Computer Integrated

Manufacturing Systems(CIMS)

UNIT-4

AUTOMATED GUIDED VEHICLE SYSTEMS

& VEHICLE MANAGEMENT SAFETY
By
Dr. G.Moorthy & Prof. Athi
Flexible Manufacturing Systems
(FMS)

A Closer Look
 What Will Be Covered

 Flexible Manufacturing Defined

 How “you” can use FMS
 Nuts and Bolts
 How FMS works
 A real world example
 Summary
What Is A Flexible Manufacturing
System?

Flexible Manufacturing System:

- “A system that consists of numerous

programmable machine tools connected by an
automated material handling system” (2)
 History of FMS

 FMS first proposed in England in 1960’s

 “System 24” operates 24 hours a day

 Automation is main purpose in beginning

 How You Can Use FMS
 To reduce set up and queue times
 Improve efficiency
 Reduce time for product completion
 Utilize human workers better
 Improve product routing
 Produce a variety of Items under one roof
 Improve product quality
 Serve a variety of vendors simultaneously
 Produce more product more quickly
 Nuts and Bolts of FMS
FMS Layouts

 Progressive Layout:
◦ Best for producing a variety of parts

 Closed Loop Layout:

◦ Parts can skip stations for flexibility
◦ Used for large part sizes
◦ Best for long process times
 FMS Layouts Continued
• Ladder Layout:
― Parts can be sent to any machine in any sequence
― Parts not limited to particular part families

• Open Field Layout:

― Most complex FMS layout
― Includes several support stations
Automated Material Handling

 Automated Guided Vehicle

(AGV)

 Automated Storage and

Retrieval System (ASRS)

 Conveyors
 Components of Flexible
Manufacturing Systems
 NC  Automated
 CNC Inspection
 DNC
 Robotics  Cells and Centers
 AGV
 ASRS
 Flexible Automation
 Ability to adapt to  Ability to accommodate
engineering changes in routing changes
parts
 Ability to rapidly change
 Increase in number of production set up
similar parts produced
on the system
FMS Nuts and Bolts

Robots
 Robots
Robots: Programmable Manipulators

― Can tolerate hostile environments

― Can work much longer hours than humans

― Can perform redundant jobs more consistently (1)

 Common Uses of Robots

 Loading and unloading

 Inspection
 Spray painting
 Machine Assembly
 Welding

 Material handling
Computer Integrated Manufacturing

 CIM: “The Integration of the total manufacturing

enterprise through the use of integrated systems and
data communications coupled with new managerial
philosophies that improve organizational and personnel
efficiency.” (4)
 Components of CIM

 CAD Computer Aided Design

 CAM Computer Aided Manufacturing

 CAE Computer Aided Engineering

 Manufacturing Technology
 This part of FMS uses:

◦ NC Numerically Controlled Machine

◦ CNC Computer Controlled Machine

◦ DNC Direct Numerical Controlled

 Challenges with FMS

 Determining if FMS the best production system for your

company (economically and socially)

 Possible expansion costs associated with implementing

FMS

 Day to day maintenance of FMS operations

Flexible Manufacturing

How Does It Work ?

 Integration of FMS

FMS

Manufacturing
CIM Robotics
Technology
 Making FMS Work
◦ By implementing the components of robotics,
manufacturing technology and computer
integrated manufacturing in a correct order
one can achieve a successful Flexible
Manufacturing System
 A Real World Example

The
Ford
Motor Company
 Ford’s Problem

 At Ford Powertrain they faced the

following challenges

- outdated cell controller

- lack of flexibility because of it
- causing loss of efficiency
 Solution

 Implemented a cell control based

on an open architecture, commonly
available tools, and industry
standard hardware, software, and
protocols. (3)
 Benefits

 Enabled Ford to mix and match machine

tools from different vendors (3)
 Reduced the number of man-years
required to implement the application (3)
 Benefits Continued

 The budget for the fully automatic closed-

loop controller was less than 1/10th the
cost for a system built in language.

