Automated Guided Vehicle Systems: Automate Your Material Flow with AGV Systems

Automated guided vehicle systems (AGV systems) have been one of the core components of the Industry 4.0 strategy of large companies for some years now. Floor-mounted conveyor systems facilitate the internal transport of materials and thus ensure that the right material is in the right place at the right time. Due to continuous technological development and the wide range of applications, AGV systems increasingly represent an effective solution for automating internal material flow even for small and medium-sized enterprises.

Advantages of automated guided vehicle systems

Scalable, reliable, and secure: Good reasons for the implementation of an automated guided vehicle system

Companies that are considering implementing an automated guided vehicle system are primarily asking themselves what added value the automated transport systems will provide. How does intralogistics benefit? What is the cost-benefit ratio and what monetary added value can be achieved? Scalability, reliability, and security are other aspects that are used as decision criteria for choosing a system for automation. The good news is that an automated guided vehicle system is perfectly capable of meeting all these requirements and standards:

Flexibility and scalability

Among automated transport systems, AGV systems are considered the solution which enables the greatest possible flexibility, including: straightforward integration into the existing warehouse organization (with or without an existing warehouse management system), the possibility of transporting different loads, and simple implementation of layout changes. The particular advantage of automated guided vehicle systems is their easy scalability. Once the basic framework is in place in the company, it can be expanded or reduced at will. In this way, the system grows with the processes and can always be adapted to the planned workload. This allows you to remain responsive and flexible even in the event of seasonal or cyclical fluctuations in orders, due to vacations or inventory.

Reliability

Significant productivity increases can be achieved through automated processes at the warehouse and in production. Automated guided vehicles (AGVs) are always ready for action to transport the right goods to the right place at the right time. AGVs ensure precise and smooth goods movement around the clock. Processes become more efficient and planning calculations more precise thanks to continuous availability and the uniform material flow. Based on the recorded data, you also create the basis for optimum coordination of all upstream and downstream processes in intralogistics. In this way, the use of an automated guided vehicle system helps to optimize the entire supply chain.

Safety

In 2020, an average of 126 work accidents per day occurred in Germany in connection with forklifts and floor conveyors (source: DGUV, Statistics: Work Accident Incidents 2020). Unsurprisingly, safety of employees is a top priority in warehouse and production environments. Automated guided vehicle systems offer two advantages when it comes to safety. On the one hand, AGV systems avoid accidents caused by people. On the other hand, the risk of costly transport damage to the cargo or the transport environment is reduced. The safety requirements for manufacturers and operators of AGV systems also provide for various protective measures. Automated guided vehicle systems are therefore equipped with safety components such as person detection systems, autonomous braking systems, warning devices, or emergency stop devices.

Further advantages of integrating an automated guided vehicle system into your internal goods transport

Optimized production and logistics processes

Industry-independent use cases

Low investment and operating costs

A high degree of transparency

Reduction of search times and downtimes

Reduction of transport damage and potential hazards

Relieving the workload of personnel

Extensive and easy scalability

Maximum flexibility

Simple integration

Space-saving installation

Technological progress and competitive advantage

Automated guided vehicle systems at the warehouse and in production

L-mobile whitepaper for direct download

Recognize and master challenges in material flow
The challenges companies face in intralogistics.
What is an automated guided vehicle system?
The components of an automated guided vehicle system and how they interact to achieve an efficient material flow.
5 tips for the successful implementation of an automated guided vehicle system
We will show you what you should consider when planning and integrating your automated guided vehicle system.

L-mobile digital warehouse management – AGV system whitepaper: How to successfully introduce automated guided vehicle systems

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Flexible to use and individual: Types and areas of application for automated guided vehicle systems

The types of automated guided vehicle systems are as diverse as their applications: AGV systems are used in the production and manufacturing industry, in logistics centers of mail order companies, as well as in the healthcare sector to carry out simple material transports. Depending on the application, you can now utilize a suitable automated guided vehicle (AGV). This can include mobile robots, AGV systems for small load carriers, AGV systems for pallets, driverless forklifts, or specific automated guided vehicles for special transports. More recent generations of AGV systems are also capable of performing picking and sorting tasks. Essentially, automated guided vehicle systems can be used wherever a reliable, safe, and efficient transport solution is required.

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AGV system for small load carrier: Constant material flow even with high cycle times

Small load carriers are ideally aligned with the requirements of intralogistics. They are stable, functional, easy to stack, and it is hard to imagine intralogistics without them. This is the ideal use case for a driverless transport system. AGV systems for small load carriers can transport small load carriers weighing over 100 kg safely and efficiently. In addition, AGV systems for small load carriers are used in the automation of order picking. They handle the storage and retrieval of small load carriers as well as empty runs during the picking process.

