Lecture 2 - AGV

Intelligent Control
for Transport Technology

Mark Duinkerken
Transport Engineering and Logistics me44200
February 21, 2017
Delft
University of
Technology
Challenge the future

Contents
Introduction to AGV systems
Hardware components
AGV
infrastructure
other system components
Some functional aspects
Research
Routing strategies for terminals
AGV laboratory
me44200 - AGV systems 2

Introduction
to
AGV systems

Definitions
simple boxrunner
Frog Navigation Systems
AGV www.frog.nl
Automated Guided Vehicle

An unmanned, computer controlled, transport vehicle
a.k.a. Mobile Robot
AGV-system
AN AGV system is an advanced automated material handling system
that consists of co-operating AGVs, transporting goods and materials
between different locations

History
1st AGV 1st Tugger 1st Assembly 1976
Vehicle
1959 1st Unit Load

1953 1973
1973 - Volvo in
Kalmar, Sweden
utilized 280
computer-controlled
AGVs instead of
using the typical
1953 First AGV created
conveyor assembly
and used. It was used to
line.
pull a trailer and follow an
overhead wire in a grocery
warehouse.

History
1st Unit Load Single Wire PC Based Wire & Wireless

Guidance Controller AGVs in same System
1985 1989
1976 1992
1987 1991 2003
Laser Guidance Inertial Changeable

Guidance Path
1970s
1976 First Unit Load AGV. Guidance
Now used for many different Systems
applications in multiple settings
of industry.

Example: production environment

Example: south Glasgow university hospital
used for:
kitchen
linen
medical supplies
(not: patients) swisslog.com

Example: park shuttle Rotterdam - Rivium
shuttle presentation in
Monaco
www.frog.nl

Example: WEpod Wageningen
EPA photo

Reasons for automation
Cost reduction
Reduce human work

Shortage of human labour
Unsafe environments
Prevent routine work
Increase capacity
Other:
Accuracy (results in f.i. less damage to goods)
Reliability (built-in redundancy, no single point of failure)
Scalability and flexibility (compared to some other transport systems)

Application areas
Types of application:
Production: job-shop, FMS
Storage : warehouse, ASRS
Transshipment: terminal
Transport: people-transport, distribution of goods
Other: military use, etc. ...
System size: From 1-3 vehicles up to 280 AGVs at Delta terminal

AGV size: 1.5 x 1.0 m / 1000 kg or 18.0 x 3.0 m / 60.000 kg
Alternative systems:
continuous transport system e.g. belt conveyor
discrete manned transport system e.g. trucks

AGV system components
AGV
driving characteristics
(un)loading characteristics
Infrastructure
pick up and delivery locations
route layout / topology
Communication system
bandwidth, frequency, protocol
Navigation and positioning system

vehicle sensors, local or global system

Tactical
Planning system functions

scheduling: define time-windows for transportjobs
dispatching: assign transportjobs to vehicles
routing: determine path or trajectory between origin and destination

Operational
(AGV) motion control

follow the planned path or trajectory
(system) traffic control

collision prevention
deadlock prevention
deadlock example with 2 AGVs

AGV system
Performance indicators
productivity (moves / hour)
accuracy (variance in arrival times)
reliability (# of deadlocks)
flexibility queue's at the quaycranes
scalability
System design is complex

large number of design alternatives Technical
many interrelated decisions aspects
Logistic
performance depends on the combination of aspects
investment in hardware
development of planning and control software

Hardware
components

AGV types
Types of AGVs:
standard carrier
tugger
forklift
unit load carrier
people mover
ALV
www.mhia.org

AGV types
Driving characteristics
speed and range
range
size and maneuverability (3 wheel, 4 wheel, 2 steering axis)
Driving technology
electric (indoor)
diesel engine (outdoor)
hybrid

AGV Safety
Via control (often: semaphore-based)
Safety sensors
bumper sensors
non-contact distance sensors
(infrared, ultrasound) Front & Rear
emergency-stop button Bumpers
Side Optical
Bumper www.mhia.org

AGV Safety
Safety and
the human
factor
Park Shuttle,
Rotterdam

Infrastructure
Topology
Map
boundaries
(permanent) obstacles
one/two-way roads
road crossings
locations of docks
M M M

M
AGV
M
AGV
M M
M AGV
M M
AGV AGV
M M M M

Infrastructure
Docks
pick-up and delivery points

loading / unloading equipment
charging or fueling location

in-vehicle charging or fueling
battery swap
inductive charging
maintenance
location for idle vehicles

Communication hardware
Communication between AGVs

and infrastructure
detection wire
light signals
FM radio signals
wireless LAN
bluetooth

Navigation
Guide path
Inertial guidance
uses a 'dead-reckoning' algorithm
cumulates errors
requires initial position
based on sensor data
odometer, speedometer or accelerometer (IMU)
gyroscope (gyrometer) or compass
Closed loop control based on position updates

