Automated Guided Vehicle

AXIS COLLEGE OF ENGINEERING & TECHNOLOGY
Murikkingal P.O, Thrissur

(Affiliated to University of Calicut)
DEPARTMENT OF MECHANICAL ENGINEERING
MINI PROJECT REPORT
FABRICATION OF AUTOMATIC
GUIDED VEHICLE
AJITH ARAVIND
JESBIN JOHNSON
VINOD.K.J
VISHNU.T.SAJEEVAN
AXIS COLLEGE OF ENGINEERING & TECHNOLOGY

P.O.MURIKKINGAL, THRISSUR
Fabrication of Automatic Guided Vehicle
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
This is to certify that this Project Report Titled
FABRICATION OF AUTOMATIC GUIDED VEHICLE
was carried out by the sixth semester students of Mechanical engineering in partial
fulfilment of the requirement for the award of Bachelor in Technology in mechanical
engineering Under University of Calicut during the year 2012-2013,of Axis College of
Engineering & Technology, Thrissur
AJITH ARAVIND, JESBIN JOHNSON, VINOD.K.J, VISHNU.T.SAJEEVAN

are members of the batch
Project Guide
Joffin Jose P
S.Krishnanunni
Project Coordinator
H.O.D Mechanical Engg
Place: Thrissur
Date:
ACKNOWLEDGEMENT
We express our deep sense of gratitude and indebtedness to Asst Prof. S.Krishnanunni, Head,
Department of Mechanical Engineering for his valuable advice, constant encouragement and
constructive criticism during the course of the project and also during the preparation of this
manuscript, We place on record the valuable suggestions and numerous constructive
comments rendered by Asst Prof. Joffin Jose.P, Lecturer, Department of Mechanical
Engineering and for being our internal guide in the design and implementation of our project.
We are highly indebted to the staff members of Mechanical Department, especially
Asst.Professors Clint.K.S, Krishnakiran.T.T, Jineesh.V.V, Sankar Raj, Renjith for their
wholehearted support and co-operation.
We also express our sincere thanks to all the classmates for their support and cooperation in completing the project work.
Above all, we should express our supreme gratitude to almighty God.
Department of Mechanical Engineering
ACET
ABSTRACT
The Automatic Guided Vehicle refers a type of system that can be used in production as well
as in other industries etc. This system includes a battery operated remote sensing locomotive
(carrier) on which a small lift is provided, specific path over which it moves, sensors for
sensing the the obstructions on the path of the carrier. Also sensors for sensing exact positions
from where load wants to carry and to where.
The remote sensing carrier moves using the electric power from the battery. It moves
with a low and constant speed on the prescribed path. The path has a specific color. The
bottom of the carrier have sensor which is always coupled with the path. From the remote
station we send only information for moving the carrier, not for steering it. The steering is
done by the path. The front side of carrier vehicle contains sensors for sensing the
obstructions on the path.
As it reaches the collecting station, its top floor lift to a small distance and lift the
stand which contains the parts wants to assemble, supply. And the carrier moves through the
path and reaches the supply station. The sensor provided on the carrier detected the station
and unload the stand contains assembly parts at that station. And move to collecting stations
again. Continues working cycles for making this project a reality.
ACET
TABLE OF CONTENT
CHAPTER
TITLE
PAGE
CHAPTER I: INTRODUCTION
1.1
Automatic Guided Vehicle
1.2
Background
1.3
Problem Statement
1.4
Project and Its Scope
1.5
Market Survey
CHAPTER II: LITERATURE REVIEW
2.1
AGV Built Worldwide Used
10
2.2
Mobile Post Distribution System (MOPS)
11
2.3
The Parkshuttle AGVs of Amsterdams Schiphol Airport
12
2.4
Line Following Robot
13
2.5
The Kerwins Line Following Robot
13
CHAPTER III: COMPONENTS SELECTION AND DESCRIPTION
14
3.1
Design Objectives
14
3.2
Design Considerations
15
3.3
Components of AGV
17
3.4
Mechanical Part
19
3.4.1
Chassis
19
3.4.2
Steering System
20
3.4.3
Lifting Mechanism
22
3.5
3.6
Electrical Components
24
3.5.1
DC Motor
24
3.5.2
Battery
25
Electronics Components
26
3.6.1
Microcontroller
26
3.6.2
Motor Driver
29
5
ACET

3.6.3
Regulators
33
3.6.3.1 7805 Regulator
33
3.6.3.2 LM317 Regulator
34
3.6.4
IR Sensor
35
3.6.5
Magnetic Sensor
38
3.6.6
Display Unit
40
3.7
Software Components
42
3.8
Program Source Code
43
CHAPTER IV: DEVELOPED PROTOTYPE
50
4.1
Structure
50
4.2
Sensors Positions
52
4.3
Flow Chart
54
4.4
Block Diagram
55
4.5
Circuit Diagram
56
4.6
Theoretical and Logical Calculations
58
4.7
Billing
61
CHAPTER V: CONCLUSION
62
REFERENCES
64
LIST OF TABLES
6
ACET
Table Number
Title
Page
2.1
Line Following Methods
13
3.1
Technical Data for Chassis
19
3.2
Steering Specifications
21
3.3
Motor Specifications
24
3.4
Battery Specifications
25
3.5
Specifications of ATmega 328
27
3.6
Important Connections
27
3.7
Technical Specifications of L293D
32
3.8
Maximum Rating of 7805
33
3.9
Technical Specifications of 7805
34
3.10
Technical Specifications of LM 317
34
3.11
Technical Specifications of IR Pair
37
3.12
Technical Specifications of Magnetic Sensors
39
3.13
Technical Specifications of Display Unit
40
3.14
Pin Configuration
40
4.1
Billing Table
61
LIST OF FIGURES
Figure Number
Title
Page
2.1
The Mobile Post System
11
2.2
The Parkshuttle AGVs of Amsterdam
12
2.3
The Kerwins Line Following Robot
13
3.1
Chassis of AGV
19
3.2
Differential Steering
20
3.3
Small Radius Turning
21
3.4
Lifting Using Threaded Shaft
22
3.5
Structure of Lift
23
3.6
DC Motor with Gearbox
24
3.7
Battery
25
3.8
ATmega 328 Microcontroller
28
Figure Number
Title
Page
7
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3.9
Motor Driver (L293D)
29
3.10
L293D Connected with Two Motors
30
3.11
L293D Connected with One Motor
30
3.12
Circuit Connection of Driving Motor
31
3.13
Connection of Lifting Motor
31
3.14
PWM
32
3.15
7805 Regulator
33
3.16
LM 317 Circuit
34
3.17
IR for Path Detection
35
3.18
IR Pair Circuit
36
3.19
Magnetic Sensor
39
3.20
Application Circuit of Display Unit
41
4.1
Front View of AGV
50
4.2
Top View of AGV
51
4.3
IR Sensor Positions of AGV
52
4.4
Magnetic Sensor Positions
53
4.5
Flow Chart
54
4.6
Block Diagram
55
4.7
Circuit Diagram
56
4.8
Fully Developed Prototype
57
ACET
ACET
CHAPTER I
INTRODUCTION
1.1 AUTOMATED GUIDED VEHICLE
An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that
follows markers or wires in the floor, or uses vision or lasers. They are most often used in
industrial applications to move materials around a manufacturing facility or a warehouse
Automated guided vehicles increase efficiency and reduce costs by helping to
automate a manufacturing facility or warehouse. The AGV can tow objects behind them
in trailers to which they can autonomously attach. The trailers can be used to move raw
materials or finished product. The AGV can also store objects on a bed. The objects can
be placed on a set of conveyor and then pushed off by reversing them. Some AGVs use
forklifts to lift objects for storage. AGVs are employed in nearly every industry,
including, pulp, paper, metals, newspaper, and general manufacturing. Transporting
materials such as food, linen or medicine in hospitals is also done.
An AGV can also be called a laser guided vehicle (LGV) or self-guided vehicle
(SGV). Lower cost versions of AGVs are often called Automated Guided Carts (AGCs)
and are usually guided by specific lines magnetic tape. AGCs are available in a variety of
models and can be used to move products on an assembly line, transport goods
throughout a plant or warehouse, and deliver loads to and from stretch wrappers and
roller conveyors.AGV applications are seemingly endless as capacities can range from
just a few kgs to hundreds of tons. The Aim of the project is to design and fabricate such
a AGV
There are many definitions of AGVs, different according to points of view.
Wikipedia, the free encyclopedia, defines AGVs as:
A robot that been used highly in industrial applications to move materials from point to
point
The American Society of Safety Engineers (ASSE) defined AGVs as:

