What is an AGV Forklift? - Manufacturers - Ultimate Guide

Imagine a factory or warehouse managed by a robotic forklift system. No human intervention, no damages, no risk... everything on time, smooth and elegantly transported.

Well! you do not have to keep on dreaming, you only need agv forklifts.

Automated Forklift Trucks for Material Handling

Are you looking info about automated forklifts? You are in the right place! Take your time because in this article I provide tons of information about driverless forklifs.

My name is Alfredo Pastor... I really love them...   I've sold and installed dozens of forklift agv and I still remain impressed when I see them moving elegantly in warehouses.

They are becoming more reliable and efficient, in fact,  Automated Guided Vehicle market will reach more than $8B by 2030. Incredible!

This article answers these questions: What is an Automated Guided Forklift? How does an Automated Forklift work? How much do AGV Forklifts Cost? What are different types of types of AGV forklifts? How does a forklift agv navigate? Are automated forklift systems safe?

 What is the best? It's free... ????   

Download The AGV Forklift Guide

       

If you are looking for other types of mobile robots, check the  AGV Suppliers List with more than 100 vendors. The companies can be filtered by the type of robots (pallet jack , reach truck, etc)

Otherwise, you can also check this list with some of the Top Automated Forklift Manufacturers. 

Ok,now it's time to discover the driverless forklifts.  

             

What is an Automated Forklift Robot?  

An AGV forklift  also know as ALT is a Self-Driving computer or pc controlled forklift.  Simply put, driverless forklifts that autonomously follow a series of predetermined instructions to accomplish missions given by a central automatic forklift fleet controller.   

Just to be clear, an automated forklift is an automated guided vehicle (agv) with forks. This specific kind of AGV is inspired by the conventional human manned forklifts.

The forklift AGV is designed to provide both horizontal and vertical movement of the load. They can also be configured to stack loads in racks.  

 

Self-driving forklifts are also called automated guided forklifts (AGFs), driverless forklifts, robot/robotic lift trucks, or automated lift trucks. 

Check these models of agv forklifts: 

       

Forklift AGV Companies

The main material handling equipment suppliers offer their own automated forklift range: 

• SMARLOGY
• Toyota AGV Forklift
• CAT (with ROCLA)
• Linde
• Dematic AGV Forklifts
• Jungheinrich AGV
• etc, 

There are many other suppliers automating big brands forklift vehicles or producing their own agv vehicles like the AGVE Group. 

AGV Network counts on several resources to help you to find your agv forklift manufacturer. I suggest to check these links:

• AGV Manufacturers (a page listing more than 100 manufacturers)

• The AGV Network Showroom (you can find many mobile robots that can be filtered by type, payload, etc) 

    

How does a Driverless Forklift System Work?

The AGV Forklift vehicle is a part of a more complex system composed by the robot forklift trucks, the management software and some peripherals, etc.

I will try to briefly explain how does and AGV forklift sytem work even if there's a lot to know if we wish to go into detail.      

➡ The Automated Guided Forklift receives a mission from the central controller (tipically a PC or PLC). Let's say "bring the pallet X from the position A to the position B".  

➡ The robotic forklifts comunicate with the controller via wifi. 

➡ The AGV forklift navigates to reach the position A. The term "navigate", means that the vehicle is able to follow a route to reach the point A.  there are several agv navigation methods (Natural navigation, laser navigation, etc) that we'll see into detail in the following paragraphs.

➡ Automated Forklifts count on several agv sensors  that are used for navigation, safety, material handling, etc.

➡ Of course, safety is one of the main topics when we speak about agvs. Automated Forklifts have safety scanners and other devices that prevent them to run into obstacles (people or things). I suggest to check this article if you wish know further about AGV safety systems. 

➡ When the robotic forklift truck reaches the point A, it picks the material and safely transport it to the point B, always using the navigation and safety devices mentioned above.

➡ Once the mission is finished, the forklift informs the central system that the mission has been accomplished and that is ready for a new mission.

As anticipated, this is a simplification. In fact, there are many other topics to be understood like how does the agv coordinates the motion, safety and navigation, how does the central system assign a mission or how does the system manage the traffic. 

 Luckily, agvnetwork's articles cover most of these topics. 

How much does an AGV Forklift cost?

    

Let's say that it is quite complex to provide an accurate answer while there are many variables involved. 

Depending on the vehicle, an automated forklift cost could range from $45,000 to $200,000.

Basically, the price will depend on the type of automated forklift, the load capacity, lifting height, battery solution and some other factors. 

I suggest to check this article with further info about Robotic Forklift Costs.

    

Where are Automated Forklifts used?

The automated forklift trucks are increasingly becoming a must in manufacturing premises and, of course, it is one of the main warehouse automation technologies where operations are highly standardized, repetitive, and easily accomplished without need of  human intervention.

Forklift robots are widely used in warehouses for high rack management. Check this article to discover all the different material handling operations that an automated guided forklift can manage in a warehouse: What can Warehouse AGV do?

