Simulation of an automated guided vehicle system (AGV): How do you calculate the number of mobile transport robots required?

An automated guided vehicle system consists of multiple mobile transport robots (AGV). But how many AGVs are needed for your task?

Depending on the size and complexity of your AGV project, we address this question through a three-step process. Together with you, we determine the exact number of mobile robots. The result is a simulation of your AGV system.

Step 1: Calculator for a rough estimate

To initially gauge the scale of your automated guided vehicle system, we utilize a specialized calculation tool. In this tool, we capture the basic parameters to estimate the complexity of your project.

For this, we require information from you on…

  • the routes to be automated, including distances
  • the number and location of sources and sinks
  • the number of transport orders per day
  • interfaces or dependencies with other trades such as ASPW or conveyor technology
  • and whether there are mixed traffic scenarios

Please be aware that these are the minimum requirements.

A calculator cannot universally determine the number of mobile transport robots needed. Intralogistic processes involve too many complex factors that a simple tool cannot adequately address.

Step 2: Project questionnaire

Each industry, operating environment, warehouse, and process has unique characteristics that are impossible to capture with a basic calculator.

Therefore, we use a detailed questionnaire to capture all the relevant parameters for planning our automated guided vehicle systems. Learn more about these parameters in our article “Successfully Implementing Automated Guided Vehicle Systems.”

Your responses help us identify the specific characteristics and challenges of your intralogistics. For example, which processes require automation through AGVs.

We categorize our transport robots into three groups:

  • Pick (for example Goods-to-Person, Person-to-Goods)
  • Move (assembly line, order picking)
  • Assemble (assembly platform)

Following an on-site inspection, we will recommend the robots best suited to your needs and specify the required number of vehicles. We will also assess the peripheral equipment necessary for your operations.

We conduct a comprehensive analysis of your intralogistics or production workflow to identify processes that can be automated using mobile transport robots. Together, we will prioritize the process chain phases to automate first.

Step 3: AGV simulation

In the final step, we develop a simulation of your automated guided vehicle system that mirrors your operational processes and the specified number of required robots.

The simulation offers a detailed visualization of how deploying our mobile robots will impact your material flow.

The simulation assists in validating the number of robots required and in identifying any shortages or potential hazards arising from internal or external factors. This proactive approach helps mitigate potential bottlenecks before the installation and commissioning stages.