Automation in materials handling has never been more important, or prevalent. Using manual labour during a labour shortage to move materials around simply doesn’t make sense when you can automate these tasks.

Using manual labour during a labour shortage to move materials around simply doesn’t make sense when you can automate these tasks, thereby improving operational efficacy, removing bottlenecks, and allowing employees to focus on higher-value activities.

Two innovative solutions have emerged in materials handling: Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs). While both serve the purpose of material transportation and share the common goal of automating logistical tasks, they differ significantly in their approach and capabilities.

AMRs operate autonomously, leveraging onboard sensors and advanced algorithms to navigate dynamic environments with agility and adaptability. These robots possess sophisticated perception, mapping, and decision-making systems, enabling them to react in real time to changes in their surroundings without relying on external guidance.

In contrast, AGVs adhere to predefined paths or tracks, offering reliability and efficiency in structured environments where tasks are repetitive and predictable. They are simpler in design and function, often requiring external control systems to direct their movements along fixed routes.

AMRs find their niche in flexible and responsive settings, like warehouses with fluctuating layouts or collaborative workspaces. AGVs, on the other hand, excel in environments where consistency and precision are key, and are commonly deployed in manufacturing facilities and warehouses with well-defined workflows.

Understanding the differences between AMRs and AGVs is essential for businesses seeking to optimise their logistics operations by selecting the most suitable robotic solution for their specific needs. Stick with us while we dive in deeper.

What is AGV Used For?

Automated guided vehicles can tow objects behind them using trailers, which enables the autonomous movement of raw materials or finished products within a facility. They can also store objects on their beds, often equipped with motorised rollers for efficient loading and unloading processes.

AGVs are integral to industrial automation, offering efficient material handling and transportation solutions. Unlike AMRs, AGVs typically follow marked lines on the floor or utilise navigation methods such as radio waves, vision cameras, magnets, or lasers for guidance.

They are used extensively in various industries, including manufacturing, warehousing, healthcare and even theme parks, for tasks such as towing, storing, and materials handling. Let’s look at this in greater detail:

Transportation of heavy materials: AGVs are employed to move heavy loads within industrial facilities like factories and warehouses. This reduces the need for employees to handle heavy manual handling tasks.

Industrial applications: automatic guided vehicles can be implemented across a wide range of industries, including pulp and paper, metals, newspaper, general manufacturing, pharmaceuticals, chemicals, automotive, food and beverage, and more.

1. Hospital logistics: in healthcare settings, AGVs are used for tasks like transporting food, linen, medicine, and other supplies. They contribute to streamlining logistical operations and ensuring efficient delivery of essential items to different hospital departments.

2. Warehousing operations: AGVs are extensively employed in warehousing operations for tasks such as loading and unloading pallets, transporting inventory between different areas of the warehouse, and delivering loads to shipping docks. They optimise material flow and enhance productivity in warehouse environments.

3. Theme park rides: in recent years, theme parks have begun using automated guided vehicles for ride systems. These AGVs transport guests on attractions, offering a unique and immersive experience. They navigate predefined paths within the ride environment, providing safe and entertaining transportation for park visitors.

4. Container handling: AGVs are used in port container terminals to move sea containers. They help reduce labour costs and ensure reliable performance in container handling operations, contributing to smoother logistics operations.

5. Automated manufacturing: AGVs play a crucial role in automated manufacturing processes by transporting materials between different stages of production. They contribute to the efficient flow of materials handling within a manufacturing facility, reducing manual labour and optimising production efficiency.

6. Transportation of rolls: in spaces like paper mills, converters, printers, and steel production, autonomous guided vehicles transport rolls of materials. They can store and stack rolls on the floor or in racks, facilitating the movement of materials within production facilities.

What is AMR Used For?

AMRs are robotic systems capable of understanding and navigating their environment without operators’ direct oversight or fixed, predetermined paths. Equipped with advanced sensors, AMRs interpret their surroundings to perform their tasks while navigating around obstacles such as buildings, racks, and people.

Integrated with warehouse control systems, AMRs create their own routes within facilities, enhancing adaptability to changing environments typical in order fulfilment operations. By handling non-value-added tasks like transportation, AMRs free up labour for value-added tasks such as picking and packing, ultimately improving productivity and efficiency in processes and workflows.

AMRs can be tailored to specific operational needs, and skilled systems integrators can assist in determining the best approach, leveraging AMRs’ modularity, scalability, and flexibility to optimise operations effectively. There are a few categories of AMRs, each specialised for different tasks.

1. Transporting inventory and product: AMRs automate the movement of inventory and products within facilities, freeing up workers for more value-added activities. Unlike traditional methods like forklifts or conveyor systems, AMRs offer a more efficient and flexible solution, handling individual cases with ease.

2. Assisting in picking: picking tasks consume significant time and resources within operations. AMRs streamline picking operations by reducing travel time for workers, thereby boosting productivity and reducing human error. They come in various types, each suited to specific picking methodologies such as conventional picking or goods-to-person picking.