Santa Maria, Columbus
using a centralized positioning system
or: autonomous position determination

Positioning
Centralized system
AGV receives position information
f.i. digital video with image recognition
Distributed system
AGV determines its own position
line (optical)
wire (electrical)
grid (magnetic, RF transponder)
GPS
laser guidance:
triangulation from reflective targets

Functional
aspects

(some) Functional aspects
communication
conflicting use of processor capacity
needed for synchronizing with other equipment
loading/unloading
passive / dependent: other equipment needed
active / indepent: self-loading and unloading
routing
static, fixed routes
dynamic, multiple fixed routes
dynamic, free ranging

Communication
communication
position information
traffic control
semaphores / 'traffic lights'
logistic control
scheduling
dispatching
example: AGV laboratory v1.0

used a central positioning system
position information: high frequency, low bandwidth
job dispatching: low frequency, high bandwidth
route planning: low frequency, high bandwidth

Loading
Dependent
horizontal or vertical
lift handling crane
roller conveyor

Loading
Independent
Automated Lifting Vehicles
www.egemin.nl
Patricks Fisherman Islands

Brisbane, Australia

Routing
fixed guide path smart floor, dumb vehicles

free ranging smarter vehicles, ......
real free ranging vehicle motion only restricted by
non-holonomic constraints

Routing
2012 Google maps

Free ranging? (DSL terminal AGV tracks)

Routing

Study
of
AGV systems

Research disciplines
Hardware Development
and
Control Systems (classic control)
stable trajectory execution
transfer of loads
sway-reduction for cranes
etc.
Mechatronics
mechanical engineering
electrical engineering
computer science

System Control (advanced control)

traffic control
collision prevention
congestion and deadlock prevention
tactical control
scheduling: job execution time/order
dispatching: job assignment
routing: job route / trajectory
battery management
idle AGV management
fleetsize and logistic chain optimization

Current trend: shift

from automated vehicles
to autonomous vehicles
and
from classic control
to advanced control
Other research aspects

safety regulations
societal effects
law, judicial implications, liability

AGV systems : classification
Control non-
hierarchical coordinated cooperative
and control control control
cooperative
Coordination control
in
Multi-Agent Systems
distributed approach
(from: Next Generation Infrastructures)

AGV systems : classification
hierarchical structures
not capable to cope with the changing environments
cooperative control structures

better suited for instabilities, uncertainties and abrupt changes
caused by disturbances, both internal and external

Non-cooperative control
www.sae.org

Literature on AGV routing
Material handling systems

Optimizing a fixed topology layout
Choosing pickup and delivery points
Network route optimization
f.i. point to point, loop, or tandem layout
Mobile robots
Holonomic robot path planning with dimensional constraints
Trajectory planning with time constraints
Exact methods: roadmaps, cell decomposition, potential fields
Probabilistic methods: randomized potential field, rapidly-exploring
random trees

Research TUDelft: DSL Rotterdam (1993)
Simulation www.gottwald.com
Emulation
Prototyping

Automated Container Terminal
1993 : Delta Sealand Terminal in Rotterdam

Uses a fixed guide path layout
Semaphore mechanism to prevent collisions
non-
hierarchical coordinated cooperative
cooperative
control control control
control
Coordinated control

ACT : simulation studies
SMAGIC model (1997) FAMAS model (2000)

Stand-alone simulation model

SMAGIC (1997)
FAMAS (2000)
Logistic simulation in Delphi/TOMAS

process description for each simulated object
description exists of physical process and control decisions
implicit logistic control of each object can be seen as its agent-based
control
Research on AGV systems

Include stochastic behavior in process times
Evaluate performance of planning and control algorithms

Application of distributed simulation (2002)
Control
System
Quay Transport Stack Container

System System System System
quay crane AGV stack lane container

layout stack crane ship


Emulation
Use of an AGV emulation model

More realistic than simulated AGV
Calculate steering and propulsion signals
d1
+
d
+
+
m
-
+ + .
0 d bs b sm 1 1 as as d 1 d
m1
-K --------- -v -
+ - -
- s+1 s

Prototyping
Real-time control
AGV prototype is part
of a simulation model
Simulation model runs
on onboard processor
1998 prototype

Routing
strategies

Comparison of routing strategies
Quay cranes
Quay cranes
Key parameters:
Terminal length
Terminal width
Number of stack cranes
Number of quay cranes
Vehicle characteristics
- Length
- Width
Stack cranes - Speed
Stack cranes

Fixed routing : Loop
distance is sum of
terminal width and
length y
ignore congestion
effects
ECT Delta terminal in

x
Rotterdam

Fixed routing : Mesh
distance is sum of x
and y y
ignore congestion
effects
CTA Terminal Hamburg-