a. Machines without drivers that can move along pre-programmed routes, or use sensory
and navigation devices to find their own way around.
b. Vehicles that are equipped with automatic guidance systems and are capable of
following prescribed paths. Or Driverless vehicles that are programmed to follow guide
path
1.2 BACKGROUND
The creations of Automated Guided Vehicle (AGV) have been around since the 1950s
and the technology was first developed by Barret Electronics from Grand Rapids,
Michigan. It was then developed by the Europeans in the 1970s and nowadays AGVs can
be found in any countries. One of the first AGVs was a towing vehicle that pulled a series
of trailers between two points, and todays there are many task given to AGVs and they
also have their own name and potentials.
Considering the full potentials and advantages of the Automated Guided Vehicle
(AGV) in our livings, it is valuable to do this project, as it also will be the first step
towards the creation of more intelligent technology or system. The simplest AGV model
may use just a sensor to provide its navigation and can be the complex one with more
sensors and advance systems to do the task. They can work or do the task everywhere
needed but the safety for the AGV as well as the people and environment surround it
must be provided.
The AGVs is just the same as mobile robot, which can moves from one place to
another to do their task, but mostly the mobile robot is used for difficult task with
dangerous environment such as bomb defusing. Furthermore, the mobile robot can be
categorized into wheeled, tracked, or legged robot. Although the AGVs may not be
glamorous of robots, but their work, which usually menial, are often be essential to the
smooth running of factories, offices, hospitals, and even houses. They can work without
any complaint around many workplaces all over the world.
1.3 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 and to make improvement to the facilities provided in the
workplaces. Usually the AGVs are implemented in factories, hospitals, offices, houses,
and even can be found anywhere outdoors without the people surround realized it.
In the industries or factories, the AGVs can ease the physical strain on human
workers by performing tiring tasks, such as lifting and carrying heavy materials, more
efficiently with no signs of fatigue creeping in. They can carry far more than human
workers, and their movements can be tracked electronically at all times. Their movements
can be timed to feed or collect products or materials from the work cells in the factories.
Besides that, in the hospitals thousands of staff spends a portion of their day moving
medical supplies, bedding, medicines and other equipment around large hospitals. By
using the AGVs, the strain on the workers can be ease as well as the hospitals system
would be more smart and systematic without any bad complaint from the patients and
people. AGVs also capable of both cutting cost and releasing more staff hours to tend and
care for patients.
Therefore it is very significant that the valuable knowledge on AGV construction is
studied and be further implemented from the result of this project. It is due to its
advantages to our own living and technology.
We have pleasure in introducing our project AGV, which is equipped by
microcontroller, motor driving mechanism, lift mechanism and battery. The power stored
in the battery is used to drive the DC motor that causes the movement as well as lifting
power to AGV. Battery assembled on the AGV is easily replaceable and detachable, used
for recharging the battery, while the AGV is under roof.
1.4 PROJECT AND ITS SCOPE

The objective and scope of this project is to create an AGV model that can follow a trail
of line on a flat surface horizontally. This AGV model is using microcontroller to control
all navigation and lifting functions during its operation. In other words, the
microcontroller acts just like the brain for the model that controls all operation of the
system.
The model is a three-wheeled mobile robot that has the ability to follow line on
floor. There are three wheels including two driving wheels controlled by two motors and
a free wheel in front that is able to rotate 360. With three wheels, both driving wheels are
always in contact with the surface, because of the robots steering relies on both its driven
wheels being in contact with the surface at all times.
This project consists of four main stages, which are theoretical design, mechanical
fabrication, electronic hardware design and as well as algorithm design in assembly
language. The matter to be considered is how the robot can follow the trail of line
continuously. It is also important to choose the most suitable microcontroller, actuators,
and sensors to achieve the project objectives.
. 1.5 MARKET SURVEY

