HO CHI

MINH UNIVERSITY OF TECHNOLOGY

AND EDUCATION

FACULTY OF HIGH QUALITY TRAINING

GRADUATED PROJECT

DESIGN AND RESEARCH OF AGV USING

SLAM (ROS) SYSTEM

LECTURER : Dr Vu Quang Huy

STUDENTS : Tran Quoc Huy 19146080
Nguyen Van Son 19146130
 ABSTRACT

Our country is becoming more and more modernized and industrialized. Compared
with other powers to catch up with them in development, our country's industry needs
to have access to modern technologies and equipment. Technology engineers need to
be equipped with broader and new knowledge to be able to meet the needs of
accelerating the country's development. Robot engineering technology has been and
will be widely applied in many countries. It brings us many benefits in terms of
productivity, high job efficiency in many fields such as industrial production,
medicine, society, space exploration, etc. However, in the robotics industry In our
country, the scale is quite large, but the quality is not high due to limitations in science
and technology, machinery and equipment are still rudimentary, so labor productivity
is only average. An automated guided vehicle is the most famous robot use in the
foreign company to transport automatic the product. We are going to searching and do
this project to figure out the information about this robot, which can improve our skills
and have an overview of the engineer.

The scientific significance of the topic:

Bringing lots of advances in the application of modern science and technology to the
production process, which is the basis for building automated processes with the best
equipment and machines. In addition, it can also show that students' understanding is
increasingly enhanced when they have mastered the basic knowledge of science and
creatively and effectively apply it to life.

Keywords: AGV, Automated Guided Vehicle, IR sensor, Ultrasonic sensor, Arduino…

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 THESIS ACKNOWLEGDEMENT

Foremost, I would like to thank my family for giving birth to me at the first place and
supporting me spiritually throughout my life.

Beside, I would like to express my sincere gratitude to my advisor Dr Vu Quang Huy

for the continuous support of my our study and research, for his patience, motivation,
enthusiasm, and immense knowledge. His guidance helped me in all the time of
research and writing of this thesis. I could not have imagined having a better advisor
and mentor for our project study.

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CONTENT

4
LIST OF TABLES

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 CHAPTER 1: AN OVERVIEW
1.1. AGV overview

· An automatic guided vehicle system (AGVS) consists of one or more computer-

controlled, wheel-based load carriers (normally battery powered) that runs on the plant
or warehouse floor (or if outdoors on a paved area) without the need for an onboard
operator or driver. (MHI)

· An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot

that follows markers or wires in the floor, or uses vision or lasers. They are most often
used in industrial applications to move materials around a manufacturing facility or a
warehouse.

· The term "automated guided vehicle" (AGV) is a general one that encompasses all
transport systems capable of functioning without driver operation. The term
"driverless" is often used in the context of automatic guided vehicles to describe
industrial trucks, used primarily in manufacturing and distribution settings, that would
conventionally have been driver-operated

· A materials handling system that uses automated vehicles such as carts, pallets or trays
which are programmed to move between different manufacturing and warehouse
stations without a driver. These systems are used to increase efficiency, decrease
damage to goods and reduce overhead by limiting the number of employees required
to complete the job.

1.2. AGV application

- Working operation: day and night.

- Replace people transporting heavy and repetitive goods.

- Reduce operating costs, especially training and labor costs. - High accuracy and
stability make the production process continuous.

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 - Reduced shipping time.

Therefore, manufacturing and trading companies have been promoting the

development of automatic factory and warehouse systems using AGV.

In the factory, AGVS used to transport goods automatically from the place of delivery
to production sites. Conventional AGVS includes vehicle (vehicle), controller
integrated on AGV, management software, communication and navigation system

1.3. Structure of AGV system

Fig 1.1. AGV structure

The management software

The software on the computer needs to handle the management of all AGVs. Duties
server services are: optimizing AGV usage, order taking and management, tracking
and inventory of goods in stock…. Thus, a high-yield AGV system or Low
dependency on

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management software. Depending on the application of the AGV . system that the
management software will play a role and the management method is also different.

