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Abstract: In this paper, we study the design and control of automated guided vehicle (AGV)
systems, with the focus on the quayside container transport in an automated container terminal.
We first set up an event-driven model for an AGV system in the zone control framework.
Then a number of layouts of the road network (guide-path) are carefully designed for the
workspace of the AGVs in a container terminal. Based on our zone control model, a traffic
control strategy is proposed, which decouples the motion conflict resolution among the AGVs
from the routing problem. A routing algorithm is also constructed with the goal of minimizing
the vehicle travel distances and the transportation time. The efficiency of the integrated design
and control is demonstrated by computer simulations in terms of a set of defined measures of
system performance. Lastly, we point out several possibilities towards improving our current
results.
called off-crossing zones. Note that any depot is an off- keeps iterating and terminates if vi is in aiei.
crossing zone as it is not on any lane. Let R and A be
We say that a vehicle arrives at, intends to leave, or
the sets of all crossings and the set of all at-crossing zones
leaves some zone at time t if the vehicle triggers the
respectively.
corresponding event at t. Note that a vehicle switches its
state only when it arrives at or leaves a zone, and must be
Neighboring zone The concept of neighboring zone char- in the zone when it intends to leave a zone.
acterizes immediate zone-to-zone connections. The set of
neighboring zones of each depot includes the SZs of all its
out-lanes. The neighboring zone of a non-EZ zone c on a 3. LAYOUT DESIGN OF THE ROAD NETWORK
lane is the adjacent zone of c on the lane with respect to
the direction of the lane. The neighboring zone of the EZ of 3.1 Quayside Container Transport at an ACT
any in-lane of a depot is the depot. The neighboring zones
of the EZ of an in-lane of a crossing (i.e., an at-crossing In this work, we consider a container handling scenario in
zone) are the SZs of all the out-lanes of the crossing. We which the quay cranes (QCs) and yard stackers (YSs) are
use Υc to denote the set of neighboring zones of zone c. in charge of the container collection operations in the quay
(One can see from Assumption 1 that neighboring zones area (QA) and yard area (YA); and a team of AGVs are
are defined for any zone in C.) used for shuttling the containers between the two areas.
The operation is illustrated in Figure 1. Specifically, in
We impose the following assumption on the layout of the discharging a vessel, the QCs take the containers off the
road network. vessel and put them in the associated container buffers.
Assumption 1. (a) Each lane is an in-lane (out-lane) of These containers will be later on picked up by some the
either a unique crossing or a unique depot; (b) each lane AGVs, and transported across the transportation area
has at least two zones; (c) any in-lane of a crossing has at (TA) to the container buffers of some specified YSs in the
least one neighboring lane. yard area. There the containers will be put in container
stacks by the YSs. The other way around, in loading a
vessel, the containers are collected from certain yard stacks
2.2 Vehicle routes, states and events by the YSs and transported to designated QCs by the
AGVs. In this case study, the workspace of the AGVs is
We consider an AGV system with N vehicles, which is considered as the combined area of the QA, TA and YA.
denoted by the set V = {v1, v2, · · · , vN }. A finite sequence
of zones ai1, ai2, · · · , aiei , ei ∈e N, is called a route of vi ∈ V Now suppose that a road network defined as in Section 2
−1 is built over the workspace, with the buffer of each QC or
if a
p+1 ∈ Υapi for any p ∈ Z1 (For any m, n ∈ N, Zm
i i n is
YS modeled as one or more zone(s) (See also Subsection
defined to be {m, m + 1, · · · , n} if n ≥ m and ∅ if n < m). 3.2). For simplicity, these zones are said to be the zones
There are only two types of vehicle states: being in aip, for of the QC or YS. Then based on the working scenario
any p ∈ Z1ei , or moving from api to ap+1 i
, for any p ∈ Ze1i−1. described above, each AGV in operation can be seen as
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being assigned a sequence of tasks, where a task of a multiple lanes, joined by crossings, on the same vertical
vehicle means an ordered pair of zones, say (c1, c2). We level. See Figure 3 for an example of such layouts.
call the former zone c1 and the latter c2 the source zone
and the destination zone of the task. In addition, a route For simplicity, each crossing is chosen to be rectangular.
of a vehicle is said to be a route for the task (c1, c2) if it In order to avoid collision between a vehicle passing some
starts with c1 and ends up with c2. crossing and another vehicle waiting at the same crossing.
Each crossing should be able to accommodate the whole
3.2 Layout Design of the Road Network body of a vehicle. Considering the turning radius of the
vehicles, the horizontal dimension of the crossings is set as
In this case study, we consider a typical large container 15m. The vertical dimension of a crossing depends on the
terminal with a TA of the dimension 2000m×40m; and 20 layout design and its location in the TA.
QCs and 66 YSs distributed on the sea side and yard side As the vertical dimension of the TA is considered here
respectively (see Figure 5). In addition, without any loss of as 40m, it allows at most 6 parallel roads. Based on
generality, we assume that there is only one depot, which this restriction, four types of layouts for the TA will be
is located outside the workspace (but connected to the TA discussed:
by its in-lanes and out-lanes), and hence not a subject of
our layout design. For this reason, in the remainder of this (T1) 4 parallel roads and small crossings.
subsection, by zones we mean non-depot zones. (T2) 4 parallel roads and big crossings.
(T3) 6 parallel roads and small crossings.
Geometrical properties of the zones First we fix the (T4) 6 parallel roads and big crossings.
shape of the zones to be rectangular because the rect- For want of space, only examples of the layouts of Types
angular shape of the vehicles. We call the dimension of T1 and T2 are shown here in Figures 3 and 4. (We refer
the edge of a zone along which a vehicle moves the length the reader to Li et al. [2011] for illustrations of other types
of the zone; the dimension of the other edge the width. of layouts.)
The geometric and kinematic specifications of the AGVs
considered in this paper are listed in the table below. A small crossing is defined as a crossing which connects
two adjacent parallel roads (See Figure 3). A big crossing
Geometric and kinematic characteristics of AGVs is a crossing which connects more than two parallel roads
Length Width Max speed Max acc. Max dec. (see Figure 4). One advantage of small crossings is that
10m 4m 7m/s 0.5m2/s 2.5m2/s only a small number of AGVs need to wait at the crossing
Based on the above specifications of AGVs, we put the while some other vehicle is passing the crossing. The main
length of a zone 22m (slightly larger than the sum of the disadvantage of using small crossings is that an AGV has
length of a vehicle and the distance a vehicle takes to make to pass a relatively large number of crossings for a QC-
a full stop from the maximum speed) and the width 7m. YS or YS-QC task. On the other hand, the use of big
The basic rationale behind this choice is that, for safety crossings might increase the waiting time of the AGVs
reasons, the body of a vehicle must be completely inside at the crossings due to possibly more vehicles competing
a zone when the state of the vehicle is in the zone. See Li for the crossings; but in general, compared with using
et al. [2011] for more details. small crossings, it reduces significantly the distances of the
transportation tasks by providing direct channels linking
Layout design for the quay area and yard area For the QA and the YA. The latter point is illustrated in
simplicity, the road network has the same layout at each Figures 3 and 4 by two routes (in dashed lines) that serve
QC or YS, which is illustrated in Figure 2. The buffer of a the same purpose for a vehicle to cross the TA.
QC or YS is modeled by the SZs on three different lanes
In Figures 3 and 4, each crossing with an upward (resp.
in between two crossings. The 2 in-lanes of one of the two
downward) arrow, called a TA-YS (resp. TA-QC) crossing
crossings (left one in Figure 2) allow vehicles to drive off
is linked with the in-lanes and out-lanes of two adjacent
the TA and towards the QC or YS; while the 2 out-lanes
YSs (resp. one QC), i.e., it allows a vehicle to move to two
of the other crossing lead the vehicles back to the TA.