A market survey is an important requirement for initiating any successful business. The
objective of a market survey is to collect information on various aspects of the business.
This survey is a tool through which we can minimize risk. After the market survey, the
results must be analyzed in order to finalize a business plan.
We are implementing automatic guided vehicle, which replaces the normal
transporting methods. So that we wants to consider all the sections related to this works
such as problems arising while installing. So we conducted a market survey by personnel
interview techniques was used with the measure emphasis on personal interview method.
Interviews were conducted through the structure questionnaire, Also we go through
people who work in large industries such as production plant, supply station etc.
The following questions are mainly taken for questionnaire:
Area of applications? i.e. inside/outside/both
Types surface of flooring?
Weights of loads max?
Distance to transportation?
From the data which we got from the market survey we are well know about the
things what the market needed, and what modifications should be taken to the system.
And we analysis the data and make objectives want to goal.
CHAPTER II
LITERATURE REVIEW
Automatic Guided Vehicles (AGVs) have played a vital role in moving material and
product for more than 50 years. The first AGV system was built and introduced in 1953.
It was a modified towing tractor that was used to pull a trailer and follow an overhead
wire in a grocery warehouse. By the late 1950's and early 1960's, towing AGVs were in
operation in many types of factories and warehouses.
The first big development for the AGV industry was the introduction of a unit
load vehicle in the mid 1970s. This unit load AGVs gained widespread acceptance in the
material handling marketplace because of their ability to serve several functions; a work
platform, a transportation device and a link in the control and information system for the
factory.
Since then, AGVs have evolved into complex material handling transport vehicles
ranging from mail handling AGVs to highly automated automatic trailer loading AGVs
using laser and natural target navigation technologies. In fact the improvement of AGVs
over the last decade is deeply indebted to development of Scheduling, Algorithm and
Steering methods. The problem of scheduling of AGVs and the other supporting
equipments has been extensively studied by Basnet and Mize and Rachamadugu and
Stecke currently providing the most up-to-date and comprehensive reviews in this area.
Han and McGinnis have developed a real time algorithm in which material
handling transporters are considered. Schriber and Stecke have shown how the additional
consideration of the material handling system and limited buffers degrades the system
performance. Sabuncuoglu and Hommertzheim have highlighted the importance of
material handling and they compared several AGV dispatching rules. They have also
shown how the buffer capacity can affect the performance of the system. Flexibility,
which is a distinguishing feature of FMSs, has received an extensive amount of attention.
Routing flexibility (i.e., alternative machines and processing routes) has been considered
by Wilhelm and Shin, Chen and Chung, and Khoshnevis and Chen . These studies have
indicated that dynamic routing (i.e., a path determined dynamically during schedule
generation) performs better than a preplanned routing.
Rachamadugu et al. Have proposed a quantitative measure of sequence flexibility
and have shown that perfect sequence Flexibility improves system performance. Similar
observations have been made by Lin and Solberg. In most work to date, tools,
pallets/fixtures and their availability are not modeled adequately. A static allocation of
tools is usually assumed in these studies.
However, some researchers have considered a limited tool magazine capacity and
the changing of tools from central tool storage. One purpose of this thesis is to develop an
algorithm that can be used to investigate the research issues discussed above. This
algorithm should not only consider the major elements of FMSs but also generate high
quality schedules in a reasonable amount of time. In this thesis, the basic structure and
characteristics of such an algorithm is described.
Kim et al. Proposed a deadlock detection and prevention algorithms for AGVs. It
was assumed that vehicles reserve grid blocks in advance to prevent collisions and
deadlocks among AGVs. A graphic representation method, called the "reservation graph,"
was proposed to express a reservation schedule in such a form that the possibility of a
deadlock can be easily detected. A method to detect possible deadlocks by using the
reservation graph was suggested.
Maxwell and Muckstadt first introduced the problem of AGV flow system design.
While their main concern is vehicle routing, they also address material flow path and
station location design issues. The flow network they used, known as conventional
configuration, is composed of unidirectional arcs. Gaskin and Tanchoco developed the
first integer programming model for material flow path design. Given a fixed network of
aisles and fixed pickup and delivery stations, the model assigns direction to arcs to
minimize the total trip distances of loaded vehicles. Goetz and Egbelu developed an
alternative model, where the station locations no longer are fixed but restricted to the
nodes on the boundary of the cells. Sun and Tchernev provide a comprehensive review on
the models developed for conventional configuration.
Afentakis states the advantages of the loop layout as simplicity and efficiency,
lowinitial and expansion costs, and product and processing flexibility. Loop layout has
been studied by many researchers including Bartholdi and Platzman , Sharp and Liu
,Kouvelis and Kim , Egbelu , Banerjee and Zhou , and Chang and Egbelu. Bozer and
Srinivasan initiate the concept of tandem configuration as a set of no overlapping,
bidirectional loops, each with a single vehicle.
Another problem in steering issues is to schedule several AGVs in a nonconflicting manner which is a complicated real-time problem, especially when the AGV
system is bi-directional. In fact, many conflicting situations may arise such as head-on
and catching-up conflicts when the AGVs or the guide-paths are bidirectional and if no
efficient control policy is used to prevent them. Several conflict-free routing strategies
have been proposed and can be classified into two categories:
Predictive methods: Aim to find an optimal path for AGVs. The conflicts are
predicted off-line, and an AGVs route is planned to avoid collisions and
deadlocks.
Reactive methods: the AGVs are not planned and the decisions are taken in a realtime manner according to the system state.
These methods are based on a zone division of the guide-path and consider them
as non sharable resources. Predictive methods give good performance, but are not very
robust since they do not take into account real time problems. However, reactive methods
are very robust but the resulting performances can be poor because the decisions are
taken by considering a very short-term time horizon. In this report due to specification of
the whole plan (presence of only one AGV) a kind of predictive method is proposed.
In early 1990s Fuzzy logic came through to control and manipulate whole of the
material flow in manufacturing floors. The main indication of employing this system on
AGVs was the ability of controlling multiple AGV in a same time without
collision.However, only simulation results are presented. Senoo et al used experimental
results of a three wheeled mobile robot to discuss the stability of a fuzzy controller. It is
also stated that fuzzy control was implemented in order to achieve reduction of steer
energy, while maintaining better steer angle when compared with PI control.
Fuzzy logic has found useful applications in control among other areas. One
useful characteristic of a fuzzy controller is its applicability to systems with model
uncertainty and/or unknown models. Another useful characteristic of a fuzzy logic
controller is that it provides a framework for the incorporation of domain knowledge in
terms of heuristic rules. Wuwei et al. They presented the new navigation method for AGV
with fuzzy neural network controller when in the presence of obstacles. Their AGV can
avoid the dynamic and static obstacle and reach the target safely and reliably.
Wu et al. used fuzzy logic control and artificial potential field (APF) for AGV
navigation. The APF method is used to calculate the repulsive force between the vehicle
and the closest obstacle and the attractive force generated by the goal. A fuzzy logic
controller is used to modify the direction of the AGV in a way to avoid the obstacle. Lin
and Wang proposed a fuzzy logic controller for collision avoidance for AGV.
They combined fuzzy logic with crisp reasoning to guide an AGV to get out of
trap since memories of path and crisp sequence flows are handled by non-fuzzy
processing. Their designed AGV was able to avoid collision with unknown obstacle.
Alves and Junior used a step motor to turn the direction of the ultra-sonic sensors, so that
each sensor can substitute two or more sensors in mobile robot navigation. Perhaps
Sugeno has done one of the pioneering researches in mobile robot navigation using fuzzy
logic control. The fuzzy control rules, which he defines for the controller, were derived
by modeling an expert driving action. He made a computer model of a car in
microcomputer to find fuzzy rules. The speed of the designed car was constant; then, the
control input to the car is only the angle of the steering angle
Mehdi Yahyaei has design a AGV using fuzzy logic system and a rotational ultra
sonic sensor to steer the AGV to avoid collisions and obstacles. He also employed a
programmable logic control (PLC) as the processor which makes the AGV to be
ultimately fit to the industrial environments.
2.1 AUTOMATED GUIDED VEHICLE BUILT WORLDWIDE

Some of the Automated Guided Vehicles (AGVs) that are well known are
discussed in brief.
2.2 MOBILE POST DISTRIBUTION SYSTEM (MOPS)

MoPS or Mobile Post Distribution System (Tschichold, Vestli, Schweitzer, 1999) is a
research AGV developed at the Institute of Robotics in Zurich, Switzerland. It is used to
transport mail around the Swiss Federal Institute of Technology in Zurich. MoPS is
powered up by rechargeable batteries which give it a 4-hour active life, weighs around
90kg and can carry up to 50 kg of postal payload. It is also capable of hot-swapping its
own batteries pack, thus ensuring 24h availability.
The MOPS provide services of picking up boxes with incoming mail at the
ground floor of the five floor building, which is sorted by human first, delivering them to
the secretaries' offices, subsequently bringing back the outgoing mail to the ground floor
station. It is also capable of switching floors by sending an infrared signal to the
buildings lifts. As the building is open to the public, protection against theft of the mail is
provided by motorized blinds over the pigeon-hole mail points, which can be opened by
the robot and by authorized staff.
Fig 2.1 The Mobile Post System MOPS
2.3 PARKSHUTTLE AGVS OF AMSTERDAMS SCHIPHOL AIRPORT
Fig 2.2 The ParkShuttle AGVs of Amsterdams Schiphol Airport.
The ParkShuttle (FROG Navigation Systems) is an automatic navigating vehicle which