3. Flexible sortation solutions: AMRs play a vital role in sortation processes, offering versatile handling technologies for diverse sorting needs. They facilitate high-speed parcel sortation, eCommerce order fulfilment, and returns handling, which contribute to order accuracy and throughput.

4. Increasing inventory visibility: AMRs enhance inventory visibility within distribution centres and warehouses, automating inventory movement and reconciliation tasks. By integrating directly with inventory systems, AMRs reduce time and costs associated with inventory management, improving overall productivity and accuracy.

AGV & AMR Navigation and Guidance Systems

Both AGVs and AMRs may navigate goods through large warehouses, across docks, and between complex obstacles.

The technology underlying these systems, therefore, is extremely specialised. As these robots are used for different applications, one AGV system is not necessarily the same as another, but here are the key elements of AGV and AMR navigation methods and obstacle-avoiding technologies:

Navigation Methods Used by AMR:

AMRs employ advanced navigation techniques to identify static features like walls, racking, and pillars to orient themselves, enabling effective navigation without reliance on fixed routes.

This flexibility in navigation allows AMRs to adapt to changing environments quickly, rerouting easily when encountering obstacles or disruptions. But how exactly do they navigate the changing environment? Here are some of the standard navigation methods used:

1. Laser-based navigation: AMRs often use laser sensors to scan their surroundings and create a map of the environment. They navigate by comparing the map to their current surroundings and making real-time adjustments to their path.

2. SLAM (Simultaneous Localisation and Mapping): SLAM technology allows AMRs to simultaneously create a map of their environment while determining their position within that map. This enables them to navigate effectively even in dynamic environments where the layout may change over time.

3. Vision-based navigation: some AMRs use cameras and computer vision algorithms to navigate based on visual cues in their surroundings. They analyse images to identify landmarks or patterns that help them determine their location and navigate to their destination.
   Wireless navigation: AMRs can use wireless communication technologies such as Wi-Fi or Bluetooth to receive signals from beacons or zone control sensors strategically placed within the environment. These signals help the AMRs determine their location and navigate predefined routes.

Guidance Systems Employed by AGV:

Traditional AGVs primarily rely on infrastructural landmarks like wires, magnets, tape, reflectors, or QR codes placed throughout the facility for navigation. These features define predetermined paths similar to a train on tracks. Here is how each system works:

1. Wired guidance: AGVs may follow wires embedded in the floor or magnetic strips to navigate along predetermined paths. The wires or strips emit signals that the AGVs detect and use to stay on course.

2. Guide tape: AGVs can follow tape lines (either coloured or magnetic) that is laid out on the floor. The tape serves as a guide for the AGVs to navigate along specific routes.

3. Laser target navigation: some AGVs use laser transmitters and receivers to detect reflective targets placed strategically in the environment. By triangulating the position of these targets, the AGVs can determine their location and navigate accordingly.

4. Steering control systems: AGVs employ various steering control systems, including differential speed control, steering wheel control, and a combination of both. These systems allow AGVs to manoeuvre effectively in different scenarios, whether transporting goods in tight spaces or towing trailers. Additionally, AGVs feature sophisticated traffic control systems to ensure smooth operation in environments with multiple vehicles. These systems utilise zone control, forward sensing control, or both to prevent collisions and optimise traffic flow.

Methods Used by AMR to Detect and Avoid Obstacles:

AMRs utilise a combination of sensors, including Lidar and cameras, to detect obstacles in their path. Through real-time data capture and processing, AMRs can identify obstacles and dynamically adjust their routes to avoid collisions. This capability reduces the need for human intervention and ensures uninterrupted operations in dynamic environments. Here’s how each method works:

1. Laser sensors: these sensors emit laser beams and measure the time it takes for the beams to reflect back, allowing the AMRs to identify obstacles and adjust their path accordingly.

2. Ultrasonic sensors: ultrasonic sensors emit high-frequency sound waves and measure the time it takes for the waves to bounce back. AMRs use these sensors to detect obstacles in their path and navigate around them.

3. Infrared sensors: infrared sensors detect the presence of objects based on their heat signature. AMRs may use infrared sensors to detect obstacles or humans in their path and avoid collisions.

Techniques Employed by AGV to Avoid Obstacles:

Traditional AGV robots may employ basic obstacle detection systems, but their ability to avoid obstacles is limited compared to AMRs. AGVs typically rely on predetermined paths and may require manual intervention to navigate around obstacles. Changes to the environment or unexpected obstructions can disrupt AGV operations, leading to potential delays and inefficiencies. That said, here is how each AGV technique for obstacle avoidance works:

1. Collision avoidance sensors: AGVs may use sensors such as sonar, optical sensors, or bumpers to detect obstacles in their path. Upon detecting an obstacle, the AGV can slow down, stop, or navigate around it to avoid collisions.

2. Zone control: AGV systems may implement zone control to prevent collisions in areas with multiple AGVs. Each AGV is assigned a specific zone, and the system ensures that AGVs do not enter occupied zones to prevent collisions.

