What is an AGV?

Definition

An AGV (Automated Guided Vehicle) is an autonomous floor-level transport vehicle that moves materials without a human driver. AGVs are part of a larger Automated Guided Vehicle System that includes the vehicles, navigation infrastructure, and fleet control software.

AGVs move goods automatically from A to B. They are an alternative to fixed conveyors, whose routes are hard to change, and to manual forklifts, which need a driver for every trip. Conveyors still suit very high, constant throughput (Is an AGV system right for you?).

How Does an AGV Work?

An AGV consists of several core components:

• Drive System: Electric motors, battery-powered. LFP batteries are today's default
• Navigation: Laser with reflectors, natural contours, magnetic tape or floor codes
• Safety: Safety laser scanners with warning and protective fields
• Load Handling: Forks, rollers, hooks, or platforms depending on type
• Communication: WiFi connection to fleet control

The vehicle receives transport orders from a central fleet control system, navigates autonomously to the destination, and reports completion.

One Transport Order, Step by Step

1. Order: A light barrier at the end of a conveyor or a button at the station triggers the transport. In larger systems, the ERP or WMS creates the order.
2. Dispatch: The fleet manager picks a suitable vehicle and sends the order over WiFi.
3. Pick-up: A forklift AGV slides its forks under the pallet. An underride AGV drives under the load at a transfer station and lifts it. A conveyor AGV takes it over with rollers.
4. Navigation: It localises itself with reflectors, natural contours, magnetic tape, or floor codes. Reflectors need a clear line of sight, contour navigation needs no extra infrastructure (navigation).
5. Safety: Its safety laser scanner watches two fields. A person in the warning field slows the vehicle down, a person in the protective field stops it. It waits until the path is clear (safety).
6. Completion: At the destination it hands over the load and reports the order as complete.
7. Charging: While it waits for the next order, it takes a short charge at a charging point (battery and energy).

Simple or Smart?

AGV systems range from a single vehicle on a loop to a coordinated fleet (infrastructure):

• Standalone: One to three vehicles drive simple, fixed routes, for example a loop. A light barrier at the end of a conveyor, a button, or a fixed schedule triggers each trip directly at the vehicle. There is no central control and no network.
• With fleet manager: A central fleet manager receives the transport demands, assigns them to the best vehicle, plans routes, and prevents deadlocks. Typical for 3 to 20 vehicles and complex layouts.
• With ERP integration: Orders come from the ERP, for example SAP EWM, and a material flow controller coordinates them before they reach the fleet manager (SAP integration).

Start as simple as your process allows. More vehicles and more complex layouts call for more central coordination.

Applications

AGVs are used across many industries:

Benefits of AGVs

Types of AGVs

Depending on the application, different vehicle types exist:

1. Forklift AGV: Lifts pallets from the floor up to high racks, typically up to 1.5 t
2. Piggyback / Conveyor AGV: Carries the load on top and hands it over with rollers or a conveyor
3. Underride AGV: Drives under carts and lifts them
4. Tugger AGV: Pulls several trailers, similar to a logistics train

More in AGV vehicle types.

Conclusion

AGVs are a proven solution for automating internal transport. They offer high reliability, safety, and efficiency – especially for repetitive transport tasks with stable processes.