
manufacturing facility. The AGV are capable of transportation task fully automated
at low expanses. The central processing system of AGV is issue the steering
command and speed command.
• For the pre-defined manufacturing environment the map is saved in the AGV
memory and control by stationary control unit of warehouse.

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 Introduction
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GUIDENCE PATH SYSTEM:

• The vehicle guidance system is the method by which AGV are defined and vehicles are controlled

to follow the path ways. AGV use the guidance path system chooses a path based on programmed

path. It uses the measurement taken from the sensor and compares them to value given to them by

programmer. When AGV approaches a decision point if only has to decide whether

follow the path.

• AGVs are a very important feature in industries.

• This is because of the implementation of Industry 4.0 norms where nearly 95% of processes are

automated.

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 Introduction
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VISION BASED SYSTEM:

• It is the latest guidance technology which operates without continuously defined the

pathway. It uses the reckoning navigation system provided position heading and angular

velocity of an autonomous mobile robot.

• Then navigation associated with available external sensor capturing information from

the work space through the proximity measurement and visual image. A design for the

fussy brain for the autonomous robot its integration with both central system and sensor

system has been used for detection of the obstacles in warehouse.

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 Literature Survey
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W.Yu

Design of a variable path tandem layout for automated guided vehicle systems

Journal of Manufacturing Systems (2001)

Conclusion:
The article discusses the design of a variable path tandem layout for automated guided vehicle (AGV)
systems. The design aims to improve the efficiency of AGV systems by allowing for the simultaneous
transportation of multiple loads using a single AGV. The variable path tandem layout is achieved by
connecting multiple AGVs together and allowing them to move in a coordinated manner. The article details the
design process and simulation results, demonstrating the effectiveness of the proposed layout in reducing
transportation time and increasing productivity.

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 Literature Survey
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G.Ulusoy

A genetic algorithm approach to the simultaneous scheduling of machines and automated gu

ided vehicles

Computers Operations Research (1997)

Conclusion:

The proposed approach considers the coordination of AGVs and machines to optimize the overall

system performance. The article provides experimental results that demonstrate the effectiveness

of the proposed approach in reducing makespan and improving system utilization. The study

suggests that genetic algorithms can be a useful tool for solving complex scheduling problems in

manufacturing systems 8
 Literature Survey
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K.K.Tan

Vehicle dispatching system based on Taguchi-tuned fuzzy rule

European Journal of Operational Research (2001)

Conclusion

This paper develops a new approach towards vehicle dispatching for a fleet of automated

guided vehicles operating in a flexible manufacturing environment with multiple

workcenters. Adaptive fuzzy rules are formulated to base the decision-making process

and the Taguchi method is applied to fine tune the rules for optimal performance.

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 Literature Survey
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Wallace Pereira Neves dos Reis, Giselle Elias Couto & Orides Morandin Junior

Automated guided vehicles position control

Conclusion

The paper presented a Systematic Literature Review conducted to identify the position control techniques

applied to the AGV position control problem in the past seven years of published research and outline the

research area. It aimed to investigate the research field from specific aspects regarding the controller design,

addressed by the research questions and sub-questions used to guide the data extraction. Although it is a

widely studied problem, including works on AGVs and mobile robots, no comparative systematic review was

proposed so far. The review started with 1185 identified PSs and selected 92 PSs for full-text reading based

on the protocol inclusion and exclusion criteria.

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 Scope and Click
Objective of the Project
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• The aim of the project is to use a market study to identify a suitable

simulation software for AGV systems in order to build a simulation

model based on a real-world case study. The created simulation model

should, in turn, be used to predict the optimal number of AGVs for the

system and to compare the result with a manual prediction calculation.

• To design the Automated Guided Vehicle.

• To fabricate the AGV and test the performance.