3. Forward sensing control: AGVs may employ forward sensing control systems to detect obstacles directly in front of them. These systems use sensors to detect obstacles and adjust the AGV’s speed or direction to avoid collisions.

Flexibility and Adaptability

AMRs are designed to excel in dynamic environments where tasks may vary, and the facility’s layout can change. Thanks to their advanced navigation systems, feature-based localisation and path planning, AMRs can dynamically adjust their routes and tasks without requiring manual intervention. This adaptability enables AMRs to navigate obstacles seamlessly, reroute in response to changing conditions, and accommodate new tasks or workflows with minimal operational disruption.

AMRs can also incorporate interchangeable top modules like robotic arms, conveyors, or shelving modules, enabling AMRs to perform various tasks across different locations within a facility. For example, a MiR AMR robot equipped with the proper attachment can navigate the warehouse, fetch a specific product, and deliver it to the required assembly line, all without a guiding track.

Traditional AGVs, on the other hand, have limitations in adapting to new situations and dynamic environments. As discussed, AGVs rely on fixed routes and infrastructural landmarks for navigation, which makes them less flexible when facing changes in the facility layout or unexpected obstacles. Modifications to AGV routes or tasks often require manual reprogramming and infrastructural updates, leading to downtime and inefficiencies in operations. Additionally, AGVs may struggle to handle unexpected situations or obstacles, requiring human intervention to resolve issues and resume operations.

So, if your organisation is interested in flexibility and adaptability, AMRs hold a clear advantage over traditional AGVs. The advanced navigation and intelligent decision-making capabilities of AMRs allow them to thrive in dynamic environments, seamlessly adapting to changing tasks and layouts without manual intervention. On the other hand, AGVs are limited by their reliance on fixed routes and infrastructure, making them less adaptable to new situations and more prone to disruptions in operations. As industries evolve and demand greater flexibility in automated material handling systems, AMRs are the preferred choice for optimising productivity and efficiency in dynamic industrial environments.

How Safe Are AMRs & AGVs?

AGVs and AMRs are both known for their advanced safety features, making them suitable for use in various environments. These systems are equipped with a range of safety scanners, cameras, and sensors to ensure safe operation within the workspace. The key difference in how these robotic systems react to safety concerns lies in how they handle obstacles. AGVs typically stop and wait for obstacles to be cleared, whereas AMRs leverage artificial intelligence to navigate around obstacles autonomously.

How Costly Are AMRs & AGVs?

The cost of implementing AMRs and AGVs varies depending on several factors, including the fleet’s size, the system’s complexity, and the application’s specific requirements. That said, it’s best to consider the initial costs for each system alongside its operational costs, to determine the most cost-effective solution long-term.

Due to their advanced technology and autonomous navigation capabilities, AMRs typically require a higher initial investment than AGVs. The cost of AMRs includes not only the hardware itself but also the necessary software, sensors, and integration services. Customisation options and the ability to adapt to various tasks may also contribute to higher upfront costs for automated guided vehicle systems. However, it’s important to note that newer AGVs that do not require infrastructure changes may have a similar initial cost to AMRs.

AMRs may have lower operational costs than traditional AGVs due to their ease of deployment and maintenance. They can be quickly deployed into existing facilities without modifications, whereas traditional AGVs often require dedicated infrastructure such as magnetic strips, tape, or wires for navigation. This infrastructure can be costly to install and maintain, contributing to higher operational expenses for AGVs.

So, while AMRs and AGVs have their cost considerations, AMRs offer advantages in terms of ease of deployment, maintenance, and overall cost of ownership, particularly in dynamic warehouse environments.

AMRs and AGVs in Brief

AMRs operate autonomously, utilising onboard sensors and advanced algorithms to navigate dynamic environments with agility and adaptability. Their sophisticated perception, mapping, and decision-making systems enables them to react in real time to changes in their surroundings, without relying on external guidance.

AGVs, in contrast, adhere to predefined paths or tracks, offering reliability and efficiency in structured environments where tasks are repetitive and predictable. They are more straightforward in design and function, often requiring external control systems to direct their movements along fixed routes.

Selecting the right technology, whether an autonomous mobile robot or an automated guided vehicle, depends on your operation’s specific requirements and operational needs. AMRs offer flexibility, adaptability, and autonomy, making them ideal for dynamic environments with changing tasks and layouts. On the other hand, AGVs provide reliability and efficiency in structured environments with repetitive tasks and predictable workflows.

Ultimately, the choice between AMRs and AGVs depends on the specific requirements of the application and the desired outcomes. However, you don’t need to choose.

If you’re ready to optimise your warehouse operations with advanced robotics solutions, Autrix is your go-to partner for warehouse robotics expertise. Our team of specialists can work closely with you to develop customised solutions that boost efficiency and productivity in your warehouse – whether that be with AGVs, AMRs, robotic arms, smart gloves or the software to implement and integrate it all.

At Autrix, our automation design solutions process is tailored to your business’s needs. We invest time in visiting your warehouse and thoroughly getting to know each step of your operations. So, if you’re struggling to decide between these two solutions, contact us today, and we’ll design your robotics solution together.