A Comprehensive Guide to Automated Guided Vehicles (AGVs)
Automated guided vehicles (AGVs) are autonomous machines that efficiently transport goods across warehouses and factories.
For warehouse operations challenged by labor shortages or limited space, AGVs streamline workflows, reduce manual labor and enhance overall efficiency.
They seamlessly navigate tight aisles, operate continuously and handle repetitive tasks, freeing up your staff to focus on more complex responsibilities, such as quality assurance.
If you’re interested in AGVs, this guide explores their types, benefits, and how Modula’s Vertical Lift Modules (VLMs) seamlessly integrate with autonomous mobile robots to increase warehouse productivity.
What Are Automated Guided Vehicles (AGVs)?
Automated guided vehicles (AGVs) are battery-operated robots that transport goods in warehouses with minimal human intervention.
They rely on predefined paths, magnetic strips, lasers, cameras, radio waves or GPS for navigation.
Types of Automated Guided Vehicles (AGVs)
Automated guided vehicles come in various forms and equipment, each suited for specific industrial tasks:
- Automated guided carts (AGCs): AGCs are the most basic type of AGV. These AGV robots are primarily used in sorting, storage, and cross-docking operations. They can handle a diverse range of inventory, from small parts to entire pallets.
- Towing AGVs: Also known as tugger AGVs, these vehicles pull multiple cargo-bearing trailers in a train-like formation. Often referred to as driverless trains, they are ideal for transporting heavy loads across extensive distances.
- Forklift AGVs: Forklift AGVs perform the same duties as traditional forklifts, such as moving pallets around a facility. They operate autonomously, eliminating the need for a human driver.
- Unit load handlers: These vehicles specialize in transporting individual units like pallets or totes from one location to another, streamlining tasks such as receiving, storage and shipping.
- Heavy burden carriers: Designed for the heaviest loads, heavy burden carriers can transport items like castings, coils, or steel plates. These AGVs often feature self-loading capabilities and various steering options, including standard, pivot and omnidirectional steering, to accommodate different industrial environments.
AGVs vs. AMRs: Key Differences
Both automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) streamline material handling but differ in navigation, flexibility and intelligence.
| FEATURE | AUTOMATED GUIDED VEHICLE (AGV) | AUTONOMOUS MOBILE ROBOT (AMR) |
| Navigation | Follows fixed paths (magnetic tape, tracks, or sensors) | Uses AI, light detection and ranging (LiDAR) and real-time mapping to move dynamically |
| Flexibility | Limited flexibility and requires infrastructure changes for route updates | Highly flexible and adjusts routes in real time based on the situation |
| Flexibility | The robot stops when it encounters an obstacle and waits for operator instructions | Reroutes around obstacles without further assistance |
| Deployment | Requires predefined paths and infrastructure | Quick deployment with minimal setup |
| Use Case | Ideal for repetitive, structured tasks and routes in factories and warehouses | Suited for dynamic environments with frequent layout changes |
| Cost & Scalability | Lower initial cost but less adaptable | Higher upfront cost with a quick ROI |
How Do Automated Guided Vehicles (AGVs) Work?
Automated guided vehicles range from simple magnetic tapes to advanced laser-guided and camera-based technologies.
AGVs navigate through facilities using magnetic sensors that follow paths created by tapes or wires embedded in the floor. These wires emit signals that the AGVs detect via sensors or antennas, guiding their movement.
To move forward or backward, AGVs synchronize the speed of their wheels. They use sensors and cameras to detect obstacles, adjusting their paths to avoid collisions and maintain safe operations.
Wireless emitters in designated areas send signals that AGVs respond to, ensuring the path ahead is clear of clutter or collisions. Vehicles equipped with collision avoidance zone control emit a signal and wait for a response to ensure no objects are in their path.
AGV software coordinates vehicles by managing tasks and routes, integrating with the facility’s management systems to receive and update tasks.
Additionally, AGVs communicate with a central control system via Wi-Fi or other wireless networks, receiving instructions and providing updates to ensure seamless operations.
Key Benefits of Automated Guided Vehicles
AGVs provide significant advantages in warehousing and manufacturing, including:
Better Productivity
AGVs operate with minimal supervision. They deliver reliable performance for repetitive tasks, reducing manual labor, and maintaining a steady work pace.
Collaborative mobile robots, a specific type of AGV, guide workers through their tasks, reducing human error and enhancing accuracy in order picking.
Additionally, these robots employ artificial intelligence to optimize routes and prioritize tasks.
Steady Costs
AGVs typically offer predictable expenses. Whether purchased per unit or rented, using AGVs reinforce more stable costs compared to the human workforce, which can vary with market conditions and demand.
Flexibility
In terms of flexibility, certain AGVs can easily alter their routes without the need for extensive infrastructure changes.
All they need are software updates and minor modifications to their navigation markers or digital maps.
Space Efficiency
AGVs are more space-efficient than other automation solutions like conveyor systems.
Their compact size allows for narrower aisles. AGVs can also optimize the use of available space compared to traditional warehouse equipment such as forklifts.
Enhanced Safety
AGVs enhance safety in warehouses, distribution centers and manufacturing facilities with their equipped collision-prevention sensors.
They protect people and infrastructure by using safety sensors that prevent collisions with objects and individuals.
Modularity
Since AGVs cost less than AMRs, this modular approach lowers upfront expenses.
Businesses can start with one or two AGVs instead of purchasing a full fleet, then gradually expand to a fully or mostly automated operation.
Transform Your Workflow by Pairing AGVs or AMRs With Vertical Lift Modules
Incorporating AGVs with our automated systems greatly improves the order fulfillment process.
Regardless of your operation’s scale, our technologies improve picking accuracy and worker safety.
A standout offering at Modula is our VLMs. Our vertical lift modules are fully automated, vertical storage solutions that optimize space by stacking items vertically.
Experiencing a surge in orders? Our VLMs accommodate both batch and multi-order picking, increasing productivity without interrupting the order fulfillment sequence.
These vertical storage systems guarantee that a large inventory is easily accessible and securely stored, presenting items directly to operators through a simple barcode scan or a touch on the user-friendly Copilot controller.
Further reinforce precision and overall throughput by integrating your current warehouse setup with our picking and warehouse management system (WMS).
Our picking solutions are straightforward to implement and boost both accuracy and speed in handling orders.
A Quick Recap on Automated Guided Vehicles (AGVs)
- Automated guided vehicles are essential in smart warehouses, as they can effortlessly transport goods and materials autonomously.
- These robotic systems navigate facilities using technologies like lasers, cameras, or magnetic tape, following predetermined routes. By handling repetitive retrieval tasks, AGVs decrease manual labor, increase efficiency and prevent mispicks.
- AGVs boost productivity across different industries, from automotive assembly to distribution centers, making them indispensable robots in high-demand environments.
Contact our team to discover how our cutting-edge robots can optimize your warehouse operations.
