UNIVERSITI TEKNIKAL MALAYSIA MELAKA

FACULTY OF ELECTRICAL ENGINEERING

BEKU 4983 FINAL YEAR PROJECT

AUTOMATED GUIDED VEHICLE (AGV)

NAME JULIE AIDAH BINTI JUSIN B010810230

SUPERVISOR EN. AZHAR BIN AHMAD

PANEL CIK ARFAH BINTI AHMAD, EN. SHAHRUDIN BIN ZAKARIA

 I hereby declare that I have read through this report entitle Automated Guided Vehicle (AGV) and found that it has comply the partial fulfillment for awarding the degree of Bachelor of Electrical Engineering (Industrial Electronics)

Signature Supervisors Name Date

: .. : AZHAR BIN AHMAD : ..

AUTOMATED GUIDED VEHICLE (AGV)

Submitted By: JULIE AIDAH BINTI JUSIN B010810230

A report submitted in partial fulfillment of the requirement for the degree of Bachelor of Engineering

Faculty of Electrical Engineering UNIVERSITI TEKNIKAL MALAYSIA MELAKA

JUNE 2012

I declare that this report entitle Automated Guided Vehicle (AGV) is the result of my own research except as cited in the references. The report has not been accepted for any degree and is not concurrently submitted in candidature of any other degree.

Signature Name Date

: : JULIE AIDAH BINTI JUSIN :

To my beloved mother and father

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ACKNOWLEDGEMENT

In the name of Allah S.W.T, The Most Beneficial and The Most Merciful. It is with deepest serve gratitude of the Al-Mighty that gives me strength and ability to complete my final year project (FYP). I would like to take this opportunity to express gratitude to my dedicated project supervisor, Mr. Azhar Bin Ahmad for guiding my final year project tolerantly by sharing his valuable ideas and expertise. Not forgotten to any other UTeM lecturer such as Mr. Zamani Bin Md. Sani, who spends his precious time to solve some problem regarding to this final year project.

My sincere thanks go to all my friends who sincerely give their opinion and continuous guidance throughout this FYP. Last but not least, I would like to express my outmost gratitude to my lovely parents and sibling for giving a support direct or indirectly during this project accomplishment progress. I appreciated for all of the co operations. Once again, thank you very much.

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ABSTRACT

The construction of Automated Guided Vehicle (AGV) model has been created all over the world. It gives many advantages in our lives and work just as a robot. It can done it task without complaint. AGV is a system that moves following a line from one point to another point regarding to it given task. This kind of technology can be found appliance at factories, offices, hospitals and even houses. The aim of this project is enhance a simplest circuit of AGV system that comes with low prices and user friendly. PIC16F877A microcontroller is use to control all navigation during the operation of AGV system. The advantage of this prototype is it has an ability to follow line on and can be further developed to do more complicated task in real life. The microcontroller is attached to a sensor that continuously reflecting to the surface condition. Therefore, this project involves of designing and fabrication of the hardware and circuitry. The main importance in this project is the algorithm to assembly language, embedded in the microcontroller. Then, the H-bridge will be use as the DC motor drive. At the end of this project, the AGV can move following the line regarding to the task that will be given.

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ABSTRAK

Pembinaan model AGV telah dicipta di seluruh dunia. Ia telah memberikan banyak manfaat dalam kehidupan seharian kita dan bekerja sebagai robot. Ia boleh melakukan tugas tanpa sebarang rungutan. AGV adalah satu sistem yang bergerak mengikut garisan dari satu tempat ke tempat yang lain berikutan dengan tugas yang telah ditetapkan. Teknologi ini boleh dilihat diaplikasikan di kilang-kilang, pejabat, hospital dan tidak terkecuali di rumah. Matlamat utama projek ini adalah untuk menambah baik pulih litar yang ringkas bagi sistem AGV yang telah sedia ada. Pengawal PIC16F877A digunakan untuk mengawal semua pergerakan sistem AGV. Kelebihan sistem ini adalah ia bergerak mengikuti garisan berpandukan pengesan dan mampu melakukan kerja yang rumit dalam kehidupan sebenar. Pengesan akan disambungkan pada pengawal untuk mendapatkan bacaan dan membolehkan AGV bergerak. Oleh itu, projek ini melibatkan penyambungan litar dan pembinaan bahasa himpunan dan dimasukkan ke dalam sistem pengawal. Hjambatan akan digunakan sebagai pemacu DC-motor. Pada akhir projek ini, AGV boleh bergerak mengikut garisan berpandukan pengesan untuk melakukan tugas yang akan diberikan.

