What effects does the type of environment detection of the AGVs (line-guided, laser scanner, radar or vision systems) have on the integration or control of the transport systems?

Alexander Melkus: This has no influence whatsoever on the fleet management system TCS (Traffic Control System) from Sigmatek. Regardless of the type of environment detection, suitable alternative routes can be selected as required if routes are blocked.

In practice, our customers combine different types of environment detection on the same vehicle. Here is an example: although SLAM (Simultaneous Localization and Mapping) delivers very precise data in most applications, the technology reaches its limits when there are no clear distinguishing marks in the environment. This is the case in long tunnels with smooth walls, for example, where classic line guidance has a clear advantage.

Why should a company simulate the use of AGVs in advance?

Alexander Melkus: As AGVs are often integrated into plant and logistics areas that are already in operation, simulation is what makes time and cost-saving implementation possible in the first place. The simulation integrated in the TCS can process processes 720 times faster than in real time. This means that the vehicle movements and loading cycles of an entire day can be visualized and routes optimized in just a few minutes. The graphical heat maps stand out from the report functions, showing where problematic zones with high traffic volumes are located, which would affect the transport volume in real operation. On the other hand, simulation is used to put the information interface between the ERP system and TCS through its paces. In short, simulation makes it possible to optimize the system processes with the aim of achieving the best possible throughput even before commissioning and to keep the commissioning phase itself very short.

How can AGVs be integrated into production/intralogistics independently of the manufacturer?

Alexander Melkus: The TCS already supports the still very new VDA5050 standard, which was created to connect vehicles from different manufacturers. If the AGV does not yet support this standard, the TCP/IP and UDP data interface can also be used, which is tailored precisely to the requirements of the respective AGV in the TCS.

What are the three main points in which a fleet management system differs from control systems or classic plant control systems?

Alexander Melkus: Compared to classic SCADA solutions, fleet management actively controls vehicle traffic and selects suitable alternative routes as required. The TCS knows the current operating status of all vehicles in the fleet and takes this into account when planning and assigning driving orders and for active traffic control. It also takes care of the intelligent battery and charging management of the vehicles in the fleet. This also includes managing the SLAM cards and ensuring that they are kept consistent and up-to-date in all vehicles.

In addition, the TCS offers specific protocols for the ERP connection and provides ready-to-use AGV-specific reports and KPIs for capacity utilization, OEE and much more.

How is the safety aspect mapped?

Alexander Melkus: According to the current safety standards, every vehicle that is used in mixed operation with people must be safe in itself. This means that safety functions must be implemented in the vehicle and are therefore not part of the functional scope of the higher-level fleet manager.

The safety controller, which is on board every vehicle, evaluates the safe information from the safety scanner and other safe actuators and ensures that the AGV decelerates to a safe speed or comes to a safe standstill.

If a global emergency stop is required, Sigmatek 's safety controllers transmit safety-relevant information and commands wirelessly via WLAN using the black channel principle

But what should companies generally pay attention to if they want to use automated guided vehicles?

Alexander Melkus: Probably the most important prerequisite is that AGV-compatible processes are already in place in the company in terms of material flow. For a successful implementation, the existing infrastructure must also be checked, for example whether the existing load carriers are designed in such a way that they can be picked up, transported and set down by the AGV and whether suitable routes can be defined. This includes ensuring that any gates and barriers can be controlled so that the AGV can pass through them without interruption. The condition of the ground on which the vehicles are to travel is also essential for a smooth process. A WLAN infrastructure is required for wireless data communication, so it is necessary to check whether an existing system can be used or whether a separate WLAN should be set up.

The issue of fire protection also needs to be considered: it must be clarified how the AGV should behave in the event of a fire alarm. While in many cases it is sufficient if the AGV is brought to a standstill, there are also cases where travel routes overlap or cross escape routes for people and AGVs may only be brought to a standstill outside these crossing points.

Sigmatek at the SPS 2022: Hall 7, Stand 270