AGV Presentation (2) (1).ppt
- 1. “Introduction to Automatic Guided Vehicles (AGV)”
- 2. What is an AGV? A Computer-Controlled, Non-manned, Electric Powered Vehicle Capable of Handling Material. Mobile robots used to move materials around a manufacturing facility or warehouse.
- 3. The automated guided vehicle (AGV) system 1 = Automated guided vehicle (AGV) 2 = Load transfer positions 3 = Load transfer equipment 4 = Guide track (wire, laser, optical) 5 = Data transmission 6 = Management system 1 2 2 3 4 5 5 6 6 6 7
- 4. What is a good use for AGVs? One of the most flexible types of MHS Ranges from small to 125 tons (25,000Kg) capacity Repetitive motion Distances over 50m Multi-shift operation Desire to save costs and improve efficiency
- 5. Why use Guided Vehicles? Not a permanent obstacle Paths can be changed easily System can be expanded easily Does not represent a single point of failure - system has built-in redundancy Favorable cost/benefit compared to other automated material handling solutions
- 6. Cost-effectiveness considerations Manned Automated forklift Transport (typical) 1. Investment cost 100% 400% 2. Manning costs 100% 5% 3. Maintenance 100% 200% 4. Transport damage 100% 5% Single shift Two shift Three shift Investment Investment Investment Years Years Years
- 7. 1953 1973 1976 1st AGV 1st Assembly Vehicle 1st Unit Load History of AGVs 1953 – First AGV created and used. It was used to pull a trailer and follow an overhead wire in a grocery warehouse. 1959 1st Tugger 1973 - Volvo in Kalmar, Sweden utilized 280 computer-controlled AGVs instead of using the typical conveyor assembly line.
- 8. 1985 1989 1976 1987 2003 Single Wire Guidance PC Based Controller 1st Unit Load Laser Guidance Inertial Guidance 1991 1992 Wire & Wireless AGVs in same System Changeable Path History of AGVs 1976 – First Unit Load AGV. Now used for many different applications in multiple settings of industry. 1970’s – Guidance Systems
- 9. Important Issues for AGVS 1. Guidance 2. Routing 3. Traffic Management 4. Load Transfer 5. System Management
- 10. How do they know where to go? Guidance Methods Guidance allows the vehicle to follow a predetermined route. 1. Wire guidance 2. Non-wire guidance 1.Wire guidance • Wires buried underground, which carries electrical current at predetermined frequencies, functions as a guide-path. • Different frequencies are used to define paths.
- 11. Guidance Methods Imbedded Guide Wires
- 12. Wire Guidance Methods Advantages 1. Handle dirty environment and heavy traffic 2. The system is free from interferences from outside sources 3. Can be used, indoors and outdoors 4. Can run conveniently through tunnels, aver bridges Disadvantage 1. Low degree of flexibility 2. It is costly to repair when the wire is damaged
- 13. Guidance Methods 2. Non-wire guidance a. Non-wire floor path i. Optical ii. Painted or chemical stripe b. Non-wire non-floor path guidance i. Laser beam ii. Dead reckoning iii. Combination of dead reckoning and laser beam iv. Beacon system v. Inertial guidance
- 14. Non-Wire Floor Path 1. Optical guidance Any type of light that comes from underneath of the vehicle is reflected The reflected lights signals are sensed by photo sensors under the vehicle. Spot marks on the floor can be used in optical guidance. Different spot mark configurations at intersections indicate the decision to be made by the vehicle 2. Painted or chemical stripes The floor is painted with a fluorescent color or chemical stripes as a guide path.
- 15. Tape Guided
- 16. Non-wire non-floor path guidance 1. Leaser Beam Reflective targets are mounted on columns, walls, machines or posts approximately 25 ft (7.6m) apart. Each facility target is surveyed and given a unique ‘X,Y’ coordinate. These coordinates are loaded into each AGV’s memory. Onboard each AGV have a rotating laser light beam source and receiver. When the laser light reflects off a target its distance and angle are automatically measured.
