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Design and Analysis of Automated Guided Vehicle

ABSTRACT:
These days because of the exceptionally expanding requests on assembling parts, these regions
have left their delivery distribution center in ruin. In like manner, the human errors adversely
influence security, capability. Subsequently these vehicles are exact in work, proficient and
errorless. In this manner the right idea of an AGV can be introduced that, it is a driverless vehicle
wherein the necessary material is gotten by the mechanization itself and afterward circulated to
the allotted goal in the distribution center. Therefore this makes circulation easy, inside as far as
possible and furthermore with legitimate precision not creating any harm. Along these lines right
now, is extremely vital for any assembling or a substantial stacked plant to utilize this trend setting
innovation so as to build efficiency.

Keywords— AGV (Automated Guided Vehicle), Proficient, Mechanization, Distribution, Precision

WORKING OF AGV:
Steering Mechanism:
i. Ackerman’s Steering Mechanism
ii. Variable Speed Motors
iii. Additional wheels for Steering

Among the three sorts recorded, we have picked Ackermann Steering Principle which is additionally guided by rack
and pinion so as to accomplish an exact controlling for the Automated Guided Vehicle.
Ackermann Steering Geometry is a geometric game plan of linkages in the controlling of a vehicle or other
vehicle intended to take care of the issue of wheels within and outside of a go expecting to follow out circles
of various radii.
Fig. 1 Ackermen’s Steering Mechanism
Selection of Traction Motor: Fig. 2 Brushless DC Motor

 For this purpose we have selected Brushless DC Motor.

 Model Number : GM 86BLW
 Specifications are as follows:
 Parameters:
i. Voltage: 24V
ii. Rated speed: 3000rpm
iii. Rated torque: 1.6N.m
iv. Rated current: 28A
v. Rated power: 500W
vi. Peak torque: 3N.m
vii. Peak current: 50A
viii. Body length: 80mm
ix. Weight: 2.5kg
Selection of Battery: Lithium Ion Battery is selected with following Parameters:
 Battery Capacity: 12Ah @ 24V
 Max charge current: 2A
 Size: 10.5”*6”*2”*
 Weight: 2.45kg
 Continuous discharge current: 15A
 Storage Temperature: 20 to 40 C
 Cycle life: 500 times
Fig. 4 Battery
Selection of Microcontroller: Microcontrollers available in market:
Microcontrollers available in market:
1. Arduino Mega
2. Beagle Bone Black
3. Raspberry Pi 3
4. Raspberry Pi 4

Arduino Mega Beagle bone Black Raspberry Pi 3

Raspberry Pi 4
Sensors:
 Ultrasonic
 Inductive
 Infrared
 Laser
Specifications:
Ultrasonic:- There are two types in this namely; Proximity Detection and Ranging Measurement.
 Cost (INR): 150-500.
 Sensing Range: 0.2 – 10 m.
 Accuracy: low.
Inductive:-
 Cost (INR): 250-1000.
 Range: upto 40mm.
 Accuracy : high
Infrared:-
 Cost(INR) :- 800
 Range: Upto 5m
 Accuracy : high
Laser:-
 Cost(INR) :- 100-150
 Range : Upto 2m
 Accuracy : high
CAD MODELS:

Lifting Mechanism Scissors (Links)

Frame

Assembly of Automated Guided Vehicle

Assembly of Automated Guided Vehicle

PROGRAMMING:
For programming purpose, the following components are used
1. Software components:
 Raspbian OS:
It is a Debian-Linux based operating system for Raspberry Pi. It is highly optimised for Raspberry
Pi’s low- performance ARM CPUs. It is very lightweight and makes a great choice for Raspberry
Pi. It includes tools for browsing, python programming and GUI desktop. Its desktop environment
is known as LXDE (Lightweight X11 Desktop Environment).
 Python:
Python is an interpreted programming language, which supports both Object Oriented and
Procedural programming. Its syntax is very clean and easy to understand. As Raspbian OSalready
include Python programming tools, and also because of its capability to connect to real world, it is
chosen as the language for project development.
2. Hardware Components:
a. Raspberry Pi microprocessor:
Raspberry Pi has been chosen to be used the main processing system. It will be responsible
for controlling all sensors, gathering data, processing it, and giving appropriate commands to
the drive system.
b. Ultrasonic Sensor:
Ultrasonic sensor is used to find out the distance between whatever object is present in front
of the AGV. It works on the principle of sound waves.
c. Infrared Sensor:
Infrared sensor is used to check the existence of an obstacle in the AGVs proximity. The output
given is digital.
d. Motor driver:
Motor driver is used for interfacing the motor with the microprocessor, so that the
microprocessor can control its speed.
Ultrasonic sensor (HC-SR04)
• We are using Ultrasonic sensor HC-SR04 for distance measurement.
• The sensor works on basic principle of sound waves, the sensor gets a trigger from the
microprocessor, it produces a sound wave, the wave bounces off the object and gets reflected then
the receiver or ECHO pin detects the reflected wave.
• By programming, the start and end time of the pulse is recorded, and as the speed ofsound is
known the distance between the object and the sensor can be known (which is half the distance
travelled by the wave).
• This sensor has a higher range, but low accuracy, because sound waves bounce on any surface and
the there is no way to know exactly how the waves are returning.
• Also, when object is moving the sensor tends to give erratic results after the first few correct
readings.
• This sensor has slightly complicated setup, s a few resistors are needed to adjust the voltage
and also to protect the sensor from burning out.
Test results for sensor

