［ Transportation ］

AGV System for Paper Rolls

Keywords

AGV, Paper rolls, Side fork, Laser-guided system, Replace

Abstract

The Automatic Guided Vehicle (AGV) is used as part of a production system
in many industrial ﬁelds. Depending on the operational conditions of a facility
and the use environment, customers tend to review overall production of theirfacility or consider replacement after the ten (10) to twenty (20) years. Comparedwith new construction, construction period for facility replacement takes about
one extra week. Since a production line has to be stopped during a construction
period, the customers always demand a minimized time of shutdown. We recently
delivered a hybrid system which combines laser-guided AGVs to replace existingones and a more automated transportation of products. The laser-guided system does not require an installation of guide paths. In addition, when this system
is adopted, it becomes unnecessary to remove existing guide cables and install
new guide paths. This means a substantial reduction of construction time. In thenew system, AGVs in three different shapes travel in the factory area by using
wireless LAN, whereby also giving standby control and destination instructions.
This system is controlled centrally by the ground control panel and manage thesystem effectively.

1 Preface
In replacing an old type Automatic Guided
Vehicle (AGV) system, it is necessary to remove theexisting guiding facility and guide path wires.
Compared with an introduction of a new AGV system, construction period for system replacement worktakes about an extra week. For production lines running around-the-clock, the customers call for anintroduction of a system requiring the shortest construction period because the system shutdown timemust be minimized. To respond to such a demand,
we have adopted a laser-guided system. When thissystem is used, it becomes unnecessary to consume time to remove electromagnetic guidepath
wires buried in an existing facility. This paper introduces a new AGV system that has been introduced
for a shorter installation period.

2 System Overview
We delivered two type AGVs: an AGV that can
carry heavy articles of paper rolls and the other aside-fork type AGV for pallet and container trans-06

Kazuyoshi Itabashi

MEIDEN REVIEW Series No.172 2018 No.1portation. As a guide system, the laser-guided system is adopted. Each AGV is guided by a measuring
distance to the reﬂector plate and by checking themap information. With this system, a paper rollweighing 3200kg (heavy article transport) or anotherpaper roll weighing 2300kg (light article transport)
can be carried. Each paper roll comes in a cylindrical shape. Since a paper roll is rolled from groundequipment when it is transferred to the AGV, themechanical shock to the AGV is very strong andsuch an impact can lead to system malfunction. TheAGV delivered for this time is equipped with outriggers that can absorb impact. This reduces failure
risk after the introduction of the system.

3 Features of the System( 1) Adoption of common base vehicles against thereplaced vehicles
The base vehicles come in two sizes; a large
and a small AGV. Since the same type of AGVs isadopted, maintenance parts can be used. Since
each the AGV is capable of omnidirectional traveling, it can run in a minimal space path. As a result,

AGV control panel

Fire shuttercontrol panel

Automatic batterycharger (HB2-M)

All 3 rooms
control panel

All 3 rooms
control panel

Product stocker
control panel

Access point
AP1

Automatic battery
charge (HB2-S)

Automatic battery
charger (HB3-M)

SW-BOXSB301

AGV CB2

Access point
AP2

Packing machine
control panel

Automatic battery
charger (HB3-S)

Original fabriccontrol panel

SW-BOX
SB112

Access point
AP3

C6 controlpanel

Inclined CV
control panel

Automatic battery
charger (HB4)

SW-BOX
SB111

Access point
AP4

SW-BOX
SB201

SW-BOX
SB203

Conveyercontrol panel

Junction box
JB3

Automatic battery
charger (HB1-M)

Access point
AP5SW-BOX
SB202

SW-BOX
SB204

Junction box
JB1-1

Junction box
JB2-5

Automatic battery
charger (HB1-S)

Access point
AP6

Hoist controlpanel

SLL control
panel

Junction box
JB1-2

Junction box
JB2-4

CB6SW-BOX
SB406

Junction box
JB1-3

Junction box
JB2-3

SW-BOX
SB205

SW-BOX
SB405

Junction box
JB1-4

Junction box
JB2-2

SW-BOX
SB302

SW-BOX
SB407

Junction box
JB1-5

Junction box
JB2-1

C7 control
panel

Small AGV

×1

Fixed rack: 1 set

Original fabric conveyer: 1 set

Side-fork
type AGV
×1

Large AGV×2Inside dimension
1400mm

1300mm
2500mmFig. 1

System Configuration

The AGV system is composed of two AGVs for carrying large-sized paper rolls, one AGV for carrying small-sized paper rolls, and one
side-fork type AGV.

