Fully Automated Driverless Transport Vehicles
Time pressures, efficiency requirements, and the demand for top performance define your industry. Staff shortages, rising costs, and a lack of automation expertise make it difficult to succeed. This is where automated guided vehicles (AGVs) offer a solution for process optimization.
FTF Driverless Transport Vehicles
An automated guided vehicle (AGV) is an automated material-handling system whose primary function is to transport materials for production and logistics processes. Autonomous guided vehicles move goods of various sizes, weights, and shapes along a network of paths, ranging from simple, standardized transport crates and pallets to complex components and entire workstations.
Autonomous guided vehicles are often deployed as a coordinated network, forming an automated guided vehicle system (AGV system). In an AGV system, multiple AGVs are networked and work together to efficiently organize and control material movements within a specific area, such as a factory or warehouse. Sensors and navigation systems enable the AGVs to avoid obstacles and move smoothly within the shared traffic area. This allows them to continuously transport materials, optimize workflows, and automate the overall flow in logistics or production.
Roadmap for the Successful Implementation of an FTF Project
Advantages of Autonomous Guided Vehicles (AGVs)
Costs of FTF
Operating costs can be reduced by eliminating the need for drivers and minimizing errors and accidents. With conventional logistics vehicles, personnel costs alone account for 80% of total costs.
FTF Reliability
Self-driving vehicles enable round-the-clock operation. Automation optimizes material flows, which significantly increases handling capacity.
FTF Safety
FTFs reduce the risk of accidents and injuries by using automated safety protocols. This helps minimize costs associated with damage. The FTS assessment report provides information on a system’s safety.
FAQ - Frequently Asked Questions About Autonomous Guided Vehicles (AGVs)
What is an automated guided vehicle (AGV)?
An automated guided vehicle (AGV) is an automated transport system used primarily for material handling in production and logistics processes. Autonomous guided vehicles transport goods of various sizes, weights, and shapes along a predetermined route network, ranging from standardized transport crates and pallets to complex components and complete workstations.
What is the difference between Autonomous Mobile Robots (AMR), Driverless Transport Systems (FTS), and Driverless Transport Vehicles (FTF)?
Automated Guided Vehicle (AGV) systems consist of one or more automated guided vehicles (AGVs) and operate on predetermined routes under central control; they are suitable for predefined tasks in stable environments, whereas Autonomous Mobile Robots (AMR) navigate dynamically and intelligently in dynamic environments using sensors and artificial intelligence. AGVs offer less flexibility, while AMRs can automatically adapt to changes and operate efficiently in real time.
What are the different types of automated guided vehicles?
Various concepts for automated guided vehicles (AGVs) have been developed to meet the diverse transportation needs in logistics and production. The following types of transport vehicles are most commonly used: forklift AGVs, piggyback AGVs, tow AGVs, underride AGVs, assembly AGVs, heavy-duty AGVs, mini AGVs, outdoor AGVs, and special-purpose AGVs.
What are the advantages of autonomous guided vehicles?
The systems offer high scalability through the expansion of the number of automated guided vehicles (AGVs) and transfer stations, as well as the ability to implement layout changes. They adapt well to fluctuations in dynamic material flows and, by adjusting the load-handling device, enable the safe and reliable transport of virtually any type of cargo.
Are autonomous guided vehicles safe?
Autonomous guided vehicles (AGVs) are safe because they are equipped with advanced sensors, real-time monitoring, emergency shutdowns, and intelligent route planning to prevent collisions and ensure consistent performance.
For what applications are automated guided vehicles suitable?
Automated guided vehicles (AGVs) are ideal for use in warehousing, logistics, manufacturing, hospitals, airports, retail, and various industries. They can essentially be used anywhere where goods need to be transported on a regular basis.
Which automated guided vehicle system is best suited for my application?
During a one-on-one consultation, we can discuss your requirements, and through our AGV feasibility study, we’ll show you whether the system is technically feasible and economically viable. You can also review our white papers, which provide valuable insights into AGV projects.
Components of Autonomous Transport Systems
Automated guided vehicle systems consist of one or more automated guided vehicles (AGVs), a control system, a positioning system, a data transmission system, and the infrastructure, including peripheral equipment.
An automated guided vehicle (AGV) essentially consists of a chassis, a computer, one or more drive units, a power supply, a load-carrying module, a communication module, a safety component, and a user interface.
If you’d like to learn more about automated guided vehicles, we recommend our AGV introductory training course or our free white papers.
