RUSSELL ROBOTICS has concentrated on development and manufacturing of automated guided vehicle system with
more reliability and more flexibility. Our system helps success of customer with total solution meets various demands.
optimization
To supply more accessible user
interface with advanced technology
To design the optimized system to
improve effeciency for operating condition
To manage supplied system with
technical training and regular inspection
Forklift vehicle is useful automatic guided vehicle to handle pallet transfer.
Low-based vehicle is useful to transport trolley by lifting or towing.
AGV can be manufactured with cosidering features of goods and equipment needs to be interfaced.
AGV meets operation criteria in clean environment and stop tolerance for loadhandling is within ±1mm on X, Y, Z, ⊝axis.
AGV can transport heavy load products like coil by being equipped with multi-wheels and drive wheel designed specially.
The Natural Navigation uses measurements from the Laser Range Sensor to recognize landmarks
such as walls and other surfaces.
There is a continuous update of the vehicle position based on encoder data that tracks vehicle movements.
The position is updated using measurements to walls and other objects. The navigation is active at all times.
- ·Detects walls and other surfaces
- ·SICK S300 and S3000 are available
The laser navigation support is based on free guidance using landmarks(reflectors).
The position is updated using landmarks.
There is a continuous update of the vehicle position based on encoder data that tracks vehicle movements.
The position is updated using measurements to reflectors.The navigation is active at all times.
- ·Detects reflections
- ·Determines angle and distance to reflectors
- ·Mounted on walls and machines
- ·Flat or Cylindrical
The barcode navigation uses barcodes placed on the floor allowing for a precise navigation
in open environments with an absence of walls preventing the use of other types of navigation.
The flexible design of barcode navigation is also advantageous in contrast to other more permanent methods,
such as spot navigation, where magnetic indicators are placed within holes drilled into the floor.
- ·Detects position marker
- ·Configured by camera and illumination unit
- ·Installed on the floor
- ·Data matrix tag (ID, coordinates)
The magnetic support is based on free guidance between landmarks(magnetic tape and distance markers).
The position is updated using the landmarks.
There is a continuous update of the vehicle position based on encoder data that tracks vehicle movements.
The position is updated using measurements to the tape and to distance markers. The navigation is active at all times.
- ·Detects magnetic tape
- ·Installed on(underneath) the floor
- ·Detects distance markers
The spot support is based on free guidance between landmarks (magnets embedded in the floor).
The position is updated using the landmarks.
There is a continuous update of the vehicle position based on encoder data that tracks vehicle movements.
The position is updated using measurements to spot magnets. The navigation is active at all times.
- ·Detects spot magnets
The wire support is based on free guidance between landmarks (Inductive wires and Distance markers).
The position is updated using the landmarks.
There is a continuous update of the vehicle position Based on encoder data that tracks vehicle movements.
The position is updated using measurements to inductive wires to distance markers. The navigation is active at all times.
- ·Detects wires
- ·Installed underneath the floor
- ·Detects distance markers
The Range Navigation uses measurements from the Laser Range Scanner to recognize landmarks
such as walls and other surfaces. This makes it an excellent choice when used For instance in corridors.
There is a continuous update of the vehicle position based on encoder data that tracks vehicle movements.
The position is updated using measurements to walls and other flat surfaces. The navigation is active at all times.
- ·Measures surrounding walls
- ·Measures surrounding flat surfaces
A Vehicle can, while driving, switch between navigations methods.
This is called Multi Navigation.
It gives the possibilities to use the flexibility of a reflector navigation in factories with one of the other navigation methods
in areas where there is not possible to mount reflectors.
AGV system should be designed with consideration of safety as the first priority.
RUSSELL ROBOTICS provides AGV system comprising safety functions into both AGV and AGV control system to minimize
potential hazards to operating personnel, including protection of fixed assets or mobile assets.
System
Safety
Vehicle
Safety
Functional
Safety
External
Devices
AGV Control System handles AGV to perform propoer action when an abnormal operating
condition is reported from any system components or other systems interfaced with.
Vehicle application will be defined in accordance with safety requirements
then vehicle controller protects itself from unexpected accident.
Vehicle should stop if control system is not working as expected.
AGV should be equipped with sensors and emergency buttons so that the vehicle will
stop if anything is too close to the vehicle while it is driving.
