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INTEGRATION OF AN AUTOMATED GUIDED VEHICLE SYSTEM
WITH A PROGRAMMABLE LOGIC CONTROLLED MATERIAL
HANDLING
This report submitted in accordance with requirement of the University Teknikal Malaysia
Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Robotics and Automation)(Hons.)
by
CHIAM CHUN HONG
B051310102
930609-07-5725
FACULTY OF MANUFACTURING ENGINEERING
2017
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Integration of an Automated Guided Vehicle System with a Programmable Logic Controlled Material Handling
SESI PENGAJIAN: 2016/17 Semester 2 Saya CHIAM CHUN HONG 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 Malaysiasebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap:
NO. 76, Jalan Teratai Indah,
Taman Teratai Indah,
Butterworth, Pulau Pinang.
Tarikh: 29/05/2017
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 “Integration of an Automated Guided Vehicle System
with a Programmable Logic Controlled Material Handling”
is the results of my own research except as cited in reference.
Signature : ………………………..
Author’s Name : CHIAM CHUN HONG
Date : 28 May 2017
ii
APPROVAL
This reported is submitted to the Faculty of Manufacturing Engineering of Universiti Teknikal
Malaysia Melaka as a partial fulfillment of the requirements for the degree of Bachelor of
Manufacturing Engineering (Robotics & Automation) (Hons).
The members of the supervisory committed are as follow:
……………………………..
(Ir. Dr.-Ing. Azrul Azwan Bin Abdul Rahman CEng)
I
ABSTRAK
Pengendalian bahan termasuk pemindahan, perlindungan, penyimpanan dan
pengawalan bahan dan produk sepanjang operasi pembuatan, pergudangan, pengedaran,
penggunaan dan pelupusan. Sistem integrasi ialah gabungan pelbagai sub-sistem menjadi satu
sistem utama. Sistem ini mampu mengintegrasikan sistem Automated Guided Vehicle (AGV)
dan Programmable Logic Controller (PLC) untuk berfungsi secara automatik. Oleh itu,
objektif utama dalam projek ini ialah membina dan memastikan sambungan antara AGV dan
PLC dalam aplikasi sistem pengendalian bahan adalah tersedia. Sistem ini juga boleh
meningkatkan produktiviti dan efisiensi dalam mengendali bahan. Projek ini menumpukan
kepada sambungan antara Pioneer 3-AT AGV dan Omron CP1L PLC melalui program C++.
Omron PLC akan menyambung ke penghantar. Projek ini boleh dibahagikan kepada tiga
seksyen iaitu seksyen AGV, seksyen PLC dan seksyen sistem integrasi. Seksyen AGV akan
menjelaskan hubungan antara perisian C++ dan AGV. Dapatan daripada projek ini, C++ telah
berjaya berintegrasi dengan AGV melalui Advanced Robotics Interface for Application
(ARIA). Seksyen PLC pula menumpukan kepada sambungan antara perisian C++ dan sistem
PLC penghantar. C++ dapat berintegrasi dengan PLC melalui OLE for Process Control (OPC).
Seksyen sistem integrasi akan menghuraikan sambungan antaran kedua-dua sistem yang telah
dinyatakan sebelum ini. Oleh itu, C++ berjaya mencipta dua hala komunikasi dengan menberi
arahan daripada AGV dan PLC. Namun begitu, projek ini hanya menjalankan percubaan
melalui simulasi di komputer tetapi tidak akan berbeza dengan sistem yang sebenar. Objektif
projek ini sudah tercapai dan disampaikan di laporan dengan terperinci.
ii
ABSTRACT
In industry, material handling involves the movement, protection, storage and control
of materials and products throughout manufacturing, warehousing, distribution, consumption
and disposal. However, the system cannot be synchronized without integration between all
machinery systems and work automatically. Integrated system is the combination of the sub-
system becoming as one large system. The purpose of this project is to verify and establish the
connection between the Automated Guided Vehicle (AGV) and Programmable Logic
Controller (PLC) material handling system to directly or indirectly improving the productivity
and efficiency. It focuses on the connection between the Pioneer 3-AT AGV and Omron CP1L
PLC by using C++ language. The Omron PLC will connect to the conveyor. This project can
be divided into third part which is AGV part, PLC part and combine part. AGV part focuses
on the connection between the C++ software and AGV. From the result, C++ program able to
connect the AGV through Advanced Robotics Interface for Application (ARIA) library. PLC
part focuses on the connection between C++ software and PLC conveyor system. C++
program is connecting the PLC by using OLE for Process Control (OPC). For the combining
part, it is focusing on the connection between both AGV and PLC system. From the results,
C++ program able to call out each coding and establish the two-way communication. Due to
some reason, the connection between each other only done in simulation. As a result, the
objective is achieved. This can be proved by the scenario for verification.
