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INTRODUCTION
In a traditional warehouse, human safety governs the productivity. With the help of
intelligent computers, the AGV can safely achieve higher speeds. Precision turning
allows it to accurately navigate in tight spaces.
The introduction of unmanned vehicles onto a warehouse floor has favorable effects on
safety. With the aid of environmental sensors, the AGV can detect objects in its collision
path. Automation eliminates vehicle traffic jams and their potential for accidents. For
companies building new warehouses, there are many monetary benefits to investing in
intelligent machinery. The workforce required to run the warehouse and the additional
overhead (e.g., insurance) required to support that overhead will be drastically reduced.
Increased product turn-around and faster shipping will result in more satisfied customers.
Also, automation reduces the risks of personal injury.
In general the forklift can be defined as a tool capable of lifting hundreds of kilograms. A
forklift is a vehicle similar to a small truck that has two metal forks on the front used to
lift cargo. The forklift operator drives the forklift forward until the forks push under the
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cargo, and can then lift the cargo several feet in the air by operating the forks. The forks,
also known as blades or tines, are usually made out of steel and can lift up to a few tons.
Forklifts are most often used in warehouses, but some are meant to be used outdoors. The
vast majority of rough terrain forklifts operate on gasoline, but some use diesel or natural
gas. Rough terrain forklifts have the highest lifting capacity of all forklifts and heavy
duty tires (like those found on trucks), making it possible to drive them on uneven
surfaces outdoors.
It is important for forklift operators to follow all safety precautions when using a forklift.
Drivers should be careful not to exceed the forklift’s weight capacity. Forklift operators
also need to be able to handle forklift’s rear wheel steering. Driving a forklift is similar to
driving a car in reverse, meaning that the driver must constantly steer to keep it moving
in a straight line. The driver must be aware of the forklift’s ever-changing center of
gravity and avoid making any quick sharp turns or going too fast. It is advisable that
anyone who operates a forklift be fully trained and licensed.
Forklift shave revolutionized warehouse work. They made it possible for one person to
move thousands of pounds at once. Well-maintained and safely operated forklifts make
lifting and transporting cargo infinitely easier. This is the general description of a normal
forklift truck. To enhances the technology further, this prototype module is constructed
with remote technology, there by the operatorcan walk along with the forklift for better
visibility & the container can be placed accurately (precision position). This increases the
safety of the operator.
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Why Forklift?
The forklifts are generally used for moving heavy goods and supplies from one
place to another quickly and with less effort.
The forklifts are small but compact machines, designed to work in tight and
narrow areas.
The best thing is that you can choose a forklift with the right configuration and
capacity depending on your needs.
One advantage of the forklifts is that they are capable to reach things located on
high locations.
Without these machines, the warehouses would not be able to operate efficiently
and with easiness.
They perform Eco-friendly operation and have longer life.
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1.1 Problem Statement
There are many reasons which yield to the creation of Automated Guided Vehicle (AGV)
around the world. Mostly the reason is to overcome the logistic problems that often
occurred in the workplaces & to make improvement to the facilities provided in the
workplaces.
Factories, industries and storage go downs need forklifts and cranes for storage and
moving large goods. Also there are a number of goods weighing around 100 – 200 kgs
that are comparatively lighter but cannot be moved around easily by human labor.
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1.2. Solution
To fill this need we here propose a 2 wheel drive forklift to lift and transport such
medium weight goods across factories & industrial warehouses. The 2 wheel drive is a
fast, efficient and low power consumption vehicle that does not require much space to
move around. It is accurate, fast, efficient and sustainable
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1.3. Objectives
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1.4 Scope Of Current Work
The AGV operated in a model warehouse, built to scale. Its primary task was to relocate
pallets within the warehouse. An external input generated by an infrared remote control
notified the AGV whether a pallet was entering or exiting the warehouse. To get to its
destination, the vehicle traversed the warehouse by following high contrast lines. When
the four pair line follower module detected an intersection, the AGV determined whether
to turn or go straight by using an algorithm that incorporated the vehicles current location
and direction. In the first situation, the remote control signaled that a pallet was entering
the warehouse. The AGV picked up the pallet off of the incoming shipping dock and
dropped it off at one of several docks at the other end of the warehouse. Through RF
communication, the AGV told another autonomous vehicle, the ASRS, the new of the
pallet. The second situation allowed for a pallet to be shipped out of the warehouse. The
AGV waited for the ASRS to confirm that it dropped off a pallet at one of the transition
docks before it picked it up and moved the pallet to the outgoing shipping dock. While
traveling, the AGV polled two forward facing infrared range finding sensors to determine
if an object was in its forward collision path. If and object was detected, the vehicle
would stop and wait for the obstruction to be cleared. While reversing, bump sensors
detected the occurrence of a rear collision, which would permanently disable the vehicle.
