What is an AGV Autonomous Vehicle? Advantages and disadvantages of AGVs

In the era of Industry 4.0, automation and optimization of production processes have become vital factors for the competitiveness and sustainable development of enterprises. One of the advanced technologies that is being widely applied is the AGV (Automated Guided Vehicle) robot. With the ability to improve performance and accuracy in warehouse management and production, AGVs are becoming the preferred choice of many businesses. However, to decide to adopt AGVs, business owners and managers need to have a clear understanding of their operating principles, benefits, and limitations. In the article below, RX Tradex will bring detailed information about AGV autonomous vehicle, helping businesses evaluate and make appropriate decisions for the automation of their warehouses and distribution centers.

1. What is an AGV Autonomous Vehicle?

What is AGV? AGV (Automated Guided Vehicle), also known as AGV autonomous vehicle, is a type of self-driving robot that is capable of moving along a predetermined route, using guidance technologies such as magnetic strips, lasers, or GPS. Powered by batteries, AGVs are equipped with safety protection systems and various assistance mechanisms.

The primary purpose of AGV robots is to transport materials, products, pallets, boxes, and other goods in smart warehouses, distribution centers (DCs), and manufacturing facilities. They carry out the process of receiving and delivering goods according to a predetermined schedule, and can also lift and move loads over long distances.

AGV autonomous robots provide a modern, economical, and safe solution for distribution and production operations, allowing for increased productivity and flexible automation without the need for additional labor, physical space, or bulky equipment.

2. Components of AGV

AGVs (Automated Guided Vehicles) consist of many key components, each of which plays an essential role in ensuring efficient and safe operation. The most important components in the construction system of AGVs are as follows:

• Vehicle Structure: sturdy structure, helping to transport goods with large tonnage, ensuring durability and stability during movement.
• Server software (Software) – Control and communication function: Helps AGVs operate without traffic congestion, only requires vehicle conversion when necessary.
• Central Control Unit – Programmable controller: Controls the vehicle to run independently, combine multiple vehicles or under the management of the operating center.
• Wireless Communication – Communication with monitoring software: Connecting to warehouse management systems, production inspection systems, and resource management systems, helping to manage and coordinate AGV operations.
• User Interface – Material Movement Request Management: Helps manage vehicle material movement requests, manage alarms, communications, and reports to analyze and improve overall operations.
• Batteries and Chargers – Modern batteries: Including flooded lead acid, NiCad, Lithium-ion, sealed batteries, induction power supplies, and fuel cells, powering AGVs to operate.
• Data Transmission Equipment – Remote Transceiver: AGVs transmit and receive data to the production operation center via RF or WiFi systems, improving flexibility and control of working lines and vehicle status.
• Load Handling Attachments – Connected to carts: Can be operated automatically or manually, helping AGVs transport and handle goods efficiently.

3. How does an AGV autonomous robot work?

As a general rule, AGV robots consist of five basic elements: navigation system, safety system, electrical system, motion system, and vehicle controller. Here are the details of each element:

3.1. Navigation System:

• Function: This is the department responsible for receiving and processing information to follow a predetermined route or direction and control the vehicle.
• Navigation types: Including laser, wire, magnetic positioning, and many other methods.

3.2. Safety System:

• Function: Make sure the movements of the AGV are carried out as safely as possible.
• For example, a laser scanner helps the car stop when it detects an obstacle along the way.

3.3. Electrical System:

• Function: Provides the necessary power for the AGV to move through the battery.
• Battery and charging: Each type of AGV has a different type of battery and charging method according to the needs of the warehouse or production center.

3.4. Motion System:

• Function: Integration of parts that allow the vehicle to move and perform tasks.
• Components: Including the engine, wheels, mast and hydraulic system used to lift the load.

3.5. Vehicle Control Unit:

• Function: Guide the AGV through a programmable logic controller (PLC), transmit information from the software, and facilitate the vehicle to move automatically.

In any case, the movement and workflow of the AGV robot depend on the commands of a higher-level program, such as a warehouse management system (WMS). This software coordinates all activities in the logistics facility and synchronizes the tasks of the various automated systems operating in the warehouse.

4. Classification of AGV autonomous robots

AGV autonomous robots come in many different types and forms, depending on the role they play. Here are the three main types of AGVs that are most commonly known:

4.1. AGV Tuggers:

AGV trolleys are the most basic type of AGVs with minimal features. These can range from simple systems like magnetic tapes to complex sensor-based navigation systems that use AI to navigate the environment. AGV trolleys can transport a variety of materials, from small parts to load-bearing pallets, and are commonly used in sorting, storage, and cross-assembly applications.