AGV systems for small load carriers can be seamlessly integrated into your internal goods movements. Even high transport volumes or changes of premises due to people or parked material do not pose any obstacles. While AGV systems wait until the route is clear, autonomous mobile robots (AMR) are even capable of avoiding obstacles or calculating a completely new route.

L-mobile digital warehouse management – AGV for pallets ek

AGV systems for pallet transport: Smooth movement of goods even in freezing temperatures

Automated guided vehicles for pallets control the transport of goods in ordinary warehouse and production environments, but are also used in areas with extreme temperatures, such as those found in refrigerated warehouses.

These maneuverable AGVs are equipped with robust pick-up devices on which load carriers such as wire mesh boxes or pallets are transported quickly, reliably, and safely. AGV systems for pallets are also increasingly used by companies with less extensive internal goods movements. Through its use in shift operation, the AGV system is fully amortized after just a few years. Fleets of up to 100 vehicles are feasible. AGV system forklifts can be converted according to your specific requirements.

L-mobile digital warehouse management – AGV Driverless narrow aisle forklifts

Driverless narrow aisle forklift: Easy to use at heights of up to 10 meters

Narrow aisles or little space due to structural conditions? No problem for driverless narrow-aisle forklifts. Automated forklifts are heavy-duty, maneuverable, versatile and, due to their overall height, particularly suitable for use in racking applications of heights exceeding 10 meters.

Driverless narrow aisle forklifts are suitable for the safe transport of goods in wire mesh boxes, large plastic containers, roll containers, or on Euro pallets. Driverless forklifts even manage to switch between rack aisles in a warehouse effortlessly and reliably. Depending on your individual requirements, narrow aisle forklifts are available both as AGV equipment or can be converted according to your specific needs.

L-mobile digital warehouse management – AGV system for special transports ek

AGV system for special transports: The right solution for your specific use case

Are you the exception to the rule? Suitable driverless transport vehicles are even available for special transports. In the case of special custom designs, the transport systems are designed for your specific use case (custom move). Automated guided vehicle systems for special transports will transport even heavy or hazardous goods accurately to their destination. Outdoor transports between different warehouse buildings can also be achieved with AGV systems.

General conditions for the use of automated guided vehicle systems in your company

Infrastructure AGV system navigation Paths and halls Outdoor
AGVs Communication Transfer stations

Infrastructure

Automated guided vehicle systems consist of several components that interact differently depending on the use case. The basis is the control system, which sends the orders to the AGV system via WLAN. Continuous communication between these components enables the control system to coordinate the transport orders and transmit them to the automated guided vehicles. The individual FTFs are each equipped with propulsion, sensors, navigation, safety technology, and a battery. It is crucial for the functionality of an AGV system that the interfaces are very well worked out. Successful and scalable systems can only be implemented through the perfect interaction of all components. The required infrastructure for automated guided vehicle systems consists of:

Travel routes

The travel routes should have a certain quality.

Transfer stations and parking spaces

Stationary transfer stations and parking spaces for the AGVs must be provided.

Energy supply

If the battery charge level of an automated guided vehicle is too low, the fleet manager coordinates a trip to the charging station to ensure that the vehicle is powered.

Interfaces

Interfaces to peripheral equipment ensure integration of the communication systems of fire protection systems, elevators, doors, or gates.

Navigation

How do automated guided vehicles now make their way through warehouses and production halls? The methods for spatial orientation and navigation are as diverse as the types and areas of application for AGV systems.

Optical or inductive track guidance

Track-based systems are known as fixed navigation systems, which are circuit-based. The AGVs follow an optical track via a sensor system, for example, with the aid of colored adhesive tape. Inductive track guidance is also possible, where navigation is performed by measuring a magnetic field.

Grid navigation

In contrast, there are freely navigating systems that follow grid navigation. In this process, the AGV scans QR codes attached to the ground and recalculates the route over the grid each time.

Laser navigation with rotating laser

The AGV moves freely in the space. The environment in which the automated guided vehicle will operate is charted and digitally mapped in advance.

SLAM navigation

A laser scanner is used to record and measure the contours of the surroundings. Therefore, the AGV system always triangulates between the different points and then navigates to the sources and destinations accordingly.

Path and hall condition

Clean, flat, dry, and non-slip path surfaces are essential for the safe use of an AGV system in indoor areas.

Extreme environmental conditions such as humidity, cold or heat must be discussed in advance with the manufacturer and the project team and checked for compatibility.