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1.5. Methodology
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CHAPTER 2
LITERATURE SURVEY
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productivity of the warehouses by developing a WMS various distribution and to analyse
the impact of effective and efficiency warehousing on competitive strength, enhanced
preservation & control and overall cost reduction and also to find out various factors
affecting efficiency and effectiveness of warehouse system.
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people who unit of measurement semi-automatic but manually controlled. self-propelled
vehicle has revolutionized warehouse work. They created to achievable for one person to
maneuver thousands of pounds promptly. Well maintained and safely operated forklifts
build lifting and transporting freight infinitely easier. this may be the ultimate description
of a conventional wheeled vehicle truck. To enhances the technology any, this image
module is created with remote technology, there by the operator can walk at the facet of
the wheeled vehicle for higher visibility & the instrumentality area unit usually placed
accurately (precision position). this may increase the protection of the operator.
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AdityaVaidya, KrunalRotliwala, Mahesh Prajapati, Nikunj Patel, Rahul Rajpurohit
“DESIGN OF PEDAL OPERATED WHEEL DRIVE FORKLIFT” Mechanical fork
lift is an improved and advance technology that helps brought about revolution in the
mechanical industries today all heavy engineering company uses it. Widespread use of
the forklift truck had revolutionized warehousing practices before the middle of the 20th
century. A mixture of material handling systems is in the use, exact from that entirely
physical to the ones that are semi-automatic but manually controlled. Forklifts have
revolutionized warehouse work. They made it possible for one person to move thousands
of pounds at once. Well-maintained and safely operated forklifts make lifting and
transporting cargo infinitely easier. This is the general description of a normal forklift
truck.In Institutes or Colleges small goods cannot moved around easily by any human
body, so to fill this need we have propose a Pedal Operated forklift (electrical operated)
to lift and transport such medium weight goods. It is a fast, efficient and low power
consumption vehicle that does not require much space to move around.
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The use of a laser scanner allowed for multiple safety zones to be configured, and thus
for the AGVs to work safely in different working environments, regardless of the space
constraint.
In the experiments, two AGVs were operated together, and independently performed the
predetermined tasks in a service loop in the absence of a cell controller. However, a
dedicated cell controller would allow for more efficient operation in applications where
cycle time is critical.
The drawback of the current design is that the sequence of tasks is hard-coded into the
PLC program of the AGV, making a dedicated cell controller necessary in order for a
new sequence of tasks to be developed in a GUI and transferred to the PLC using the
Modbus protocol.
The application of System in this research demonstrated that the MBSE approach can
facilitate the sound functional design of complex controllers for industrial automation and
systems.
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lifting mechanism would to interesting and provide direction towards the application of
this forklift.
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MUARC OHS GROUP ,“A FORKLIFT REVIEW”, There is no shortage of statistics
corroborating the degree and severity to which forklifts are involved in workplace
accidents. This problem is of a global nature and exists throughout all industries
revolving around a core of root causal factors (Janicak, 1999). To date most of the
research regarding forklift safety has taken an ergonomic, occupational hygiene and
training based approach. Subsequently little advancement has occurred in the way of risk
reduction in the form of actual applied interventions.
What is most perplexing is the reluctance of the various forklift stakeholders to adopt
similar risk control strategies as initiated in road and aviation. More universal attention
needs to be directed towards the issue of forklift stability, so as ‘SAS-like’ technology is
viewed as the norm, rather than an exception. This philosophy should also extend
address the quality of the information that operators receive when handling loads.
The issue of load stability could be effectively managed by adopting a two-stage process.
This should firstly aim to provide continuous data, as to how the movement of raised load
impacts on the forklifts safe load-handling limit. This could work in a similar manner to
how an ‘attitude indicator’ provides feedback to pilots so as to overcome sensory
misconception (Allstar Networks, 2000). The second stage of this process could use the
‘attitude indicator-like’ system to prevent movement of a particular load, when the
system senses the action would compromise the overall stability of the forklift.
