Smart AGV Based Logistics System For Pakistani Industries

Project Title

Smart AGV Based Logistics System For Pakistani Industries

Project Area of Specialization Mechatronics EngineeringProject Summary

With the introduction of the 4th industrial revolution or Industry 4.0, the modern world is switching from conventional machining methods to autonomous systems with a proven increase in production and cost decrease. The concept of industry 4.0 is not new and has already been implemented on a large scale in developed countries, and they are already extracting fruits from it.  However, in developing countries like Pakistan, this concept is still new and in the pilot stages of implementation. However, now it's become necessary for countries like us to switch to modern manufacturing techniques to sustain the global/local market requirements. Studies show that most of the idle time in machines during a production cycle comes in the form of transportation. The transportation of material from one place to another has been carried out by labor. There are various human, psychological and physical factors involved that lead to more significant time for reaching the desired destination. Moreover, with the manufacturing sector's contribution of over 12.59% of the total country GDP, most of this comes from the job shop sector rather than production. In the JobShop environment, the intelligent allocation of jobs concerning available resources is significant for maximum productivity. “Smart AGV Based Logistics System For Pakistani Industries” is designed to meet the modern-day needs of the manufacturing sector in Pakistan, where factors such as increased demand for the supply of products and other logistics-related hurdles are addressed. The system is adaptive to the current local industrial environment. It comprises an Automated Guided Vehicle (AGV), which is smartly programmed to transport raw material to different manufacturing machinery present in the industry. It helps save both time and cost of manufacturing through such programmed algorithms.

Project Objectives

1. The AGV will be designed keeping in view the factor of cost-effectiveness, enabling the AGV to carry a load upto 20kg. AGV will consist of a carrier on top designed to hold various sizes and shapes of work jobs. 

2. A scheduling algorithm specifically designed for an AGV will be such that it would schedule jobs in the most optimal outcome where profit is maximized while idle time is minimized.

3. An algorithm will be designed such that it could help AGV reach the desired destination through the shortest possible path in order to minimize the traveling time.

Project Implementation Method

The design and algorithm of AGV is to be designed according to specified manufacturing arena size and fixed number of manufacturing machines present there. A shielded carrier on top of the AGV will help keep raw material from falling on the ground while it is to be transported for the manufacturing process. AGV will take into account both Scheduling and SJF algorithms for decision-making regarding which work job is to be transported first and then afterwards based on saving the time and cost of manufacturing. RFID sensors & tags along with ultrasonic sensors will be integrated with the algorithm so AGV can determine its next move. The scheduling algorithm will take into account the time and cost potential of each workpiece available in the job shop and have the combined ratio of both mathematically as a data then it will compare the ratios of each workpiece and prioritize them accordingly with the one having the lowest so as to reap maximum potential profit while routing algorithm will ensure that AGV chooses the shortest possible path for transporting workpieces by choosing the minimal distance between node points through which AGV will travel accordingly.

Benefits of the Project

The project will benefit manufacturing industries in Pakistan by eliminating costs incurred due to idle state time of machinery. It will also help in decreasing accidents & errors, causing preventive or corrective maintenance measures to take place in the manufacturing sector of Pakistan. This project will ensure a smooth and safe flow of work jobs or manufacturing raw materials when it comes to logistics of the manufacturing industry. There will be a demand for less human intervention in the manufacturing industry's logistics operation, which will ensure higher productivity, efficiency, and flexibility in such procedures. It will also address one of the UN SDG Goal #9 set to be achieved by 2030: Industry, Innovation, and Infrastructure. This automation system takes logistics to the next level of optimization, where possibilities of meeting the ever-growing demand for manufactured products will come true and thus hugely benefit Pakistan, especially in the context of CPEC projects to fast-track the work.

Technical Details of Final Deliverable

The final deliverable will consist of a working prototype AGV that can schedule and route jobs to the destination as per our designed algorithm. The velocity of AGV is to be 0.4166m/s as it covers 1 meter in 4.8 seconds. However, the AGV cart weight will be around 40kg whereas the external weight loaded on AGV can vary between the applicable range. The radius of the wheels is 0.120 meters. If a 10 Kg of external weight is put over an AGV, then there will be torque generation of 51Nm while the power dissipated will be 88.5 watts. Scheduling and routing algorithms will be perfectly integrated with RFID tags and other sensors so AGV would be to achieve desired objectives of this project. The work jobs will be first prioritized through a scheduling algorithm keeping in view cost and time overheads to maximize the profit potential and the routing algorithm will ensure the shortest route for transportation of work jobs to and from manufacturing machines.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther IndustriesCore Technology RoboticsOther TechnologiesSustainable Development Goals Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	73500
Driving Motor	Equipment	2	12000	24000
Soldering Costs	Miscellaneous	1	300	300
Printing Costs	Miscellaneous	1	1000	1000
Battery Costs	Equipment	1	25000	25000
Sheet Costs	Equipment	700	5	3500
Paint Costs	Equipment	1	700	700
Fuel Costs	Miscellaneous	1	8500	8500
Motor Armature works & other modifications	Equipment	1	1500	1500
Tyre Costs	Equipment	1	4000	4000
Mechanical Components	Equipment	1	5000	5000