FABRICATION OF AUTOMATED GUIDED VEHICLE

Mini Project Report 2011

Submitted By ARVIND S.A SOORAJ.V.R ANKITHA SHARMA ALKA MOHAN PHILIP VISHNU MURALI MENON

Department of Production Engineering Government Engineering College, Thrissur

Department of Production Engineering, Govt Engineering College, Thrissur

FABRICATION OF AUTOMATED GUIDED VEHICLE

Mini Project Report 2011

Submitted By ARVIND S.A SOORAJ.V.R ANKITHA SHARMA ALKA MOHAN PHILIP VISHNU MURALI MENON

Department of Production Engineering Government Engineering College, Thrissur

Department of Production Engineering, Govt Engineering College, Thrissur

DEPARTMENT OF PRODUCTION ENGINEERING

2011 CERTIFICATE This is to certify that the Mini-Project Report entitled Fabrication of Automated Guided Vehicle was presented by ARAVIND S.A SOORAJ.V.R ANKITHA SHARMA ALKA MOHAN PHILIP VISHNU MURALI MENON Of the Sixth Semester Production Engineering in partial fulfillment of the requirement for the award of the Degree of Bachelor of Technology in Production engineering under the University of Calicut in the year 2011 Staff in Charge Prof.Dr. Sathish K P Dept. of Production Prof. P V Gopinathan Head of the department Dept. of Production Place: Thrissur Date:

Department of Production Engineering, Govt Engineering College, Thrissur

ABSTRACT

Automated Guided vehicle is a robot that can deliver the materials from the supply area to the technician automatically. This is faster and more efficient.. The robot can be accessed wirelessly. I.e. a technician can directly order the robot to deliver the components rather than order it via a human operator (over phone, computer etc. who has to program the robot or ask a delivery person to make the delivery). To avoid collision with human workers, a proximity detector has been added which causes the robot to stop as long as there is an obstacle in its way, thus avoiding accidents.

Department of Production Engineering, Govt Engineering College, Thrissur

ACKNOWLEDGEMENT We express our deep sense of gratitude and indebtedness to Prof. P V Gopinathan, Head, Department of Production Engineering for her valuable advice, constant encouragement and constructive criticism during the course of the project and also during the preparation of this manuscript, We place on record the valuable suggestions and numerous constructive comments rendered by Prof.Dr.Sathish K P, Lecturer, Department of Production Engineering and for being our internal guide in the design and implementation of our project We are highly indebted to all the staff members of Production Department for their wholehearted support and co-operation. We also express our sincere thanks to all the classmates for their support and cooperation in completing the project work. Above all, we should express our supreme gratitude to almighty God for making this project a reality.

Department of Production Engineering, Govt Engineering College, Thrissur

TABLE OF CONTENTS

1.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

INTRODUCTION AVG COMPONENTS BLOCK DIAGRAM MECHANICAL DESIGN ELECTRICAL AND ELECTRONICS COMPONENTS COMPUTER PATH PLANNING PROJECT COST CONCLUSION BIBLIOGRAPHY APPENDIX

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LIST OF TABLES
Chassis specification (3.1) Steering specification table (3.2) Load Test (3.3) Transmitter receiver specification (4.1) Atemega16 Technical specification (4.2) Connections of atmega16 (4.3) L293d Technical specification (4.4) Motor Technical specification (4.5) Connections of USB Bridge (4.6) Model Costs (7.1)

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LIST OF FIGURES
Differential steering 3.2 Spinning by differential steering 3.3 Small radius turning 3.4 Large radius turning 3.5 Transmitter receiver pair 4.1 H-Bridge 4.2 Circuit diagram of Motor driver 4.3 PWM 4.4 USB Bridge 4.5 Programming algorithm 4.6 Example of path planning 6.1