Development of effective stability and load controls for forklifts should occur as well as,
not instead of ROPS/FOPS devices and operator restraint systems. The array of
circumstances where these operator protection devices are effective is immense. Not to
mention the 20% predicted reduction in fatalities when these controls are implemented
together. (NOHSC, 1998)
Poor logistics planning for forklift operation in factory and warehouse environments
spawns a mass of ensuing hazards. Collisions between powered industrial vehicles,
pedestrian workers and both stationary/mobile objects, are major mechanisms of forklift
accidents. The risk of such accidents is further magnified when aisles are obstructed and
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when the forklift is loaded. Subsequently a need exists to control and alert the forklift to
the presence of such potential hazards.
An on-board proximity control system, fully integrated with logistics based speed zoning,
would be the most conclusive method of reducing the instance of fatalities occurring as a
result of various collisions. Given that most of the necessary ITS technology is already
available and that many transport terminals are now computer modeled prior to
installation, the time for such an approach is imminent.
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has all the general parameters, dimensions and weight. Trucks performance and
electronic system are all included here. Future Research includes research on forklift’s
weight change and stability during the turning and speeding up process, and developing a
shifting counterweight automatically adjust the balance of the truck.
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CHAPTER 3
PROPOSED WORK
The forklift required the capability to move around a model warehouse built out of a
sheet of plywood and to pick up pallets once it reached it’s destination. Two types of
actuation where needed to meet these objectives. Drive motors and tires added the
function of movement, while a third motor supported a pallet jack.
The AGV was propelled by two 200 R.P.M. D.C. gear head motors, which were attached
to the rear tires. The tires were 2.2 inches in diameter and one inch wide. With the
addition of the third caster, the majority of the vehicle’s weight rested on the rear caster,
and the tires were slipping. Thick coats of rubber cement were painted onto the tires and
the vehicle regained traction. The AGV had an excellent turning radius as a result of the
platform layout. The tires resided one inch from the middle of the robot, which almost
allowed it to turn in place.
The forklift was created out of metal and mounted to the platform with screw. The screw
is made with cast iron and designed as per the pallet load requirement. The screw is
special type of lead screw which has holding capacity (for holding loads). A servomotor
or DC motor is used for movement of lead screw. Forks are mounted on lead screw with
screw nut arrangement. A controlled signal is given to the dc motor for lifting pallets to
the required height (height of shelf).
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3.2. Components of the System
Lead screws are quiet, smooth, resistant to corrosion, self-lubricating, and often less
expensive. They are favored in situations that require higher levels of customization.
Because lead screws are virtually silent and vibration-free, they’re often used for medical
equipment like insulin pumps and in personal computing devices like desktop PCs.
Now, we use lead screw in our project i.e. up-down mechanism.
Lead screws are self-locking; there is typically no need to apply additional brakes, even
in situations where you’re lifting a vertical load during an electricity outage. However,
the higher the friction is on the sliding surface, the more power is required to drive the
load up or forward.
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3.2.2. DC Motor
A DC motor is any of a class of rotary electrical machines that converts direct current
electrical energy into mechanical energy. The most common types rely on the forces
produced by magnetic fields. Nearly all types of DC motors have some internal
mechanism, either electromechanical or electronic; to periodically change the direction of
current flow in part of the motor. DC motors were the first form of motor widely used, as
they could be powered from existing direct-current lighting power distribution systems. A
DC motor's speed can be controlled over a wide range, using either a variable supply
voltage or by changing the strength of current in its field windings. Small DC motors are
used in tools, toys, and appliances. Larger DC motors are currently used in propulsion of
electric vehicles, elevator and hoists, and in drives for steel rolling mills. The advent of
power electronics has made replacement of DC motors with AC motors possible in many
applications.
Specifications of DC motor
Type= dc motor
Speed=30rpm
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Warranty= 1 Years
Operating Voltage(V): 12
Stepper motor
Number of Phase: 2
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Weight:300 grams
Lifting fork is main part of fork lift .The lifting fork that directly lift the load from its
position and move the load from one position to another position safely.
3.2.4 Wheels
The wheels rolls and moves the forklift from one place to another place. We use four
wheels two at front side attached at bottom at support legs and two are at rear side. We
will provide drive to front two wheel and rear two wheels are supporting wheels .
