How AGVS Enhance Safety and Productivity

AGVs automate repetitive tasks and reduce the need for human intervention.

 A Q&A with Joe Coleman, PhD, AGV Specialist, Combilift

AGV charging stations at Central Steel & Wire. Image courtesy of Combilift.

Autonomous Guided Vehicles (AGVs) are robotic machines used in material handling, programmed to operate independently within a warehouse or storage facility. Equipped with sensors and navigation technology. AGVs can follow paths or predefined routes, and execute complex tasks like loading, unloading, and transporting goods to specific locations without human intervention, and some can navigate around obstacles. AGVs can receive standalone orders from operators or be fully integrated into a facility warehouse management system (WMS).

Which industries/applications are ideal for autonomous guided forklift trucks?

When thinking of automated storage you would normally think of unified palletized goods in industries such as food, pharma, parts and healthcare industries, but sideloading AGVs like the Combi-AGT — the first Autonomous Guided Trucks that can still be operated manually from within the cabs, are ideally suited for industries that handle large volumes of long heavy materials or long items that require precision storage.

Industries such as metals processing, manufacturing, and large-scale warehousing have seen significant benefits from using Combi-AGTs where long metal products are stored in cantilever racks

At Central Steel & Wire, for example, they use a fleet of 21 Combi-AGTs in their newly developed 900,000sqft warehouse to carry long loads of up to 24ft steel stock that can weigh up to 11,000lbs.
These AGTs currently operate in full autonomous mode, using natural feature navigation and advanced sensors to navigate these long, heavy loads precisely, minimizing damage while increasing storage and order-picking efficiency.

Central Steel & Wire uses a fleet of 21 Combi-AGTs in their newly developed 900,000 square foot warehouse. Image courtesy of Combilift.

What are the safety standards for autonomous guided forklift trucks?

Safety standards for the Combi-AGTs include pedestrian and obstacle detection, emergency stopping, load stability and safe navigation to protect both the equipment and personnel. Many AGVs feature onboard sensors that detect objects and slow or stop when something unexpected is encountered in their path or from overhanging objects in aisles. These safety measures are especially crucial in facilities with pedestrian traffic to avoid collisions. Additionally, frequent evaluations and adherence to industry standards, such as ANSI and ISO guidelines for industrial robots and automated systems, are essential for maintaining AGV safety.

With the AGT safety systems at Combilift, we have designed the safety systems to meet the combined safety system standards making the vehicle suitable for international use in Europe and North America.

How has AGV navigation and safety technology evolved?

Over time, AGV navigation technology has advanced from simple guided paths to sophisticated natural feature navigation that allows AGVs to operate more independently and adaptively. Modern AGVs use laser sensors, cameras, and machine learning to map environments, recognize changes, and detect and counteract obstacles. For instance, in the University Park facility, the AGVs use natural feature navigation to map and store specific metal containers, eliminating manual adjustments. Enhanced sensors for obstacle detection and advanced software for task management have made AGVs more reliable, adaptable, and safe.

Picking trays at Ryerson’s Plymouth, Minnesota facility. Image courtesy of Combilift.

How do autonomous guided forklift trucks optimize material handling?

AGVs optimize material handling by automating repetitive tasks and reducing the need for human intervention in transporting goods. This automation leads to greater accuracy and efficiency in the storage and retrieval process, as seen in Central Steel & Wire’s facility where AGVs autonomously transport and place large loads without human intervention, improving speed and reducing labor and training costs.

AGVs also streamline the workflow, “We haven’t realized the full benefits of the AGV fleet yet, but we continue to realize more benefits every day,” says  Nicole Giesie, vice president of operations at CS&W. “It goes beyond labor efficiency. The benefits are more around having automation that optimizes our routings and our tasks — being better able to look at order patterns and use that to digitally optimize how we are going to pick today, or how are going to put materials away.”

When the initial trail tests were implemented into Ryerson’s Plymouth, Minnesota facility, they found that the AGT’s showed the potential to double their production, as the trucks did the repetitive tasks of order pulling allowing manual operators to focus on more complex tasks and enhancing the overall productivity of the facility.

Contrary to popular belief the AGT’s don’t replace staff, the increasing work flow created means it’s all hands on deck in other crucial areas, so is a win-win for the site, employees and the customers it supplies to.

How do AGVs improve safety and reliability?

The automated precision and consistency of AGVs lead to reduced error rates, minimizing damage to goods and risks to personnel. AGVs are engineered to perform tasks accurately within narrow spaces, AGVs handle challenging, heavy loads within aisles only slightly wider than the AGVs themselves. By eliminating manual handling of large loads, AGVs reduce the risk of workplace injuries and contribute to a safer working environment.

Unlike regular AGVs the Combi-AGT can be driven manually, employees who are trained to drive side loaders can operate AGVs in manual mode if needed, which can be particularly valuable during power outages or Wi-Fi disruptions to keep production moving.

They also make use of Opportunity Charging, if the truck has idle time between picking and placing and it could use a battery charge, it heads off to its charging dock. It will begin charging until a new order is received. Multiple AGTs can also share chargers, one will leave the charging dock for a general parking location so that another can use the charger if it is in greater need. The precise behaviour of this system is adjusted to suit each sites production requirements.

AGT’s showed the potential to double production during initial trail tests at Ryerson’s Plymouth, Minnesota facility. Image courtesy of Combilift.

Is it safe to operate an autonomous guided forklift truck in facilities with pedestrian traffic?

It is generally safe to operate AGVs in facilities with pedestrian traffic, provided that safety protocols are followed. AGVs are equipped with sensors and programming to slow down or stop when obstacles or people are detected in their path. For example, AGVs automatically decelerate and stop if they encounter any obstruction. However, facilities must also implement safety zones, signage, and training to further mitigate risk. The best practice is always to minimise the scope for interactions between pedestrians and automated machinery.

What are the key safety considerations when integrating an autonomous guided forklift truck into operations?

Key safety considerations include ensuring that AGVs are programmed with reliable, fail-safe obstacle detection and emergency stop functions, designing layouts that allow AGVs to operate smoothly, and creating clear pedestrian pathways to avoid cross-traffic incidents. At Central Steel & Wire, careful layout planning and cantilever racking configurations ensure that AGVs operate within designated paths. Additionally, integrating AGV operations with a facility’s ERP or WMS system helps monitor and adjust AGV routes in real-time, enhancing both safety and efficiency.

What types of training are required/recommended?

Operators and facility staff should be trained on AGV interaction protocols, safety zones – including safety practices for working in close proximity to AGVs, and manual override functions.

Training should also cover the procedures for managing AGV fleet software to ensure efficient task assignment and monitoring, as well as enterprise resource planning (ERP) system software to manage orders, procurement and materials.

Since its founding in 1998, Combilift has continuously pushed the boundaries of innovation in the material handling industry. From its early days, the company has embraced a culture of thinking big and delivering products that meet the evolving needs of its customers. Learn more at https://combilift.com.