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 Methodology
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DESIGN AND FABRICATION OF AUTOMATED GUIDED VEHICLE

Studying the parameters required to design and develop the AGV

Designing the 2d and 3d models of the AGV using design software

• Procurement of the raw materials and control

devices
• Fabrication of the AGV
i) Frame work
ii) Assembly of sensors & Arduino
• Programming
• Final Assembly

Testing of the product and final refinement

Preparation of Report & Research

Articles

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Components

• FrameWork:
MS Square Tube – 1. 60 x 40 mm
2. 25 x 25 mm
• Wheels:
Rubber Wheels – 1. Dia. 100 mm (Front)
2. Dia. 200 mm (Back)
• Motor:
DC Wiper Motor – 12 volt 18 watt 0.024HP

• 4 Channel Relay:
A DC 5V-10A relay is an electromechanical switch that can be used to control high power devices using a low
power signal.
5V 10A Relay - Input voltage: DC 5V
Maximum switching current: 10A
Mechanical life: 10 million cycles
Electrical life: 100,000 cycles at maximum switching load

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Components

• PLA Relay MPC Series – It is used to convert the 5V signal to 12V signal and run the motor.

1. Contact Configuration: 2C (Double Pole Double Throw)

2. Maximum Switching Voltage: 250V AC, 30V DC

3. Maximum Switching Current: 12A

4. Mechanical Life: 10 million cycles

5. Electrical Life: 100,000 cycles at maximum switching load

• Arduino: ARDUINO NANO – CH340

1. Operating Voltage: 5V

2. Input Voltage (recommended): 7-12V

3. Input Voltage (limits): 6-20V

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Components

4. Digital I/O Pins: 14 (of which 6 provide PWM output)

5. Analog Input Pins: 8

6. USB Interface: CH340

7. Dimensions: 18mm x 45mm

• Motor Driver Controller: L298 DC Motor Driver

L298N DC Motor Controller Driver can control two DC motors independently or one stepper motor with up to 4
phases.

1. Operating Voltage: 5V - 35V

2. Control Interface: IN1, IN2, IN3, IN4

3. Motor Output Interface: OUT1, OUT2, OUT3, OUT4

4. Dimensions: 43mm x 43mm x 27mm

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Components

• Battery: A 12V 10A Lithium Ion Battery is a rechargeable battery that can deliver a maximum current of 10A at a

nominal voltage of 12V.

1. Nominal Voltage: 12V

2. Maximum Voltage: 12.6V

3. Minimum Voltage: 9V

4. Capacity: 10Ah (ampere-hours)

5. Maximum Charging Voltage: 12.6V – Maximum Running Time – 6 – 7 hours – Maximum Charging Time – 4 hours

6. Charging Current: 2A (recommended), 5A (maximum)

7. Dimensions: 150mm x 65mm x 95mm

8. Weight: approximately 1.2kg

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Components

• Sensor: SONAR HC-SR04 Sensor

HC-SR04 Ultrasonic Sensor works by sending out a high-frequency sound wave and measuring the

time it takes for the wave to bounce back after hitting an object.

1. Operating Voltage: 5V DC

2. Operating Current: 15mA

3. Maximum Range: 1 meter (3.28 feet)

4. Minimum Range: 2cm (0.8 inches)

5. Accuracy: 3mm

6. Dimensions: 45mm x 20mm x 15mm

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Of The AGV

ISOMETRIC VIEW FRONT VIEW

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Of The AGV

Top View

Side View

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Of The AGV

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Of The AGV

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Working Videos
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Of AGV

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Calculations

Without Load:
1. WEIGHT OF LOWER FRAME:
L = 60mm
B = 40mm
T = 1.2mm
Overall area = 2600mm^2
Weight = 4.78kgs

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Calculations

2. Weight of Upper Frame:

L = 25mm
B = 25mm
T = 1.2mm
Overall area = 5000mm^2
Weight = 4.84kgs
3. Weight of Solid Sheet Metal:
L = 600mm
B = 500mm
T = 1.2mm
Weight = 2.83kg
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Calculations

4.Weight of Perforated Sheet Metal:

Side 1 : l = 600mm
B = 100mm
T = 1.2mm
Weight = 1.13kgs
 
Side 2: l = 500mm
B = 100mm
T = 1.2mm
Weight = 0.94kgs
 
 

TOTAL WEIGHT WITHOUT LOAD = 14.52KGS

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Calculations

Assume a load of 25kgs.