Main components of the AGV are connected via internal network and the vehicle controller is the master on the network.
Its responsibility is to start, configure and supervise all connected devices on the network.
Internally, the master has two basic running status: Normal State and Safe State.
After power on, it always enters Normal State in which it executes full AGV functionality according to the definition.
In case of functional errors, reported by a device
on the network or detected by master itself
the master will report the error with system event code
and restart itself in Safe State. as a Safe State is a passive
vehicle state, it enables only diagnostic functionality.
- ·AllOK will always remain false
- ·Only all devices marked to be active in Safe State
will be started and put in operational mode
on the control network - ·The vehicle controller will not exit Safe State by itself
In order to prevent collision, at least one programmable
Obstacle Detection Sensor is installed on the vehicle.
The sensor has two protection zones running simultaneously.
When the outer most zone is infringed,
the vehicle slows to a pre-defined speed first.
Then the inner zone is breached, vehicle stops immediately.
Generally, Laser sensors used for obstacle detection can see only
horizontally. For this reason, two or more sensors can be installed
in diffetent height at one side as shown left figure.
By this configuration, vehicle body can be protected from collision
hrozontally and vertically as well.
Safety Bumper is installed around vehicle chassis to protect person and vehicle from injury and damage by collision.
As an integral part of the AGV safety circuit, it works even if AGV is under uncontrollable status.
When pressure is applied, the internal normally open circuit is closed to emit a signal to the controller in response.
When activated, Safety Bumper acts as an emergency stop that removes power from the AGV.
Various dimensions and shapes are available to be fitted to all kinds of vehicles.
Differen type of safety bumper or safety edge can be applied with consideration of vehicle appearance and safety
equirements as shown below figures.
In order to assure that the vehicle follows the AGV path as expected, Safety Zone should be defined in vehicle application.
A Safety zone is set by a rectangle and an angle as shown below fiure.
If the vehicle reference point is outside the rectangle and or the angle of the vehicle relative to the AGV path is greater than
the limit value, it is outside the Safety Zone. If the vehicle is outside the Safety Zone, it can not drive in Automatic mode
and the vehicle will decelerate and stop following the Emergency stop slope.
- ·Safety Angle
Allowable tollerance ralative to
angle of AGV Path. - ·Safety Zone X
Allowable tollerance ralative to
X coordinate of AGV Path. - ·Safety Zone Y
Allowable tollerance ralative to
Y coordinate of AGV Path.
Instruments related to safety functions, are recommended to be installed on the AGV.
As they are programmable, their functions can be defined through PLC program integrated in vehicle application
to be optimized for operating condition on the site. Generally, below devices are installed on the AGV essentially.
-
Laser Bumper Since AGV is moving around the factory always, programmable obstacle detecting
laser sensors should be installed on the AGV as basic specification to prevent collision between AGV
and person or other equipments. -
Emergency Switch Emergency buttons are installed as many as required on the AGV body for safety.
Whenevr any emergency stop button is pushed, the vehicle will stop immediately and remains stopped
until the button is manually reset. -
Horn To warn the position of AGV to around personnel, horn is installed on the AGV and operating
always. Depending on operating condition, pre-defined melody is boomed out. -
Beacon To notify what operation mode is proceeding to around personnel, beacon is installed
on the AGV and operating always. Depending on the operation and control mode, pre-defined color
beacon is turned on of flashing.
RUSSELL ROBOTICS provides AGV system integrating all aspects of the automated material handling and including
all HW and SW to facilitate not only AGV's movement between stations but also interface with other systems or equipment.
Basically, AGV system is configured as shown below figure but can be changed in accordance with system requirements.
AGV Control System is consist of Stationary Software and AGV System Operating Program.
Stationary Software provides foundation for actual transportation in the AGV System but it is just a background program.
Hence, AGV System Operating Program is needed for interface with other systems and other components and it provides
many convenient interface functions for user to control AGV System.
Generally, HMI is configured as shown below figure. However required functions can be added by request of customer.
-
A. Main Menu Bar
Positioned at the left-top position on the screen, is configured with
main menu buttons. Once a button was tapped, corresponding page or
window would be appeared then user can confirm required information
for operating system such as work history or alarm log file.