TABLE OF CONTENT

CHAPTER

TITLE DEDICATION ACKNOWLEDGEMENT ABSTRACT ABSTRAK TABLE OF CONTENT LIST OF FIGURE LIST OF TABLE LIST OF APPENDICES

PAGE i ii iii iv v viii x xi 1 1 2 2 3 3 4

INTRODUCTION 1.1 Problem Statement 1.2 Objectives 1.3 Scope of Project LITERATURE REVIEW 2.1 2.2 Control and path prediction of an Automated Guided Vehicle Control (AGV) Makespan Minimization of Machines and Automated Guided Vehicles (AGV) Schedule using Binary Particle Swarm Optimization 2.3 2.4 Automated Guided Vehicle (AGV) using 68HC11 Microcontroller Development of control system for Automated Guided Vehicle (AGV) 2.5 2.6 Carrying Robot (C-Bot) Microelectronic (MicroC)

4 5

6 6

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2.7

Proteus 7 professional

METHODOLOGY 3.1 3.2 3.3 Title understanding Literature review AGV operation Development 3.3.1 3.3.2 3.4 3.5 3.6 Flow chart Motor Driver

9 11 11 11 11 12 13 15 17 17 18 19 20 21 22 23 23 25 24

Programming Development Software Implementation Hardware Development 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 PIC16F877A Microcontroller Power Supply Unit Line Follower Sensor IR Transmitter and Receiver LCD Display 3.6.5.1 LCD pin layout 3.6.5.1 LCD pin connection

3.7 4

Testing

RESULT 4.1 Software Part

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4.2 4.3

Developed Prototype Result And Outcome 4.3.1 4.3.2 Simulation Hardware 4.3.2.1 Power Supply and Microcontroller Circuit 4.3.2.2 Line Follower Sensor Circuit 4.3.2.3 IR Sensor Circuit 4.3.2.4 Motor Driver Circuit 4.3.2.5 The prototype of AGV

25 26 26 27 27 28 29 30 30

ANALYSIS AND DISCUSSION 5.1 Analysis 5.1.1 5.1.2 5.1.3 5.2 Calibration of Line Follower Sensor Calibration of PIC Calibration of Motor Driver

33 33 34 35 35 36

Discussion

CONCLUSION AND RECOMMENDATION 6.1 6.2 Conclusion Recommendation

37 37 38

REFERENCES APPENDICES

39 41

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LIST OF FIGURE

FIGURE 2.1 2.2 2.3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 4.1 4.2 4.3 4.4

TITLE AGV command architecture C-Bot Proteus Virtual System Modelling Flow Chart of the Methodology Flow Chart of the AGV Basic connection of H-Bridge circuit Programming Development Generating HEX file PIC16F877A circuit Compiler in Proteus The output of this project Microcontroller reset circuit Power Supply by using Voltage Regulator The circuit of line follower sensor using four emitters and four receivers. IR Transmitter and Receiver Common LCD pin diagram LCD connection by using 4 bit Block diagram for the whole system Simulation of DC Motor Combination circuit of Power Supply and PIC16F877A Circuit of Line Follower Sensor

PAGE 3 6 8 10 12 13 14 14 15 16 16 18 19 20 20 22 23 25 26 28 29

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4.5 4.6 4.7 4.8 4.9 4.10

IR Sensor Motor Driver Circuit Top view Side view Bottom view Back view

29 30 31 31 32 32

LIST OF TABLE

TABLE 3.1 3.2 5.1 5.2 5.3 5.4

TITLE The list of component for basic circuit of PIC Microcontroller LCD pin description The movement of AGVs motor Aimed the sensors units on various materials Output from PIC to L293D Output from L293D to motor

PAGE 18 22 34 34 35 35

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LIST OF APPENDIX

APPENDIX A

TITLE Technical Data of PIC16F877A

PAGE 42

CHAPTER 1

INTRODUCTION

This chapter will give a brief explanation about this project including the problem statement, objectives also the scopes of the project. This project is to develop automated guided vehicle (AGV) by using microcontroller.

1.1

Problem Statement Automatic Guided Vehicles (AGV) has been using since the 1950's. First AGV

developed in 1954 by A.M.Barrett,Jr. The AGV used an overhead wire to guide a modified towing truck pulling a trailer in a grocery warehouse. Then, commercial AGV were introduced by Barrett. In 1973 Volvo developed automated guided vehicles to serve assembly platforms for moving car bodies through its final assembly plants. Later, Volvo marketed their unit load AGVs to other car companies. [5] Several important aspects of AGV system problem should be acknowledged and need an in-depth research in order to understand the problems. Nowadays, industries already used complicated control system of AGV which its comes with high cost. So, by enhance and design a simplest AGV circuit it will automatically comes with low prices. Then, in the industries, human workers will take more movement to do their work. With the application of AGV system can ease the strain on human workers by performing tiring task such as lifting and carrying heavy material. In handle the heavy work, AGV is more effectively with no signs of creeping. Therefore, the valuable knowledge on AGV construction is very significant to be studied

and be further implemented from the result of this project. It will come with many benefits to our live and technologies.

1.2

Objective The main objective of this project is: i. ii. iii. To find information about circuit of AGV system and PIC programming To design and enhance a simplest circuit for AGV application by using PIC microcontroller. To construct and develop the prototype of the circuit design.

1.3

Project Scopes

The scopes of this project are: i. ii. iii. Design and development of AGV system. PIC microcontroller control all the navigation of the AGV operation Produce one complete system that can be user friendly.

CHAPTER 2

LITERATURE REVIEW

In this chapter will explain about the literature reviews that been reviewed. In order to design and construct of AGV system, research in AGV need to be performed. This chapter would discuss the previous studies of AGV that have been developed. This literature review section will also provide knowledge and understanding the application of the AGV system.

