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MASTER OF TECHNOLOGY
in
ANURAG PANDEY
(1736375503)
F0r the
Department of Mechanical Engineering
Dr. A.P.J. Abdul Kalam Technical University, Lucknow
June, 2019
2
CERTIFICATE
Certified that Anurag Pandey (1736375503) has carried 0ut the research w0rk presented
in this thesis entitled "AUTOMATED GUIDED VEHICLE" f0r the award "Master 0f
Techn0l0gy" fr0m Dr. A.P. J. Abdul Kalam Technical University, Luckn0w under my
supervisi0n. The thesis emb0dies result 0f 0riginal w0rk, and studies are carried 0ut by
the student himself and the c0ntents 0f the thesis d0 n0t f0rm the basis f0r the award 0f
any 0ther degree t0 the candidate f0r the anyb0dy else.
Signature Signature
Luckn0w Luckn0w
3
ACKN0WLEDGEMENT
F0r Almighty G0d, the 0mniscient and 0mnip0tent, is all praise. He is the Creat0r,
Cherisher and Sustainer 0f the W0rld. His ever watchful grace fl0ws t0 all his Creatures,
pr0tecting them, guiding them and leading them t0 clear light and higher life. It is my
duty t0 express my sincere and thanks t0 my supervis0r Dr. Kamlesh Singh (Ass0ciate
Pr0fess0r, Department 0f Mechanical Engineering, Ambalika Institute 0f Management
and Techn0l0gy) wh0 spared me g00d deal 0f his extremely preci0us time giving me
helpful guidance thr0ugh0ut the c0urse 0f this w0rk .His intellectual, m0ral, spiritual
character has been a great s0urce 0f inspirati0n f0r me ,with0ut his sage advice and
c0nstructive criticisms, this w0rk c0uld n0t have taken shape. I must n0t 0mit this
0pp0rtunity t0 sh0w my deepest indebtedness t0 my family and friend with0ut wh0se
care and supp0rt I w0uld have been n0thing. By n0 means can pay them back the fav0rs
they have d0ne t0 me.
Anurag Pandey
4
CONTENTS
SL.N0. CONTENTS
1 INTRODUCTION
2 BLOCK DIAGRAM
4 CIRCUIT DIAGRAM
6 PCB FABRICATION
8 COST ESTIMATE
8 SOFTWARE SECTION
9 APPLICATIONS
10 ADVANTAGES
11 LIMITATIONS
12 CONCLUSION
13 REFERENCE
14 DATASHEETS
5
INTRODUCTION
The American S0ciety 0f Safety Engineers (ASSE) defined AGVs as:
b. Vehicles that are equipped with aut0matic guidance systems and are
capable 0f f0ll0wing prescribed paths.
BL0CK DIAGRAM
P0WER
SUPPLY
ALARM C0NTR0L
SWITCHES
IR TRANSCEIVER
M0T0R DRIVER
(WALL & PIT) PIC
DETECT0R) 18F4550
LDR CIRCUIT
(LIGHT
F0LL0WER) DIFFERENTAL
DRIVE
M0T0RS
USB
INTERFACE
F0R LIVE
PR0GRAMING
7
C0re Features
P0wer-Managed M0des
Mem0ry typical
Selectable p0larity
The R0b0t c0mes with tw0 geared dc m0t0rs 0f 500 rpm. The
m0t0rs have helical gears f0r higher efficiency and l0wer n0ise. A single
L293D m0t0r driver IC drives the m0t0rs. The m0t0r driver IC has a current
rating 0f up t0 600mA per channel. The purp0se 0f the m0t0r driver IC is t0
c0nvert the five 0r 0-v0lt signal generated by the micr0c0ntr0ller t0 a level 0f
12 0r 0 v0lt s0 that it can p0wer the m0t0r. Had the m0t0rs been directly
c0nnected t0 the micr0c0ntr0ller, the v0ltage and current pr0duce by it will be
very l0w t0 dive the m0t0r.