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3.2.5 Battery
In an internal combustion engine -powered vehicle, the battery is used mainly to start the
engine. It is quite small but still pretty heavy, say 15kg- using lead-acid chemistry and
will have a capacity of 40–100Amp-hours (Ah). Lead-acid is a very well established
technology, it’s inexpensive and reliable.
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3.3. Sensors
It was desirable for the AGV to be capable of safely traversing a warehouse without
colliding with obstacles in its path. Two forward facing Sharp GPD2D12 infrared range
finders were placed approximately two inches apart. Both where pointed 30 degrees
toward the center of the robot. Obstacles were detected when something passed into the
sensor’s line of sight. The sensors were preassembled and powered up with 3.3 volts.
The analog output was connected to the microprocessor. Because the robot was operating
in a model warehouse, close range sensors where chosen to stay consistent with scale.
The farthest distance the GPD2D12 can measure is 80 centimeters. With a body length
of 13 centimeters, the AGV is considered to be a 1:14 scale. Applying the scale, a life
size AGV could detect obstacles 35 feet in front of it.
Navigation will be achieved by following black lines on the warehouse floor. A four pair
line-tracking module is constructed with Optek OPB745 Reflective Object Sensors. They
are constructed with infrared light emitting diodes coupled with phototransistors, because
the reflective properties of black and white surfaces are different, the sensor will return
varying analog values relative to the surface they are above. The 12 microprocessor polls
these analog values and converts them to digital data: black is 23016 and white is 13516.
Two sensors are offset one half of a centimeter from the center of the module. This
allows the robot to center itself on a two centimeter wide strip of electrical tape. Both of
the other sensors are three centimeters from the middle. They serve to detect intersecting
black lines. Combining two center sensors with an outside sensor allows the AGV to
distinguish intersections from curves.
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Figure 3.5 Line Follower Schematic
3.3.3. collision
Two active low bump sensors are located on the back of the robot. They are wired in
parallel, and the output is tied to a low priority interrupt. The interrupt is configured to a
falling edge. In the event that the interrupt is fired, the AGV permanently stops.
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3.3.4. RF link
The AGV is designed to work hand to hand with another vehicle on the warehouse floor.
Communication is achieved with a Laipac TRF-2.4G RF transceiver. The development
of this system was completed by Albert Chung, and it will be inserted into the AGV as a
“plug and play” device. Laipac merged several devices into one convenient package: a
bidirectional transmitter, Cyclic Redundancy Check generator, and an antenna. The
transceiver uses an external clock to serially input data from a microprocessor. Once the
internal data buffer is full, the chip uses Shock Burst technology to assemble a packet:
including an internally calculated preamble and CRC. Data is transmitted with a signaling
rate as high as 1Mbps. To address the possibilities of errors, the Stop and Wait Automatic
Request protocol was used.
This had several advantages over direct communication including an alternating frame
number and positive acknowledgment. If frames were received out of order, the receiver
would NAK the sender and wait for the correct frame. However, things were not perfect
and the two robots went quickly out of synchronization. To account for this, software
allowed for the dynamic resynchronization of frame numbers. The biggest source of error
was ambient noise that cross talked to our system. We implemented header error control
to help counter this. By inserting a standard header in the unused bits, the receiver could
test the incoming message. Another possibility of error comes from both devices
transmitting at the same time. Both robots were programmed with separate timeout
lengths. Thus, if one robot sent something and never received and ACK, it would resend
its packet before the other would.
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3.4 Prototype
3.5 Work
3.5.1 communication
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3.5.2 queue
The AGV was much faster than the ASRS, so the delivery and storage of pallets was not
one to one. The implementation of a queue insured that the neither of the robots would
ever be sitting idly by. Upon the successful reception of an RF packet, the AGV pushed
it onto the queue. When there were no jobs being processed, the robot continually polled
the queue for a new job. The jobs where handled in a “First In First Out” order.
3.5.3 tracking
The four pair line tracking module was used to navigate the AGV on a dark brown,
glossy floor with white strips of electrical tape. Three motors speeds were defined:
medium fast, medium, and slow. Normal navigation was done with the medium fast
speed. If the vehicle started to stray off of the line, the software would notice a
difference in the values from one of the two center sensors and decrease the appropriate
motor’s speed to medium. If the vehicle completely left the line, the robot turns in the
opposite direction of the last sensor read. For example, if the robot last saw “white” on
the right-center sensor, it would turn left. The software detected an intersection when the
output from either of the outer line following sensors read “white.”