The AGV system used in the assembly line uses only management software acquires
type information, as moves are pre-programmed on each AGV. The path from the
production and storage area to the permanent assembly area, in no order requires a lot
of server computation. The moving speed of the AGV depends on the assembly speed
of the line.

For a warehouse, the processing center must acquire all information about the location,
goods on the AGV to control the whole system. It could be choosing which position
robot, calculate the effective path, the right speed to avoid meeting other robots,
reduce the time moving time when arranging goods in the warehouse.

Fig 1.2. The warehouse system diagram

Communicate system

Includes host-to-robot and robot-to-robot communication. Moved by robots should use

wireless communication methods. Pressure radio wave technology is commonly useed

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in industry such as wireless LAN (Local Area Network) and Bluetooth. Wireless
technology requirements of the system.

The AGV system has:

- Stable connection.

- High security features.

- Simple configuration and communication method.

Bluetooth technology suitable for devices that automatically request power low, low
cost. Bluetooth range is about 10 (m), however a few special module can cover the
area 200 ÷ 400 (m).

Wireless LAN technology is well suited for AGV . systems frequently scale, monitor
and analyze data at high speed. Visibility the normal operation of the 2.4 GHz
bandwidth is 200 (m), the 5 GHz bandwidth is 50 (m).

1.4. Types of the AGV vehicles

Each type of goods has different requirements when storing and transporting, so there
are multiple shipping methods. In the factory, there are usually 3 types of AGV, this
type of AGV covers most transportation jobs.

1.4.1. Unit load AGV vehicles:

In simple terms, these robots are portable and autonomous cargo delivery systems that
are able to travel around a warehouse or facilities performing differrent AGV
navigation technologies.
These fascinating robots are mainly used for industrial transport of goods and heavy
materials around warehouses or storage facilities.
A unit load AGV is a powered, wheel based transport vehicle that carries a discrete
load, such as an individual item (e.g. a large roll of paper, coil of steel or automobile
engine) or items contained on a pallet or in a tote or similar temporary storage
medium. AGVs operate under computer control without the need for human operators
or drivers.
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 Figure 1.3. Unit load AGV

1.4.2. AGV forklifts

An Automatic Guided Forklift also known as ALT is a Self-Driving computer-

controlled Forklift. So a forklift moving around and transporting goods by its own
without human intervention, it's just a driverless forklift. It is the typical automated
guided vehicle (agv) with forks.
The AGV Forklift is a part of a complex AGV System composed of robots, software,
peripherals, etc.
This specific kind of AGV is inspired by the conventional human manned forklifts.
The forklift AGV is designed to provide both horizontal and vertical movement of the
load. They can also be configured to stack loads in racks.
The automated forklift trucks are increasingly becoming a must in manufacturing
premises and warehouses where operations are highly standardized, repetitive, and
easily accomplished without need of human intervention.
Forklift robots are widely used in warehouses for high rack management.

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 Figure 1.4. AGV forklifts

1.4.3. Towing (or tugger) AGV:

Towing vehicles, or tugger automatic guided vehicles, pull one or more non-powered,
load-carrying vehicles behind them in a train-like formation. Sometimes called
driverless trains, powered towing vehicles travel on wheels. Tugger automatic guided
vehicles are often used for transporting heavy loads over longer distances. They may
have several drop-off and pick-up stops along a defined path through a warehouse or
factory.

Figure 1.5. Towing AGV

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 CHAPTER 2: SYSTEM CALCULATION AND
DESGIN
2.1. Introduce

Coming up with an idea for a machine or robot, the important and indispensable thing is the
mechanical design. In this chapter, I will introduce the mechanical design process to form a
basic self-propelled vehicle. Including: design calculations, modeling details, engine
selection and system durability testing.
2.1.1 Application
Today, in the autonomous vehicle industry, automated transport vehicles are applied in
many different fields to enhance performance, reduce costs and increase safety. Here are
some of the main areas where autonomous vehicles are used:

Factory and Industry: AGVs (Automated Guided Vehicles) are used to transport and move
materials and products in factories, warehouses, and other industrial environments
automatically.