YSs (one QC) from the TA and vice versa by passing it.
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5. SIMULATION STUDIES with T ji the time (in second) for vehicle vi to complete its
jth task. (Recall that N is the number of vehicles; and Mi
In this section, via computer simulations, we investigate is the number of tasks for vehicle vi .)
the performance of the AGV systems with the designs and
controls presented in the preceding content. From an energy cost point of view, another performance
measure of interest is the “average travel distance” (ATD)
5.1 Task dispatching scheme whose definition mimics that of ATT with Tji replaced by
Dij , the travel distance for the jth task of vi .
Here we introduce a simple stochastic task dispatching
The last two performance measures, namely “average tar-
scheme that is used to drive the simulations. An in-depth
diness” (ATR) and “standard deviation of the tardiness”
discussion on this topic is beyond the scope of the paper.
(STDTR), indicate how much are the motions of the AGVs
See Steenken et al. [2004] and Stahlbock and Voß [2008b]
delayed by the traffic. The formula for computing the ATR
for recent progress in the research on this subject.
has the same form as (2) but with T ji substituted by
There are three types of tasks for each AGV:
(1) traveling from the depot to a zone of a QC or YS Dij = T ji − min time required to complete task j of vi
(first task only); Here the second term on the right hand side is the time
(2) traveling across the TA, i.e., from a zone of a QC to for vi to complete the task via the shortest route while
a zone of a YS or the other way around; assuming vi the only vehicle running in the workspace.
(3) traveling from a zone of a QC or YS to the depot (last
The STDTR is computed by
task only).
‚ ∑M i
For the tasks of the second type, the source and destination . ∑N (Di − ATR)2
.
stations are not arbitrarily chosen. Instead, according to ∑N
ST DT R = ,
i=1
a typical container transshipment scenario, the 20 QCs j=1 j . (3)
i=1 Mi
and 66 YSs are divided into 5 groups respectively. The
groups of the QCs are disjoint, each of which consists
of 4 QCs; while the groups of the YSs are overlapping 5.3 Simulation results
with each group containing 24 YSs. For each vehicle, the
source and destination zones for any task of the second We run simulations with N = 20, 30, · · ·, 120 and Mi = 50
type are randomly selected respectively from the zones of for any i ∈ZN 1. In order to obtain adequate precision of
the related QC and YS groups (see Figure 5). analysis, we repeat the simulations for each layout for 20
times, and take the average value for each performance
In addition, for the tasks of types (1) and (2), after a measure. Because of the page limit, we refer the reader to
vehicle arrives at the destination zone of each task, it will Li et al. [2011] for the numerical results.
stay stationary in the zone for 30 seconds for a container
loading or discharging process before being assigned a new We see from the simulation results that the layout with
task. four roads and big crossings remains the best choice for
this wide range of the size of the vehicle team. This can be
roughly explained as follows: As mentioned in Subsection
3.2, the use of small crossings may have less vehicles
waiting at the crossings in the TA (not much less since
simultaneous passings of a big crossing by two vehicles
are not necessarily conflict with each other). However, in
average, the travel distance of the vehicles in this case
is considerably larger than that in the case of using big
crossings. The use of six roads, compared with four roads,
renders more space (lanes, zones) for vehicles’ movement.
But this benefit is offset by increased travel distances and
Fig. 5. Task dispatching scheme number of vehicles competing for crossings.
In addition, we note that using the layout with four roads
5.2 Performance measures and big crossings gives moderate ATR and STDTR even
for a large team of operational vehicles, which implies that
Several performance measures are defined here in different in this case (1) the traffic congestion is not too bad; and
aspects of concern. The first measure is related to the (2) one can estimate for each task the arriving time of the
throughput of the terminal, called “average tasks per- vehicle performing the task with an acceptable error.
formed per hour” (ATP), which is defined as
3600 6. CONCLUSIONS AND DISCUSSIONS
ATP = , (1)
ATT In this paper, we give a solution to the design and
where ATT denotes the “average task time” calculated by control of the AGV system for an automated container
∑ N ∑ Mi j terminal. The popular zone control approach is used here
ATT = i=1 j=1 T i, (2) to ease the traffic management. Various road network
∑N
i=1 Mi
layouts are designed based on the practical dimension of
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18th IFAC World Congress (IFAC'11)
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a container terminal. A traffic control scheme as well as K. H. Kim and J. W. Bae. A dispatching method for auto-
a routing algorithm are developed. Computer simulations mated guided vehicles to minimize delays of container-
demonstrate the efficiency of our results in terms of some ship operations. International Journal of Management
defined performance measures. Science, 5:1–25, 1999.
K. H. Kim, S. M. Jeon, and K. R. Ryu. Deadlock
For an interesting comparison, we also did computer prevention for automated guided vehicles in automated
simulations with free ranging AGVs, where the collision container terminals. OR Spectrum, 28:659–679, 2006.
avoidance is realized by the so called potential field based M. Lehmann, M. Grunow, and H.-O Günther. Deadlock
approaches [Whitcomb et al., 1992]. We refer the reader handling for real-time control of agvs at automated
to the conclusion part of Li et al. [2011] for our findings. container terminals. OR Spectrum, 28:631–657, 2006.
There are several possible directions for further research. Q. Li, J. T. Udding, and A. Y. Pogromsky. Mod-
First, in our traffic control strategy, it is required that each eling and control of the AGV system in an au-
lane of the road network must contain at least two zones. tomated container terminal. In Proc. of the Asi-
To somehow weaken this restriction may be important for aMIC 2010, Phuket, Thailand, 2010. (available at
some applications where the workspace of the AGVs is http://yp.wtb.tue.nl/pdfs/12192.pdf).
very limited. In addition, one could think of a relaxation of Q. Li, A. C. Adriaansen, J. T. Udding, and A. Y. Pogrom-
the token-holding requirement in the traffic control scheme sky. Design and control of automated guided vehicle sys-
so that multiple vehicles can leave different at-crossing tems: A case study. Technical report, Mar. 2011. (avail-
zones simultaneously, and hence the performance of the able at http://yp.wtb.tue.nl/pdfs/12777.pdf).
AGV system can be improved. As far as we could tell, using V. D. Nguyen and K. H. Kim. A dispatching method for
local crossing tokens, instead of a global one required in automated lifting vehicles in automated port container
this work, and adding inter-crossing communications may terminals. Computers & Industrial Engineering, 56:
lead to a successful trial. 1002–1020, 2009.
L. M. Rajeeva, H. G. Wee, W. C. Ng, C. P. Teo, and
The designs of the layout of the road network and the N. S. Yang. Cyclic deadlock prediction and avoidance
routing algorithm are vital to the performance of the for zone-controlled agv system. International Journal of
AGV system. The designs presented in this paper are Production Economics, 83:309–324, 2003.
partially heuristic with the help of intuitions and practical S. A. Reveliotis. Conflict resolution in agv systems. IIE
experiences. Better results could be obtained by setting Transactions, 32:647–659, 2000.
up and solving formal optimization problems. Along this R. Stahlbock and S. Voß. Vehicle routing problems and
line of thinking, the balance between the optimality and container terminal operations - an update of research.
real-time applicability of the solutions become critical for In S. Raghavan B. Golden and E. Wasil, editors, The
practical applications. Vehicle Routing Problem - Latest Advances and New
In this work, the tasks of the AGVs are assigned in a Challenges, pages 551–589. Springer, Berlin, 2008a.
purely random manner. We predict a room for perfor- R. Stahlbock and S. Voß. Operations research at container
mance improvement in the future if a sophisticated task terminals: a literature update. OR Spectrum, 30:1–52,
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of operational AGVs with our current strategy. Such a of straddle carriers at a container terminal with the
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operation and operations research - a classification and
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Procedia Engineering 97 (2014) 2011 – 2021
Abstract
Development of automated guided vehicle plays a major role in engineering industries to improve the material handling
technique for recent years. In this paper, an automated guided vehicle (AGV) includes a material transfer system located on the
top and driving device at the bottom to move the vehicle as desired. The vehicle is a customised AGV in which it will do the
special material handling task and also used for custom applications. The vehicle works on its own once the program is feed into
the control device. The control device is common to both driving device and transfer device which are connected together. The
control device operates the vehicle and maintains the ultimate process of automated guided vehicle.