provides transportation for passengers. It is a people mover system. There is no driver
onboard, instead a computer and an electronic navigation system do the driving. This
ParkShuttle has a safety system of sensitive and intelligent sensors. The sensors scan the
area in front of the vehicle and will decelerate or stop the vehicle when an unknown
obstacle is detected.
An additional safety feature is provided by the bumper system that brings the
vehicle to an immediate halt when it is impressed. In addition, the vehicle has emergency
stop buttons (both inside and outside) that can be operated by the passengers. The speed
is limited to 40 km/h obtain a good ride quality. 8 The ParkShuttle vehicle runs on four
rubber tires. Traction is provided by an electric motor powered by a rechargeable battery.
Up to 100 km can be covered on one battery-load. It has a capacity of 10 passengers, 6
seated and 4 standees. It is easy to get into and out of the vehicle (wheelchair accessible)
and provides good all-round visibility. Inside the vehicle is a console on which the
passengers can indicate their destination.
Each vehicle is also fitted with an information display that announces the stop at which
the vehicle has arrived. The maximum load is 800 kg. The maximum vehicle weight is
monitored by means of weight sensor.
2.4 LINE FOLLOWING ROBOT

Line following robot is generally a wheeled mobile robot. The method of line following
varied depending on the number of sensors available and the type of line to be followed.
There are four methods identified including edge following, line search, line trap, and
cross-over. These four methods are different in number of sensors that used and also the
results that will be obtained are different. With only one light sensor, the robot will have
to know where the line is, or spends time searching to find it. Whereas with two light
sensors, the robot is possible to remember which direction the line went. With more
sensors, the result that will be obtained would be more excellent and the robot will be
more intelligent.
Table 2.1 Line Following Method
Method
Characteristics
Edge following
Stay on the edge of the line
Line search
Stay on the line
Line trap
Keep the line between the sensors
Cross over
Move back and forth over the line
2.5 KERWINS LINE FOLLOWING ROBOT
Fig 2.3 The Kerwins line following robot using three matched IR transmit/receive pairs
The Kerwins line following robot (ranchbots) is a design with Futaba S-148
servo motors mounted to the bottom of the plexiglass. It has three wheels with the front
wheel is the omni-directional wheel. The sensor system consists of an array of three
matched IR transmit/receive pairs mounted on a circuit board that can be raised or
lowered to fine tune the sensitivity. It uses the Atmel microcontroller as the controller
part. The microcontroller takes input from sensor array and drives the servo motors in
response.
CHAPTER III
COMPONENTS SELECTION & DESCRIPTION
3.1 DESIGN OBJECTIVES
In nowadays AGV has a greater influence in the production field. Why we prefer this
system is mainly because of its accuracy to transport goods, avoiding accidents at
industrial zone, decreasing production overall cost etc.
In our project the important factor is that, we give an additional functions to AGV,
i.e. we provide a lifting mechanism to take loads from station to station. The lift will
actuate at those particular stations using sensors. Also we provide a sensor which detects
the objects in the paths to avoid collision with those objects, by stopping the vehicle and
moves after the when object leaves the path.
3.2 DESIGN CONSIDERATIONS

In design problems many decision variables arise. The impact of decisions on mutual
interactions and performance might be difficult to predict. It might be hard to decide on
one thing without considering other decision variables. At least the following tactical and
operational issues have to be addressed in designing an AGV system
Flow path layout
Traffic management: prediction and avoidance of collisions and deadlocks
Number and location of pick-up and delivery points
Vehicle requirements
Vehicle routing
Vehicle scheduling
Battery management
A flow path layout compromises the fixed guided paths on which vehicles can
travel to the various pick-up and delivery points of loads. Traffic management is required
to avoid collisions and deadlock situations in which two or more vehicles are blocked
completely. To ensure that loads are transported in time, sufficient vehicles should be
available and the right vehicle should be dispatched to the right load.
This layout is usually represented by a directed network in which aisles
intersections and pickup and delivery locations can be considered as nodes. The arcs
represent the guide path the AGVs can travel on. Directed arcs indicate the direction of
travel of vehicles in the system. The layout of this flow path directly influences the
performance of the system. In our project we just mark two stations only. One loading
and one unloading station. The carrier moves in the loop which connects these two
stations.
In controlling and designing AGV systems the problem of prevention of AGV
collisions and deadlocks should be addressed. By attaching sensors on AGVs, physical
collisions can be avoided. An AGV should have the ability to avoid obstacles and the
ability to return to its original path without any collisions. We had fabricated only one
AGV. So the traffic management has only less important in our case. But while using
more than one carrier we should take care about them.
To determine an optimal AGVs system, capable of meeting all requirements,
many factors have to be taken into account. Several of these factors are:
Number of units to be transported
Points in time at which units can be or need to be transported
Capacity of the vehicle
Speed of the vehicle
Costs of the system
Layout of the system and guide path
Traffic congestion
Vehicle dispatching strategies
Number and location of pick-up and delivery points
If AGVs use batteries, frequent battery changing might be required. McHaney
(1995) presents an overview of AGV battery technology. The time required for replacing
or charging batteries can impact the number of vehicles required. Simulation results from
McHaney (1995) indicate a significant increase in the number of AGVs required while
incorporating battery management issues in the simulation study compared to neglecting
these issues in the studies. Furthermore, the time required for charging batteries impacts
throughput, congestion and costs.
3.3 COMPONENTS OF AGV
1. MECHANICAL PARTS
The Mechanical components includes,
1. Chassis
2. Steering system
3. Lift mechanism
Chassis
Act as a frame for attaching other components

Carry the load of other components and the payload.
Act as sacrificial component to prevent damage of expensive payload in case of
accidents
Steering System
Steering system is for steering the AGV. The two individual motors are directly attached
with the wheel for steering
Lifting Mechanism
Lifting mechanism is one of the main part of AGV, the lifting surface moves upward and
downward at specified stations. And carry the load during load transfer.
2. ELECTRICAL COMPONENTS
Electrical components include the motor and the power supply unit for the motor,
sensoring unit
3. ELECTRONIC COMPONENTS
Electronic components provide sensing, logical decision and control of the vehicle. It
includes microcontroller, which is the brain of the vehicle for the decision logic, the
motor driver as both sensing and control of motor, regulator ICs, LCD Display unit,
sensors for sensing the path, position of loading and unloading stations, detect object in
the path etc.
4. SOFTWARE COMPONENTS
Computer is used for making and implementing program for the microcontroller, using
embedded computer programming language.
For this project we use Arduino Uno
microcontroller board based on the ATmega328 .The Arduino Uno can be programmed
with the Arduino software.
3.4 MECHANICAL PART

3.4.1 CHASSIS
The chassis is fabricated from Acrylic sheet. This is done for ease of fabrication, and to
reduce the overall weight. It was designed in Catia; part of fabrication was outsourced
due to unavailability of precision cutting tools. The chassis was designed to take a static
load of 3kg.
The Top part of chassis has lots of drilled holes which serves as holes for bolting
other parts and reduce the weight of the chassis. The Holes are arranged in a zigzag linear
arrangement so that the decrease in strength of chassis is not considerable.
The flange which holds the motor was designed using Aluminium and is bolted to
the chassis. So that the driving motors can easily accommodate below the chassis. The
chassis incorporates hole for attaching front globe wheel, and also for attaching the lift
structure
Fig 3.1 Chassis of AGV