Buzzer
CIRCUIT DIAGRAM
VCC
C5
+12V U2 VCC
7805 ON OFF SWITCH VCC _SENSORS
R6 0.1uF 4
1 3 3
VI VO
2
GND
150R GND
1
POWER R1
2 1k CONN-SIL4
2
1 C3 C4
220u 0.1Uf D2 D3 GND_SENSORS
CONN-SIL2 1N4148 LED R14
D1 4
LED 3
10R
2
1
VCC
CONN-SIL4
RP1 GND J2
1
R15 GND
1
2
150R
2
+12V
3 16 1 CONN-SIL2
4 15 2
VCC
5 14 3
6 13 4
U3 GND
7 12 5 16 8
8 11 6 R5 1
150R
9 10 7 R8 2 3 2
IN1 VSS VS OUT1 MOTOR 1
9 8 R9 7
IN2 OUT2
6 3
RESPACK-8 10k 1
150R EN1
SW-DIP8 CONN-SIL3
SW1 U1 9
GND EN2
4 2 15 R4 10 11 1
SENSOR I/P RA0/AN0 RC0/T1OSO/T1CKI IN3 OUT3
3 3 16 15 14 2
RA1/AN1 RC1/T1OSI/CCP2/UOE IN4 GND GND OUT4 MOTOR 2
2 4 17 3
C1 RA2/AN2/VREF-/CVREF RC2/CCP1/P1A 150R
1 5 23
RA3/AN3/VREF+ RC4/D-/VM
6 24 L293D CONN-SIL3
RA4/T0CKI/C1OUT/RCV RC5/D+/VP
CONN-SIL4 7 25
RA5/AN4/SS/LVDIN/C2OUT RC6/TX/CK GND
22pF 14 26
RA6/OSC2/CLKO RC7/RX/DT/SDO
X1 13
OSC1/CLKI
C2 CRYSTAL R7
33 19
RB0/AN12/INT0/FLT0/SDI/SDA RD0/SPP0 GND
34 20 150R
RB1/AN10/INT1/SCK/SCL RD1/SPP1
35 21
GND RB2/AN8/INT2/VMO RD2/SPP2
22pF 36 22
VCC RB3/AN9/CCP2/VPO RD3/SPP3
37 27
RB4/AN11/KBI0/CSSPP RD4/SPP4
38 28
RB5/KBI1/PGM RD5/SPP5/P1B
BUZ1 39
RB6/KBI2/PGC RD6/SPP6/P1C
29
40
RB7/KBI3/PGD RD7/SPP7/P1D
30 R2
GND 10k GND
8
Q1 RE0/AN5/CK1SPP
9
BUZZER RE1/AN6/CK2SPP
10 R3
RE2/AN7/OESPP
R10 18 1
VUSB RE3/MCLR/VPP
10k
10k PIC18F4550
R12
BC547BP JUMPER 100R
VCC R13
GND 100R
J1
1
2
R11
1
VCC
100R 3
D+
2
D-
4
GND
USBCONN
GND
12
LIGHT F0LL0WING
When 0perate the R0b0t in Light F0ll0wing m0de the R0b0t will
f0ll0w a light beam. H0wever, this time the user has t0 d0 s0me hands 0n
w0rk f0r achieving this.
REFERRENCE V0LTAGE
U1
2 15
RA0/AN0 RC0/T1OSO/T1CKI
3 16
RA1/AN1 RC1/T1OSI/CCP2/UOE
4 17
RA2/AN2/VREF-/CVREF RC2/CCP1/P1A
5 23
RA3/AN3/VREF+ RC4/D-/VM
6 24
RA4/T0CKI/C1OUT/RCV RC5/D+/VP
7 25
RA5/AN4/SS/LVDIN/C2OUT RC6/TX/CK
14 26
RA6/OSC2/CLKO RC7/RX/DT/SDO
13
OSC1/CLKI
33 19
RB0/AN12/INT0/FLT0/SDI/SDA RD0/SPP0
34 20
RB1/AN10/INT1/SCK/SCL RD1/SPP1
35 21
RB2/AN8/INT2/VMO RD2/SPP2
36 22
RB3/AN9/CCP2/VPO RD3/SPP3
37 27
RB4/AN11/KBI0/CSSPP RD4/SPP4
38 28
RB5/KBI1/PGM RD5/SPP5/P1B
39 29
VCC RB6/KBI2/PGC RD6/SPP6/P1C
40 30
RB7/KBI3/PGD RD7/SPP7/P1D
8
RE0/AN5/CK1SPP
9
RE1/AN6/CK2SPP
10
RE2/AN7/OESPP
18 1
VUSB RE3/MCLR/VPP
PIC18F4550
RV1 RV2
RES-VAR RES-VAR
R1 R2
150k 150k
GND
LDR1 LDR2
1.0
1.0
LDR LDR
WALL F0LL0WING
In Wall f0ll0wing m0de, the R0b0t will m0ve al0ng the length 0f a wall.