 No formal training was required for the

floor shop operators
 References Used

(1) Class and lecture notes from Dr. Tom

Fosters Ops. Mgmt. 345 class.

(2) Russell-Taylor text from Dr. Tom Fosters

Ops. Mgmt 345 class. Pgs 263-264, 304.
 References Used

http://www.gensym.com/manufacturing/ss
(3)

_ford.shtml

http://www.howard.engr.siu.edu/staff2/spo
(4)

erre/Roblec6.htm
 Closing

I would just like to thank you Dr. Foster

for your instruction which has made this
assignment much easier, as well as for the
authors that I have gathered information
from for this project.
AUTOMATED GUIDED VEHICLE
SYSTEMS(AGVS)
 AGVS is a material handling system that
uses independently operated, self-
propelled vehicles guided along defined
pathways.
 The vehicles are powered by on-board
batteries that allow many hours of
operation (8-16 hr is typical) between
recharging.
“Automated guided vehicle system”
AGV?
 AGV is a material handling system that uses
independently operated, self-propelled vehicles
guided along defined pathways
 Driverless Vehicle
 Electric motors, battery powered
 Programming capabilities
◦ Destination
◦ Path selection
◦ Positioning
◦ Collision avoidance
 System Discipline
 Types of AGVS
AGVS towing vehicle
AGVS unit load carriers
AGVS pallet trucks
AGVS forklift trucks
AGVS light-load transporters
AGVS assembly-line vehicles
 AGVS Towing Vehicles

First type of AGV introduced.

Towing vehicle is called an
automated guided tractor
Flatbed trailers, pallet trucks, custom
trailers can be used.
Generally, used for large volumes
(>1 tons) and long moving distances
(>1000 feet).

Load Capacity:1tons Vehicle Type:Laser

Guided Tugger AGV Products, Inc
AGVS Unit load Carriers

 To transport individual unit load onboard the

vehicle.
 Equipped with powered or non-powered
roller, chain or belt deck, or custom deck.
 Loads can be moved by Pallet truck, forklift
truck, automatic loading/unloading equipment,
etc.
Load Capacity3,0 Vehicle Type: Unit
Load with variable Height Conveyor
AGVS Pallet Trucks
 No special device is needed for
loading except the loads should be
on pallet
 Limited to floor level loading and
unloading with palletized load
 Widely used in distribution functions
 Speed > 200ft/min
 Pallet truck can be loaded either
manually or automatically

AGVS Forklift Trucks

 Ability to pickup and drop palletized
load both at floor level and on
stands.
 Pickup and drop off heights can be
different
 Vehicle can position its fork
according to load stands with
different heights
 Very expensive Vehicle Type: Laser Guided Fork
 Selected where complete automationLift AGV Products, Inc
is necessary/required.
 Advantages of AGV’s
Unobstructed movement
Flexibility
 Locations, path, P/D points can be reprogrammed
 Easy to change guide path system
 Number of vehicles can be altered depending on
requirement
Greater reliability
 Lessenvironmental problems
 AGV can be replaced by another, in case of failure.
Lower investment
Higher operating savings on long run
 Minimallabor cost
 Easy maintenance
 Modern AGVs
 computer-controlled vehicles
with onboard microprocessors
 AGVS Control Systems
Computer controlled system
The path controller controls the guidepath of AGVS.
Sends information to AGVS process controller.
Process controller directs movement of vehicles
Interchanges information with the host computer
Most Expensive and complex type of control