the new type of AGV can travel to the areas where
replaced AGVs cannot reach.
( 2 ) Adoption of a side-fork AGV for new production
facilities
A side-fork AGV has been adopted for carrying
pallets and containers. In regard to the load transfer
level, an article can be lifted to a maximum lift of1600mm above the ﬂoor. It is, therefore, possible tolift a cargo to the upper stage of the two-stage rack.
This AGV can run through a narrow path (width ofpath: 2400mm) and transfer the load there. Using
this system, work with a manned forklift can beautomated.
( 3 ) Reducing construction period by adopting alaser-guided system
To reduce the construction period, a laser-guided
system has been adopted throughout the guidepath.
Work time for removal of existing guidepath wires bychipping is 3 days and installation of new guidepath
wires takes 3 days. Such a timeline could be reducedby this new system. Modiﬁcation of layout and ﬁneadjustments were carried out by using the CAD
date. Since modiﬁcation data can be downloaded tothe AGV in this fashion, delicate route change canbe instantly handled.

4 System Conﬁguration
The supplied AGV system is composed ofthree ( 3 ) AGVs for paper roll transportation and one( 1) side-fork type AGV for carrying a container on
the exclusive rack. As an ancillary facility, a roller
conveyer system is attached. This is for cargo
reception and shipping. Fig. 1 shows a system conﬁguration and Table 1 shows a list of speciﬁcations
for the delivered AGVs and transporting articles.

4.1 AGV for Transporting Large-Sized PaperRolls
Fig. 2 shows an external appearance of theMEIDEN REVIEW Series No.172 2018 No.107

Table 1 List of Specifications
The list below shows three types of AGV speciﬁcations applied
to this system.

Item

AGV forAGV forfortransporting transporting AGV
transporting
large-sized small-sized container
paper rolls paper rolls

Type description

3MC-M30

3MC-M30

3ML-M11

Type

Truck type
AGV

Truck type
AGV

Side-fork type
AGV211Quantity (units)
Performance

Guidance Laser-guided systemsystemDrivingsystem

Front/rear wheel driving, steering system

Traveling
direction

Forward, reverse, traverse, spin turn

Traveling
speed(m/min)

10〜40

10〜60Fig. 2

AGV for Transporting Large-Sized Paper Rolls

An external appearance of an AGV for transporting large-sized
paper rolls is shown. It is equipped with a V-bucket load transfer
machine.

10〜60

Gradabili- 2% (within 5m continuously)ty
Stopping ±10
accuracy(mm)
Major
dimensions

Vehiclewidth(mm)

1522

1522

2278

Vehiclelength(mm)3265

3800

1748

Vehicleheight(mm)

2525

2525

1738

Minimum 1200
turningradius(mm)

1200

1500

Oil-hydraulic Oil-hydraulic Reach fork
V-bucket
V-bucketsystemsystemsystemRight/lefttransfer

Right/lefttransferOne-sidedtransfer

FL ＋ 840

FL ＋ 640

FL〜1600

Transfer Name
Paper rollarticleSize (mm) L2250 ×
φ1500

Paper rollContainer

L2250 ×
φ1400

W1500 ×
L1150

Mass (kg) Max. 3200

Max. 2300

Max. 1230

Transferheight(mm)Safety device

Non-contact type of obstacle sensor, allaround tape switch, bumper, emergency stopswitch, warning sound alarm, warning lampAGV for transporting large-sized paper rolls. ThisAGV has been modiﬁed to assure a weight capacityof 3200kg and be available as omnidirectional transportation. The drive unit is composed of two-wheel
differential driving mechanisms. In order to suppress the vehicle height, the steering motor has
been eliminated. The V-bucket for loading a paper

08

MEIDEN REVIEW Series No.172 2018 No.1

AGV for Transporting Small-Sized Paper Rolls

An external appearance of an AGV for transporting small-sizedpaper rolls is shown. It is equipped with a V-bucket load transfermachine.