Department of Production Engineering, Govt Engineering College, Thrissur

1. INTRODUCTION
AUTOMATED GUIDED VEHICLE An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that follows markers or wires in the floor, or uses vision or lasers. They are most often used in industrial applications to move materials around a manufacturing facility or a warehouse Automated guided vehicles increase efficiency and reduce costs by helping to automate a manufacturing facility or warehouse. The AGV can tow objects behind them in trailers to which they can autonomously attach. The trailers can be used to move raw materials or finished product. The AGV can also store objects on a bed. The objects can be placed on a set of conveyor and then pushed off by reversing them. Some AGVs use fork lifts to lift objects for storage. AGVs are employed in nearly every industry, including, pulp, paper, metals, newspaper, and general manufacturing. Transporting materials such as food, linen or medicine in hospitals is also done. An AGV can also be called a laser guided vehicle (LGV) or self-guided vehicle (SGV). Lower cost versions of AGVs are often called Automated Guided Carts (AGCs) and are usually guided by magnetic tape. AGCs are available in a variety of models and can be used to move products on an assembly line, transport goods throughout a plant or warehouse, and deliver loads to and from stretch wrappers and roller conveyors. AGV applications are seemingly endless as capacities can range from just a few kgs to hundreds of tons. The Aim of the project is to design and fabricate such a AGV

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2. AGV COMPONENTS
MECHANICAL The Mechanical components include chassis and the steering system. Functions of chassis Act as a frame for attaching other components Carry the load of other components and the payload. Act as sacrificial component to prevent damage of expensive payload in case of accidents Steering system is for steering the AGV ELECTRICAL Electrical components include the motor and the power supply for the motor itself. ELECTRONIC Electronic components provide sensing, logical decision and control of the vehicle. It includes microprocessor for the decision logic, the motor driver as both sensing and control of motor. COMPUTER The Computer acts as a viable substitute for a central computer that provide the AGVs with the path to proceed.

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BLOCK DIAGRAM

SIGNAL

CENTRAL COMPUTER PROGRAM INSTRUCTION

BRIDGE

RADIO TRANSMITTER

RECEIVER

MICRO CONTROLLER

MOTOR DRIVER

MOTOR

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3. MECHANICAL DESIGN
CHASSIS The chassis is fabricated from Aluminum alloy sheet metal. This is done for ease of

fabrication. It was designed in ProE, part of fabrication was outsourced due to unavailability of precision cutting tools. The Bending was done in then college workshop. The chassis was designed to take a static load of 10kg minimum. The Top part of chassis has lots of drilled holes which serves as holes for bolting other parts and reduce the weight of the chassis. The Holes are arranged in a zigzag linear arrangement so that the decrease in strength of chassis is not considerable. The flange which holds the motor was designed in a way that there is at least 10mm so that it can safely accommodate any bending due to loading above the designed value. The chassis incorporates mounting holes for both Ackermann steering and Differential steering system Technical Data for Chassis (Table 3.1) Feature Length: Breadth: Height: Material: Aesthetics: Maximum static load: Maximum dynamic load: Maximum impact load: Mounting Holes: Data 194mm 105mm 42mm Al Alloy Power Coating 12.6Kg 6.3Kg 1.2Kg from 1000mm 413mm Holes for motor 118mm Hole for castor >505mm Holes for general mounts

Department of Production Engineering, Govt Engineering College, Thrissur

STEERING SYSTEM The steering system used in the model is of differential type. A differential wheeled vehicle is a vehicle whose movement is based on two separately driven wheels placed on either side of the body. It can thus change its direction by varying the relative rate of rotation of its wheels and hence does not require an additional steering motion. It allows the turning center to be on the vehicle body thus the ability to rotate on the point

Fig 3.1: Differential Steering If both wheels rotate at the same speed and in the same direction, the robot will move in a straight line.

Fig: 3.2 Spinning by differential steering

Department of Production Engineering, Govt Engineering College, Thrissur

If the wheels rotate at equal speed, but in opposite directions, both wheels will traverse a circular path around a point centered half way between the two wheels. Therefore the robot will pivot, or spin in place. (Figure 3.2)

Fig 3.3 Small radius turning If one of the wheels is stopped, while the other continues to rotate, the robot will pivot around a point centered approximately at the mid-point of the stopped wheel. (Figure 3.3)

Fig: 3.4 Large radius turning

If one wheel rotates faster than the other, the robot will follow a curved path, turning inward toward the slower wheel. (Figure 3.4)