4.2. AGV Forklifts:

Automated guided forklifts are considered another popular type of AGV. They are designed to perform the same functions as human-operated forklifts (pallet transport), but without the need for a human operator. AGV forklifts are commonly used in warehouses and distribution centers to lift and transport pallets.

4.3. AGV Towing Vehicles:

Automated guided trailers pull one or more non-motorized vehicles with a rear load in a formation like a train. AGV trailers are sometimes referred to as driverless trains, powered towing vehicles that move on wheels. They are often used to transport heavy goods over longer distances and may have several stops along a defined path through a warehouse or factory.

5. Applications of AGV Robot

AGV autonomous vehicle systems are used for jobs that are typically handled by forklifts, conveyor systems, or manual trolleys, moving large volumes of materials in a repetitive manner. AGV robots are typically responsible for performing logistics operations such as distributing goods between different storage areas in the facility, loading and unloading goods in the receiving and dispatching areas, and other tasks. Since AGV robots can transport heavy loads, they are also used in production centers to move parts of different sizes to the assembly line. Some of their applications can be mentioned such as:

• Truck Loading and Unloading: AGV robots can perform the functions of forklifts or other common handling equipment. For example, these robots can automatically load or unload goods onto trucks, helping to minimize labor and increase efficiency.
• Product storage and retrieval: The AGV robot can place the item in the corresponding storage location and move the goods to the order fulfillment area. These operations facilitate the fast, safe and automated replenishment of goods to racks and picking stations for both products and operators.
• Connection to production centers: AGV robots can be configured to transport large, heavy, and bulky goods, making them a suitable choice in warehouses near production centers. AGVs transport loads to assembly lines, especially in sectors such as the automotive and aerospace industries.
• Distribution of supplies: AGV robots not only move heavy goods but also distribute goods at facilities with equipment sales stations. According to a predetermined roadmap, these autonomous vehicles streamline the replenishment of goods to various assembly stations, distributing goods in the exact quantities required.

6. Outstanding advantages and disadvantages of AGVs

When considering automating the operation of production systems using AGVs, it is important to consider their pros and cons. Here are some of the outstanding advantages of using AGVs:

6.1. Reduce labor costs

AGVs help reduce labor costs by replacing labor. A company only needs to pay a single cost for AGV equipment, compared to the ongoing costs associated with new hires such as health care insurance, payroll taxes, salary increases, and vacation time.

6.2. Increased safety

AGVs are programmed with safety in mind, fully equipped with cameras, lasers and sensors to operate safely around the facility. Human-operated equipment, like forklifts, does not have many built-in safety mechanisms and depends on the operator’s concentration. Employees may be distracted or tired, causing accidents, but this is not a problem with AGVs.

In addition, AGVs can also operate in conditions where humans cannot work or do not operate optimally, such as extreme or cold temperatures or around hazardous materials. This safety helps reduce costs and downtime, increasing profitability for many operations.

6.3. Increase accuracy and productivity

Replacing the human factor with AGVs eliminates the possibility of errors in workflows, reduces waste, and increases output, making business operations more productive and accurate. AGVs are capable of operating 24/7, without time limitations such as personnel. By integrating AGVs with a warehouse control system or warehouse management system, businesses can streamline processes such as material inventory and ordering.

6.4. Modularity

As your business expands, you can easily add additional AGVs as needed. This helps to avoid an exorbitant initial investment, which can start with one or two AGVs and gradually expand the fleet to transition to fully automated or mostly automated operation.

6.5. Less expensive than fixed automation systems

AGVs typically perform the same tasks as stationary automation solutions such as conveyors, but the cost of deployment is lower. Fixed automation systems can be expensive to deploy and often affect the workflow during implementation, while AGVs do not affect operations during deployment.

In addition, AGVs can be easily reprogrammed to follow new paths, while fixed automation systems are difficult to move and expensive when changes need to be made.