Warehouse and Logistics: AGVs are used in distribution centers to automate the storage,
packaging, and transportation of goods.

Healthcare: In the healthcare industry, AGVs are used to move medical materials, drugs and
medical instruments in hospitals and operating rooms.

Agriculture: Autonomous vehicles are used in agriculture to automate processes such as

harvesting, tilling, and transporting agricultural products.

Food Service: In the food service industry, AGVs are used in restaurants and eateries to
serve food and drinks to customers.

Retail: In retail stores, autonomous vehicles are used to move goods from warehouses to
display areas or checkout counters.

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Smart Home: In smart home models, AGVs can be used to automate the transportation of
goods or materials within homes and suburbs.

These applications not only help optimize work processes but also reduce the risk of labor
accidents and increase the efficiency of industries.

2.1.2 Requirements

● Self-propelled vehicles operate in the mode: Detect and handle obstacles, read location
and control to the correct return location.
● Move on flat terrain, inside a room.
● Ensure rigidity and load capacity: 5 kg (including vehicle weight)
● Maximum acceleration 10 mm/ s2
● Maximum stopping error 10mm.
● Angular error at each position is less than 3 degrees.
● Movement orientation and noise reduction.
● Goods have a maximum load size of 5kg

2.1.3 Analyze options

 Option 1 : Moving with 3 wheels

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14
Servo Motors are used throughout many industries and have the following advantages;
High efficiency
High output power relative to their size
More constant torque at higher speed
Closed-loop control
Quiet operation
Highly reliable
High ratio of torque to inertia
High acceleration
High-speed performance

With ability to work with high efficiency, high accuracy, bigger torque and speed
performance, servo motor is a suitable actuator for our project, which requires to
carry heavy loads and transport them to a desired position

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 CHAPTER 3: DESIGN
3.1. Driving design

There are four basic ways of providing drive and steering [8]. These are show in
Figure 2 below. Some types are easier to build, others have better steering
characteristics. Two of these designs are fully symmetrical and may be operated
in both directions.

Figure 3.1. Types of drive and steering

Design Simplicity Steering Reversible

4 wheel drive Simplest Coarse Yes
Center drive & casters Simple Precise Yes
Steer drive motor Medium Very precise No
Rear drive Rack Steer Complex Precise Difficult

Table 1: Characteristics of different wheel design

In this project center drive was chosen because of the ease of control and accuracy
of movement. The prime mover of AGV can be selected between using a DC
motor or brushless DC (BLDC). DC motors can be controlled with PWM drivers
and signals [6][10], but DC motors does not have enough torque to load up to 500
kg. BLDC motors are high torque that the most commonly used motors in the
industrial world, such as automotive, medical automation and instrumentation

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equipment. The BLDC motor does not use brush (brush) for magnetic field
changes (commutation), but done electronically commutated.

3.2. Wheel selection

The wheel is one of the important component in the line tracing robots since it has
roll on the concrete floor without any slippage. The wheels are covered with
rubber material for better efficiency and friction towards the concrete surface. The
wheels plays a major role in the overall kinematics of the robot. The standard
wheels and the castor wheels have primary axis and are thus highly directional.

 Drive wheel:

Figure 3.2. Drive wheel

The wheel is made of steel alloy and has outer diameter made of PU plastic. This
material gives advantages of durability, oil resistance and high abrasion resistance.

Outer diameter 150mm

Width 50mm
Shaft diameter 20mm
Keyway 8mm
Table 2: Wheel specifications

 Castor wheel:

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 Figure 3.3. Castor wheel

The castor wheel is also made of PU plastic, which gives the same advantages as
listed

Outer diameter 100mm

Width 40mm
Height 133mm
Shaft diameter 10.1mm
Table 3: Castor wheel specification

3.3. Chassis design

Figure 3.4. Chassis design

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The frame is built from 3mm thick, squared cross-section, steel profile. It has a 4-
wheel kinematics architecture, with two powered wheels and two castors. The
frame is 74 cm long, 40 cm wide and 28 cm high (Fig. 1). The powered wheels
protrude from the main frame resulting more accurate turning.

