Automated Guided Dolly (AGD)

MATERIAL HANDLING IMPROVEMENT AUTOMATED GUIDED VEHICLE (AGV)

AUTOMATED GUIDED VEHICLE (AGV)

Approach

Parameter

s

• Feasibility study on new material handling concept – Automated Guided Vehicle (AGV) at Body Shop• To estimate cost incurred for AGV implementation• To enhance engineers & technicians skill

• Plant : MVF• Transfer Point :

Underbody to Mainbody

Target Line Speed : 2 uph

Feasibility study & DesignComponen

ts purchase

System integration & Programming

Assembly & Mechanical modification

In - House

PROJECT DESCRIPTION

DESIGN CONCEPT


Underbody Dolly CartExisting dolly cart

Modified existing dolly cart equipped with AGV kits

Automated Guided Dolly (AGD)

AGD design layout

Basic Process Flow

Loading body to trolley cart

Press “Start” button

AGD runs

Body check

AGD

Ope

ratio

nJig

O

pera

tio

n

PROCESS PLANNING & LAYOUT


Underbody Line

Mainbody Line

Respot Line

The estimated travelling distance for AGD from Underbody to Mainbody line is 136 meter per trip (complete 1 cycle)

Estimated Distance:68 meter

ATTACHMENT

OVERALL SYSTEM ARCHITECTURE PLANNING


Loading body to

trolley cart

Complete loading process confirm

Unloading body

Process complete

Man

ual

Ope

ratio

nAG

D O

pera

tion

Man

ual

Ope

ratio

n

AGV Main Controller

PLC

Mai

n C

ontr

olD

rive

& S

teer

ing

Con

trol

Sensors & module setting

Read sensorRead Button

(Start)

Safety control activation

Drive unit setting (Speed)

Left drive =Right drive

Tape detected?

Off track?

Drive unit setting (Speed)

LHS? Left drive > Right

driveRHS?

Right drive > Left drive

Y

Y

NOPN

N

• Read external command

from HMI

AGD move to set destination

AGD CONTROL SYSTEM PLANNING


Main Control

Drive & Steering Control

A/D

D/AM

agne

tic

Sens

or

Mot

or

Dri

ver

M

Mot

or

Dri

ver

M LHS

RHS

HMI

Power Module

• Operation mode : Manual / Auto

• Manual jog operation• Speed setting

Obs

tac

le

Sens

or

E-s

top

/ co

llisi

on

dete

ct

Mar

ke r Se

nsor• Setting for

Destination High / Low speed section

• Path Follower

Controller

Y

AGD PROGRAMMING FLOWCHART PLANNING


Read HMI

Auto Mode?

Manual / Pendant Control

Y

N

Set obstacle sensor

Set collision detect sensor

Set marker sensor

Set magnetic sensor

Tape detected

?

Set speed,LHS : 50 %RHS : 50%

Y

Set speed, 0%

N

1 marker present?

2 marker present?

Low speed, 20%

Y

N• Stop • Reset sensors & module• Waiting Ext

CommandN

Dri

ving

Con

trol

Stee

ring

Con

trol

Safe

ty

Con

trol

Off track to LHS?

7 step speed conditional

settingCondition 1:Set speed LH : 50%Set speed RH : 40%Condition 2:Set speed LH : 50%Set speed RH : 30%

.

.Condition 7:Set speed LH : 50%Set speed RH : 0%

Y

Off track to RHS?

N

N

Collision detected

?

Stop

Y

N

HM

ISe

nsor

s / M

odul

e In

itial

izat

ion

Obstacle detected

?

N

Y

7 step speed conditional

settingCondition 1:Set speed RH : 50%Set speed LH : 40%Condition 2:Set speed RH : 50%Set speed LH : 30%

.

.Condition 7:Set speed RH : 50%Set speed LH : 0%

Y

Read SensorRead Button

(Start)

DRIVE MOTOR SELECTION


Design Parameters:• Load : 750kg• Wheel Diameter : 5 inch• Motor Type : Brushless DC Motor• Drive Unit : 2 (1u LHD, 1u RHD) - Differential• Motor power rating > 128.4W (50% efficiency) *Proposal : 150W x 2 Drive Unit

3 X - 3

rad/sm/s Speed Chart

0.5 8.0

s

3s

3s

3s

rad/s2m/s2 Acceleration Chart

0.2 2.7

N.m Torque Chart

8.0

W Power Chart

64.2

X + 3

X - 3 X + 3

X - 3 X + 3

X - 3 X + 3

rpm

75

Kg.cm

81.6

Automated Guided Dolly (AGD)

Automotive

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