June 2020 Version 1.

4 reasons the right

controller is vital in AGV
manufacturing
The AGV controller is at the heart of the
AGV and a vital component for functionality,
reliability and safety. The controller has to
meet a number of specifications for these
requirements.

First, the controller needs to meet physical

specifications for the environment,
including shock resistance, humidity/dust
resistance, and compatibility with the
on-board power supply. Second, it must
also embed communications with sensors,
direction control, and management system.
Finally, it must comply with all safety
regulations. The controller needs to be
strong in industrial real-time control, data
handling and (wireless) communications.

Author: Jim ten Broeke

E-mail: jim.tenbroeke@advantech.com

www.advantech.eu
 June 2020 Version 1. 1

Table of Contents
Why is the controller so vital? ........................................................................................................... 1

1. Meet safety regulations ..................................................................................................... 1

2. Develop effective route guidance & control systems ........................................................ 2

3. Ensure product longevity ................................................................................................... 2

4. Maintain a competitive edge & business innovation ......................................................... 2

Next steps ......................................................................................................................................... 3

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What is an AGV?
The abbreviation AGV stands for Automated Guided Vehicle. This is the commonly used short
name for an industrial cart or vehicle that automatically — without driver or remote control—
moves products in an industrial environment. An AGV is engine driven or electromotor driven,
has an on-board controller (industrial PC or PLC) and navigates using marked long lines or
wires on the floor, radio waves, vision cameras, magnets, or lasers.

Why is the controller so vital?

In the first versions of AGVs, there was a programmable logic controller (PLC) for all in/outputs and control
functions. However, due to the demanding specifications regarding safety, control, visual inspection,
communications, and data handling, there has been an increase in the request for a powerful platform.

With functionalities such as predictive maintenance, vision, inter-communications and AI/machine learning, the
controller is more of a high-end edge computer. Today, most AGVs are controlled by an Industrial PC –
embedded, board, or modular.

This industrial PC needs to be able to perform in an industrial environmental. Not only handling the conditions,
such as vibration, temperature, and humidity, but also needs to meet requirements regarding the size, fanless
design, flash memory, resistance against EMC and industrial power supply. These are all important factors to
have a flawless, reliable and maintainable AGV.

This white paper addresses four reasons why having the right controller is essential for successful AGV
development.

1. Meet safety regulations

By European law EN1525, an AGV is never allowed to/or create an opportunity to harm people in any way.

In some cases, the AGVs are running in a separated and secured area where no unauthorized people are
allowed. Applying the safety regulations in this environment is not difficult. However, in most cases, the AGVs
operate in an area where people and other equipment are active. This requires an extensive number of technical
solutions in order to:
 Control the AGV in the most secured way
 Detect and avoid a collision when there are obstacles, to avoid damage or personal injuries as result.

The safety systems and the technologies behind them are complex. It is similar to autonomous driving, where
many things need to be sensed with a correcting action as result. The AGV manufacturer needs to integrate
safety scanners, cameras, contact sensors and warning equipment in order to have a safe AGV.

Also the interaction with other AGVs and equipment is important to integrate. This brings many challenges for the
AGV manufacturer.

The right controller is able to solve this challenge by supporting multiple I/O, protocols and GPU solutions.
Especially important is the compatibility of all embedded technologies (including third party products) and the life
cycle management in order to support the AGV during its lifecycle.

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 2. Develop effective route guidance & control systems
The controller needs to serve the multiple technologies that are controlling the AGV:
 Real-time control and I/O for the direct controlling of the motors, sensors and additional functionality,
such as loading/unloading, rotating the load, etc.
 Data collection, handling and communication
 Communication for the path/track control and other functionalities regarding the position and movement
of the AGV

There are multiple route guiding technologies for AGVs. There are options with fewer requirements, including
magnets or cable, but they also limit the functionality and flexibility of the AGV.

More common are wireless technologies such as radio and laser. The specifications are quite demanding to
embed these into the controlling platform. Think about additional boards and communication ports and protocols,
processing power, EMC protection, antenna technologies and radio reflections.

A platform that supports all of these aspects will make the difference in a smooth implementation followed by
flawless operation. In this area, it is also vital to consider compatibility management and the support of third party
hardware, software, drivers crucial.

3. Ensure product longevity

As an AGV manufacturer, you need to maintain a platform for a long time. There are two popular business models
for AGV manufacturers:
 Selling the product with a guarantee and service level agreement
 Leasing or renting AGVs

In both cases, the challenge is to maintain the platform including all third party equipment and communications
and software compatibility. This requires the close collaboration with a platform solution provider who is
specialized in this industrial platform support and management. The vendor needs to stay innovative, driven by
major technology developments (microprocessor evolutions, chipsets changes, wireless technologies etc).

4. Maintain a competitive edge & business innovation

There are many types and versions of AGVs for multiple applications. Think about warehouses/logistics,
manufacturing, container movement, pallet handling, medical applications like medicine and supplies pick and
movements in hospitals, pharmaceutical production, paper and printing applications etc.

Most AGV manufacturers are specialized in one area of application.

This requires domain knowledge and a range of AGVs covering all focus applications/projects. This results in the
need for a flexible or even modular platform. With the trend of applying predictive maintenance, AI/machine
learning and other technologies, the need for such a platform is even higher. The challenge for the AGV
manufacturer is to find and select a platform and supplier who can support their need for the long term.

In the AGV market, there are many players. The competition is strong and with new players entering the AGV
market. In addition to the product and technology challenges, AGV manufacturers also need to think about their
go-to-market strategy and product and services portfolio.

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Next steps
To summarize, the use of AGVs in multiple processes is increasing.

The complexity of the controls is increasing, driven by higher demands, regulations and available technologies.

AGV manufacturers are focused on the development of the AGV itself and its functionalities. Additional challenges
regarding the controls, data handling and communication limit the business in other ways.

Advantech has a broad range of products and technologies helping to address the AGV manufacturers’ needs. With the
range of experience Advantech has together with manufacturers and system integrators, Advantech and our partners
can help you with successful implementations.

Interested in learning more about hardware for AGVs?

Reach out to Advantech to start a conversation with one of our specialists.

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