2.1

Control and path prediction of an Automated Guided Vehicle Control (AGV) This journal discuss about the development of an AGV. The navigation of the AGV

will be control by Programmable Logic Control (PLC) module as shown in the figure below.

Figure 2.1: AGV command architecture

The position and orientation of the AGV will determined by the parameters of the motion are driving speed and steering angle. The input from both left and right rear wheel and analog output signal are interfaced with PLC module. Then, the steering and driving command signal can be calculated. The PLC convert the digital output to analog signal to drive amplifier of the driving motor and steering motor as shown in figure 4.1. The DC motor are been using in this project. [1] The developed algorithm is based on memorised path and kinematics determination of the movement. The vehicle position and deviation are calculated from rear wheels rotation measurement. The steering and driving command are determined from this deviation. Localization of AGV by Kaman filtering algorithm is presented. Overall structure of designing AGV is described. Control of AGV motion is implemented by using PID control scheme. Displacement axis and steering axis are separated to implement the motion control. [1] From this review that has been examined can be concluding that this kind of AGV has an ability to estimate and adjust the error sources during it position and orientation along the defined path. However, there is no safety that has been developing for this kind of technology in this project such as to detect any obstacle.

2.2

Makespan Minimization of Machines and Automated Guided Vehicles (AGV) Schedule using Binary Particle Swarm Optimization This paper discuss about the implementation of Flexible Manufacturing System

(FMS) to the AGV task. FMS is a high automated machine cell that controlled by a computer system. At the factory, the AGV need to do more than one task. So, this study is based on minimizing the total completion time of the AGV by using Binary Particle Swarm Optimization (BPSO). The algorithm is developing to control the navigation of the

AGV by using MATLAB software. Among the elements in the implementation of AGV is task scheduling. The efficient of scheduling will reduce the cost of delivery. [2] As the conclusion, the schedule of AGV can be minimizing by using BPSO. The BPSO managed to provide a better optimization solution particularly for simultaneous scheduling of machines and automated vehicles in production environment. This kind of method can be implementing in the simple development of AGVs project.

2.3

Automated Guided Vehicle (AGV) using 68HC11 Microcontroller This project is about an AGV prototype can move on a flat surface with its two

driving wheels and a free wheel. The prototype will be control by M68HC11 microcontroller which it acts as main brain that will control all the navigation and responses to the environment. This project just develops for line follower. The ability to follow line on floor was an advantage of this prototype as it can be further developed to do more complicated task in real life. It using voltage sensor to detect the line. [4] Therefore, this project involves both of designing and fabrication of the hardware and circuitry. The key study in this project is the algorithm designed in assembly language, embedded in the microcontroller. This prototype is able to move on a flat surface and move along black line on a white surface, depending on how much of the darkness and brightness of the surface as well as the width of the line. The microcontroller MC68HC11 can be use to control all the navigation of this prototype. The microcontroller is the important part that makes this prototype has quite a simple circuitry, as it already has complete internal circuitry in the chip. The line follower sensor and the DC motors are very reliable and suitable for the prototype. As the sensors gives continuous input to the microcontroller about the surface physical variables. There is no safety for the prototype of this project that has been installed.

2.4

Development of control system for Automated Guided Vehicle (AGV)

This project was focused on development of the control system for Automated Guided Vehicle (AGV). It concentrates on developing the control system for the AGV operation, movement and loading & unloading mechanism. The objectives of this project are to develop the control system parts involving by using the electronic circuit system and computer programming. The wired guided navigation will communicate with the computer to the AGV to ensure the AGV work proper according to its operation. Subsequently, this kind of project needs to be fabricating each of the electronic com9ponents to become one complete circuit. All the computer programmings are building by using Code Blocks software, the compiler which is compatible with electronic components and Visual Basic software. Afterwards, Visual Basic 6 is used in this project to create user friendly interface which is better than C interface (Command Prompt). [6]

2.5

Carrying Robot (C-Bot)

Figure 2.2: C-Bot This kind of robot is was one of type of AGV application. It was designed to move in linear or curved route. C-Bot has a gripper tat function as gripping the work piece. It uses a high torque of servo motor for both function of gripping and vertical movement.

Then, it also uses dual motor drive system where both of the motor were coupled directly to the wheel. The safety bumper is use to detect any obstacle that come in front of its way. In the prototype, there were three wheels with two independently controllable wheels at the front and a free unpowered caster at the back. [3]

2.6

Microelectronic (MicroC) MikroC is a powerful, attribute rich growth tool for PIC microcontroller. It is

designed to present the programmer with the easiest possible solution for developing applications for fixed systems, without compromising performance or control. This kind of software is easy to built programming compare to the other software. While develop the programming, this software will show if there is any error. The operation of the AVG is design in the C language and imbedded in the PIC microcontroller. PIC and C fit together well which PIC is the most popular 8-bit chip in the world, used in a wide variety of applications, and C prized for its efficiency, is the natural choice for developing embedded systems. [7] MikroC allows quickly developing and deploying complex applications. First, write C source code using the built-in Code Editor (Code and Parameter Assistants, Syntax Highlighting, Auto Correct, Code Templates, and more. Then, use the included mikroC libraries to considerably speed up the development: data acquisition, memory, displays, conversions, communication. Practically all P12, P16, and P18 chips are supported. After that, monitor the program structure, variables, and functions in the Code Explorer. Generate commented, human-readable assembly, and standard HEX compatible with all programmers. The program flow should be tnspect and debug executable logic with the integrated Debugger and get detailed reports and graphs: RAM and ROM map, code statistics, assembly listing, calling tree, and more. [7]