Proximity sensors are set up in the AGV’s pathway to detect the vehicle movement which directly controls the start and
stop process of AGV. Photo sensors are incorporated to detect the material or object in the station. A material transfer syst em
includes loading and unloading of material through set of specific device, in which the electrical connections are interconnected.
The control device receives signal from the transfer device once transferring gets completed and transmits signal to the
driving system to move the vehicle to the next destination point. In accordance with the flow path, the magnetic tape method is
best suited to this vehicle for best outcome. The best flow path is designed considering all aspects. It is a battery powered vehicle
in which it charges automatically. Inductive power transfermethods were implemented in the vehicle to enhance better
performance.
©©2014
2014TheTheAuthors. Published
Authors. by Elsevier
Published Ltd. ThisLtd.
by Elsevier is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the Organizing Committee of GCMM 2014.
Selection and peer-review under responsibility of the Organizing Committee of GCMM 2014
1877-7058 © 2014 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the Organizing Committee of GCMM 2014
doi:10.1016/j.proeng.2014.12.444
2012 V. Jaiganesh et al. / Procedia Engineering 97 (2014) 2011 – 2021
1. Introduction
The world is approaching for a new design, why not it should be applied for the material movement system.
To improve efficiency and reduce the cost of human operators in manufacturing as well assign logistics, the
corporate and organizations use the robots as an efficient tool in order to achieve the remarkable tasks. Automated
guided vehicle (AGV) is one typeof effeminatemobile vehicle designed primarily to move the material from one
place to another. AGV’s are commonly used in manufacturing plant, warehouses, distribution centers and terminals.
For navigation, AGV’s mostly use lane paths, signal paths or signal beacons. Various predominant sensors were also
using in the AGV’s; for example, optical sensor, laser sensor, magnetic sensor and camera. Modern AGV’s are free
ranging AGV’s in which their tracks are software programmed and especially they are customized one when new
stations and flows are added. The obstacles were also detected by the AGVand forthcoming danger in their path.
The prodigious automation tool in the industry for automation is Programmable Logic Controller (PLC).
To accomplish the desired functions Programmable digital computer (PLC) are used. PLC is user friendly and it will
not affect the environment at any cause which allows the processing of analog and digital signals from the sensors
so the present investigation use PLC [2]. In this proposal, an articulated robotic arm is mounted over the vehicle to
transfer the load from station to the AGV and from AGV to the station [3]. Since robots are the efficient equipment
for the use of movement of material which neglects the human operator.
The control device controls the vehicle movement and the speed of the vehicle up to a greater accuracy
through some set of specially convened equipment’s. The control device controls the entire vehicle up to a certain
distinct. The auxiliary components of the control device are PLC operated brushless DC motor, proximity sensor,
photo sensor and etc.
Brushed DC motors have been used in industry because of their linear characteristics and also due to their
ease of adjusting their speed through by means a simple power electronic circuit. The main drawback for such
system is the commutation used in brushed DC motors. However, these types of motors are able to operate at low
efficiency especially those which have low power ratings. TheBrushless DC motor (BLDCM) gives the solution for
the limitations in brushed AC motors and DC motors, with superior performance. The present investigation deals
with the PLC operated BLDCM for better performance [1] [7] [8].
Brushless DC motors can be divided into two types, Sinusoidal back-EMF (BEMF) and Trapezoidal
BEMF. The AGV always deals with the BLDC motor with a trapezoidal BEMF [1]. The constant torque in
BLDCMs’ BEMF is achieved by a trapezoidal wave form and also the stator winding which is fed to the circuit by a
rectangular current. The three phase windings are mounted on the stator while the rotor (with magnets) is free to
move. Two phases at any one time is always present to provide a continuous torque.
V. Jaiganesh et al. / Procedia Engineering 97 (2014) 2011 – 2021 2013
The complete scheme for a BLDCM is shown in Fig. 1 which illustrates the sequence followed to drive
such systems. As the concept is explained, the controller waits until the position sensor sends the signal. The
controller controls the windings based on the position of the rotor. If the system constructs a loop system, the motor
will continue running.[1].
It is mounted on the lower bottom of the vehicle and it works under by applying voltage to couple of LEDs which in
order emits infrared light passed to the object through the air and reflected back. When the object is nearby to the
vehicle, the light is very stronger which is used to sense and stop the vehicle. It includes the operation such as
detection, positioning and inspection. It avoids collision and it is also termed as distance sensors. On the other hand,
a couple of proximity sensors were incorporated in the stations to sense the presence of AGV in the station, which in
turn signals the vehicle to stop [10].
A Programmable Logic Controller (PLC) is an industrial computer control system that monitors the input
devices and makes resolution to control the output devices. PLC consists desperate circuits such as data transfer
circuit, fundamental programmable logic circuits, programmable wiring circuits, a decoder Circuit, and an input/
output circuit. The PLC microprocessor is substantially termed as industrial computer which as vast and spacious
application in developing industries. It performs automated tasks and resolving problem by itself without
intervention of humans according to the loaded programs which manipulate relay logic technology. To meet the
necessitate demands of hard industrial environments; PLCs are designed to be extremely robust, capable of
withstanding paramount temperatures, vibration, and noise. Due to the well said advantages the present proposal
uses PLC rather than the microcontroller which act as an effective tool for better performance [2].
2014 V. Jaiganesh et al. / Procedia Engineering 97 (2014) 2011 – 2021
2.4 Navigation
AGV‘s use tape for guide path. This sensor decides the path of AGV which guides the vehicle in a confined
direction. The magnetic tape method is used here where the vehicle follow the magnetic tape which is affixed or
adhered on the floor. This process can be done by magnetic guide sensor and motor controller. The magnetic sensor
detects the length and distance of magnetic tape and sends signal to motor controller. The motor controller steers the
vehicles according to the received signal which will maintain the vehicle in the centre of the magnetic tape in order
to avoid collision. One of the major advantages of this tape guidance method is that it can be easily removed and
relocated if the routing needs to change. The tape can also set the AGV to speed up, slow down or to stop. The dual
polarity is the trump card of these magnetic tape methods in AG carts. This helps in conflict-free routing and
scheduling of vehicles in flexible manufacturing system. In addition to that photo sensors are also used for better
accuracy and performance. For collision avoidance, the unexcelled sensor is vision based sensor [9].
The material transfer control system design consisted of the installation of the electronic components (the
PLC,a voltage regulator, a control pendent, a motor controller and a bride board circuit) [3].The entangled
programming was possible in the PLC for the automatic mode of operation. It was found that a Robotic Arm with a
simple mechanism can be manipulated in a different complicated way by using a PLC. A programmable logic
controller (PLC) is a type of digital computer that has an input and an output interface, controlled by a simulated
program designed in a computer and it is used for automation for electromechanical process, typically for industrial
use. In industry, PLCs are made to control the machinery of production lines. A PLC is designed for multiple input
and output arrangements and these inputs and outputs are logically programmed in different forms, such as a ladder
diagram, a structural text and a functional block diagram and stored in the PLC’s memory. PLCs are
reprogrammable and it can have monitors online to know the status of the operation. A PLC is best example for hard
real time system since output results must be produced in response to input conditions within a limited time,
otherwise an unintended operation will result.
