October 29, 2024 Are AGVs the Solution? A Guide to Mobile Automation

Discover what AGVs are, when to use them, and why to implement mobile robots to make informed decisions for your business.

By Tommy Hessler, CEO of America in Motion

Not knowing about a beneficial tool for your business is like having a powerful engine under the hood of your car but never learning how to drive. You might have the potential for speed and efficiency, but without understanding how to harness it, you’re stuck idling in the driveway.

As the world increasingly embraces automation, Automated Guided Vehicles (AGVs) remain relatively unknown to many. Learning more about AGV mobile robots is crucial for future growth in various industries, as these technologies play a vital role in enhancing operational efficiency and addressing contemporary challenges. With labor retention becoming increasingly important, AGVs can help alleviate the burden on human workers by taking over repetitive and physically demanding tasks, allowing employees to focus on higher-value activities. Additionally, by reducing labor costs and minimizing errors in material handling, AGVs can lead to significant savings for businesses. They also contribute to a safer work environment by minimizing the risk of workplace accidents associated with manual handling.

By understanding these three W’s—what AGVs are, when to use them, and why to implement them—organizations can make informed decisions about integrating automated solutions into their operations.

What are AGVs?

Automated Guided Vehicles (AGVs) are mobile robots used to transport materials within a facility. They navigate along predefined paths, often using magnetic strips, lasers, or cameras for guidance. AGVs can handle various tasks, such as moving goods between different areas, delivering products to assembly lines, or transporting items within warehouses. There are several AGV vehicle types, including pallet trucks, tow vehicles, and conveyor vehicles.

An AGV system consists of several components working together. We will discuss the three main components: the vehicle itself, the system/fleet manager, and the roadway network.

The Mobile Robot

The Vehicle: The mobile robot vehicle can be thought of as the arms and legs doing the actual work, lifting and moving product from point A to point B. There are multiple types of vehicles depending on the type of product that needs to be moved. The chart below explains each carrier type.

Power: While traditional manual forklifts are generally powered by gas or propane, mobile robots are powered by either lithium or Lead Acid AGM batteries. Click here if you’d like to learn more regarding the differences. Since AGVs are battery powered, this means they are more energy efficient, produce minimal noise pollution, and allow for extended operation periods.

Payload Capacity: Weight capacity varies widely depending on the specific model and design. Generally, AGVs can carry loads ranging from a few hundred pounds to several tons.

Safety System: Equipped with safety sensors and emergency stop functions, AGVs are designed to detect obstacles and prevent accidents, ensuring safe operation around human workers.

The System Manager

AGVs are becoming more commonplace but still not understood well. Most people understand the vehicle itself is a robot that moves products within a facility. The part that can get complicated is the System that runs the AGV.

The system manager of an AGV system is a central control unit that oversees and coordinates the operations of multiple AGVs within a facility, you can think of it as the brains of the operation. The system plays a crucial role in ensuring efficient workflow and integration with other systems.

An AGV system is similar to how Uber software works behind the scenes. When someone requests a ride, the system creates a mission. The system automatically determines the best driver to handle the requests then initiates the pickup process. The system is constantly optimizing in order to give the user the best solution. Rides can be rerouted or changed at any point within the trip and the system adapts. After the passenger is dropped off, the mission ends and the car is freed up to begin its next mission. This is similar to how a fleet manager system works for AGVs. The fleet manager software is running in the background telling the AGVs what to do, when to charge, and is constantly optimizing the process.

Roadway Network

The roadway network is a crucial aspect of an Automated Guided Vehicle (AGV) system, as it defines the paths or routes that AGVs can follow to navigate within a facility. Just like cars adhere to roadways for safe and efficient travel, AGVs rely on predetermined paths to transport products effectively. These roadways can be changed within the system manager at any point as an operation grows and changes.

When to Use Mobile Automation?

In certain applications, depending on throughput and distance, conveyors and manual forklifts won’t adequately get the job done. This is where AGVs excel. Below are some key scenarios when implementing AGVs is particularly beneficial:

High-Volume Material Handling: AGVs excel in environments where large quantities of goods need to be transported regularly, such as warehouses and distribution centers. Their ability to operate continuously can streamline the movement of products, reducing manual labor.

Repetitive Transport Tasks: In operations where the same tasks are performed repeatedly—such as moving items between specific locations—AGVs can automate these processes, freeing human workers for more complex or value-added activities.

