AGV navigation systems

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The ever-improving navigation systems of AGVs

All types of automated guided vehicles rely on an automated guidance system to navigate their movements and continuously update the management system with the AGV’s current position.

The AGV navigation systems are improving quickly – a development that is possible thanks to the reliable and cost-effective AGV navigation sensors and software. Depending on the application, AGVs navigate with the help of such technology as laser, range, visual, spot magnetic, and wire navigation.

Understanding how AGV navigation systems operate

Laser scanners and reflector-based navigation

The AGV’s laser scanners detect reflectors placed throughout the facility, usually on walls, pillars, machines, and other fixed structures near its path. These reflectors help the AGV to calculate its position by reflecting the laser beams sent out by the scanner.

This setup enables free-range navigation, which means that the AGV doesn’t need floor markers, wires, or pre-set position IDs to navigate. Instead, it uses the surrounding reflectors as reference points, thus offering greater adaptability within the facility.

Reflector map and Master Controller

A map of the entire route, showing where all the reflectors are, is stored on the Master Controller in a fixed PC. This helps the AGV to update its position while moving, so it can stay on course during its journey.

The Master Controller acts as the brain of the operation, supplying the AGVs with real-time position information from the reflector map. This setup makes sure everything runs reliably and with precision as the AGVs move through the facility.

AGV navigation types

Four of the most common AGV navigation methods are:

  • Laser-guided navigation
  • Magnetic tape navigation
  • Natural navigation – free navigation
  • Magnetic spot navigation
  • QR code navigation

Some AGV methods can also be combined for further accuracy in changing operational environments.

Laser-guided navigation

A laser-guided vehicle is equipped with a 2-dimensional navigation sensor, also referred to as a laser emitter. The navigational laser emits a continuous beam of modulated laser light in a 360-degree pattern. That laser beam interacts with reflectors, also called targets, positioned in the area where the AGV operates. The center of the target must be positioned at the same height as the navigation device and a maximum of 30 meters from the AGV.

Depending on the laser device manufacturer, these vehicles calculate and correct their positioning between 30–40 times per second, making these devices incredibly accurate. Once the laser hits the target, the beam is sent back to the navigation laser that calculates the laser’s traveling time together with radial coordinates. This data makes it possible to calculate the coordinates of the reflectors and the AGV.

Magnetic tape navigation

AGVs that use magnetic tape navigation are equipped with magnetic sensors that follow a predefined path. This path is created by laying magnetic tape on the floor surface. The AGV’s sensors detect the magnetic field from the tape and guide the vehicle along the designated route.

Magnetic tape is easy to install thanks to its high-bond adhesive backing. With standard dimensions of 1 mm in thickness and 5 cm in width, the tape is low-profile and non-invasive to the floor environment.

Natural navigation AGV – free navigation

In general, AGVs using natural navigation can autonomously move by identifying and mapping the surrounding areas. Natural navigation, also commonly referred to as free navigation, is the most evolved AGV navigation method.

Driverless vehicles with natural navigation can identify fixed structures, such as walls, and travel while maintaining a specified distance from them. This approach does in fact encompass several technologies, with contour recognition being the most common. Vehicles utilizing this technology navigate by identifying and mapping their surroundings using various types of sensors commonly used in mobile vehicles.

Magnetic spot navigation

AGVs can navigate using small cylindrical magnetic spots embedded in the floor. These magnets, typically around 20×10 mm in size, are placed at intervals of 250–500 mm to form a virtual path.

The AGVs travel from one spot to the next using sensors, controls sensors, encoders, and counters to calibrate against steering angle errors. While the vehicle follows a preloaded CAD map in its management system, the magnetic spots provide reference points to ensure accurate path tracking.

QR code navigation

Some AGVs rely on floor QR codes for navigation, using camera systems to read markers and determine their exact position and direction. The simplicity of setting up and adjusting QR codes makes this method highly adaptable for evolving facility layouts. This type of technology, with its accurate positioning and ease of maintenance, is a reliable and affordable alternative for modern automated operations.

Benefits of modern AGV navigation systems

High flexibility and scalability

AGV navigation systems are designed with flexibility as a significant priority, which allows for easy expansion as your needs grow or change. For that reason, new production lines, storage areas, or additional equipment can be seamlessly integrated without any major adjustments.

Integrating new AGVs or other devices into the system is straightforward, and the Master Controller can handle these additions without any setbacks. Due to its versatility, the AGV navigation system is poised to scale, remain effective, and quickly adjust to any future changes.