Guided path
AGV

Controller for AGVS process Display

guided path controller terminal

Display Host computer

terminal
AGVS Guidance system
The goal of an AGVS guidance system keep the AGV
on track/predefined path
The guidance systems can be selected based on the
type of AGV selected, its application, requirement and
environmental limitation
•Wire-guided
•Optical
•Inertial
•Infrared
•Laser
•Tape guided
 Wired navigation
The wired sensor is placed on bottom of the AGV’S and is
placed facing the ground.
A slot is cut in the ground and a wire is placed
approximately 1 inch below the ground.
The sensors detects the radio frequency being transmitted
from the wire and follows it.
 Guide tape navigation
The AGV’S( some known as automated guided carts or AGC’S)
use magnetic tape for the guide path.
The AGC’S is fitted with the appropriate guide sensors to
follow the path of the tape.
It is considered a “passive” system since it does not require
the guide medium to be energized as wire does.
 Laser target navigation
● The AGV’S carry’s a laser transmitter and receiver on a
rotating turret.
● The laser is sent off then received again the angle and
distances are automatically calculated and stored into AGV’S
memory.
● The AGV’S has reflector map stored in memory and can correct
its position based on errors between the expected and received
measurements.
 AGV task allocation

Collection point
(source)
Destination

'from' / 'to' order Current

Vehicle knows location
the street network
(layout)
TAX
I

Crossing
management
Collision Avoidance
 ROAD DETECTION
•Road detection based on laser scanner and vision sensor

•Classifies traversible segments and obstacles using laser scanner

(area just in front of the robot = 2.5m)

•Front looking camera classifies the road from 2.5 and beyond to
estimate the outline of the visible part of the road (seed area based
from results of laser scan)
Traversability
Problems
Experts
 Savant
 Amerden
 HK
 FMC Technologies
 JBT Coorporation
 Jervis B. Webb Company
 Automation Production Group (APG)
 Corecon
 FMC Technologies
 Trilogiq
 Egemin
 Elettric80
 Genesis Systems Group
 KMT Robotic Solutions
 Lantech
 Retrotech
 Mobile Robots, Inc.
 Westfalia
 References
 http://www.agvsystems.com/faqs/q5.htm
 http://www.amerden.com/AmerdenWeb/agvinformation.html
 “A Guide to Robotic Logistics – LGVs (AGVs)”. Elettric 80 S.p.A. 26 April 2008
 "The Appropriate Application of Automated Guided Vehicles ". HK Systems, Inc.
01 October 2007
 http://www.hksystems.com/agv/index.cfm
 Automation Ørsted•DTU, Technical University of Denmark, DTU-build. 326, DK-
2800 Kgs. Lyngby, Denmark.
AGVS (continued)

A distinguishing feature of an AGVs compared to

rail guided vehicle systems and most conveyor
systems, is that the pathways are unobtrusive.
Application
◦ AGVs are appropriate where different materials are
removed from various load points to various unload
points.
◦ AGVs are suitable for automating material handling in
batch production and mixed model production.
Historical Note
 The first AGV was developed in 1954 by
A.M. Barret, who used an overhead wire to
guide a modified towing truck pulling a
trailer in grocery ware house.
 Commercial AGVs were subsequently
introduced by Barret.
 Around 1973, Volvo the Swedish car maker
developed AGVs to serve as assemblies
platforms for moving cars bodies through
its final assembly plants.
Types of AGVs
Automated guided vehicles can be divided
into the following three categories:
1. Driverless Trains.
2. Pallet Trucks.
3. Unit Load Careers.
Driverless trains.
 A driverless train consists of a towing
vehicle (which is the AGV) that pulls one
or more trailers to form a train
 It was the first type of AGVS to be
introduced and is still widely used today.
 A common APPLICATION is moving
heavy payloads over large distances in
warehouses or factories with or without
intermediate pickup and drop-off points
along the route.
Driverless trains.
 Trains consisting of five to ten trailers is an
efficient transport system.
Automated Guided Pellet Trucks.
 Automated guided pellet trucks are used to move
palletized loads along predetermined routes.

