Automated Guided Vehicles (AGVs) are an important part of the smart factory and Industry 4.0/smart factory paradigm. AGVs are self-propelled, computer-controlled wheeled vehicles that autonomously transport materials to designated locations within a facility. They are used in many indoor environments, such as manufacturing warehouses, where only instructed personnel are allowed. AGVs have become increasingly popular due to their performance, reliability and increased digitalization of factories even in challenging environments. This has enabled them to be used more effectively in industrial factory logistics than ever before.
Types of operations carried out by AGVs
Automated Guided Vehicles (AGVs) are an essential component of industrial robot automation, particularly in the automotive, electrical/electronics, metal, chemical, rubber and plastics, and food and beverage industries. AGVs are versatile and can be equipped with various tools and devices, such as containers for storing goods (“carrier types”), transferring devices like forklifts (“fork types”), article transfer belts, slides or arms for loading and unloading (“mobile manipulation types”), and towing carts (“tow type”).
Initially, AGVs relied on prepared floors, such as embedded wires or magnets, for motion guidance but have now evolved to adopt various cheap measures to prepare the proper environment, such as magnetic beacons, tapes on the floor, or other means to facilitate navigation. AGVs also operate autonomously in large-scale manufacturing and logistics, and to distinguish them from those operating in controlled areas, the term AMR (Autonomous Mobile Robot) was coined.
These mobile robots operate using laser scanners, which provide an accurate two-dimensional map of the environment for self-localization and obstacle avoidance. Early navigation solutions relied on fixed reference points like reflector markers; recent developments in LiDAR and other optical sensors now make it possible for AGVs to navigate without fixed reference points, making them more robust for dynamic environments. AGVs are versatile and have been combined with robotic arms to load and unload machine tools.
Typical tasks for AGVs include assembly, kitting, transportation, staging, warehousing, order picking, parts/just-in-time (JIT) delivery, and transfer/shuttle of goods. The automotive industry has been leading in the installation of AGVs as part of their lean and agile manufacturing concepts, replacing conveyor belts and facilitating just-in-time, just-in-sequence (JIT/JIS) deliveries. AGVs have immense future potential, and companies are constantly exploring new ways to leverage this technology.
In addition to their use in traditional manufacturing and logistics industries, AGVs also operate in quite a new and prospering field of transporting chassis in automotive production to enable a more flexible and agile production as it is realizable with a conveyor belt. Fraunhofer IPA developed such a solution together with Bär Automation GmbH already in 2014, and other companies are following suit with similar advancements.
Level of distribution of AGVs for indoor environment
Autonomous Guided Vehicles (AGVs) are quickly becoming a staple in the manufacturing industry. With advancements in automation and the introduction of Industry 4.0, AGVs will become even more commonplace as they can play an integral role in achieving production goals while providing a safe workplace for employees.
At present, there are several types of AGV systems available on the market — including stationary AGVs (which use wires or magnets embedded into the floor to guide them), teleoperated AGVs (which require human control), and freely navigating AGVs (which operate autonomously without fixed wires).
Freely navigating AGV technology is becoming increasingly popular due to its ability to be used across any type of production line without needing external guidance. As a result, businesses are able to achieve greater efficiency and reduce labor costs associated with manual operations. This technology is also preferred in workplaces that require precise navigation due to its ability to quickly react to changes without the need for operator intervention.
Furthermore, AGVs can play an important role in future Industry 4.0 or IoT scenarios as they can facilitate communication and data collection across various components of the production line. For example, they can be used to monitor and collect information on various elements such as temperature, humidity and other environmental factors; this data can then be utilized by operators or manufacturers to adjust their processes accordingly and increase efficiency even further.
The level of distribution of AGV technology will continue to grow over time as more companies recognize the potential benefits they can offer to their businesses. By utilizing AGVs, businesses will be able to reduce labor costs and increase efficiency on their production lines while providing a safe working environment for employees. The incorporation of AGV technology into Industry 4.0 or IoT scenarios will also enable manufacturers to collect data from various components of the production line, which can then be used to make informed decisions about processes and improve overall output.
