Driverless transportation systems - definition, benefits, costs and intelligent alternatives

Since the 1950s, driverless transport systems (AGVs) have ensured maximum reliability and efficiency in the internal transportation of a wide range of products, goods and merchandise. However, classic AGVs have one disadvantage: they are mostly track-guided and only work on predefined routes. If processes or company buildings change, considerable effort is required to redesign the route network. Autonomous mobile robots (AMR), which find their routes independently using previously loaded plans or self-generated maps, are much more flexible. They therefore offer greater flexibility in changing working environments and are also suitable for unstructured environments such as outdoor areas.

Table of contents:

• What are driverless transport systems?
• Types of driverless transport systems
• Driverless transport systems in logistics: these are the advantages
  
• AGV vs. AMR: these are the differences
  
• Outdoor capability: why is the AMR the better driverless transport system?
• How quickly does an outdoor-capable AGV or AMR pay for itself?
• How to find the perfect automated guided vehicle system for your needs

In the following article, you will learn more about the two variants of driverless transport and find out what advantages AMRs such as those from Innok Robotics offer in combined indoor and outdoor use or in brownfield applications.

What are driverless transportation systems?

Automated guided vehicles (AGVs) are units of automated, self-driving vehicles or tugger trains. They are often used to make internal material flows more efficient, flexible and economical. Individual means of transport in such fleets are referred to as automated guided vehicles (AGVs).

The special feature of driverless transport systems is that they can transport materials and goods from one place to another autonomously, i.e. without human intervention, and thus replace manual transportation or transportation with a forklift truck, for example. Innovative navigation, lane guidance and sensor technologies ensure precise movement on the site.

Transport systems without a human driver are an important element in the automation of production, storage and logistics processes. Their range of applications extends from raw materials, semi-finished and finished products, tools, containers and pallets to waste or special loads such as hazardous goods.

Types of automated guided vehicles

There are different types of driverless transport vehicles that are used depending on the requirements and conditions. Here is an overview of the most important ones:

Forklift trucks

Forklift truck AGVs combine the function of classic forklift trucks with the automation of an automated guided vehicle system. They can pick up, transport and stack palletized loads, sort them vertically into racks or set them down on the floor. They are capable of handling loads of up to several thousand kilograms. The most important areas of application include the storage and retrieval of goods, for example in racking warehouses in distribution and logistics centers.

Undercarriages

These particularly flat-built AGVs can drive directly under load carriers such as pallets, transport racks or shelves and lift them using a lifting device in order to transport them independently. Thanks to their often compact design, they can move flexibly through narrow storage areas. Automated guided vehicles of this type are predestined for smaller loads of up to 500 kg. The most important areas of application include the storage and retrieval of goods.

Piggyback vehicles

Piggyback vehicles pick up pallet cages, small load carriers or pallets using load handling attachments (LAM) such as chain and belt conveyors, toothed belt conveyors or roller conveyors. Piggyback AGVs are equipped with hydraulic or pneumatic systems to compensate for height differences between different transport platforms or loading areas. Some modern models are equipped with sensors that automatically adjust the height. These vehicles are particularly at home in logistics and intermodal transport.

Assembly vehicles

Assembly AGVs were specially designed for use in assembly processes. Their task is to transport and position components or complete assemblies within a production line so that they can be further processed or assembled directly. Assembly vehicles can handle weights of up to 5,000 kg. In the automotive industry, they are used to transport vehicles between assembly stations. In mechanical engineering, they support the assembly of entire machines and systems.

Towing vehicles

Tow tractor AGVs pull trailers, transport trolleys, pallet trucks, pallet cages and much more. The vehicles, also known as tuggers or often as tugger trains, can move large quantities of goods efficiently. This makes them particularly useful for intralogistics in manufacturing companies, especially for transporting loads over long distances, transporting materials between production stations and moving goods efficiently without a fixed infrastructure.

Their tractive force allows them to pull several trailers at the same time, depending on their weight. Some models have an automatic trailer coupling, which makes attaching and detaching loads much more efficient and easier and speeds up the process considerably. Typical applications include transporting materials between production stations and moving containers and pallets within warehouses. The INDUROS from Innok Robotics, for example, performs all tasks in this and the next category simply and effectively.

Universal vehicles

Universal AGVs can be modified and are therefore particularly versatile. They are not limited to one specific type of transport, but can flexibly move different loads such as pallet cages, pallets or other containers. As they adapt dynamically to changing production layouts, they are particularly popular in Industry 4.0 scenarios. They can be used to support the flexible provision of materials in assembly processes as well as to transport pallets and containers in warehouses or to move components between production lines in the automotive industry.

Automated guided vehicles in logistics: these are the advantages

Automated transportation has a whole range of advantages. On the one hand, AGVs reduce the need for human labor. In this way, they close personnel gaps caused by a shortage of skilled workers and reduce personnel costs. As the human factor is eliminated in many areas of work, the error rate is significantly reduced. In addition, driverless transport systems can be used around the clock, ensuring a continuous supply of the required goods at any time of day or night.

Compared to fixed transport technology such as conveyor belts and roller conveyors, driverless transport systems require less space. In the long term, they are more cost-efficient than conventional conveyor systems or forklift trucks. As they can detect and avoid obstacles, they minimize the risk of accidents. They can also work in environments that are problematic for people, e.g. (deep) cold stores or chemical-exposed areas in the chemical or plastics industry.