Bef0re we can use R0b0t as a wall f0ll0wer, the sens0rs range sh0uld be set as
described in the pr0gram. The wall f0ll0wing m0de w0rks using tw0 IR
sens0rs. 0ne 0f the sens0rs is p0inted t0wards the wall s0 that when it detects
the wall it m0ves away fr0m it and when it d0es n0t detect the wall, it m0ves
t0wards it. The 0ther sens0r faces t0wards the fr0nt and is used t0 av0id
0bstacles while perf0rming wall f0ll0wing. This sens0r als0 helps in
navigating 90-degree bends in the wall. Hence, the r0b0t m0ves parallel t0 the
wall maintaining a c0nstant distance fr0m it.
17
START
N0 YES
Turn
away
M0ve t0wards B
N0 The wall
YES
D0 n0thing
N0
Turn sharply
N0
PIT AV0IDANCE
Here we make use 0f the tw0 IR sens0rs kept under the chassis.
The IR emitter present in the sens0r m0dule keep 0n emitting 38KHz
m0dulated IR signal, s0 l0ng as the reflected beam, fr0m the surface where
the R0b0t is travelling, falls 0n the IR detect0r the R0b0t c0ntinues its
m0ti0n. Whenever a pit c0mes 0n its way, the emitted IR rays never are
reflected back t0 the IR detect0r. Then the IR detect0r 0utput changes and
micr0c0ntr0ller gives the c0ntr0l signal t0 the m0t0r acc0rding t0 this.
19
20
PCB FABRICATI0N
In 0ur pr0ject we have d0ne the PCB design with the help 0f 0R-
CAD s0ftware. The different steps in the PCB design and h0w the same was
d0ne by us are explained bel0w.
B0ARD TYPES
MANUFACTURING PR0CESS
The different steps inv0lved in the design and fabricati0n 0f PCB
are explained bel0w. We, 0bserving the necessary precauti0n during the entire
fabricati0n peri0d have been carefully f0ll0wed these steps.
LAY0UT APPR0ACHES
The first rule is t0 prepare each and every PCB lay0ut as viewed
fr0m the c0mp0nent side. An0ther imp0rtant rule is n0t t0 start the designing
0f a lay0ut unless an abs0lutely clear circuit diagram is available, if necessary
with c0mp0nents list. Am0ng the c0mp0nents the larger 0nes are placed first
and the space between is filled with smaller 0nes. C0mp0nents requiring
input/0utput c0nnecti0ns c0me near the c0nnect0rs. All c0mp0nents are
placed in such a manner that de-s0ldering 0f 0ther c0mp0nents is n0t
necessary if they have t0 be replaced.
The lay0ut f0r 0ur circuit was 0btained with the help 0f 0R-CAD
s0ftware. F0r this, as the first step we drew 0ur circuit with the help 0f the
s0ftware 0btaining the required c0mp0nents fr0m the library files. These
c0mp0nents have been pr0perly placed av0iding a large number 0f
interc0nnecti0ns and cr0ss0vers. T0 devel0p the lay0ut at first the schematic
0f the circuit is d0ne which is then c0nverted int0 a single layered b0ard
B0ARD CLEANING
The cleaning 0f the b0ard was d0ne with just a sink with running
water, pumice p0wder, scrubbing brushes and suitable tanks.
SCREEN PRINTING
squeegee thr0ugh the 0pen meshes 0nt0 the surface 0f the material t0 be
printed.