2.7

7 professional Proteus is a zero-power research operated at the Paul Scherrer Institute,

Switzerland. High degree of flexibility in study about the wide range of a different system is one of its main characteristics. At present, it is being used to provide an extended integral database for the validation of modern light water reactor fuel designs. [8]

Figure 2.3: Proteus Virtual System Modelling Figure 2.3 shows one the Proteus Virtual System Modelling (VSM) application. VSM combines mixed mode SPICE circuit simulation, animated components and microprocessor models to facilitate co-simulation of complete microcontroller based designs. The most exciting and important feature of Proteus VSM is its ability to simulate the interaction between software running on a microcontroller and any analog or digital electronics connected to it. The micro-controller model sits on the schematic along with the other elements of the product design. It simulates the execution of the object code (machine code), just like a real chip. [8]

CHAPTER 3

METHODOLOGY

In order to complete the final year project, a methodology has been organized to ensure the progress of the project running well and as a strategy to overcome problems. Project methodology also describes the procedures and methods been used to achieve the objectives of the project. Methodologies of this project are title understanding, literature review, comparisons, development programming, development of AGV operation, development for hardware and testing. Figure 3.1 show the flow chart of the methodology of the project. The most highlighted method in this methodology is programming and hardware development. For software part are focus on circuit design, simulation and programming. Circuit designs consist of PIC circuit and power supply circuit. The circuit is design in Proteus 7.7 professional. MicroC software is to write a programming by using c language and compile it with PIC16F877A in the Proteus. Other than that, this project also using LCD to display the movement of the AGV prototype. Thus, the software part should be solve first before proceed to next step where the hardware part to generate the value of power. Then, in hardware part Hardware part are focus on distribution board circuit, component assemble and circuit soldering. The main component used to construct this project is PIC 16F877A, Line follower (IR transmitter and receiver) sensor, analog distance sensor and LCD.

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Flow Chart:

Automated Guided Vehicle

ENERGY

Literature review
ROTARY SHORT BREAK SYSTEM

STORAGE

AGV Operation COMBINED Development SHORT BREAK

AND GENERATING SET SYSTEMS Programming

Development ROTARY UPS SYSTEMS Implementation WITHOUT YES INTERRUPT Hardware ION Development WITH Testing INTERRUPT ION
GENERATING End SET SYSTEM FLYWHEEL ENERGY STORAGE ROTARY UPS Software SYSTEM

NO

Figure 3.1: Flow Chart of the Methodology

NO ENERGY STORAGE

Start

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3.1

Title understanding This title of project has been proposed to supervisor and has been approve. Then,

verify the objective and scope of this project. The problem statement has been stated to identify the significance of this project.

3.2

Literature review

Study about the background of this project by refers to the similar project and any various sources like references book, journal and any information from the internet that related to the project.

3.3

AGV Operation Development This chapter will elaborate on motor drive, flow chart and simulation circuit. Motor

driver will discuss about the operation of the motor whether the motor will move forward or reversed. The flow chart will tell about concept studying in this project. While, motor driver will discuss about how the motor is operation. Circuit simulation will demonstrate the operation of the circuit in the computer.

3.3.1

Flow chart As below figure 3.2 below is a flow chart that constructed for this project.

The operation will start by switch on and the sensor will starts operating. If sensor senses magnetic or colour tape, the motor will start energized. Then, the AGV will move forward or backward. If there any obstacle or blockage exist while the AGV was moving, the ultrasonic sensor will detect and cut of the circuit and stop the

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motor for a moment. When the motor is stop, the alarm will turn on. The AGV will not back to it operation until the blockage is remove. After the blockage is remove, the AGV will start over the flow from motor energized and will go through it destination if there is no blockage.

Figure 3.2: Flow Chart of the AGV.

3.3.2

Motor Driver The motor driver is used to drive the motors of the robot. Since even a small

motor requires high current to operate, the high current could certainly causing damage to the microcontroller if the motor is connected directly to the microcontroller. Then, normally the motor driver or a relay is required to prevent

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the reverse current and protect the microcontroller chip. The resistor 10k of the motor driver circuit is also used to limit the rush current. The microcontroller is lacks of sufficient current to drive the motors, so the driver is needed to energize the stator of the motor. The drivers for DC motors are H-Bridge circuit as well as L293D. For this project, the H-Bridge driver circuit is the best solution to be interface with the dc motors.