There is a main loading surface that can handle heavy loads. All the electrical
and electronic hardware can be installed in the interior of the vehicle. This way,
sensitive equipment is protected from external affects and hazardous
environmental conditions. This is a necessity in order the machine to able to work
in most industrial environments. We note also that the space available for batteries
is isolated from the space dedicated for electronic circuits, to avoid interpolation
to these circuits from the magnetic field created around batteries in power

Tensile stress 425MPa

Wall thickness 2mm
Size 20x20mm
Internal dimension 16x16mm
Density 7859kg/𝑚3
Modulus of Elasticity 2.07
Table 4: Carbon steel sheet specification

3.4. Motor calculation

3.4.1. Input parameters

Vehicle weight+load 50kg

Maximum speed 0.5m/s
Acceleration 0.25m/s^2
Wheel diameter 150mm
Friction coefficient 0.03
Table 5: Input parameters

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 Total force acted on a drive wheel

Figure 3.5. Total force acting on vehicle

𝐹𝑚𝑠 Static friction

𝑛
𝐹𝑤 Traction force made by motor torque
N Reaction force
𝑃1 Vehicle’s half gravity force
𝑀1 Motor torque
𝑚1 Half of vehicle and load’s weight (𝑚1 =
𝑚/2)
Table 6: Definition

 Considering that the vehicle has straight motion with the two motors
having the same velocity at 0.5m/s. The wheel velocity is:

𝑛 = 60∗1000∗𝑣 60∗1000∗0.5
= = 64(𝑟𝑝𝑚) (1)
2𝜋𝑟 3.14∗150

Force equilibrium equation:

𝐹𝑚𝑠𝑛 + 𝐹𝑤 + 𝑁 + 𝑃1 = 𝑚1 ∗ 𝑎 (2)

 When vehicle moves with constant speed:

𝑃1 𝑚1
Reaction force on two wheel: 𝑁 = = (3)
∗𝑔

2 2

25 ∗
9.8 = 122.5(𝑁)
=
2

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Traction force made by motor:𝐹𝑤 = 𝐹𝑚𝑠𝑛 = 𝜇 ∗ 𝑁 (4)

= 0.01 ∗ 122.5 = 1.225(𝑁)

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 Required power for the vehicle to move steadily with velocity of 0.5m/s

𝑃1 = 𝐹𝑤 ∗ 𝑣 = 3.7 ∗ 0.5 = 1.85(𝑊 ) (5)

 When the vehicle accelerates

The acceleration is 0.25m/s^2 so that the package can stay on the vehicle
Traction force made by motor:
𝐹𝑤 = 𝐹𝑚𝑠𝑛 + 𝑚1 ∗ 𝑎 = 𝜇 ∗ 𝑁 + 𝑚1 ∗ 𝑎 (6)

= 1 ∗ 122.5 + 25 ∗ 0.25 = 128.75(𝑁)

With static friction coefficient µ=1
Required moment at wheel shaft for the vehicle to accelerate
𝑀1 = 𝐹𝑤 ∗ 𝑟 = 128.75 ∗ 0.075 = 9.66(𝑁𝑚) (7)
Required power at wheel shafts for the vehicle to accelerate to 0.5m/s
𝑃1 = 𝐹𝑤 ∗ 𝑣 = 128.75 ∗ 0.5 = 64.375(𝑊 ) (8)

Thus we need an motor with power at about 35W

→We choose 37D30-EN Series DC Servo motor

Figure 3.6. 37D30-EN DC servo motor

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 Voltage 12V
Power 40W
Angular velocity 150rpm
No load current 0.3A
Stall torque 8kg.cm
Table 7: 37D30-EN DC servo motor specifications