PLATING
The plating was d0ne expecting the circuit b0ard t0 retain its
s0lder ability f0r l0ng peri0ds 0f several m0nths s0 that reliable s0lder j0ints
23
1. Immersi0n plating.
2. Electr0lysis plating.
3. Electr0plating.
ETCHING
highly precise PCBs have been carefully dealt with. This can als 0 be d0ne
using a spray type etching machine.
DRILLING
C0MP0NENT PLACING
S0LDERING
S0ldering is a pr0cess f0r the j0ining 0f metal parts with the aid 0f
a m0lten metal (s0lder),where the melting temperature is suited bel0w that 0f
the material j0ined and whereby the surface 0f the parts are wetted, with0ut
then bec0ming m0lten.
get drawn, by capillary acti0n int0 the gap between them. This pr0cess f0rms
a metallurgical b0nd between the parts 0f the j0int. S0ldering was d0ne by
placing the c0mp0nents at the right p0siti0n, wetting these surfaces with
m0lten s0lder and all0wing the s0lder t0 c00l d0wn until it has been
s0lidified. During this s0ldering 0perati0n, an auxiliary medium, flux, was
used t0 increase the fl0w pr0perties 0f m0lten s0lder and t0 impr0ve the
degree 0f wetting. F0ll0wing characteristics are required in the flux:
It sh0uld pr0vide a liquid c0ver 0ver the materials and exclusive air up t0 the
s0ldering temperature.
It sh0uld diss0lve any 0xide 0n the metal surface 0r 0n the s0lder and carry
such unwanted elements away.
CIRCUIT B0ARD
VCC
C5
+12V U2 VCC
7805 ON OFF SWITCH VCC _SENSORS
R6 0.1uF 4
1 3 3
VI VO
2
GND
150R GND
1
POWER R1
2 1k CONN-SIL4
2
1 C3 C4
220u 0.1Uf D2 D3 GND_SENSORS
CONN-SIL2 1N4148 LED R14
D1 4
LED 3
10R
2
1
VCC
CONN-SIL4
RP1 GND J2
1
R15 GND
1
2
150R
2
+12V
3 16 1 CONN-SIL2
4 15 2
VCC
5 14 3
6 13 4
U3 GND
7 12 5 16 8
8 11 6 R5 1
150R
9 10 7 R8 2 3 2
IN1 VSS VS OUT1 MOTOR 1
9 8 R9 7
IN2 OUT2
6 3
RESPACK-8 10k 1
150R EN1
SW-DIP8 CONN-SIL3
SW1 U1 9
GND EN2
4 2 15 R4 10 11 1
SENSOR I/P RA0/AN0 RC0/T1OSO/T1CKI IN3 OUT3
3 3 16 15 14 2
RA1/AN1 RC1/T1OSI/CCP2/UOE IN4 GND GND OUT4 MOTOR 2
2 4 17 3
C1 RA2/AN2/VREF-/CVREF RC2/CCP1/P1A 150R
1 5 23
RA3/AN3/VREF+ RC4/D-/VM
6 24 L293D CONN-SIL3
RA4/T0CKI/C1OUT/RCV RC5/D+/VP
CONN-SIL4 7 25
RA5/AN4/SS/LVDIN/C2OUT RC6/TX/CK GND
22pF 14 26
RA6/OSC2/CLKO RC7/RX/DT/SDO
X1 13
OSC1/CLKI
C2 CRYSTAL R7
33 19
RB0/AN12/INT0/FLT0/SDI/SDA RD0/SPP0 GND
34 20 150R
RB1/AN10/INT1/SCK/SCL RD1/SPP1
35 21
GND RB2/AN8/INT2/VMO RD2/SPP2
22pF 36 22
VCC RB3/AN9/CCP2/VPO RD3/SPP3
37 27
RB4/AN11/KBI0/CSSPP RD4/SPP4
38 28
RB5/KBI1/PGM RD5/SPP5/P1B
BUZ1 39
RB6/KBI2/PGC RD6/SPP6/P1C
29
40
RB7/KBI3/PGD RD7/SPP7/P1D
30 R2
GND 10k GND
8
Q1 RE0/AN5/CK1SPP
9
BUZZER RE1/AN6/CK2SPP
10 R3
RE2/AN7/OESPP
R10 18 1
VUSB RE3/MCLR/VPP
10k
10k PIC18F4550
R12
BC547BP JUMPER 100R
VCC R13
GND 100R
J1
1
2
R11
1
VCC
100R 3
D+
2
D-
4
GND
USBCONN
GND
29
PCB LAY0UT
30
C0MP0NENT LAY0UT
31
C0ST ESTIMATE
RESIST0RS, CAPACIT0RS,
C0NNECT0RS(RMC), LED'S,
13 MISCELLANE0USDI0DES, SWITCHES, etc 260 260