Storage Voltage/ DC48V・100Ah
batter- capacity
iesCharging Automatic charging systemsystemLoadSystemtransfermachineTransferdirection

Fig. 3roll is controlled oil-hydraulically and mechanicalimpact to be generated at the time of paper roll loading is absorbed by using outriggers.

4.2 AGV for Transporting Small-Sized PaperRolls
Fig. 3 shows an external appearance of theAGV for transporting small-sized paper rolls. The
basic structure of this AGV is the same as that of theAGV for large paper roll transportation. Comparedwith the large paper roll type, the paper roll transfer
height is lowered by 200mm. The component allocation layout inside the AGV was reviewed and by
patting the shaft section of the V-bucket component
inside the AGV it realized a reduction of transfer
height.

4.3 AGV with Side Fork
Fig. 4 shows an external appearance of theAGV for a transporting container. This model wasmade by modifying the AGV introduced on order
page (see p.14) in this paper under the title of“Development of Side-Fork Type AGV.” The transfer
mass is 1230kg (rated transfer mass: 1100kg) andthis value exceeds the rated level. As such, theFig. 4

structures of the traveling and lifter sections werereviewed and the speed reducer of the lifter wasmodiﬁed.

5 System Operation
Fig. 5 shows the system layout.
( 1) Each AGV is called up from the operator box
located in each process. The system control panel
grasps the call-up situation in order to dispatch aright ﬁt.
( 2 ) There are three operation modes available as
described below.
( a ) Mode in which a dedicated AGV is operatedin the transport area.
( b ) Mode in which multiple AGVs are used fortransportation in a speciﬁc process.
( c ) Mode in which transportation is carried out
considering the order priority.
The user can manage the system by making aswitchover to an adequate mode by conﬁrming themanufacturing status. By the modal charge capability, the production yield can be increased by 20%

AGV for Transporting Container

An external appearance of a side-fork type AGV for transportinga small-sized container is shown.

Inclined conveyer control panel

Packing machine control panel

SB204

S203

S204

Automatic battery charger unit 3 (M, S)
Charger actuator 3Discharge plate
HB3

HB2

S409S408
S407

S405

S406

Automatic battery charger unit 2 (M, S)
Charger actuator 2
Discharge plate

S205

S114
S502

S302
AP2

AP1
S112

S113

AGV control panel

HB1

S202

Product stocker
control panel
S201

S111

AP4

AP5

S213
S212
S211

Automatic battery charger unit 1 (M, S)
Charger actuator 1
Discharge plate

S216
S215
S214

AP3

Hoist controlpanel (2F)

CB6 (2F)

AP6

Wireless LAN access point

S301

SB301

Paper roll stocker
control panel

S110
S404
S403

Guidepath
Mark plate

S402
S401 (HB4)

Conveyer control panel

Fig. 5

System Layout

The layout of the AGV system (4 AGV units in all) is shown. Since the AGV routes cross each other, crossing point control and standby
control are carried out by using wireless LAN.

MEIDEN REVIEW Series No.172 2018 No.109

compared with conventional volumes because it
can ﬂexibly handle the production peak time.
( 3 ) All AGVs are centrally controlled by using wireless LAN. It is, therefore, possible to grasp the realtime AGV running conditions. Any error information
can be announced without delay. As an error reset
operation is shown in the screen of the system control panel, it can be done without referring to an
instruction manual.

6 Postscript
The AGV system introduced in this paper
adopted is intended as a laser-guided system toperform the replacement work of an existing facility.
This is because replacement work must be ﬁnished

10MEIDEN REVIEW Series No.172 2018 No.1

in the shortest possible time. Since the major components are the same ones used in the different
types of AGVs, it can contribute to maintenancecost reduction for the customer.
Meeting the requests of our customers: fromintroduction planning to maintenance, we customized the AGV system and the AGV itself. To be aleading supplier of transport systems, we would liketo provide system solutions that realize the added
values of low cost and high performance AGV system with added functions. In so doing, our work will
not be limited to the simple replacing work of theaged AGV facilities.
・All product and company names mentioned in this paper are
the trademarks and/or service marks of their respective owners.