 

What are the main types automated forklift trucks?

      

The main types of robot forklift trucks  are:

• Pallet Jack AGV for floor to floor operations
• Pallet Stacker
• Counterbalanced Automated Guided Fork truck
• Straddle AGVs
• VNA- Very Narrow Aisles AGVs
• Reach Truck AGVs

 

Automated forklifts are inspired on traditional manual forklifts. We can find the same types of manned vehicles but working in self driving mode  

Check out the following articles for further information on each of these vehicles: 

• Types of Robotic Forklifts
• Automated Pallet Jack
• AGV Reach Truck
• Automated VNA

     

Are AGV Forklifts Safe? Standards?

Safety first! Safety is one of the main advantages of mobile robots compared to human manned vehicles:

Of course, Automated Forklifts are designed to priorize safety and are crammed with performant sensors to ensure safety. 

Moreover, the AGV Forklifts must comply with rigorous Safety Standards in the US is ANSI/ITSDF B56.5-2019  and in EU EN ISO 3691-4:2023.

 

      

Almost every automated forklift counts on non-contact sensors such as safety laser scanners. Otherwise the AGVs should run very slow.

If you want to know more about AGV Safety Constraints, Devices and Standards, do not miss this article: AGV Safety System. SAFETY IS KING.

Robot Forklifts can mount one, two, three, four, or more safety lasers depending on the project itself.

There is the Front Safety laser, to ensure safety conditions in “forward” operations, when AGV uses to travel at high speed

  

  There is a Safety Laser on the mast that targets diagonally to the floor. It is used to detect suspended loads.

   

 Picture from https://3dwarehouse.sketchup.com

  There is a Backward Safety Laser that is used while performing backward operations and unit load deposit or removal.

Picture from https://3dwarehouse.sketchup.com

There are other types of safety devices such bumpers, emergency push buttons and warning lights and sounds.

For example, rather than having a backward laser scanner (that costs around $3000), the AGV could have bumpers on the forks to stop the vehicle if something is contacted.  

Of course, in this case, AGV movement must be slow enough to avoid damages or harming someone.

 

Picture from https://3dwarehouse.sketchup.co 

 Safety is a complex and critical matter with many implications. The following whitepaper explains the main safety topics into detail. Remember to contact your supplier for specific details.  

Click here to download the whitepaper

   

How do Automated Forklifts Navigate? 

Automated forklifts move following  pre-programmed virtual routes or paths. These paths are defined using the vehicle’s navigation software. 95% of Forklift AGVS performs Laser Navigation.

For this reason AGV Forklift are commonly called LGV, so Laser Navigation Vehicles.

This same software used to define routes,  is also used to program specific actions, which happen at specific points (or nodes) along a route. For example: STOP, ACCELERATE, TURN LEFT, WAIT A PLC SIGNAL, PICK A PALLET, etc.

      Automated Forklift with Laser Navigation

Typically, each vehicle is equipped with a Navigation Laser (let’s call it Navigation Device) positioned on top of a mast that interacts with targets positioned in the AGV working area. This article explains Laser Guided Vehicle technology into detail.  

The AGV Navigation device sends rotating laser arrays all around 360 degrees.

These arrays impact in several reflector targets. Reflectors are reflective tapes or cylinders that send the laser array back to the laser navigation device.

Picture extract from the "Robotic Forklift Guide"     

Click here if you wish to download the Guide

The LGV acquires at least three of these laser array feedbacks allowing to calculate its positioning following very complex algorithms.

In warehouse aisle applications, mainly for VNAs,  it could be convenient to have inductive wire navigation for fast and tight tolerance operations.

 

Autonomous Forklift with Laser Navigation

As you probably know, there is a new trend in the AGV industry, it is called the “NATURAL NAVIGATION”. Many Automated forklift suppliers are implementing this technology.   

In this case, rather  than targeting reflectors, robots with natural navigation uses data received from the environment (walls, columns, etc). These data are acquired from one or more sensors (scanners, IMU, cameras, etc) to calculate its position. 

Forklifts with Natural navigation are also known as "AUTONOMOUS FORKLIFTS or AMR Forklifts" rather than Automated Forklifts.

Autonomous Forklifts do not need any kind of dedicated infrastructure to navigate (reflectors, wires, etc) and could even decide its own path even if not previously programmed. 

If you wish to have a deeper understanding about the differences between AGVs and AMRs, I suggest to download the following dedicated AGV Network's free Whitepaper.     

   

Click here to download the whitepaper

Do not miss this article explaining Natural  Navigation AGV into detail.

Related articles...to  learn more about Automated Forklifts AGV  Payback - Download our free Payback Calculator What is an Autonomous Forklift? - What is the difference compared to an automated forklift? What can Warehouse Robotic Forklifts do? AGV Pick Up Pallet Methods  Automated Reach Trucks - The king of the warehouse VNA AGV - List of Manufacturers and Characteristics of Very Narrow Aisle Robots Automated Pallet Jack . Discovering the Self Driving Pallet Jack