Energy and Route Optimization of Moving Devices

This thesis highlights our efforts in energy and route optimization of moving devices. We have focused on three categories of such devices; industrial robots in a multi-robot environment, generic vehicles in a vehicle routing problem (VRP) context, automatedguided vehicles (AGVs) in a large-scale flexible manufacturing system (FMS). In the first category, the aim is to develop a non-intrusive energy optimization technique, based on a given set of paths and sequences of operations, such that the original cycle time is not exceeded. We develop an optimization procedure based on a mathematical programming model that aims to minimize the energy consumption and peak power. Our technique has several advantages. It is non-intrusive, i.e. it requires limited changes in the robot program and can be implemented easily. Moreover,it is model-free, in the sense that no particular, and perhaps secret, parameter or dynamic model is required. Furthermore, the optimization can be done offline, within seconds using a generic solver. Through careful experiments, we have shown that it is possible to reduce energy and peak-power up to about 30% and 50% respectively. The second category of moving devices comprises of generic vehicles in a VRP context. We have developed a hybrid optimization approach that integrates a distributed algorithm based on a gossip protocol with a column generation (CG) algorithm, which manages to solve the tested problems faster than the CG algorithm alone. The algorithm is developed for a VRP variation including time windows (VRPTW), which is meant to model the task of scheduling and routing of caregivers in the context of home healthcare routing and scheduling problems (HHRSPs). Moreover,the developed algorithm can easily be parallelized to further increase its efficiency. The last category deals with AGVs. The choice of AGVs was not arbitrary; by design, we decided to transfer our knowledge of energy optimization and routing algorithms to a class of moving devices in which both techniques are of interest. Initially, we improve an existing method of conflict-free AGV scheduling and routing, such that the new algorithm can manage larger problems. A heuristic version of the algorithm manages to solve the problem instances in a reasonable amount of time. Later, we develop strategies to reduce the energy consumption. The study is carried out using an AGV system installed at Volvo Cars. The results are promising; (1)the algorithm reduces performance measures such as makespan up to 50%, while reducing the total travelled distance of the vehicles about 14%, leading to an energy saving of roughly 14%, compared to the results obtained from the original traffic controller. (2) It is possible to reduce the cruise velocities such that more energy is saved, up to 20%, while the new makespan remains better than the original one

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Improving just-in-time delivery performance of IoT-enabled flexible manufacturing systems with AGV based material transportation

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. Autonomous guided vehicles (AGVs) are driverless material handling systems used for transportation of pallets and line side supply of materials to provide flexibility and agility in shop-floor logistics. Scheduling of shop-floor logistics in such systems is a challenging task due to their complex nature associated with the multiple part types and alternate material transfer routings. This paper presents a decision support system capable of supporting shop-floor decision-making activities during the event of manufacturing disruptions by automatically adjusting both AGV and machine schedules in Flexible Manufacturing Systems (FMSs). The proposed system uses discrete event simulation (DES) models enhanced by the Internet-of-Things (IoT) enabled digital integration and employs a nonlinear mixed integer programming Genetic Algorithm (GA) to find near-optimal production schedules prioritising the just-in-time (JIT) material delivery performance and energy efficiency of the material transportation. The performance of the proposed system is tested on the Integrated Manufacturing and Logistics (IML) demonstrator at WMG, University of Warwick. The results showed that the developed system can find the near-optimal solutions for production schedules subjected to production anomalies in a negligible time, thereby supporting shop-floor decision-making activities effectively and rapidly

Platooning-based control techniques in transportation and logistic

This thesis explores the integration of autonomous vehicle technology with smart manufacturing systems. At first, essential control methods for autonomous vehicles, including Linear Matrix Inequalities (LMIs), Linear Quadratic Regulation (LQR)/Linear Quadratic Tracking (LQT), PID controllers, and dynamic control logic via flowcharts, are examined. These techniques are adapted for platooning to enhance coordination, safety, and efficiency within vehicle fleets, and various scenarios are analyzed to confirm their effectiveness in achieving predetermined performance goals such as inter-vehicle distance and fuel consumption. A first approach on simplified hardware, yet realistic to model the vehicle's behavior, is treated to further prove the theoretical results. Subsequently, performance improvement in smart manufacturing systems (SMS) is treated. The focus is placed on offline and online scheduling techniques exploiting Mixed Integer Linear Programming (MILP) to model the shop floor and Model Predictive Control (MPC) to adapt scheduling to unforeseen events, in order to understand how optimization algorithms and decision-making frameworks can transform resource allocation and production processes, ultimately improving manufacturing efficiency. In the final part of the work, platooning techniques are employed within SMS. Autonomous Guided Vehicles (AGVs) are reimagined as autonomous vehicles, grouping them within platoon formations according to different criteria, and controlled to avoid collisions while carrying out production orders. This strategic integration applies platooning principles to transform AGV logistics within the SMS. The impact of AGV platooning on key performance metrics, such as makespan, is devised, providing insights into optimizing manufacturing processes. Throughout this work, various research fields are examined, with intersecting future technologies from precise control in autonomous vehicles to the coordination of manufacturing resources. This thesis provides a comprehensive view of how optimization and automation can reshape efficiency and productivity not only in the domain of autonomous vehicles but also in manufacturing

