Controls and software for AGVs and AMRs

How are automated guided vehicles (AGVs) and autonomous mobile robots (AMRs) controlled?

In order for AGVs or AMRs to fulfill the required orders, the interaction of different systems and technologies is necessary. Among other things, various software modules work together to navigate the vehicles efficiently and safely through the warehouse and complete transport tasks. A basic distinction is made here between:

1. The superior warehouse management system (WMS) – which creates the transport orders

2. The fleet manager – which coordinates the vehicles and decides which vehicle transports which order

3. The integrated vehicle software – which controls the vehicle itself and navigates from one point to another so that it can carry out the actual order 

AMR and AGV control using the fleet manager

A fleet controller is a central control unit that is used to coordinate and monitor multiple vehicles within an AGV/AMR system. Here are some of the main functions and features of a fleet controller:

• Vehicle coordination: The fleet controller monitors and coordinates the movements of all vehicles within the system. It plans the optimum routes for the vehicles in order to organize material transport efficiently and avoid bottlenecks. It also manages traffic control, especially at junctions, so that vehicles are not blocked.

• Order management: The controller receives and manages transport orders from various sources, such as a superordinate warehouse management system or manual entries. It prioritizes and distributes the orders to the available vehicles based on various criteria such as urgency, distance and available capacity.

• Charging management: It ensures that the vehicle batteries are recharged in good time. Intelligent algorithms decide which vehicles are temporarily taken out of the work process and sent to the charging station. This is all done fully automatically, ensuring that all batteries are charged regularly and carefully. By maintaining and sufficiently balancing the battery cells, the service life of these important modules is extended and running costs are kept low.

• Communication: The fleet controller acts as a central communication interface between the vehicles and other systems or devices. It communicates with warehouse management systems, production planning systems and other control units in order to exchange real-time data and optimize the material flow.

• Error recognition and diagnosis: The controller continuously monitors the operating state of the vehicles and automatically recognizes potential malfunctions or errors. It can collect and analyze diagnostic data in order to identify problems at an early stage and initiate maintenance measures before downtimes occur.

• Performance analysis and optimization: By collecting operational data and performance statistics, the fleet controller supports the continuous optimization of the system. It identifies bottlenecks and inefficient processes to increase the overall performance of the system. It can collect diagnostic data to identify problems at an early stage, initiate maintenance measures and thus minimize downtimes.

Overall, a fleet controller enables efficient and reliable control of material transport in industrial environments, resulting in improved productivity, flexibility and cost optimization.

AMR and AGV software: Intelligent vehicle control

In order for the vehicles to be able to act and implement the commands of the guidance system, the vehicles require their own control system. This controls the basic movements of the vehicle, including acceleration, braking, turning and stopping. Different sensors – e.g. LiDAR or cameras – detect obstacles, which are processed by the vehicle software in real time. This ensures that the planned route is followed.

ARCOS: Control vehicles intelligently

DS Automotion equips all of its vehicles with the ARCOS vehicle software. This enables them to make their own decisions and to do so based on the respective situation. This increases safety for employees as the vehicle recognizes them immediately and stops. Obstacles, however, can be circumnavigated and the equipment protected. 

Advantages and disadvantages of ARCOS:

• Compatible with VDA 5050: ARCOS is compatible with standardized interfaces. This means that all vehicles can be connected not only to NAVIOS, but also to other VDA-compatible fleet controllers.

• Navigation and localization: ARCOS navigates virtually or autonomously and can be localized either contour-based or using lasers or magnetic points.

• Safety for staff and objects: To guarantee safety in mixed operation, we work with state-of-the-art safety components. These also protect objects that are in the way.

• Plannable autonomy: ARCOS offers the possibility to define the autonomy of the vehicles and thus maintain efficiency.

More information on the Vehicle software ARCOS from DS Automotion can be found on the website.

VDA 5050: A standard for controlling AGVs

The market offers a large number of automated guided vehicles for a wide range of applications from numerous providers. To ensure that customers really have the choice to use the optimum vehicle and combine it with other vehicles, independence from the manufacturer’s own fleet management software must be guaranteed.

VDA 5050 is a standardized interface for the standardized communication between different AGVs and a fleet controller. Vehicles with this interface can be integrated into an overall system – whether they are physically track-bound or freely navigating. 

The standard, which stems from a collaboration between the German Association of the Automotive Industry (VDA) and the VDMA Association of Material Handling and Intralogistics (Verband Deutscher Maschinen- und Anlagenbau e.V.), is to be globally rolled out and will make future-proof purchase decisions independent of suppliers.

All DS Automotion vehicles are equipped with the VDA 5050 interface.

Plannable autonomy: Flexible freedom for vehicles

Highly developed vehicle software has only recently made it possible to use AGVs and AMRs in parallel and thus get the best of both worlds. 

The vehicles navigate on a shared work surface both (virtually) track-guided and – in so-called “autonomous zones” – autonomously. 

Autonomous functions, such as autonomous obstacle avoidance, increase flexibility, while collision-free, congestion-free and predictably planned fixed tracks and sequences optimize planning and efficiency.

The aim of “plannable autonomy” is to prevent autonomous functions where they could have a detrimental effect and to make targeted use of them in areas where they are advantageous. 

More information on the Plannable Autonomy from DS Automotion can be found on the website.