7. Some other options to replace AGVs

AGV robots offer many significant benefits and are highly valued by warehouse managers and supply chain executives when considering automation. However, AGVs are not always suitable for every business. If you’re looking for ways to automate your operations but are worried that AGVs aren’t meeting specific needs, you may want to consider some other alternatives. Warehouse automation comes in various forms and technologies, which can help increase the efficiency and profitability of your operations. Here are some potential alternatives to AGVs:

• Conveyor System
• Automated Storage & Retrieval System (AS/RS)
• Overhead Trolley Conveyor
• Automated Mobile Robots (AMRs)

Among these options, Automated Mobile Robots (AMRs) may be the best fit for AGVs in terms of use and purpose.

Automated Mobile Robots (AMRs)

AMRs are a newer type of warehouse robot, capable of performing the same basic task as AGVs, which is to transport inventory. However, there are some key differences between AMR and AGV:

• Flexible and intuitive: While AGVs are large, bulky technology and navigate along pre-set fixed routes, AMRs use a complex set of sensors and maps on board, allowing them to interpret their surroundings. This makes it possible for AMRs to be used in a more flexible and intuitive way.

AMRs can be used to:

• Transportation of inventory and products between regions: AMRs have the ability to move inventory and products from one area to another in the warehouse.
• Support in the order picking process: AMRs can help employees in order picking, increasing speed and accuracy.
• Product and Inventory Classification: AMRs can sort and organize inventory as required.
• Increased Inventory Visibility: With sophisticated sensor and mapping technology, AMRs help improve inventory tracking and management.

8. Estimate of implementation costs

In order to estimate the cost of deploying and installing AGV robots reasonably, businesses need to pay attention to the following main contents:

Application of AGV Robot:

• AGVs in logistics and logistics
• AGV in packaging
• AGV in assembly
• AGVs in Loading and Unloading Trucks
• AGV handling raw materials

The number of AGV robots that need to be invested: Depending on the area of transportation space and the number of goods to be transported, the number of AGV robots that need to be invested will vary. Determining the right quantity will help optimize costs and operational efficiency.

Tonnage of autonomous vehicles:  The load factor is an important factor affecting the cost and productivity of AGV robots. Businesses need to determine the right tonnage to meet their needs to ensure maximum efficiency.

Some other expenses include:

• Cost of peripherals: Includes sensors, navigation systems, and other supporting devices.
• Software management costs: Includes the cost of developing, deploying, and maintaining AGV management software.
• Staff training costs: Training staff to operate and maintain AGV systems.
• Maintenance and repair costs: Provision for periodic maintenance and repair costs.

9. Are AGVs suitable for your business?

AGVs can be an extremely useful tool, helping to increase efficiency and profitability in many order fulfillment activities. However, they are not suitable for every business. To determine whether AGVs are right for your business, it is important to carefully weigh the benefits and drawbacks of using automated guided vehicles and decide whether they will supplement or hinder business. Depending on the specifics of a business’s operations, another type of automation technology, such as automated mobile robots (AMRs) or automated storage and retrieval (AS/RS) systems, can better meet the business needs of the business. The following factors should be considered:

Benefits of AGVs:

• Increased efficiency and reduced labor costs: AGVs help replace labor, reducing costs related to wages and benefits.
• High safety: AGVs are equipped with advanced safety mechanisms such as cameras and sensors, which help minimize accidents.
• High accuracy and productivity: AGVs operate 24/7, helping to optimize processes and increase productivity.

Limitations of AGV:

• High initial investment costs: While AGVs can reduce labor costs in the long run, the initial investment costs can be high.
• Need for a large space: AGVs often require large spaces to operate efficiently.
• Limited flexibility: AGVs move along fixed routes, which may not be as flexible as some other technologies.

When to Consider Alternatives:

If you have specific needs that AGVs can’t meet, other automation technologies such as AMR or AS/RS may be a better option:

• Automated Mobile Robots (AMRs): AMRs use sensors and maps for more flexible navigation, making them suitable for rapidly changing and complex environments.
• Automated Storage and Retrieval System (AS/RS): AS/RS provides an effective automation solution for the storage and retrieval of goods, making it suitable for large warehouses with tight inventory management requirements.

10. Conclusion

AGV autonomous vehicle are becoming an integral part of smart warehouses and modern manufacturing facilities, offering outstanding benefits in terms of efficiency, accuracy, and safety. With the ability to reduce labor costs, increase productivity, and flexibility in operation, AGVs not only optimize workflows but also open up new opportunities for businesses in automation and sustainable development. To discover more about advanced technology solutions such as AGVs and learn how to optimize smart production lines, businesses can register to attend  the Vietnam Manufacturing Expo (VME) 2024 organized by RX Tradex Vietnam. Register here to participate.