Somnath Chattopadhyaya

Assistant Professor/ Workshop Superintendent

Indian School of Mines University, Dhanbad
Dhanbad 826004

Slides of AGV S. Chattopadhyaya,ISMU 1

 What is AGV?
Automated Guided Vehicles (AGVs) are
driverless industrial trucks, usually powered
by electric motors and batteries.
Applications of AGV-systems, with loads
ranging from (cardboard) boxes to pallets
and (steel) coils, can typically be found in
and between production- and storage
environments.

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 Introduction to AGV
Automated Guided Vehicles, termed AGV's,
carry the containers from the marine quay to
the adjacent storage area.
There, smaller vehicles take care of the
temporary storage.
 In order to attain optimum road behaviour
and efficient traffic control modern computer
simulation techniques are used during the
design process.

Slides of AGV S. Chattopadhyaya,ISMU 3

 Introduction to AGV
The AGV must position itself not
only quickly, but also accurately
under the hoisting equipment.

That ensures the safe coupling

of the spreader, the hoisting gear
of the equipment.

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 What is AGV?
The Automatic Guided Vehicle (AGV) is a safe,
reliable, and efficient material transport system
that can be used instead of forklifts to move
loads of all sizes.
AGVs are available in tape, wire, and laser
guidance configurations for maximum layout
flexibility, and their crabbing capability saves
floor space.
AGV models are available to transport weights
from 220 to 550 lbs., as well as pallets up to
6,600 lbs.

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 What is AGV?
Automated Guided Vehicles (or
Automatic Guided Vehicles) have
been moving materials and
products over 50 years.
 The first AGV system, a modified
towing tractor with trailer following
an overhead wire, was built and
introduced in 1953 in a grocery
warehouse.

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 What is AGV?
By the late 50's and early 60's towing AGVs
were in operation in many types of factories
and warehouses.
 This type of AGV, a tugger, is still applied
today.
 In 2003 Frog AGV Systems supplied four
automated 7tons Tuggers for a chassis
marriage process within an automotive
factory.

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 Components of AGV
Vehicle.

Guidance system.

Input/output/transfer mechanism.

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Classification criteria of
AGVs
Tote/box or pallet handling.
Guidance system
 Tape.
 Wire.
 Laser.
Input/output/transfer mechanism
 Roller conveyor.
 Chain conveyor.
 Fork top.
 Rear fork.
Battery charge/recharge option.
Number of vehicles.

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Technological features of
AGV
 Permanent 10-year battery eliminates
need for battery changing.

 Opportunity charging allows automatic

battery charging without removing
vehicle from service.

 Quiet operation (<65 db).

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Technological features of
AGV
 Multi-directional wheels allow travel forward,
backward and sideways, with 90º crabbing,
minimizing space requirements.

 Microprocessor control with Radio Frequency

(RF) communications.

 Laser guidance option allows maximum

layout flexibility.

Slides of AGV S. Chattopadhyaya,ISMU 11

 History of AGVs
In 1973, Volvo in Kalmar, Sweden set
out to develop non-synchronous
assembly equipment as an alternative
to the conventional conveyor assembly
line.
The result was 280 computer-controlled
assembly AGVs.

In the mid 1970s the unit load AGV was

introduced - a big development for the
AGV industry.
Slides of AGV S. Chattopadhyaya,ISMU 12
 History of AGVS
The unit load Automated Guided Vehicle gained
widespread acceptance in the material handling
marketplace because of its' ability to serve
multiple functions: assembly platform,
transportation device and linking the control and
information systems within a production facility.
Nowadays AGVs are applied in all types of markets
for the transportation of material: warehouse
environments, factories, hospitals and other
industrial and commercial settings. Frog also
supplies AGVs for outdoor applications in harbors
and for the transportation of people - in a public
transportation setting, but also for rides in the
entertainment industry.

Slides of AGV S. Chattopadhyaya,ISMU 13

 History of AGVS
The unit load Automated Guided
Vehicle gained widespread acceptance
in the material handling marketplace
because of its' ability to serve multiple
functions: assembly platform,
transportation device and linking the
control and information systems within
a production facility.

Nowadays AGVs are applied in all types

of markets for the
Slides of AGV S. Chattopadhyaya,ISMU 14
 History of AGV
Wire guidance was the principal AGV guidance
technology in the 1970's.
An electronic frequency is induced in a wire
that is buried in the floor.
A device called a 'floor controller' turned the
frequency on the wires on and off and directed
the AGV through its intended route.
 As the intelligence of the system was in the
floor controllers, these systems were typified as
'smart floors, dumb vehicles'.