 In the typical APPLICATION, the vehicle is backed into

the loaded pallet by a human worker who steers the truck
and uses its forks to elevate the load slightly.
 Then the worker drives the pallet truck to the guide path,
programs its destination, and the vehicle proceeds
automatically to the destination for unloading.
Automated Guided Pellet Trucks.
 The CAPACITY of an AGVs pallet truck ranges up
to several thousand kilograms, and some trucks
are capable of handling two pallets rather than
one.
 A more recent introduction related to the pallet
truck is the fork lift AGV.
 This vehicle can achieve significant vertical
movement of its forks to reach loads on racks and
shelves.
Automated Guided Pellet Trucks.
AGV Unit Load Carriers
 AGV unit load carriers are used to move
unit loads from one station to another.
 They are often equipped for automatic
loading and unloading of pallets or tote
pans by means of powered rollers, moving
belts, mechanized lift platforms, or other
devices built into the vehicle deck.
 VARIATIONS of unit load carriers
include light load AGVs and assembly
line AGVs.
AGV Unit Load Carriers
 The light load AGV is a relatively small
vehicle with corresponding light load
capacity (typically 250 kg or less).
 It does not require the same large aisle
width as a conventional AGV.
APPLICATION
 Light load guided vehicles are designed to
move small loads (single parts, small baskets
or tote-pans of parts etc.) through plants of
limited size engaged in light manufacturing.
AGV Unit Load Carriers
 An assembly line AGV is designed to
carry a partially completed subassembly
through a sequence of assembly
workstations to build the product.
Applications of AGVs
 Automated guided vehicle systems are
used in a growing number and variety
of applications.
 previously described applications.
 An other application area is in storage
and distribution.
 Unit load carriers and pallet trucks are
typically used in these applications, which
involve movement of material in unit loads.
 Applications of AGVs
 The applications often interface the AGVS with
some other automated handling or storage
system such as an automated
storage/retrieval system in a distribution
center.
 The AGVS delivers incoming unit loads
contained on pallets from the receiving dock
to the AS/RS, which places the items into
storage, and the AS/RS retrieves individual pallet
loads from storage and transfers them to
vehicles for delivery to the shipping dock.
 Applications of AGVs
 Storage/distribution operations also include
light manufacturing and assembly plants
in which work-in-process is stored in a central
storage area and distributed to individual
workstations for processing.
 Electronics assembly is an example of these
kinds of applications.
 Components are "kitted'' at the storage area
and delivered in tote pans or trays by the
guided vehicles to the assembly workstations
in the plant.
 Light load AGVs are the appropriate vehicles in
these applications.
Assembly line Applications of AGVs
 AGV systems are used in assembly line
applications, based on a trend that began in
Europe.
 Unit load carriers and light load guided
vehicles are used in these lines.
 In the usual application, the production
rate is relatively low (the product
spending perhaps 4-10 min per station), and
there are several different product models
made on the line, each requiring a different
processing time.
Assembly line Applications of AGVs
 Workstations are generally arranged in
parallel to allow the line to deal with
differences in assembly cycle time for different
products.
 Between stations, components are kitted and
placed on the vehicle for the assembly
operations to be performed at the next
station.
 The assembly tasks are usually performed with
the work unit on-board the vehicle, thus
avoiding the extra time required for unloading
and reloading
Application in FMS
 Another application area for AGVs
technology is flexible manufacturing systems
(FMSs).
 In the typical operation, starting work
parts are placed onto pallet fixtures by
human workers in a staging area, and the
AGVs deliver the parts to the
individual workstations in the system.
Application in FMS
 When the AGV arrives at the assigned
station, the pallet is transferred from the
vehicle platform to the station (such as the
worktable of a machine tool) for processing.
 At the completion of processing, a vehicle
returns to pick up the work and transport
it to the next assigned station.
 An AGVS provides a versatile material
handling system to complement the
flexibility of the FMS.
