UNIVERSITI TEKNIKAL MALAYSIA MELAKA BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA TAJUK: DESIGN OF AUTOMATED GUIDED VEHICLE (AGV) FOR WORKPIECES TRANSPORTATION IN MANUFACTURING PLANT SESI PENGAJIAN: 2014/2015 Saya MOHAMAD ZAWAWI BIN ABDUL RAZAK mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD TIDAK TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) Alamat Tetap: NO 82 A, KAMPUNG BELUM BARU 33300 GERIK PERAK DARUL RIDZUAN Tarikh: ________________________ Disahkan oleh: Cop Rasmi: Tarikh: _______________________ ** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: DESIGN OF AUTOMATED GUIDED VEHICLE (AGV) FOR WORKPIECES TRANSPORTATION IN MANUFACTURING PLANT SESI PENGAJIAN: 2014/2015 Saya MOHAMAD ZAWAWI BIN ABDUL RAZAK mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan ( )
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap:
NO 82 A, KAMPUNG BELUM BARU
33300 GERIK PERAK DARUL
RIDZUAN
Tarikh: ________________________
Disahkan oleh:
Cop Rasmi: Tarikh: _______________________
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
i
DECLARATION
I hereby, declared this report entitled “Design of Automated Guided Vehicle (AGV) for
Workpiece Transportation in Manufacturing Plant” is the result of my own research
except as cited in references.
Signature : ………………………………………………
Author’s Name : ………………………………………………
Date : ………………………………………………
ii
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirement for the degree of Bachelor of Manufacturing
Engineering (Robotic and Automation) (Hons.). The member of the supervisory is as
follow:
……………………………………………….
(Project Supervisor)
(Prof. Dr. Bashir Mohamad Bin Bali Mohamad)
iii
ABSTRAK
Laporan projek ini membentangkan kerja-kerja yang dilakukan pada rekabentuk dan
permodelan mudah kenderaan berpandu automatik. AGV yang merupakan salah satu
system yang mengendalikan peralatan yang telah digunakan secara meluas dalam industri
pembuatan kebanyakan hari. Ini adalah kerana ia memberi lebih banyak kemudahan
sistem pengendalian. Konsep asas AGV yang menggabungkan kenderaan berkuasa bateri
dan tidak memerlukan dengan pengaturcaraan keupayaan untuk pemilihan laluan dan
kedudukan. Ia dilengkapi untuk menavigasi dalam rangkaian laluan panduan fleksibel
yang boleh diubahsuai dengan mudah dan berkembang. Perisian untuk mereka bentuk
AGV yang dipilih berdasarkan pengetahuan penulis. Beberapa idea-idea rekabentuk telah
dihasilkan dan dibahagikan kepada dua komponen utama iaitu kenderaan badan dan
rangka struktur. Dari idea-idea ini direka bentuk, perbandingan telah dibuat untuk
memilih idea Reka bentuk yang terbaik dari mereka bentuk AGV itu. Bahagian penting
AGV direka berdasarkan spesifikasi dan keperluan bahagian-bahagian yang perlu
dipasangkan padanya. Senarai semua bahagian perlu direka dan bahagian-bahagian yang
standard dibentangkan dalam laporan ini. Bahagian-bahagian terperinci dan spesifikasi
dibentangkan dalam solid model dengan dimensi yang memenuhi keperluan
pembangunan masa hadapan. Analisis unsur terhingga (FEA) telah digunakan untuk
menganalisis rekabentuk struktur AGV. Tekanan, anjakan, perubahan bentuk dan faktor
keselamatan adalah diperolehi dari analisis dan dibentangkan. Untuk pembangunan masa
depan, ia dicadangkan untuk fabrikasi dan menguji rekabentuk AGV. Daripada keputusan
ujian, tindakan perlu diambil (jika perlu) untuk penambahbaikan Reka bentuk AGV.
iv
ABSTRACT
This project report presents the work done on the design and soft modeling of automated
guided vehicle. An AGV is one of a material handling equipment that has been used
widely in most manufacturing industry today. This is because it provides more flexibility
to the material handling system. The basic concept of the AGV incorporates battery-
powered and driverless vehicles with programming capabilities for path selection and
positioning. They are equipped to navigate a flexible guide path network that can be
easily modified and expanded. The software for designing the AGV is chosen based on
the author knowledge. Several design ideas have been generated and divided into two
major components which are the body vehicle and the structure frame. From these
designed ideas, a comparison has been made to choose the best design idea from
designing the AGV. The AGV important parts are designed based on the specification
and requirement of the parts to be attached to it. The list of all parts needs to be fabricated
and the standard parts are presented in this report. The detail of the parts and their
specifications are presented in solid model with the dimensions which fulfills the
requirement for future development. Finite element analysis (FEA) has been used to
analyse the design of the AGV structure. The stress, displacement, deformation and
factor of safety are obtained from the analysis and presented. For future development, it
was suggested to fabricate and test the designed AGV. From the test result, action should
be taken (if necessary) for further improvement of the designed AGV design.
v
DEDICATION
My special dedication to my beloved mother, Che Embun Binti Yaacob, for their loves
and supports which never end and with the loves and supports given to me, I managed to
go through 4 years of my study which full with challenges and hunches. To beloved
friends of 4BMFA who have been with me through my journey in education. Also thank
you for all the motivation and their beliefs towards me.
vi
ACKNOWLEDGEMENT
I would like to express my appreciation to all those who provided me the possibility to
complete this report. A special gratitude give to my final year project supervisor, Prof.