 Applying belt drive transmission to transmit power from motor to wheel

shaft
Transmission ratio: u= 150
𝑛𝑚𝑜𝑡𝑜�� = = 2.3 (9)
64
𝑛𝑤ℎ𝑒𝑒𝑙

Transmission efficiency:
𝜑 = 0.992 ∗ 0.95 = 0.93𝑃𝑚𝑜𝑡𝑜𝑟 (10)

Power of motor
𝑃 𝑃𝑤ℎ𝑒𝑒𝑙 = 34.4(𝑊) (11)
=
32 =
𝑚𝑜𝑡𝑜𝑟 𝜑 0.93

3.5. Belt drive calculation

Power: 𝑃1 = 34.4W = 0.0344kW

𝑛1 = 150𝑟𝑝𝑚
u=2.3
3 0.0334
 Small pulley diamter: d1=(1100÷1300) (12)
150
√
=66.67÷78.79mm

->Select d1=71mm

 Belt velocity 𝑣
𝜋∗𝑑𝑚
1 ∗𝑛1 𝜋∗71∗150 (13)
=
0.56 = =
1 60000 60000 𝑠

 Selecting slip ratio 𝜀 = 0.01

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d2=𝑢 ∗ 𝑑1 ∗ (1 − 𝜀) (14)

= 2.3 ∗ 71 ∗ (1 − 0.01) = 161.667𝑚𝑚

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 ->Select d2=160mm

 Absolute transmission ratio:

𝑑2
𝑢= 160
𝑑1 (1−𝜀) = = 2.27 (15)
71(1−0.01)

 When selecting distance between shafts, it must satisfy the condition

15000≥ 𝑎 ≥ 2(𝑑1 + 𝑑2)=2*(160+71)=462mm (16)

-> a=462mm
 Belt length:
𝜋∗(𝑑1 +𝑑2) (𝑑2 −𝑑1 )
L = 2a+ + = 1291𝑚𝑚 (17)
2 4𝑎

->Select L=1300mm=1.3m

 Contact angle: 𝑑2 −𝑑1

= 180 − 57 ∗ = 1690 = 2.94𝑟𝑎𝑑 (18)
𝛼1 𝑎
𝑑1
 Belt thickness: 𝛿 = 2.5 to satisfy the condition ≥ 25
𝛿

 Coefficient that affect the contact angle:

𝐶𝑎 = 1 − 0.003(180 − 𝛼1) =: 0.967 (19)

Coefficient that affect the velocity:

𝐶𝑣 = 1 − 0.04(0.01 ∗ 𝑣1 − 1) = 1.039 (20)

Coefficient that affect the position and method; 𝐶0 = 1

Coefficient that affect the working condition: 𝐶𝑟 = 0.6

Selecting allowable stress by the below standard table

d1

Belt type 20 25 30 35 40 45 50 60 75 100

Rubber 2,10 2,17 2,21 2,25 2,28 2,30 2,33 2,37 2,40
Leather 1,40 1,70 1,90 2,04 2,15 2,23 2,30 2,40 2,50 2,60
Cotton 1,35 1,50 1,60 1,67 1,72 1,80 1,85 1,90 1,90 1,95
Wool 1,05 1,20 1,30 1,37 1,42 1,47 1,50 1,55 1,60 1,65

Table 8: Allowable stress selection table

𝑑1 71
= ≈ 25 Select allowable stress 𝜎 = 2.1𝑀𝑃𝑎
25
𝛿 2.5

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 1000∗𝑃1 1000∗0.0344 = 19.4𝑚𝑚
So we have b≥ 𝛿∗𝑣∗𝜎
= 2.5∗0.56∗2.1∗0.6∗1∗1.039∗0.967

Base on table, we choose b=20mm

 Belt width

b,(mm) 10 16 20 25 32 40 50 63 71 80 90
B,(mm) 16 20 25 32 40 50 63 71 80 90 100
Table 9: Belt width selection

