AGV/AMR mobile robots are modern solutions that have revolutionized internal logistics in many industries. Automation of material handling, using transport robots, has become an important part of modern manufacturing and warehouse processes. In this article you will read:
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Mobile robots are devices that can move autonomously or with minimal supervision around a designated area, performing transportation tasks. Through the use of advanced technologies such as artificial intelligence, sensors, cameras and navigation systems, they are able to precisely traverse production and warehouse halls transporting goods from point A to point B.
Automated or traditional warehouse – which to choose?
They operate based on pre-programmed routes. AGVs move by using magnetic strips or sensors to guide their movement. AMR robots, on the other hand, are more advanced in terms of navigation. They don’t need pre-set routes – they can analyze their surroundings on their own, avoid obstacles and adapt their route to the current situation in the environment.
Autonomous carts can be divided according to the functions they perform and how they are used:
Transport trucks, which carry materials and goods between specific points. They can carry loads on top of each other as a “turtle,” tow wagons or hook up to storage garbage cans with wheels.
pallet trucks, which replace typical “pallet trucks,” are designed to lift and carry loads on pallets.
autonomous lift trucks, a version of forklifts equipped with lifting mechanisms that allows not only horizontal but also vertical transport (e.g., transporting pallets to racks)
specialized robots dedicated to more complex tasks, retrieving and depositing loads onto racks or conveyors.
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The main difference between AGVs and AMR carts comes from the way they navigate and their flexibility in operation.
AGVs move along pre-programmed routes. They are precise, but require fixed infrastructure such as magnetic lines, sensors or guides to show them the way. They are ideal for environments where movement must be tightly controlled and repeatable.
AMR robots are more technologically advanced. They don’t need fixed routes because they can analyze the environment in real time. For example, they use LIDAR (Light Detection and Ranging) technology and a camera to map the space. This allows them to avoid obstacles and adapt their routes to the dynamically changing environment.
AMR robots are more flexible and versatile in operation, making them ideal for changing work environments where there may be human and other machine movement. AGVs, on the other hand, are better suited to fixed, repetitive transportation tasks.
AGV/AMR systems are widely used in many industries, mainly where internal transportation of materials is necessary. They are most often used in:
AGV/AMRs reduce the need for forklift operators, which in turn reduces labor costs. In addition, they work without breaks, vacations or sick leave which increases the efficiency of warehouse processes and company productivity. The fleet of robots heterogeneously works 3 shifts, 24 hours a day, 7 days a week with the same efficiency.
The cost of purchasing an AGV/AMR robot and management system may seem high, but such an investment pays off in the long run. This is mainly due to labor savings, fewer accidents and damage to goods, and increased process efficiency. Moreover, AGV/AMR robots are more precise than traditional forklifts, which minimizes the risk of errors and accidents.
Buying robots together with a management system requires a cost-effectiveness analysis of the implementation beforehand. That’s why it’s worth working with reputable suppliers and manufacturers that offer not only the mobile devices themselves, but also consulting services and comprehensive technical support. Etisoft offers professional intralogistics systems, designed and manufactured by the Polish company Etisoft Smart Solutions. The company also conducts pre-implementation analyses to help decide on implementation, presents the level of investment required, as well as the benefits to the customer after the introduction of a robotic intralogistics system.
Autonomous mobile robots. Use pre-implementation analysis!
ESS also offers long-term rental of AGV/AMR trucks, which can be an attractive alternative for companies that are not ready to make large one-time investments.
Automated guided vehicles travel along a pre-determined route or path. This path can be physical (e.g. marked on the floor with magnetic tape or tags) or virtual (programmed through the AGV's navigation software).
An AGV’s position and its movement are calculated and controlled using a combination of software (such as ANT lab) and sensors (such as LiDAR-based laser scanners). Together these technologies are what guides an AGV. They help the vehicle understand: where it is currently, where it needs to go (and what to do when it gets there), and how to get there.
Advanced AGVs can work alone or as part of a larger connected fleet. AGV fleet management software (such as ANT server) is used to schedule tasks, distribute these between vehicles, and control traffic.
Although early generation AGVs often used diesel power, these days automated vehicles are almost always battery powered. Many use automatic charging stations, meaning they do not need to be plugged in manually.
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An AGV’s speed is a fine balance between achieving optimal efficiency (maximizing the number of missions per shift) and making sure the vehicle is safe (ensuring optimum stopping distances). Most AGVs on the market today reach speeds of up to 1.5 m/s (3.3 mph). Vehicles that are driven by ANT navigation can drive up to 3.5 m/s (7.8 mph). With some vehicles and applications even faster speeds are possible, but safety must always remain the priority.
There are many different types of AGV steering. The most common are shown below.
Automated guided vehicles typically move around by following pre-defined paths or routes. Different AGV navigation methods accomplish this in different ways, but generally speaking two main methods exist:
Automated vehicles that follow physical lines of some sort have been in use for several decades.
With line following types of AGV navigation, vehicles are literally guided through the facility by a physical line, such as:
In the case of a tape-following AGV for instance, this features a downward-facing sensor that ‘looks’ at a line on the floor. It then measures the left and right error, and corrects the vehicle’s trajectory as needed. Tag following works in a similar way.
Automated vehicles that follow virtual paths are newer. There are several types of virtual path following technology, the key difference between them being how they calculate the position of the vehicle (localization).
These technologies include:
Laser triangulation uses references in the form of permanently-installed reflective targets to triangulate the position of the vehicle. It does this by firing beams around the space from a laser scanner installed on the vehicle. As its name implies, at least three targets must be recognized at any one time.
Vision guidance uses cameras to recognize features in the environment. These features are then compared to a 3D map in order for the vehicle to calculate its position and navigate effectively.
Natural navigation uses data from a vehicle’s laser scanners (often the AGV’s safety scanners) to calculate the vehicle’s position. It does this by comparing or ‘matching’ the laser scanner data to either: the cells of a grid-based 2D reference map of the environment (scan matching), or permanent map references like walls (natural feature navigation).
You may have explored a vehicle’s functionality, but have you considered how it is installed? Will it take a matter of hours, just a few days, or weeks of integration with third-party personnel on-site disrupting your normal operations?
The main factor determining commissioning times is the type of navigation technology used to run the vehicle. AGVs based on natural navigation, such as ANT navigation, are typically quick to install since they do not require permanent changes to a site’s infrastructure.
Read -> AGV integration explained
Businesses change and sites evolve. At some point you are likely to want to change the routes that your AGVs travel. Will this be as simple as reprogramming digital (virtual) paths, or will updates require more substantial and time-consuming physical changes? Make sure your AGV investment is not going to create a large new expense every time your needs change.
You may not require multiple automated vehicles today, but if your AGV installation is a success then you might in future. Adding a new vehicle to your operation should not mean a whole new installation project, so look closely at what fleet management options are offered with the AGV you are considering. Make sure you understand how easy it is, and how long it takes, to add new vehicles to your project.
Also, will a supplier’s fleet management software tie you to one type or brand of vehicle? Or can it accommodate other brands of AGV (as ANT navigation can), so that you are not locked into one vehicle vendor and have the widest possible choice of vehicles?
Automated guided vehicles are only useful when they are doing what they are programmed to do, so be sure you plan how to keep them working.
Ensure you have access to an AGV maintenance plan that suits your business’ needs and budget. You should typically budget around 10% of an AGV’s sticker price for maintenance per year.
You need to understand the risks associated with your choice. So, be sure to understand whether you are an AGV startup’s first customer, or whether the company has thousands of vehicles installed and proven in global applications. Ideally, try to speak to several other users of your preferred AGV system before you sign that purchase order.
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