Table 3.1 Technical Data of Chassis
Features
Length
Breadth
Height
Material
Maximum load
Mounting Holes
Data
300mm
160mm
62mm
Colored Acrylic sheet, Aluminum
143mm Holes for general mounts
28mm Holes for motor
110mm Hole for switch
3.4.2 STEERING SYSTEM

The steering system used in the model is of differential type. A differential wheeled
vehicle is a vehicle whose movement is based on two separately driven wheels placed on
either side of the body. It can thus change its direction by varying the relative rate of
rotation of its wheels and hence does not require an additional steering motion. It allows
the turning center to be on the vehicle body thus the ability to rotate on the point
Fig3.2 Differential Steering
If both wheels rotate at the same speed and in the same direction, the robot will
move in a straight line.
Fig 3.3 Small radius turning
If one of the wheels is stopped, while the other continues to rotate, the robot will
pivot around a point centred approximately at the mid-point of the stopped wheel.
Table 3.2 Steering Specifications

Feature
Wheel Base
Wheel Diameter
Track Distance
Material
Turning radius
Data
180mm
70mm
170mm
Rubber and plastic
190mm
3.4.3 LIFTING MECHANISM

The lift is the main component of this AGV. The lift takes and gives loads at specific
stations. The vehicle under stands the stations using sensors. Lift is attached in the front
portion of the chassis. The power for lift is transmitted from a motor using a threaded
shaft.
The lift consists of mainly two plates. One is centrally drilled and tapped. Second
plate is attached with the lower one, using bolts, at a distance. The shaft of the motor
drilled axially and made internal threads using tap. Both the plates moves in between two
guide ways. The threaded shaft is passed through the centrally tapped hole of lower plate.
During the rotation of shaft the lower plate moves up or down. And the upper
plate moves according to it. The time for the rotation is limited for few seconds. It can be
adjusted by making changes in the microcontroller program. A magnet is attached above
the upper plate, which helps to hold the items to be lift, which have magnetic behavior.
Fig 3.4 Lifting using threaded shaft
In order to reduce the overall cost and weight of the AGV, we used acrylic sheets
for the manufacturing of lifting surfaces, Aluminum C channels for the guide ways in
between the plates moves are used for the fabrication.
2
3
Fig 3.5 Structure of lift

1.
2.
3.
4.
Guide ways
Threaded shaft
Lower plate
Upper plate
3.5 ELECTRICAL COMPONENTS

3.5.1 DC MOTOR
100 RPM DC Motor with Gearbox generally used for robotic application are used for the
driving mechanism, steering mechanism and lifting mechanism. We can adjust it to
desired RPM using gear box. Very easy to use. It is excellent for line tracking robotic
application.
Fig 3.6 DC Motor with Gear box
Table 3.3 Motor Specifications

Feature
Supply voltage
Speed
Shaft Diameter
Weight
Torque
No-load current
Load current
Data
12V DC
100 RPM with gear box
6mm
125gm
12Kgcm
60mA(Max)
250ma(Max)
3.5.2 BATTERY
The power required for the entire working process is given by a Rechargeable valve
regulated Lead-Acid battery. The power from the battery is split it into two and one part
is given to microcontroller, display unit, driving unit and other part is given to lifting
motor.
Fig 3.7 Battery
Table 3.4 Battery Specification

Features
Speed
Voltage
Torque
No load current
Load current
Data
100rpm
12V DC
12Kg-cm
60mA
250mA
3.6 ELECTRONICS COMPONENTS

3.6.1 MICROCONTROLLER
A microcontroller (C, uC or MCU) is a small computer on a single integrated circuit
containing a processor core, memory, and programmable input/output peripherals.
Microcontrollers are designed for embedded applications, in contrast to the
microprocessors used in personal computers or other general purpose applications.
We use ATmega 328 in our AGV.The AtmelAVR ATmega 328 is a low-power
CMOS 8-bit microcontroller based on the AVR RISC architecture. By executing powerful
instructions in a single clock cycle, the ATmega8 achieves throughputs approaching
1MIPS per MHz, allowing the system designed to optimize power consumption versus
processing speed.
The reasons for using ATmega 328 are:
Low cost
Easy to program
High-performance, Low-power
Fully Static Operation
High Endurance Non-volatile Memory segments
Power-on Reset and Programmable Brown-out Detection
Internal Calibrated RC Oscillator
External and Internal Interrupt Sources
High stress value
Five Sleep Modes: Idle, ADC Noise Reduction, Power-save, Power-down, and
Standby
I/O and Packages
23 Programmable I/O Lines
28-lead PDIP, 32-lead TQFP, and 32-pad QFN/MLF
Operating Voltages
2.7V - 5.5v to 4.5V - 5.5V
The Microcontroller is programmed with the required program to accept the data
from the sensing unit, interpret it, and give responses to the driving and lifting
mechanism in very small time interval.
Table 3.5 Specification of ATmega 328

Type:
Flash
I/O pins
Minimum/Maximum Voltage:
Maximum current:
Number of PORTS
No of channels
Bus width
Oscillation Speed
PWM
28Pin DIP Package

32K Bytes
23 Pins
1.8/5.5V
20mA
4
6
10Bit
20Mhz
6
Table 3.6 Important Connections

PIN Name
Pin No
Vcc
GND
8,22
XTAL1
XTAL2
10
RXD/PD0
PB4
16
PB5
19
PB6
PB7
10
Reset
Rxd
Txd
AVCC
20
AREF
21
Fig 3.8 ATmega 328 microcontroller
3.6.2 MOTOR DRIVER

It is an electronic circuit which enables a voltage to be applied across a load in either
direction. It allows a circuit full control over a standard electric DC motor. That is, with
an H-bridge, a microcontroller, logic chip, or remote control can electronically command
the motor to go forward, reverse, brake, and coast.
A "double pole double throw" relay can generally achieve the same electrical
functionality as an H-bridge, but an H-bridge would be preferable where a smaller
physical size is needed, high speed switching, low driving voltage, or where the wearing
out of mechanical parts is undesirable. The term "H-bridge" is derived from the typical
graphical representation of such a circuit, which is built with four switches, either solidstate (e.g., L293/ L298) or mechanical (e.g., relays).
In our AGV we use the driver IC L293d. There are two driver ICs are provided in
the design, because three motor are in the AGV. One driver circuit is connected to the two
motors of driving mechanism. And second one is used for the motor which is
incorporated with the lift.
Fig 3.9 Motor Driver (L293D)
The following figure shows the connection of the driving mechanism.
Fig 3.10 L293D connected with two motors