Base on the standard, we select the belt which is 25mm in width

->B=25mm

 Initial tension in belt

𝐹0 = 𝜎0 ∗ 𝑏 ∗ 𝛿 =2.1*20*2.5=105(N) (21)

 Force acting on shaft: 𝛼

𝐹𝑟 = 3 ∗ 𝐹0 ∗ sin 1(
2
)= ( ) (22)
99.986 𝑁

 Useful centrifugal force: 𝐹𝑡

= 77.32(𝑁) (23)
=
1000∗𝑃𝑚𝑜𝑡𝑜�
�
𝑣1

 Condition for slippage not to occur:

𝐹0 𝐹𝑡(𝑒𝑓𝑎+1) (24)
≥ 2∗(𝑒𝑓𝑎 −1)
1 2∗𝐹0
→ 𝑓 = 𝑙𝑛 +𝐹𝑡 =0.26
𝛼
2∗𝐹0
−𝐹𝑡

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28
(

3.6. Electrical Design

Figure 3.11. Electric design

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 The line follower's fundamental operations are as follows: the power
supply sends the electricity to Arduino, the project's brain, and then Arduino
sends signals to operate the Driver DC motor 1 and 2. The signals were sent from
the driver's dc motor to the two DC motors that were linked with Wheels 1 and
2 to move forward. Driver DC motor 2, on the other hand, drove DC motor, which
activated the transmission of conveyor belt to move material. The Arduino is also
linked to two, three, and four infrared sensors that assist the vehicle in driving
along the black line, as opposed to one infrared sensor that assists the vehicle in
stopping and preparing to receive or move an object. Furthermore, when the
ultrasonic sensor detects digital, such as persons or objects, it sends a signal to
Arduino, which causes the two DC motors to halt and the user to be notified.

3.7. Simulation

We only be able to conduct the simulation for the displacement of the chassis
acted by desired force. As can be seen from the figure below, we used
Simulation features in Solidworks software to perform the simulation.
The result in the figure shows that the maximum displacement is at center of the
chassis, with the magnitude of 0.3028 mm. Although we can’t carry out the
stress simulation, we can see that the chassis can carry the load since the
displacement is negligible.

Figure 3.12. Chassis displacement simulation

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 CHAPTER 4 : CONCLUSION
4.1. Evaluate

4.1.1. Result

Through this project, the team learned the system of AGV vehicles and classified
different AGVs. From the knowledge learned, the team calculated and designed an
AGV vehicle on 3D drawing software.

4.1.2. Limit

Because of covid 19, the team was unable to gather and do at least a low tech model of
the car
We were not able to carry out simulation of the stress applied to the chassis to have a
better look at the performance of the vehicle.

4.2. Development direction of the topic

Designing the mechanical structure, choosing the appropriate type of motor and source
helps AGV to be able to higher payload capacity, up to several tons.
Design an automatic battery charging station for AGV vehicles simultaneously with
the navigation system Local GPS in the workshop or factory for precise control of
journey, status status of the AGV.
Improve the control interface on the computer, develop the running features
automatically according to the preset route, or according to the preset time.
Improve efficiency (increasing operating time, saving energy..), Precise control of the
vehicle's position and speed.

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 REFERENCE
[1] PGS.TS Nguyễn Hữu Lộc “Cơ sở thiết kế máy” NXB ĐHQG TP HCM

[2] LUẬN VĂN TỐT NGHIỆP ĐẠI HỌC - THIẾT KẾ ROBOT TỰ HÀNH
THEO VẾT HOẠT ĐỘNG TRONG NHÀ XƯỞNG - SVTH: Võ Phong Thiện -
MSSV: 21303868 - TRƯỜNG ĐẠI HỌC BÁCH KHOA

[3] https://123docz.net/document/2304001-do-an-tot-nghiep-co-dien-tu-thiet-ke-
va-thi-cong-xe-keo-hang-tu-dong-agv.htm

[4] https://maysanxuattudong.com/xe-tu-hanh-agv/

[5] https://www.agvegroup.com/

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