Dr. Bashir Mohamad Bin Bali Mohamad, whose contribution in suggestion and
encouragement, helped to coordinate my project especially in writing this report.
vii
TABLE OF CONTENT
Declaration i
Approval ii
Abstrak iii
Abstract iv
Dedication v
Acknowledgement vi
Table of Content vii
List of Tables x
List of Figures xi
List of Abbreviations, Symbols and Nomenclature xiv
CHAPTER 1: INTRODUCTION 1
1.1 Background of study 1
1.2 Problem statement 2
1.3 Project objective 3
1.4 Scope of the project 3
CHAPTER 2: LITERATURE REVIEW 4
2.1 AGVs Classification 4
2.1.1 Guide path Determination 5
2.1.2 Vehicle Load Capacity 6
2.1.3 Vehicle Addressing Mechanism 8
2.2 Automated Guided Vehicle (AGV) 9
2.2.1 Driverless Train 9
2.2.2 Pallet Trucks 10
2.2.3 Unit Load Carrier 10
viii
2.3 AGV Navigation 11
2.3.1 Fixed Path 11
2.3.1 Free Ranging or Non-wire Navigation 13
2.4 Positioning Techniques 14
2.4.1 Odometry 15
2.4.2 Inertial Navigation 16
2.4.3 Magnetic Compasses 16
2.4.4 Active Beacon 17
2.4.5 Global Positioning System (GPS) 18
2.4.6 Landmark Navigation 19
2.4.7 Map Based Positioning 20
2.5 Steering Consideration 21
2.5.1 Steered-Wheel System 22
2.5.2 Skid-Steered System 24
2.5.3 Ackerman Steering 25
2.5.4 Differential Drive System 26
2.6 Microcontroller 33
2.7 Computer-Aided Design (CAD) software 35
2.7.1 AutoCAD 35
2.7.2 SolidWorks 35
2.7.3 Catia 36
2.8 Conclusion 36
CHAPTER 3: METHODOLOGY 37
3.1 Flow Chart of Project 37
3.2 Generate preliminary design ideas and specification 39
3.3 Analysis of the preliminary design ideas and specification 42
3.4 Conclusion 44
ix
CHAPTER 4: DESIGN AND ANALYSIS OF THE AUTOMATED
GUIDED VEHICLE 45
4.1 AGV parts 45
4.1.1 Assembly design and AGV structure 48
4.1.2 Parts specification 51
4.2 Model analysis 60
4.3 Von Mises Stress analysis 61
4.3.1 Element quality 61
4.3.2 Direct method computation 64
4.4 Factor of Safety 67
4.5 Encoder DC motor 68
CHAPTER 5: CONCLUSION AND SUGGESTION FOR FUTURE WORK 71
5.1 Conclusion 71
5.2 Suggestion for future work 72
REFERENCES 73
APPENDICES 75
A Project Gantt Chart 76
B Detail drawings and dimensions of the parts to be fabricated 77
x
LIST OF TABLES
3.1 The comparison for design ideas of body vehicle 41
3.2 The comparison for design ideas of structure frame 41
4.1 List of parts need to be fabricated 46
4.2 List of standard parts 47
4.3 Shows the fabricated parts and their specifications 51
4.4 Shows the standard parts and their specifications 55
4.5 The element quality of the chassis of AGV 61
4.6 Parameter of Aluminium Alloy 6061 61
4.7 Applied load resultant on chassis of AGV 62
4.8 Minimum and maximum pivot 63
4.9 Minimum pivot 63
4.10 Translational pivot distribution 63
4.11 The values of force (x,y,z) and moment (x,y,z) of model 64
4.12 Show the detailed about the pin connection encoder motor 69
xi
LIST OF FIGURES
1.1 AGV application for warehousing industry 1
1.2 The present condition between bandsaw machine and CNC machine at FKP 2
2.1 Deadlock situation in manufacturing systems 6
2.2 Single load vehicle 7
2.3 AGVS Classification Scheme 8
2.4 Driverless train 10
2.5 Pallet truck control by human operator 11
2.6 Unit load carrier for heavy product 12
2.7 Existing navigation technologies of AGV 14
2.8 Magnetic compasses used to detected the route of AGV 17
2.9 Active beacon system 18
2.10 GPS working principle 19
2.11 A map claim with landmarks labeled 20
2.12 A typical scan of a room 21
2.13 (a) Ackerman-steered system; (b) Differential-steered system 22
2.14 Steered-wheel system in tricycle configuration 23
2.15 Steered-wheel configuration as used in automobiles 23
2.16 Skid-steered system in four wheel vehicle 25
2.17 Schematic of a robot with Ackerman steering 26
2.18 Differential drive system in most robots 27
xii
2.19 Differential steering is a result of different wheel speeds causing the
robot to change direction 28
2.20 Basic operation of a shaft encoder 29
2.21 Pulses showing distance travelled by an AGV obtained by the use of encoder 30
2.22 Path of wheels through a turn 32
2.23 Microchip 16F877A is one of microcontroller 33
2.24 A typical microprocessor system 34
3.1 Flow chart of project methodology 38
3.2 Sketch of the body vehicle design ideas 40
3.3 Sketch of the structure frame design ideas 41
3.4 Conceptual design of automated guided vehicle (AGV) 43
4.1 The assembly design of automated guided vehicle 48
4.2 Structure of automated guided vehicle 49
4.3 Exploded view of AGV with the name of each part 50