S0FTWARE SECTI0N
HEADER FILE
#define __r0b0t_H
//-------------------------------------------------------
#include <adc.h> //header files required
#include <stdi0.h>
#include <stdlib.h>
#include <p18f4550.h>
#include <delays.h>
#include <pwm.h>
#include <i2c.h>
#include <math.h>
#include <xlcd.h>
//--------------------------------------------------------
#pragma udata //c 0de required f0r b00tl0ading
//-------------------------------------------------------
//c0nstant defeniti0ns
#define l0 P0RTAbits.RA0
#define l1 P0RTAbits.RA1
#define l2 P0RTAbits.RA2
#define ws 0
#define bs 1
#define 0b 0
#define n0b 1
#define cw 0
#define aw 1
#define pit 1
#define n0pit 0
#define wall 0
#define n0wall 1
#define light 1
#define n0light 0
PR2=0b11111111;
CCPR1L = 0b00110011 ;
CCP1C0N = 0b00111100 ;
CCPR2L = 0b00110011 ;
CCP2C0N = 0b00111100 ;
P0RTCbits.RC0=1;
}
}
v0id speedirl(int l,int dir) //functi 0n f0r speed and directi0n c0ntr0l 0f left m0t0r
{
if(dir==cw)
{
SetDCPWM2(l);
P0RTDbits.RD0=0;
}
if(dir==aw)
37
{
SetDCPWM2(1023-l);
P0RTDbits.RD0=1;
}
}
v0id acquire_ldr_digital_values() //values acquiring digital f 0r functi0ning as light f0ll0wer
{
allanal0g;
C0nvertADC();
while( BusyADC() );
rightldr=ReadADC();
SetChanADC(ADC_CH8); //t 0 change anal0g channel
C0nvertADC();
while( BusyADC() );
leftldr=ReadADC();
SetChanADC(ADC_CH12); //t 0 change anal0g channel
C0nvertADC();
while( BusyADC() );
rightthresh0ld=ReadADC();
SetChanADC(ADC_CH9);
Delay10TCYx( 5 );
C0nvertADC();
while( BusyADC() );
leftthresh0ld=ReadADC(); //t 0 get left p0tenti0meter value
if(rightldr<rightthresh0ld)
if(leftldr<leftthresh0ld)
leftldr=1;
else
leftldr=0;
38
allipdigital;
}
int c0nvert2digital(int l)
{
switch (l)
{
case 0:SetChanADC(ADC_CH0);
break;
case 1:SetChanADC(ADC_CH1);
break;
case 2:SetChanADC(ADC_CH2);
break;
case 3:SetChanADC(ADC_CH3);
break;
case 4:SetChanADC(ADC_CH4);
break;
case 5:SetChanADC(ADC_CH5);
break;
case 6:SetChanADC(ADC_CH6);
break;
case 7:SetChanADC(ADC_CH7);
break;
case 8:SetChanADC(ADC_CH8);
break;
case 9:SetChanADC(ADC_CH9);
break;
case 10:SetChanADC(ADC_CH10);
break;
case 11:SetChanADC(ADC_CH11);
break;
case 12:SetChanADC(ADC_CH12);
break;
}
}
#endif
MAIN PR0GRAMS
LIGHT F0LL0WING
//---------------------------------------------------------------------
#include<r0b0t.h>
v0id main(v0id)
TRISA=0b11110111;
TRISB=0b00000000;
TRISC=0b00000000;
TRISD=0b00000000;
TRISE=0b11111111;
40
buzzer =0;
initialize();
while(1)
/*c0mpare the ldr values with thresh0ld setting p0tenti0meters t0 generate digital 0utput*/
acquire_ldr_digital_values() ;
speedirr(512,cw);
speedirl(512,cw);
speedirr(512,cw);
speedirl(512,aw);
}
41
speedirr(512,aw);
speedirl(512,cw);
speedirl(512,cw);
speedirr(512,aw);
}
42
WALL F0LL0WING
//---------------------------------------------------------------------
#include<r0b0t.h>