Slides of AGV S. Chattopadhyaya,ISMU 15

 History of AGV
Wire guidance was the principal AGV guidance
technology in the 1970's. An electronic frequency is
induced in a wire that is buried in the floor.
A device called a 'floor controller' turned the frequency
on the wires on and off and directed the AGV through its
intended route. As the intelligence of the system was in
the floor controllers, these systems were typified as
'smart floors, dumb vehicles'.
The AGVs were equipped with an antenna that would
seek out the frequency and guide the vehicle based on
the strength of the signal.
For decision points and intersections, multiple (costly)
wires need to be installed. The system would energize
the wire that would correspond to the intended direction
of travel.

Slides of AGV S. Chattopadhyaya,ISMU 16

 Introduction to AGV
Automated Guided Vehicles, termed AGV's, carry the
containers from the marine quay to the adjacent
storage area.
There, smaller vehicles take care of the temporary
storage.
 In order to attain optimum road behaviour and
efficient traffic control modern computer simulation
techniques are used during the design process.
 The AGV must position itself not only quickly, but
also accurately under the hoisting equipment.
That ensures the safe coupling of the spreader, the
hoisting gear of the equipment.

Slides of AGV S. Chattopadhyaya,ISMU 17

 Benefits of AGV
 Eliminates forklift traffic.

 Individual load tracking from pickup to

delivery for precise inventory control.

 Safe, reliable operation using ultrasonic

sensors, acoustical and visual operating
indicators, emergency stop button, and
full-perimeter contact bumper.

Slides of AGV S. Chattopadhyaya,ISMU 18

 Applications and
Controls
Within industrial environments, the use of
AGVs has evolved drastically: from traditional
distribution-oriented applications at one end of
the spectrum to complex computer-controlled
automobile assembly systems with robotic
interfaces at the other end.
They can be stand-alone systems, an integral
part of another system, or aid in pulling
together islands of automation.

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 Applications and
Controls
AGV originally designed for horizontal
transportation of palletized material, the
design and application of AGVs and controls
are now as varied as those of industrial
robots.

Outside industrial environments,

Automated Guided Vehicles are now also
being applied for transhipment at ports, as
people movers and in the entertainment
industry.
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 Applications of AGV
Recommended applications by product
type:
Transport raw materials, work-in-
process, and/or finished goods between
storage buffers and workstations.

Transport finished goods from order-

picking workstations to consolidation and
shipping.

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 Navigation system of
AGVs
These first generation navigation schemes were
expensive to install.
The exact path of the AGV needed to be 'cut' in the
floor to bury the wire in.
The cut for a turn had to follow the radius curve that
the vehicle would make when turning.
Many systems had to embed four wires - three for
guidance and one for communications.
Often, rebar or electronic signals would interfere with
the guidance signals imposed on the wires.

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 Navigation system of
AGVs
Today the wire-guided technology is
outdated. New AGV guidance systems,
such as the FROG-technology, offer many
advantages (installation costs, flexibility,
maintainability) over the wire-guided AGV
technology.
 For very basic applications, this
technology is sometimes still applied.

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 Navigation system of
AGVs
As electronics and microprocessors advanced, so
did AGV applications. More intelligent Automatic
Guided Vehicles were created and the need for a
sophisticated path was reduced.
The first major development was 'dead reckoning'.
Dead reckoning is the ability to traverse space
without having to rely on the physical presence of a
guidance wire. The biggest advantage was that
dead reckoning eliminated the need to make the cut
radius turns at intersections. The AGVs could leave
the wire, turn at a programmed radius, and then
pick-up the wire to continue its course of travel. The
path still required multiple wires in the floor, but the
installation was greatly simplified.

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 Navigation system of
AGVs
During the 1980s, non-wire guided AGV
systems were introduced.
Laser and inertia guidance are two AGV
guidance technologies allowing for increased
system flexibility and accuracy.
Changes to the path can be made without
costly, time-consuming floor alterations or
production interruptions.


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 Navigation system of
AGVs
Modern AGVs are computer-controlled vehicles
with onboard microprocessors (such as the
FrogBox and FrogBox Light).
Most AGV-systems also have a supervisory
control system (e.g. SuperFROG) to optimise the
AGV utilization, generate and/or distribute
transport orders, tracking and tracing modules
and acting as 'traffic cop' based on priorities.

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IM70 an inductive
modem for wireless
guidance of AGV

Slides of AGV S. Chattopadhyaya,ISMU 27

 IM70
It is a wireless communication device used
for the intercommunication between a
driverless carrier (AWG) and the central
control system.
When the AWG gets an order to pick up an
article from the store.
It needs to navigate its way along a wire
sling which is buried in the concrete floor.