Figure 3.3: Basic connection of H-Bridge circuit The circuit in figure above show the basic connection of H-bridge circuit. It consists of motor, 2 supply rails and 4 switches. Any of the circuit can be close at any time and just 3 combination of the switch close will turn on the motor. If the A1 and A2 switches are turn on, the current will flow in one direction through the motor, causing the motor turn on. Then, if the B1 and B2 switches are turn on, the current will flow in the opposite direction through the motor, causing it to spin in the opposite direction. If all the switches are turn off, there is no current flow through the motor and it free to spin.

3.4

Programming Development C language is use to develop the programming of PIC microcontroller. The

programming must be learn and analyze to get the output of project. The software

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development includes the process of determining which communication port of microcontroller that will interface with other component. It is also the important part towards the completion of this project. The software of use is such as PIC Compiler, MicroC and etc. The coding that has been developed need to convert to HEX file, so that it can be burn into the PIC16F877A microcontroller.

Figure 3.4: Programming development

Figure 3.5: Generating HEX file

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3.5

Software Implementation In software development there are three stages needed to complete this whole

project. In the first stages MicroC is software that is needed to make a coding as the programmed to define the value of the sensor will detect. To obtain this result, in the programming also contain to convert current load that is analog to digital (ADC). This MicroC using 10 bit which has higher resolution that means the step size between one digital levels to the next one are smaller. In the second staged, Proteus is the software that used to design the PIC16F877A as a main circuit that required to this whole project. In this software is contain the LCD Display and Motors as function to display the result that will obtain through the programming that already been created. Figures below show the step of software implementation before go the last step that is hardware development.

Figure 3.6: PIC16F877A circuit

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Figure 3.7: Compiler in Proteus

Figure 3.8: The output of this project

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3.6

Hardware Development The hardware development consists of the process of developing the components

and parts to be assembled and at last become the final product of the prototype. It is the important part of the project that determines the successful of the project. There are two type of sensor that has been use on this AGV prototype. First is infrared and second is analogue distance sensor.

3.6.1

PIC16F877A Microcontroller Generally, there are numerous control methods to control a robot. The

methods are ranged from classical method like PI controller, PD controller and PID controller to artificial intelligence such as Fuzzy Logic, Genetic Algorithm and Neural Networks. Microprocessor and microcontroller are also can be use to control robots which acts just like the brain for the robot. The brain that controls this prototype is the PIC16F877A 40 pins PIC microcontroller. The PIC16F877A can control the entire DC motors and the behaviour of the line-following sensor. Microcontroller also can be recognized as computer-on-a-chip optimized to control electronic devices which consist of CPU, ROM, RAM, I/O port and timer embedded together inside the single chip. It can follows instructions, read information, communicates, measures time and switches things on and off and also does other things too depending on the model. It is often criteria to be considered to which microcontroller to be used, such as the microcontroller should meet the computing needs for the task at cost efficiency and also has simple architecture and language. Figure below show the identified hardware requirements the following is a summary of required material for prototype implementation.

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Figure 3.9: Microcontroller reset circuit

Table 3.1: The list of component for basic circuit of PIC Microcontroller Quantity 1 1 2 1 1 1 1 1 References Resistor Resistor Capacitor1 Capacitor2, Capacitor3 LCD Display Microcontroller Crystal Oscillator Push Button Switch Value 1k 10k 30pF 0.1F JHD1602A PIC16F877A 20MHz Sensor

3.6.2

Power Supply Unit The microcontroller is powered up by a low voltage value ranging from 0V

to the maximum 5V. It will cause to the internal circuitry damage to the microcontroller 16F877A if it is directly connected to a high value of supply voltage. In this project, the voltage regulator is very important to turn the 9V supply from the adapter to a constant 5V, to power on the microcontroller. This regulator

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is already interfaced on the motor driver board that is a smart enough connection. The 6V of voltage value supplied by four of 1.5V batteries is just to power on the dc motors and this 6V is not connected directly to the microcontroller. The basic connection of voltage regulator to turn any input voltage to a constant 5V value is as shown by Figure 3.10 below.

Figure 3.10: Power Supply by using Voltage Regulator

3.6.3

Line Follower Sensor The Line Follower sensor uses a pair of IR sensors that aimed downwards

close to the floor. Each pair consists of transmitter and receiver, so the light from the transmitter is reflected back by a light coloured surface and absorbed by a dark coloured surface and the receiver is responding to the amount of light reflected back.

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Figure 3.11: The circuit of line follower sensor using four emitters and four receivers. From the figure above, the LM324N was use as the comparator. The emitter will transmit while the receiver will detect the light that has been transmitted. The receiver will act as switch. When it receive high input (max. 5v), it will send input to the comparator. Then comparator will send input to the PIC. The PIC will read 5V (min. 3.3V and max. 5V) as high or 1 and 0V (below 3.3V will declared as 0V) as low or 0.