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3.5.4 lifting
For all jobs, the AGV first picked up a pallet and then dropped it off at a new location.
Two white lines were placed in front of each dock and allowed the arbitrating function to
make different actions. At the first line, the AGV would lower its fork before driving in.
It would raise its fork at the second line before turning around and heading toward its
destination. Similar procedures were followed when the AGV went to drop the pallet off.
Although there was no need for humans in the automated warehouse, people could be
unpredictable (unlike robots). Distance sensors determined if an object was in the
forward path of the vehicle. If they detected something, the robot would pause before
hecking to see if the obstruction was still present. For obvious reasons, the sensors were
temporarily disabled when the AGV was approaching the shelves. While backing up, the
rear bump sensors were activated so a rear collision could be detected. If this event
occurred, the vehicle would be permanently disabled.
Since we already have the data about the mass properties of all the components, we need
to investigate if the forklift is safe under static conditions. This entails that forklift center
of gravity needs to stay within the safety triangle, as shown in Figure; otherwise the
forklift will tip over.
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CHAPTER 4
EXPERIMENTAL CALCULATIONS
Page 30
So σallow= 210/2 = 105 MPa = 105 N/mm2
Comparing above we get,
σb < σallow
i.e. 4.36< 105 N/mm 2
So, design is safe.
Nominal Diameter(d)
Axial load (p) =100×9.81 =981 N
Assume length=1200 mm
P= fb × (dr4/12002) ×104
981 =1 × (dr4/12002) ×104
dr =19.38≈20 mm
Take standard or nominal diameter = 22 mm
………………from DOM Khurmi Gupta ,page no. 180, table no 6.1
We get, pitch(p)= 5 mm
Core diameter (dc)
dc = d-p
= 22-5
dc =17 mm
Mean diameter of screw (dm)
dm = d-0.5×p
=22-0.5×5
dm=19.5 mm≈20 mm
Velocity ratio
V.R. =π ×d/l……………l=p=5 for single threaded screw
=π × 22/5
V.R.= 13.82
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tanα=(l/π×dm)
α=tan-1(l/π×dm)
= tan-1(5/π×20)
α=4.66
Friction angle (Ø)
tan Ø=µ
Ø= tan-1(µ)
= tan-1(0.15)
Ø=8.5310
Dimensions of Nut
Z=4×W/π×Sb×(d2-dc2)
= 4×981/π×15×(222-172)
Z=0.422≈1
Number of turns=1
Therefore, length of nut= z × p
=1 × 5
= 5 mm
Efficiency of screw
ἠ = tanα / tan(α+Ø)
= tan(4.664)/tan(8.531+4.664)
ἠ=0.3476≈34.76%
Hence, efficiency should be less than 50% and friction angle should be greater
than helix angle to get self locking mechanism.
Mechanical Advantage
M.A. =V.R. × ἠ
= 13.82 × 0.3476
M.A. = 4.80
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4.3 Programs / Algorithms
#include <Stepper.h>
constintstepsPerRevolution = 200; // change this to fit the number of steps per revolution
int IRsensor1 = 2;
int IRsensor2 = 3;
int val1;
int val2;
//robot
constint I1 = 4;
constint I2 = 5;
constint I3 = 6;
constint I4 = 7;
int state;
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//ultra
inttrigPin = 8;
intechoPin = 9;
long duration;
intdistance_cm;
intdistance_in;
void setup()
pinMode(I1, OUTPUT);
pinMode(I2, OUTPUT);
pinMode(I3, OUTPUT);
pinMode(I4, OUTPUT);
pinMode(IRsensor1, INPUT);
pinMode(IRsensor2, INPUT);
pinMode(trigPin, OUTPUT);
pinMode(echoPin, INPUT);
Serial.begin(9600);
myStepper.setSpeed(100);
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}
void loop()
Ultra();
state = Serial.read();
//reverse
if (state == '1')
digitalWrite(I1, HIGH);
digitalWrite(I2, LOW);
digitalWrite(I3, HIGH);
digitalWrite(I4, HIGH);
//backward
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digitalWrite(I1, LOW);
digitalWrite(I2, HIGH);
digitalWrite(I3, LOW);
digitalWrite(I4, HIGH);
//right
digitalWrite(I1, LOW);
digitalWrite(I2, LOW);
digitalWrite(I3, HIGH);
digitalWrite(I4, LOW);
//left
digitalWrite(I1, HIGH);
digitalWrite(I2, LOW);
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digitalWrite(I3, LOW);
digitalWrite(I4, LOW);
