Analysis of the application principle, advantages and development trend of automatic guided vehicles (AGVs) in automated stereoscopic warehouses

1. Application principle: flexible mobile intelligent handling unit

AGV (automatic guided vehicle) realizes the automated transportation of goods in automated stereoscopic warehouses through "navigation positioning-path planning-task execution". Its core principles are as follows:

1. Navigation system: path tracking is achieved through a variety of technologies:

◦ QR code navigation: laying QR codes on the ground, AGV recognizes and locates through cameras;

◦ Laser navigation: using laser radar to scan reflectors in the environment, build maps and locate;

◦ Visual navigation: combining cameras with AI algorithms to identify ground signs or natural environment features;

◦ Inertial navigation: recording motion trajectories through gyroscopes and encoders, suitable for short-distance scenarios.

2. Control system: receiving WMS (warehouse management system) instructions, interacting with the dispatching system through wireless communications (such as 5G, WiFi), dynamically adjusting the driving path, and avoiding obstacles.

3. Actuator: Carry goods by traction, carrying, forking, etc. Some AGVs are equipped with robotic arms, which can directly complete shelf replenishment or picking.

2. Core advantages: flexible, intelligent, and flexible storage "nerve endings"

1. High flexibility to adapt to complex scenarios

◦ No fixed track is required, and the path can be adjusted according to the warehouse layout. It is especially suitable for stereoscopic warehouses with multiple lanes and multiple entrances and exits, reducing the transformation cost by 30% compared with traditional conveyor lines.

◦ Support "plug and play", and new AGVs can be quickly connected to the system to adapt to business volume fluctuations (such as temporary addition of equipment during e-commerce promotions).

2. Unmanned and efficient collaboration

◦ 24-hour continuous operation, no manual driving required, reducing labor costs; multiple AGVs can work together through cluster scheduling algorithms (such as ant colony algorithms) to avoid congestion and improve overall efficiency. For example, hundreds of AGVs in the Cainiao smart warehouse work synchronously, and the sorting efficiency is 10 times that of manual labor.

3. Optimization of space utilization and safety

◦ The vehicle body is compact in size (width 0.8-1.5 meters), which can flexibly shuttle in narrow lanes and reduce channel occupancy; equipped with laser radar, ultrasonic sensors, etc., it can detect obstacles in real time and brake urgently, and the collision accident rate is close to zero.

4. Data-driven intelligent decision-making

◦ Optimize scheduling strategies by collecting operation data (such as energy consumption and path time); real-time linkage with stackers, conveyor lines and other equipment, such as AGV automatically docking with stackers to complete cargo docking, reducing the time spent in the intermediate links.

III. Development trend: Intelligent, lightweight and ecological technological breakthroughs

1. Navigation and positioning technology upgrade

◦ Fusion navigation: Combining laser, vision and inertial navigation, the positioning accuracy in complex environments is improved to ±10 mm, which can adapt to the dynamic changes of unmanned warehouses (such as temporary stacking of goods).

◦ Navigation without logo: Through SLAM (simultaneous localization and mapping) technology, there is no need to lay QR codes or reflective plates, which reduces deployment costs and is suitable for the transformation of old warehouses.

2. High-speed and lightweight design

◦ The running speed is increased from the traditional 1-2 m/s to 3-5 m/s. With the lightweight body (made of carbon fiber), the load efficiency ratio (load/weight) is increased by 50%, which is suitable for the transportation of light and small items such as electronic components and medicines.

3. Innovation of energy and charging mode

◦ Application of solid-state batteries: The battery life is extended to 8-10 hours, and the charging efficiency is increased by 3 times. Some AGVs support automatic charging pile docking to achieve "charge and go";

◦ Wireless charging technology: Charging through electromagnetic induction at fixed stops to reduce mechanical contact loss, suitable for clean scenes such as food and medicine.

4. Deep integration of AI and edge computing

◦ Autonomous decision-making ability: Equipped with edge computing chips, local processing of sensor data (such as identification of damaged goods), the response speed is shortened from seconds to milliseconds;

◦ Predictive maintenance: Predict failures of motors, batteries and other components through vibration sensors and temperature sensors, arrange maintenance in advance, and reduce downtime by 40%.

5. Multi-device collaboration and ecological interconnection

◦ Cross-brand compatibility: Through standardized interfaces (such as the VDA 5050 protocol developed by the AGV Alliance), seamless docking between AGVs from different manufacturers and stereoscopic warehouse systems is achieved;

◦ Cloud-edge collaboration: The cloud platform monitors the operating status of hundreds of AGVs in real time and dynamically adjusts task allocation, such as automatically dispatching idle equipment to support high-traffic areas during the Double Eleven period.

IV. Expansion of typical application scenarios

• E-commerce warehousing: For example, Amazon Kiva robots (AGVs) are combined with stereoscopic warehouses to achieve "goods to people" picking, and picking efficiency is increased by 50%;

• Automobile manufacturing: AGVs automatically distribute heavy parts such as engines and tires in the chassis assembly process, with a positioning accuracy of ±5 mm, which is suitable for the high-precision docking requirements of the production line;

• Medical cold chain: Explosion-proof AGVs transport vaccines in a -25℃ environment, and dock with stereoscopic warehouses through a temperature control system, and the temperature and humidity data throughout the process are traceable.

AGV is evolving from a single handling tool to an "intelligent logistics node". Its technological breakthroughs not only enhance the flexible operating capabilities of automated warehouses, but also promote the transformation of warehousing models from "fixed assembly lines" to "dynamic flexible networks", becoming the core link between intelligent manufacturing and smart logistics.

Zita Jian

25th, June 2025