3.6.4

IR Transmitter and Receiver

Figure 3.12: IR Transmitter and Receiver

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IR transmitter and receiver are built to detect any obstacle in the front of the AGV when it moves in the surface. In this pair of infra red sensors, when the transmitter emits IR ray, as long as the receiver receives the ray, the electricity will flow in the receiver. Of course in this, the electricity if not measure by ON or OFF like the hand analogy. There is a range from full current to zero current. The current can be any value from zero to the maximum depending on the strength of the IR ray. The stronger the ray, the more current will pass through. To connect, 5 volts voltage supply, 330 Ohm Resistor and 4.7k Ohm resistor. The signal are getting is analogue voltage. When the ray is present, meanings the switch is closed, therefore signal will be close to 0V. If the ray is absents, the switch is opened; therefore the signal will close to 5V.

3.6.5

LCD Display LCD (liquid Crystal Display) is a passive device that uses light modulating

properties of liquid crystals. By applying the power to LCD, light will transmitted through liquid crystal in different direction compared to the when there is no power supplied. LCD display is specifically designed and manufactured to be used with microcontrollers. It cannot be active by using standards IC circuits. There are many types of LCD for instance alphanumeric LCD and graphic LCD. Alphanumeric can display a large number of character and symbols for examples, alphabet (A, B, x, y, z, &) and number (0, 1, 2.., 9). While graphic LCD can display shape for examples laptop screen and television screen.

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3.6.5.1 LCD pin layout There are a lot of types of LCD display which can be founded in market nowadays such as with backlight, without backlight and various type of colours display. Usually LCD with one controller have 14 pins or 16 pins which have two extra pins for back light LED connection. The pins diagram for common LCD displays is shown in Figure 2.4 and Table 2.1 shows the pin description for LCD display.

Figure 3.13: Common LCD pin diagram

Table 2.1: LCD pin description

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3.6.5.2 LCD pin connection There are two types of LCD connection which are eight bit and four bit connection. In this project 4 bit connection of LCD display has been used. 4 bit connection that has two libraries consist of LCD library and LCD custom library then has 4 pin data bus. The similarity of 8 bit connection and 4 bit connection, they have three pin of Vss, Vdd and Vee and also three pin of RS, RW and EN. The figure below shows the connection 4 bit of LCD.

Figure 3.14: LCD connection by using 4 bit

3.7

Testing After design and development done, the project will be testing to get the expected

result. If the objectives not achieves then the circuit need to study again. The prototype will test at the breadboard before transfer the circuit and solder it on the strip board. The prototype will be test on the surface with black and white paper.

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CHAPTER 4

RESULTS

This chapter will explained and discusses about the results obtained from what was done on the designing process of this AGVs prototype.

4.1

Software Part The software used in the implementation of this project is Proteus 7.7 Professional

software and C Compiler software (CCS). Proteus 7.7 professional is used to build circuits and perform simulations while CCS is to make programming for the mobile robot microcontroller. To obtain a constant power supply for PIC either from batteries or AC/DC adaptor, a power supply circuit with fixed output voltage has been designed. The output voltage of power supply circuit will be supplied to the input of PIC circuit. For activate outputs from the PIC, the voltage and current level must adhere to the PICs level. Generally, the maximum PIC voltage accepted is 5 Volts and the PIC can produce an output of 20mA of current per pin (PIC 16F877A).

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4.2

Developed Prototype

PIC16F877A MICROCONTROLLER

PORTA /ADC PORTB

ANALOG DISTANCE SENSOR

LINE FOLLOWER SENSOR MOTOR DRIVE 6V BATTERY

PORTC

VOLTAGE REGULATOR RIGHT MOTOR LEFT MOTOR

9V

Figure 4.1: Block diagram for the whole system

The detail block diagram shows all the important parts of this prototype. The microcontroller unit controls all the circuitry and operation. The microcontroller is the PIC16F877A 40 pin. There are two power sources, the 9V from adapter and the 6V batteries. Since the microcontroller operating voltage is 5V, the 9V from the batteries is powered down to 5V by the voltage regulator 7805 that also maintain the fixed 5V to the microcontroller.

The line follower sensor acts as input to the microcontroller, so that the microcontroller will respond to the physical variables that it receives and make appropriate feedback according to the program inside. The left and right motors are the dc motors that

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function as the output for the microcontroller and there are motor drivers that prevent the 6V and high current from causing damage to the microcontroller. The dc motors operates in 6V batteries. Both of the dc motors of the prototype provide the mechanical movement for the prototype. The batteries are used instead of external power supply to let the prototype to move smoothly without any difficulties. It is more suitable to use batteries instead of external power supply although the motors use more voltage power to the developed prototype.

4.3

Result And Outcome The result and outcome divided in this project development divided into simulation and hardware.

4.3.1

Simulation

Figure 4.2: Simulation of DC Motor

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Figure above show the simulation of two DC motor by using PIC16F877A and L293D as the driver. In this simulation the IR sensor has been replace with logic toggle and the analog distance sensor replace by 1k of variable resistor. The logic toggle will give 1 as high and 0 as low condition. The 1k variable resistor will give input voltage to the PIC until the certain value of voltage that receive will stop the motor and turn on the led at port c. LCD has been connecting to the PIC to show the movement of the robot. As shown at the figure 4.2, both of the dc motor is moving forward and at the LCD is appearing Robot Forward.