Department of Production Engineering, Govt Engineering College, Thrissur

Steering Specifications: Table 3.2 Feature Wheel Base Wheel Diameter Turning Radius range Point of Zero Radius Turn Data 142mm 70mm 0- Halfway along Breadth,

LOAD TESTS The following load tests were made on the chassis and the result Table 3.3 Movement under 10Kg Load Movement under 10Kg load at Front &back edgeload Movement under 10Kg side edge load Maximum angle uphill (Unloaded) Maximum angle downhill (Unloaded) Maximim side angle (Unloaded) Passed Passed Failed 40degree 55degree 25degree

Department of Production Engineering, Govt Engineering College, Thrissur

4. ELECTRICAL AND ELECTRONIC COMPONENTS

TRANSMITTER-RECIEVER The transmitter receiver pair transmits and receives electronic signal wireless. It is used for transmitting the path data to the AGV from the central computer. The transmitter Module has 4 pins: Vcc, Data, GND and Antenna. Vcc is connected to +5V. The Data is connected to the TX of the bridge. The Antenna pin is connected to the Antenna.

Fig 4.1 Transmitter-Receiver Pair Technical Specification of Transmitter-Reciever Pair, Table 4.1 Feature Frequency Speed Range Data 433Mhz (License free) 1200Baud 3m Indoors 10m Outdoors Max&Min Vcc: Interference with Safety epquipment Encoding 5.3/3.7V NO Amplitute Shift Keying

The receiver has 8 Pins, 2 Vcc, 3Gnd, 1 Antenna, 2 Data

Department of Production Engineering, Govt Engineering College, Thrissur

MICROCONTROLLER A microcontroller (C, uC or MCU) is a small computer on a single integrated circuit containing a processor core, memory, and programmable input/output peripherals. Microcontrollers are designed for embedded applications, in contrast to the microprocessors used in personal computers or other general purpose applications. The Microcontroller used in the AGV is ATMEL Atmega 16. The reasons for using atmega 16 are 1. Cheap cost 2. Easy to program 3. Availability of UART Communication 4. High stress values The Microcontroller is programmed with the required program to accept the data from the wireless transmitter, interpret it , calculate the path in terms of spatial orientation and five logical values to the Motor driver. Specification of ATmega 16: Table: 4.2 Type: Width: Height: Minimunm/Maximum Voltage: Maximum current: Number of PORTS No of Data Pins per port Bus width Oscillation Speed UART Receiving Speed 4.5/5.5V 20mA 4 8 8Bit 16Mhz 1200Baud 40Pin Dual Inline Package

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Connections: Table 4.3 PIN Name Vcc GND XTAL1 XTAL2 RXD/PD0 PB4 PB5 PB6 PB7 Pin No 10 11 12 13 14 3 4 5 6 Connected to: +5V GND 16Mhz Crystal 16Mhz Crystal Data Pin of Reciever L293D

MOTOR DRIVER It is an electronic circuit which enables a voltage to be applied across a load in either direction. It allows a circuit full control over a standard electric DC motor. That is, with an Hbridge, a microcontroller, logic chip, or remote control can electronically command the motor to go forward, reverse, brake, and coast. The current provided by the MCU is of the order of 20mA and that required by a motor is ~500mA. Hence, motor cant be controlled directly by MCU and we need an interface between the MCU and the motor. A "double pole double throw" relay can generally achieve the same electrical functionality as an H-bridge, but an H-bridge would be preferable where a smaller physical size is needed, high speed switching, low driving voltage, or where the wearing out of mechanical parts is undesirable. The term "H-bridge" is derived from the typical graphical representation of such a circuit, which is built with four switches, either solid-state (eg, L293/ L298) or mechanical (eg, relays).

Department of Production Engineering, Govt Engineering College, Thrissur

Fig: 4.2 H Bridge

Fig: 4.3 Circuit of Motor Driver To control motor speed we can use pulse width modulation (PWM), applied to the enable pins of L293 driver. PWM is the scheme in which the duty cycle of a square wave output from the microcontroller is varied to provide a varying average DC output.