• At long range (100cm) only sufficiently large objects have right distances produced,
forsmall objects, the readings are either erratic or null.
• At medium range (40-60 cm) most objects are correctly detected, but curved/small
objects may give erratic readings.
 • At short range (10-20cm) all objects get detected with acceptable accuracy.

• Error at long range is 6-10cm, at medium range is 2-10cm, and at short range is 0-3cm.
• Basically, the reading for an object is highly dependent on its size, material, and
orientation.(if object is tilted at an angle, readings become erratic)
• Also, readings may stop when object is brought extremely close.
Infrared sensor
• The sensor produces the output as HIGH or LOW (0 or 1, digital output). When the object
is in range the result is 0 while the object is away the output is 1.
• The working of the sensor is subject to light conditions.
• The sensitivity of the sensor is also subject to the size of an object, for Eg: a large object like
a box gets detected at a distance of approximately 15-17 cm, but a thin object like a pen gets
detected at a much closer distance.
• The sensor actually produces an analog voltage as output which is subject to the objects
distance, but is converted to digital output.
• It was also found that the detection range of the sensor can be altered to some extent using
the adjustment screw.
• To acquire actual distance measurements, firstly the digital output (0 or 1) has to be converted
to analog output (voltage).
• If this is not done, the sensor can still be used to detect the presence of an object. But the
distance cannot be understood
• For this an ADC (ANALOGTO DIGITAL CONVERTER) can be used.
Example: M3008ADC
Test results for sensor:
• The infrared sensor module can be calibrated for its range.
• 2 calibrations were studied, short and long range.
• Before studying the data, it should be noted that as the sensor works on light principles, the readings
differ according to objects color and reflectivity.
Considering this, black colored and objects become the worst case (lower bound) while white or reflective objects
become best case (upper bound).
 For long range calibration, normal objects get detected between 25-35cm from sensor,Black objects at
10-15cm, and white/reflective objects between30-60 cm
 For short range calibration, normal objects get detected between 15-20cm from sensor,Black objects at
5-8cm, and white/reflective objects between25-50 cm.
 Basically, detection is dependent on size, color and reflectivity of object.
Motor interfacing:
• The AGV wheels will be driven by 5V DC motors, which will be controlled by the
Raspberry Pi microcontroller.
• For interfacing the motor, a driver module is needed. We have used the L293D motor driver.
• The motor is connected to the driver, and the driver to RPi. Also a power source is needed.
(In our case of testing we took power from raspberry pi itself).
• For controlling speed of motor, pulse width modulation technique is used. PWM is
implemented in program using inbuilt library GPIO.PWM in Python/ Raspbian OS.
Combination:
• An attempt was made to combine sensors and motor to work in unison.
 • 2 IR sensors (Long and short range), Ultrasonic sensor, and 5V motor were connected to RPi, and
were programmed according to requirements.
• The working is as follows,
• Long range IR detects obstacle and lowers speed.
• Short range IR detects obstacle and stops vehicle, triggers US sensor.
• US sensor is activated and distance is measured.
If obstacle moves away, the motor starts working again at low or high speed according to proximity. Also, short
range infrared sensors MAY be setup on the corners (front and back) whichwill help in parking, charging, and
extreme proximity scenarios.

RESULTS AND DISCUSSION

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. Speed of conveyance
2. Modification of vehicle speed
3. Adaptability of way
4. Versatile to changes in industrial facility formats
5. Maintain a strategic distance from crash with different items
6. Decrease in labor cost
7. Decrease in running expense contrasted with transport frameworks
8. Capacity to add sensors to identify the payload conditions
9. Proceeds with pattern of working
10. Conditions for line following can be changed without any problem
CONCLUSIONS
Mechanized guided vehicles assume a significant job in adaptable assembling frameworks. The task
primarily manages working of an AGV and controlling it with PC. The disentangled plant format is
considered in the work and the vehicle is effectively controlled from one machine unit to the next
with machine number as the main info. There are a few potential headings for additional
examination. We can improved the guided tape type AGV using better route strategy. It tends to
be embraced any condition and modest among self-sufficient robot. There is critical measure of
contrast among hypothetical and down to earth work cycle estimation of time which can be
advanced by embracing diverse strategy.