Simple programming has been developed to run the motor forward, reverse and stop. In this simulation, the aim is to control the DC motor speed. The PWM is importance to control the speed of motor. In this coding, the maximum value1 and value2 are 225(in decimal) or 5V. The duty cycle for motor1fwd change to 125 or 2.45V and motor2fwd change to 250 or 4.9V. The AGV required some basic wiring for the circuit to run. PIC16F877A was used as the microcontroller for the AGV and PIC circuit required some basic circuit to run the circuit. The simplest test run circuit requires a 5 volt direct current (DC) power supply, a pull-up resistor to the reset (MCLR) pin, a reset switch, an oscillator/crystal and capacitors.

4.3.2 Hardware

4.3.2.1 Power Supply and Microcontroller Circuit From the Fig. 4.3 above, shows the connection between power supply and PIC16F877A. Before the circuit has connected to the real circuit, all the port of PIC has been check whether it can function or not. Then, it will apply with the rest of the circuit.

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Figure 4.3: Combination circuit of Power Supply and PIC16F877A

4.3.2.2 Line Follower Sensor Circuit Fig. 4.4 shows the circuit of the circuit of Line Follower Sensor. The voltage that flow to the transmitter is 4.5V while to the receiver is 1.10V. When a piece of white paper put in front of the IR sensor, current will flow to the led and the led will turn on. The led will show which of the sensors have detect the line. After that, the comparator will send input to the PIC16F877A Microcontroller.

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Figure 4.4: Circuit of Line Follower Sensor

4.3.2.3 IR Sensor Circuit In this project, IR sensor will be put in front of the body of the AGV prototype to sense an obstacle as shown in figure 4.5.

Figure 4.5: IR Sensor

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4.3.2.4 Motor Driver Circuit

Figure 4.6: Circuit of Motor Driver The figure 4.6 shows the circuit of driver motor that has been develop. The Vss is connected to 5V of voltage supply while the Vs are connected to 6V. If the Vss and Vs was connect parallel, there is not enough current to run the motor. This is because, two motor needed higher starting current. The capacitor functions as to constant the flowing current to the motor.

4.3.2.5 The prototype of AGV

The body of the AGV prototype is been constructed by using control car body and cardboard. DC motor also use the motor that already install in

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the control car. The chassis of the AGV is design by using the green cardboard and has been combined by using glue gun. The alarm that attached in the circuit is come with LED and BUZZER. The LCD also put at the top of the prototype to show the AGV movement. The Figures below show top, side, bottom and back view of the prototype.

Figure 4.7: Top view

Figure 4.8: Side view

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Figure 4.9: Bottom view

Figure 4.10: Back view

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CHAPTER 5

ANALYISIS AND DISCUSSION

This chapter discusses about analysis and discussion on the result obtained of the project.

5.1

Analysis In the simulation by using Proteus 7 professional, the PIC16F877A has been used.

This type of PIC has 5 I/O which are PORTA, B, C, D and E. It also has 8 analog to digital converter (ADC). This project uses two type of sensor on its application and one of the sensors is analog, so the input (analog) needs to convert to digital. This is because microcontroller just can read digital input. The main voltage of PIC is 0-5V. The IR sensor actually also give analog output, but the analog output has been convert to digital input before give signal to the PIC. During test the circuit of AGV prototype, the PIC only will define digital input voltage at range between 0V until 3.2V as 0 and voltage at range between 3.3V until 5V as 1. While for analogue input, the voltage to trigger PIC is range between 0V until 5V. The motor movement of the AGV is depends on the line following sensor programming. The movement of the robot is shown in Table 5.1. 1 is defining as ON while 0 is OFF.

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Table 5.1: The movement of AGVs motor Line Following Sensor Movement Left 0 0 0 Middle 1 1 0 0 Middle 2 1 1 0 Right 0 1 0 Forward Right Stop

5.1.1 Calibration of Line Follower Sensor The calibration for Line Follower sensor is to identify what kind of material the sensor will detect. Table 4.1 below shows the result from the calibration.

Table 5.2: Aimed the sensors units on various materials Situation Aimed the sensors units downwards close to white surface of a piece of paper. Aimed the sensors units downwards close to black surface Voltage (V) 3.60

0.00

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5.1.2 Calibration of PIC The line following sensor will detect the line and send the signal to the PIC. PIC will trigger when the input is high or 1. Then, the PIC will send the signal to the motor driver. Table 5.3: Output from PIC to L293D Sensor Detection 0110 0011 0000 Input 1 (V) 4.67 4.67 0.00 Input 2 (V) 0.10 0.00 0.00 Input 3(V) 0.18 4.54 0.00 Input4(V) 0.03 0.12 0.00

5.1.3 Calibration of Motor Driver The PIC will send signal to trigger the L293D. The input of the L293D depends on the sensor detection. Table 5.4: Output from L293D to motor Sensor Detection 0110 0011 0000 Output1 (V) 5.04 5.04 0.00 Output2(V) 0.23 0.00 0.00 Output3(V) 0.20 4.04 0.00 Output4(V) -0.03 -0.12 0.00