L-mobile FTS, Wege und Hallenbeschaffenheit

Outdoor AGVs

Are you looking for an outdoor solution to ensure an uninterrupted flow of goods? This use case can also be realized using automated transport vehicles. There are now various outdoor applications that can cover transport distances of up to 500 meters between two factory buildings. However, various factors have to be taken into account:

Safety
Requirement for personal safety lasers to be approved for outdoor use and for the specific application.
Weather conditions
Sensors for vehicle navigation can be soiled by snow or dirt and their functionality can be restricted. Newer navigation methods, such as using RFID, can remedy this situation.
Flooring
AGV systems are not designed for asphalt. Flat surfaces, such as concrete slabs, are more suitable.

Communication

Communication between the master controller or fleet manager, the charging infrastructure, and the AGV system should generally be possible with all WLAN standards. The communication line is used both to address other systems, such as transfer stations, and to retrieve status notifications from the individual AGVs, such as the battery charge status.

If necessary, the AGVs are re-coordinated accordingly, for example by instructing them to charge their battery at the charging station. The goal is to achieve optimum order coordination of all AGV systems in use to ensure uninterrupted material flow.

L-mobile AGV system, L-mobile digital warehouse management, automated guided vehicle system, AGV system fleet manager

Transfer stations

Defined transfer stations are used for loading and unloading the automated guided vehicle systems. In order to ensure the safety of personnel, spatially separated or at least specifically marked areas need to be provided for this purpose. A distinction can be made between active and passive transfer stations.

Passive transfer stations

Active stations are equipped with a conveyor system, such as chain, roller, or belt conveyors, telescopic systems, or lifting devices that place the material on the automated guided vehicle system.

Passive transfer stations

Passive stations are platforms, floor block storage or storage areas with sensors to detect whether the space is empty or occupied, which are used for interim storage areas until further transport.

Automated guided vehicle systems with L-mobile AGV system

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Functionality of automated guided vehicle systems
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Live demo of the commissioning of an automated guided vehicle system
We will give you a detailed insight into the commissioning of an automated guided vehicle system.
Added value of automated guided vehicle systems
You will learn about the advantages of AGV systems and how to successfully implement an AGV system project in your company.

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Our events on the topic of digital warehouse management

Find out what the first three steps in an AGV system project might look like in episode 30 of our Industry 4.0 podcast by Christian Siegle.

Events

What role do automated guided vehicle systems now play on the path to Industry 4.0? For which companies and applications are AGV systems the best choice? When are other solutions the better alternative? And how much do automated guided vehicle systems actually cost? We ask our experts these and other interesting questions in our AGV system online events.

L-mobile AGV system: Software and integration options for optimized material flow

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Prior to the implementation of an AGV system solution, our experts develop a custom concept based on a comprehensive analysis of your current situation. In this context, the existing framework conditions are decisive criteria for design and feasibility.

What kind of goods are to be transported?

In which areas will the AGV system be used?

What special environmental impacts need to be considered?

Will there also be foot traffic in the area?

What is the condition of the path surface?

How much staff capacity is provided for project management and implementation?

These and other questions on our AGV system checklist form the basis for further consultation and joint cooperation.

Fleet management: The central control unit of your AGV fleet

An automated guided vehicle system is rarely used on its own. As a rule, a fleet of vehicles of varying sizes is used to ensure a continuous material flow. Central configuration, management, and communication with the automated guided vehicles is the task of fleet management. Thanks to the interface to your ERP or warehouse management system, transport orders are transmitted directly and paperlessly to the fleet manager.

The fleet manager knows exactly which AGV can be scheduled for which transport order on which route. In addition, the current availability of the automated guided vehicles is queried and organized by the fleet manager using status notifications. If, for example, the battery charge level of an AGV falls below a defined threshold, no transport order will be issued, instead a journey to the charging station will be arranged.

The prioritization and distribution of orders as well as the coordination of routes are therefore carried out digitally and fully automatically. The fleet manager always gives you a complete overview of the location of your vehicle fleet as well as of the status of your transport orders.

And best of all: You can remain responsive and flexible. You can manage short-term adjustments quickly and conveniently on your mobile devices.

Further interfaces and integration options

First steps towards digital warehouse management

You will take the first step towards digital warehouse management with L-mobile WMS and L-mobile warehouse. The digital warehouse management solution is used for efficient planning, provisioning, controlling, and testing of all processes that take place at the warehouse on a daily basis. It enables you to design lean warehouse processes, obtain transparency about goods and material inventories, and reduce search and travel times. The combination of our warehouse management solution with an automated guided vehicle system provides an excellent opportunity to optimize and automate your entire intralogistics.

More information

Launch of paperless production

We will also accompany you on your path to paperless production. You can experience first-hand the ideal combination of software and hardware solutions for warehousing and production at our award-winning Digital Factory. Learn about our digital solutions without media discontinuities during your tour through the digital factory—from order receipt and assembly at the lot size 1 work station to RFID-supported shipping and reporting. And best of all: You can experience our Digital Factory live on site or learn about it from the comfort of your own home by watching our video series.

