SOLUTION

  • Natural Navigation

    Natural Navigation uses measurements from a laser range sensor to recognize landmarks such as walls and other surfaces. The vehicle’s position is continuously updated based on encoder data that tracks its movement. Additionally, the position is refined using measurements from walls and other objects. The navigation system always remains active.

    Navigation System
    Laser Scanner
    • Detects walls and other surfaces
    • SICK S200 and S3000 are available

  • Laser Navigation

    Laser Navigation utilizes reflector-based landmark localization to enable autonomous vehicle guidance. The system continuously updates the vehicle’s position using data from fixed reflectors. Positional corrections are made through triangulation of laser measurements to known reflector coordinates. The navigation algorithm always remains active to ensure real-time positional accuracy and reliability.

    Navigation System
    Laser Scanner
    • Detects reflections
    • Determines angle and distance to reflectors
    Reflectors
    • Mounted on walls and machines
    • Flat or Cylindrical

  • Barcode Navigation

    Barcode Navigation employs floor-mounted barcodes to enable accurate positioning in open environments where structural landmarks (e.g., walls) are unavailable, limiting the use of other navigation systems. Its modular and easy-to-install design provides a flexible alternative to fixed infrastructure solutions, such as spot navigation systems that rely on embedded magnetic markers drilled into the floor.

    Barcode Sensor
    Barcode Sensor
    • Detects position marker
    • Configured by camera and illumination unit
    Position Marker
    • Installed on the floor
    • Data matrix tag (ID, coordinates)

  • Magnetic Tape Navigation

    Magnetic Tape Navigation is based on free guidance using landmarks such as magnetic tape and distance markers. The vehicle’s position is continuously updated by referencing these landmarks. Additionally, encoder data is used to track vehicle movement and enhance position accuracy. Position corrections are made through measurements to the magnetic tape and distance markers. The navigation always remains active.

    Navigation System
    Guide Sensor
    • Detects magnetic tape
    Magnetic Tape
    • Installed on(underneath) the floor
    Inductive Sensor
    • Detects distance markers

  • Spot Navigation

    Spot Navigation is based on free vehicle guidance using fixed landmarks, specifically magnets embedded in the floor. The vehicle’s position is continuously updated by referencing these landmarks. Encoder data is simultaneously used to track vehicle movement and ensure reliable position estimation. Position updates are performed through measurements to the spot magnets, and the navigation system remains active at all times.

    Navigation System
    Guide Sensor
    • Detects spot magnets
    Spot Magnet
    • Installed on(under) the floor

  • Inductive Wire Navigation

    Inductive Wire Navigation operates on free guidance principles using landmarks such as inductive wires and distance markers. The vehicle’s position is continuously updated by referencing these landmarks. Encoder data is used in parallel to track vehicle movement and support accurate position calculation. Position updates are achieved through measurements taken relative to the inductive wires and distance markers, ensuring the navigation system remains active at all times.

    Navigation System
    Inductive Antenna
    • Detects wires
    Wire
    • Installed underneath the floor
    Inductive Sensor
    • Detects distance markers

  • Range Navigation

    Range Navigation utilizes data from the Laser Range Scanner to identify environmental landmarks such as walls and flat surfaces. This method is particularly effective in structured environments like corridors, where consistent reflective surfaces are present. The vehicle’s position is continuously updated using measurements from the scanner, supported by encoder data to track movement. Accurate localization is maintained through consistent referencing of walls and other planar surfaces, ensuring the navigation system remains active at all times.

    Navigation System
    Laser Range Scanner
    • Measures surrounding walls
    • Measures surrounding flat surfaces

  • Multi Navigation

    Multi Navigation enables a vehicle to dynamically switch between different navigation methods during operation. This approach combines the flexibility of reflector-based navigation with alternative navigation techniques, making it particularly advantageous in factory environments where installing reflectors may not be feasible in certain zones.

    Navigation System
    Combine Laser or Range with one of the other types
    • Switch between methods at any time or location
    Environments with limited sight to reflectors
    • Pallet aisles
    • Roll Storages

  • AGV/AMR Safety System

    AGV system should be designed with consideration of safety as the first priority.RUSSELL ROBOTICS provides AGV system comprising safety functions into both AGV and AGV control system to minimize potential hazards to operating personnel, including protection of fixed assets or mobile assets.

    • AGV Control System handles AGV to perform proper action when an abnormal operating condition is reported from any system components or other systems interfaced with.
    • Vehicle application will be defined in accordance with safety requirements then vehicle controller protects itself from unexpected accident.
    • Vehicle should stop if control system is not working as expected.
    • AGV should be equipped with sensors and emergency buttons so that the vehicle will stop if anything is too close to the vehicle while it is driving.

