Simulation and Optimization of an Intelligent Transport System Based on Freely Moving Automated Guided Vehicles

AGV-based intra-company transport systems are indispensable in the manufacturing industry of Industry 4.0. Designing the systems involves determining AGV movement paths that are predefined dynamically or adjusted based on real-time events. This study focuses on the simulation and optimization of an intelligent transport system. The aim is to create a system model with freely moving AGVs controlled based on the requirements of production facilities. The simulation model was designed in the Tecnomatix Plant Simulation environment. A fictional case study with a flexible manufacturing system was used. Specific methods have been developed for AGV operation, control, and dynamic product handling. The initial simulation model served as the basis for optimization. Model optimization, performed using a genetic algorithm, aimed to maximize production volume while minimizing the number of AGVs. Simulation results showed that AGV movements were dynamically adjusted based on real-time machine requests, and the optimal configuration of AGVs achieved a production volume that was significantly higher than the initial setup. This study demonstrates a new approach to modeling AGV traffic systems emphasizing real-time dynamic adjustments of AGV paths. The findings contribute to integrating intelligent transport systems into production processes, and this study provides valuable insights for future investigation in this area.