Application in Hospitals & Office
Mails
 Other applications of automated guided vehicle
systems include office mail delivery and
hospital material transport.
 Hospital guided vehicles transport meal trays,
linen, medical and laboratory supplies,
and other materials between various
departments in the building.
 These transports typically require movement
of vehicles between different floors in the
hospital, and hospital AGV systems have the
capability to summon and use elevators for this
purpose
AGVs interface with Robot
 AGVS technology is still developing and the industry is
continually working to design new systems to respond to
new application requirements.
 An interesting example that combines two technologies
involves the use of a robotic manipulator mounted on
an automated guided vehicle to provide a mobile robot
for performing complex handling tasks at various locations
in a plant.
 These robot-vehicles have potential APPLICATIONS in
cleaning rooms & in the semiconductor industry.
Example#01
An automated guided vehicle system is being
planned for a warehouse complex. The AGVs
will be a driverless train system, and each train
will consist of the towing vehicle plus four pulled
carts. The speed of the trains will be 160ft/min.
Only the pulled carts carry loads.
The average loaded travel distance per delivery
cycle is 2000 ft and empty travel distance is the
same. Anticipated travel factor =0.95. The load
handling time per train per delivery is expected
to be 10 min, If the requirements on the AGVs
are 25 cart loads/hr, determine the number of
trains required. Assume A = 1.0
Solution
 Example#02
An AGVS has an average loaded travel distance
per delivery = 400 ft. The average empty travel
distance is not known. Required number of
deliveries per hour = 60. Load and unload
times are each 0.6 min and the AGV speed =
125 ft/min.
Anticipated traffic factor = 0.85, availability =
0.95, and efficiency = 1.0. Develop an equation
which relates the number of vehicles required
to operate the system as a function of the
average empty travel distance Le.
Solution
Vehicle Guidance Technology
Three technologies that are used in
commercial systems for vehicle guidance:
(1) imbedded guide wires,
(2) paint strips,
(3) self-guided vehicles.
Imbedded Guide Wires and Paint
Strips.
 electrical wires are placed in a small
channel cut into the surface of the floor.
 The channel is typically .3-12 mm wide
and 11-26 mm deep.
 The guide wire is connected to a
frequency generator, which emits a low-
voltage, low-current signal with a
frequency in the range 1-15 kHz.
Imbedded Guide Wires and Paint
Strips.
This induces a magnetic field
along the pathway that can be followed by
sensors on-board each vehicle.
Imbedded Guide Wires and Paint
Strips.
 When paint strips are used to define the
pathway, the vehicle uses an optical
sensor system capable of tracking the
paint
 The strips can be taped, sprayed, or
painted on the floor.
 Paint strip guidance is useful in
environments where electrical noise
renders the guide wire system unreliable
or when the installation of guide wires in
the floor surface is not practical.
Self-guided vehicles (SGVs)
 SGVs operate without continuously
defined pathways.
 use a combination of dead reckoning
and beacons located throughout the
plant,
Self-guided vehicles (SGVs)
 Dead reckoning refers to the capability of a
vehicle to follow a given route in the
absence of a defined pathway in the floor.
 Movement of the vehicle along the route is
accomplished by computing the required
number of wheel rotations in a sequence of
specified steering angles.
 The computations are performed by the
vehicle's on-board computer.
 positioning accuracy of dead reckoning
decreases with increasing distance.
Self-guided vehicles (SGVs)
 the location of the self-guided vehicle is
periodically verified by comparing the
calculated position with one or more
known positions.
 These known positions are established
using beacons located strategically
throughout the plant.
Vehicle Management
 Traffic Control.
◦ On board Vehicle Sensing
◦ Zonal Control

 Vehicle Dispatching.
 Remote call station
Safety
 An inherent safety feature of an AGV is that its traveling
speed is slower than the normal walking pace of a.
human.
 automatic stopping of the vehicle if it strays more than a
short distance, typically 50-150 mm
 vehicles are programmed either to stop when an
obstacle is sensed ahead or to slow down.
 When the safety bumper makes contact with an object,
the vehicle is programmed to brake immediately.