It is evident that the level of distribution of AGV technology is steadily increasing as more businesses realize its potential benefits in terms of improved efficiency, cost savings and safety. With advancements in automation and the introduction of Industry 4.0, it is expected that this trend will continue as more organizations begin to incorporate AGVs into their production lines. Consequently, the level of distribution of AGV technology is likely to increase in the near future as its advantages become more widely recognized and adopted.
Despite the existence of many suppliers, only recently freely navigating AGVs (without fixed wires or other methods of the prepared floor) have become industrial practice. Furthermore, Industry 4.0 or IoT scenarios favor the diffusion of AGV technology in manufacturing practice. It is expected that forklifts - a standard resource in logistics, will be increasingly operated autonomously by autonomous forklifts. All major forklift manufacturers are currently experimenting with autonomous navigation, environmental and pallet recognition, or have already launched amusing products. Kuka offers quite a few mobile manipulator platforms equipped with different robotic arms depending on the task at hand. Examples are the omniMove and the KMR iiwa unit, a mobile platform with mecanum wheels for omnidirectional maneuvers. The former can be equipped with a KR Quantec arm for heavy-duty tasks, whereas the KMR iiwa uses a lightweight LBR iiwa arm for delicate assembly work.
Further developments are the MiR family of multi-purpose mobile platforms by Mobile Industrial Robots and the Otto by Clearpath Robotics which are freely configurable, modular platforms, preferably for general indoor logistics. Both systems rely heavily on ROS and are easy to configure and integrate into different environments.
Mobile Platforms developed by Kuka 195, such as KMR- KR Quantec and flexFellow, navigate autonomously, act in swarms, and offer total flexibility for industrial manufacturing. It is especially significant for internal logistics. Kuka offers a vast mobility portfolio, from manually movable to autonomously navigating solutions. In addition, the fully autonomous variants work without any induction loops, floor markings, or magnets.
Omron offers the LD-60/90 and the LD-250 with a maximum payload of 90kg and 250kg respectively. About the company’s website, - they are designed to dramatically increase productivity in manufacturing and logistics operations. New features of Omron platforms are self-mapping with onboard PC, rapid installation, easy interaction on tablet by using the updated “Mobile Planner” software, and improved safety features.
Bluebotics 196 is another mobile platform producer that provides both the hardware and the necessary software to use it. The software ANT uses natural structures in the environment as its reference for localization. Therefore, no infrastructure like inductive wires, magnets, or reflectors for triangulation is required. ANT can also use simple deflectors either: in combination with natural structures or alone to provide navigation solutions.
Cost-benefit considerations and marketing challenges
AGV systems offer improved flexibility and efficiency in manufacturing. They reduce the need for manual labor, allowing companies to streamline production operations and save costs. Additionally, as AGVs rely on digital data for task management and environmental planning, they are less prone to human errors that can occur when manually operated machines are used in production processes.
When planning an AGV system for profitability and benefit, it is important to consider several factors such as the intended purpose of the system, its features, compatibility with existing systems, applicable regulations and safety requirements. Companies should also anticipate potential risks associated with their use of AGVs, such as faulty programming or equipment failure that could potentially lead to loss of material or injury.
In addition to the potential cost savings and increased safety, AGVs offer numerous other benefits. For example, they can reduce production time as tasks are performed faster and more accurately. These systems also allow for remote monitoring of operations so companies have increased visibility into their production processes. They also provide greater flexibility in terms of customization and scalability as they can be easily adapted to suit a variety of needs.
Overall, AGV systems can bring many advantages to factory logistics, such as cost savings, improved safety and efficiency, enhanced flexibility, and increased visibility into production processes. By carefully considering their purpose and features when planning an AGV system for profitability and benefit companies can reap the full value of this technology.
Given the wide-ranging advantages of these systems, AGVs look set to gain further traction in factory logistics in the coming years as companies increasingly recognize their potential.
In conclusion, AGV systems offer a number of benefits when it comes to factory logistics such as cost savings, improved safety and efficiency, enhanced flexibility, and increased visibility into production processes. Companies should take care to consider their purpose and features when planning an AGV system for profitability and benefit in order to reap the full value of this technology. With increasing recognition of its potential, AGVs look set to be utilized more widely by factories across the world.