iii
DEDICATION
Only
my respected grandfather and grandmother, Chiam Ah Bak and Siah Geet Suan
my beloved father, Chiam Kok San
my appreciated mother, Lim Ai Tee
my adored sisters, Xue Chyi, Xue Mei and Xue Jing
for giving me moral support, money, cooperation, encouragement and also understandings
Thank You So Much & Love You All Forever
iv
ACKNOWLEDGEMENT
First, I would like to take this opportunity to thank my respected supervisor, Ir. Dr.-Ing.
Azrul Azwan Bin Abdul Rahman CEng for his precious time of encouraging, sharing,
mentoring and patient that was given throughout the entire project. Without his assistance and
knowledge, this project would not have been successful.
Besides, I also want to thank my family for their love and support throughout my life.
They have given me discipline and drive to tackle any task with enthusiasm. Without their
love and support, my studies journey would not be so smoothly.
In addition, I would like to thank lecturer of UTeM for teaching the knowledge of
manufacturing engineering that was extremely useful for my project. I would like to thank the
faculty member who served on the laboratory staffs and the master students for them
cooperate and generous for their expertise.
Last but not least, I would like to give special thanks to my friend who gives me much
motivation and cooperation mentally in completing this report.
Finally, I would like to thank everybody who was important to this FYP report, as well
as expressing my apology that I could not mention personally each one of you.
v
TABLE OF CONTENTS
ABSTRAK i
ABSTRACT ii
DEDICATION iii
ACKNOWLEDGEMENT iv
TABLE OF CONTENTS v
LIST OF TABLES viii
LIST OF FIGURES ix
LIST OF ABBREVIATIONS xii
CHAPTER 1: INTRODUCTION
1.1 Background 1
1.2 Problem Statement 2
1.3 Objectives 3
1.4 Scope 3
CHAPTER 2: LITERATURE REVIEW
2.1 Material Handling 4
2.1.1 AGVs 5
2.1.1.1 Free Ranging and Autonomous 7
2.1.1.2 Consideration Implementation 8
2.1.1.3 Mapping, Localization, Path Planning and Navigation 9
2.1.1.4 Communication 10
2.1.1.5 LAN 12
2.1.1.6 WLAN and Wi-Fi 13
2.1.1.7 Control System 15
2.1.1.8 Programming Language 17
2.1.2 Conveyor System 17
vi
2.1.2.1 System Design 19
2.1.2.2 Consideration Implementation 19
2.1.2.3 Control System 20
2.2 Material Handling System Integration 30
2.2.1 Open System Interconnection (OSI) protocol 32
CHAPTER 3: METHODOLOGY 34
3.1 Overall Methodology 34
3.2 Initial Assessment 35
3.3 Development of Communication System 36
3.4 Software and Programming 38
3.5 Data Transfer 40
3.6 Verification, Improvement, and Implementation of the Project 41
CHAPTER 4: RESULTS AND DISCUSSION 43
4.1 Validation Table 43
4.2 Connection of the complete system 44
4.3 Connection with AGV system 47
4.3.1 Connection of C++ and ARIA 48
4.3.2 Connection of ARIA and MobileSim 53
4.3.3 Connect to the Real AGV P3-AT 60
4.4 Connection with Conveyor System 63
4.4.1 Connection of C++ and QuickOPC 64
4.4.2 Connection between QuickOPC and MatrikonOPC Server for Omron PLC 66
4.4.2.1 Coding for Write Data to OPC Server 67
4.4.2.2 Coding for Read Data from OPC server 70
4.4.3 Connection between the MatrikonOPC Server and MatrikonOPC Explorer 71
4.4.4 Connect to the real Omron CP1L PLC 76
4.5 Scenario for Verification 76
4.6 Sustainability 78
vii
CHAPTER 5: CONCLUSION AND RECOMMENDATIONS 79
5.1 Conclusion 79
5.2 Suggestions and Future Works 80
REFERENCES 81
APPENDIX A 87
APPENDIX B 88
APPENDIX C 89
APPENDIX D 92
APPENDIX E 96
APPENDIX F 98
viii
LIST OF TABLES
4.1 Validation Table for the coding 43
ix
LIST OF FIGURES
Figure 2.1: Simple example of material handling system 5
Figure 2.2: Example of an AGV 7
Figure 2.3: Pioneer 3-AT robot 8
Figure 2.4: The procedure of the data transmits 11
Figure 2.5: Example of the LAN networking 13
Figure 2.6: Example of the Wi-Fi communication 14
Figure 2.7: Example of the computer control system 16
Figure 2.8: Example of the Belt Conveyor 18
Figure 2.9: Block diagram of DCS 22
Figure 2.10: Example of PLC 24
Figure 2.11:Example of PLC system 26
Figure 2.12: Component of the PLC to control the conveyor system 27
Figure 2.13: Example of the LD 28
Figure 2.14: Example of the system integration 32
Figure 2.15: Example of the data transferring through OSI protocol 33
Figure 3.1: Overall Methodology 34
Figure 3.2: Pioneer 3 research AGV 35
Figure 3.3: Omron SYSMAC CP1L-E 36
Figure 3.4: Communication between AGV and PLC conveyor system through host computer
36
Figure 3.5: PC-104 card 37