3.1Robotic Arm
V. Jaiganesh et al. / Procedia Engineering 97 (2014) 2011 – 2021 2015
In the industrial world, automation is one of the most important elements for development. It helps to
reduce the need for humans and increase efficiency and productivity [5]. The field of automation occupies large
areas, mostly in industrial manufacturing and in addition to this; automation is applied to build a lot of sophisticated
equipment [6]. Among all of these outcomes, the Robotic Arm is one of them, which is widely used in industrial
purposes. A Robotic Arm can be compared to a human hand. It has a free rotating joint (rotation) and a translational
joint (displacement) for the movement of the arm. This arm movement is driven by an electric driver (motor).The
forthcoming sections cover the various parts of the Robotic Arm for its movement [3].
A motor controller is a device that serves to control in a predetermined manner of the performance of an
electric motor. A motor controller may also include an automatic or manual means for starting and stopping the
motor and also in the selection of the forward or reverse rotation, selection and regulation of the speed, regulation or
limitation of the torque, and also in protection against overloads and faults. For this application, the two base motors
axes have a large amount of load because of the heavy arm and to drive motor smoothly a motor controller is
needed. During starting and stopping, the motor controller helps to accelerate and decelerate the motor in a
predefined speed to avoid damage and inaccuracy. Also the reason is that, the PLC analog output interface current is
not sufficient to operate the motors. Depending upon the task, the motors are driven at defined speeds and directions
which can be easy controlled using the motor controller. A DC motor is an electric motor that runs on direct current
(DC). A DC motor is used for driving the axis of the robot. The axis of the arm needs a larger amount of torque than
the nominal torque which is supplied by the DC motor in its nominal speed. So, the torque of the motor is amplified
with the help of a gear system which is embedded in the DC motor. A potentiometer is a three terminal resistor with
a sliding contact that forms an adjustable voltage divider for measuring the electric potential (voltage). It is
commonly used in many electrical devices such as volume controls in audio equipment, position transducers, signal
adjustment etc. [3].
A simple method for the movement of a Robotic Arm can be monitored and controlled by using a
potentiometer. This system is built to control every joint movement manually. The shaft of a potentiometer is
attached to the shoulder or elbow joint or motor.As the joint rotates, it turns the shaft of the potentiometer which
changes the resistance; this change in resistance indicates the precise position of the joint.
2016 V. Jaiganesh et al. / Procedia Engineering 97 (2014) 2011 – 2021
In our conditions, the Robotic Arm has all the rotating joints so the present discussion uses the rotary
potentiometer for every joint. The rotary potentiometers have the limitation of angular freedom. Typically it has
about a 0°-280° rotation angle which is sufficient to move the Robotic Armin all directions.
A constant voltage is connected for each of the potentiometers and the position of the arm is given in an
Analog form, i.e. voltage. The analog value of voltage is converted to digital bits by the PLC and the calculation is
done on the basis of the digital values.
The axis of the Robotic Arm is driven by DC motors and each DC motor has a potentiometer attached to
the gear axis so that the potentiometer revolves as the motor rotates. The potentiometer gives a certain value of
voltage as a feedback which is used to detect the position of that particular motor. The analog input voltage is
converted to digital value and is saved as the position of the point. It is done for each point of the potentiometer. A
set of analog values from all the potentiometers is saved in the PLC as a digital number and this set of digital
numbers give the position and direction of the arm.
The saved digital number is now converted to an analog output voltage which is connected to a comparator.
The comparator compares the input voltage from the potentiometer and the output voltage from the PLC to control
the motor and the motor is stopped only when both voltages are the same. With the help of the comparator, the
motor is driven to the position where it should be. Depending upon the task, the Robotic Arm is then programmed to
move to every position in sequence and performs the gripping and releasing task [3].
This section includes the design and construction phase of the gripper. As compare to real design process in
a real working life, this gripper design also includes all the essentials aspects of a product development. The
following picture shows the mechanical gripper for a robotic arm. This mechanical grippers use the linear actuator
which can be easily controlled by the DC motor. The main aim to use the DC motor in gripper is to make all the
functions controlled by electrically. Using extra pneumatic or hydraulic system for gripper adds more complication
and expenses and unwanted needs as well as makes the vehicle more complex.
V. Jaiganesh et al. / Procedia Engineering 97 (2014) 2011 – 2021 2017
TheFig.6 shows the closing position of the gripper. The gripping action is flexible for any size of object due
2018 V. Jaiganesh et al. / Procedia Engineering 97 (2014) 2011 – 2021
to the parallel movement of the hands. The working mechanism of the gripper is based on the formation of
parallelogram by four joints. The gripping action takes place due to the sliding of threaded bolt in a linear actuator
which changes the orientation of the parallelogram.The Fig.7 shows the Opening action of the gripper. Another
options for the gripper is magnetic gripper. The magnetic gripper can be bought from the market and, simply
assemble to the arm which save the time and the cost. But the lack of time and availability of the resources makes
the construction of gripper to be terminated. It is not recommended to use any kinds of gripper in this arm [3].
Fig.8 shows the components of the PLC and functional parts for the movement of Robotic Arm. output
voltage for driving the motor depends upon the two potentiometers voltage value: the driving potentiometer and the
axis potentiometer. Two potentiometers are integrated into the feedback amplifier circuit. The driving potentiometer
voltage works like an input voltage and it can be set by the user whereas the axis potentiometer works like feedback
voltage, altering the output. The axis potentiometer voltage depends upon the position of the axis and its changes
due to the rotation of the axis. When the input voltage and feedback voltage are in the same phase, then the output
becomes positive and it drives the motors in a positive direction until the input voltage(driving potentiometer) and
the feedback voltage (axis potentiometer) have the same voltage value. When the input voltage and feedback voltage
are in the inverse phase, then the output becomes negative and it drives the motors in a negative direction until these
voltages are the same. In every case, the direction of the motor is set in such a way that it rotates to change the
voltage of the axis potentiometer the same as the driving potentiometer voltage and then the
Fig.8 shows the components of the PLC to control the Robotic Arm
V. Jaiganesh et al. / Procedia Engineering 97 (2014) 2011 – 2021 2019
4. Construction of AGV
In the fig. 9, The PLC operated BLDCM is positioned on the rear end of the vehicle to move the vehicle as
desired. A PLC panel board is sited behind the front axle of the vehicle. The battery of the vehicle is situated behind
the PLC panel board for easy connections. A robotic arm s mounted on the top of the vehicle and the PLC
components for robotic arm is placed in the panel board. The BLDCM and Robotic Arm were interconnected with
the PLC panel. The photo sensor is placed on the upper front of the vehicle and a proximity sensor is placed on the
lower front of the vehicle which is interconnected to the PLC panel board. A provision is provided on the top of the
vehicle for the accommodation of materials to be transferred.
The AGV receives signal from the common network so that it starts from the chambers and reach the
destination point, the AGV will be stopped by the couple of proximity sensor which is placed before each and every
stations. Once the AGV reached the station, the sensor will read whether the material is available or not if so it is
observed then the robotic arm will turn around right angle and move a little forward to pick the material and comes
back to its original position after placing the material in its right place provided a provision in the vehicle. The
output signal of the robotic arm will send a signal to the PLC which generates a pulse to move the vehicle through
brushless DC motor so that it will reach the next destination point and the process continues until it receives signal
from the network.
The charging process is done by a constant interaction between the track supply and the onboard battery
management system. The track supply only provides the required power. The Inductive Power Transfer primarily
consists of primary parts which is coupled with track supply and secondary part which is coupled with rectifiers in
the vehicle. Both the parts are magnetically and slackly coupled with an air gap. When the guided vehicle is in the off-
charging position, the primary coil is de-energized by the track supply. The minimum boarded storage energy is
adequate to move the vehicle to adjacent station. There is no need of cables and plugs and it is safer and reliable
operation [4].
7. Conclusion
It is clear that the design of this proposal is very modern and advanced, achieved through the help of PLC.
