How do AGVs work?

One of the major challenges for logistics managers is optimizing the flow of materials within the warehouse. There is an ongoing search to develop strategies that help reduce movements and routes along the distribution center, bringing more speed and accuracy to material handling. To achieve this important goal, a widely used technology is AGVs, Automated Guided Vehicles, which can operate continuously without human intervention.

AGVs have existed since the 1950s when the Barrett company launched a tug that followed a wire on the ground instead of a track. From that first version, a new type of AGV emerged, which followed invisible UV markers on the ground. Since then, new models have been launched, advancing based on the technology used.

To get an idea of how these automated guided vehicles are increasingly employed in warehouse logistics, it is estimated that the AGV market will reach about $3.6 billion by 2025. According to the report, the justification for the increasing use of AGVs lies in the pursuit of workplace safety and the need to reduce operational costs and increase productivity.

How does an AGV work?

An AGV is essentially a portable robot that follows long lines or wires traced on the ground, or it can also use radio waves, cameras, magnets, and lasers to guide its movement. The equipment is driven by a specific software system and powered by batteries.

This type of automatic vehicle transports small to large loads and can operate in integration with the Warehouse Management System (WMS), which transmits movement waves so that the AGV can move materials. Its use ranges from production and assembly lines to distribution centers, allowing mixed traffic composed of AGVs and people.

For AGV control, there is a location panel, a color CRT graphic display, and a recording and reporting center. The location panel provides information on the area where the vehicle is located. If the AGV is in an area for too long, it may mean it is stuck or broken. The color display, in addition to indicating the AGV’s position in real-time, also details the AGV‘s status, its unique identification, battery voltage, and can show blocked points. The central log stores all data and history of each vehicle, greatly aiding technical support.

Due to their variety of models, AGVs can have other nomenclatures, such as: Laser Guided Vehicle (LGV), when guided by laser; Fahrerlose Transport System (FTS), a name given in Germany; and Automated Guided Carts (AGC), for low-cost versions. With the technological evolution of AGVs, today most vehicles used are laser navigation, the LGVs. It is worth noting that current versions have devices that prevent a vehicle from colliding with another, as well as ensuring that each AGV arrives perfectly at its destination.

Why do warehouses use AGVs?

Due to the complexity of modern warehouses, everyone is looking for ways to increase efficiency. AGVs have a cost, but in most cases, the benefits outweigh the costs. As we explained earlier, by automatically moving products, the AGV can solve the problem of labor shortage, optimize material flow, and even bring more accuracy to stock. Movement time is reduced, and consequently, there is an increase in productivity.

It is also important to emphasize that these vehicles bring more safety to the warehouse. Not only that, they can perform more difficult or strenuous tasks for employees, such as moving in cold storage or performing repetitive actions, like retrieving empty pallets in continuous operation 24/7 without interruptions. While AGVs perform monotonous tasks, operators can be shifted to more strategic processes, bringing greater productivity and work precision.

Currently, to implement a more modern AGV model, warehouses no longer have to undergo major changes in their infrastructure, facilitating its implementation. Basically, some modifications are needed to ensure that the floors are flat and the slopes are not too steep. Additionally, if the operation uses pallets of different types and materials, it is necessary to evaluate the vehicle’s ability to transport them. AGV is easy to integrate with systems and also has low IT infrastructure requirements.

Another advantage of AGVs is that they are flexible, meaning if there is a change in layout, products, or processes, they can be reconfigured to execute new routes. Therefore, we can say that the AGV is ready to face market and production changes.

In which operations are AGVs indicated and what to observe before using them

Due to the fact that there are different models of AGVs, which transport from small to larger and heavier loads, they can be used in various types of warehouses, whether retail, wholesale, food and beverage, automotive, paper, clothing, among others.

These vehicles are suitable for repetitive material movements, in operations with at least two shifts, in processes where product traceability is important, and also in operations that require quick and precise deliveries.

Before using it, it is important to conduct a detailed study of its implementation during the design phase, as well as simulations and tests that can help define the best configurations, so that the equipment can meet the set goals and expectations. It is also important to promote a cultural change in the company, training employees to handle the new tool well. Finally, it is always recommended to have a preventive maintenance program, ensuring maximum equipment lifespan.

High yield and competitiveness

Indeed, AGVs bring benefits that far outweigh their costs. In a highly competitive scenario, labor shortages, and the continuous pressure to meet increasingly shorter delivery times, having AGVs in operation can greatly help overcome these challenges. Autonomous vehicles promise a high level of precision, greater speed, and lower costs. That’s why ROI is a popular factor when investing in such equipment, as AGVs allow for intelligent use of the operation’s valuable resources.

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