Also a menu for AGV manual control is provided. -
B. System Monitoring
Current AGV position and status is updated in real time on the screen
and layout information inculding stations, AGV path and traffic control
is displayed graphically. -
C. Interface Information
As communication and interface status is important for AGV system,
operator can confirm required information through color of lamp. -
D. AGV Status Information
Displays error or warning message relevant to generated alarm.
-
E. Order Information
Provides allocated order and current AGV driving information in detail.
It is recommended that AGV control system is configured as redundant system to prepare emergency situation as like
shut-down. In order to achieve redundant configuration, AGV control system is consist of primary control system and
backup control system.
In normal state, primary control system controls AGVs and communicates data needed with main components in the system.
This information is shared with backup control system in real time and backup system manages data as same as primary
control system. Once primary control system can’t be operated anymore by some malfunction, right to control will be given
to backup control system. Since the same data has existed in backup control system, AGV system can be operated without
any trouble continuously.
To change right to control from primary control system to backup control system can be done automatically, since backup
control system supervises state of primary control system via communication of OK message.
Since required power for AGV is supplied by battery,
battery charging plan is very important for AGV system.
When making a battery charging plan, battery type, capacity,
power consumption rate and other operating conditions
for AGV system should be considered comprehensively.
Generally, either opportunity charging or exchanging method
is recommended for battery charging.
Battery Charging
If the system is designed to have lower operation rate, opportunity charging method is recommended for battery charging.
Basically, chaging station is located on the AGV path or home position to make battery be charged every cycle enough to
perform the following good transport order.
If it is required for AGV to operate 24-hours per day with higher operation rate, battery exchanging method is recommended.
Lower battery is replaced with chraged one by specially designed exchanger without any human intervention.
Manual battery exchaning method is recommended when constructing battery charging system with reasonable cost.
If manual exchanging method is applied, battery capacity should be calculated to keep the level for at least one shift a day.
Once battery level is lower than pre-defined level or one good transport cycle is completed,
AGV moves to the charing station or drop in there to charge internal battery enough.
Opportunity charging method is a good solution as well in case that one shift is off a day.
- · Battery charger with charing booth-bar is installed
beside charging station. - · Battery charger is required as many as numbers of
vehicles or charging station. - · Required charging time should be considered.
- Lithium-Polymer(Ion) battery : 1C
- Lead-Acid Battery : 0.2C - · Battery capacity should be calcuated with
consideration of charging cycle. - · Any battery type can be applied with.
In case that there is a vehicle in low battery state in the system, Control System orders it move to the battery exchanging
station to replace internal lowered battery to full charged one by itself. As the AGV is able to be in the system except a few
minutes per every battery exchanging cycle, system can be operated with higher operation rate.
- · Specially designed battery exchanger is required.
- · Cells in battery exchanger are required as many as
vehicles in the system. - · Batteries are required doubly.
- · Enough space should be secured to install equipment
and AGV drives in and out of the station. - · A secondary power supply plan need to be considered
since power supply is discontinued while battery
exchanging procedures are going on. - · Any battery type can be applied with.
If there is an AGV in low battery state in the system, Control System doesn't allocate any good transport order to it and
it drives to the designated place and waits for battery manual exchagnig at there. once battery exchanging was completed
manually and AGV was recovered from low battery status, then AGV is allowed to be in the system by Control System.
- · Battery transport cart is required separately.
- · The cart is designed to be optimized for docking with
battery cell on the AGV. - · Batteries are required doubly.
- · Power connection and disconnection needs to be
done directly by operator as well. - · Reasonable construction cost than Auto-Exchanging
system but not Opprotunity Charging system. - · Any battery type can be applied with.
IPT(Inductive Power Transfer) System supplies the required power to the AGV by non-contact method based on technology
of high-frequency transformation. Also wire installed under floor can be used to support vehicle guidance as introduced in
Inductive Wire Navigation system by interface with specialized guide sensor on the vehicle.
- · Supports to maintain high system operation rate.
- · It costs much to build up non-contact power supply
system relative to others. - · Suitable for layout having short travel distance or
closed path like circle shape. - · The more vehicles, the more advantageous.
- · All guidance method can be applied.
- · More flexible when auxiliary battery is used together
with.