The salient feature of this proposal is that the vehicle suppresses a Robotic arm on the top for easy transaction of
material. It is expected that this investigation will give higher efficiency than the existing vehicles. The cost saving
is another privilege of this proposal wherein the existing AGV’s need a separate material transfer system for the
transaction of material. Though each and every component in the vehicle is operated with the help of PLC, therefore
PLC plays a paramount role in this proposal. BLDCM, Robotic arm are the crucial parts in the vehicle which gives
accurate movements due to the influence of PLC, which will further increases the efficiency of the entire vehicle.
The inductive battery system implemented in the vehicle gives an additional benefit to the vehicle, which acts as a
battery frees AGV. Therefore the entire set up will be procured with the enlightenment of PLC.
References
[1]M. Tawadros, J. Rizk, and M. Nagrial “Brushless DC motor control using PLC” University of Western Sydney (Australia)
[2]Avvaru Ravi Kiran, B.VenkatSundeep, Ch. SreeVardhan, Neel Mathews, “The Principle of Programmable Logic Controller
And its role in Automation” International Journal of Engineering Trends and Technology- Volume4Issue3- 2013
[3] BhimBahadur Lama “Controlling a Robotic Arm manipulator with a PLC” HAMK university of applied science.
[4] Grant A. Covic, Senior Member IEEE, and John T. Boys, Inductive Power Transfer, Proceedings of the IEEE | Vol. 101, No. 6, June 2013
[5]V.Srinivasan, MichealBalraj, “Design and analysis of an articulated robot arm”, Proceedings of the “National Conference on Emerging Trends
in Mechanical Engineering 2k13”
[6]S.Pachaiyappan , M.MichealBalraj, T.Sridhar, design and analysis of an articulated robot arm for various industrial applications, iosr Journal
of Mechanical and Civil Engineering (IOSR-JMCE) e- ISSN: 2278-1684, p-ISSN : 2320–334X PP 42-53
[7] parvizAmiri, MahsaBagheri, “Speed Control of DC Motor by Programmable Logic Control with High Accuracy”Universal Journal of Control
and Automation 1(4): 91-97, 2013 http://www.hrpub.org DOI: 10.13189/ujca.2013.010401
[8] MohdShakir& Abraham T Mathew, “Programmable Logic Control Based Simultaneous Speed Control for Brushless DC Motor & Linear
Induction Motor”, National Institute of Technology Calicut, Kozhikode, India
[9] Zahari Taha1, and JessnorArif Mat Jizat, “A Comparison of Two Approaches for Collision Avoidance of an Automated Guided Vehicle Using
Monocular Vision”, Applied Mechanics and Materials Vol. 145 (2012) pp 547-551Online available since 2011/Dec/08 at www.scientific.net©
(2012) Trans Tech Publications, Switzerlanddoi:10.4028/www.scientific.net/AMM.145.547
[10] Goeger. D, Blankertz. M and Woern. H, “A tactile Proximity sensor” Institute for process control, Autom& Robot, Karlsruhe Inst. Of
technol., Karlsruhe, Germany
Procedia Manufacturing
Volume 5, 2016, Pages 1092–1106
Abstract
Customized mobile robots are commonplace in manufacturing and material handling applications. One
class of mobile robots, known as Automatic Guided Vehicles (AGV), follow a fixed path along the floor
using tracks, RFID tags, or magnetic tape. These robots typically travel along predetermined routes and
offer limited flexibility for changes to be made or for their use in environments like hospitals or military
installations. Moving away from traditional fixed AGV systems to wireless and dynamic control and
monitoring presents some distinct advantages and new opportunities. This type of robot is known as an
Autonomous AGV. A prototype smart materials warehouse is presented in this paper as a platform to
explore some particular aspects of this technology. First, four multi-purpose mobile robots were built
using off-the-shelf BattleBot kits, wireless Arduino controls, and fabricated components. Secondly, a
Microsoft Kinect camera was installed on one robot for visual feedback, obstacle avoidance, and shape
recognition. Lastly, a ceiling mounted IP camera was used with software developed using Visual Studio
.NET and the C# wrapper for OpenCV (EmguCV) to facilitate robot path development, video processing
and real-time tracking. Testing of the completed system was done in a 2000 sq. ft. mock warehouse set
up with stations for shipping/receiving, storage, staging areas, and processes including cutting, milling,
and turning for preparing raw stock to be used in production. As cyber-physical systems research
continues to grow, the integration of computational algorithms, physical systems, wireless controls, and
custom user interfaces will undoubtedly lead to their increased use throughout society. This work was
completed as part of the Northwest Manufacturing Initiative at the Oregon Institute of Technology.
Possibilities for applying the results of this work in the military, retail and service sectors are also
identified. All hardware and software for the project was developed to facilitate future work.
Keywords: cyber-physical systems, vision, smart automation, open source, Automated Guided Vehicle (AGV)
*
Professor, Manufacturing and Mechanical Engineering and Technology (MMET), PI on ARL 2010-2012 project, Author.
†
Professor, Computer Software Engineering Technology (CSET), Software architecture/programming advisor.
1092 Selection and peer-review under responsibility of the Scientific Programme Committee of NAMRI/SME
§
c The Authors. Published by Elsevier B.V.
doi:10.1016/j.promfg.2016.08.080
A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
Open Source Vision Technology Developed using EmguCV David Culler and James Long
1 Introduction
Product and material handling and transportation systems have been used in manufacturing
companies for many years. The level of automation utilized in industry has continued to grow over time
as robotic, electronic, and computer technologies have improved in terms of functionality, ease of use,
integration with other devices, and affordability. With this progress, the level of complexity and inter-
activity between all types of systems has increased dramatically. International interest in innovating and
sharing advances with these systems is being driven by the need to collaborate on projects and increase
global competitiveness. Since mechanical, physical, electrical, and software components cannot be
isolated and do not function independently, the term Cyber-Physical Systems (CPS) has been coined to
guide present and future work. Some definitions for CPS were taken from a recent international
conference and are presented here to provide a foundation and perspective for the work in this paper
(Isaksson & Drath, 2016).
• A system of collaborating computational elements controlling physical entities
• Interconnection between a physical and a virtual world (models)
• Ability for autonomous behavior, self-control, self-optimization
• Different system borders: CPS including or excluding of a physical world
Examples of CPS in manufacturing are being used to modernize and add flexibility to production
systems and integrate them in control networks that span departments and multi-site engineering or
distribution facilities. As mass customization and agility in production line changeovers become a higher
priority, the ability to deliver materials, tooling and supplies must also be considered. The use of multi-
function mobile robots for this purpose is a viable alternative. An Automated Guided Vehicle System
(AGVS) enables flexible material routing and dispatching, and is especially suited for flexible
manufacturing environments in which product mix and priorities may continuously vary (Reveliotis,
2000). Their movement is directed by a combination of software and sensor-based guidance systems.
As this technology continues to expand, many areas outside of manufacturing will benefit from
innovations in the following areas: 1) mobile and autonomous robots, 2) open source software, 3) vision
systems, and 4) wireless communications. Some of the applications to think about are medicine
distribution in hospitals, replenishing products in retail settings, military field operations, and
supplies/tool deployment in large construction projects. Mechanical, manufacturing, industrial,
electrical, and computer engineers must collaborate to develop versatile systems for the future.
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
Open Source Vision Technology Developed using EmguCV David Culler and James Long
suggested a simple characterization that mentions important characteristics of multi-robot systems and
fits with the description of the warehouse system used in this project (Cao, Fukunaga, & Kahng, 1997).
1) Architecture, Centralized or Decentralized.
2) Differentiation of agents, Homogeneous (similar control systems), Heterogeneous (different).
3) Communication structure, Via the environment, Via sensing, Via communication (intentional)
4) Models of other agents, Intentions, Capabilities, States, Beliefs.