Figure 3.6: Data transfer from AGVs to host computer 40
Figure 3.7: Data transfer from PLC conveyor system to AGVs 41
Figure 3.8: Example of the validation table 42
Figure 4.1: Using C++ sotware to link AGV and PLC systems. 45
x
Figure 4.2: Header for the main coding. 46
Figure 4.3: Coding for connect both system. 46
Figure 4.4: Desktop situation when debugging all system. 47
Figure 4.5: The software logo that uses to communication between the C++ sotware and the
AGV simulation. 48
Figure 4.6: C++ software properties setting. 49
Figure 4.7: C++ software general configuration properties. 50
Figure 4.8: C++ software adding library in Additional Dependencies. 50
Figure 4.9: C++ software adding Aria library 51
Figure 4.10: C++ software changing Runtime Library. 52
Figure 4.11: Adding Aria.h into the coding 52
Figure 4.12: Drawing map by using Mapper3Basic. 53
Figure 4.13: Select the robot and load the map 54
Figure 4.14: After loaded the map 54
Figure 4.15: The example coding of AGV moving forward. 55
Figure 4.16: The example coding of AGV moving backward. 56
Figure 4.17: The example coding for the AGV to rotate anticlockwise. 56
Figure 4.18: The example coding of AGV clockwise rotate. 57
Figure 4.19: The example coding of AGV stopping. 58
Figure 4.20: Simulation AGV moving forward 58
Figure 4.21: Simulation AGV after moving forward and start to rotate 59
Figure 4.22: Simulation AGV after finish rotate and start to move forward again 59
Figure 4.23: IP address checking 61
Figure 4.24: VNC viewer connect to VNC server 61
Figure 4.25: Real robot moving. 62
Figure 4.26: The software logo that uses to communication between C++ and PLC 63
Figure 4.27: Adding a new header file. 64
Figure 4.28: Giving the new header files name QuickOPC. 65
Figure 4.29: Adding OPC library into the coding 65
Figure 4.30: Using EasyOPC Demo Application to find server class and item id. 66
Figure 4.31: The coding that writes the value become True. 67
xi
Figure 4.32: The coding that writes the value to False. 68
Figure 4.33: The coding that makes an array for the number of items. 68
Figure 4.34: Coding for Write data from array 69
Figure 4.35: Coding for select the server-class and item id to read value 70
Figure 4.36: The coding that makes an array for the number of items. 70
Figure 4.37: Coding for read data to array 71
Figure 4.38: MatrikonOPC server create a new alias 72
Figure 4.39: Insert detail of alias 73
Figure 4.40: MatrikonOPC Explorer is connecting to the server. 73
Figure 4.41: Adding tag into the MatrikonOPC Explorer Group 0. 74
Figure 4.42: Adding available tags. 75
Figure 4.43: The tags are added and can be read the value from MatrikonOPC server. 75
Figure 4.44: Scenario for verification 77
xii
LIST OF ABBREVIATIONS
ADC - Analog-to-Digital Converter
AGV - Automated Guided Vehicle
CAN - Controller Area Network
CSMA/CA - Carrier Sense Multiple Access with Collision Avoidance
DAC - Digital-to-Analog Converter
DCS - Discrete Control System
FBD - Function Block Diagram
IC - Integrated Circuit
IL - Instruction List
IPCF - Industrial Point Coordination Functions
IPCF-MC - Industrial Point Coordination Function – Management Channel
ISO - International Organization for Standardization
I/O - Input and Output
IWLAN - Industrial Wireless LAN
LAN - Local Area Network
LAWN - Local Area Wireless Network
LD - Ladder Diagram
LED - Light Emitting Diodes
OLE - Object Linking and Embedding
OPC - OLE for Process Control
OS - Operating System
OSI - Open System Interconnection
PC - Personal Computer
PCMCIA - Personal Computer Memory Card Industry Association
PLC - Programmable Logic Controller
RF - Radio Frequency
ROI - Return of Investment
SCADA - Supervisory Control and Data Acquisition
xiii
SFC - Sequential Function Chart
ST - Structural Text
Wi-Fi - Wireless Fidelity
WLAN - Wireless LAN
1
CHAPTER 1 INTRODUCTION
1.1 Background
Manufacturing industry plays an important role and made a large influence in the
economic growth. But, the manufacturing industry need to face a lot of challenges due to
globalization in this 21st century (Ong, 2015). So, the manufacturing industry is always
searching for improvement. To improve it directly or indirectly, one of the methods is to
integrate the system each other to increase the productivity. There are a lot of systems in
manufacturing industrial such as material handling system, packaging system, fabrication
system and so on (Kajan et at., 2013), (Jaiganesh et at., 2014).
