How AGVs Maintain High Safety During Automatic Operation

AGVs can achieve efficient and low-cost material transportation, and in terms of safety, AGVs are very safe compared to other material transportation methods, especially when compared to manual handling.

Efficient and low-cost material transportation is a significant measure for many manufacturing plants and warehouses to improve operations. AGVs can achieve efficient and low-cost material transportation, and in terms of safety, AGVs are very safe compared to other material transportation methods, especially when compared to manual handling.

 

 

How is such high safety achieved by AGVs? Below, we will explain that AGVs are equipped with many safety devices to prevent accidents, such as flashing lights, audio devices, physical emergency bumpers, infrared sensors, and ultrasonic devices.

 

How to avoid collisions between AGVs running on the same path? This involves traffic control. For example, a flexible manufacturing system with multiple AGVs requires traffic control to ensure that AGVs do not collide with each other. Traffic control can be executed locally on the AGVs or through software on a fixed computer elsewhere in the factory

 

 

1. Zone Control

 

Zone control is the most preferred method in most environments because it is simple to install and easy to expand. Zone control uses wireless transmitters to send signals within a fixed area. Each AGV contains a sensor to receive the signal and respond to the transmitter. If a zone is empty, the signal is set to "clear," allowing any AGV to enter and pass through the zone. If an AGV is in the zone, a "stop" signal is sent, and all AGVs attempting to enter the zone will stop and wait for their turn.

 

Once the AGV in the zone has moved out, a "clear" signal is immediately sent to one of the waiting AGVs. Another way to establish zone control traffic management is to equip each robot with its own small transmitter/receiver. Each AGV sends its own "do not enter" message to all AGVs approaching its spatial area. A problem with this method is that if a zone fails, all AGVs are at risk of colliding with each other. Zone control is a low-cost and effective method for managing AGVs in specific areas.

 

 

2. Sensor Control

 

Sensor control uses obstacle avoidance sensors to prevent collisions with other AGVs in the area. Sensors include ultrasonic sensors, which work similarly to radar; optical sensors, which use infrared sensors; and bumpers, which are physical contact sensors. Most AGVs are equipped with some form of bumper sensor as a fail-safe. Ultrasonic sensors emit chirps or high-frequency signals and then wait for a response. The AGV determines whether there is an object ahead by analyzing the response signal and takes necessary actions to avoid collisions. Optical sensors use infrared transmitters/receivers to emit an infrared signal, which is then reflected back, operating on a similar concept to ultrasonic sensors. The issue with these methods is that they can only protect the AGV within a limited angle.

 

 

3. Integrated Control

 

Integrated control combines collision avoidance sensors and zone control sensors. The combination of the two helps prevent collisions in any situation. Under normal operating conditions, zone control is used, while obstacle avoidance serves as a fail-safe. For example, if the zone control system fails, the obstacle avoidance system will protect the AGV from collisions.

 

Integrated control combines sensor control and zone control to manage traffic between AGVs. Each AGV in the system is equipped with two infrared obstacle avoidance sensors: one at the front to detect obstacles ahead and another at the front-right to detect oncoming vehicles from the side. For added safety, the system also uses zone control. The dispatch center sets a mutual exclusion signal in areas where collisions are likely to occur. When an AGV enters the area, it occupies the mutual exclusion signal, and the dispatch center sends a stop signal to other AGVs attempting to enter the area. Once the first AGV leaves the area, the mutual exclusion signal is released, allowing the next AGV to enter.

 

 

AGVs are not only a key technology in modern logistics and manufacturing but also a symbol of technological advancement for enterprises. They enhance production efficiency, reduce labor costs, enable refined management, and increase logistics flexibility. With continuous technological development and innovation, AGVs are expected to play a broader role in more fields, bringing greater value to enterprises and industries. Let us look forward to the surprises and transformations that AGVs will bring in the future!

 

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