Some previous work was used as a foundation for the project described in this paper such as the
utilization of multi-use, multi-robot AGVs that are controlled under a centralized, homogeneous, direct
signaling and that possess specific capabilities to perform jobs within a warehouse setting (forklift,
platform, light/heavy workload). The addition of the ceiling mounted cameras along with the multi-
capability software to build paths, track the robots and make adjustments based on feedback through the
video processing makes the work presented here different and innovative.
The approach to developing the smart materials warehouse also demonstrates the multi-disciplinary
contributions to the project. Manufacturing, mechanical, and computer engineers initially worked
independently on robot construction and control systems development for mobile robots, computer
software applications, user interfaces, and vision technologies of various types. The subsystem approach
was borrowed from previous work in AGVS evaluation methods. The authors stated that “each sub-
module was thoroughly evaluated in a stand-alone mode. Due to the inherent properties of each sub-
module, system management was evaluated only in simulation, navigation was evaluated both in
simulation and in hardware. The AGVs are equipped with wireless Ethernet communication devices and
communicate with the workstations via the factory intranet (Berman, Schechtman, & Edan, 2008).
Engineering faculty and students from the Oregon Institute of Technology combined off the shelf
items, existing technology, and developed hardware/software to design and implement a prototype smart
materials warehouse where robots were utilized to deliver materials to a series of stations. Real time
tracking was implemented using a ceiling mounted IP camera and a software application built in C-
Sharp (C#) using the .Net wrapper for OpenCV called EmguCV. Initial path development and live
processing of video for locating and monitoring multiple robots working on the warehouse floor was
implemented. Special capabilities like RFID readers, sonar, and
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
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Once the robots were tested, they were ready to be used in a warehouse setting. Computer Software
Engineering Technology (CSET) students and faculty developed a vision system that utilized an “Eye
in the Sky” 3S IP camera and software developed using Visual Studio and EmguCV (the C# version of
OPENCV) to detect the presence of robots in a manufacturing materials warehouse, track their
movement, and identify pathways and obstacles on the floor. As a simulated working scenario for this
research project, the small
robots must transport
materials to be stored,
moved, cut to size,
processed and delivered to
students that are
completing course projects
in the machine shop using
lathes, mills, drill presses,
and grinders. Figure 2
shows the layout and
distribution of equipment
for the mock warehouse
used for the project. Figure 2: Layout for Smart Materials Warehouse
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
Open Source Vision Technology Developed using EmguCV David Culler and James Long
periodically broadcasts a message on a wireless channel. In a passive mobile architecture, fixed nodes
at known positions periodically transmit their location (or identity) on a wireless channel, and passive
receivers on mobile devices listen to each beacon.” (Smith, Balakrishnan, Goraczko, & Priyantha, 2004)
By using wireless signals sent by the robots in this work, and using visual tracking by colors placed on
each robot, there is some additional feedback to the system that can be helpful as well as visual for
tracking and path re-generation that is being studied in the project presented here. Some successful
systems for tracking robots and humans in well-structured environments using cameras have been
presented. For example, a mobile robotic system for tracking and following moving people was
developed using a combination of cameras and lasers to overcome the shortcomings of camera-only
systems that are limited to slow moving objects and environments without many obstacles. Such a
system provides important capabilities for human robot interaction and assistance of humans in various
settings. Tracking with mobile robots has been an active research area with many systems developed,
such as for museum, hospital assistance, or pedestrian tracking. (Kobilarov & Sukhatme, 2006)
Projects have been done which resemble the project presented in this paper. In one research project
a prototype was designed in which a solution will be developed to track assets inside a warehouse using
two cameras on a rooftop, products with RFID tags, and a forklift with Wi-Fi to transfer data in real
time. An Omron F-150 camera was used in a very small workspace (0.5M by 2.5M), with the camera
only 3M from the floor (Aryal, 2012). The project did produce some good images but was not able to
track positions or produce routing/re-routing capabilities. Another project used mobile robots with
cameras mounted to them to recognize colors on the floor so as to stay in specific work-zones. For this
EMGU CV (the .NET wrapper for Visual Studio) was used. Each robot periodically takes a snapshot of
the floor in front of it and then perform color processing to check whether it is capable of continuing on
the floor/terrain. Each robot has its own role and will be aware of which terrain it cannot cross; the floor
will be divided into different colored regions each representing a difficulty level. This provided some
background for the work completed in this project (Saunders, Sterritt, & Wilkie, 2016). Another
approach has been to explore mounting robots with cameras on the ceiling so a wide area of coverage
is achieved and these systems can be connected computer systems. (Sentry, 2016)
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
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relays to control the polarity across the motor leads. The relays are controlled by the primary Arduino
using the commands “LU” and “LD” to move the forklift up and down (for a number of seconds).
The frame and drive train were built slightly different for the robots. All of the robots are using 4
inch (in.) diameter drive wheels. SmallBot and ProtoBot are both two wheel drive with a caster for
support in the back. ProtoBot
uses hard plastic wheels that
are directly connected to the
output shafts on the motor. The
wheels are attached using a set
screw. SmallBot uses rubber
wheels that are connected to
the motors through a gear and
chain transmission. This
transmission is identical to
what is used for the battle bot
chassis except that the battle
bot chassis has four motors and
the front and back motors on
each side are connected by an
additional chain. Figure 6
shows the completed platform
and Figure 7 the Graphical
User Interface developed for
the LiftBot configuration. Figure 6: Mounting of Components on BattleBot Chassis
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
Open Source Vision Technology Developed using EmguCV David Culler and James Long
Many of the principles and concepts used for the mobile robots are very different from what would
be used for a robot with a fixed base. Because the robot can only move on the floor, the robots location
only needs to be determined in terms of X and Y position. The existing robots could also be interfaced
with other robots such as
articulated arms. In this way
they could be used as part of a
fully automated manufacturing
demonstration. Some additional
capabilities could be built on to
these robots to allow them
greater mobility. More
functionality could be added to
the Arduino to allow for
multiple commands to be
received in one transmission.
The robot would then be able to
execute the commands one at a
time. Communication routines
could also be added to allow for
control of multiple robots
simultaneously. Figure 7: User Interface Created for Robot Operation
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
Open Source Vision Technology Developed using EmguCV David Culler and James Long
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
Open Source Vision Technology Developed using EmguCV David Culler and James Long
Although all of the functionality listed in the following section was not implemented, most of the
capability was realized during the testing and demonstration phases of the project. The system was
implemented using the robots described in section 3.1 along with the following software tools: programs
in C#, OpenCV libraries to process live footage from the cameras (EMGU is a C# wrapper used with
OpenCV), runs on Windows 7 Operating System, utilizes the Arduino board to relay signals between
the system and robot. The physical system, physical component and functional architecture diagrams of
the prototype warehouse are presented in Figures 8, 9 & 10 respectively.
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
Open Source Vision Technology Developed using EmguCV David Culler and James Long
The goal of the project was to combine the work from the standard mobile robot design (3 robots) with
a single mobile robot that could detect obstacles using a front mounted MS Kinect camera, and then use
the ceiling mounted camera with the centralized computer. These components were used to run a sample
scenario where an order for parts comes in and a robot is deployed to the warehouse floor using a
specified path to take the parts from the receiving area to each one of the processing stations and then
to the finished parts area. A 3S 5MP Box camera was used for the application with a wide angle lens to
cover the 50’ X 40’ area used for the materials warehouse. The camera was mounted on the truss nearly
20’ above the floor. See the picture and data sheet information presented in Figure 11 below.