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5.2

Discussion Generally, this project includes hardware and software parts. For the first final year

project (FYP 1) it more focus on software part and learn AGVs controller programming by CCS C Compiler software. Controller programming parts throw down the gauntlet because it never used previously, so it needs to start from basic and give full attention and reasonability on the controller programming part to achieve the project objective. This is because the controller is most important part inside the robot it acted like brain. Then, in the FYP 2 is more focusing in hardware development. During complete this project, there are many problems occur. Firstly, the IR sensor cannot detect the line. There are short circuit while test the sensor. The input and output voltage are the same. After get some advice from supervisor, the problem of the sensor has been solved. The problem is the leg of receiver did not same with the leg of the transmitter. For normal leg of led, the short leg will be negative while the other leg will be positive. But for receiver, the short leg will be positive. Another problem of the circuit is the motor driver. The motor driver cannot run the motor. During testing, the 3V-12V DC motor has been used. Firstly, the motor driver just gets one supply. But after the output voltage is low, the Vs have been connecting to different supply but command ground. By using power generator, the motor can be run. But then when the circuit has been solder to the bread board, all the circuit did not function accept the line following sensor. Troubleshooting has been done to fine the main problem of the circuit. Then, the analogue distance sensor also has been burn. This kind of sensor is easily damage. The transmitter did not function even there is supply. So, by solve this problem analogue distance sensor been replace with IR sensor which is can sense white and black colour only.

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CHAPTER 6

CONCLUSION AND RECOMMENDATION

6.1

Conclusion As for conclusion, this projects objective to build an Automated Guided Vehicle

prototype is has been done. This prototype is able to move on a flat surface and move along white line on a black surface. Understanding in C language is very important in order to do programming that can control all the navigation of AGV. PIC16F877A microcontroller can be use to control all the navigation of this prototype. The microcontroller is the important part that makes this prototype has quite a simple circuitry, as it already has complete internal circuitry in the chip. The line following sensor and the DC motors are suitable for the prototype while the wheel is not suitable for the movement of the AGV. As the sensors gives continuous input to the microcontroller about the surface physical variables. Then, the IR sensors that use as substitute to Analogue Distance Sensor also function to detect an obstacle. By separately each circuit, it will more easy to troubleshoot the circuit. This project has been build with equipment that not suitable for it functions, but the main objective that is move along white line is done. During done this project, the simulation in Proteus is only 70 percent same with the hardware development. The cost of this project is also effective and there are much profitable aspects if this prototype is developed in the future. Hope the idea of this project can be used for other creation of AGV system.

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6.2

Recommendation

World of engineering is always looking for the best solution for every problem exist to ensure a better future. As for this project, lots of development and improvement can be made to ensure better outcome. There are many ideas and suggestions can be added towards developing this prototype in the future as this prototype could be as one of all the AGVs around the countries that help in human living. As one of the suggestions is that, this prototype can be attached with more sensors to make it could work in much more complex task. There are many sensors nowadays, and the choices of sensors could be varied, but the selection of sensors must be applicable to this prototype. This models chassis could be adjusted to make it suitable for future task, and some other components could also be added. The adjustment may consider the factors of desired function to be built to the prototype, making it look more smart, interesting, and commercial. Other than that, the microcontroller PIC chip can be change to other type such as PLCC that could save the space of the board and also seem to look smarter. Therefore, this prototype has the potential and could be the basic to the future adjustment of this prototype to work in the workplaces or in helping the residents to do their housework.

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REFERENCES

[1] Butdee, A. Suebsomran, F. Vignat, P.K.D.V. Yarlagadda, Control and path prediction of an Automate Guided Vehicle. Journal of Achievement in Materials and Manufacturing Engineering, Vol. 31, Issue 2, Dec. 2008.

[2]Muhammad Hafidz Fazli bin Md Fauadi and Tomohiro Murata, Makespan Minimization of Machines and Automated Guided Vehicles (AGV) Schedule using Binary Particle Swarm Optimization. Proceedings of the International Multi Conference of Engineers and Computer Scientists 2010 vol III, IMECS 2010, March 17-19,20101, Hong Kong.

[3] M. Yakut Ali, S.G.M. Hossain, H.Jamil and M.Z. Haq, Development of Automated Guided Vehicles for Industrial Logistics Applications in Developing Countries Using Appropriate Technology. International Journal of Mrchanical & Mectronics Engineering IJMME-IJENS, Vol. 10, No. 02.

[4] Hassan, Zuria Zaidura, Automated Guided Vehicle (AGV) using Microcontroller, EngD thesis, Universiti Malaysia Pahang, Malaysia, 2006.

68HC11

[5] Automated Guided Vehicles URL: www.meche.net/MAE%20464/Notes/AGV-latest.ppt Accessed on: September 2011

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[6] Development of control system for Automated Guided Vehicle (AGV) URL: http://umpir.ump.edu.my/1168/1/CD4433.pdf Accessed on: October 8, 2011.

[7] mikroC, microElektronika C compiler for Microcip PIC microcontrollers URL: http://www.mikroelektronika.co.yu Accessed on: November 20, 2011.

[8] Proteus 7 Professional URL: http://www.labcenter.com/products/vsm_overview.cfm Accessed on: November 20, 2011.

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APPENDIX A

TECHNICAL DATA OF PIC16F877A

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