Automated guided vehicles optimize internal material flows and make them more transparent. Order peaks and market fluctuations can thus be flexibly absorbed. In addition, the systems make it possible to efficiently and precisely control the logistical transportation of goods according to the just-in-time strategy.

AGVs vs. AMR: these are the differences

The driverless transport system is an overall system consisting of a control system, a data communication system, at least one driverless transport vehicle, devices for determining the location and peripheral elements such as charging stations. The interaction between driverless transport vehicles and the central control and fleet management system takes place via special communication protocols such as the VDA5050 interface or software provided by the manufacturer such as InnokCockpit. The AGVs are usually designed for fixed transport routes. They use the following technologies, among others, for navigation:

• Inductive guidelines: Wires are embedded in the floor that generate an electromagnetic field. The AGVs follow these with the help of sensors.
• Optical guidance: AGVs equipped with camera or laser systems move along markings such as lines or QR codes.
• Magnetic navigation: Magnetic strips on the floor serve as waypoints that the AGV recognizes and follows.
• RFID or barcode control: RFID tags or barcodes are placed in the environment, which the vehicles can use to determine their position and route.
• Central control: In this variant, central software specifies the exact routes.

At first glance, autonomous mobile robots may often look similar to driverless transport vehicles, but they differ from them in terms of the degree of innovation and autonomy. Coming from the field of mobile robotics, they focus more on flexible navigation without additional infrastructure such as the aforementioned guidelines, codes or reflectors. They offer particular advantages when routes are already implemented in the robot's software but need to be adapted or supplemented. The control system of these robots is able to recalculate routes in real time based on assigned priorities for the individual missions in order to process transport orders optimally.

While AGVs always use the same transport routes between two locations, the routes of highly flexible AMR systems can vary if, for example, an employee manually assigns an order with the highest priority to the AMR. This also results in differences in transport times. On average, transports can therefore be completed more quickly.

Autonomous mobile robots use SLAM (Simultaneous Localization and Mapping) to find their way around and detect obstacles. This process is based on sensors such as cameras, ultrasound or LIDAR (light detection and ranging). The transport robot uses their data to create a map of its surroundings (mapping), which it uses to determine its own position (localization).

It remains to be seen how long the distinction between driverless transport systems and autonomous mobile robots will last. The boundaries are becoming increasingly blurred.

Outdoor capability: Why is the AMR the better driverless transport system?

When it comes to outdoor transportation, autonomous mobile robots are clearly ahead on various levels. Unlike conventional driverless transport systems, they are not dependent on infrastructures such as magnetic strips, floor markings or generally absolutely flat and clean industrial floors, but can also drive their route outdoors as previously defined. This makes them the perfect transport solution for unstructured, changeable outdoor areas.

AMRs developed for outdoor use are designed in such a way that they can perform their tasks even in changing light conditions, rain, snow and uneven terrain. Even obstacles such as thresholds or ramps should pose no problems for these mobile robots. Protective housings and robust sensor systems ensure continuous operation outdoors, while conventional automated guided vehicles are designed for controlled indoor environments.

AMRs are currently still reaching their limits in terms of their maximum payloads. Conventional automated guided vehicles can usually cope with weights of several tons. The new mobile transport robots are in the range of one ton, just below or above that. In many application scenarios, it can make sense to replace the tried-and-tested systems with autonomous robots. In the automotive industry, for example, cycle production is usually precisely planned, which is why the components have to reach the conveyor belt in a fixed time sequence that an AMR can optimally adhere to with the right route and mission control.

It is not uncommon for mobile transportation solutions in these environments to have to react to people crossing the route. The high degree of autonomy and the high standards of AMR safety sensors are an advantage in this field of application for safety reasons alone and to prevent accidents.

How quickly does an outdoor-capable AGV or AMR pay for itself?

The profitability of such systems depends on several factors, in particular the area of application, the frequency of use, the transportation and material handling rate and the operational conditions. Therefore, no general statements can be made in this regard. If the system is used intensively and leads to optimized material flows and considerable cost savings in the personnel sector, it can pay for itself within one to two years , as in this example.

In the outdoor sector, it is not only efficiency that is important, but also robustness, as this is an important prerequisite for continuous operation. Systems that work reliably even in unstable weather conditions reduce downtime and avoid unforeseen costs due to weather-related production downtime. This permanent operational capability also accelerates the return on investment (ROI), especially in fields of application such as large logistics areas or the automated transportation of materials or goods between several buildings.

How to find the perfect automated guided vehicle system for your needs

There are various aspects to consider when selecting a driverless transport system. Consider which goods are to be transported, in what quantities and how long the transport routes are. Also take a close look at the operating environment. Which type of system is more suitable: a track-bound transport system or an autonomous mobile robot (AMR).

Include in your considerations which technology can be better integrated into your existing infrastructure. Can you make modifications and conversions to your buildings, do you need VDA5050 at all or do you want quick and easy integration of automated guided vehicles for logistics with the manufacturer's software that matches the vehicle?

If you are looking for an automated guided vehicle system for indoor and outdoor use that adapts flexibly to dynamic environments, can withstand changing weather conditions and also works smoothly on uneven terrain, you have found the right partner in Innok Robotics. Get in touch with us and let our experts provide you with comprehensive advice on our AMR INDUROS.