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
Open Source Vision Technology Developed using EmguCV David Culler and James Long
when a dynamic obstacle is encountered, set the time that the robot remains at the destination, stop the
robot at any time, queue up paths from the selected layout, or load up a stored path. User interaction can
be depicted in many ways for most software applications. In this case, the user interactions are limited
to how the user can manipulate the system. The user, first, will have to log-into the system so they can
have access to all the functionality of the “Eye in the Sky” system. The user can define both loading and
destination points for the robot to follow. The user can define paths manually via the included path
creator if necessary. The user can control the robot via robot control system if they need to halt a robot,
or need to move it. Through the Path Creator, users create paths based on a picture of the live footage
from the ceiling mounted camera. With this path creator, users can draw paths for the robot to travel on.
The user can draw connecting 90 degree lines based on a frame of the image from the camera. When
the user draws the first line, it will have nodes that can be named and the start/end nodes can be set once
each line is created. Nodes where the robot will stop on the way to the destination can be selected. The
results are then stored to the database, where they can then be edited or reloaded at a later time.
Figure 12 below is a picture of the mock warehouse that was used for the use case stories below.
The picture to the right depicts the image from the overhead camera as it appears in the user interface
(Figure 13) including robot docking stations, where the robots are parked here when they are not being
actively used by the system. The receiving dock station is where materials are received and placed for
Figure 12: Mock Warehouse Figure 13: User Interface with Video Feed
the robots. The storage is where all materials are inventoried until they are to be used. The processing
area is a general section where the robots will transport the raw materials to be pre-cut. The staging
stations are areas where the robots take processed materials to be inspected by engineering staffs.
This use case survey will describe a normal session on a manufacturing floor, where materials from
the loading docks are then stored, processed, prepared, or moved to be specific areas. This following
story describes a manufacturing engineer, the shop supervisor, receiving some packaged materials that
need to be processed and then transported to the staging areas. The shop supervisor receives a message
from his superiors that the company has received material. They want him to process the incoming
materials at the saw machine, where it is handled by on-site manufacturing engineers. After being
processed by the engineers, the shop supervisor will then need to move the processed materials to the
staging area where they are inspected by the inspection team before further use. With that in mind, the
shop supervisor opens the Eye in the Sky application, logs into the application, and then checks to see
which of the docked robots are inactive. The robot is commanded to move from the docking station to
the materials docking station. The robot will then proceed to move the materials from the docking station
to the processing station where engineers can take over. After the materials have been processed, the
shop supervisor commands the robot to move the materials from the processing area to the staging
stations, where it is loaded onto the stage and inspected. When completed, the robot returns to the
docking station and waits for further commands.
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
Open Source Vision Technology Developed using EmguCV David Culler and James Long
The Path Determination user case survey describes a scenario where the system will generate paths
for the robot to follow. If the user finds the determined paths satisfactory, then the user can select that
path, or the user can draw paths on the image so the robot can follow the paths that the user has drawn
out. The shop supervisor receives an order from his superiors that requires him to move materials across
the manufacturing floor. After the shop supervisor has received materials from the docking station, he
then sets the station coordinate points and tasks that the robot needs to complete. The system then
automatically generates paths for the robot to follow. After the system has calculated the paths, it will
then display the paths for the shop supervisor to decide. The shop supervisor doesn’t like any of the
paths that the system has created, so he decided to draw out the paths on the program. After drawing out
the paths for the robot to follow, he starts the task up, and the robots now follow the new path that the
shop supervisor has drawn out.
The Obstacles Handling user story will describe a scenario where the robot encounters an obstacle
in its path as it is on its way to deliver the raw materials to the destination. The system will utilize the
cameras mounted on the ceiling to see if any obstacles have moved from the start of the process. If the
system detects a new obstacle, it will either re-route the robot to a new path, or halt and contact the user
for an advisory action. In the case of the advisory
action, the system will then contact the user that
the system is unable to re-route the robot, and
requires an advisory action to proceed. The shop
supervisor notices from the cameras that one of
the engineers is blocking the robot’s path. The
robot will stop, and the system will display a
warning to the program. The shop supervisor
notices this warning and recognizes the engineer
who is blocking the robot’s path. The shop
supervisor will then call the engineer and tell him
to move out of the robot’s path. Once the engineer
has moved, the system will detect that there are
no more obstacles that are encountered in the
path. The system will then command the robot to
proceed to drop off the raw materials to the
robot’s destination. The shop supervisor can
resume doing his own work as the robot navigates
the floor unhindered. Sample code developed in
EmguCV is shown here in Figure 14. Figure 14: Open Source Eye in the Sky Code
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A Prototype Smart Materials Warehouse Application Implemented using Custom Mobile Robots and
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The equipment and software that has been developed for this project could be utilized for many
future projects. The vision systems could be refined to the level that the robots could be guided to
specific storage locations and retrieve and store materials. The information from the sonar units could
be utilized for more accurate robot positioning when the robot is in close proximity to objects of known
location. Other items that could be used as next steps in this project include improve image detection,
add complexity to how the robot is tracked, add to the types of obstacles that can be detected, allow for
higher resolutions, multiple robots running simultaneously, incorporate multiple cameras.
The existing robots could also be interfaced with other robots such as articulated arms. In this way
they could be used as part of a completely automated manufacturing demonstration. Additional
capabilities could be added to these robots to allow them greater mobility. More functionality could be
added to the Arduino to allow for multiple commands to be received in one transmission. The robot
could then execute the commands one at a time. Additional communication routines could be used to
allow for control of multiple robots simultaneously.
These types of systems could eventually be used for military applications such as search and rescue,
warehouse management, munitions management, arming and disarming of military vehicles, and in
medical facilities for deliveries. Many of these tasks are simple enough that the robot could handle the
entire task, and some task could be assisted by robot for improved safety and reduced cost.
5 Acknowledgements
The students of Manufacturing and Mechanical Engineering and Technology and the students of
Computer Software Engineering Technology at the Oregon Institute of Technology were key
contributors to the material presented in this paper. Also thanks to the work of John Anderson who
began this work in 2008-2009 before retiring in 2012. Graduate students Noah Anderson, Matthew
Floyd and HoeJin Kim were instrumental in keeping this project moving forward.
References
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1106
Available online at www.sciencedirect.com
ScienceDirect
Procedia Engineering 192 (2017) 665 – 670
TRANSCOM 2017: International scientific conference on sustainable, modern and safe transport
Abstract
The article deals with the use of automated guided vehicle (AGV) system in the hospital. This paper provides the requirements and
technical specifications of AGV cart designed for healthcare facility. The second part describes the application and benefits of
AGV implementation in selected health care facility gained from computer simulation that is used as a verification tool. This part
also contains the economic evaluation of this implementation and summary of further investments related to this technology.
© 2017The
© 2017 TheAuthors.
Authors. Published
Published by Elsevier
by Elsevier Ltd. is an open access article under the CC BY-NC-ND license
Ltd. This
Peer-review under responsibility ofthe scientific committee of TRANSCOM 2017: International scientific conference on
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review
sustainable,under responsibility
modern of the scientific committee of TRANSCOM 2017: International scientific conference on sustainable,
and safe transport.
modern and safe transport
Keywords: AGV; healthcare; improvement; simulation; efficiency
Automatic Guided Vehicles (AGV) or self-guided vehicles (SGV), have been widely used in material handling for
decades [1]. In these days, the demand for mobile robots and their use in hospitals has increased due to changes in
demographic trends and medical cost control. For healthcare facilities, these automated systems are designed
specifically for handling bulk material, pharmacy medicines, laboratories samples, central supply and transportation
of food, dirty dishes, bed laundry, waste (biological, recyclable), biomedical instruments etc. Operating efficiency is
gained by automating these supplies, which allows the transfer of human resources to other departments or activities.
1877-7058 © 2017 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of TRANSCOM 2017: International scientific conference on sustainable, modern and safe transport
doi:10.1016/j.proeng.2017.06.115
666 Marko Pedan et al. / Procedia Engineering 192 (2017) 665 – 670
Automated systems are working 24 hours a day, 7 days a week. Automated solution can streamline traffic flow of
material in the hospital, control costs, reduce workload. Hospital operating installation have to fulfill some important
requirements, see Fig. 1. These requirements and the use of modern logistics systems significantly affects the operation
of the entire facility and its economy, improves the quality of patient care and increases their safety. [2]
Fig. 1. The requirements for AGV integration in healthcare facility (Source: author).