To simplify use as two bridges each pair of channels is equipped with an enable
input. A separate supply input is provided for the logic, allowing operation at a lower
voltage.
This device is suitable for use in switching applications at frequencies up to 5 kHz.
In the lifting section one motor is utilized. So the one side of the driver circuit is not
connected.
Fig 3.11 L293D connected with one motor
In the both end of a motor voltage is always 5v. So there no potential difference between
the two terminals of the motor. Therefore there is no current flow between terminals, and
motor will not work. During the operation at one terminal the voltage becomes zero volts.
And thus the current flows through the motor and it works. We can rotate the motor in
two directions.
In the driving mechanism, in our design one direction of rotation of motor is
needed. Because the AGV doesnt wants to moves in reverse. But the connection is made
in such a way that both two motors rotate in opposite direction. i.e., the motor which
rotates the right wheel in clockwise direction and that of left wheel rotates in counter
clockwise direction.
But the lifting motor wants to rotate in the both directions. For the clock wise
rotation lift move up and for counter clockwise it moves down. The movement of the lift
surface depends on the internal thread of the lower plate also.
Fig 3.12 Circuit connection of driving motor
Fig 3.13 Connection of lifting motor for clock wise and counter clock wise rotation
To control motor speed we can use pulse width modulation (PWM), applied to the enable
pins of L293d driver. PWM is the scheme in which the duty cycle of a square wave
output from the microcontroller is varied to provide a varying average DC output.
Fig 3.14 PWM

Table 3.7 Technical Specification of L293D
Symbol
Vs
Vss
Vi
Ven
Io
Ptot
Tstg,Tj
Parameter
Supply Voltage
Logic Supply Voltage
Input Voltage
Enable Voltage
Peak Output Current
Total Power Dissipation at Tpins=90c
Storage and Junction Temperature
Data
36V
36V
7V
7V
1.2A
4W
-40 to 150 c
3.6.3 REGULATORS
Mainly two types of voltage regulators are used in the design. One is variable and the
next is not. The non variable belongs to 78 series. And variable is LM series. The main
supply is 12V. But we need only 5V. It is made possible using these regulators
3.6.3.1 7805 Regulator
It is the one of the important electronic part. The motor, driving IC, microcontroller etc
need only 5V for their operations. Before the supply is given to these circuits it is given
to the 7805 voltage regulator. It reduces the voltage from 12V to 5V.
Fig 3.15 7805 REGULATOR
The main features of these regulators are:
Internal Thermal Overload Protection.

Internal Short Circuit Current Limiting.
Output Current up to 1.5A.
Satisfies IEC-65 Specification.
Table 3.8 Maximum Ratings of 7805
Characteristic
Input Voltage
Operating Junction
Temperature
Storage Temperature
Max. junction Temperature
Symbol
Vin
Tj
Rating
35V
-40 to 150 c
Tstg
Tj(max)
-55 to 150 c
150 c
Table 3.9 Technical Specifications of 7805

ELECTRICAL CHARACTERISTICS (VIN=10V, IOUT=500mA, 0c Tj
125c)
Characteristic
Data
Output Voltage
4.8 to 5.2 V
Input Regulation
100 mV
Output Noise Voltage
50 microVrms
Ripple Rejection Ratio
78dB
Drop Out Voltage
2.0V
3.6.3.2 LM317 VARIABLE REGULATOR
There are five variable regulators are used in our design. Its used for reduce the
voltage to the motor and to sensors. It will helps to reduce the speed of rotation of
the motor and thus we can adjust the speed of the vehicle.
Fig 3.16 LM317 circuit

Table 3.10 Technical Specificationsof LM 317
Parameter
Line Regulation
Load Regulation
Thermal Regulation
Current Limit
Ripple Rejection Ratio
Long term stability
RMS Output Noise
Data
0.01 %/V
0.1%/V
0.04%/W
2.2A
65dB
0.3%
0.003%
3.6.4 INFRARED SENSORS

IR Sensor is one of the important parts. Path detection and obstrucle detection is done
with the help of IR Sensors. There are five IR Sensors are in our AGV. Out of them four
are used for the path detection and rest of one is used for obstrucle detection.
IR sensor have a transmitter and a receiver port.
The strength of signal reached at the receiver port after the reflection of light is
used to detect the path. Path is marked in the black background by white lines. Sensor
detect the white line by the strength of IR wave. The reflected wave from white line has
high strength than that of from black. TSOP1730 are used in the design.
Fig 3.17 IR for Path Detection
The IR pair circuits are shown in the figure give below:
Fig 3.18 IR pair Circuit
The main features of this IR pair are:
Photo detector and preamplifier in one package

Internal filter for PCM frequency
Improved shielding against electrical field disturbance
TTL and CMOS compatibility
Output active low
Low power consumption
High immunity against ambient light
Continuous data transmission possible (up to 2400 bps)
Suitable burst length 10 cycles/burst
Table 3.11 Technical Specifications of IR pair

Characteristics
Supply Voltage
Output Voltage
Junction Temperature
Operating Temperature
Power Consumption
Irradiance
Directivity
Data
-0.3 to 6.0V
-0.3 to 6.0V
100 c
-2.5 to 85c
50mW
30W/m
45
3.6.5 MAGNETIC SENSOR

Magnetic sensors or magnetic switches are electronic switches that close under the
magnetic field. In this AGV there are two magnetic sensors. XEN-1210 is the sensor used
in this design.
The XEN-1210is a CMOS linear magnetic field sensor with a very low offset. It
uses Xensor's patented high performance spinning-current Hall-plate technology, a
precision amplifier and a sigma delta AD converter, and offers full digital control and
communication through a SPI serial bus. The device does not need calibration and in
contrast to low-offset AMR sensors does not use a set/reset method. It has no hysteresis
and is indestructible by high magnetic fields. It does not need any external components
and is truly a one-chip solution.
These sensors are used for the purpose of position detection. It is used for detect
the loading and unloading station. The sensor is attached with the vehicle at two different
positions. Magnets are placed in such a way that one sensor close when the vehicle comes
to the loading station. And when that switch close lift operates and moves up. After
loading the vehicle moves along the path. When it reach the unloading station the next
sensor close and lift operates to move down.
The main features of this sensor are
Single axis magnetic measurement

One chip solution
15nT resolution
Wide magnetic field range (63mT)
No magnetic hysteresis
Low voltage operation (2.5V to 3.3V)
Single supply
-40C to 125C Temperature Range
Fig 3.19 Magnetic sensor
Its a glass capsule, inside the tube there are two reed blades, which is connected to the
voltage terminal. Reed blades are placed over lapped, but not connected. There is a
contact gap between the blades. And the tube is filled with inert gas.
Table 3.12 Technical Specifications of Magnetic sensors
Specifications
Data
VDD
3.3V
Field Range
63mT
Resolution(24 bits)
7.5nT/LSB
Hysteresis
10nT
Noise
55nT/Hz^
Temperature range
-40 to 125 C
3.6.6 DISPLAY UNIT

Its just to display the inputs and outputs of the system. It mainly displays the inputs of
path sensing IR sensors and working of the vehicle. Inputs are displayed using numbers.
JHD162A SERIES is the display unit used in the AGV.
Characteristics:
Char. Dots 5 x 8
Display content 16 CHAR x 2ROW
Driving mode 1/16d
Available types:
TN STN (yellow green)
Reflective with El or Led Backlight
EL/100VAC 400HZ
LED/4.2VDC
Table 3.13 Technical Specifications of Display unit
Parameter
Supply Voltage
Input High Voltage
Output High Voltage
Operating Voltage
Table 3.14 Pin Configurations

Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Connection
Vss
Vcc
VEE
RS
R/W
E
DB0
DB1
DB2
DB3
DB4
DB5
DB6
DB7
LED+
LED-
Data
5.0V
2.2V
2.4V
1.5mA
Fig 3.20 Application Circuit of display unit
3.7 SOFTWARE COMPONENTS

We use ATmega328 microcontroller in this AGV. The microcontroller is the brain of the
vehicle. So the programming of the microcontroller has great imporantance in the
working.
Arduino software is used to program the microcontroller. Program is burned using special
microcontroller board. For this ATmega328 microcontroller Arduino Uno board is used.
The Arduino Uno is a microcontroller board based on the ATmega328 . It has 14
digital input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, a
16 MHz ceramic resonator, a USB connection, a power jack, an ICSP header, and a reset
button. It contains everything needed to support the microcontroller; simply connect it to
a computer with a USB cable or power it with a AC-to-DC adapter or battery to get
started.
Arduino is an open-source electronics prototyping platform based on flexible,
easy-to-use hardware and software. It's intended for artists, designers, hobbyists, and
anyone interested in creating interactive objects or environments.
The program is written in the Arduino software using special commands. The
main feature of this software is that we can run the program before burning in to the
microcontroller. And we can check the function. It will helps to make changes in the
program, in easy way.
The program is written in such a way that when the vehicle is in on condition, the
four line detecting sensors works and detect the line. If the middle sensors close, the two
driving motor rotates. If left sensors close right motor works, if right sensors close left
motor works. If the object detector sensor closes, all the two motors stops whatever may
be the line detecting conditions.
When the right magnetic switch closes the third motor rotates in clockwise, when
left switch closes it rotates in anti clockwise direction. All the input signals for the line
detection and position detection are shown in the LCD display. Also the working status is
shown in the display
3.8 PROGRAM SOURCE CODE

#include <LiquidCrystal.h>
int a = 0;
int b = 0;
int c = 0;
int d = 0;
int e = 0;
int f = 0;
LiquidCrystal lcd(8, 9, 10, 11, 12, 13);

void setup()
{
Serial.begin(9600);
pinMode(A0, INPUT);
pinMode(A1, INPUT);
pinMode(A2, INPUT);
pinMode(A3, INPUT);
pinMode(A4, INPUT);
pinMode(A5, INPUT);
pinMode(7, OUTPUT);
pinMode(6, OUTPUT);
pinMode(5, OUTPUT);
pinMode(4, OUTPUT);
pinMode(2, OUTPUT);
pinMode(3, OUTPUT);
lcd.begin(16, 2);
lcd.clear();
lcd.setCursor(0, 0);
lcd.print("L F Robot");
delay(1000);
}
void loop()
{
a = digitalRead(A5);
b = digitalRead(A4);
c = digitalRead(A3);
d = digitalRead(A2);
e = digitalRead(A1);
f = digitalRead(A0);
lcd.print("A:");
lcd.print(a);
lcd.print("B:");
lcd.print(b);
lcd.print("C:");
lcd.print(c);
lcd.print("D:");
lcd.print(d);
delay(100);
if((a==LOW && b==HIGH && c==HIGH && d==LOW) || (a==HIGH && b==LOW
&& c==LOW && d==HIGH))
{
lcd.clear();
lcd.print("Forward");
Serial.print("Forward\t");
digitalWrite(3, HIGH);
digitalWrite(6, LOW );
delay(200);
else if((a==LOW && b==LOW && c==HIGH && d== LOW ) || (a==HIGH &&
b==HIGH && c==LOW && d== HIGH ))
{
lcd.clear();
lcd.print("Left");
Serial.print("Left\t");
delay(200);
}
else if((a==LOW && b== HIGH && c==LOW && d==LOW) ||(a==HIGH &&
b==LOW && c==HIGH && d==HIGH))
{
lcd.clear();
lcd.print("Rihgt");
Serial.print("Rihgt\t");
delay(200);
}
else if((a==HIGH && b==HIGH && c==HIGH && d==HIGH )|| (a==LOW &&
b==LOW && c==LOW && d==LOW) )
{
lcd.clear();
lcd.print("Stop");
Serial.print("Stop\t");
delay(200);
}
if(f==HIGH)
{
while(1)
{
lcd.clear();
lcd.print("arm up");
digitalWrite(3, LOW);
delay(18000);
delay(200);
break;
}}
if(e==HIGH)
{
while(1)
{
lcd.clear();
lcd.print("arm down");
digitalWrite(2, LOW);
delay(18000);
delay(200);
break;
}}
delay(100);
}
CHAPTER IV
DEVELOPED PROTOTYPE
4.1 STRUCTURE
The vehicle is designed in such a way that, have stability during loading and working.
The lifting parts are provided in the front position. It comes above the front globe tyre.
The electronic and electrical parts are situated the rest of surface. Motor for driving are
provided in the rear region. Hence during dynamic loading the vehicle will be stable.
The structure of the vehicle is shown in the figure,
Fig 4.1 Front view of AGV
Fig 4.2 Top view of AGV
4.2 SENSORS POSITIONS

The positions of sensors are important factor to detect the position. The sensors for
detecting the path are situated after the front wheel. But the obstruction detection sensor
is placed below the chassis, and in front of the front tyre. There are four IR sensors used
to detect the path. They are along a line parallel to the breadth. And side sensors are
placed at an equal distances from middle sensors.
The width of the white line is little more than the distance between two sensors.
All the four sensors were give different movements during different combination. The
combination means closing of IR sensors. According to it the working of the driving
motors change. Initially the AGV is placed above the line, in such a way that the two
middle sensor comes above the white line.
During the straight path the middle sensors close, the two motors run in forward
direction with equal speed. Thus the vehicle moves in the straight line. When two of the
left side close left motor stops and right works. Then the AGV takes a left turn depending
upon the curvature. And when two right side sensors close,right side motor stops and the
left works. Thus the AGV takes a right turn.
Obstruction Detection
Fig 4.3 IR Sensors positions of AGV

The design of path is very important for an AGV. The magnetic sensors are placed below
the driving motors. Two magnets are used to detect the loading and unloading station.
There is a particular distance between those sensors and the lift. The loading stand should
be placed about at that distance from the magnet. Lifting up sensor is placed below the
right motor. So one of the magnet is placed in the right side of the path. Lifting stand is
placed about a distance from that magnet. The magnets are placed in such a way that any
one of its poles comes to top. Only then the magnetic switch works.
Fig 4.4 Magnetic sensors positions
4.3 FLOW CHART
Not Detect
Detect
Lift works
Off
Fig 4.5 Flow chart
On
4.4 BLOCK DIAGRAM
LCD
POWER SUPPLY
OBJECT DETECTOR
SENSOR
MOTOR
MOTOR 1
DRIVER
MOTOR 2
LINE DETECTOR
SENSOR
MICROCONTROLLER
MOTOR
DRIVER
MOTOR 3
MAGNETC REED
SENSOR
Fig 4.6 Block Diagram
Block diagram is a diagram of a system, in which the principal parts or functions are
represented by blocks connected by lines that show the relationships of the blocks. They
are heavily used in the engineering world in hardware design, electronic design, software
design, and process flow diagrams. In this diagram direction of all arrows are either from
or to the microcontroller.
4.5 CIRCUIT DIAGRAM
Fig 4.7 Circuit Diagram
The fully fabricated prototype of Automatic Guided Vehicle has possessed the
intelligences such as following a particular line, loading and unloading at particular
stations and collision avoidance etc.
Fig 4.8 Fully Developed Prototype
4.6 THEORETICAL AND LOGICAL CALCULATIONS
Torque of DC motor used, T
= 12Kg-cm
= 1.1772 N-m
Speed of motor, N
= 100 RPM
Angular Velocity,
= 2N/60
= (2**100)/60
= 10.47 rad/sec
Physically Power is the rate of doing work. For linear motion, power is the product of
force multiplied by the distance per unit time. In the case rotational motion, the analogous
calculation for power is the product of Torque multiplied by the rotational distance per
unit time
Rotational Power, P
=T*
= 1.1772*10.42
=12.33 W
No. of motors available for driving mechanism = 2 motors