- 17. Laser Target Navigation The wireless navigation is done by mounting retroreflective tape on walls, poles or machines. The AGV carrys a laser transmitter and receiver on a rotating turret. The laser is sent off and received again, and the angle and distance can be calculated and stored in the AGV’s memory. The AGV has reflector map stored in memory and can correct its position based on errors between the expected and received measurements.It can then navigate to a destination target using the constantly updating position Pros/Cons: Tape is not in danger of wearing down or breaking in a high-traffic area, and the AGV path can be changed by reprogramming the AGV rather than moving tape. Many laser guided AGV’s have rather sophisticated technology that make changing paths very quick and easy. Costly. Non-wire non-floor path guidance
- 19. 2. Dead Reckoning • Usually using odometer (indicates the distance traveled) • The vehicle is equipped with a computer that calculates the position of the vehicle based on the wheel rotations referenced to a starting point of motion. 3. Combination of dead reckoning and laser beam Non-wire non-floor path guidance
- 20. Non-wire non-floor path guidance 4. Inertial/Gyro Guidance Each AGV is equipped with a solid-state gyroscope. A Gyroscope is a device for measuring or maintaining orientation. The AGV path is a virtual set of coordinates stored in its memory. A small marker (magnet) with a unique ‘X,Y’ coordinate is installed in the floor approximately every 25 ft (7.6m) along the AGV virtual path. As the AGV negotiates the path the onboard gyro detects slight change in travel direction and this is compared with the actual stored travel path.
- 22. Inertial (or gyroscopic) Navigation A computer control system directs and assigns tasks to the vehicles. Transponders are embedded in the floor of the work place. The AGV uses these transponders to verify that the vehicle is on course. A gyroscope is able to detect the slightest change in the direction of the vehicle and corrects it in order to keep the AGV on its path. The margin of error for the inertial is ±1 inch. Pros/Cons: Inertial can operate in nearly any environment including tight aisles or extreme temperatures and has a longer lifespan than other guidance options. Non-wire non-floor path guidance
- 23. Routing Is the vehicle's ability to make decisions along the guidance path in order to select optimum routes to specific destinations. 1. Frequency select method the wire guided AGVS vehicle • Different frequencies are used to define paths 2. Spot mark configurations at intersections- Optical • A vehicle can be programmed to turn left once it hits a triangular spot mark at the intersection 3. Path select method the non-wire AGVS vehicle • The path map is stored in the AGV’s memory • Chooses which of the memorized paths to follow based on its ultimate destination.
- 24. Traffic Management Is a system or vehicle ability to avoid collisions with other vehicles while at the same time maximizing vehicle flow. Types of traffic management: 1. Zone Control 2. Forward Sensing Control 3. Combination Control
- 25. Traffic Management 1. Zone Control Segmenting the path into separate zones. The rules of zone control are that only one vehicle is permitted in a given zone at a time.
- 26. Traffic Management 2. Forward Sensing Control • Sensing system onboard the guided vehicles that detect the presence of a vehicle in front of it
- 27. Traffic Management 3. Combination Control Vehicles would respond to both types of traffic control depending upon the area in which they are operating
- 28. Load Transfer AGVS load transfer can be accomplished in many different ways: 1. Manual Load Transfer 2. Automatic Couple and Uncouple 3. Power Roller, Belt, Chain 4. Power Lift/Lower 5. Power Push/Pull
- 29. How do AGV control systems differ? 1. Centralized controller • PC or other computer device to manage the movement of vehicles along the path • “smart central approach” • central controller controls routing and traffic controls • AGVs receive direction via communications link 2. Decentralized vehicle control approach • no central controller device for basic vehicle movement • vehicles perform their own routing and traffic control functions • “smart vehicle approach” • AGVs use their onboard intelligence to select their route to a destination • avoid running into other AGVs by direct AGV-AGV communication System Management
- 30. Different Types of AGVs 1. Pallet Trucks 2. Fork 3. Tow/Tugger 4. Unit Load 5. Custom
- 31. Vehicle Types - AGV Pallet truck Used to transport palletized loads
- 32. Vehicle Types - Fork Outrigger (Straddle) Reach Side Reach
- 33. Counterbalance Narrow Aisle Fork Over Vehicle Types - Fork
- 34. Vehicle Types – Tow/Tugger • Can be applied in variety of uses including bulk movements • Several trailers can be attached to form a train
- 35. Vehicle Types – Unit Load Conveyor Lift Standard Combination Lift & Conveyor
- 36. Vehicle Types – Custom
- 37. How are they powered? Charge it! Allows operation 8 – 16 Hours Standard Charging (battery swap) In-Vehicle (opportunity) Charging Inductive Charging
- 38. What about Safety? What about Safety? Mechanical Protection Group Side Optical Bumper Front & Rear Bumpers Most industrial-use AGVs travel at a speed between 100 and 300 feet per minute (30.5 – 91.5m/minute).