//stop
digitalWrite(I1, LOW);
digitalWrite(I2, LOW);
digitalWrite(I3, LOW);
digitalWrite(I4, LOW);
Serial.println("clockwise");
myStepper.step(stepsPerRevolution);
// delay(500);
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{
Serial.println("counterclockwise");
myStepper.step(-stepsPerRevolution);
// delay(500);
void Ultra()
digitalWrite(trigPin, LOW);
delayMicroseconds(100);
digitalWrite(trigPin, HIGH);
delayMicroseconds(100);
digitalWrite(trigPin, LOW);
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Serial.print("Distance: ");
Serial.print(distance_cm);
Serial.println(" centimeters");
delay(1000);
if ( distance_cm>= 5)
digitalWrite(I1, LOW);
digitalWrite(I2, LOW);
digitalWrite(I3, LOW);
digitalWrite(I4, LOW);
// voidMotorstep()
// {
//
// if( state=='1')
// {
// Serial.println("clockwise");
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// myStepper.step(stepsPerRevolution);
// // delay(500);
// }
//else if ( state=='2')
//{
// Serial.println("counterclockwise");
// myStepper.step(-stepsPerRevolution);
// // delay(500);
//}
//}
#include <Stepper.h>
constintstepsPerRevolution = 200; // change this to fit the number of steps per revolution
int IRsensor1 = 2;
int IRsensor2 = 3;
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int val1;
int val2;
//robot
constint I1 = 4;
constint I2 = 5;
constint I3 = 6;
constint I4 = 7;
int state;
//ultra
inttrigPin = 8;
intechoPin = 9;
long duration;
intdistance_cm;
intdistance_in;
void setup()
pinMode(I1, OUTPUT);
pinMode(I2, OUTPUT);
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pinMode(I3, OUTPUT);
pinMode(I4, OUTPUT);
pinMode(IRsensor1, INPUT);
pinMode(IRsensor2, INPUT);
pinMode(trigPin, OUTPUT);
pinMode(echoPin, INPUT);
Serial.begin(9600);
myStepper.setSpeed(100);
void loop()
Ultra();
state = Serial.read();
//reverse
if (state == '1')
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digitalWrite(I1, HIGH);
digitalWrite(I2, LOW);
digitalWrite(I3, HIGH);
digitalWrite(I4, LOW);
//backward
digitalWrite(I1, LOW);
digitalWrite(I2, HIGH);
digitalWrite(I3, LOW);
digitalWrite(I4, HIGH);
//right
digitalWrite(I1, LOW);
digitalWrite(I2, LOW);
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digitalWrite(I3, HIGH);
digitalWrite(I4, LOW);
//left
digitalWrite(I1, HIGH);
digitalWrite(I2, LOW);
digitalWrite(I3, LOW);
digitalWrite(I4, LOW);
//stop
digitalWrite(I1, LOW);
digitalWrite(I2, LOW);
digitalWrite(I3, LOW);
digitalWrite(I4, LOW);
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}
Serial.println("clockwise");
myStepper.step(stepsPerRevolution);
// delay(500);
Serial.println("counterclockwise");
myStepper.step(-stepsPerRevolution);
// delay(500);
void Ultra()
digitalWrite(trigPin, LOW);
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delayMicroseconds(100);
digitalWrite(trigPin, HIGH);
delayMicroseconds(100);
digitalWrite(trigPin, LOW);
Serial.print("Distance: ");
Serial.print(distance_cm);
Serial.println(" centimeters");
delay(1000);
if ( distance_cm>= 5)
digitalWrite(I1, LOW);
digitalWrite(I2, LOW);
digitalWrite(I3, LOW);
digitalWrite(I4, LOW);
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}
// voidMotorstep()
// {
//
// if( state=='1')
// {
// Serial.println("clockwise");
// myStepper.step(stepsPerRevolution);
// // delay(500);
// }
//else if ( state=='2')
//{
// Serial.println("counterclockwise");
// myStepper.step(-stepsPerRevolution);
// // delay(500);
//}
//}
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CHAPTER 5
For the static analysis, we have already got result from calculations that maximum
loading capacity of forklift is 100kg.100kg convert to force is around 1000N. We have a
fork structure like a plate; therefore all the force acts symmetrically on its surface. As
fig.5.1.1 is the geometry and fig.5.1.2 is the model get after meshing. Then we apply a
surface load of 1000N on fork, since top of the fork is attached to the screw (lead screw)
and frame. Hence we fixed ‘A’ as a boundary condition.