Reduced installation time and cost

AGV navigation systems are built for fast and cost-effective setup. The process is simple, as it cuts down on the need for extensive site prep, which in turn reduces expensive infrastructure modifications. By using existing reflectors on walls and pillars, the system bypasses the need for costly floor markers or wiring, saving both time and money during installation.

Easier system modifications and upgrades

Due to their modular design and flexible architecture, upgrades can be implemented into the AGV navigation system with minimal downtime. This includes adding more AGVs, expanding routes and changing facility layouts. With this level of flexibility, your operations can quickly adapt to changing production needs, without the hassle of a complete system update.

Choose the right AGV navigation method

When it comes to selecting a navigation method for your AGV, the best choice comes down to your specific needs. As a consumer, it is important to consider factors like budget, facility layout, the level of flexibility required, and how much you plan to scale over time.

Many AGV systems now blend multiple navigation technologies. By doing so, the AGVs can compensate for the weaknesses of any single approach and adapt to a wider range of operational environments. This hybrid strategy provides seamless navigation, especially in complex or dynamic facilities.

Here’s a quick overview to guide your decision:

  • Laser-guided navigation offers excellent accuracy, making it well-suited for complex layouts. However, it comes with higher costs and requires precise placement of reflectors as it’s installed.
  • Magnetic tape navigation is budget-friendly and easy to install, making it a good fit for simple, fixed routes. Its main limitation is flexibility, as changing a route means physically replacing the tape.
  • Natural navigation (or free navigation) provides the highest level of flexibility and is easy to scale as your business grows. It requires a more complex setup and a higher initial investment.
  • Magnetic spot navigation offers reliable accuracy and moderate flexibility. It is however less intrusive than tape in some environments, but still requires floor modifications when it’s installed.
  • QR code navigation delivers accurate location tracking with flexible routing that adapts easily to changes. It is a cost-effective fit for dynamic spaces, though it does require maintenance and a flat floor to function optimally.

Safety features in modern AGV navigation

Safety is a top priority in AGV design, and modern systems are built with this in mind. Obstacle detection is handled by technologies like LiDAR, ultrasonic sensors, and cameras, which enable the AGV system to detect and avoid collisions as it operates. In high-risk areas, such as near human workers or intersections, the AGV automatically slows down to reduce potential dangers. Emergency stop systems are integrated to halt the vehicle instantly if an unexpected obstacle appears.

AGV navigation in different environments

Every workspace is different, and so are the navigation needs of AGVs. Here’s a quick overview of which AGV navigation methods tend to work best in different kinds of environments:

  • Manufacturing facilities: Often benefit from laser or magnetic spot navigation due to the high levels of precision and consistency. These facilities integrate well with fixed paths that support predictable, repeatable workflows.
  • Warehousing and logistics centers: All AGV navigation types can work well in these spaces, but natural navigation and laser-guided systems are particularly popular for their flexibility and scalability in high-traffic, ever-changing layouts.
  • Cleanroom environments: For settings where contamination and disruption must be kept to a minimum, magnetic tape or magnetic spot navigation is most favorable. This is due to their simplicity and low interference with sensitive operations.
  • Outdoor or mixed environments: Require robust systems that can handle varying light, weather, and terrain. Natural navigation, enhanced with sensors like GPS or RTK positioning, can be used to ensure smooth operation across these dynamic conditions.

Future trends in AGV navigation

AI and Machine Learning integration

The future of AGVs is heavily influenced by the integration of Artificial Intelligence (AI) and Machine Learning (ML). AI and ML allow AGVs to analyze data on the fly, improve their routes, predict maintenance needs, and adjust to changing environments. With the ability to continuously learn from experience, AGVs are becoming increasingly autonomous, improving their performance, energy efficiency, and overall operational effectiveness.

Warehouse Management Systems (WMS) integration

Another important trend is how AGVs are being integrated with Warehouse Management Systems (WMS). This will allow AGVs to get on-the-spot instructions, prioritize tasks, and work smoothly alongside other automated systems in the warehouse. When AGVs are integrated with conveyor belts, picking robots and other systems, businesses can propel their material flow and coordination, making tasks quicker and easier to perform.

Smoova, our advanced Traffic Management system, serves as a link between WMS and the AGV fleet. It is integrated with conveyor systems and other technologies to help businesses achieve faster, more coordinated warehouse processes and thus improve their material flow. Smoova also optimizes the use of AGVs, saving both energy and time.

Tailored solutions for every need

Looking ahead, AGV navigation systems will be designed with flexibility and customization in mind. Modular systems will enable them to handle everything from bulky pallets to fragile or irregular items. This advancement will pave the way for new applications, making AGVs adaptable to various industries. Their easy reconfiguration will also ensure they remain effective as material handling needs change.

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