  • Vehicle Controller Supervising

    All primary AGV components are connected via an internal network, with the vehicle controller acting as the master node. The controller is responsible for initializing, configuring, and supervising all devices connected to the network. It operates in two distinct states: Normal State and Safe State. Upon system startup, the controller defaults to Normal State, executing the full range of AGV functionalities as defined.

    If a functional error is detected—either by a device on the network or by the controller itself—the master logs the fault using a system event code and transitions into Safe State. The Safe State is a passive operational mode that allows only diagnostic tasks to be performed, ensuring system safety.

    Key Characteristics of Safe State: :
    • All OK status remains false at all times.
    • Only those devices explicitly marked as active in Safe State are initialized and placed into operational mode on the control network.
    • The vehicle controller does not autonomously exit Safe State; external intervention is required.

  • Obstacle Detection Sensor

    To prevent collisions, each vehicle is equipped with at least one programmable obstacle detection sensor. These sensors operate with two simultaneous protective zones: an outer zone and an inner zone. If an object enters the outer zone, the vehicle reduces speed to a preset limit. If the object breaches the inner zone, the vehicle comes to an immediate stop.

    Typically, laser-based obstacle detection sensors have a horizontal field of view. To ensure comprehensive coverage, multiple sensors can be mounted at different heights on the same side of the vehicle, as illustrated. This setup enables protection against collisions in both horizontal and vertical directions.

  • Safety Bumper

    The safety bumper is mounted around the vehicle chassis to protect both personnel and the vehicle from injuries and damage caused by collisions. As a critical component of the AGV safety circuit, it remains operational even when the AGV is in an uncontrollable state. When external pressure is applied, the normally open circuit inside the bumper closes, sending a signal to the controller. Upon activation, the safety bumper functions as an emergency stop mechanism by cutting power to the AGV. It is available in various shapes and sizes to accommodate different types of vehicles.

    Type of Safety Bumper & Safety Edge
    Various types of safety bumpers and safety edges can be selected based on vehicle design and specific safety requirements.

  • Guidance Monitoring

    To ensure the vehicle follows the AGV path as intended, a safety zone must be defined within the vehicle application. This safety zone is typically established using a rectangular area and an angular limit. If the vehicle's reference point falls outside this rectangle or if its orientation relative to the AGV path exceeds the defined angle threshold, it is considered outside the safety zone. When this occurs, the vehicle is no longer permitted to operate in automatic mode. Instead, it will decelerate and come to a stop using the emergency stop slope.

    • Safety Angle
      Allowable tollerance ralative to angle of AGV Path.
    • Safety Zone X
      Allowable tollerance ralative to X coordinate of AGV Path.
    • Safety Zone Y
      Allowable tollerance ralative to Y coordinate of AGV Path.

  • Safety Devices

    It is recommended to install instruments related to safety functions on the AGV. Since these devices are programmable, their functions can be customized through a PLC program integrated into the vehicle application, allowing optimization for specific site conditions. The following devices are typically considered essential and are commonly installed on AGVs.

    Necessary Safety Devices

    • Laser Bumper
      Since AGV is moving around the factory always, programmable obstacle detecting laser sensors should be installed on the AGV as basic specification to prevent collision between AGV and person or other equipments.
    • Emergency Switch
      Emergency buttons are installed as many as required on the AGV body for safety.
      Whenevr any emergency stop button is pushed, the vehicle will stop immediately and remains stopped until the button is manually reset.
    • Horn
      To warn the position of AGV to around personnel, horn is installed on the AGV and operating always.
      Depending on operating condition, pre-defined melody is boomed out.
    • Beacon
      To notify what operation mode is proceeding to around personnel, beacon is installed on the AGV and operating always. Depending on the operation and control mode, pre-defined color beacon is turned on of flashing.

  • System Configuration

    RUSSELL ROBOTICS delivers a comprehensive AGV system that integrates all aspects of automated material handling, incorporating both hardware (HW) and software (SW) components. The solution supports not only seamless AGV movement between stations but also enables reliable interfacing with external systems or equipment. The AGV system is typically configured as illustrated in the figure below; however, the configuration is flexible and can be adapted based on specific system requirements.