Hazardous or High-Risk Environments: AGVs are ideal for environments where safety is a concern, such as chemical plants or areas with heavy machinery. By automating material handling, AGVs can minimize risks to human workers.

Limited Labor Availability: In regions facing labor shortages or challenges in retaining staff, AGVs can help maintain productivity levels. By reducing reliance on manual labor, businesses can continue operations smoothly. Learn more about how AGVs are revolutionizing industry amidst labor shortages here.

Need for Improved Safety Measures: If a facility has a history of accidents related to manual material handling or deals with large/unsafe products, implementing AGVs can help reduce the risk of injuries by automating these tasks.

Integration with Other Automated Systems: AGVs work well in facilities already utilizing automation, such as conveyor systems or robotic arms. Their ability to integrate with these systems enhances overall operational efficiency.

Why Implement AGVs?

Mobile robots offer numerous advantages that can significantly enhance operational efficiency and overall productivity. Here are some compelling reasons to consider their adoption:

Increased Efficiency: AGVs can operate continuously without breaks, leading to faster material handling and reduced transit times. This increased efficiency can help businesses meet higher demand and improve overall workflow.

Cost Savings: By automating material transport, AGVs reduce labor costs associated with manual handling. They also minimize errors and damage in product movement, leading to savings on rework and replacements.

Enhanced Safety: AGVs are designed with safety features, such as obstacle detection and emergency stop functions, which reduce the risk of accidents in the workplace. This can lead to a safer environment for both human workers and the vehicles themselves. They also have the ability to safely transport large capacity goods and potentially hazardous products keeping employees out of harm’s way.

Challenges with Finding and Retaining Workers: In today’s competitive labor market, organizations face significant challenges in finding and retaining skilled workers. Rising turnover rates, shifting employee expectations, and a limited talent pool create hurdles for businesses striving to maintain productivity and innovation. Borkar of Markets and Markets explains that labor shortages across the region are pushing companies to invest in automated solutions to maintain productivity without relying heavily on manual labor.

Scalability: AGV systems can easily be scaled up or down based on changing operational needs. This flexibility allows businesses to adapt to market fluctuations or shifts in production requirements without significant overhauls.

Reusability: Mobile robots offer significant reusability benefits, similar to cars or forklifts, which can be resold or repurposed rather than scrapped. Unlike traditional production equipment that often ends up as waste, AGVs can be retasked for different functions, extending their lifespan and value.

Data Collection and Analytics: Many AGVs come equipped with sensors and tracking technology that collect valuable data on operations. This data can be analyzed to identify trends, optimize workflows, and make informed decisions about future improvements.

Reduced Labor Strain: By taking over repetitive and physically demanding tasks, AGVs help alleviate strain on human workers, reducing fatigue and the potential for workplace injuries. This can lead to improved employee satisfaction and retention.

Future-Proofing: Every aspect of manufacturing operations is heading towards a more technology-driven future. As described by Burian from IDC, Hyper-automation will be prominent in the production environment of the future…driven by AI-powered orchestration solutions that can oversee intelligent machines, fleets of industrial robots, and autonomous mobile robots. To stay competitive and foster growth, embracing mobile automation and other forms of automation will become essential.

Conclusion

Embracing AGV mobile robots is not just a trend; it’s a strategic move towards a more efficient, safe, and cost-effective future. As industries continue to navigate the complexities of modern challenges, the integration of AGVs will be essential in optimizing workflows and empowering human workers to focus on innovation and problem-solving. By investing in these technologies, organizations can enhance their operational capabilities, reduce costs, and create a safer work environment, ultimately positioning themselves for long-term success in a rapidly evolving landscape. The future of automation is here, and AGVs are at the forefront, ready to transform how we work and thrive in the world of manufacturing.

If you’re interested in learning more about AGV mobile robots, check out the resources below.

https://www.my-ebot.com/learn
https://www.agvnetwork.com/
https://www.kollmorgen.com/en-us/resources

About the Author:
In 2007, Tommy Hessler was appointed President and CEO of America in Motion. With extensive experience in the industry, he recognized a critical need for customizable AGV mobile robotic solutions. Tommy envisioned a customized mobile automation approach that meets the unique needs of each customer rather than the traditional one size fits all approach.

Originally from Sweden, Tommy has dedicated his entire career to the mobile robotics and AGV sectors. He spent several years at NDC Technology in Australia before taking ownership, further solidifying his expertise and commitment to innovation in this field.

This article is sponsored by America in Motion.

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