Mechanically Optimized Design and Validation of an Outdoor Automated Guided Vehicle

Abstract

Automated guided vehicles (AGVs) improve productivity by automating material transport; however, outdoor environments present challenges such as variable friction, uneven terrain, and dynamic loads. Traditional AGV designs lack robustness for outdoor use, requiring a mechanically optimized solution. This study presents the mechanical design and performance analysis of a dual-motor outdoor AGV, emphasizing compactness ≤70 kg, lightweight structure, and reliable operation across diverse surfaces. The design addresses frictional resistance, drivetrain selection, and structural integrity under dynamic loading. Using CAD tools, the AGV was modeled, and key components were validated through analytical calculations focusing on torque transmission, gear reduction, and synchronization. The total resistance of 1260.83 N was determined by summing the frictional resistance of 1200 N, the acceleration of 60 N, and negligible air resistance. Two D80-02430B5-E DC servo motors (0.75 kW, 2.39 Nm) were employed in a dual-drive configuration, each paired with a two-stage planetary gear reducer (PLE-080, 40:1) for torque amplification. An 8 M-type synchronous belt (40 mm width) with automatic tensioning ensured synchronized wheel motion. Shaft diameters 22-27 mm and A-type flat key connections were verified through stress analysis to meet 45-steel limits σ ≤ 60 MPa. The AGV achieved a total driving force of 1260 N with all stresses 20.5-81.8 MPa within allowable limits. The proposed design demonstrates suitability for outdoor logistics, flexible manufacturing, and warehouse automation, offering adaptability, compactness, and cost-effective operation. Future work may integrate advanced navigation and perception systems to enhance autonomous performance.