Department of Production Engineering, Govt Engineering College, Thrissur

Fig: 4.4 PWM. Technical Specification of L293D Table 4.4 Type: Max Logic Voltage: Max Supply Voltage: Channels: Current per channel: 16Pin Dual Inline package 5V 36V 2 600mA

MOTOR Gear motor is used in this machine because it deliver more torque and full rotation compared to servo motor.Actuator that converts electrical signal to rotational motion.Contrary to usual belief it is an open loop control, A new technology of Back Emf interference is used to approximate a closed loop. Technical specification of Motor: Table 4.5 Speed Rated voltage No load current Full load current Stall current Back emf interference range torque 200rpm 12 V 60mA 500mA 580mA 300 to 500uA 2 kg cm

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USB-UART BRIDGE As the Compter has 64/32Bit Data and the microcontroller and 8Bit data, A USB-UART bridge is used to convert the 64/32Bit data to 8Bit data. It also converts the USB Protocol to UART Protocol which is recognized by the Microcontroller:

Fig: 4.5 Bridge Connections: Table 4.6 Connections of Bridge Bridge: +5V GND TX Transmitter Vcc GND Data

PCB DEVELOPMENT BOARD To aid in the Ease of construction a PCB development board has been used which allows easy change in circuit if necessary.

Fig: 4.6 Development Board

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5. COMPUTER
PROGRAMMING ALGORITHM USED

Fig: 5.1 Programming Algorithm

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FEATURED CODES Establishing Connection: s = serial.Serial(COM8,1200) Sending data to the Bridge s.write(f) Going forward 3 Units self.do(3) Turning right 90 s.write(r) self.do(90)

Department of Production Engineering, Govt Engineering College, Thrissur

6. PATH PLANNING
SPATIAL GRAPH THEORY

Fig 6.1: Example of path planning Let us assume the factory machines arranged in grids. The Blue Lines represent the pathway through which the AGV can move. For reaching the destination, the AGV has to go 6 Units right and 4 units forward. For ease, let us denote going up as u and right as r. Therefore the path shown above is rrrruuuurrr By Using Permutations and combination the different combinations for the path is equal to

Therefore to move x units in one direction and y units in another perpendicular direction to reach the destination, a AGV has ( )

Ways. The ways are still less when more than one AGV is used as the path allotted to an AGV is subject to the following considerations 1. The path is not currently in use by other AGV Department of Production Engineering, Govt Engineering College, Thrissur

2. The path does not cross the lines being used by other AGV. 3. The path is under maintenance FORMULAS USED For straight line motion between and ,

=
For straight line between , and ,

=
Formula for taking a turn

tan = ( = (

) )

Formula for calculating distance

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RUN TESTS
SPEED ACCURACY POWER CONSUMPTION PER UNIT LOAD

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7. PROJECT COSTS
MODEL COSTS Table 7.1 Microprocessor Board Bridge Microprocessor Transmitter-Reciever Pair Motor Chassis Motor Driver Tyres Battery 1110 900 210 500 350 400 50 130 500 (Lead), 900(LiPo)

LOAD DEPENDENT COSTS Motor, chassis, driver, tyres etc are dependent on the payload. The cost per unit load is 350+400+50+130+900/10 = 183Rs per Kg payload. It is estimated that these loads vary linearly.

Department of Production Engineering, Govt Engineering College, Thrissur

CONCLUSION
The AGV is an productivity increasing feature in a factory that has the following advantages 1. Speed of delivery 2. Flexibility of path 3. Adaptive to changes in factory layouts 4. Central control 5. Reduction in labour cost 6. Reduction in running cost compared to conveyer systems 7. Ability to add sensors to detect the payload conditions

Disadvantages: 1. Should be recharged periodically 2. Will stop delivery when the AGV is forced off the path. 3. High Initial cost

The Advantages of the AGV far shadow over the disadvantages and hence it is concluded that in a mass production factory with large area, a AGV will definitely increase productivity, decrease expenditure

Department of Production Engineering, Govt Engineering College, Thrissur

BIBLIOGRAPHY

Automation production systems, and computer integrated manufacturing by Mikell P.Groover www.wikipedia.com TVS Hosur Plant

Department of Production Engineering, Govt Engineering College, Thrissur