Therefore,
TOTAL WEIGHT WITH LOAD = 40KGS (approx.)

5.TORQUE OF MOTOR:
N – Speed of motor
P – power of motor

T= (Px60)/(2x3.14xN)
= (18x60)/(2x3.14x200)
T = 0.859x10^3 Nmm
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Calculations

6. Diameter of Connecting Rod:

T = 3.14 x fs x d^3/16
0.859 x 10^3 = 3.14 x 42 x d^3/16
D = 4.8mm = 5mm

7. Force Acting On One Wheel (no load)

W=MxG
= 14.52 x 9.81
= 142.5 N

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Calculations

Dia of wheels = 200mm

Coefficient of friction = 0.6
Force = 0.6 x 142.5 = 85.5 N
Force on both wheels = 171 N = 17.437 kg-f

8. Force Acting On One Wheel (with load)

W = 392.4 N
Force on both wheels = 471 N = 48.028 kg-f

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Calculations

9. Rolling Friction (Back Wheel) :

R = 100mm
µ = 10mm
F = wµ/√(r^2) – (µ^2)
F = 392.4 Nmm – for 1 wheel
F for 2 wheels = 784.8 Nmm
10. Shear Stress (↊) for spring:
↊ = 16 x W x R / 3.14 x d^3
= 16 x 392.26 x 30 / 3.14 x (8^3)
= 117.95 N/mm^2
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Calculations

11. Deflection (∂) in spring:

∂ = 64 x W x R^3 x n / G x d^4
= 64 x 392.26 x (30^3) x 6 / (0.84 x 10^5) x (8^4)
= 11.82mm
12. Bending Stress In Center Beam:
W = 600mm D = 400mm L = 500mm Load = 392.26N
M / I = σ max / y
M = WL / 4 = 392 x 500 / 4
= 49000 Nmm
I = b x d^3 / 12 Y = 250 / 2 = 125mm
= 250 x 250^3 / 12 σ max = 49000 / 325.52 x 10^6 = 1.50 x
10^-3 x 125
= 325.52 x 10^6 mm^4 = 0.01881 N/mm^2

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Consideration

• Number of units to be transported

• Points in time at which units can be or need to be transported

• Capacity of the vehicle

• Speed of the vehicle

• Costs of the system

• Layout of the system and guide path

• Traffic congestion

• Vehicle dispatching strategies

• Number and location of pick-up and delivery points

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• Flow path layout

• Traffic management: prediction and avoidance of collisions and deadlocks

• Number and location of pick-up and delivery points

• Vehicle requirements

• Vehicle routing

• Vehicle scheduling

• Battery management

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 Results
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The AGV is an efficiency expanding highlight in a plant. During planning this AGV
we have given the essential capacities like line follows and impact keeping away from.
Also, the primary capacity, transportation of merchandise from station to station. The
followings are the principle highlights of the model which we have planned.
1. Modification of vehicle speed
2. Adaptability of way
3. Versatile to changes in industrial facility formats
4. Maintain a strategic distance from crash with different items
5. Decrease in labor cost
6. Decrease in running expense contrasted with transport frameworks
7. Capacity to add sensors to identify the payload conditions
8. Proceeds with pattern of working

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 Conclusions
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The AGV is a productivity increasing feature in a factory. During the manufacturing of this AGV we
had found many of intelligence that can be given to it. We provide the basic functions like line
following and collision avoiding. And the main function, transportation of goods from station to
station. The followings are the main features of the prototype which we fabricated.
1. Flexibility of path
2. Adaptive to changes in factory layouts
3. Avoid collision with other objects
4. Reduction in labor cost
5. Reduction in running cost compared to conveyer systems
6. Ability to add sensors to detect the payload conditions
7. Ability to adjust the lifting time
8. Continues cycle of working
9. Conditions for line following can be change easily.

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THANK YOU

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