  • ACS Introduction

    The AGV Control System (ACS) comprises two main components: Stationary Software and the AGV System Operating Program. The Stationary Software forms the foundational layer that supports transportation tasks within the AGV system, operating in the background. In contrast, the AGV System Operating Program facilitates integration with other systems and components, offering a wide range of user-friendly interface functions for effective control and monitoring of the AGV system.

  • ACS User Interface

    Generally, HMI is configured as shown below figure. However required functions can be added by request of customer.

    • A. Main Menu Bar
      Positioned at the left-top position on the screen, is configured with
      main menu buttons. Once a button was tapped, corresponding page or
      window would be appeared then user can confirm required information
      for operating system such as work history or alarm log file.
      Also a menu for AGV manual control is provided.
    • B. System Monitoring
      Current AGV position and status is updated in real time on the screen and layout information inculding stations, AGV path and traffic control is displayed graphically.
    • C. Interface Information
      As communication and interface status is important for AGV system, operator can confirm required information through color of lamp.
    • D. AGV Status Information
      Displays error or warning message relevant to generated alarm.
    • E. Order Information
      Provides allocated order and current AGV driving information in detail.

  • Redundant System

    It is recommended that the AGV control system be configured with redundancy to ensure continued operation during emergency situations, such as system shutdowns. To implement this redundant configuration, the AGV system includes both a primary control unit and a backup control unit. Under normal conditions, the primary control system manages the AGV and communicates essential data with key system components. This data is simultaneously shared with the backup control system in real time, which mirrors the primary system’s data. If the primary control system fails due to a malfunction, control is automatically transferred to the backup system.
    Because the backup already holds the same data, the AGV can continue operating without interruption. This transfer of control occurs automatically, as the backup system continuously monitors the status of the primary system through a confirmation (OK) message.

  • Power Supply Plan

    As AGVs are powered by batteries, an optimized battery charging plan is critical for the reliability and uptime of AGV/AMR systems. Developing such a plan requires careful consideration of battery type, capacity, power consumption rate, and the AGV's operational profile. Typically, opportunity charging or battery exchange methods are adopted based on the system’s operational demands.

    • Opportunity Charging
      When the AGV system operates at a lower duty cycle, opportunity charging is an efficient method. Charging stations are strategically placed along the AGV route or at the home position, allowing the vehicle to top up the battery during idle moments or between transport cycles, ensuring sufficient charge for continued operation.
    • Automatic Exchanging
      For high-throughput operations requiring 24/7 performance, automatic battery exchange is preferred. This method enables quick replacement of depleted batteries with fully charged ones via a dedicated automated exchanger, eliminating the need for manual intervention and minimizing downtime.
    • Manual Exchanging
      Where cost-effectiveness is a priority, manual battery exchange is recommended. In such cases, battery capacity should be planned to support at least one full operational shift, ensuring the AGV can function without interruptions before the battery is manually replaced.

  • Opportunity Charging

    When the battery level falls below a predefined threshold, or after completing a successful transport cycle, the AGV proceeds to the charging station to recharge its internal battery sufficiently. This method is also effective when one shift is inactive during the day, providing an ideal window for recharging.

    Configuration & Features
    • Battery charger with charing booth-bar is installed beside charging station.
    • Battery charger is required as many as numbers of vehicles or charging station.
    • Required charging time should be considered.
      • - Lithium-Polymer(Ion) Battery : 1C
      • - Lead-Acid Battery : 0.2C
    • Battery capacity should be calcuated with consideration of charging cycle.
    • Any battery type can be applied with.

  • Battery Auto-Exchanging

    In case that there is a vehicle in low battery state in the system, Control System orders it move to the battery exchanging station to replace internal lowered battery to full charged one by itself. As the AGV is able to be in the system except a few minutes per every battery exchanging cycle, system can be operated with higher operation rate.

    Configuration & Features
    • Specially designed battery exchanger is required.
    • Cells in battery exchanger are required as many as vehicles in the system.
    • Batteries are required doubly.
    • Enough space should be secured to install equipment and AGV drives in and out of the station.
    • A secondary power supply plan need to be considered since power supply is discontinued while battery exchanging procedures are going on.
    • Any battery type can be applied with.

  • Battery Manual Exchanging

    If there is an AGV in low battery state in the system, Control System doesn't allocate any good transport order to it and it drives to the designated place and waits for battery manual exchagnig at there. once battery exchanging was completed manually and AGV was recovered from low battery status, then AGV is allowed to be in the system by Control System.

    Configuration & Features
    • Battery transport cart is required separately.
    • The cart is designed to be optimized for docking with battery cell on the AGV.
    • Batteries are required doubly.
    • Power connection and disconnection needs to be done directly by operator as well.
    • Reasonable construction cost than Auto-Exchanging system but not Opprotunity Charging system.
    • Any battery type can be applied with.

