The automotive industry is one of the most automated sectors in the world, and the way its intralogistics processes have evolved is defined by a series of phases: from the use of manual forklift trucks to the deployment of automated guided vehicles (AGVs) and then to the introduction of autonomous mobile robots (AMR).
These transitions did not lead to one technology being replaced by another, but rather they have taken the form of an evolutionary process towards smarter, more flexible and more cost-effective systems that enable more efficient management of the logistics processes on a production line. Companies that operate in the automotive sector are defined by high production volumes and tight delivery schedules, and so they stand to benefit most from this type of transformation.
Automation is not only necessary, but also a strategy that guarantees competitiveness and sustainability in a constantly evolving industry. Aritex is leading this change, offering comprehensive solutions that optimise internal logistics for production plants in the automotive sector.
This article goes deeper into the reasons behind technological innovation in automotive intralogistics management and the benefits and challenges involved.
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Evolving in line with manufacturers’ pain points
Two decades ago, AGV implementation emerged as a direct response to the structural costs associated with labour, human error and accidents. By standardising closed and automated routes with wire and laser guidance, AGVs improved efficiency and safety in production processes for original equipment manufacturers (OEMs) and their suppliers (Tier 1 and Tier 2).
However, Tier 1, Tier 2 and OEMs now operate in different contexts and have different needs. This has led to a new technological ecosystem in which conditions for OEMs are more demanding, which imposes the need for more independent and autonomous automated solutions. What OEMs seek now are ways to overcome closed circuits and frequent stops caused by rigid AGV routes; the issue being that an AGV may be automated, but it is not so smart.
Most older AGVs nowadays are expensive to maintain as many units are needed in each logistics automation project. Furthermore, the complex scheduling and fixed infrastructure for these systems generate a black box. In other words, they make companies depend on automated vehicle suppliers, thus adding new costs every time they want to implement new routes.
Technological differences between an AMR and an AGV
Although AGVs and AMRs are very similar in terms of hardware, one of their main differences can be seen in a key component: the programmable logic controller (PLC). In the case of AGVs, this device consists of a non-volatile electronic memory system that stores instructions for the machine to execute. It is the brain that guides the automated process, but its commands are not open to interpretation and so instructions are followed to the letter with no autonomy. By way of contrast, AMRs work directly with PCs and more powerful software to acquire more data, process it faster and thus be able to react better to processes.
The simplicity and adaptability of AMRs make them an excellent answer to the limitations of AGVs. They do not require fixed infrastructures, but function according to virtual routes calculated via zone-based or graph-based programming.
This approach enables AMRs to manage their own navigation and make their own decisions in dynamic environments without the need for each route to be manually programmed. Each network is made up of nodes, which are specific points on a map or environment where decisions need to be made (key locations such as charging stations, drop-off points or intersections); and edges, which are connections between nodes that stand for possible displacement routes. Such networks enable an AMR to move anywhere in the area, thus preventing closed loops and providing greater flexibility.
Unlike the systems used for AGVs, AMR graphs allow the robot to make automatic detours to alternative routes in certain situations such as when an unforeseen obstacle blocks the way. They can also prioritise traffic when there are several AMRs in the same area. Aritex has had the experience of observing a fleet of just two AMRs doing the work of four robots for the same tasks and meeting all the delivery targets in a client’s facility, since AMR technology allows for more tasks to be simply and effectively shared amongst the same fleet, without imposing a single route, as is the case with AGVs.
The independence gained from the environmental recognition technology of an AMR is higher than it is for an AGV, while flexible programming enables smaller fleets to be used, with the added benefit of lower labour costs now that workers no longer need to watch over machinery. AMRs are so independent that they can go to the charging stations on demand without human assistance, so the OPEX savings are obvious.
So, is it time to say goodbye to AGVs?
The fact is that AGVs are not likely to disappear, and the technologies used in AGVs are also advancing to make them more robust. We are seeing high levels of modernisation to their software to enable them to cope with the competition from AMRs. This evolution is partly driven by companies deciding to optimise and maintain AGV technologies that were acquired in the past rather than purchasing new AMRs. However, the complexities involved in programming them and their dependence on fixed infrastructures still makes companies over-dependent on the automation vendor.
In this regard, it should be remembered that universal solutions in the automotive sector are rare and what may be a limitation for some is an advantage for others. For example, there are companies that prefer the rigidity of AGVs, since AMRs may cause unexpected changes of pace in the workflow or accidents caused by ignorance of a robot’s route.
Competition between AMRs: the differential power of a fleet manager
The fleet manager is the software in charge of interpreting the movement graphs in order to orchestrate the AMRs. With different degrees of sophistication, fleet managers are a distinguishing factor amongst automated robot manufacturers, and they enable product ranges and prices to be diversified. The role of logistics automation integrators such as Aritex is to listen to a customer’s needs and then offer the most adequate product for their use case and aims. Optimal results are achieved when performance is aligned with needs.
An even higher level of management is offered by the IMP (Intralogistic Management Platform). An IMP enables an AMR fleet to be managed and coordinated regardless of the brand or supplier. Communication protocols such as VDA 5050 allows AMRs from different manufacturers to “talk” to each other and to the host system.
The IMP receives work orders, e.g. transporting parts from one point to another, and distributes them among the available AMRs based on criteria such as AMR type, location and the robot’s proximity to the pick-up point, current AMR workload and battery status. This ensures that the task is completed as efficiently as possible, reducing waiting times and lowering costs. This platform is a strategic element that maximises efficiency and competitiveness in automated environments.
Trust in mobile robotics as a key for change
At Aritex, we work with the best AMR manufacturers such as KUKA and MiR, to adapt your project to what you really need. There is also the added guarantee of growing your project in the future thanks to the scalability characteristic of AMR systems.
We know only too well that technological changes such as automation can create mistrust, because they are used to replace human labour. Normally, this type of strategy is used to relocate human effort to other areas, where the added value simply cannot be replaced by a machine.
Knowledge and skills for interacting with AMRs help to build confidence in this technology, which is why our team also takes charge of training our clients’ operators. Projects always include basic training. We also run more advanced training courses for companies interested in expanding their interaction with automated robots and taking advantage of its simple programming to generate new layouts and processes.
Furthermore, as a global leader in production line automation, Aritex is working towards intralogistics transformation, setting new standards in automation and contributing to a smarter, safer and more sustainable industrial future. Our mission amidst these changes in automotive companies is to develop and deliver advanced mobile robotics solutions that optimise operational efficiency, improve safety and promote sustainability in vehicle manufacture and other industries through continuous innovation and collaboration with our customers and technology partners.