- 39. Front Warning Zone Front Stop Zone Rear Warning & Stop Zones Optional Tower Protection Side Protection Electronic Protection Group What about Safety?
- 40. New Markets/Applications • Assembly Deck • Batch Tank Transport • Battlefield Unmanned Vehicles • Cleanroom Mobile Robot • Crabbing • Dumping • Extreme Precision • Flat Bed Truck Side Loading • Hospital Materials • Hybrid • Mars Rover • Military Shooting Range • Miniature • Monster (Humongous) • Non-System AGV • Paper Roll/Metal Coil • People Mover • Sea Cargo Container • Very Narrow Aisle (VNA)
- 41. Gillette Boston, Massachusetts • 1.5-million sq ft facility • 5-billion razor blades produced per year at one manufacturing center • 18 AGVs are utilized with 8,000 ft of guide path and over 400 pickup & dropoff points • Just in Time manufacturing • The new AGVs combined with an AS/RS has eliminated 14 handling steps associated with storage in an off-site warehouse *Information obtained from Modern Materials Handling Online.
- 42. Sharp Osaka, Japan • 485,000 sq ft building, 8 stories tall • 900,000 air conditioners produced per year • 17 AGVs are utilized on 2 separate guide paths • The AGVs serve to deliver raw materials to the assembly line, carrying up to 1 ton at a time • Just in Time manufacturing The new AGV system along with several miniload systems and a monorail: tripled production capacity with 2/3’s less staff cuts WIP by 50% * Information obtained from MaterialHandlingInfo.com.
- 43. Level 1: Simple Manual Vehicle Dispatch, Load/Unload, No Central Controller, No Host Interface. Level 2: Medium Automatic Vehicle Dispatch, Load/Unload, Central Controller, Product Tracking, Multiple Path Options. Level 3: More Automatic Vehicle Dispatch, Load/Unload, automatic coupling/uncoupling (applies to tuggers only), Central Controller, Complex Host Interface, Ethernet Link, Product Tracking, Multiple Path Options Multiple Transfer Heights, etc. Total system cost can be estimated by multiplying the projected number of vehicles times the unit costs shown in the following tables. Pricing Guides (per vehicle) Information from: http://www.mhia.org/psc/PSC_Products_GuidedVehicle_costEstimating.cfm.
- 44. • Member Companies – AGV Products, Inc. – Cattron-Theimeg International Ltd. – Control Engineering Company – Egemin Automation Inc. – FMC Technologies – Frog Navigation Systems – HK Systems – Mentor AGVS, Formtek Cleveland, Inc. – Siemens Dematic Material Handling Automation Division – Transbotics Corporation Automated Guided Vehicle Systems Product Section of MHIA www.mhia.org/agvs/
- 49. Hybrid AGVs
- 50. Mars Rover
- 51. Military Shooting Range Tugger • Uses Differential GPS; + - 1 Ft. • 10 Mile (16093.44m) Guide Path • Tugs Target for Firing Practice
- 52. Monster AGVs
- 54. People Movers
- 55. An unmanned aerial vehicle (UAV)
- 56. Automated Storage and Retrieval Systems (AS/RS) A combination of equipment and controls which handle, store and retrieves materials with precision, accuracy and speed under a defined degree of automation. AS/R system plays a significant role in a warehousing. Under complete control, AS/R system can store, keep track of, and retrieve a large numbers of part type and unit loads.
- 57. Components and operating features of an AS/RS 1. Storage structure 2. Storage/Retrieval machine 3. Storage module 4. One or more pickup-and-deposit station
- 58. Unit load AS/RS Storage structure S/R machine Storage module pickup-and-deposit station