  • Contactless Power System

    IPT(Inductive Power Transfer) System supplies the required power to the AGV by non-contact method based on technology of high-frequency transformation. Also wire installed under floor can be used to support vehicle guidance as introduced in Inductive Wire Navigation system by interface with specialized guide sensor on the vehicle.

    Configuration & Features
    • Supports to maintain high system operation rate.
    • It costs much to build up non-contact power supply system relative to others.
    • Suitable for layout having short travel distance or closed path like circle shape.
    • The more vehicles, the more advantageous.
    • All guidance method can be applied.
    • More flexible when auxiliary battery is used together with.

  • NDC

    The NDC platform, developed and provided by Kollmorgen, is a versatile, fully integrated, and scalable control system designed to support a wide range of Autonomus Guided Vehicles (AGVs) from compact, simple units to large-scale, complex systems. As a recognized member of the Kollmorgen Partner Group, RUSSELL ROBOTICS not only supplies AGV systems built on the NDC architecture but also delivers comprehensive training and support services for the deployment and operation of NDC solutions.

    NDC works with all established navigation technologies. Advanced navigation technology Natural navigation introduced above video, is a concept for navigation in the existing environment. By using Natural navigation there is no need to install reflectors and markers, leading to lower commissioning costs.

    NDC gives you access to a set of effcient design and service tools. The design tools helps you outline all kinds of layouts as well as system and vehicle applications. Service tools include vehicle maintenance (e.g. fault-training, statistics and software downloads) and automatic surveying of the environment.

    NDC hardware consists of powerful and reliable components in a number of areas. All components are designed for tough environments where vibrations, dust, moisture and temperature vibrations are all part of daily life.

    End-users require high uptime, efficient daily operations and applications that are easy to change.
    we help you meet these demands with NDC services. Our service portfolio consists of training service, support service and consulting service.

  • PLC

    RUSSELL ROBOTICS has supplied various types of AGVs that operate using PLC-based control solutions. A key advantage of PLC systems is that they offer maintenance personnel a user-friendly and easily accessible control environment. When used as a vehicle controller, the PLC manages all driving functions by interfacing with navigation sensors and oversees all critical components related to safety and load handling.

  • ACU 1000 Series

    The ACU 1000 Series, developed by RUSSELL ROBOTICS, offers a specialized controller designed exclusively for driving control. It supports all floor-based guidance methods and accommodates various driving patterns along with other solutions. For complex load handling or additional functions, integration with an auxiliary controller such as a PLC can be used. An integrated design tool is also provided, enabling easy vehicle application development and offering diagnostic functionalities.

    • VEHICLE CONTROLLER
    • SPECIFICATION
      • Floor based guidance
      • Supports all vehicle types
      • Supports all driving patterns
      • Max. 48m/min speed
      • ± 10mm stop tolerance
      • Programmable laser bumper
      • Manual control device
      • Graphical operator interface
    • FEATURES
      • 32-bit RISC processor
      • Linux operating system
      • RS - 232 · 422 · CANbus
      • All OK relay
      • SD card reader
      • LED Indicators
      • Protection for reverse polarity
      • Protection for over voltage

  • Forward & Reverse

    All AGV types are capable of bidirectional movement, allowing both forward and reverse navigation on straight paths as well as curved trajectories. When designing the AGV layout, it is important to note that Steer Drive (SD) vehicles behave similarly to conventional automobiles on curves. As a result, SD vehicles may experience ‘overshoot’ while maneuvering curves to maintain their reference point aligned with the designed path. In contrast, QUAD drive vehicles typically avoid such overshooting, as their reference point is usually aligned with the center line, allowing them to track curves more precisely.

  • Crabwise Drive

    Crab segments are designed to link parallel drive paths while utilizing minimal space. During a crabwise segment, the vehicle maintains its initial orientation from the beginning to the end of the segment.

  • Differential Drive

    On a 'Diff' segment the vehicle steers by speeding up one wheel and slowing-down the other, the vehicle will always turn towards the side of the slower traveling wheel. Notice that the drive wheels never change angle while the vehicle is moving through the curves. Also this driving mechanism used when AGV moves to the side as wheel is being rotated 90 degrees .

  • Rotation

    It may be necessary to rotate the vehicle in the layout. In such cases a rotation segment is used. If the vehicle arrived at the rotation point, it rotates to the desired angle. The rotation will be around the reference point of the vehicle .