So total power available for driving = 2* 12.33
= 24.66 W
There is only one motor is used for the lifting purposes,
So maximum power available at lifting mechanism
= 12.33 W
We have relation, v = r*
Where, v= Linear velocity
R= Radius
= Angular velocity
Diameter of shaft, d= 0.6cm

Radius of shaft, r= 0.3cm
=0.3*10^ (-2)
Linear velocity, v = (0.3*10^ (-2)) * 10.47
= 0.03141 m/s
= 3.14 cm/s
Weight of carrier = 1.495 Kg

Width of line marking= 4.3cm
For Lifting section,

Shaft Torque, Tsh = output/2N
= 1.1772/ (2*100)
= 1.8735* 10^ (-3) N-m
Force * Distance = Torque

Distance to be lifted, l= 5mm
Force * (5*10^ (-3)) = 1.8735*10^ (-3)
Force, F = 3.75 N
Force, F= Load * g
2
Acceleration due to gravity, g= 9.81m/ s
Load = 3.75/9.81
= 0.383 Kg
400 gms
4.7 BILLING
NO
ITEM
DC Motor
Micro Controller
NO. ITEM
COST/ITEM
TOTAL COST,
(R.S)
200
600
350
350
Driver IC
100
200
LCD Display
350
350
IR Sensors
175
875
Magnetic Switch
80
160
Acrylic Sheet
160
160
Aluminum channel
30
30
Battery
400
400
10
Fasteners
25
25
11
Magnets
25
75
12
Sticking Glues
30
60
13
Electronic Components
14
Arduino board
250
1350
Total
1350
4885
Table 4.1 Billing Table
CHAPTER V
CONCLUSION
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 avoiding. And the main function, transportation
of goods from station to station. The followings are the main features of the prototype
which we fabricated.
1. Speed of delivery
2. Adjustment of vehicle speed
3. Flexibility of path
4. Adaptive to changes in factory layouts
5. Avoid collision with other objects
6. Reduction in labour cost
7. Reduction in running cost compared to conveyer systems
8. Ability to add sensors to detect the payload conditions
9. Ability to adjust the lifting time
10. Continues cycle of working
11. Conditions for line following can be change easily
Automatic Guided Vehicle can be used in a wide variety of applications to

transport many different types of material including pallets, rolls, racks, carts, and
containers. AGVs excel in applications with the following characteristics:
Repetitive movement of material over a distance

Regular delivery of stable loads
Medium throughput/volume
When on time delivery is critical and late deliveries are causing inefficiencies
Operation with at least two shifts
Archive Systems
Cross Docking
Distribution
High Density Storage
High Speed Sortation
Material Flow and Transport
Production and Manufacturing Delivery Systems
Production and Manufacturing Support Systems
Warehouse Management and Control
Work-In-Process Buffers
The fabricated models have following advantages while comparing with the
existing models of this kind. The analyzing of advantages helps to motivate the
fabrication of AGV in the manufacturing industries. The important advantages of
the prototype are given below
Reduce manpower
Increase productivity
Eliminate unwanted fork trucks
Reduce product damages
Maintain better control of material management
Traffic control is not needed in this system because of single carrier
Suitable to transfer frames
Each of the machines has their own merits and demerits. During the production
we had faced many problems. Much of them were solved during the assembling.
But still some of them stand here, which cant have to remove. The followings are
the limitations of the prototype fabricated:
Installation cost is very high.

AGVs are fragile and should be handled with care.
Regular care, inspection and maintenance needed
Should be recharged periodically
AGV will stop delivery when it is forced off the path.
Battery should be recharged during intervals.
Sun light affect the movement.
REFERENCES
www.elsevier.com/locate/ejor/Survey of research in the design and control
of automated guided vehicle systems
www.jbtcorporation.com/en/Solutions/Automatic-Guided-Vehicles
http://www.arduino.cc/
www.atmel.com/devices/atmega328
www.sunroms.com
Automation, Production Systems, And Computer Integrated Manufacturing, By Groover,
Mikell.P, ISBN 8120334183

Automated Guided Vehicle

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AXIS COLLEGE OF ENGINEERING & TECHNOLOGY

Murikkingal P.O, Thrissur

DEPARTMENT OF MECHANICAL ENGINEERING

MINI PROJECT REPORT

AXIS COLLEGE OF ENGINEERING & TECHNOLOGY

Fabrication of Automatic Guided Vehicle

DEPARTMENT OF MECHANICAL ENGINEERING

AJITH ARAVIND, JESBIN JOHNSON, VINOD.K.J, VISHNU.T.SAJEEVAN

H.O.D Mechanical Engg

Fabrication of Automatic Guided Vehicle

Department of Mechanical Engineering

Fabrication of Automatic Guided Vehicle

Department of Mechanical Engineering

Fabrication of Automatic Guided Vehicle

Automatic Guided Vehicle

Project and Its Scope

CHAPTER II: LITERATURE REVIEW

AGV Built Worldwide Used

Mobile Post Distribution System (MOPS)

The Parkshuttle AGVs of Amsterdams Schiphol Airport

Line Following Robot

The Kerwins Line Following Robot

CHAPTER III: COMPONENTS SELECTION AND DESCRIPTION

Department of Mechanical Engineering

Fabrication of Automatic Guided Vehicle

3.6.3.1 7805 Regulator

3.6.3.2 LM317 Regulator

Program Source Code

CHAPTER IV: DEVELOPED PROTOTYPE

Theoretical and Logical Calculations

Department of Mechanical Engineering

Fabrication of Automatic Guided Vehicle

Line Following Methods

Technical Data for Chassis

Specifications of ATmega 328

Technical Specifications of L293D

Maximum Rating of 7805

Technical Specifications of 7805

Technical Specifications of LM 317

Technical Specifications of IR Pair

Technical Specifications of Magnetic Sensors

Technical Specifications of Display Unit

The Mobile Post System

The Parkshuttle AGVs of Amsterdam

The Kerwins Line Following Robot

Small Radius Turning

Lifting Using Threaded Shaft

DC Motor with Gearbox

ATmega 328 Microcontroller

Department of Mechanical Engineering

Fabrication of Automatic Guided Vehicle

Motor Driver (L293D)

L293D Connected with Two Motors

L293D Connected with One Motor

Circuit Connection of Driving Motor

Connection of Lifting Motor

IR for Path Detection

Application Circuit of Display Unit

Front View of AGV

Top View of AGV

IR Sensor Positions of AGV

Magnetic Sensor Positions

Fully Developed Prototype

Department of Mechanical Engineering