Agent Based Routing Control for Multi Mobile Robots in Transportation

Auto Guided Vehicles (AGVs) are widely used in a semi-conductor fabricating factory and contribute to the stable production of a high quality semi-conductor products. In the near future, further expansion of the transportation system is expected accompanied with the rapid growth of semi-conductor industries. In such situation, the necessity of performing quick planning of transportation route and transportation control will be elevated. In this paper, practicable planning of the transportation route and transportation control are studied based on the decentralized agent method. Especially, the geometrical sizes of AGVs are considered in the determination of transportation routes and control strategy avoiding the occurrence of mutual collisions or deadlock of AGVs

Agent-based material transportation scheduling of AGV systems and its manufacturing applications

制度:新 ; 報告番号:甲3743号 ; 学位の種類:博士(工学) ; 授与年月日:2012/9/10 ; 早大学位記番号:新6114Waseda Universit

Optimization of Automated Guided Vehicles (AGV) Fleet Size With Incorporation of Battery Management

An important aspect in manufacturing automation is material handling. To facilitate material handling, automated transport systems are implemented and employed. The AGV (automated guided vehicle) has become widely used for internal and external transport of materials. A critical aspect in the use of AGVs is determining the number of vehicles required for the system to meet the material handling requirements. Several models and simulations have been applied to determine the fleet size. Most of these models and simulations do not incorporate the battery usage of the vehicles and the effect it can have on the throughput and the number of AGVs required for the system. The goal of this research is to develop a simulation model to determine the optimized number of AGVs that is capable of increasing throughput while meeting the material handling requirements of the system. This model incorporates the battery management aspect and issues, which are usually omitted in AGV research. This includes the charging options and strategies, the number and location of charging stations, maintenance, and extended charging. The analysis entails studying various scenarios by applying different charging options and strategies and changing different parameters to achieve improved throughput and an optimized AGV fleet size. The results clearly show that battery management can have a significant effect on the average throughput and the AGV usage. It is important that the battery management of the AGVs is addressed adequately to run an AGV system efficiently

Development of an Industrial Internet of Things (IIoT) based Smart Robotic Warehouse Management System

According to data of Census and Statistics Department, freight transport and storage services contributed to 90% of the employment of logistics sector in the period from 2010 to 2014. Traditional warehouse operations in Hong Kong are labor-intensive without much automation. With the rapid increasing transaction volume through multi-channel, the preference for next-day delivery service has been increasing. As a result, 3rd party logistics providers have realized the importance of operational efficiency. With the advent of Industry 4.0 emerging technologies including Autonomous Robots, Industrial Internet of Things (IIoT), Cloud Computing, etc., a smart robotic warehouse management system is proposed as it redefines the warehouse put-away and picking operations from man-to-goods to goods-to-man using autonomous mobile robots. This paper aims to develop and implement an IIoT-based smart robotic warehouse system for managing goods and autonomous robots, as well as to make use of the autonomous mobile robots to deliver the goods automatically for put-away and picking operations. The significance of the paper is to leverage the Industry 4.0 emerging technologies to implement the concept of smart warehousing for better utilization of floor space and labor force so as to improve logistics operational efficiency

Planning and control of autonomous mobile robots for intralogistics: Literature review and research agenda

Autonomous mobile robots (AMR) are currently being introduced in many intralogistics operations, like manufacturing, warehousing, cross-docks, terminals, and hospitals. Their advanced hardware and control software allow autonomous operations in dynamic environments. Compared to an automated guided vehicle (AGV) system in which a central unit takes control of scheduling, routing, and dispatching decisions for all AGVs, AMRs can communicate and negotiate independently with other resources like machines and systems and thus decentralize the decision-making process. Decentralized decision-making allows the system to react dynamically to changes in the system state and environment. These developments have influenced the traditional methods and decision-making processes for planning and control. This study identifies and classifies research related to the planning and control of AMRs in intralogistics. We provide an extended literature review that highlights how AMR technological advances affect planning and control decisions. We contribute to the literature by introducing an AMR planning and control framework t