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Forklift localization made easy: With the L-mobile forklift guidance system

Automated guided vehicle systems are not always the ideal solution, especially for companies with large outdoor storage areas. Fortunately, the L-mobile forklift guidance system (FGS) is an excellent alternative for mapping the internal material flow. The mobile transport management system manages forklifts and industrial trucks and, with a precise forklift location system, ensures efficient routes, automatic, and paperless use in the warehouse or in production. The goal is to make your logistics processes transparent and efficient and to raise them to a new level.

More information

You will take a big step towards Industry 4.0 with automated guided vehicle systems

L-mobile will support you as a strong partner and Industry 4.0 expert on the path to digitalization

Perfectly integrated: The L-mobile AGV system solution fits perfectly into your ERP system

With more than 20 years of experience in the design, development, and implementation of software solutions, we offer our medium-sized customers a wide range of mobile solutions and modern technologies. We are pleased to offer you everything from a single source. This also includes monitoring the project progress through professional project management to ensure successful project completion. When developing products, we attach great importance to connectivity regardless of the ERP system. Our solutions therefore have standard interfaces for all common ERP systems.

Our technology partners

Through close cooperation with our partners ek robotics and OMRON, we can offer a custom AGV system solution concept from a single source. This includes the initial discussion with our AGV system experts, the joint conceptual design, and the development and integration of the software solution and hardware in your company.

ek robotics is the world’s leading manufacturer and system integrator of innovative high-tech transport robotics for production and warehouse management. The transport robotics specialist creates intelligent, networked and flexible transport solutions for the fully automated, internal material flow of its global customers at five locations in Europe (Rosengarten, Germany, headquarters), Reutlingen (Germany), Milan (Italy), Prague (Czech Republic) and Buckingham (UK), with over 250 employees. With more than 50 years of experience in design, development, manufacturing, integration, turnkey delivery, and support throughout the entire life cycle of automated guided vehicle systems (AGV systems), ek robotics is among the technical elite in this fast-growing industry of the future.

OMRON Industrial Automation is a global leader in the field of sensor technology and automation. With more than 80 years of experience, OMRON offers technologically advanced solutions for a wide range of applications including industrial automation, electronic component manufacturing, and healthcare. OMRON has over 25 years of experience in mobile robotics. In addition to hardware with different payloads from 60 to 1500 kg, the Autonomous Mobile Robots (AMR) also offer a fleet management system that can be used to manage and continuously optimize the entire fleet. A wide range of accessories is available for optimized scalability and the portfolio is also rounded off by a fleet simulation tool that provides planning security in the early stages of projects.

Automated Guided Vehicle Systems: Automate Your Material Flow with AGV Systems

Advantages of automated guided vehicle systems

Further advantages of integrating an automated guided vehicle system into your internal goods transport

Optimized production and logistics processes

Industry-independent use cases

Low investment and operating costs

A high degree of transparency

Reduction of search times and downtimes

Reduction of transport damage and potential hazards

Relieving the workload of personnel

Extensive and easy scalability

Maximum flexibility

Simple integration

Space-saving installation

Technological progress and competitive advantage

Automated guided vehicle systems at the warehouse and in production

Flexible to use and individual: Types and areas of application for automated guided vehicle systems

AGV system for small load carrier: Constant material flow even with high cycle times

AGV systems for pallet transport: Smooth movement of goods even in freezing temperatures

Driverless narrow aisle forklift: Easy to use at heights of up to 10 meters

AGV system for special transports: The right solution for your specific use case

General conditions for the use of automated guided vehicle systems in your company

Infrastructure

Navigation

Path and hall condition

Outdoor AGVs

Communication

Transfer stations

Automated guided vehicle systems with L-mobile AGV system

Our events on the topic of digital warehouse management

L-mobile AGV system: Software and integration options for optimized material flow

Checklist L-mobile AGV system

Fleet management: The central control unit of your AGV fleet

Further interfaces and integration options

First steps towards digital warehouse management

Launch of paperless production

Forklift localization made easy: With the L-mobile forklift guidance system

You will take a big step towards Industry 4.0 with automated guided vehicle systems

Advanced planning and scheduling

Production data collection

Machine data collection

Electronic labels (E-Label)

Digital assembly instruction system

Reporting

Electronic Kanban (E-Kanban)

Tracking technologies (RFID, UWB, GPS)

Automated guided vehicle system (AGV system)

Forklift guidance system (FGS)

Digital warehouse management

Perfectly integrated: The L-mobile AGV system solution fits perfectly into your ERP system

Our technology partners