Figure5.1.1 Geometry
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Figure 5.1.2 Meshing
Page 49
JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)
Page 50
Figure 5.1.4 Boundary conditions
Figure5.1.
5 Directional deformation
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Figure 5.1.6 Equivalent Stress
Page 52
Fig.5.1.6 & Fig.5.1.7 are the stress analysis of the fork. As shown in fig. corner of the
fork is bend which means that a part of fork is taking biggest stress. So the corner is the
place where fracture will mostly occur.
Fig.5.1.8 is the displacement result of the fork the maximum displacement is 0.67mm and
happens at the front of fork tip. The colour of fork is all blue which means the fork is safe
when applied 1000N force.
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5.2 Lead screw
The load considered on lead screw is uniform in all direction; therefore we have to define
the load throughout the length of lead screw. We have calculated the load on lead screw
from bending moment of fork and applied the load for analysis.
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Figure 5.2.3 Number of Nodes & Elements
Figure 5.2.4 shows the support boundary conditions as the one end of lead screw is fixed
to the motor.
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Figure 5.2.5 Maximum shear stress
Fig.5.2.5 & Fig.5.2.6 are stress analysis and blue colour shows there would not be any
stress of failure.
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Figure 5.2.7 Total Deformation
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5.3 Frame
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Figure 5.3.4
Fig.5.3.4 shows the surface load of about 495N it carries battery, electronic circuits and
other components. So we have considered it as a surface load.
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Figur
e 5.3.6 Maximum shear stress
From the analysis of frame in Fig. 5.3.6 we got that, there would not be any damage to
the frame.
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CHAPTER 6
COST ESTIMATION
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CHAPTER 7
CONCLUSION
The system that is being produced is totally based on mechanical and electronics
contents. With the help of sensors and actuators the system would do the work of
controlling warehouses. As one of the objective of this project High demands on
manufacturers have left their shipping warehouses in havoc. Human error has a negative
effect on safety, efficiency, and quality. These expenses will reduced with the
introduction of an Automated Guided Vehicle, AGV. A driverless, intelligent forklift
uses an optical path to quickly and safely traverse a warehouse. Its capabilities will be
enhanced by the ability to send and receive tasks through RF data communication.
Applications in the various field such as industry, military, medical, etc. can be used in
great extent. Optimization of the mobile robot can be achieved by the utilization of
universal driving wheel.
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The AGV is a productivity increasing feature in a factory. During the manufacturing of
this AGV we had found many of intelligence that can be given to it. We provide the basic
functions like line following and collision avoidance. And the main function,
transportation of goods from station to station.
Features of Model
Current work
Figure 7.1
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CHAPTER 8
REFERENCES
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Sachin Ugale et al, “Design, Development and Modelling of Forklift”,
International Journal of Engineering Research & Technology, ISSN: 2278-0181,
Vol. 3, Issue 4, April 2014, pp- 1234-1238
Sachin Ugale et al, “Design and Structural Analysis of Mechanical Forklift using
ANSYS Software”, International Journal of Research in Advent Technology, E-
ISSN: 2321-9637, Vol. 2, No. 5, May 2014, pp-234-237
Books-
R. S. Bridger, “Introduction to Ergonomics”, CRC press , 3rd edition
V. B. Bhandari, “Design of Machine Element”, Tata McGraw-Hill, 3rd edition,
2010.
S. S. Ratan, Theory of Machine, Tata McGraw-Hill, 3rd edition, 2009.
B. L. Theraja, “Electrical Techonology”, S. Chand Publications, 23rd edition
Kalaikathir Achchagam, “Design Data- Data Book of Engineers”, P.S.G. College
of Technology, Coimbatore
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JSPM NARHE TECHNICAL CAMPUS, PUNE BE (MECHANICAL)
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