AGV Fleet Synchronization for Takt Time Control

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Solution Overview

Problem

Current automatic guided vehicles (AGVs) lack the capability to coordinate movement in a cost-effective and reliable manner to match a desired takt time, which is essential for synchronized travel in manufacturing operations, due to issues with timing and spacing, particularly in environments with permanent conveyor systems.

Innovation Solution

A system of AGVs equipped with controllers and guidance systems that determine travel paths, assign unique IDs, and automatically adjust spacing and lead positions to maintain a designated minimum spacing and desired takt time, allowing for synchronized travel along a path without the need for traditional conveyor systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional conveyor systems are used to provide consistent workflow, then manufacturing precision and reliability are improved, but device complexity and installation cost increase

Engineering Contradiction:

Improveworkflow consistencyVSAvoidconveyor system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical conveyor systems with automatic guided vehicles that use guidance systems (optical, magnetic, or laser-based) and automated control to transport workpieces. This substitution eliminates the need for permanent mechanical infrastructure while maintaining reliable workflow through electronic guidance and control mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The AGV system introduces dynamic adaptability by allowing vehicles to adjust their speed, position, and routing in real-time based on system conditions and workpiece requirements. This dynamic control replaces the static, fixed-path nature of traditional conveyors while maintaining workflow consistency through automated coordination.

Inventive Principle:

Principle #15Dynamics

2Reliability

If traditional conveyor systems are installed permanently into the facility, then consistent work flow is achieved, but adaptability and reconfiguration ease deteriorate

Engineering Contradiction:

Improveworkflow consistencyVSAvoidreconfiguration flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The AGV system enables dynamic reconfiguration by allowing changes to travel paths, routing, and operational parameters through software updates rather than physical reinstallation. The vehicles can adapt to different workpiece types, destinations, and workflow requirements while maintaining consistent delivery performance.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The AGV platform serves multiple functions including transporting different types of workpieces, navigating various paths, and interfacing with different manufacturing equipment. This universal design replaces the specialized, single-purpose nature of traditional conveyor systems while maintaining reliable workflow for diverse applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If AGVs are used for material handling, then adaptability and cost-effectiveness are improved, but coordination capability and timing precision worsen

Engineering Contradiction:

Improvesystem flexibilityVSAvoidcoordination accuracy

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The AGV system incorporates continuous feedback mechanisms where vehicles report their position, speed, and status to a central controller, which adjusts routing and timing in real-time. This feedback loop ensures precise coordination and timing accuracy while maintaining the adaptability of individual vehicle operations.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent merges multiple AGVs into a coordinated fleet that operates as an integrated system. By combining individual vehicle capabilities with centralized coordination, the system achieves both the adaptability of independent vehicles and the timing precision of a unified conveyor-like operation.

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If conveyor systems are used to maintain uniform spacing, then manufacturing precision is improved, but ease of operation and access deteriorate

Engineering Contradiction:

Improveworkpiece spacing consistencyVSAvoidworker access to parts

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent replaces the physical mechanical coupling of conveyors with electronic coordination between AGVs. Each vehicle independently maintains its spacing from others through automated control and communication, eliminating the need for physical connections while preserving spacing consistency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9014902B1Method of material handling with automatic guided vehicles

Publication Date: 2015.04.21 WEBB JERVIS B CO

AI summary

A system and method of automatic guided vehicles (AGVs) that is capable of providing synchronized travel along a line or path while maintaining a desired takt time such that regular manufacturing operations may be performed to material or workpieces on the vehicle without the need for a traditional conveyor systems.