Navigation Concepts for Autonomous Guided Vehicles (AGVs)
Choosing the right navigation method is a critical factor in the success of your automated guided vehicle system. ProLog Automation has the necessary expertise to ensure that the navigation is perfectly tailored to your requirements. Below is an overview of the most common types of navigation:
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Physical Lane-Guided Navigation
These cost-effective solutions use guide wires, magnetic strips, or colored lines that vehicles follow along a predetermined lane. The disadvantages of this system are its limited flexibility and susceptibility to damage. -
Virtual lane-bound navigation
Technologies such as magnetic dot/grid navigation or laser triangulation combine high precision with flexibility. Instead of physical tracks, these systems use digital maps or magnetic grids, making them more versatile. -
Free (autonomous) navigation
With contour navigation (SLAM), vehicles adapt to their surroundings on their own. This method does not require any additional infrastructure, but is more sensitive to changes in the environment.
With ProLog Automation, you’ll find the ideal navigation solution for your specific needs.
Safety Concepts for Autonomous Guided Vehicles (AGVs)
Safety is our top priority! Autonomous guided vehicles are equipped with state-of-the-art safety solutions to ensure safe operation and protect both people and equipment.
- Person detection scanner: Dynamic adjustment of the safety fields to the speed of the AGV. People in the warning zone automatically trigger a speed reduction or a stop.
- Ultrasonic sensors: Reliable obstacle detection; resistant to dust, moisture, and ambient light.
- 3D Cameras: Precise detection of obstacles such as overhanging loads or the forks of other vehicles.
- Visual and audible warning signals: Directional lights, turn signals, and audible warning signals ensure maximum visibility and safety, especially in areas with heavy traffic.
- Bumpers: Mechanical bumpers that immediately stop the AGV upon contact.
- Emergency Stop Buttons: Manual emergency stop functions that enable a quick response in hazardous situations.
Our expertise enables us to provide you with comprehensive advice on safety for automated guided vehicles—ensuring that your facility is optimally protected.
Difference Between Towing and Load-Carrying Autonomous Guided Vehicles (AGVs)
Autonomous guided vehicles (AGVs) are a key component of modern intralogistics systems. Depending on their intended use, AGVs are generally classified as either load-carrying or load-pulling AGVs.
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Towing AGVs are designed to pull trailers or tugger trains carrying goods. They function as towing vehicles and are frequently used in lean or just-in-time logistics processes.
Typical configurations include:
- Long-haul tractor-trailers with multiple trailers
- Electric Tractor with a Coupling System
Applications:
Particularly suitable for sequenced delivery in assembly operations, such as in the automotive industry.
Advantages:
- High transport capacity
- Consolidation of Multiple Shipments
- Ideal for cycle and line power supply
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Load-carrying AGVs transport their cargo directly on the vehicle. The load is carried on an integrated loading platform, a lift table, or via special attachments such as conveyor belts, rollers, or forks.
Typical examples include:
- Platform Vehicles
- Forklift FTF (e.g., driverless forklifts)
- Material Handling – FTF with Roller Conveyor or Belt
Applications:
Ideal for the in-plant transport of KLTs, pallets, or workpiece carriers over short to medium distances.
Advantages:
- Precise Transport of Individual Goods
- Integration of conveyor systems is possible
- Flexible for various loading aids
DRIVERLESS TRANSPORT VEHICLES
The Benefits of Autonomous Transport Vehicles at a Glance:
Flexible
Tailored to individual needs: Autonomous guided vehicles are versatile and can be adapted to changes.
Reduction in Load
Because automated guided vehicles perform heavy and repetitive tasks, they reduce the physical strain and the risk of injury for human workers.
Improving Efficiency in Material Flow
An automated vehicle operates reliably 24/7—without any breaks. This optimizes throughput times, minimizes downtime, and significantly increases productivity.
Autonomous Transport System in a High-Bay Warehouse
In high-rack warehouses, automated guided vehicles function as an intelligent automated transport system that automatically and precisely stores and retrieves goods.
Long-Term Cost Reduction
Long-term reductions in operating costs, personnel costs, and error rates ensure a quick return on investment (ROI) on the initial purchase costs.
Safety
Autonomous guided vehicles are equipped with sensors and advanced safety systems that prevent accidents and collisions.
Traceability and Transparency
Autonomous guided vehicles are often integrated into digital systems that enable real-time monitoring and tracking of materials and products.
Scalability
An autonomous transport vehicle can be expanded using a modular design. New vehicles can be easily integrated into existing systems to flexibly meet growing demands.
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Our AGV and AMR expert Felix Imhof is available to answer any questions you may have about your AGV project.