Material handling system involves short distance movement within the confines of a
building or between a building and a transportation vehicle. It utilizes a wide range of manual,
semi-automated, and automated equipment and included consideration of the protection,
storage, and control of material throughout their manufacturing, warehousing, distribution,
consumption, and disposal (Aized, 2010). In a simple way to explanation, material handling
system is a system concerned about loading, moving and unloading of materials. Some
example of the material handling system is Automated Guided Vehicle (AGV) system and
conveyor system.
AGVs is a flexible manufacturing system (Butdee et at., 2008). This system can
improve response time for material movement due to it suitable for long and short distance
moves (Hollier, 1985). There are a lot of industries choosing AGVs as material handling
2
system (Wu et at., 2012). The example of AGV are towing AGV, unit-load AGV, pallet truck
AGV, fork truck AGV and others (Wu et at., 2012).
Conveyor systems are especially useful in the application involving the transportation
of heavy or bulky materials. Conveyor systems allow quick and efficient transportation for a
wide variety of materials which make them very popular in the material handling and
packaging industries (Ong, 2015). There is a positive growth for conveyor system on
manufacturing industry (TECHNAVIO, 2016). The example of the conveyor system likes
pneumatic conveyor, vibrating conveyor, flexible conveyor, vertical conveyor and others.
There are many conveyor systems is using Programmable Logic Controller (PLC) to control it.
PLC is an industrial digital computer which is flexible, ruggedized and adapted for the
control of manufacturing processes, such as assembly lines, or robotic devices, or any activity
that requires high-reliability control and ease of the programming and process fault diagnosis
(MAKOX, 2014), (Aized, 2010). By using the PLC, the output results must be produced in
response to input condition within a limited time.
In future, the material movement should be fully integrated to form a coordinated,
operational system which including receiving, inspection, storage, production, assembly,
packaging, unitizing, order selection, shipping, transportation and the handling of return
(Aized, 2010).
1.2 Problem Statement
Currently, the problem that faced by manufacturing industry is most industry choose
manual as product transfer. The worker or operator needs to take the product from the machine
and send it to another section. Even they use AGV, the human operator still a needed for tasks
like loading/unloading that are difficult to fully automate. To avoid non-value added activity,
integration between systems is needed. Besides that, the whole system in the manufacturing
industry is not synchronizing without integration between all machinery systems and work
3
automatically. To link the whole system together, we need to do it step by step. So, the
research starts from integrating the AGV and PLC material handling system. In addition, there
are just a few of research being done about the integration system between AGVs and the
material handling system. So, to prove the AGVs works on integrating with material handling
system, we try to communicate each other through experimentation. By integration difference
system together, it can be improving the productivity and decrease the cost efficiency while
the whole system in the industry can be more synchronize without any operator interrupt after
few years.
1.3 Objectives
The objectives of this project are:
(a) To establish the communication between AGV and PLC conveyor system using
communication protocol.
(b) To verify the integration capability between AGV and PLC conveyor system through
experimentation.
1.4 Scope
The scope works for this project are:
(a) The type of material handling system is using conveyor system and AGV system.
(b) The type of AGVs is using Pioneer 3-AT (P3-AT) research AGV.
(c) The conveyor system is using Omron PLC to control.
(d) The type of communication is using Local Area Network (LAN).