Altenwerder x

Free ranging
cross-over distance is
shortest possible path
calculate start time that
y
guarantees unhindered
crossing
use vehicle dimensions
add safety time between
vehicles x

Free ranging pedestrians

DEFT: Free ranging AGVs
DEFT:
based on NOMAD: pedestrian simulation model
individual (non-cooperative) route optimization
multiple static and dynamic obstacles
arrival time is crucial
cost minimizing method
proven performance of the solving algorithms

DEFT : Dynamic Free Range Routing
DEFT
Dynamic Evasive Free-ranging Trajectories
deft = quick; skillful in physical movements
Based on pedestrian behavior model NOMAD (Hoogendoorn e.a.)
Three layer model

strategic hierarchical coordinated cooperative
non-
cooperative
tactical control control control
control
operational
Cooperative control

DEFT : Simulation of tactical layer
Area of 6 x 8 meter Random selection of

2 static obstacles destination
2 x 7 destinations Ignoring end orientation
Compared with mesh and
loop layouts

DEFT : Tactical results
Average trajectory length (m)
Method Average Relative Deviation
Cross-over 5.44 1.00 0.67
DEFT 5.60 1.03 0.69
Mesh 6.90 1.27 1.51
Loop 11.89 2.19 -

AGV
laboratory

AGV laboratory
Gain support for new routing methods

lab based on automated container terminal
1:25 scale models of container-transporting AGV
Proof of concept: from simulation to the real world

no irrealistic simplifications possible (f.i. endzone position)
Study the importance of

sensor and actuator accuracy
information update frequency
irregular communication delays
Identify and solve (other) unforeseen problems

AGV lab : Hardware
AGV v1.0
motherboard with Pentium
processor
harddisk
wireless network card
DAQ-card (allows distance
sensors, camera etc.)
7.0 Ah battery
AGV v2.0
Arduino Uno
Zigbee antenna
7.0 Ah battery

AGV lab : Hardware
AGV (continued)
actuators : motor and steering servo, on both axis
sensors : none
servo controller

AGV lab : Hardware
Local positioning system v1.0

digital camera
motherboard with processor
LEDs
network card
passive markers on AGVs

active marker on AGVs

AGV lab : Hardware
Positioning 2.0
OptiTrack
passive markers on AGVs

AGV lab : Software
Matlab

Demo AGV laboratory
2001 : Opening of Miniworld
2004 : Podium at Business in Ahoy
2006 : AGV laboratory

in TV-show Delft Blauw

Lab assignment
Transport a list of containers

use multiple AGVs
elementary TOS available
develop your own dispatching, scheduling, routing
Goal
shortest makespan
1 or more groups

Lecture 2 - AGV

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Lecture 2 - AGV

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Intelligent Control

for Transport Technology

Challenge the future

Introduction to AGV systems

Some functional aspects

me44200 - AGV systems 2

me44200 - AGV systems 3

Automated Guided Vehicle

me44200 - AGV systems 4

1959 1st Unit Load

me44200 - AGV systems 5

1st Unit Load Single Wire PC Based Wire & Wireless

1987 1991 2003

Laser Guidance Inertial Changeable

me44200 - AGV systems 6

me44200 - AGV systems 7

(not: patients) swisslog.com

me44200 - AGV systems 8

me44200 - AGV systems 9

me44200 - AGV systems 10

Reduce human work

me44200 - AGV systems 11

System size: From 1-3 vehicles up to 280 AGVs at Delta terminal

me44200 - AGV systems 12

Navigation and positioning system

me44200 - AGV systems 13

Planning system functions

me44200 - AGV systems 14

(AGV) motion control

(system) traffic control

deadlock example with 2 AGVs

me44200 - AGV systems 15

System design is complex

me44200 - AGV systems 16

me44200 - AGV systems 17

me44200 - AGV systems 18

me44200 - AGV systems 19

Via control (often: semaphore-based)

me44200 - AGV systems 20

me44200 - AGV systems 21

me44200 - AGV systems 22

pick-up and delivery points

charging or fueling location

location for idle vehicles

me44200 - AGV systems 23

Communication between AGVs

me44200 - AGV systems 24

Closed loop control based on position updates

me44200 - AGV systems 25

me44200 - AGV systems 26

me44200 - AGV systems 27

me44200 - AGV systems 28

example: AGV laboratory v1.0

me44200 - AGV systems 29

me44200 - AGV systems 30

Patricks Fisherman Islands

me44200 - AGV systems 31

fixed guide path smart floor, dumb vehicles

me44200 - AGV systems 32

2012 Google maps

me44200 - AGV systems 33

me44200 - AGV systems 34

me44200 - AGV systems 35

me44200 - AGV systems 36