The use of automated transport system (AGV) relieves hospital staff and allows them to spend most of their time
on direct patient care. This increases safety in the hospital by minimizing potential injury to the staff when pushing
heavy carts. The system monitors all major movements in the hospital and may prefer the most important jobs and
tasks that can be completed first (e.g. surgical instruments transported first, then food for patients, bedding, eventually
garbage, etc.) [3]. AGV is equipped with sensors to detect obstacles that allow safe stop before hitting obstacles that
might be in the way. The system and its vehicles is reliable, safe, efficient and cost-effective [4]. Applications and
commands are mediated through a user-friendly touch screen. The system is fully integrated for automatic control of
doors, elevators, trolley washers, garbage dump truck, etc.
Fig. 2. Low profile Automated Guided Vehicle for healthcare facilities (Source: our research).
This designed 3D model of vehicle, see Fig. 2., has technical specifications specified in Table 1, and we will use it
in the simulation model, which verifies its potential implementation in the hospital [5].
Marko Pedan et al. / Procedia Engineering 192 (2017) 665 – 670 667
The transport principle will be carried out in such a way that the medical supplies will be transported by special
transport boxes that AGV cart undercuts and then lifts up. Fig. 3. describes the principle of object transportation using
designed AGV cart. Fig. 3. also shows the key dimensions of the vehicle and transported objects which are necessary
to be observed when transporting boxes.
Fig. 3. The minimum dimensions of the transport box and the distance between the vehicle and transport box (Source: our research).
In selected healthcare facility we designed AGV integration in the following areas [6]:
Food transportation to the patient rooms. This process represents the provision of food transportation from the
food arrival, which provides the external company, to the food transportation provided by AGV's to the kitchen,
then sorting the meals for patients by healthcare staff and distributing the meals by AGV's to the patient rooms.
The rooms have designed areas for precise stopping and unloading food from AGV's.
Collection and transportation of used and clean laundry. Healthcare facility has their external company,
which carries away and washes the dirty laundry and delivers the clean one back. The facility can use AGV's for
the internal transport service. Transportation would consist of loading the laundry box and transporting it to the
desired location (central storage). Transportation through the floors will be carried by freight elevator.
Waste transportation. Waste will be transported from a well-marked spaces and areas from the whole ward.
The waste will be collected on these places in special boxes. The AGV's will then take and move the waste to the
temporary storage of waste to the base floor.
668 Marko Pedan et al. / Procedia Engineering 192 (2017) 665 – 670
We used simulation software for verification of our suggested implementations of AGV's in inpatient ward. For
this purpose, we used software Simio in which we have imported the real objects and the physical disposition of
healthcare facility. Fig. 4. shows the transportation process of food in the ward in digital environment [5,6]. AGV's in
this simulation software follows the inpatient ward streams that we have mapped and analyzed (i.e. the movement of
medical staff and medical material). Transport between the floors will be carried by freight elevator, see Fig. 4a. AGV's
will then transport the food to a designated locations in patient rooms [7], see Fig. 4b.
Fig. 4. (a) food transportation to the inpatient ward by freight elevator; food unloading in patient room (Source: our research).
Simulation in healthcare can be considered as an effective tool, technique or method [8]. Healthcare personnel
especially decision makers - directors and managers - need reliable operational tool that supports them in decision-
making process. Such techniques and tools help them in reductions of costs, waiting time of patients, future predictions
of patients arrivals and provide them with visualization that enables them to prepare staff and all resources that are
necessary for provision of high-quality healthcare service to the patients at the right time [9]. These tools should also
facilitate the decision making evidence and informative environment. Simulation models, especially those with
transparent structure to their core variables that can be easily understood and trusted by people with decision-making
competence, are a useful tool to support decision-making, communication, discussion, ideas, policies, scenario
analysis, from which they can gain knowledge and from which they can learn [10]. That was also our case, since we
needed to create a simulation model of a real healthcare facility that will help the management to decide whether to
implement the AGV system or not. After many interviews with the hospital leaders we have created several model
variants. Whereas the creation and process of a simulation study is very extensive, in the next chapter, we bring and
summarize the most important outcomes and results that were the key ones for healthcare managers [7].
3.3. The benefits from AGV integration gained from simulation runs
With the AGV integration we were able to save 345 minutes of total 1440 minutes (representing 23.96 %) for
medical assistant (MA) per day, see Table 2. This can result in the transfer or movement of medical assistants to
activities and tasks that our legislation allows them [5,6], so they can spend more time with patients. Furthermore, we
were able to relieve the cleaning and transporting services of heavy and dangerous waste by AGV system integration.
Among other things, the AGV can be also used for transportation of medicines and medical supplies with low
requirements on safety or hygiene. This integration will bring benefits associated with the reduction of damage,
unreasonable and incorrect shipments, and physically heavy transport. Another advantage is that the vehicle can
operate 24 hours a day while meeting the requirements of charge.
Marko Pedan et al. / Procedia Engineering 192 (2017) 665 – 670 669
The final chapter brings the economic evaluation of AGV integration in selected healthcare facility. In Table 3 we
can see the investment intensity of the project. It must be said that the costs are calculated according to initial analysis
only approximately, so for precise determination of the exact amount of the costs of such a project there will be needed
additional analyzes [6]. These analyzes have not been carried out, due to the short duration of the project and other
requirements from healthcare facility.
To calculate the hourly costs for running an AGV's we used input costs, which are around € 115,700. From these
calculated costs we expressed our monthly operating costs of 4 % (specified by the AGV manufacturer) [6],
representing a value of € 4,628/month. From this value we expressed the operating costs necessary for one day
provision (€ 154.27/day). In the last stage of the calculation, we found out the hourly cost of running the AGV at
around € 6.43/hour. These values were then compared to the hourly cost of medical assistant in inpatient ward (€ 3.5)
from which we can see that operating costs of AGV are almost 2 times higher, see Table 4. And although this is a
rough calculation of operating costs, it gives an approximate idea to the managers of healthcare facilities whether it is
good to think about the implementation of this technology.
4. Conclusion
Case study, which we have tried to introduce to you in this article was carried out at the request of the director of
healthcare facility in order to identify the potential implementation of AGV system in the hospital. In the case study,
we designed AGV cart and transport methods for inpatient ward of healthcare facility. This way of transport we
subsequently created in a 3D environment where we have simulated and verified the movement of AGV in terms of
the physical layout of the building and material flows in the ward. The final economic assessment then pointed out
that the AGV technology is currently not cheap and is affordable only for bigger facilities managing in profit. Proper
and effective implementation for a given type of healthcare facility depends on many factors and requires a detailed
assessment and analysis [11]. The world's top hospitals, have already adopted this technology and therefore they are
reducing operating costs and increasing the quality of their healthcare services, which lead them to rapid cost recovery.
However, from our view, Slovakia and its healthcare facilities are not ready to integrate this technology now. The
healthcare system is in a position in which he could not benefit from the advantages of AGV systems in a way that
the world does [12]. AGV is also a technology, which potential is high but its specific application must be analyzed
through several methods of industrial engineering (e.g. simulation). Since many healthcare facilities are deterred
particularly by high acquisition costs of this technology [13], healthcare managers need to realize that the purpose of
the new, modern technology is mainly to help healthcare professionals to work more efficiently and improve the
quality of healthcare services. If our healthcare facilities want to respond to technology-driven environment of care
and be prepared for the future development, the designers must not only design healthcare facilities as a buildings.
They need to meet the requirements of patients and staff, and must predict the future.
Acknowledgements
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