4
CHAPTER 2 LITERATURE REVIEW
2.1 Material Handling
Material handling is one of the basic components in manufacturing industry. Material
handling means the loading, unloading, movement, protection, storage and control of materials
and products throughout manufacturing, warehousing, distribution, consumption and disposal
especially by the aid of mechanical devices. As a process, material handling incorporates a
wide range of manual, semi-automated and fully automated equipment and systems that
support logistics and make the supply chain work. Material handling helps with forecasting,
resource allocation, production planning, flow and process management, inventory
management and control, customer delivery, and after sales support and service. A company’s
material handling system and processes are put in place to improve customer service, reduce
inventory, shorten delivery time, and lower overall handling costs in manufacturing,
distribution and transportation (MHI, 2014). So, material handling system is becoming
increasingly important to manufacturing industry nowadays due to this technique which can
help system planners to measure the total productivity of a business and identify the full
opportunity for economic improvement through the use of more efficient material handling
activities (Hollier, 1985). There are a lot of type of material handling system such as conveyor
system, AGVs and robot arm each (Lindsay et at., 2000). Figure 2.1 shows that the example of
the material handling system. The example of material handling system is cover by red circle.
5
Figure 2.1: Simple example of material handling system (Toray, 2016)
2.1.1 AGVs
AGV is a type of driverless, steerable, wheeled industrial mobile vehicle designed
primarily to carry material, tow objects behind them in trailers and transport individuals.
According to the Vosniakos and Mamalis (1990), AGVs are an industrial transportation
system equipped with electronic devices to follow a wire buried in the ground, pick up and
deliver their load at work stations, communicate with each other hardware devices, and move
around the network controlled by a supervisory computer and possible by microprocessors on-
board. AGVs are commonly used in manufacturing plants, warehouses, distribution centres,
paper industry, printing industry, textiles industry, steel industry and terminals (Kajan et at.,
2013), (Wu et at., 2012). There are four important elements in AGVs which are:
6
(a) vehicles
Vehicles are the most important elements of an AGVs as they perform the
actual transportation tasks. All vehicles are design individually according to their
specific working tasks, working condition and working environment (Schulze et at.,
2008). Vehicle can be classified as toward AGV, unit load AGV, pallet truck AGV and
fork truck AGV (Wu et at., 2012), (Vosniakos and Mamalis, 1990).
(b) guidance and information transfer system
Most of them will using signal paths, lane paths or signal beacons for
navigation. The examples of the sensors that AGV will use to senses are optical
sensors, laser scanner, magnetic sensors and also camera (Wu et at., 2012), (Vosniakos
and Mamalis, 1990).
(c) traffic control system
The traffic control system covers superordinate control component. It tasks is
administration of the transportation orders, the optimization of schedules, the
communication with other control system. The system also provides graphical
visualization and statistical analysis (Schulze et at., 2008). The AGV routing method
can be classified from the viewpoint of trajectory shape which is single loop or bi-
directional (Kajan et at., 2013).
(d) pick-up and deposit station and load transfer equipment (Vosniakos and Mamalis, 1990)
AGVs pick-up and deposit station and load transfer can be accomplished in
many way such as manual load transfer, automatic couple and uncouple, power roller,
belt, chain, power lift/lower and power push/pull (Ülgen and Kedia, 1990). Besides, a
robot such as robot arm installed on an AGV, which can give the robot the mobility it
lacks and the AGV the flexible manipulator it lacks (Vosniakos and Mamalis, 1990).
7
The advantages of AGVs is flexibility system, safety technology, and accuracy and
productivity. It is a flexibility system due to the vehicle can quickly reprogram to change
direction, path or operation. The system also can eliminate the need for expensive retrofitting
and new directions, tasks, and work cells can be created almost instantaneously without the
need for physical equipment installation. Besides, the AGVs is safety due to it can avoiding
interference with human or building. It also can work at the environment that may be not
suitable to human operators. In addition, the AGVs is accuracy after combined with Radio
Frequency (RF) technology and it can operate at a fixed rate to meet a predictable metric for
operational activity (Vosniakos and Mamalis, 1990), (Jaiganesh et at., 2014). Development of
the AGVs plays the major role in industry to improve the technology of the material handling
system (Kajan et at., 2013), (Jaiganesh et at., 2014). Figure 2.2 show that an AGV is
transporting the material.
Figure 2.2: Example of an AGV (Schafer, 2015)
2.1.1.1 Free Ranging and Autonomous
Todays, the AGVs is already update, compare to the classic ones which is floor based
type AGV, it instead of using free ranging AGV and autonomous AGV (Wu et at., 2012),
(Vosniakos and Mamalis, 1990). Free ranging and autonomous AGV is an automatic machine
that is capable of locomotion (Vosniakos and Mamalis, 1990). It means the AGV will use
software to program without a physical path. The factory or warehouse must be installed
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