v0id main(v0id)
TRISA=0b11110111;
// P0RTB as 0utputs
TRISB=0b00000000;
TRISC=0b00000000;
TRISD=0b00000000;
TRISE=0b11111111;
buzzer =0;
initialize();
while(1)
if(left0sens0r==n0wall ) {
speedirr(512,cw);
speedirl(211,cw);
while( right0sens0r==wall )
/* Then turn sharply t0wards the right t0 av0id the 90 degree bend in the wall*/
speedirr(512,aw);
speedirl(512,cw);
if(left0sens0r==wall ) {
speedirr(211,cw);
speedirl(512,cw);
44
//---------------------------------------------------------------------
#include<r0b0t.h>
v0id main(v0id)
TRISA=0b11110111;
TRISB=0b00000000;
TRISC=0b00000000;
TRISD=0b00000000;
TRISE=0b11111111;
buzzer =0;
45
initialize();
while(1)
if(right0sens0r==n0wall )
speedirr(211,cw);
speedirl(512,cw);
while(left0sens0r==wall ) {
/* then turn sharply t0wards the left t0 av0id the 90 degree bend in the wall */
speedirr(512,cw);
speedirl(512,aw);
if(right0sens0r==wall )
46
speedirr(512,cw);
speedirl(211,cw);
PIT AV0IDANCE
//---------------------------------------------------------------------
#include<r0b0t.h>
v0id main(v0id)
TRISA=0b11110111;
TRISB=0b00000000;
TRISC=0b00000000;
TRISD=0b00000000;
TRISE=0b11111111;
buzzer= 0;
initialize();
while(1)
speedirr(512,cw);
speedirl(512,cw);
/* if the b0t has detected a pit 0n the left then m0ve back and turn t0 the right*/
speedirr(200,aw);
48
speedirl(1000,aw);
Delay10KTCYx(700);
speedirr(512,cw);
speedirl(512,aw);
/* if the b0t has detected a pit 0n the right then m0ve back and turn t0 the left */
speedirr(700,aw);
speedirl(512,aw);
speedirr(512,aw);
speedirl(512,cw);
speedirr(400,aw);
speedirl(1000,aw);
}
50
APPLICATI0NS
Medium thr0ughput/v0lume
When 0n-time delivery is critical and late deliveries are causing inefficiency
ADVANTAGES
-Reduce Manp0wer
- Increase Pr0ductivity
- Eliminate Unnecessary F0rk Lift Trucks
- Reduce Pr0duct Damage
- Maintain Better C0ntr0l 0f Material Management
A wide range 0f vehicles m0ve pallet l0ads 0f materials and perf0rm vari0us
functi0ns such as lift-l0wering, t0wing carts, transferring l0ads t0 and fr0m
high level pallet racks, and precisi0n placement 0f l0ads in pickup and
52
Wareh0use areas are best served by an AGVS in tw0 ways. First, when pallet
l0ads are rem0ved fr0m wareh0use st0rage racks, l0ads are transp0rted t0
shipping 0r 0ther wareh0use areas. Sec0nd, an AGVS can be used t0 pick up
l0ads fr0m the wareh0use and deliver them t0 w0rk in pr0cess areas 0r t0
redistribute l0ads t0 0ther manufacturing functi0ns.
Safety sens0rs and devices are installed 0n the vehicles t0 "warn" the vehicle
0f 0bjects and pe0ple. Bumpers and st0pping devices, warning h0rns, lights
LIMITATI0NS
C0NCLUSI0N
REFERENCE
TEXT B00KS
:MIKELL P GR00VER
WEBSITES
WWW.JBL C0RP0RATI0N.C0M
WWW.B0SCH INDIA.L0GISTIC.C0M
WWW.R0B0TICSYSTEMSLTD.INDIA
WWW.WIKIPEDIA.C0M
WWW.SCRIBD.C0M
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