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 IM70
IM70 is a little box under the vehicle
capable of using this wire sling as a
bi-directional data link.
 Our task was to design the
electronics inside this IM70-box.
All digital electronics was built
around a Xilinx. FPGA. There were
also some analogue filters and tuned
power amplifiers.

Slides of AGV S. Chattopadhyaya,ISMU 29

 Navigation system of
AGVs
It is a wireless communication device used for
the intercommunication between a driverless
carrier (AWG) and the central control system.
When the AGW gets an order to pick up an
article from the store.
It needs to navigate its way along a wire sling
which is buried in the concrete floor.


Slides of AGV S. Chattopadhyaya,ISMU 30

 Navigation system of
AGVs
IM70 is a little box under the vehicle
capable of using this wire sling as a bi-
directional data link.
 Our task was to design the electronics
inside this IM70-box. All digital
electronics was built around a Xilinx.
FPGA. There were also some analogue
filters and tuned power amplifiers.

Slides of AGV S. Chattopadhyaya,ISMU 31

Replacement Applications of
AGV
Conveyors

Forklift trucks.

Hand carts.

Slides of AGV S. Chattopadhyaya,ISMU 32

Advances of AGVS over
previous technology
Reduced load damage.
Less facility wear and tear.
Requires less operating space.
System capacity increased by adding
vehicles.
Elimination of single-point failure; system
can continue operating if a vehicle fails.

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Problems addressed by
AGV
Floor space
Provides more space for production.
Productivity
Supplements limited capacity in storage
and production areas.
Inventory
Solves the problem of poor product
accessibility

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Problems addressed by
AGV
Ergonomics
Workers in hostile environments.
Workers walking long distances
Excessive noise levels from material
handling equipment
Safety hazards
Labor-intensive processes

Slides of AGV S. Chattopadhyaya,ISMU 35

Problems addressed by
AGV
Disjointed Operations (Lack of Integration)
Multiple staging areas
Product is often moved from one staging area
to another
Labor
High employee turnover
High labor costs
Small labor pool
Low job satisfaction

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Exemplary specifications of
AGV
Maximum load weight: 220-6,600 lbs. (100-3000 kg).

Maximum load size:

Length: 30-51 in. (0.76-1.30 m).
Width: 20-47 in. (0.50-1.19 m).

Maximum speed: 164-196 ft./min. (50-60 m/min.).

Crabbing speed: 49 ft./min. (15 m/min.).
Turning radius: 24-56 in. (.60-1.42 m).

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Exemplary specifications
of AGV
Transfer height: 16-21 in. (.41-.53 m).
Traveling direction: multi-directional.
Battery voltage: 48 V.
Battery capacity: 40-80 Amp. hrs.
Battery charging/discharging ratio: 1:10.
Communication: spread spectrum radio
frequency.
Steering system: direct drive power wheel
steering.

Slides of AGV S. Chattopadhyaya,ISMU 38

Photographic view of a
forklift type AGV with
wireless guiding system

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AGV accessing materials from
different racks

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Applications of AGV in
Automobile Industry
Typical AGV applications in the automotive
industry include automated raw material delivery,
automated work in process movements between
manufacturing cells, and finished goods transport.
 AGVs link shipping/receiving, warehousing, and
production with just-in-time part deliveries that
minimize line side storage requirements. 
AGV systems help to create the fork-free
manufacturing environment which many plants in
the automotive industry are seeking.

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Photographic view of an
AGV

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 Software related to AGVs
AGV Manager is the name of a software
which is basically dealing with the flow
management.
This is based on a modular core which
allows it not only to manage AGVs
fleet but also operators, palletisation
cells,  stretch-wrapping or pallet
covering machines, automatic or
manual warehousing, dispatching.

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 Software related to AGVs
Its flexibility allows it to easily
integrate with any industrial process —
production and logistics — and to
communicate with all management
systems (ERP, WMS, GPAO, etc). 
With its Focus functionalities, it can
manage a simple automatic point-to-
point transfer,  ends of lines, storing
missions, or a whole warehouse. 

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 Operations of an AGV
For an easy operation of the installation and an
effective gain in productivity, 
AGV Manager (a branded software) pilots and
coordinates all the flows.
Automated Guided Vehicles (AGVs)
Movements and missions of forklift operators
Conveying networks
Peripheral devices

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Traceability and
Adaptation by AGV
AGV Manager also integrates the identification and
traceability of all loads transported. 
It provides a complete tracking of the products, from
production to dispatching and warehousing.
• Whether installations are existing or not, manual or
automatic, computerized or not, AGV Manager adapts to
all your constraints in order to manage your production
logistics and meet all your needs.

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